SEBM016500K SEBM016503
1
MACHINE MODEL
SERIAL NUMBER
WA30-5
22005 and up
•
This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice.
•
WA30-5 mount the 3D84E-3D and 3D84E-5X engine. For details of the engine, see the 68E-88E Series Engine Shop Manual.
© 2004 1 All Rights Reserved Printed in Japan 03-04(03)00001
00-1 (3)
CONTENTS No. of page
01
GENERAL .........................................................................
01-1
10
STRUCTURE AND FUNCTION .......................................
10-1
20
TESTING AND ADJUSTING ...........................................
20-1
30
DISASSEMBLY AND ASSEMBLY ..................................
30-1
40
MAINTENANCE STANDARD ..........................................
40-1
90
OTHERS............................................................................
90-1
00-2 1
WA30-5
The affected pages are indicated by the use of the following marks. It is requested that necessary actions must be taken to these pages according to the list below.
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WA30-5
SAFETY
SAFETY NOTICE
SAFETY SAFETY NOTICE IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. • •
Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, hand shield, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. PREPARATIONS FOR WORK 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10.Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
00-3
SAFETY
PRECAUTIONS DURING WORK 11.When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 12.The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 13.Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 14.When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15.When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16.When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17.When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18.As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts.
00-4
SAFETY NOTICE
19.Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. • When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 20.When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21.When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23.When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 24.Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.
FOREWORD
GENERAL
FOREWORD GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating "Problems" with "Causes" are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them. MAINTENANCE STANDARD This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION. OTHERS This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
REVISED EDITION MARK
VOLUMES Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:
When a manual is revised, an edition mark ((1)(2)(3)....) is recorded on the bottom of the pages.
Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Each issued as one Electrical volume: Attachments volume: ¡ volume to cover all models
REVISIONS
}
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. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-todate information before you start any work.
FILING METHOD 1. See 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): 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume): 12 - 5 Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. 3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example. Example: 12-203 10-4 12-203-1 10-4-1 Added pages 12-203-2 10-4-2 12-204 10-5
00-6
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.
Symbol
Item
Remarks
k
Safety
Special safety precautions are necessary when performing the work.
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing the work.
Weight
Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc.
Tightening torque
Places that require special attention for the tightening torque during assembly.
Coat
Places to be coated with adhesives and lubricants, etc.
5
Oil, water
Places where oil, water or fuel must be added, and the capacity.
6
Drain
Places where oil or water must be drained, and quantity to be drained.
a
4
3 2
FOREWORD
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS HOISTING k 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 4 •
If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existence of another part causing interference with the part to be removed.
WIRE ROPES 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard "Z" or "S" twist ropes without galvanizing) Rope diameter
★
Allowable load
mm
kN
tons
10 11.5 12.5 14 16 18 20 22.4 30 40 50 60
9.8 13.7 15.7 21.6 27.5 35.3 43.1 54.9 98.1 176.5 274.6 392.2
1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0
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.
100%
88%
79%
71%
41% SAD00479
3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. k 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.
4) Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, 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. When two ropes sling a load vertically, up to 19.6 kN {2000 kg} of total weight can be suspended. This weight becomes 9.8 kN {1000 kg} when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 39.2 kN {4000 kg} if they sling a 19.6 kN {2000 kg} load at a lifting angle of 150°.
The allowable load value is estimated to be onesixth or one-seventh of the breaking strength of the rope used.
2) Sling wire ropes from the middle portion of the hook.
00-7
FOREWORD
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER k Before carrying out the following work, release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container. Disconnection 1) Release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. 2) Hold adapter (1) and push hose joint (2) into mating adapter (3). (See Fig. 1) ★ The adapter can be pushed in about 3.5 mm. ★ Do not hold rubber cap portion (4). 3) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against (3) until it clicks. (See Fig. 2) 4) Hold hose adapter (1) or hose (5) and pull it out. (See Fig. 3) ★ Since some hydraulic oil flows out, prepare an oil receiving container. Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (See Fig. 4) ★ Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (See Fig. 5) ★ When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.
00-8
Type 1
FOREWORD
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 3
1) 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.
1) 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.
2) Hold in the condition in Step 1), and turn lever (4) to the right (clockwise).
2) Hold in the condition in Step 1), and push until cover (3) contacts contact surface a of the hexagonal portion at the male end.
3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.
3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.
•
•
Disassembly
Type 2
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.
Connection
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
FOREWORD
COATING MATERIALS
COATING MATERIALS ★ ★
The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below. For coating materials not listed below, use the equivalent of products shown in this list. Category
Komatsu code
Part No.
Q'ty
Container
Main applications, featuresr
LT-1A
790-129-9030
150 g
Tube
• Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out.
LT-1B
790-129-9050
20 g (2 pcs.)
Polyethylene container
• Used in places requiring an immediately effective, strong adhesive. Used for plastics (except polyethylene, polyprophylene, tetrafluoroethlene and vinyl chloride), rubber, metal and non-metal.
LT-2
09940-00030
50 g
Polyethylene container
• Features: Resistance to heat and chemicals • Used for anti-loosening and sealant purpose for bolts and plugs.
LT-3
790-129-9060 (Set of adhesive and hardening agent)
Adhesive: 1 kg Hardening agent: 500 g
Can
LT-4
790-129-9040
250 g
Polyethylene container
Holtz MH 705
790-126-9120
75 g
Tube
• Used as heat-resisting sealant for repairing engine.
50 g
Polyethylene container
• Quick hardening type adhesive • Cure time: within 5 sec. to 3 min. • Used mainly for adhesion of metals, rubbers, plastics and woods.
Adhesives
Three bond 1735
790-129-9140
• Used as adhesive or sealant for metal, glass and plastic.
Aron-alpha 201
790-129-9130
2g
Polyethylene container
• Quick hardening type adhesive • Quick cure type (max. strength after 30 minutes) • Used mainly for adhesion of rubbers, plastics and metals.
Loctite 648-50
79A-129-9110
50 cc
Polyethylene container
• Resistance to heat, chemicals • Used at joint portions subject to high temperatures.
LG-1
790-129-9010
200 g
Tube
• Used as adhesive or sealant for gaskets and packing of power train case, etc.
LG-5
790-129-9080
1 kg
Can
• Used as sealant for various threads, pipe joints, flanges. • Used as sealant for tapered plugs, elbows, nipples of hydraulic piping.
Tube
• Features: Silicon based, resistance to heat, cold • Used as sealant for flange surface, tread. • Used as sealant for oil pan, final drive case, etc.
LG-6
790-129-9020
200 g
Gasket sealant LG-7
790-129-9070
1g
Tube
• Features: Silicon based, quick hardening type • Used as sealant for flywheel housing, intake manifold, oil an, thermostat housing, etc.
Three bond 1211
790-129-9090
100 g
Tube
• Used as heat-resisting sealant for repairing engine.
Tube
• Features: Silicone type, heat resistant, vibration resistant, and impact resistant sealing material • Used as sealing material for transfer case
Three bond 1207B
00-10
• Used as sealant for machined holes.
419-15-18131
100 g
FOREWORD
Molybdenum disulphide lubricant
Grease
Primer
Adhesive
Caulking material
Komatsu code
Part No.
Q'ty
Container
Main applications, featuresr
LM-G
09940-00051
60 g
Can
• Used as lubricant for sliding portion (to prevent from squeaking).
Tube
• Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting. • Used as lubricant for linkage, bearings, etc.
LM-P
09940-00040
G2-LI
SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI
G2-CA
SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-160CNCA
200 g
• General purpose type Various
Various
Various
Various
• Used for normal temperature, light load bearing at places in contact with water or steam.
• Used for heavy load portion
Molybdenum disulphide grease LM-G (G2-M)
SYG2-400M SYG2-400M-A SYGA-16CNM
Hyper White Grease G2-T G0-T (*) *: For use in cold district
SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) SYG0-16CNT (*)
400 g 16 kg
• Seizure resistance and heat resistance higher than molybdenum diBellows type sulfide grease Can • Since this grease is white, it does not stand out against machine body.
Biogrease G2B G2-BT (*) *: For high temperature and large load
SYG2-400B SYGA-16CNB SYG2-400BT (*) SYGA-16CNBT (*)
400 g 16 kg
Bellows type Can
SUNSTAR PAINT PRIMER 580 SUPER
20 ml
Glass container
SUNSTAR GLASS PRIMER 580 SUPER
20 ml
Glass container
400 g × 10 Bellows type 400 g × 20 Bellows type 16 kg Can
417-926-3910
SUNSTAR PENGUINE SEAL 580 SUPER "S" or "W"
320 ml
Polyethylene container
Sika Japan, Sikaflex 256HV
20Y-54-39850
310 ml
Polyethylene container
SUNSTAR PENGUINE SEAL No. 2505
417-926-3920
320 ml
Polyethylene container
SEKISUI SILICONE SEALANT
20Y-54-55130
333 ml
Polyethylene container
• Since this grease is decomposed by bacteria in short period, it has less effects on microorganisms, animals, and plants. • Used as primer for cab side (Using limit: 4 months) • Used as primer for glass side (Using limit: 4 months) Adhesive for cab glass
Category
COATING MATERIALS
• "S" is used for high-temperature season (April - October) and "W" for low-temperature season (November - April) as adhesive for glass. (Using limit: 4 months) • Used as adhesive for glass. (Using limit: 6 months) • Used to seal joints of glass parts. (Using limit: 4 months) • Used to seal front window. (Using limit: 6 months)
00-11
FOREWORD
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) ★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the table below. Tightening torque Thread diameter of bolt
Width across flats
mm
mm
Nm
kgm
6 8 10 12 14
10 13 17 19 22
11.8 – 14.7 27 – 34 59 – 74 98 – 123 153 – 190
1.2 – 1.5 2.8 – 3.5 6 – 7.5 10 – 12.5 15.5 – 19.5
16 18 20 22 24
24 27 30 32 36
235 – 285 320 – 400 455 – 565 610 – 765 785 – 980
23.5 – 29.5 33 – 41 46.5 – 58 62.5 – 78 80 – 100
27 30 33 36 39
41 46 50 55 60
1150 – 1440 1520 – 1910 1960 – 2450 2450 – 3040 2890 – 3630
118 – 147 155 – 195 200 – 250 250 – 310 295 – 370
Thread diameter of bolt
Width across flats
mm
mm
Nm
kgm
6 8 10 12
10 13 14 27
5.9 – 9.8 13.7 – 23.5 34.3 – 46.1 74.5 – 90.2
0.6 – 1.0 1.4 – 2.4 3.5 – 4.7 7.6 – 9.2
Tightening torque
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS ★ In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table below.
SAD00483
Thread diameter
Width across flat
mm
mm
Nm
kgm
14 18 22 24 30 33 36 42
19 24 27 32 36 41 46 55
24.5 ± 4.9 49 ± 19.6 78.5 ± 19.6 137.3 ± 29.4 176.5 ± 29.4 196.1 ± 49 245.2 ± 49 294.2 ± 49
2.5 ± 0.5 5±2 8±2 14 ± 3 18 ± 3 20 ± 5 25 ± 5 30 ± 5
00-12
Tightening torque
FOREWORD
STANDARD TIGHTENING TORQUE
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS ★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the table below.
Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
kgm
10 12 16
14 17 22
59 – 74 98 – 123 235 – 285
6 – 7.5 10 – 12.5 23.5 – 29.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS ★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter
Width across flat
mm
mm
14 20 24 33 42
Varies depending on type of connector.
Tightening torque (Nm {kgm})
Norminal No.
02 03, 04 05, 06 10, 12 14
Range 35 – 63 84 – 132 128 – 186 363 – 480 746 – 1010
{3.5 – 6.5} {8.5 – 13.5} {13.0 – 19.0} {37.0 – 49.0} {76.0 – 103}
Target 44 {4.5} 103 {10.5} 157 {16.0} 422 {43.0} 883 {90.0}
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS ★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter
Width across flat
mm
mm
08 10 12 14 16 18 20 24 30 33 36 42 52
14 17 19 22 24 27 30 32 32 — 36 — —
Tightening torque (Nm {kgm})
Norminal No.
08 10 12 14 16 18 20 24 30 33 36 42 52
Range 5.88 – 8.82 9.8 – 12.74 14.7 – 19.6 19.6 – 24.5 24.5 – 34.3 34.3 – 44.1 44.1 – 53.9 58.8 – 78.4 93.1 – 122.5 107.8 – 147.0 127.4 – 176.4 181.3 – 240.1 274.4 – 367.5
{0.6 – 0.9} {1.0 – 1.3} {1.5 – 2.0} {2.0 – 2.5} {2.5 – 3.5} {3.5 – 4.5} {4.5 – 5.5} {6.0 – 8.0} {9.5 – 12.5} {11.0 – 15.0} {13.0 – 18.0} {18.5 – 24.5} {28.0 – 37.5}
Target 7.35 {0.75} 11.27 {1.15} 17.64 {1.8} 22.54 {2.3} 29.4 {3.0} 39.2 {4.0} 49.0 {5.0} 68.6 {7.0} 107.8 {11.0} 124.4 {13.0} 151.9 {15.5} 210.7 {21.5} 323.4 {33.0}
00-13
FOREWORD
STANDARD TIGHTENING TORQUE
TIGHTENING TORQUE FOR 102 ENGINE SERIES 1) BOLT AND NUTS Use these torques for bolts and nuts (unit: mm) of Cummins Engine. Thread diameter
Tightening torque
mm
Nm
kgm
10 0 2 24 0 4 43 0 6 77 0 12
6 8 10 12
1.02 0 0.20 2.45 0 0.41 4.38 0 0.61 7.85 0 1.22
2) EYE JOINTS Use these torques for eye joints (unit: mm) of Cummins Engine. Thread diameter
Tightening torque
mm
Nm
kgm
802 10 0 2 12 0 2 24 0 4 36 0 5
6 8 10 12 14
0.81 0 0.20 1.02 0 0.20 1.22 0 0.20 2.45 0 0.41 3.67 0 0.51
3) TAPERED SCREWS Use these torques for tapered screws (unit: inch) of Cummins Engine. Thread diameter
Tightening torque
inch
Nm
kgm
301 802 12 0 2 15 0 2 24 0 4 36 0 5 60 0 9
1 / 16 1/8 1/4 3/8 1/2 3/4 1
0.31 0 0.10 0.81 0 0.20 1.22 0 0.20 1.53 0 0.41 2.45 0 0.41 3.67 0 0.51 6.12 0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) ★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified. ★ Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque (Nm {kgm}) Nominal size Width across of hose flats
Taper seal type
Face seal type
Nominal thread Thread size size Root diameter - Threads per (mm) inch, Thread series (mm) (Reference)
Range
Target
19
34 - 63 {3.5 - 6.5}
44 {4.5}
14
9 – - 18UNF 16
14.3
22
54 - 93 {5.5 - 9.5}
74 {4.5}
–
11 – - 16UN 16
17.5
24
59 - 98 {6.0 - 10.0}
78 {8.0}
18
–
–
04
27
84 - 132 {8.5 - 13.5}
103 {10.5}
22
13 – - 16UN 16
20.7
05
32
128 - 186 {13.0 - 19.0}
157 {16.0}
24
1 - 14UNS
25.4
06
36
177 - 245 {18.0 - 25.0}
216 {22.0}
30
3 1 – - 12UNF 16
30.3
(10)
41
177 - 245 {18.0 - 25.0}
216 {22.0}
33
–
–
(12)
46
197 - 294 {20.0 - 30.0}
245 {25.0}
36
–
–
(14)
55
246 - 343 {25.0 - 35.0}
294 {30.0}
42
–
–
02
03
00-14
FOREWORD
ELECTRIC WIRE CODE
ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS Copper wire Cable O.D. (mm)
Current rating (A)
Applicable circuit
0.88
2.4
12
Starting, lighting, signal etc.
0.32
2.09
3.1
20
Lighting, signal etc.
65
0.32
5.23
4.6
37
Charging and signal
15
84
0.45
13.36
7.0
59
Starting (Glow plug)
40
85
0.80
42.73
11.4
135
Starting
60
127
0.80
63.84
13.6
178
Starting
100
217
0.80
109.1
17.6
230
Starting
Norminal number
Number of strands
Dia. of strands (mm2)
Cross section (mm2)
0.85
11
0.32
2
26
5
CLASSIFICATION BY COLOR AND CODE Circuits Priority Classification
1
Primary
Charging
Ground
Starting
Lighting
Instrument
Signal
Other
Code
W
B
B
R
Y
G
L
Color
White
Black
Black
Red
Yellow
Green
Blue
Code
WR
—
BW
RW
YR
GW
LW
2 Color White & Red
—
Code
—
WB
White & Black Red & White Rellow & Red Green & White Blue & White BY
RB
YB
GR
LR
3
4
Auxiliary
Color White & Black
—
Code
—
WL
Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow BR
Color White & Blue
—
Code
—
—
Color White & Green
—
—
Code
—
—
—
Color
—
—
—
WG
RY
Black & Red Red & Yellow RG
YG
GY
LY
Yellow & Green
Green & Yellow
Blue & Yellow
YL
GB
LB
5 Red & Green Yellow & Blue Green & Black Blue & Black RL
YW
GL
6 Red & Blue Yellow & White Green & Blue
n n
00-15
FOREWORD
CONVERSION TABLE
CONVERSION TABLE METHOD OF USING THE CONVERSION TABLE The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below.
EXAMPLE • Method of using the Conversion Table to convert from millimeters to inches 1. Convert 55 mm into inches. (1) Locate the number 50 in the vertical column at the left side, take this as A, then draw a horizontal line from A. (2) Locate the number 5 in the row across the top, take this as B, then draw a perpendicular line down from B. (3) Take the point where the two lines cross as C. This point C gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. 2. Convert 550 mm into inches. (1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to convert it to 55 mm. (2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. (3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches. B Millimeters to inches 1 mm = 0.03937 in
A
00-16
0
1
2
3
4
0 10 20 30 40
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
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
2.008 2.402 2.795 3.189 3.583
2.047 2.441 2.835 3.228 3.622
2.087 2.480 2.874 3.268 3.661
2.126 2.520 2.913 3.307 3.701
5 0.197 0.591 0.984 1.378 1.772 C 2.165 2.559 2.953 3.346 3.740
6
7
8
9
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
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
FOREWORD
CONVERSION TABLE
Millimeters to Inches 1 mm = 0.03937 in
0
1
2
3
4
5
6
7
8
9
0
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
10
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
20
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
30
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.536
40
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
50
1.969
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
2.323
60
2.362
2.402
2.441
2.480
2.520
2.559
2.598
2.638
2.677
2.717
70
2.756
2.795
2.835
2.874
2.913
2.953
2.992
3.032
3.071
3.110
80
3.150
3.189
3.228
3.268
3.307
3.346
3.386
3.425
3.465
3.504
90
3.543
3.583
3.622
3.661
3.701
3.740
3.780
3.819
3.858
3.898
0
Kilogram to Pound 1 kg = 2.2046 lb
0 0
0
1
2
3
4
5
6
7
8
9
2.20
4.41
6.61
8.82
11.02
13.23
15.43
17.64
19.84
10
22.05
24.25
26.46
28.66
30.86
33.07
35.27
37.48
39.68
41.89
20
44.09
46.30
48.50
50.71
51.91
55.12
57.32
59.53
61.73
63.93
30
66.14
68.34
70.55
72.75
74.96
77.16
79.37
81.57
83.78
85.98
40
88.18
90.39
92.59
94.80
97.00
99.21
101.41
103.62
105.82
108.03
50
110.23
112.44
114.64
116.85
119.05
121.25
123.46
125.66
127.87
130.07
60
132.28
134.48
136.69
138.89
141.10
143.30
145.51
147.71
149.91
152.12
70
154.32
156.53
158.73
160.94
163.14
165.35
167.55
169.76
171.96
174.17
80
176.37
178.57
180.78
182.98
185.19
187.39
189.60
191.80
194.01
196.21
90
198.42
200.62
202.83
205.03
207.24
209.44
211.64
213.85
216.05
218.26
00-17
FOREWORD
CONVERSION TABLE
Liter to U.S. Gallon 1l = 0.2642 U.S. Gal
0
1
2
3
4
5
6
7
8
9
0
0.264
0.528
0.793
1.057
1.321
1.585
1.849
2.113
2.378
10
2.642
2.906
3.170
3.434
3.698
3.963
4.227
4.491
4.755
5.019
20
5.283
5.548
5.812
6.076
6.340
6.604
6.869
7.133
7.397
7.661
30
7.925
8.189
8.454
8.718
8.982
9.246
9.510
9.774
10.039
10.303
40
10.567
10.831
11.095
11.359
11.624
11.888
12.152
12.416
12.680
12.944
50
13.209
13.473
13.737
14.001
14.265
14.529
14.795
15.058
15.322
15.586
60
15.850
16.115
16.379
16.643
16.907
17.171
17.435
17.700
17.964
18.228
70
18.492
18.756
19.020
19.285
19.549
19.813
20.077
20.341
20.605
20.870
80
21.134
21.398
21.662
21.926
22.190
22.455
22.719
22.983
23.247
23.511
90
23.775
24.040
24.304
24.568
24.832
25.096
25.361
25.625
25.889
26.153
0
Liter to U.K. Gallon 1l = 0.21997 U.K. Gal
0
1
2
3
4
5
6
7
8
9
0
0.220
0.440
0.660
0.880
1.100
1.320
1.540
1.760
1.980
10
2.200
2.420
2.640
2.860
3.080
3.300
3.520
3.740
3.950
4.179
20
4.399
4.619
4.839
5.059
5.279
5.499
5.719
5.939
6.159
6.379
30
6.599
6.819
7.039
7.259
7.479
7.969
7.919
8.139
8.359
8.579
40
8.799
9.019
9.239
9.459
9.679
9.899
10.119
10.339
10.559
10.778
50
10.998
11.281
11.438
11.658
11.878
12.098
12.318
12.528
12.758
12.978
60
13.198
13.418
13.638
13.858
14.078
14.298
14.518
14.738
14.958
15.178
70
15.398
15.618
15.838
16.058
16.278
16.498
16.718
16.938
17.158
17.378
80
17.598
17.818
18.037
18.257
18.477
18.697
18.917
19.137
19.357
19.577
90
19.797
20.017
20.237
20.457
20.677
20.897
21.117
21.337
21.557
21.777
0
00-18
FOREWORD
CONVERSION TABLE
kgm to ft. lb 1 kgm = 7.233 ft. lb
0
1
2
3
4
5
6
7
8
9
0
0
7.2
14.5
21.7
28.9
36.2
43.4
50.6
57.9
65.1
10
72.3
79.6
86.8
94.0
101.3
108.5
115.7
123.0
130.2
137.4
20
144.7
151.9
159.1
166.4
173.6
180.8
188.1
195.3
202.5
209.8
30
217.0
224.2
231.5
238.7
245.9
253.2
260.4
267.6
274.9
282.1
40
289.3
296.6
303.8
311.0
318.3
325.5
332.7
340.0
347.2
354.4
50
361.7
368.9
376.1
383.4
390.6
397.8
405.1
412.3
419.5
426.8
60
434.0
441.2
448.5
455.7
462.9
470.2
477.4
484.6
491.8
499.1
70
506.3
513.5
520.8
528.0
535.2
542.5
549.7
556.9
564.2
571.4
80
578.6
585.9
593.1
600.3
607.6
614.8
622.0
629.3
636.5
643.7
90
651.0
658.2
665.4
672.7
679.9
687.1
694.4
701.6
708.8
716.1
100
723.3
730.5
737.8
745.0
752.2
759.5
766.7
773.9
781.2
788.4
110
795.6
802.9
810.1
817.3
824.6
831.8
839.0
846.3
853.5
860.7
120
868.0
875.2
882.4
889.7
896.9
904.1
911.4
918.6
925.8
933.1
130
940.3
947.5
954.8
962.0
969.2
976.5
983.7
990.9
998.2
1005.4
140
1012.6
1019.9
1027.1
1034.3
1041.5
1048.8
1056.0
1063.2
1070.5
1077.7
150
1084.9
1092.2
1099.4
1106.6
1113.9
1121.1
1128.3
1135.6
1142.8
1150.0
160
1157.3
1164.5
1171.7
1179.0
1186.2
1193.4
1200.7
1207.9
1215.1
1222.4
170
1129.6
1236.8
1244.1
1251.3
1258.5
1265.8
1273.0
1280.1
1287.5
1294.7
180
1301.9
1309.2
1316.4
1323.6
1330.9
1338.1
1345.3
1352.6
1359.8
1367.0
190
1374.3
1381.5
1388.7
1396.0
1403.2
1410.4
1417.7
1424.9
1432.1
1439.4
00-19
FOREWORD
CONVERSION TABLE
kg/cm2 to lb/in2 1kg/cm2 = 14.2233 lb/in2
0
1
2
3
4
5
6
7
8
9
0
0
14.2
28.4
42.7
56.9
71.1
85.3
99.6
113.8
128.0
10
142.2
156.5
170.7
184.9
199.1
213.4
227.6
241.8
256.0
270.2
20
284.5
298.7
312.9
327.1
341.4
355.6
369.8
384.0
398.3
412.5
30
426.7
440.9
455.1
469.4
483.6
497.8
512.0
526.3
540.5
554.7
40
568.9
583.2
597.4
611.6
625.8
640.1
654.3
668.5
682.7
696.9
50
711.2
725.4
739.6
753.8
768.1
782.3
796.5
810.7
825.0
839.2
60
853.4
867.6
881.8
896.1
910.3
924.5
938.7
953.0
967.2
981.4
70
995.6
1010
1024
1038
1053
1067
1081
1095
1109
1124
80
1138
1152
1166
1181
1195
1209
1223
1237
1252
1266
90
1280
1294
1309
1323
1337
1351
1365
1380
1394
1408
100
1422
1437
1451
1465
1479
1493
1508
1522
1536
1550
110
1565
1579
1593
1607
1621
1636
1650
1664
1678
1693
120
1707
1721
1735
1749
1764
1778
1792
1806
1821
1835
130
1849
1863
1877
1892
1906
1920
1934
1949
1963
1977
140
1991
2005
2020
2034
2048
2062
2077
2091
2105
2119
150
2134
2148
2162
2176
2190
2205
2219
2233
2247
2262
160
2276
2290
2304
2318
2333
2347
2361
2375
2389
2404
170
2418
2432
2446
2460
2475
2489
2503
2518
2532
2546
180
2560
2574
2589
2603
2617
2631
2646
2660
2674
2688
190
2702
2717
2731
2745
2759
2773
2788
2802
2816
2830
200
2845
2859
2873
2887
2901
2916
2930
2944
2958
2973
210
2987
3001
3015
3030
3044
3058
3072
3086
3101
3115
220
3129
3143
3158
3172
3186
3200
3214
3229
3243
3257
230
3271
3286
3300
3314
3328
3343
3357
3371
3385
3399
240
3414
3428
3442
3456
3470
3485
3499
3513
3527
3542
00-20
FOREWORD
CONVERSION TABLE
Temperature Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right. 1°C = 33.8°F
°C
°F
°C
°F
°C
°F
°C
°F
–40.4 –37.2 –34.4 –31.7 –28.9
–40 –35 –30 –25 –20
–40.0 –31.0 –22.0 –13.0 –4.0
–11.7 –11.1 –10.6 –10.0 –9.4
11 12 13 14 15
51.8 53.6 55.4 57.2 59.0
7.8 8.3 8.9 9.4 10.0
46 47 48 49 50
114.8 116.6 118.4 120.2 122.0
27.2 27.8 28.3 28.9 29.4
81 82 83 84 85
117.8 179.6 181.4 183.2 185.0
–28.3 –27.8 –27.2 –26.7 –26.1
–19 –18 –17 –16 –15
–2.2 –0.4 1.4 3.2 5.0
–8.9 –8.3 –7.8 –7.2 –6.7
16 17 18 19 20
60.8 62.6 64.4 66.2 68.0
10.6 11.1 11.7 12.2 12.8
51 52 53 54 55
123.8 125.6 127.4 129.2 131.0
30.0 30.6 31.1 31.7 32.2
86 87 88 89 90
186.8 188.6 190.4 192.2 194.0
–25.6 –25.0 –24.4 –23.9 –23.3
–14 –13 –12 –11 –10
6.8 8.6 10.4 12.2 14.0
–6.1 –5.6 –5.0 –4.4 –3.9
21 22 23 24 25
69.8 71.6 73.4 75.2 77.0
13.3 13.9 14.4 15.0 15.6
56 57 58 59 0
132.8 134.6 136.4 138.2 140.0
32.8 33.3 33.9 34.4 35.0
91 92 93 94 95
195.8 197.6 199.4 201.2 203.0
–22.8 –22.2 –21.7 –21.1 –20.6
–9 –8 –7 –6 –5
15.8 17.6 19.4 21.2 23.0
–3.3 –2.8 –2.2 –1.7 –1.1
26 27 28 29 30
78.8 80.6 82.4 84.2 86.0
16.1 16.7 17.2 17.8 18.3
61 62 63 64 65
141.8 143.6 145.4 147.2 149.0
35.6 36.1 36.7 37.2 37.8
96 97 98 99 100
204.8 206.6 208.4 210.2 212.0
–20.0 –19.4 –18.9 –18.3 –17.8
–4 –3 –2 –1 0
24.8 26.6 28.4 30.2 32.0
–0.6 0 0.6 1.1 1.7
31 32 33 34 35
87.8 89.6 91.4 93.2 95.0
18.9 19.4 20.0 20.6 21.1
66 67 68 69 70
150.8 152.6 154.4 156.2 158.0
40.6 43.3 46.1 48.9 51.7
105 110 115 120 125
221.0 230.0 239.0 248.0 257.0
–17.2 –16.7 –16.1 –15.6 –15.0
1 2 3 4 5
33.8 35.6 37.4 39.2 41.0
2.2 2.8 3.3 3.9 4.4
36 37 38 39 40
96.8 98.6 100.4 102.2 104.0
21.7 22.2 22.8 23.3 23.9
71 72 73 74 75
159.8 161.6 163.4 165.2 167.0
54.4 57.2 60.0 62.7 65.6
130 135 140 145 150
266.0 275.0 284.0 293.0 302.0
–14.4 –13.9 –13.3 –12.8 –12.2
6 7 8 9 10
42.8 44.6 46.4 48.2 50.0
5.0 5.6 6.1 6.7 7.2
41 42 43 44 45
105.8 107.6 109.4 111.2 113.0
24.4 25.0 25.6 26.1 26.7
76 77 78 79 80
168.8 170.6 172.4 174.2 176.0
68.3 71.1 73.9 76.7 79.4
155 160 165 170 175
311.0 320.0 329.0 338.0 347.0
00-21
FOREWORD
UNITS
UNITS In this manual, the measuring units are indicated with Internatinal System of units (SI). As for reference, conventionally used Gravitational System of units are indicated in parentheses { Example: N {kg} Nm {kgm} MPa {kg/cm2} kPa {mmH2O} kPa {mmHg} kW/rpm {HP/rpm} g/kWh {g/HPh}
00-22
}.
01
GENERAL
General assembly drawing ......................... 01Specifications ................................................ 01Weight table ................................................. 01List of lubricant and water .......................... 01-
WA30-5
2 4 7 8
01-1 1
GENERAL
GENERAL ASSEMBLY DRAWING
GENERAL ASSEMBLY DRAWING WA30-5 Unit: mm
01-2 (2)
WA30-5
GENERAL
GENERAL ASSEMBLY DRAWING
WA30-5 (with ROPS canopy) Unit: mm
WA30-5
01-3 (2)
GENERAL
SPECIFICATIONS
Performance
Weight
SPECIFICATIONS Machine model
WA30-5
Serial No.
22005 and up Without ROPS canopy
Operating weight
kg
2,555
2,740
Distribution (front)
kg
1,190
1,055
Distribution (rear)
kg
1,365
1,685
Bucket capacity (heaped) (With tooth)
m3
0.4
Rated load
kg
640
Travel speed (Forward)
km/h
15
(Reverse)
km/h
15
kN {kg}
25.5 {2,600}
deg
30
Max. rimpull (Forward) Gradeability Center of outside wheel
mm
Outside portion of bucket
mm
3,610
Overall length (bucket on the ground)
mm
3,975
Overall width
mm
1,495
Bucket width
mm
1,575
Overall height (Top of ROPS canopy)
mm
Min. turning radius
(Bucket raised)
Dimensions
Without ROPS canopy
3,060
2,455
2,700
mm
3,375
Wheelbase
mm
1,750
Tread
mm
1,180
Min. ground clearance
mm
270
Height of bucket hinge pin
mm
2,680
Dumping clearance (tip of BOC)
mm
2,140
Dumping reach (tip of BOC)
mm
785
Bucket dump angle (front)
deg
45
Bucket tilt angle (Rear, travelling posture)
deg
53
Digging depth (10Ëš front and rear)
mm
150
BOC: Bolt-on cutting edge.
01-4 (3)
WA30-5
GENERAL
SPECIFICATIONS
Machine model
WA30-5
Serial No. Model Type No. of cylinders – bore x stroke Piston displacement
3D84E-3D 3D84E-5X 4-cycle, water-cooled, in-line, 4-cycle, water-cooled, in-line, 3-cylinder, direct injection 3-cylinder, direct injection No. – mm x mm 3 – 84 x 90 3 – 84 x 90 ¬ {cc}
1.496 {1,496}
1.496 {1,496}
21.3 {28.6}/2,500
21.3 {28.6}/2,500
Max. torque
Nm{kgm}/rpm
90.2 {9.2}/1,600
90.2 {9.2}/1,600
Min. Fuel consumption ratio
g/kWh {g/HPh}
231.1 {172.4}
251.7 {187.8}
High idling speed (with load)
rpm
2,575
2,575
Low idling speed (with load)
rpm
Alternator Starting motor Battery
Axle, wheel
Power train
Main piston pump
950
950
12V 40A
12V 40A
24V 2.0kW
24V 2.0kW
12V 80Ah x 1
12V 80Ah x 1
DA control, swash plate type
Piston motor
DA control, bent axis type piston pump
Reduction gear
Spiral bevel gear
Differential
Straight bevel gear
Final drive
Planetary gear, single reduction
Drive type
Front/rear-wheel drive
Front axle
Fixed-frame, semi-floating
Rear axle
Center pin support type, semi-floating
Tire
12.5/70-16-6PR
Wheel rim Inflation pressure
Steering Brakes device
26001 and up
kW{HP}/rpm
Flywheel horsepower
Engine
22005 – 26000
Foot brake (also parking brake) Type Structure
WA30-5
10LB – 16DC MPa {kg/cm2}
0.2 {2.0} Transmission shaft braking, wet type multiple disc brake Articulated type Fully hydraulically power steering (orbit roll)
01-5 (2)
WA30-5
Serial No.
22005 and up
0 – 28 High pressure relief set pressure: 34.3 MPa {350 kg/cm2}
Charge pump (for HST) Theoretical delivery
cc/rev
8.6 Rated 2.500 rpm Set pressure: 2 MPa {21 kg/cm2}
Variable displacement motor (for HST) Theoretical delivery
cc/rev
16 – 58.7 High pressure relief set pressure: 34.3 MPa {350 kg/cm2}
Work equipment • steering pump Theoretical delivery
cc/rev
Cylinder Work equipment
Machine model
cc/rev
Gear pump 14.2 Rated 2.500 rpm Set pressure: 20.6 MPa {210 kg/cm2} (Work equipment) Set pressure: 17.2MPa {175 kg/cm2} (steering)
Set pressure for steering
MPa {kg/cm2}
Orbit roll 17.2 {175}
Set pressure for work equipment
MPa {kg/cm2}
3-spool type 20.6 {210}
Steering cylinder No.– bore + stroke
mm
Reciprocating piston 1 – 55 x 218
Lift cylinder No.– bore + stroke
mm
Reciprocating piston 2 – 65 x 379
Dump cylinder No.– bore + stroke
mm
Reciprocating piston 1 – 60 x 367
Link type Bucket edge type
01-6 1
SPECIFICATIONS
Variable displacement piston pump (for HST) Theoretical delivery
Control valve
Hydraulic system
GENERAL
Z bar link With bolt on edge
WA30-5
GENERAL
WEIGHT TABLE
WEIGHT TABLE ¤ This weight table is a guide for use when transporting or handling component. Unit: kg Machine model
WA30-5
Machine model
WA30-5
Serial No.
22005 and up
Serial No.
22005 and up
Engine
155
ROPS canopy
155
Radiator
12
Counter weight
400
Fuel tank
21.5
Front frame
181
HST pump (including charge pump)
33
Rear frame
210
HST motor
29
Hydraulic tank
Transfer
68
Work equipment • Steering pump
2.3 9
Front drive shaft
8.5
Work equipment valve
Rear drive shaft
3.6
Lift cylinder
24.5
(1)
19.2
Front axle
127
Dump cylinder
14
Rear axle
123
Bucket link
10
23.2
Bell crank
51
Axle support Wheel
(1)
18
Lift arm (including bushing)
151
Tire
(1)
30
Bucket with B O C
177
Steering valve
8.2
Steering cylinder
8
Engine hood
13.5
Floor
18
Operator's seat Assembly
9
BOC: Bolt-on cutting edge.
WA30-5
01-7 (2)
GENERAL
LIST OF LUBRICANT AND WATER
LIST OF LUBRICANT AND WATER
RESERVOIR
KIND OF FLUID
AMBIENT TEMPERATURE –22 –4 –30 –20
14 –10
32 0
50 10
68 20
86 30
CAPACITY (¬) 104122˚F 40 50˚C
Specified
Refill
5.2
4.7
1.4
1.3
38.0
28.0
Front: 4.8 Rear: 4.5
Front: 4.8 Rear: 4.5
–
–
42.0
–
5.5
–
SAE30 SAE10W Engine oil pan
SAE10W-30 Engine oil
SAE15W-40
Transfer case
SAE10W
Hydraulic system
SAE10W-30 (*1) AXO80
Axle oil Axle
SAE30
Engine oil Pins
Fuel tank
Grease
NLGI No.2 ASTM D975 No.2
Diesel fuel ASTM D975 No. 1
Cooling system
01-8 (2)
Coolant
Add antifreeze
WA30-5
GENERAL
LIST OF LUBRICANT AND WATER
*1: Use SAE 10W30 oil for the oil in the hydraulic system. If Komatsu genuine oil is not available, select the oil from the table below. Supplier BP
EXXON (ESSO)
Engine Oil (The 15W40 oil marked * is CE.) Vanellus C3 (15W40) Essolube D3 *Essolube XD-3 *Essolube XD-3 Extra *Esso heavy duty Exxon heavy duty
GULF
Super duty motor oil *Super duty plus
MOBIL
Delvac 1300 *Delvac super (10W-30, 15W-40)
SHELL
Rimura X Rotella T 10W30
REMARK ‡ 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%. ‡ When starting the engine in an atmospheric temperature of lower than 0˚C, be sure to use engine oil of SAE10W, SAE10W-30 and SAE15W-40, even though an atmospheric temperature goes up to 10˚C more or less in the day time. ‡
Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to half.
‡
There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be sure to add single grade oil that matches the temperature in the table.
‡
We recommend Komatsu genuine oil which 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. ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers API: American Petroleum Institute
Fuel sulphur content
Change interval of oil in engin oil pan
0.5 to 1.0%
1/2 of regular interval
Above 1.0%
1/4 of regular interval
WA30-5
01-9 (2)
10
STRUCTURE AND FUNCTION
Power train .................................................... Power train system.. ..................................... Radiator oil cooler.. .................................... Damper coupling .......................................... HST piping .................................................... HST hydraulic system diagram ................... HST hydraulic circuit diagram ..................... Main piston pump ........................................ High-pressure relief valve ............................ Low-pressure relief valve.. ........................... Work equipment steering pump, HST charge pump .................................. Charge pump oil filter .................................. Speed related valve (DA valve) ................... Piston motor ................................................. Directional shuttle valve .............................. Servo valve ................................................... Inching valve ................................................. Transfer ......................................................... HST control ................................................... Drive shaft ..................................................... Axle ................................................................ Differential ..................................................... Final drive ..................................................... Axle mount.. .................................................. Tire wheel ................................................... Center hinge pin ........................................... Steering piping ............................................. Steering column ........................................... Priority valve ................................................. Steering valve (orbit-roll) ............................. Brake, parking brake control.. ...................... Brake (also used as parking brake) ............. Work equipment piping ............................... work equipment hydraulic system diagram.. .................................... l
IO- 3 IO- 4 IO- 6 IO- 7 IO- 8 IO-IO IO-I 1 IO-12 IO-I 4 10-I 6
l
l
WA30-5
IO-17 IO-18 IO-19 IO-20 1o-22 1O-23 IO-24 1O-25 1O-26 1O-27 IO-28 IO-30 IO-33 IO-35 IO-36 IO-37 IO-38 IO-39 IO-40 1 O-44 IO-52 IO-53 IO-54
Work equipment hydraulic circuit diagram ....................................... Work equipment lever linkage.. ................... Hydraulic tank ............................................... Hydraulic filter ............................................... Main control valve ........................................ Work equipment linkage .............................. Bucket ............................................................ Bucket positioner.. ........................................ Proximity switch ........................................... ROPS canopy ................................................ Central panel (cluster gauge). ...................... Engine start circuit.. ...................................... Engine stop circuit.. ...................................... Preheating circuit.. ........................................ Parking brake circuit .....................................
IO-57 IO-58 IO-59 IO-60 IO-62 IO-69 IO-71 IO-72 1O-73 IO-74 IO-75 IO-76 IO-76 IO-77 IO-78
IO-56
10-l 0
STRUCTURE AND FUNCTION
POWER TRAIN
POWER TRAIN
362FO5003
Outline 1. Engine 2. Main piston pump 3. Piston motor 4. Transfer 5. 6. 7. 8.
Front Front Rear Rear
drive shaft axle drive shaft axle
.
.
WAN-5
The power from engine (I) is transmitted to main piston pump (2) through damper coupling installed to flywheel. A directional selector valve and servo cylinder are installed to main piston pump (2). When transmission is operated in either forward or reverse direction, the directional selector valve is actuated, and the angle of the swash plate in the pump is changed to send the oil in the normal or reverse direction. The oil sent from the main piston pump flows to piston motor (3) and drive the motor. The piston motor (3) is connected to transfer (4). The power from the motor is transmitted from transfer output shaft through front drive shaft (5) and rear drive shaft (7) to front axle (6) and rear axle (8). It is then transmitted by the wheels and the tires.
1o-3
STRUCTURE AND FUNCTION
POWER TRAIN SYSTEM
POWER TRAIN SYSTEM 13\
362FO5004
1o-4
WA30-5
POWER TRAIN SYSTEM
STRUCTURE AND FUNCTION
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
Engine Coupling Main piston pump Work equipment, steering pump HST charge pump Piston motor Transfer Foot brake (also used as parking Front drive shaft Front differential Front axle Front final drive Front tire Rear drive shaft Rear axle Rear differential Rear final drive Rear tire
brake)
Outline . The power from engine (1) is transmitted to main piston pump (3) through damper coupling (2) installed to the flywheel. A directional selector valve and servo cylinder are installed to main piston pump (3). When the transmission is operated in either the forward or reverse direction, the directional selector valve is actuated, and the angle of the swash plate in the pump is changed to send the oil in the normal or reverse direction. . The power from the engine is transmitted to the HST charge pump (4) built into the main piston pump and the hydraulic and steering pump (5) installed to the rear of the pump, and drives the pumps. . Main piston pump (3) and piston motor (6) are connected with hoses, and the oil sent under pressure by the main piston pump flows to the piston motor, and drives the motor. The direction of the flow of oil is changed to the normal and reverse directions by the directional selector valve and servo cylinder, and changes the direction of rotation of the motor. The selection of direction is carried out manually. . Piston motor (6) transmits the power to the output shaft through the gear installed to transfer (7). The power is then transmitted to the front and rear axles. A wet-type multiple disc brake (81, which mechanically controls the output shaft, is installed to transfer (71, and acts as the service brake and the parking brake. At the front, the power passes through front drive shaft (9) and is transmitted to front axle (11). At the rear, the power passes through rear drive shaft (14) and is transmitted to rear axle (15). . The power transmitted to front axle (1 I) and rear axle (15) is reduced by the bevel gears of differentials (IO) and (16). It is then transmitted through the differential mechanism to the sun gear shafts of final drives (12) and (17). . The power of the sun gear is reduced by a planetary mechanism, passes through the axle shaft, and is transmitted from the wheel to tires (13) and (18). l
WA30-5
1o-5 0
STRUCTURE AND FUNCTION
RADIATOR
l
RADIATOR
l
OIL COOLER
OIL COOLER
362FO5005
1. HST oil cooler 2. Water inlet 3. Radiator A. B. C. D.
Cooling water inlet Cooling water outlet Oil cooler inlet Oil cooler outlet
Specifications Radiator Core type : Corrugate fin Total heat dissipation surface : 6.098 m2 Cross section area for passing water : 0.0023m2
. .
Oil cooler . Core type : Corrugate l
Total
heat dissipation
fin surface
: 4.202 m2
l
1 O-6
WA30-5
STRUCTURE AND FUNCTION
DAMPER COUPLING
DAMPER COUPLING
1. 2. 3. 4. 5.
Rubber Boss Main piston pump input shaft Pin Bolt
WA30-5
Outline • The damper coupling reduces the torsional vibration caused by variations in the engine torque, and acts to protect the engine and downstream drive system from the torsional vibration. • The power from the engine is transmitted from the flywheel to damper coupling rubber (1). The rubber absorbs the torsional vibration and transmits the power through boss (2) to the main piston pump.
10-7 (2)
STRUCTURE AND FUNCTION
HST PIPING
HST PIPING
1. 2. 3. 4.
Hydraulic tank Work equipment • steering pump Main piston pump Transfer case
Outline • The oil from HST charge pump flows through the filter to the speed related valve. The oil flow is divided into two supply circuits: one part goes to the circuit for the directional selector valve and inching valve, while the other part passes through the low-pressure relief valve and goes to the main piston pump. • The directional selector solenoid valve is actuated by the operation of the transmission to forward or reverse, and the oil flowing to
10-8 1
5. Piston motor 6. Oil filter 7. HST charge pump
•
the directional selector valve then flows to the servo cylinder of the main piston pump. The swash plate of the piston pump is angled by the operation of this cylinder, and the oil flows in the normal or reverse direction. The oil flow that was divided before the directional selector valve flows to the inching valve, and makes inching operations possible by opening or closing this valve.
WA30-5
STRUCTURE AND FUNCTION
HST HYDRAULIC SYSTEM DIAGRAM
HST HYDRAULIC SYSTEM DIAGRAM
10-10 (2)
WA30-5
STRUCTURE AND FUNCTION
HST HYDRAULIC CIRCUIT DIAGRAM
HST HYDRAULIC CIRCUIT DIAGRAM
1. 2. 3. 4. 5. 6.
Hydraulic tank Main piston pump Servo cylinder Charge pump Oil filter Speed related valve (DA valve) 7. Last chance filter
WA30-5
8. 9. 10. 11. 12. 13. 14. 15.
Directional selector valve Inching valve High pressure relief valve Low pressure relief valve — Piton motor Check valve Directional shuttle valve
16. 17. 18. 19. 20. 21. 22. 23.
Servo valve Servo cylinder Check valve Oil cooler Transfer Orifice (inching) Orifice (drain) Last chance filter
10-11 (2)
STRUCTURE AND FUNCTION
MAIN PISTON PUMP
MAIN PISTON PUMP
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Speed related valve (DA valve) High pressure relief valve Drive shaft Swash plate Piston Servo cylinder Directional selector valve Low pressure relief valve (Built in type) Control plate Cylinder block
10-12 (2)
Specifications Model: 4 VG28 DA Type: Variable displacement, swash plate type piston pump Theoretical delivery: 0 – 28 cc/rev. Set pressure for high pressure cut-off valve: 34MPa {350kg/cm2} Set pressure for low pressure relief valve: 2MPa {21kg/cm2}
WA30-5
STRUCTURE AND FUNCTION
MAIN PISTON PUMP
Operation of main piston pump Flow of power • The main piston pump is connected to the coupling installed to the engine flywheel. • The power from the engine goes from the flywheel through the coupling and enters the piston pump. • Directional selector valve (7) and servo cylinder (6) are installed to the main piston pump. When the directional lever is operated, the directional selector valve is actuated and swash plate (4) inside the piston pump is angled to send the oil flow in the normal or reverse direction. • Cylinder block (10) and piston (5) inside the cylinder block rotate together with drive shaft (3), and the tip of the piston slides on the surface of swash plate (4), which does not rotate. There are 9 pistons installed in the pump. Flow of oil • The piston pump moves piston (5) (which is in contact with the swash plate surface) in a reciprocal movement according to the angle of swash plate (4). This reciprocal movement acts as a pump and the oil inside cylinder block (10) is continuously sucked in or discharged. • As a result of this discharge action, the highpressure oil flows in a fixed direction, and goes to the piston motor. • If the angle of swash plate (4) is reversed, the suction and discharge are also reversed, so the direction of the oil flow can be in the normal or reverse direction. • By making the angle of swash plate (4) larger or smaller, it is possible to change the stroke of the piston and control the travel speed. • Because oil leaks from the piston motor, piston pump, and control valve, there is a lack of oil in the low-pressure circuit (the circuit returning from the motor to the pump). To make up for the lack of oil, oil is supplied from the charge pump through speed related valve (1) to the check valve of high-pressure relief valve (2). fl At neutral (the piston does not move, so no oil is dischrged
WA30-5
10-13 (2)
STRUCTURE AND FUNCTION
HIGH-PRESSURE RELIEF VALVE
HIGH-PRESSURE RELIEF VALVE
1. 2. 3. 4. 5. 6. 7. 8.
Cap nut Locknut Poppet spring Check spring Main piston Valve seat Pilot poppet Adjustment screw
10-14 (2)
Function • The high-pressure relief valve is installed to the main piston pump, and when the oil pressure between the piston pump and piston motor goes above the set pressure, it drains the oil to the low-pressure circuit. In this way, it sets the maximum pressure in the circuit, and protects the circuit. • If there is lack of oil inside the circuit, it sends oil from the charge pump to prevent cavitation.
WA30-5
STRUCTURE AND FUNCTION
HIGH-PRESSURE RELIEF VALVE
Operation . Port A is connected
to the high-pressure circuit of the main piston pump and piston motor, and ports C and D are connected to the low-pressure circuit of the main piston
.
.
l
pump. The oil passes through the orifice in main piston (5) and fills port B. Pilot poppet (7) is seated in valve seat (6). When the oil pressure inside ports A and B reaches the set pressure of poppet spring (31, pilot poppet (7) opens. The oil pressure at port B escapes from port D to port C, so the pressure at port B goes down. When the pressure at port B goes down, a difference in pressure between ports A and B is generated by the orifice of main piston (51, so the main piston is pushed open, and the oil at port A flows to port C to release the abnormal pressure. It is possible to change the set pressure by changing the tension of poppet spring (3). To change the set pressure, remove the cap nut, loosen the locknut, then turn adjustment screw (8) to change the set pressure. To INCREASE the set pressure, TIGHTEN the screw To DECREASE the set pressure, LOOSEN the screw When the pressure at port A becomes lower than the pressure at port C, main piston (5) bends check spring (41, takes the oil at port C from port D to port A, and prevents any lack of oil at port A.
7
5
3
SEW02171
4
5 SEW02172
WA30-5
10-15
LOW-PRESSURE RELIEF VALVE
STRUCTURE AND FUNCTION
LOW-PRESSURE RELIEF VALVE
1. Case
2. Shim 3. Poppet spring 4. Poppet
i
i
3
4
361FO2013
Function l
The low-pressure relief valve is installed to the main piston pump, and charges the circuit between the piston pump and piston motor from the low-pressure side of the main piston pump. When the oil pressure in the charge circuit goes above the set pressure, it drains oil to the hydraulic tank. In this way, it sets the pressure of the charge circuit and protects the circuit.
Operation Port A is connected to the main piston pump charge circuit and port B is connected to the drain circuit. If the pressure does not go above the set pressure, no oil flows to port B. If the pressure at port A becomes high for some reason, it pushes pilot poppet (4) and opens the circuit. This allows the oil at port A to escape to port B, and lowers the pressure at port A. The set pressure can be changed by changing the tension of poppet spring (3). To change the set pressure, loosen case (I) and insert adjustment shim (2). To INCREASE the set pressure, insert adjustment shim. To DECREASE the set pressure, take off the adjustment shim.
lo-16
WA365
WORK EQUIPMENT
STRUCTURE AND FUNCTION
WORK EQUIPMENT
l
STEERING
STEERING PUMP, HST CHARGE PUMP
l
PUMP
HST CHARGE PUMP
1. Front cover 2. Gear case (Work equipment 3. Drive gear (Work equipment 4. Driven gear (Work equipment
l
steering
pump)
l
steering
pump)
l
steering
pump)
5. 6. 7. 8.
Outline
Specifications Work equipment steering pump Type : Gear pump Theoretical delivery : 14.5 cc/rev . Rated output pressure : 20.6MPa 1210kg/cm21 . Max speed : 3,500 rpm l
l
l
l
. HST charge pump . Type : Gear pump . Theoretical delivery : 8.6 cc/rev . Rated output pressure : 1.9MPa {20kg/cm21 . Max speed : 3,600 rpm
WA30-5
Gear frame Drive gear (HST charge pump) Driven gear (HST charge pump) Gear cover (HST charge pump)
Work equipment steering pump is installed in the rear of the main pump, and driven by power of the engine and supplied the oil to work equipment circuit or steering circuit through the priority valve. HST charge pump is installed in the rear of the work equipment steering pump supplies the oil to the HST speed related valve and low pressure relief valve of the main piston pump. These pumps suck up oil from the bottom of the hydraulic tank. l
l
10-17 0
CHARGE PUMP OIL FILTER
STRUCTURE AND FUNCTION
CHARGE PUMP OIL FILTER 1. 2. 3. 4.
Relief valve Indicator Case Element
Specifications . Filtering precision: 10 ~1 . Filtering area: 1100 cm2 . Relief pressure: 0.34MPa {3.5kg/cm2) . Indicator actuating pressure: 0.25MPa
{2.5kg/cm21
Operation The oil from the charge pump enters filter inlet port A, passes from the outside of element (4) to the inside, and then flows to outlet port B. l
Charge PUrnP
SEW02847
.
If element (4) becomes clogged with dirt or the oil temperature is low and the pressure at inlet port A increases, indicator (2) is actuated, the pilot lamp on the panel lights up. If the pressure increases further, the oil from inlet port A opens relief valve (I) and flows directly to outlet port B to prevent damage to the pump or element (4).
Charge DUrnD
t!i lo-18
Y___.-e
SEW02848
WA30-5
STRUCTURE AND FUNCTION
SPEED RELATED VALVE (DA VALVE)
SPEED RELATED VALVE (DA VALVE)
Function • The speed related valve is installed to the main piston pump. The oil from the charge pump flows through the throttle valve to the piston pump directional selector valve circuit. The speed related valve also acts as a flow divider to send the oil to the low-pressure relief valve of the piston pump charge circuit.
1. 2. 3. 4. 5. 6.
Nut cover Locknut Adjustment screw Poppet spring Spring seat Pilot poppet
Operation • Port A is connected from the charge pump circuit, port D is connected to the piston pump low-pressure relief valve circuit, and port C is connected to the directional selector valve circuit. The oil from the charge pump passes through the throttle valve of pilot poppet (6), and is always connected from port B to piston pump charge circuit D. With the oil from the charge pump, a difference in pressure is generated at port A and port B by the throttle valve of pilot poppet (6). This actuates pilot poppet (6) and the oil flows from port B to directional selector valve circuit C. • Pilot poppet (6) forms a set with poppet spring (4) and spring seat (5). To change the set pressure, remove nut cover (1), then loosen locknut (2) and turn adjustment screw (3). To INCREASE the set pressure, TIGHTEN the screw To DECREASE the set pressure, LOOSEN the screw
WA30-5
10-19 (2)
STRUCTURE AND FUNCTION
PISTON MOTOR
PISTON MOTOR
1. 2. 3. 4. 5. 6.
Drive shaft Piston Cylinder block Directional shuttle valve Servo valve Port plate
Specifications Model: A6V59DA Type: Variable displacement, bent axis type piston pump Theoretical delivery: 16 – 59 cc/rev Set pressure for high pressure cut-off valve: 34MPa {350kg/cm2} Set pressure for low pressure relief valve: 2MPa {21kg/cm2}
10-20 (2)
WA30-5
STRUCTURE AND FUNCTION
PISTON MOTOR
Operation of piston motor Principle • Assume that the shaft of the disc is supported to allow the disc to rotate freely. If force F acts at an angle on this disc, force F is divided into force F1 acting at right angles to the disc and force F2 acting in the direction of the circumference of the disc. Force F1 pushes the disc in the axial direction, and force F2 rotates the disc clockwise. • Again, if force F’ acts on the disc instead of force F, in the same way, the force is divided into forces F’1 and F’2, and the disc is rotated counterclockwise by force F’2. Outline of structure • Seven pistons (2) are installed with a spherical connection to the disc portion of drive shaft (1). Piston (2) is at a certain angle to drive shaft (1) and is stowed inside cylinder block (3). • The angle of cylinder block (3) and piston (2) is decided by directional shuttle valve (4) and servo valve (5) so that if the external load acting on the motor becomes larger, the angle of piston (2) also becomes larger, so the rotation speed drops and the torque becomes larger. Operation • The oil sent under pressure from the main piston pump enters from the piston motor inlet port. Oil pressure is formed at the rear face of piston (2), and drive shaft (1) is rotated by the angle of piston (2) and the cylinder block. • In the piston motor, the oil from the main piston pump is taken from between the directional selector valve and servo cylinder, and flows to directional shuttle valve (4) of the piston motor. In addition, oil from the motor directional highpressure discharge side is sent to this shuttle valve, and when load is applied to the motor connected to servo valve (5) inside the piston motor, the oil flows to the servo cylinder of the motor because of the difference in pressure from the shuttle valve end, so the angle of the cylinder block becomes greater.
WA30-5
10-21 (2)
STRUCTURE AND FUNCTION
DIRECTIONAL SHUTTLE VALVE
DIRECTIONAL SHUTTLE VALVE
Function • Directional shuttle valve is installed in the rear of the piston motor, which receives the hydraulic signal from the circuit between the directional selector valve and servo cylinder of the piston pump. It detects if directional selector valve is at the FORWARD or REVERSE position and sends the oil to change the position. • It then sends oil in the piston motor high-pressure circuit to the servo valve or servo cylinder.
10-22 (2)
WA30-5
STRUCTURE AND FUNCTION
SERVO VALVE
SERVO VALVE
Function • The servo valve is installed to the rear of the piston motor, and controls the angle of the servo cylinder to provide the output from the motor to handle the external load on the motor. It controls the angle of the servo cylinder of the motor by the differential pressure from the directional selector valve of the piston pump and the pressure from the high-pressure circuit of the motor.
WA30-5
Operation • The oil from the directional selector valve of the piston pump and the oil from the highpressure circuit of the motor passes through the directional shuttle valve and flows to the servo valve. The oil also flows to the small angle side of the servo valve and servo cylinder, and flows to the large angle side through the servo valve. • The servo valve is always switched by the pressure at the directional selector valve end. The servo cylinder of the motor becomes the small angle side of and the servo cylinder is actuated. • When a large load is brought to bear on the high-pressure circuit of the motor, such as when the machine is traveling uphill, a difference in pressure is generated between the circuit at the directional selector valve side of the servo valve and the high-pressure circuit of the motor. The valve circuit is switched, the angle of the servo cylinder becomes larger, and a large torque is generated in the motor.
10-23 (2)
STRUCTURE AND FUNCTION
INCHING VALVE
INCHING VALVE
1. Left brake pedal 2. Inching valve
Outline • This controls the distribution of power when operating and when traveling by reducing the pressure in the high-pressure cut-off valve to match the turning angle of shaft (3) of inching valve (2).
10-24
WA30-5
STRUCTURE AND FUNCTION
TRANSFER
TRANSFER
1. 2. 3. 4. 5. 6. 7.
Input gear (Numbers of teeth: 33) Rear coupling Output shaft Output gear (Numbers of teeth: 64) Foot brake (Also used as parking brake) Front coupling Piston motor
WA30-5
Outline • The transfer is secured by bolts to the rear frame (rubber mount). Path for transmission of power • Piston motor (7) and transfer input gear (1) are secured by a spline, so the power is transmitted to output shaft (3). • Part of the power transmitted to output shaft (3) is transmitted from front coupling (6) through the front drive shaft to the front axle. The other part of the power is transmitted from rear coupling (2) through the rear drive shaft to the rear axle.
10-25 (2)
STRUCTURE AND FUNCTION
HST CONTROL
HST CONTROL
1. Directional selector lever 2. Safety lock 3. Directional selector switch
10-26 (2)
Outline • With the HST control, when directional lever (1) is operated to select forward or reverse, an electric signal flows to the directional selector valve from directional selector switch (3), and this controls the main piston pump.
WA30-5
STRUCTURE AND FUNCTION
DRIVE SHAFT
DRIVE SHAFT
1. Front axle 2. Front drive shaft 3. Rear drive shaft
Outline • The power from the engine drives the main piston pump, and the oil supplied under pressure from the pump rotates the piston motor. The piston motor is installed to transfer (5), and transmits the power through the transfer gear to the rear axle of rear drive shaft (3) on one side, and to the front axle of front drive shaft (2) on the other side. • In addition to simply transmitting the power, the drive shaft also has the following aims. When the machine is articulated, and when
WA30-5
4. Rear axle 5. Transfer
•
there is shock from the road surface during travel operations or shock during operations, the positions of the transfer and front and rear axles change. To allow the power to be transmitted without damage to any parts even when there is impact or change in the position of components, the drive shaft is equipped with a universal joint and sliding connection to enable it to cope with the changes in angle and length.
10-27 (2)
STRUCTURE AND FUNCTION
AXLE
AXLE Front axle
1. 2. 3. 4.
Axle housing Axle shaft Final drive Differential housing
10-28
5. Differential 6. Oil filler port, level plug 7. Drain plug
WA30-5
AXLE
STRUCTURE AND FUNCTION
Rea axle
6
A-A View X
i 362F 05039
1. Axle housing 2. Axle shaft 3. Final drive 4. Differential housing
WA30-5
5. Differential 6. Oil filler port, IeVd 7. Drain plug
plug
1 O-29
STRUCTURE AND FUNCTION
DIFFERENTIAL
DIFFERENTIAL Front differential
362FO5WO
1. Bevel gear (Numbers of teeth: 38) 2. 3. 4. 5. 6.
Shaft Pinion gear (Numbers of teeth: IO) Side gear (Numbers of teeth: 16) Sun gear shaft Bevel pinion (Numbers of teeth: 9)
1O-30
WA30-5
STRUCTURE AND FUNCTION
DIFFERENTIAL
Rear differential
362FO5W2
1. 2. 3. 4. 5. 6.
Bevel gear (Numbers of teeth: 38) Shaft Pinion gear (Numbers of teeth: IO) Side gear (Numbers of teeth: 16) Sun gear shaft Bevel pinion (Numbers of teeth: 9)
WAX-5
10-31
STRUCTURE AND FUNCTION
DIFFERENTIAL
Outline The power from the engine drives the main piston pump, and the oil supplied under pressure from the pump rotates the piston motor. The piston motor is installed to the transfer, and transmits the power through the transfer gear and the front and rear drive shafts to the front and rear axles. In the axle, the motive force is transmitted from bevel pinion (1) to bevel gear (51, shifted 90’ and reduced, and transmitted to sun gear shaft (2) via pinion gear (4). The motive force of the sun gear shaft is further reduced by planetary gear-type final drive, and transmitted to the axle shaft and wheel. SEW00077
When moving straight forward . When moving straight forward,
the speed of rotation of the left and right wheels is equal, so pinion gear (4) in the differential assembly does not rotate, and the motive force of carrier (6) is transmitted equally to the left and right sun gear shafts (2) via the pinion gear (4) and side gear (3).
When slewing . When slewing,
the speed of rotation of the left and right wheels is unequal, so pinion gear (4) and side gear (3) in the differential assembly rotate according to the difference in the left and right rotation speeds, and the motive force of carrier (6) is transmitted to the sun gear shafts (2).
1 O-32
WA3Q-5
STRUCTURE AND FUNCTION
FINAL DRIVE
FINAL DRIVE
362FO5043
%
1. Axle shaft
2. Planetary
carrier 3. Ring gear (Numbers of teeth: 61) 4. Planetary gear (Numbers of teeth: 23) 5. Sun gear shaft (Numbers of teeth: 14)
WA30-5
The differential portion in the drawing is the rear differential, but the final drive is the same for both the front and rear.
Outline l
The final drive carries out the final reduction of the power from the piston motor and increases the drive force.
1o-33
STRUCTURE AND FUNCTION
FINAL DRIVE
Operation of final drive . Ring gear (3) is pressed fitted to the axle housl
ing and is secured with a pin. The power transmitted from the differential to sun gear shaft (5) is then transmitted to planetary gear (41, and the planetary gear rotates inside fixed ring gear (3). When planetary gear (4) rotates, the reduced drive force transmits the increased rotating force to the wheels through planetary carrier (2) and axle shaft (I).
362FO5044
1o-34
WA30-5
STRUCTURE
AXLE MOUNT
AND FUNCTION
AXLE MOUNT
A-A
View 2 362FO50-45
1. 2. 3. 4. 5. 6.
Tension bolt Front frame Rear frame Rear axle Front axle Pivot
WA30-5
Front axle The front axle (5) receives the force directly during operations, so it is fixed directly to the front frame (2) by tension bolts (I). l
Rear axle . The rear axle (4) has a structure which allows the center of the rear axle to float, so that all tires can be in contact with the ground when traveling over soft ground.
1o-35
STRUCTURE
TIRE
l
AND
TIRE
FUNCTION
l
WHEEL
WHEEL
362FO5’346
1. 2. 3.
Tire Rim Air valve
Specifications Tire type: 12.5/70-16-6PR (tubeless) TRA cord: L2 . Nominal wheel: 10 LB x 16DC . Normal air pressure: 0.2 MPa 12.0 kg/cm*) l
l
Function The tires act to absorb the shock from the ground surface to the machine, and at the same time they must rotate in contact with the ground to gain the power which drives the machine.
.
1O-36
WA30-5
CENTER HINGE PIN
STRUCTURE AND FUNCTION
CENTER HINGE PIN
B-B 362FO5048
A-A
1. 2. 3. 4.
Front frame Rear frame Center hinge pin Steering pivot pin
WA30-5
Outline . The front frame
(I) and rear frame (2) are connected through a bearing by the center hinge pin (3). The steering cylinders are connected to the left front and rear frames, so when the cylinders are operated, the frame bends at the middle to give the desired angle, that is the desired turning radius.
1o-37
STRUCTURE AND FUNCTION
STEERING PIPING
STEERING PIPING
362FO5049
1. 2. 3. 4. 5. 6. 7. 8.
Steering wheel Steering valve (orbit roll) Work equipment, steering pump Anti void valve Steering cylinder Hydraulic oil filter Hydraulic tank Priority valve
1 O-38
WA30-5
STRUCTURE AND FUNCTION
STEERING COLUMN
STEERING COLUMN
1. 2. 3. 4.
Steering wheel Steering column Priority valve Steering valve (orbit roll)
WA30-5
10-39 (2)
STRUCTURE AND FUNCTION
PRIORITY VALVE
PRIORITY VALVE
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Plug Valve body Spool Return spring Plug Relief plug Ball Ball guide Valve spring Seat Adjustment screw
10-40 (2)
Outline • The priority valve is in the circuit between the hydraulic and steering pump and the steering valve and main control valve. It acts to divide the oil from the hydraulic and steering pump and to send it to the steering valve or work equipment circuit. It also protects the circuit by setting the pressure of the oil in the circuit from the priority valve to the steering valve at 17.2MPa {175kg/ cm2}.
WA30-5
STRUCTURE AND FUNCTION
Operation of priority valve 1. Steering wheel at neutral The oil discharge from the pump enters port P, passes in turn through priority valve chamber P → chamber CF → orifice Cdy → pressure chamber B → orifice Cls → LS line check valve, enters the LS port of the Orbit-roll, then flows to the tank. When this happens, the balance of the hose of the control spring and the pressure difference at orifice Cdy (dynamic orifice) moves
WA30-5
PRIORITY VALVE
the control spool to the right. As a result, almost all the oil discharged from the pump flows to port EF. The small amount of oil flowing from port CF through the Orbit-roll and finally flowing to the tank acts to preheat the Orbit-roll. In this way, when the steering wheel is at neutral, almost all the oil flow can be used for the work equipment circuit.
10-41 (2)
STRUCTURE AND FUNCTION
2. When steering When the steering wheel is turned to the right, the oil passage inside the Orbit-roll switches as shown in the diagram below. In this condition, the oil entering the Orbit-roll which can be used for the steering is divided into the following two passages. 1 Chamber CF → CF line check valve → Orbit-roll port P → orifice C1 (variable control orifice) → Gerotor → Port R 2 Chamber CF → orifice Cdy → pressure chamber B → orifice Cls → LS line check valve → Orbit-roll port LS → Gerotor → port R When this happens, the balance between the force of the control spring and the difference in pressure between pressure cham-
10-42 (2)
PRIORITY VALVE
bers A and B moves the control spool to the left from the steering wheel neutral position. The size of the area of opening of variable control orifice C1 sends an oil flow necessary for the steering and balances at the position. Except for the low-speed steering circuit area, 1 passage flow > 2 passage flow, so the pressure - oil flow characteristics passing through orifice C1 are important. In other words, when the steering is operated, only the oil flow needed for the steering is sent under priority to the Orbit-roll. The rest can be used for the other actuator circuits.
WA30-5
STRUCTURE AND FUNCTION
3. Steering operated fully When the steering cylinder reaches the end of its stroke, and the operator attempts to turn the steering wheel further, the steering relief valve inside the priority valve relieves the circuit. The relief oil passage is chamber P → chamber CF → orifice Cdy → pressure chamber B → filter → steering relief valve → tank.
WA30-5
PRIORITY VALVE
When this happens, the balance between the force of the control spring and the difference in pressure created by orifice Cdy determines the position of the control spool. The relief flow at this point is approx. 1 - 2 ¬/ min, so when the circuit is relieved, almost all the oil flow can be used for the other actuator circuits.
10-43 (2)
STRUCTURE AND FUNCTION
STEERING VALVE
STEERING VALVE (ORBIT-ROLL)
1. 2. 3. 4. 5.
Needle bearing Cover Center pin Sleeve Priority valve
10-44 (2)
6. 7. 8. 9. 10.
Spool Stator Cover Rotor Valve body
11. Drive shaft 12. Centering spring 13. Check valve
WA30-5
STRUCTURE AND FUNCTION
STEERING VALVE
Outline • The steering system is a fully hydraulic type, and an amount of oil to match the amount that the steering wheel is turned is sent by the steering valve to the steering cylinders. • In addition, this valve is a built-in hand pump, so if the pump or engine fails, it sucks in oil directly from the tank and makes it possible to carry out steering. Structure • The shaft connected to the steering wheel is meshed with the spline at the top of the spool, and spool (10) is fitted inside sleeve (9). • In addition, the spool and sleeve are connected by center pin (7) (this does not touch the spool when the steering wheel is not being operated) and centering spring (4). • Drive shaft (3) is inside the spool. The top is meshed to the center pin and the bottom is meshed to the spline of hand pump rotor (1). • This hand pump acts to adjust the amount of oil sent to the cylinder according to the amount that the steering wheel is turned. At the same time, if the pump or engine fails, the turning force of the steering wheel is used to suck in oil directly from the tank and send it to the cylinder. • There are 4 ports in the valve body, and these are connected to the pump circuit, tank circuit, and the steering cylinder head and steering cylinder bottom circuits. In addition, the port at the pump end and the port at the tank end are connected by the check valves inside the body, so if the pump or engine fail, these check valves act to suck in oil directly from the tank.
WA30-5
10-45
STRUCTURE AND FUNCTION
STEERING VALVE
Operation of steering valve 1) When steering wheel is not being operated
•
•
•
When the steering wheel is not being operated, center pin (3) is set to a position at the center of the oblong hole in the spool (6) by centering spring (12), and the spool and sleeve (4) remain in the same position. For this reason, the vertical grooves of the spool and each port going to the cylinder of the sleeve and the hand pump are shut off, and the small holes (2 holes each at 12 points around the circumference) at the bottom of the sleeve and spool are connected. The oil sent from the pump goes from the inlet port of the valve through the small holes in the spool and sleeve, flows inside the spool, then flows out from the spool oblong hole and spring mount to the valve outlet port, and is drained to the tank.
10-46 (2)
WA30-5
STRUCTURE AND FUNCTION
STEERING VALVE
2) When steering wheel is turned (turning to left)
•
•
When the steering wheel is turned to the left, spool (6), which is connected by the steering shaft spline, turns to the left. However, sleeve (4) and the spool are interconnected by centering spring (12), so the spool compresses the centering spring. A difference in the turning angle of the spool and sleeve is created which is equal to the amount of compression of the centering spring. Because of this difference, the ports in the sleeve are connected with the vertical grooves cut in the spool. This connection joins the hand pump port in the sleeve and the steering cylinder head end (the end steering to the left), and the valve outlet port and the steering cylinder
WA30-5
•
•
bottom end (the end steering to the right) through the vertical grooves in the spool. The oil sent from the pump flows from the valve inlet port to the hand pump and returns to the sleeve. From the vertical groove in the spool, it flows to the steering cylinder head port in the sleeve. In addition, the oil at the steering cylinder bottom end flows from the sleeve port through the vertical groove in the spool and is drained to the tank. When the operation of the steering wheel is stopped, the difference in rotation of the sleeve and spool is returned to the non-operated position by the centering spring.
10-47 (2)
STRUCTURE AND FUNCTION
STEERING VALVE
3) Steering when pump fails (turning right)
•
•
If the pump or the engine fail, and the machine has to be towed, it is dangerous if the steering does not work normally. For this reason, there is a built-in hand pump at the bottom of the steering valve. When the situation is normal, this hand pump acts only to control the oil flow, and receives rotating force from the pressure oil, but if the pressure oil from the pump stops, center pin (3) hits the end face of the oblong hole in spool (6), and the turning force of the steering wheel acts as the drive force for the hand pump.
10-48 (2)
•
•
•
In this case, in the same way as in item 2) on the previous page, a difference in the rotation of spool (6) and sleeve (4) is created, and the ports of the sleeve are connected with the vertical grooves in the spool. When the steering wheel is turned, the hand pump turns. At the suction portion of the hand pump, oil is sucked in directly from the tank through check valve (13) between the inlet port and outlet port of the valve, and oil is sent to the bottom end of the steering cylinder from the discharge portion. The hand pump is similar to a trochoid pump, but there are ports at the bottom of the stator teeth, and these carry out suction and discharge.
WA30-5
STRUCTURE
Connection
AND
FUNCTION
between
hand pump
STEERING
and sleeve
“““““’ (Fig. 1)
l
.
The diagrams above show the connections with the sleeve ports used to connect the suction and discharge ports of the hand pump. If the steering wheel has been turned to the right, ports a, c, e, g, i, and k are connected by the vertical grooves in the spoof to the pump side. At the same time, ports b, d, f, h, j, and I are connected to the head end of the left steering cylinder in the same way. In the condition in Fig. 1, ports 1, 2, and 3 are the discharge ports of the hand pump set. They are connected to ports I, b, and d, so the oil is sent to the cylinder. Ports 5,6, and 7 are connected and the oil flows in from the pump. If the steering wheel is turned 90°, the condition changes to the condition shown in Fig. 2. In this case, ports 1,2, and 3 are the suction ports, and are connected to ports i, k, and c. Ports 5,6, and 7 are the discharge ports, and are connected to ports d, f, and h.
WA30-5
VALVE
J
111
G SBWO0726
(Fig. 2)
Suctiion I discharge port /
SBWOO727
SBWOO726
10-49
STRUCTURE
AND
STEERING
FUNCTION
In this way, the ports acting as the discharge ports of the hand pump are connected to the ports going to the steering cylinder, while the ports acting as the suction ports are connected to the pump circuit.
If the pump or engine fail, the suction and discharge of this hand pump is carried out forcibly and oil is sent to the steering cylinder, so it is possible to carry out steering.
Differences between trochoid steering pump hand pump
.
Trochoid
pump
l
.
VALVE
To carry out adjustment of the discharge amount to match the amount the steering wheel is turned, the oil from the pump always passes through this hand pump, and for each l/7 turn of the steering wheel, the internal tooth gear of the hand pump advances by one tooth. An amount of oil equal to this movement is discharged, so the discharge oil amount is directly proportional to the amount the steering wheel is turned. If the pump or engine should fail, the condition is exactly the same, so the same amount of oil is discharged as when the pump is normal.
and
pump
I
2
6
3
SEP02252 l
.
The trochoid pump is divided into an inlet port and an outlet port, and when the shaft rotates as shown in the diagram above, oil is sucked in from the inlet port and discharged from the outlet port as shown in 2 6. Steering
I
pump
hand pump
2
3
4
6 SEP02253
.
In the case of the hand pump, there are inlet ports and outlet ports at the bottom of the internal teeth of the stator, and when the shaft is rotated, the steering pump and port are connected as shown in 2 - 3 in the diagram above, and oil is sucked in. If the shaft rotated further, the steering cylinder and port are connected as shown in 5 - 6, and the oil is delivered to the cylinder. This action is carried out at each port.
1O-50
WA30-5
STRUCTURE
STEERING
AND FUNCTION
Role of centering spring . Centering spring (4) consists of four X-shaped leaf springs and two flat leaf springs. It is assembled between spool (IO) and sleeve (9) as shown in the diagram on the right. When the steering wheel is turned, the spool compresses the spring, and a difference (angle variation) is generated in the turning angle of the spool and sleeve. As a result, the port of the spool and sleeve is connected and oil is sent to the cylinder. However, when the rotation of the steering wheel is stopped, the rotation of the hand pump also stops, so no more oil is sent to the cylinder, and the oil pressure rises. To prevent this, when the turning of the steering wheel is stopped, the action of the centering spring only allows it to turn by an amount equal to the difference in angle of rotation (angle variation) of the sleeve and spool, so the steering wheel returns to the NEUTRAL position.
VALVE
Anale variation
4 SDW02868
WAD5
1o-51
BRAKE, PARKING BRAKE CONTROL
STRUCTURE AND FUNCTION
BRAKE, PARKING BRAKE CONTROL
A-A
a 362FO5061
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Right brake pedal Parking brake release lever Left brake pedal Parking brake pedal Multiple disc brake lever Control cable Link Multiple disc brake Inching valve Accellerator pedal
1o-52
Outline When right brake pedal (I) is depressed, brake lever (5) is pulled up by link (7) and control cable (61, and the multiple disc brake installed to the transfer output shaft is actuated. Left brake pedal (3) is interconnected with inching valve (9) by a link. When the left brake pedal is depressed, the inching valve is actuated, and the swash plate of the piston pump moves together with the angle of the pedal towards the neutral position. After it moves to the neutral position, the brake is applied. The parking brake is actuated by depressing parking pedal (4) and braking force is applied to the output shaft in the same way as with the right brake pedal. The parking brake is released by pulling parking brake release lever (2).
WA30-5
STRUCTURE AND FUNCTION
BRAKE (ALSO USED AS PARKING BRAKE)
BRAKE (ALSO USED AS PARKING BRAKE)
1. 2. 3. 4. 5. 6. 7. 8.
Transfer Transfer output shaft Disc Plate Piston Housing Ball Lever
WA30-5
Outline • Brake (also used as parking brake) is a mechanically operated wet type multiple disc brake which applies braking force to transfer output shaft (2). • Lever (8) is connected to the control cable, and when the lever is pulled, ball (7), which is between housing (6) and piston (5) connected to the lever, moves on the slope of the piston groove. The piston pushes the discs and plates together, and applies braking force to output shaft (2).
10-53 (2)
STRUCTURE AND FUNCTION
WORK EQUIPMENT PIPING
WORK EQUIPMENT PIPING
1. 2. 3. 4. 5.
Outline • The hydraulic system consists of the work equipment circuit and steering circuit. The work equipment circuit controls the operation of the bucket or attachment. • The oil in hydraulic tank (7) is sent from hydraulic and steering pump (6) to priority valve (3). Here the flow is divided and sent to main control valve (10). • When the dump and lift spools of main control valve (10) are at NEUTRAL, the oil from main control valve (10) passes through the drain circuit, is filtered by hydraulic filter (8), and returns to the hydraulic tank.
10-54 1
6. 7. 8. 9. 10.
Lift cylinder Dump cylinder Priority valve Steering valve Work equipment lever
•
•
•
Work equipment, steering pump Hydraulic tank Hydraulic filter Steering cylinder Main control valve
When work equipment lever (5) is operated, the dump or lift spool of main control valve (10) is actuated. Oil flows from main control valve (10) to lift cylinder (1) or dump cylinder (2) to operate the boom or bucket. The maximum pressure setting of the hydraulic circuit is carried out by the relief valve inside the main control valve and the priority valve. A safety valve (with suction) is installed to the bucket cylinder circuit to protect the circuit. Hydraulic tank (7) is a sealed type.
WA30-5
STRUCTURE AND FUNCTION
WORK EQUIPMENT
HYDRAULIC
SYSTEM
DIAGRAM
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM Engine
running,
control
lever at neutral
SWW04638
lo-56 0
WA30-5
STRUCTURE AND FUNCTION
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
1. 2. 3. 4. 5. 6. 7. 8.
Hydraulic tank Hydraulic filter Work equipment, Steering Pump HST charge pump HST main piston pump Priority valve Steering valve Relief valve Set Pressure : 17.2 MPa {175 kg/cm2}
WA30-5
9. Anti void valve 10. Steering cylinder 11. Main relief valve Set Pressure : 20.6 MPa {210 kg/cm2} 12. Service spool 13. Suction safety valve Set pressure : 22.6 MPa {230 kg/cm2} 14. Dump spool 15. Lift spool
16. 17. 18. 19.
Suction valve Lift cylinder Dump cylinder Service cylinder
10-57 (2)
STRUCTURE AND FUNCTION
WORK EQUIPMENT LEVER LINKAGE
WORK EQUIPMENT LEVER LINKAGE
1. 2. 3. 4.
Main control valve Work equipment lever Lock lever Operation mode select lever
10-58
WA30-5
STRUCTURE AND FUNCTION
HYDRAULIC TANK
HYDRAULIC TANK
1. 2. 3. 4. 5.
Hydraulic tank Oil filler port Oil level gauge Drain plug Hydraulic filter
WA30-5
Outline • The oil from the hydraulic tank passing through the pump, priority valve, steering valve, and main control valve and sent to the cylinders merges with the oil from other parts in the return circuit. It is filtered by the hydraulic filter and returns to the tank. • The hydraulic filter filters all the oil flow in the circuit, and when the oil filter becomes clogged, the bypass valve is actuated to return the oil directly to the tank in order to prevent damage to the filter.
10-59 1
STRUCTURE AND FUNCTION
HYDRAULIC FILTER
HYDRAULIC FILTER
1. 2. 3. 4.
Bypass valve Body Element Cartridge
10-60 (2)
Specifications Filtering precision: 10 microns Bypass valve cracking pressure: 0.25MPa {2.5kg/cm2}
WA30-5
MAIN CONTROL VALVE
STRUCTURE AND FUNCTION
MAIN CONTROL VALVE
sww04640
1. 2. 3. 4. 5. 6. 7, 8.
Lift spool Dump spool Service spool Main relief valve Suction safety valve Suction valve Check valve Magnet for dump
1O-62 0
Al. A2. A3. Bl. 82. B3. PI. T.
To attachment circuit To dump cylinder head end To Lift cylinder head end To attachment circuit To dump cylinder bottom end To Lift cylinder bottom end Pump port Drain port (to tank)
.WA30-5
MAIN CONTROL VALVE
STRUCTURE AND FUNCTION
A-A
Outline . The main control valve is a control valve which controls the operation of the bucket and attachments in the hydraulic system. It is a tandem circuit for the bucket priority circuit. . The oil from the pump enters port h and the maximum pressure is set by the relief valve. The oil passes through the bypass circuits of service spool (2) and dump spool (3) and lift spool (41, flows from port g to the drain circuit, then passes through the filter and returns to the tank. If the dump and lift spools are actuated, the oil flows to the dump and lift cylinders.
WA30-5
SWWO4641
.
However, a bucket priority circuit is used, so when the dump spool is operated, the lift is not actuated even if the lift spool is operated. Two safety valves (with suction) (5) are installed to protect the circuit if abnormal pres-. sure is generated in the bucket circuit. The two safety valves have two functions: acting as relief valves and acting as suction valves to compensate for lack of oil.
lo-63 a
STRUCTURE
AND
MAIN
FUNCTION
Main control valve operation Lift and dump spools at NEUTRAL
CONTROL
VALVE
position
FLOAT ?-I
1/1111,,,,, 1111/111,,,,,,,, 11111//1,,,,,,, /111,,,,//,,,,, ~11111,///,,,,, ~~1111,1//,,,, /111,,/,/,,,,, /1/1,,,//,,,,,
Operation l The oil from hydraulic pump (1) passes through the priority valve, and enters port A. The maximum pressure is set by relief valve (2). l Service spool (9) and dump spool (3) is at the neutral position, so the bypass circuit is open and the oil in port A passes around
lo-64 0
the spool and flows to port B. Lift spool (4) is also at the neutral position, so the bypass circuit is open and the oil in port B passes around the spool, enters port C of the drain circuit, passes through the filter (71, and returns to the tank (8).
WA30-5
MAIN CONTROL VALVE
STRUCTURE AND FUNCTION
Lift spool at RAISE position
FLOAT 3 LOWER ':
D
DUMP
SWWO4643
Operation l
l
When the main control lever is pulled, lift spool (4) is pushed in to the RAISE position. The oil from the pump (I) flows through the bypass circuit of the service spool (9) and dump spool (3) and flows to the bypass circuit of lift spool (4). The bypass circuit is closed by the spool, so the oil from port B pushes check valve (5) open.
WA3Q-5
l
The oil from port B then flows from port E to the bottom end of the lift cylinder. At the same time, the oil at the cylinder head end flows from port D to drain port C and returns to the tank (8). As a result, the lift arm is raised.
1 O-65 0
MAIN CONTROL VALVE
STRUCTURE AND FUNCTION
Lift spool at FLOAT position
DUMP
To steer valve
SWW04644
Operation . If the main control is pushed beyond the LOWER position, lift spool (4) is pulled out l
to the FLOAT position. The oil from the pump passes around the bypass circuit of the service spool (9) and dump spool (3) and flows to the lift spool bypass circuit. The oil in the bypass circuit is sent to the drain circuit by the spool and cannot push open check valve (5). Both the
l
RAISE circuit E and LOWER circuit D of the lift cylinder are connected to the drain circuit, so the lift arm goes down under its own weight. When the bucket is in contact with the ground surface, the bucket can move up or down in accordance with the shape of the ground surface.
WA30-5
MAIN CONTROL VALVE
STRUCTURE AND FUNCTION
Dump spool at DUMP position
FLOAT 9
DUMP
SWW04645
Operation l
l
When the main control lever is pushed to right side, dump spool (3) is pulled out to the DUMP position. The bypass circuit is closed by the spool, so the oil from port A pushes open check valve (6). The oil from port A then flows from port H to the rod end of the cylinder.
WA30-5
l
At the same time, the oil at the cylinder bottom flows from port G to drain port C, and returns to the tank. As a result, the bucket is dumping.
1O-67 0
STRUCTURE AND FUNCTION
MAIN CONTROL VALVE
Service spool operation
D
DUMP
SWW04646
Operation l
When the service valve (9) is pulled to right direction show by an illustration, the bypass circuit is closed so the oil from port A pushes open check valve (IO). The oil from port A then flows from port K to service circuit.
l
At the same time, the oil at the service circuit flows from port J to drain port C, and returns to the tank.
WA30-5
STRUCTURE
AND
WORK EQUIPMENT
1. 2. 3. 4. 5. 6.
WORK
FUNCTION
EQUIPMENT
LINKAGE
LINKAGE
Bucket Bell crank Dump cylinder Lift cylinder Lift arm Bucket link
WA30-5
1 O-69 0
BUCKET
STRUCTURE AND FUNCTION
BUCKET
A-A 362FO5077
1. Bucket (0.4 m3) 2. Cutting edge (Bolt on type)
WA30-5
10-71 0
STRUCTURE AND FUNCTION
BUCKET POSITIONER
BUCKET POSITIONER
1. Bucket cylinder rod switch
2. Proximity 3. Lever
View i!
Outline The bucket positioner is an electrically actuated system which is used to set the bucket to the desired angle when the bucket is moved from the DUMP position to the TILT position. When the bucket reaches the desired position, the bucket lever is returned from the TILT position to the NEUTRAL position, and the bucket is automatically set to the suitable digging angle. Lever (3) is secured to bucket cylinder rod (I) by bolts. In addition, proximity switch (2) fixed to the cylinder by bolts. When the bucket is moved from the DUMP position to the TILT position, the bucket cylinder rod moves to the left, and at the same time, lever (3) also moves to the left. Proximity switch (2) separates from lever (2) at the desired position, and the bucket lever is returned to neutral.
1 O-72 0
42AFO3005
42AFO3006
WA30-5
STRUCTURE
AND
PROXIMITY
FUNCTION
SWITCH
PROXIMITY SWITCH l
Detector
TILT
The proximiq switch is installed to the bucket dump cylinder by a support. If the bucket is moved to the tilt back position to match the operating condition, and it reaches the desired position that matches the operating condition, the current from the proximity switch is cut off, and the bucket lever is returned to the neutral position. Therefore, the main control valve is also set to neutral, and the movement of the bucket stops.
(steel
date1
I DUMP
Main
control
valve positioner
n% Operation . When the bucket is at the dump side of the position set by the bucket positioner, the detector (steel plate) is positioned above the detector surface of the bucket proximity switch. Electric current flows from starting switch terminal BR to positioner relay terminal 1 - 2 + bucket proximity switch termiBecause of this, nal 2 - 3 + ground. positioner relay terminals 3 and 5 are closed, and the electricity from the battery flows from starting switch terminal BR + positioner relay terminal 3 - 5 + positioner magnet + ground. When the bucket lever is moved to the TILT position, the dump spool is held at the tilt position by the magnet at the dump spool detent of the main control valve, and the bucket is tilted.
.
SDW02881
As the bucket is tilted, and the bucket moves away from the set position of the bucket positioner (that is, the detector (steel plate) moves away from the detector surface of the proximity switch), the electric current from the proximity switch is shut off, positioner relay terminals 3 and 5 are opened, and the electric current to the positioner magnet is cut. When this happens, the bucket spool is returned to the neutral position by the return spring.
l
Operation
of proximity
switch
Position
When detector is positioned at detector surface of proximity switch
When detector is separated from detector surface of proximity switch
Proximity
switch
Current flows from proximity switch to positioner relay
Current from proximity switch to positioner relay is cut
Positioner
relay
Current magnet
Current is cut
Positioner
magnet
Electricity flows (magnet is actuated)
WA30-5
flows
to
positioner
Electricity actuated)
to positioner
is cut (magnet
magnet
is not
10-73 0
ROPS CANOPY
STRUCTURE AND FUNCTION
ROPS CANOPY
‘\
/
SWWO4648
1. ROPS canopy
2. ROPS bracket L.H. 3. ROPS bracket
1o-74 0
R.H.
WA30-5
CENTRAL PANEL (CLUSTER GAUGE)
STRUCTURE AND FUNCTION
CENTRAL PANEL (CLUSTER GAUGE)
Ii
il
IO
9
.7 SWW04649
1. Service meter 2. Fuel gauge 3. Turn signal pilot lamp 4. Tachometer 5. Engine water temperature gauge 6. HST oil temperature gauge
WA30-5
7. 8. 9. 10. 11. 12.
HST oil Parking Engine Battery Preheat Parking
filter clogging alarm pilot lamp brake pilot lamp oil pressure warning lamp charge warning lamp pilot lamp brake not applied caution lamp
1o-75 a
STRUCTURE
AND
ENGINE START CIRCUIT .
ENGINE START CIRCUIT ENGINE STOP CIRCUIT
FUNCTION
Start
Turning the start switch “on”, connecting the electricity in the order of battery (+) + starting switch B terminal - BK terminal + engine stop relay and engine stop timer. Then, through the relay to add load to the stop solenoid. The stop solenoid has the circuits of HOLD, Pull (suction) and earth. The time for relay and timer to control the current to flow into the stop solenoid is about 1 second, the solenoid will start to work and the suction is cut off. The “HOLD” is kept with electricity for the battery role. Therefor, the spray pump governor lever works, fuel circuit opens and engine starts.
ENGINE STOP CIRCUIT .
Turning the switch to OFF from on, the current of the battery (+) is cut off between starting switch B terminal and BR terminals. So, the current in the HOLD circuit of the engine stop solenoid is cut off and the engine stop solenoid returns to the original position. The spay pump governor lever works and cuts off the fuel circuit. The engine stops
1 O-76 0
tnelne
Governor
stop
lever
Engine relay
stop
engine
Governor
stop
stop
lever
ensine relay
stop
WA30-5
STRUCTURE AND FUNCTION
PREHEATING CIRCUIT
PREHEATING CIRCUIT •
Turning the starting switch towards the left from the OFF position for one scale to the preheating position. B terminal is connected with R1 terminal. The current flows in the order of battery (+) → start switch B terminal – R1 terminal → air heater and air heater timer → heater signal.
WA30-5
10-77 1
STRUCTURE AND FUNCTION
PARKING BRAKE CIRCUIT
PARKING BRAKE CIRCUIT *1. Serial No. 22005 – 26000 *2. Serial No. 26001 and up
Parking brake drag prevention device • When parking brake is applied, the parking brake switch is OFF and electric current does not flow into terminal (1) of parking brake relay, so terminal (3) and terminal (6) are connected. • Therefore, the electricity flows in a circuit from starting switch ACC terminal – parking brake action detection relay (1) to terminal (2) – parking brake action detection relay (6) to terminal (3) – to ground, so terminal (3) – (6) of parking brake action detection relay open and current from terminal (6) is cut off and does not flow to FR solenoid. • In this way, when parking brake is applied, if directional lever to put into F or R, electricity current does not flow to solenoid, so machine does not start.
10-78 (2)
Parking brake not applied prevention device • when the parking brake is released, the parking brake switch is ON and electricity flows from starting switch terminal B – parking brake switch – parking brake relay (1) to terminal (2) – ground, and terminal (3) and terminal (6) are connected. • When the engine is stopped, terminal (3) and terminal (6) of engine speed sensor relay are connected, and current flows from starting switch terminal B – alarm buzzer engine speed sensor relay (3) to terminal (6) – parking brake relay (5) to terminal (3) – ground, so the alarm buzzer sounds. In addition, electricity flows in the circuit from starting switch terminal B to parking brake not applied caution lamp, and the lamp lights up.
WA30-5
20 TESTING AND ADJUSTING Standard value table for engine ...................... Standard value table for chassis ...................... Table of tools for testing, adjusting, and troubleshooting ................................... Adjusting valve clearance ................................. Measuring compression pressure .................... Testing and adjusting fuel injection timing .... Bleeding air from fuel circuit............................ Testing and adjusting fan belt tension ........... Testing for abnormality in fuel level sensor .... Measuring accelerator pedal ............................ Measuring operating effort, travel of directional lever ...................................... Measuring stall speed ....................................... Measuring HST oil pressure ............................. Testing and adjusting steering wheel ............. Measuring operating time for steering wheel ....................................... Measuring steering pressure ............................ Testing and adjusting brake pedal ..................
2020-
2 3
2020202020202020-
8 9 10 11 13 -4 14 15 16
20202020-
18 19 20 21
Measuring operating effort, travel of brake pedal ............................................. Measuring brake performance ......................... Measuring parking brake performance ........... Measuring brake disk wear .............................. Testing and adjusting inching valve linkage ............................................... Measuring and adjusting work equipment control lever............................. Measuring travel of main control valve spool .................................................. Measuring work equipment pressure ............. Testing and adjusting bucket positioner ......... TROUBLESHOOTING .........................................
20202020-
26 27 28 29
20- 30 20- 31 20- 33 20- 34 20- 36 20- 201
20- 22 20- 23 20- 24
fl
When using the standard value table to make judgement for testing and adjusting, and troubleshooting, the following precautions are necessary.
1.
The standard values in the table are the values for a new machine and are given as reference values for the time when the machine is shipped from the factory. These values should be used as a guide when estimating wear and tear after the machine is operated, and when carrying out repairs.
2.
The permissible values given in the table are values estimated based on the results of various tests carried out on the machines shipped from the factory, so they should be used together with the information on the repair condition and other information such as the operating history of the machine when judging the condition of the machine.
3.
These standard values do not form a basis for judging claims.
¤ When
carrying out testing, adjusting, or troubleshooting, park the machine on level ground and use the safety pins and blocks to prevent the machine from moving.
¤ When carrying out work together with other workers, always use signals and do not let unauthorized people near the machine.
¤ When checking the water level, always wait for the water to cool down. If the radiator cap is removed when the water is still hot, the water will spurt out and cause burns.
¤ Be careful not to get caught in the fan, fan belt, or other rotating parts.
WA30-5
20-1 (3)
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE Serial No. 22005 – 26000 Machine Model
WA30-5
Engine
3D84E-3D
Item
Measurement conditions
Unit
High idling Engine speed
2,275 ± 50
— —
2,500
—
Max. 3.5
Min. 5.5
Max. 1.5
Min. 2.5
0.2
—
0.2
—
MPa {kg/cm2}
Min. 3.2 {Min. 33}
2.5 {26}
%
Max. 0.8
Min. 1.2
At rated speed MPa (SAE10W-30) {kg/cm2}
0.34 – 0,49 {3.5 – 5.0}
—
At low idling (SAE10W-30)
Min. 0.15 {Min. 1.5}
Max. 0.1 {Max. 1.05}
Max. 120
—
Low idling
At sudden acceleration Exhaust gas color At high idling
Compression pressure
Service limit value
+50 950 –25
rpm
Rated speed
Valve clearance (cold)
Standard value for new machine
Bosch index
Intake valve mm Exhaust valve Oil temperature: 40 – 60°C (engine speed: 250 rpm) High idling
Blow by ratio
(At 1/3 lower part of the white range of the engine water temperature gauge)
(Water temperature: Operating range) Oil pressure
Oil temperature
Whole speed range (inside oil pan)
Fuel injection timing
Before top dead center degree
14 ± 1
14 ± 1
Fan belt tension
Deflection when pressed with finger force of approx. 58.8 N {6 kg}. (Alternator pulley – Fan pulley)
10 – 15
—
20-2 (3)
°C
mm
WA30-5
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE
Serial No. 26001 and up Machine Model
WA30-5
Engine
3D84E-5X
Item
Measurement conditions
Unit
High idling Engine speed
2,275 ± 50
— —
2,500
—
Max. 4.0
Min. 5.5
Max. 1.5
Min. 2.5
0.2
—
0.2
—
MPa {kg/cm2}
Min. 3.2 {Min. 33}
2.5 {26}
%
Max. 0.8
Min. 1.2
At rated speed MPa (SAE10W-30) {kg/cm2}
0.39 – 0.54 {4.0 – 5.5}
—
At low idling (SAE10W-30)
Min. 0.15 {Min. 1.5}
Max. 0.1 {Max. 1.05}
Max. 120
—
Low idling
At sudden acceleration Exhaust gas color At high idling
Compression pressure
Service limit value
+50 950 –25
rpm
Rated speed
Valve clearance (cold)
Standard value for new machine
Bosch index
Intake valve mm Exhaust valve Oil temperature: 40 – 60°C (engine speed: 250 rpm) High idling
Blow by ratio
(At 1/3 lower part of the white range of the engine water temperature gauge)
(Water temperature: Operating range) Oil pressure
Oil temperature
Whole speed range (inside oil pan)
Fuel injection timing
Before top dead center degree
15 ± 1
15 ± 1
Fan belt tension
Deflection when pressed with finger force of approx. 58.8 N {6 kg}. (Alternator pulley – Fan pulley)
8 – 10
—
WA30-5
°C
mm
20-2-1 (3)
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS Model Category
Item
Measurement conditions A: Low idling B: high idling
Accelerator pedal
Operating effort
Operating angle
WA30-5
Directional lever
HST oil pressure
N {kg}
α1
Service limit value
29.4 – 78.4 {3.0 – 8.0}
Min. 107.9 {Min. 11.0}
50 ± 5
—
Deg. (*1) 20 ± 3
—
(*2) 15 ± 3
—
(*1) 30 ± 3
—
(*2) 40 ± 3
—
N {kg}
6.9 – 14.7 {0.7 – 1.5}
Min. 17.6 {Min. 1.8}
mm
40 ± 10
40 ± 15
+1.96 34.3 –0.49
+2.94 34.3 –0.98
{350 +20 –5 }
+30 {350 –10 }
1.47 +0.29 –0.10
1.57 +0.39 –0.20
{15 +3 –1 }
{16 +4 –2 }
1.96 ± 0.20 {20 ± 2}
1.96 ± 0.29 {20 ± 3}
2,400 ± 100
2,400 ± 150
2,450 ± 100
2,450 ± 150
α2
Stopper height H
mm • Engine stopped
N–F
• Engine water temperature: 1/3 of the lower part of the white range
N–R
Operating effort
N–F
Travel N–R High-pressure cut off pressure (High-pressure relief pressure) Low-pressure relief pressure
• Engine water temperature: 1/3 of the lower part of the white range • Hydraulic oil temperature: 45 – 55°C • • • • •
Stall
HST stall
Steering wheel
Control pressure
Play
Priority valve
Standard value Unit for new machine
Hydraulic stall
Operating effort
Operating time
Relief pressure
MPa {kg/cm2}
F or R Low idling Neutral Rated speed Neutral
• Engine water temprature: 1/3 of the lower part of the white range • Hydraulic oil temperature: 45 – 55˚C
rpm
• Engine stopped • Machine facing straight
mm
10 – 20
Min. 40
N {kg}
9.8 – 4.9 {1.0 – 0.5}
Min. 29.4 {Min. 3.0}
Max. 3.5
Min. 3.8
Max. 2.0
Min. 2.5
17.2 +0.29 –0.98
17.2 +0.49 –1.47
{175 +3 –10 }
{175 +3 –15 }
• Hydraulic oil temperature: 45 – 55˚C • Engine speed: Low idling Low idle • Flat, horizontal, straight, dry paved road surface high idle • Hydraulic oil pressure: 45 – 55˚C • Engine speed: High idling
Deg.
MPa {kg/cm2}
*1. For serial No. 22005 – 26000 *2. For serial No. 26001 and up
WA30-5
20-3 (3)
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
Model Category
Parking brake
Brake
Pedal
Item
WA30-5
Measurement conditions
Standard value Unit for new machine N {kg}
196 {20}
Min. 392.3 {Min. 40}
mm
70 ± 10
Min. 85
m
Max. 3.0
Min. 3.0
mm
4.7 ± 0.08
Max. 4.25
3–6
Min. 8
35 – 50
—
+0.5 24.5 +4.9 –9.8 {2.5 –1.0}
Min. 42.2 {Min. 4.3}
+0.5 24.5 +4.9 –9.8 {2.5 –1.0}
Min. 42.2 {Min. 4.3}
HOLD → LOWER
+0.5 24.5 +4.9 –9.8 {2.5 –1.0}
Min. 42.2 {Min. 4.3}
LOWER → HOLD
+0.5 24.5 +4.9 –9.8 {2.5 –1.0}
Min. 42.2 {Min. 4.3}
+0.5 49.5 +4.9 –9.8 {5.0 –1.0}
Min. 73.6 {Min. 7.5}
FLOAT → HOLD
+0.5 29.4 +4.9 –9.8 {3.0 –1.0}
Min. 53.9 {Min. 5.5}
HOLD → DUMP
+0.5 24.5 +4.9 –9.8 {2.5 –1.0}
Min. 42.2 {Min. 4.3}
HOLD → TILT
+0.5 24.5 +4.9 –9.8 {2.5 –1.0}
Min. 42.2 {Min. 4.3}
TILT → HOLD
+0.5 24.5 +4.9 –9.8 {2.5 –1.0}
Min. 42.2 {Min. 4.3}
85 ± 15
85 ± 30
85 ± 15
85 ± 30
130 ± 15
130 ± 30
HOLD ↔ DUMP
75 ± 15
80 ± 30
HOLD ↔ TILT
75 ± 15
80 ± 30
Operating effort — Travel
Performance
• Flat, horizontal, straight, dry paved road surface • Speed when applying brake: 15 km/h • Braking delay: Within 0.1 sec • Brake pedal operating effort: 490N {50kg} • Tire inflation pressure: Specified pressure
Disc wear
• Measuring thickness of disc
Performance
• Tire inflation pressure: Specified pressure • Flat paved road with 1/5 (11°20') grade, dry road surface • Machine at operating condition
Pedal travel
• Operating effort: 196 N {20kg} (Notch)
Releasing lever travel
—
—
mm
Operating effort
Work equipment control lever
• Hydraulic oil HOLD → RAISE temperature: 45 – 55˚C RAISE → HOLD • Engine speed: Low idling Lift lever
LOWER → FLOAT
Dump lever
Travel
Lift lever
Service limit value
N {kg}
• Hydraulic oil HOLD ↔ RAISE temperature: 45 – 55˚C HOLD ↔ LOWER • Engine speed: Low idling • From the center HOLD ↔ FLOAT mm of play
Dump lever
20-4
WA30-5
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
Model
Work equipment control valve
Category
Item Relief pressure
Lift spool travel
WA30-5
Measurement conditions
Standard value Unit for new machine
• Hydraulic oil temperature: MPa +10 20.59 +0.98 –0.49 {210 –5 } 45 – 55˚C {kg/cm2} • Hydraulic oil HOLD → RAISE temperature: 45 – 55˚C HOLD → LOWER • Engine speed: Low idling HOLD → FLOAT
Service limit value +15 20.59 +1.47 –1.47 {210 –15 }
7.2 ± 0.5
—
12.8 ± 0.5
—
7.2 ± 0.5
—
Sec.
4.4 ± 0.3
Min. 6.6
Sec.
2.7 ± 0.5
Min. 4.0
mm
HOLD → DUMP
Dump spool travel HOLD → TILT
Work equipment speed
Time for lift arm raising
Time for lift arm lowering
WA30-5
• Engine water temperature, 1/3 of the lower part of the white range • Hydraulic oil temperature: 45 – 55˚C • Engine speed: High idling • Machine facing straight • Bucket lowered to ground (bucket bottom face horizontal). Time taken to move to max. lifting height of boom
• Engine water temperature, 1/3 of the lower part of the white range • Hydraulic oil temperature: 45 – 55˚C • Engine speed: High idling • Machine facing straight • Bucket lowered to ground (bucket bottom face horizontal). Time taken to move from max. lift to max. lower
20-5
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
Model Category
Item
Measurement conditions
• Engine water temperature, 1/3 of the lower part of the white range • Hydraulic oil temperature: 45 – 55˚C • Engine speed: High idling • Machine facing straight • Time taken to move bucket from max. tilt to max. dump
Standard value Unit for new machine
Sec.
20-6
0.8 ± 0.3
Min. 1.2
1.3 ± 0.3
Min. 2.0
0.7 ± 0.3
Min. 1.1
Sec.
Bucket horizontal
Time for bucket tilt back
• Engine water temperature, 1/3 of the lower part of the white range • Hydraulic oil temperature: 45 – 55˚C • Engine speed: High idling • Machine facing straight 1. Raise bucket to maximum lift arm height, and measure time taken to move bucket from full dump position to full tilt back position. 2. Set bucket horizontal to ground, then measure time taken to move bucket from horizontal position to full tilt back position.
Service limit value
Full stroke
Work equipment speed
Time for bucket forward tilt
WA30-5
WA30-5
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
Model
Proximity switch
Natural lowering down amount for work equipment
Category
Item
Measurement conditions
WA30-5 Standard value Unit for new machine
Retraction amount for dump cylinder rod (A)
Service limit value
Max. 10
Min. 20
Max. 10
Min. 20
3–5
—
mm
Retraction amount for lift cylinder rod (B)
Clearance of bucket positioner switch
WA30-5
• Engine water temperature: 1/3 of the lower part of the white range • Hydraulic oil temperature: 45 – 55˚C • Work equipment posture: Boom, bucket horizontal • Engine stopped • Leave for 5 minutes after stopping engine then measure retraction of rod for next 15 minutes
mm
20-7
TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
TESTING AND ADJUSTING
TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING Test, adjustment item
Engine speed
Symbol
A
Water, oil temperatures
B
Oil pressure
Compression pressure
Part Name
1 799-203-8001
Multi–tachometer
2 (799-203-8901)
(Clamp set)
799-101-5002
Hydraulic tester
790-261-1203
Digital hydraulic tester
2 795-101-1580 Commercially F available 1 799-201-9000 Commercially 2 available
G
Compression gauge
Feeler gauge Handy smoke checker Smoke meter
Working equipment speed
J
Hydraulic pump performance
K
20-8
— Discoloration 0 – 70% (with standard color) ..Bosch in(Discoloration % x 1/10 = dex) 0 – 294 N {0 – 30 kg} 0 – 490 N {0 – 50 kg}
79A-264-0090 I
Pressure gauge 68.6 MPa {700 kg/cm2} Kit part No. 795-502-1205 0 – 6.9 MPa {0 – 70 kg/cm2}
Push-pull scale
H
Stroke, hydraulic drift
Pressure gauge 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2}
Adapter
79A-264-0020 Operating effort
Kit part No. 799-203-9000 Digital display L: 60 – 2,000rpm H: 60 – 19,999rpm
Digital temperature gauge –50 – 1,200°C
1 795-502-1590 D
Remarks
799-101-1502
C
Valve clearance Exhaust color
Part No.
Commercially available Commercially available
Scale
—
Stopwatch
—
790-303-1003
Flow meter kit
—
WA30-5
TESTING AND ADJUSTING
ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE Serial No. 22005 – 26000 fl Tools for adjusting valve clearance Symbol F
Part No. Commercially available
Part name Feeler gauge
1. Remove the cylinder head cover. 2. Rotate the crankshaft in the normal direction and check the clearance at the compression top dead center (the position where the valves do not move). When rotating, check the movement of the valves. (while rotating the crankshaft 90° from the compression top dead center) fl When the crankshaft is rotated, the valves of the cylinder at top dead center do not move. If the valves are moving, rotate the crankshaft one more turn and align the timing mark. 3. To adjust the valve clearance, insert feeler gauge F between rocker lever (3) and valve cap (4), and check that the clearance is a sliding fit. If the gauge cannot be inserted or the clearance is larger than the specified value, adjust as follows. fl Adjust the valve clearance so that the clearance between the valve cap and rocker lever is the value given below.
When cold
Intake valve 0.2
Unit: mm Exhaust valve 0.2
1) Loosen locknut (6) of adjustment screw (5). 2) Insert tool F between rocker lever (3) and valve cap (4), adjust with adjustment screw (5), then tighten locknut (6) to hold the adjustment screw in position. Locknut : 25.5±2.9 Nm {2.6±0.3 kgm} fl After tightening the locknut, check the clearance again. 4. Check and adjust the remaining cylinders in the same way. fl Firing order: 3 – 1 – 2
WA30-5
20-9 (3)
TESTING AND ADJUSTING
ADJUSTING VALVE CLEARANCE
Serial No. 26001 and up 1. Disconnect 3 fuel injection pipes (1), then remove the cylinder head cover (2).
2. Rotate the crankshaft forward to set the No. 1 cylinder to the compression top dead center, watching the intake valve and exhaust valve of the cylinder. 3. Make match mark (4) on the gear case side to be matched to the stamped 1TOP line of crank pulley (3).  The No. 1 cylinder is at the flywheel end (rear of the chassis).  To check the top dead center, check that there is a clearance at the rocker arms on both the intake and exhaust sides. 4. To adjust the valve clearance, loosen locknut (6) of adjustment screw (5), then insert feeler gauge F of the specified thickness in clearance a between valve cap (7) and rocker arm (8) and turn the adjustment scew until the clearance is a sliding fit.
20-9-1 (3)
WA30-5
TESTING AND ADJUSTING
ADJUSTING VALVE CLEARANCE
fl Check that valve cap (7) is not worn or at an angle.
5. Rotate the crankshaft forward by 240 degrees to match the No. 3 cylinder to match mark (4) and adjust the clearance. Rotate the crankshaft forward by 240° further and adjust the No. 2 cylinder.
6. After adjusting the valve clearance, tighten locknut (6) to hold adjustment screw (5) in position. Locknut : 17.2 + 2.5 Nm {1.75 + 0.25 kgm} fl After tightening the locknut, check the valve clearance again.
WA30-5
20-9-2 (3)
TESTING AND ADJUSTING
MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION PRESSURE ¤ When measuring the compression pressure, be
1)
2) 3)
4) 5) 6)
careful not to touch the exhaust manifold or muffler, or to get your clothes caught in the fan, fan belt or other rotating parts. fl Measure the compression pressure if the performance test or troubleshooting shows that there may be wear of the piston, piston ring, or cylinder liner. Adjust the valve clearance. fl For details, see ADJUSTING VALVE CLEARANCE. Warm up the engine to make the oil temperature at least 40°C. Remove the nozzle holder assembly from the cylinder to be measured. fl For details, see DISASSEMBLY AND ASSEMBLY, REMOVAL OF NOZZLE HOLDER ASSEMBLY. Install tool D (adapter, pressure gauge) to the mount of the nozzle holder. Set the engine tachometer in position. Disconnect the control rod at the fuel injection pump end, when secure the pump throttle lever at the NO INJECTION position with wire.
7) Crank the engine with the starting motor and measure the compression pressure. fl Measure the compression pressure at the point where the compression gauge indicator remains steady. fl When measuring the compression pressure, measure the engine speed to confirm that it is within the specified range. fl If the result of the measurement shows that the compression pressure and engine speed are not within the specified value, remove another nozzle holder and check. fl After measuring the compression pressure, install the nozzle holder assembly. For details, see DISASSEMBLY AND ASSEMBLY, INSTALLATION OF NOZZLE HOLDER ASSEMBLY.
20-10
WA30-5
TESTING AND ADJUSTING
TESTING AND ADJUSTING FUEL INJECTION TIMING
TESTING AND ADJUSTING FUEL INJECTION TIMING Serial No. 22005 – 26000 There are the following methods for testing and adjusting the fuel injection timing of the injection pump. • The counter mark aligning method, used when assembling the injection pump to the original engine without repairing it. • The delivery valve check method, used when assembling an injection pump that has been repaired or replaced. fl Set the No. 3 cylinder to the compression top dead center before testing and adjusting. For details, see ADJUSTING VALVE CLEARANCE.
TESTING AND ADJUSTING BY ALIGNING MATCH MARKS Testing • Before removing the injection pump, check the points where counter mark (c) on the injection pump and line (d) on the flange are aligned, or make a counter mark on the flange side or pump side. Adjusting • If the counter mark and line are not aligned, loosen the pump mounting nut, move the injection pump to align the marks, then tighten the nut. fl Injection timing line (d) on the front plate changes 1.25° for one mark on the scale. fl If the injection pump is moved to the inside (towards the engine), the injection timing is delayed.
WA30-5
20-11 (3)
TESTING AND ADJUSTING
TESTING AND ADJUSTING FUEL INJECTION TIMING
TESTING AND ADJUSTING BY DELIVERY VALVE METHOD Testing 1. Testing at crankshaft pulley end 1) Remove No. 3 fuel injection pipe (1). 2) Loosen delivery valve holder (2), then bleed the air from the fuel circuit by cranking the engine in the normal direction until no more bubbles come out from the delivery valve holder. fl After bleeding the air, tighten the delivery valve. 3) Place the fuel control lever at the FULL position. 4) Crank the engine in the normal direction, and check the relationship between the position of timing mark (a) on the gear case and injection timing mark (b) on the crankshaft pulley at the point where fuel starts to flow from delivery valve holder (2). Injection timing mark (b) is marked at the 15.5° (from TDC) position, so read the position of the fuel timing. fl The injection timing changes 1° for each 1 mm on the outside circumference of the crankshaft pulley. fl If the injection timing is not correctly aligned, loosen the nut at the fuel injection pump mount, and adjust the position of the fuel injection pump itself. 2. Testing at flywheel end 1) Remove No. 3 fuel injection pipe (1). 2) Loosen delivery valve holder (2), then bleed the air from the fuel circuit by cranking the engine in the normal direction until no more bubbles come out from the delivery valve holder. 3) After bleeding the air, tighten the delivery valve. 4) Place the fuel control lever at the FULL position. 5) Crank the engine in the normal direction, and check that the timing mark on the mounting flange and the injection timing mark on the flywheel are aligned at the point where fuel starts to flow from the delivery valve holder.
20-12 (3)
WA30-5
TESTING AND ADJUSTING
TESTING AND ADJUSTING FUEL INJECTION TIMING
Adjusting If the result of the inspection shows that the injection timing is not correctly aligned, adjust the fuel injection timing as follows. 1. Rotate the crankshaft back 30 – 40° in the reverse direction from top dead center. 2. Rotate the crankshaft in the normal direction and align the injection timing on the crankshaft pulley with the pointer. 3. Loosen nut (3) at the oblong hole in the injection pump mount flange. 4. Move the injection pump to the inside (towards the cylinder block), then operate the priming lever of the feed pump, and move the injection pump towards the outside a little at a time. Stop at the position where fuel starts to flow from the delivery valve holder. 5. Tighten nut (3) at the oblong hole in the injection pump mount flange. fl Check the injection timing again to confirm that the injection timing is correct. 9 Delivery valve holder: 36.8±2.5 Nm {3.75±0.25 kgm} 9 Fuel injection pipe sleeve nut: 25.5±0.98 Nm {2.6±0.1 kgm} 6. Make counter marks.
WA30-5
20-13
TESTING AND ADJUSTING
TESTING AND ADJUSTING FUEL INJECTION TIMING
Serial No. 26001 and up TESTING Check mounting nut (1) of the fuel injection pump for looseness.  The fuel injection timing does not change as long as the mounting nut is not loosened. Accordingly, when removing and installing or replacing the fuel injection pump, refer to the following adjusting procedure.
ADJUSTING  The injection timing of the MP-type fuel injection pump used engine cannot be measured like the former models. Accordingly, adjust the injection angle instead of measuring the injection timing. 1. Before removing fuel injection pump (2), remove the cover in front of the timing gear case and make match marks on the meshing parts of pump drive gear (3) and idle gear (4).
2. Accurately record the relative positions of stamped line (5) of the fuel injection pump body and stamped line (6) of the gear case with markoff lines (7), etc.
3. Stick injection angle adjustment seal (8) to the gear case, matching its center line to stamped line (5) of the fuel injection pump body.
20-13-1 (3)
WA30-5
TESTING AND ADJUSTING
TESTING AND ADJUSTING FUEL INJECTION TIMING
4. Referring to DISASSEMBLY AND ASSEMBLY, Removal of fuel injection pump assembly, remove the fuel injection pump and read “injection angle θi” recorded on it. fl Injection angle θi is stamped at position “a” on the left side (engine block side) of the fuel injection pump. fl The stamped value is 10 times the value of injection angle θi. (Example) Injection angle θi (Cam angle)
Stamp
7.7
77
8.5
85
fl If the injection angle is difficult to read, notify YAMMAR of the injection pump No. and ask the injection angle. fl For details of injection angle θi, see REMARKS in the following section.
WA30-5
20-13-2 (3)
TESTING AND ADJUSTING
TESTING AND ADJUSTING FUEL INJECTION TIMING
5. Read the “injection angle θi” recorded on the fuel injection pump to be installed and calculate the difference between it and the “injection angle θi” of the removed fuel injection pump. fl When the same fuel injection pump is installed again, the angle difference is 0. fl Injection angle difference (Cam angle) = (Injection angle θi of fuel injection pump to be installed) – (Injection angle θi of removed fuel injection pump)
6. Install the fuel injection pump temporarily and tighten the nut at the shaft end. fl See Removal, installation of fuel injection pump. 7. Read the injection angle difference calculated in step 5 above by the scale of the adjustment seal (Minimum division: 0.5° of cam angle) and adjust the installed angle of the fuel injection pump. fl In the injection angle difference is +1°, lean the fuel injection pump away from the cylinder block by 1°. If the injection angle difference is –1°, lean the fuel injection pump toward the cylinder block by 1°. 8. Tighten the fuel injection pump mounting nut. REMARK Injection angle θi is the difference between the cam angle at which injection is started and the cam angle at which the plunger lift of the fuel injection pump is 2.5 mm while the fuel injection pump unit is driven with a motor. Actual injection angle θi is measured for each fuel injection pump and recorded on the pump body. REFERENCE Standard installed angle θ of fuel injection pump: 25°
20-13-3 (3)
WA30-5
TESTING AND ADJUSTING
BLEEDING AIR FROM FUEL CIRCUIT
BLEEDING AIR FROM FUEL CIRCUIT Keep the starting switch key in the ON position for 20 – 30 seconds, and the electric fuel pump bleeds air automatically.
WA30-5
20-13-4 (3)
TESTING AND ADJUSTING
TESTING AND ADJUSTING FAN BELT TENSION
TESTING AND ADJUSTING FAN BELT TENSION Serial No. 22005 – 26000 Testing fan belt tension 1. Remove fan guard (1). 2. Measure the deflection of the fan belt when it is pushed with a force of approx. 58.8 N {6 kg} at a point midway between the fan pulley and the alternator pulley.
Adjusting fan belt tension 1. Loosen the mounting bolt of the alternator assembly and belt tension adjustment bolt (2). 2. Using a pipe, move the alternator to adjust the tension of belt (3), tighten adjustment bolt (2) first, then finally tighten the alternator mounting bolt.
20-14 (3)
WA30-5
TESTING AND ADJUSTING
TESTING AND ADJUSTING FAN BELT TENSION
Serial No. 26001 and up (When standard alternator is installed) Testing fan belt tension 1. Check the amount of the fan belt deflection a when pushed with a force of F at a point midway between the fan pulley and the alternator pulley. a: 8 – 10 mm F: 98.1 N{10 kg}
Adjusting fan belt tension 1. Loosen the mounting bolt of the alternator assembly and belt tension adjustment bolt (1). 2. Using a bar, move the alternator to the outside, and adjust the fan belt tension. 3. Tighten adjustment bolt (1), the tighten the alternator mounting bolt.
WA30-5
20-14-1 (3)
TESTING AND ADJUSTING
TESTING FOR ABNORMALITY IN FUEL LEVEL SENSOR
TESTING FOR ABNORMALITY IN FUEL LEVEL SENSOR If there is any marked difference between the actual amount of fuel remaining in the tank and the display on the fuel gauge (the tank is full but the fuel gauge does not indicate FULL), check the fuel level sensor as an individual part, and measure the resistance of the float at the positions shown in the diagram on the right.
Method of measuring • Put the probe of the tester in contact with the connector terminal and measure the resistance.
Relationship between fuel level and resistance of level sensor
Full (Approx. 40¬) 1.0 10 +– 0.5
WA30-5
1/2 (Approx. 25¬)
Unit : Ω Empty (Approx. 8¬)
32 ± 3
12 80 + +2
20-15 (3)
TESTING AND ADJUSTING
MEASURING ACCELERATOR PEDAL
MEASURING ACCELERATOR PEDAL fl Measurement conditions • Engine water temperature: Bottom 1/3 of white range of engine water temperature gauge
OPERATING EFFORT OF ACCELERATOR PEDAL Method of measuring 1. Set push-pull scale H at a position 150 mm from pedal fulcrum a. fl Put the center of push-pull scale H in contact with a point 150 mm from the pedal fulcrum. 2. Start the engine, then measure the maximum value when the pedal is moved from the pushed position (low idling) to the end of its travel (high idling).
Method of testing 1. Stop the engine. 2. Disconnect yoke (1) and spring (2) under the accelerator pedal, and check that the pedal and linkage move smoothly. 3. Connect yoke (1) and spring (2) under the pedal, and check that ball joint (3) at the connection of the lever at the injection pump end moves smoothly. fl After carrying out these tests, adjust or replace parts as necessary, then measure the operating effort again to check that it is within the standard value. 4. Adjust so that the governor lever of the fuel injection pump contacts low idling stopper bolt (4) (clearance: 0) when the accelerator pedal is released (low idling position). fl Check that the engine low idling speed is standard value.
20-16 (3)
WA30-5
TESTING AND ADJUSTING
MEASURING ACCELERATOR PEDAL
TRAVEL OF ACCELERATOR PEDAL Measurement method 1. Stop the engine. 2. Put angle meter [1] in contact with the accelerator pedal and measure angle α2 from low idling to high idling. fl α2 = α1 – α3
Method of adjusting 1. Set the governor lever of the fuel injection pump to the low idling position, and with ball joint (1) at the governor lever end still installed, adjust the length with the cable connector under the accelerator pedal. 2. Loosen locknut (2) of the high idling stopper bolt and adjust installed height h with stopper bolt (3) so that the engine speed is standard value at high idling. (The engine speed changes approx. 70 rpm for 1/2 turn of the stopper bolt. Set the stopper bolt so that portion (A) faces the left and right.) fl After completing the above adjustment, carry out the measurement again to check that it is within the standard value.
WA30-5
20-17 (3)
TESTING AND ADJUSTING
MEASURING OPERATING EFFORT, TRAVEL OF DIRECTIONAL LEVER
MEASURING OPERATING EFFORT, TRAVEL OF DIRECTIONAL LEVER ¤ Apply
the parking brake and put blocks under the tires.
fl Measurement conditions • HST oil temperature: Bottom 1/3 of white range of HST oil temperature gauge • Engine speed: Engine stopped
Operating effort of directional lever • Install push-pull scale H or a spring balance to the center of the knob of the control lever, then measure the operating effort when the lever is pushed or pulled in the direction of actuation.
Travel of directional lever • Make mark (1) on the center of the knob of the control lever, then measure the travel when the lever is operated in the direction of actuation.
20-18
WA30-5
TESTING AND ADJUSTING
MEASURING STALL SPEED
MEASURING STALL SPEED ¤ Apply
the parking brake and put blocks under the tires. fl Check that the low idling and high idling speeds are within the standard value. fl Check that there is no looseness or play in the accelerator linkage. fl Before measuring the stall speed, set multitachometer (A1) to the No. 3 pipe of the fuel injection pump.
HST STALL 1. Remove the ball joint at the tip of rod (1) of the inching valve linkage. 2. Start the engine and run at low idling. 3. Place the directional lever in FORWARD or REVERSE. 4. Hold the machine stationary with the brake, and measure the engine speed when the engine is run at high idling. HYDRAULIC STALL 1. Start the engine and run at high idling. 2. Operate the dump or lift lever to move the cylinder to the end of its stroke and actuate the main relief valve of the main control valve. 3. Measure the engine speed in this condition. fl Do not continue the stall condition for more than 20 seconds, and operate the control lever quickly.
WA30-5
20-19
TESTING AND ADJUSTING
MEASURING HST OIL PRESSURE
MEASURING HST OIL PRESSURE ¤ Apply
the parking brake and put blocks under the tires. fl Measurement conditions • Engine water temperature: Bottom 1/3 of white range of engine water temperature gauge • Hydraulic oil temperature: 45 – 55°C Method of measurement ¤ Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. fl Check that there is no leakage of oil from any joint. fl When measuring the oil pressure, use the right brake pedal. fl When installing the hydraulic tester kit, install the nipple (790-301-1270) and O-ring (0700211023) contained in the kit. Measuring oil pressure in FORWARD 1. Remove the floor plate, remove the plug at the piping between the main piston pump and the piston motor, then install hydraulic tester kit C. 2. Start the engine and depress the right brake pedal. 3. Place the directional lever at the FORWARD position, and measure the pressure when the engine is run at high idling. Measuring oil pressure in REVERSE 1. Remove the plug at the piping between the main piston pump and the piston motor, then install hydraulic tester kit C. 2. Start the engine and depress the right brake pedal. 3. Place the directional lever at the REVERSE position, and measure the pressure when the engine is run at high idling. Measuring oil pressure at low-pressure relief 1. Remove one plug at the piping between the pump and motor, then install hydraulic tester kit C. 2. Start the engine. 3. Place the directional lever at the Neutral position, and measure the pressure when the engine is run at low idling. Measuring oil pressure in control line 1. Remove the plug at the inlet port elbow of the inching valve, then install hydraulic tester kit C. 2. Start the engine. 3. Place the directional lever at the Neutral position, and measure the pressure when the engine is run at rated speed. Measuring oil pressure in servo cylinder
20-20
WA30-5
TESTING AND ADJUSTING
TESTING AND ADJUSTING STEERING WHEEL
TESTING AND ADJUSTING STEERING WHEEL fl Measurement conditions • Road surface: Flat, horizontal, dry paved surface • Hydraulic oil temperature: 45 – 55°C • Engine speed: Low idling • Machine posture: Facing straight forward • Tire inflation pressure: Specified pressure MEASURING PLAY OF STEERING WHEEL 1. Move the steering wheel 2 or 3 times lightly to the left and right, check that the steering mechanism is at the neutral position, then make a mark 1 on directional lever (1). 2. Turn the steering wheel to the left, and align mark 1 and the point where the tires start to move, then make mark 2 on the steering wheel. 3. Turn the steering wheel to the right in the opposite direction from Step 2, and align mark 1 and the point where the tires start to move, then make mark 3 on the steering wheel and measure the distance in a straight line to the mark made in Step 2. MEASURING OPERATING EFFORT OF STEERING WHEEL 1. Install push-pull scale H to the steering wheel knob. fl Install the push-pull scale to the center of the knob. 2. Start the engine. fl After starting the engine, raise the bucket approx. 400 mm and remove the safety bar. 3. Pull push-pull scale H in the tangential direction and measure the value when the steering wheel moves smoothly. fl The play of the steering wheel is not included in the measurement range. fl Avoid measuring when the steering wheel starts to move.
WA30-5
20-21
TESTING AND ADJUSTING
MEASURING OPERATING TIME FOR STEERING WHEEL
MEASURING OPERATING TIME FOR STEERING WHEEL fl Measurement conditions • Road surface: Flat, horizontal, dry paved surface • Hydraulic oil temperature: 45 – 55°C • Engine speed: Low and high idling • Machine posture: Facing straight forward • Tire inflation pressure: Specified pressure
Measurement method 1. Start the engine. fl After starting the engine, raise the bucket approx. 400 mm and remove the safety bar (1). 2. Operate the steering wheel to the full lock to turn the machine to the left or right. 3. Measure the time taken to operate the steering wheel to the full lock to the right (left). fl Operate the steering wheel as quickly as possible without using force. fl Carry out the measurements both at low idling and high idling, and to both the left and right.
20-22
WA30-5
TESTING AND ADJUSTING
MEASURING STEERING PRESSURE
MEASURING STEERING PRESSURE fl Measurement conditions • Hydraulic oil temperature: 45 – 55°C • Engine speed: High idling Method of measuring main relief pressure ¤ Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Then operate the both the bucket and lift arm control levers several times to release the remaining pressure in the hydraulic piping. In addition, turn the steering wheel several times to release the remaining pressure in the steering piping. fl To release the air in the work equipment line, tilt the bucket up, and raise the lift arm slightly above the ground, then operate the levers and check that the lift arm and bucket both go down to the ground. 1. Apply safety bar (1) to the frame. 2. Remove plug (2) for measuring the left turn steering circuit. 3. Install hydraulic tester kit C to the measurement port. 4. Start the engine, run the engine at high idling, then turn the steering wheel to the left and measure the oil pressure when relief valve (3) of the priority valve is actuated. fl If the tester is set to the plug for the right turn steering circuit, turn the steering wheel to the right when measuring. Adjusting main relief pressure ¤ Always stop the engine before adjusting the pressure. 1. Stop the engine, then remove steering column cover (4). 2. Remove 3 bolts (5) from the steering valve mounting bracket. 3. Loosen locknut (6) on top of the priority valve in the steering valve, then turn adjustment screw (7) to adjust. fl Change in pressure for one turn of adjustment screw: 4.4 MPa {45 kg/cm2} fl Turn the adjustment screw to adjust the set pressure as follows. To INCREASE pressure, TIGHTEN adjustment screw To DECREASE pressure, LOOSEN adjustment screw fl If the relief pressure cannot be measured accurately, do not adjust it.
WA30-5
20-23
TESTING AND ADJUSTING
TESTING AND ADJUSTING BRAKE PEDAL
TESTING AND ADJUSTING BRAKE PEDAL fl Measurement conditions • Engine stopped Testing brake pedal linkage 1. Disconnect rod (1) under the brake pedal (both left and right), and disconnect spring (2) and inching valve rod (3), then check that ball joint (4) and linkage lever (5) move smoothly without interference. Adjusting brake pedal 1. Release the parking brake. 2. Remove the floor plate behind the pedal, then loosen locknuts (6) and (7). fl Locknut (6) has a left hand thread, and locknut (7) has a right hand thread, so be careful to turn them in the correct direction. 3. Turn adjustment screw (8) to adjust the length of rod (9). fl Turn adjustment screw (8) as follows. To EXTEND rod, turn CLOCKWISE. To RETRACT rod, turn COUNTERCLOCKWISE. 4. After adjusting, tighten locknuts (6) and (7) to the specified tightening torque. 9 Locknut: 14.7 – 19.6Nm {1.5 – 2.0kgm} Adjusting brake linkage If the brake pedal cannot be adjusted with the adjustment screw as explained above, adjust as follows. 1. Remove ball joint (10) from the cable at the brake lever end, set the brake lever in the FREE position, and adjust the position of lever (11) so that it is dimension L. fl Dimension L: 209 mm fl Loosen nut (12) of the ball joint when adjusting the installed length of the cable.
20-24
WA30-5
TESTING AND ADJUSTING
TESTING AND ADJUSTING BRAKE PEDAL
Adjusting parking brake release cable 1. Depress the parking brake pedal 1 – 2 notches. 2. Pull the parking brake release lever, and adjust at the cable mount so that the parking brake is released at a point approx. 1/2 (35 – 50 mm) of the total movement of the lever after the parking brake pedal is released. fl Total movement of parking brake release lever: 90 mm fl To adjust the cable, loosen the locknut at the cable mount, and adjust so that the installed dimension is A. Dimension A: 34 – 40 mm Testing and adjusting brake switch • Stop lamp switch Method of testing 1. Carry out adjustment if dimension L1 of the stop lamp switch is not within a range of 44±1 mm. Method of adjusting 1. After adjusting rod length a, adjust the stop lamp switch so that dimension L1 is within 44±1 mm when brake pedal (1) is free. fl Standard screwing-in length of dimension a: 16 mm fl If the adjustment dimension is incorrect, boot (2) of the switch will be greatly deformed. As a result, when the brake pedal is depressed, it will take time for it to be reset, and there will be a delay in the actuation. • Parking brake pilot lamp switch Method of testing 1. Carry out adjustment if dimension L2 of the parking brake pilot lamp switch is not within a range of 44±1 mm. Method of adjusting 1. Adjust the parking brake pilot lamp switch so that dimension L2 is within 44±1 mm when brake pedal (1) is depressed one click. fl The switch is turned ON when the brake is released.
WA30-5
20-25
TESTING AND ADJUSTING
MEASURING OPERATING EFFORT, TRAVEL OF BRAKE PEDAL
MEASURING OPERATING EFFORT, TRAVEL OF BRAKE PEDAL fl Measurement conditions • Engine stopped • Measure both brake and parking brake under the following conditions. Measuring operating effort of pedal 1. Install push gauge 1 to the operator's foot. fl Align the center of the push gauge with the center of the pedal. 2. Measure the operating effort when the pedal is depressed.
Measuring travel of pedal 1. Install push gauge 1 to the operator's foot. fl Align the center of the push gauge with the center of the pedal. 2. Measure the travel of the pedal when it is depressed with a force of 196N {20kg}.
Measuring travel of inching 1. Push left brake pedal (1) in lightly by hand and measure the travel to the point where the brake starts to become heavy. fl Travel: 20° fl Dimension L: 60 mm
20-26
WA30-5
TESTING AND ADJUSTING
MEASURING BRAKE PERFORMANCE
MEASURING BRAKE PERFORMANCE fl • • •
Measurement conditions Road surface: Flat, horizontal, dry paved surface Travel speed: 15 km/h when brakes are applied Tire inflation pressure: Specified pressure
Measurement method 1. Start the engine and move the machine. 2. Set the speed lever to the highest speed position and drive the machine. 3. When the travel speed reaches 20 km/h, depress the left brake pedal with the specified operating force. Specified operating force: 490 N {50 kg} fl Before carrying out this operation, determine the run-up path and the point for applying the brakes, then apply the brakes when the machine reaches that point. 4. Measure the distance from the point where the brakes were applied to the point where the machine stopped. fl Repeat this measurement three times and take the average.
WA30-5
20-27
TESTING AND ADJUSTING
MEASURING PARKING BRAKE PERFORMANCE
MEASURING PARKING BRAKE PERFORMANCE fl Test the parking brake performance as follows. • Road surface: Flat, dry paved road surface with slope of 1/5 grade (11°20'). • Machine: Operating condition • Operating effort of pedal: 245 N or more {25 kg or more} • Tire inflation pressure: Specified pressure (235.4 kPa {2.4 kg/cm2}) 1. Start the engine, set the machine facing in a straight line, then drive the machine up a 1/5 grade slope with the bucket empty. 2. Depress the brake, stop the machine, set the directional lever to the neutral position, then stop the engine. 3. Depress the parking brake pedal, then gradually release the brake pedal. 4. Check that the machine is held in position for 5 minutes. fl If the machine is held in position for 5 minutes without moving, the parking brake is correct. fl Carry out the measurement in two ways: Once with the machine facing uphill, and once more with the machine facing downhill.
20-28
WA30-5
TESTING AND ADJUSTING
MEASURING BRAKE DISC WEAR
MEASURING BRAKE DISC WEAR ¤ Block the tires. fl If the braking effect has become poor or the transfer has been overhauled, check the brake disc wear. fl For details of the method of disassembling and assembling the brake, see DISASSEMBLY AND ASSEMBLY OF TRANSFER.
Method of measuring To check the wear of disc (1), check that dimension W is at least the value given below. fl Dimension W > – 4.25 mm fl For details of the procedure for adjusting the brake linkage, see TESTING AND ADJUSTING BRAKE PEDAL.
WA30-5
20-29
TESTING AND ADJUSTING
TESTING AND ADJUSTING INCHING VALVE LINKAGE
TESTING AND ADJUSTING INCHING VALVE LINKAGE Testing inching valve linkage 1. Stop the engine, disconnect springs (2) and rod (1) under the brake pedals (both left and right pedals), and check that the ball joint and linkage lever moves smoothly. 2. Disconnect the ball joints at both ends of rod (3), and check that the ball joints and inching valve (4) move smoothly. 3. Check that there is a clearance of 0.5 – 1.5 mm between inching valve shaft (6) and stopper (5) of inching valve (4) when the left brake pedal is at the standard angle (40°).
Adjusting inching valve linkage 1. Adjust length L of rod (3) so that inching valve shaft (6) contacts stopper (5) when the brake pedal is at the specified angle (40°). fl Dimension L: 182 mm 2. Loosen locknut (7) and adjust the length of rod (3). fl When installing inching valve shaft (6) to the valve, turn the valve shaft in the direction shown by the arrow so that the valve
20-30
WA30-5
TESTING AND ADJUSTING
MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER
MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER fl Measurement conditions • Engine water temperature: Bottom 1/3 of white range of engine water temperature gauge • Hydraulic oil temperature: 45 – 55°C • Engine speed: Low idling ¤ Install the safety bar (1) to the frame.
Measurement method 1. Operating effort of work equipment control lever • Install push-pull scale H to the work equipment control lever and measure the operating effort. fl Install the push-pull scale to the center of the knob. fl Operate the control lever at the same speed as for normal operations, and measure the minimum value for the effort needed to operate the knob.
2. Travel of work equipment control lever • Measure the travel and play at each position when operating the work equipment control lever. fl Mark the lever knob and use scale I to measure. fl If the travel or play are not within the specified value, check for play in the linkage and wear of the bushing. fl The values for the travel in the MAINTENANCE STANDARD table for chassis related parts do not include the play.
WA30-5
20-31
TESTING AND ADJUSTING
MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER
METHOD OF TESTING AND ADJUSTING Method of testing 1. Remove boot (2) of work equipment control lever (1) from the mounting hole, open the engine hood, lock work equipment control lever (1) at the HOLD position, then check clearance a of tilt stopper (3) and clearances b and c of RAISE stopper (4). fl Clearance a: 9.5+0.5 0 mm b: 4.5±0.5 mm c: 12±1 mm fl Adjust if the clearance is not within the standard value. Method of adjusting 1. Adjusting tilt stopper 1) Set in the condition for Step 1 for testing, loosen locknut (5) of tilt stopper (3), then adjust so that clearance a is within the standard value. 2) Tighten locknut (5). Locknut: 30.9±3.4 Nm {3.15±0.35 kgm} 2. Adjusting RAISE stopper 1) Set in the condition for Step 1 for testing, loosen mounting bolt (6) of RAISE stopper (4), then adjust so that clearances b and c are within the standard value. 2) Tighten mounting bolt (6). Mounting bolt: 13.2±1.5 Nm {1.35±0.15 kgm}
20-32 (3)
WA30-5
TESTING AND ADJUSTING
MEASURING TRAVEL OF MAIN CONTROL VALVE SPOOL
MEASURING TRAVEL OF MAIN CONTROL VALVE SPOOL fl Measurement conditions • Engine water temperature: Bottom 1/3 of white range of engine water temperature gauge • Hydraulic oil temperature: 45 – 55°C • Engine speed: Low idling
¤ Install safety bar (1) to the frame. Method of measuring 1. Measure the travel of valve spool (2) when the work equipment control lever is moved to each position. fl Carry out the measurement with 2 workers, and use signals while carrying out the work. fl One worker should operate the control lever while the other worker measures the travel. fl For details of adjusting the travel of the work equipment control lever, see MEASUREMENT OF WORK EQUIPMENT CONTROL LEVER.
WA30-5
20-33
TESTING AND ADJUSTING
MEASURING WORK EQUIPMENT PRESSURE
MEASURING WORK EQUIPMENT PRESSURE fl Measurement conditions • Engine water temperature: Bottom 1/3 of white range of engine water temperature gauge • Hydraulic oil temperature: 45 – 55°C
MEASURING AND ADJUSTING MAIN RELIEF VALVE Method of measuring ¤ Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Then operate the control levers several times to release the remaining pressure in the hydraulic piping. fl To release the air in the piping, tilt the bucket up, and raise the lift arm slightly above the ground. Then operate the levers and check that the lift arm and bucket both go down to the ground. 1. Remove plug (1) from the hydraulic pressure inlet port of the main control valve. 2. Install hydraulic tester kit (C1) to the measurement port. fl Check that there is no leakage of oil from any joint. fl Use a hydraulic hose that is long enough to reach the operator's compartment. 3. Start the engine, raise the lift arm approx. 400 mm, run the engine at high idling, tilt the bucket back, and measure the pressure when the main relief valve is actuated. fl Be careful not to apply the pressure suddenly to the oil pressure gauge.
¤ When removing the oil pressure gauge, release the pressure inside the circuit in the same way as when installing the gauge. Method of adjusting ¤ Always stop the engine before adjusting the pressure. 1. Loosen locknut (2) of the main control valve and main relief valve (4), then turn adjustment screw (3) to adjust. fl Change in pressure for one turn of adjustment screw: 17.7 MPa {181 kg/cm2} fl Turn the adjustment screw to adjust the set pressure as follows. To INCREASE pressure, TIGHTEN adjustment screw To DECREASE pressure, LOOSEN adjustment screw fl If the relief pressure cannot be measured accurately, do not adjust it.
20-34
WA30-5
TESTING AND ADJUSTING
MEASURING WORK EQUIPMENT PRESSURE
ADJUSTING SAFETY VALVE
¤ Always
stop the engine before adjusting the pressure.
1. Raise the lift arm, set a support under the arm, then remove front cover (1) of the front frame. 2. Loosen locknut (2) of the main control valve and safety valve, then turn adjustment screw (3) to adjust. fl Change in pressure for one turn of adjustment screw: 15.7 MPa {160 kg/cm2} fl Turn the adjustment screw to adjust the set pressure as follows. To INCREASE pressure, TIGHTEN adjustment screw To DECREASE pressure, LOOSEN adjustment screw fl If the relief pressure cannot be measured accurately, do not adjust it.
WA30-5
20-35
TESTING AND ADJUSTING
TESTING AND ADJUSTING BUCKET POSITIONER
TESTING AND ADJUSTING BUCKET POSITIONER fl Measurement conditions • Engine water temperature: Bottom 1/3 of white range of engine water temperature gauge • Hydraulic oil temperature: 45 – 55°C
Method of testing 1. With the engine stopped, check that the clearance between switch (1) and detection bar (2) is the standard value. 2. Start the engine, run at high idling, and check the actuation point. (Check three times and take the average.)
Method of adjusting 1. Lower the bucket to the ground, set the bucket to the desired digging angle, return the lever to the HOLD position, and stop the engine. 2. Adjust switch (1) so that the clearance between the sensing surface of switch (1) and the tip of bracket (3) is dimension a. fl Dimension a: Min. 1 mm 9 Switch mounting nut: 17.6±1.9 Nm {1.8±0.2 kgm} 3. Adjust so that the clearance between the sensing surface of switch (1) and detector bar (2) is dimension b. fl Dimension b: 3 – 5 mm fl After adjusting, operate the bucket lever and check that the bucket positioner is actuated at the desired position.
20-36
WA30-5
TESTING AND ADJUSTING
TESTING AND ADJUSTING BUCKET POSITIONER
Testing actuation pilot lamp (red) of proximity switch • When adjusting, check pilot lamp A which is installed to the proximity switch and indicates the condition of operation.
Proximity switch pilot lamp
Position of detector
ON
OFF
When detector is positioned at sensing surface of proximity switch
When detector is separated from sensing surface of proximity switch
Bucket positioner
WA30-5
20-37
TROUBLESHOOTING Points to remember when troubleshooting ........................................................................................ 20-202 Sequence of events in troubleshooting .............................................................................................. 20-203 Point to remember when carrying out maintenance ........................................................................ 20-204 Checks before troubleshooting ............................................................................................................ 20-212 Troubleshooting for electrical system .................................................................................................. 20-251 Troubleshooting of hydraulic system (H mode) ................................................................................ 20-301
WA30-5
20-201 (3)
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING ¤ 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.
¤ If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for the engine to cool down before starting troubleshooting.
¤ 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 or cap from a location which is under pressure from oil, water, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly. The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1.
2.
3.
When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately any failure occurs: • Parts that have no connection with the failure or other unnecessary parts will be disassembled. • 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. Points to ask user or operator 1) Have any other problems occurred 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? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before? Check before troubleshooting 1) Check the oil level. 2) Check for any external leakage of oil from the piping or hydraulic equipment. 3) Check the travel of the control levers.
20-202
4) 5)
4.
5.
6.
Check the stroke of the control valve spool. Other maintenance items can be checked externally, so check any item that is considered to be necessary. Confirming failure 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. fl When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. Troubleshooting Use the results of the investigation and inspection in Items 2 – 4 to narrow down the causes of failure, then use the troubleshooting flowchart to locate the position of the failure exactly. fl 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. Measures to remove root cause of failure 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.
WA30-5
TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING Office, shop
Jobsite TEW00180
TEW00181
Step 1 Examination, confirmation of symptoms 1) When a request for repairs is received, first ask the following points. • Name of customer • Type, serial number of machine • Details of jobsite, etc. 2) Ask questions to gain an outline of the problem. • Condition of failure • Work being carried out at the time of the failure • Operating environment • Past history, details of maintenance, etc.
TEW00182
Step 2 Determining probable location of cause 1) Look at the troubleshooting section of the shop manual to find locations of possible causes.
Step 3 Preparation of troubleshooting tools 1) Look at the table of troubleshooting tools in the shop manual and prepare the necessary tools. • T-adapter • Hydraulic pressure gauge kit, etc. 2) Look in the parts book and prepare the necessary replacement parts.
Step 7 • Pinpoint locations of failure (carry out troubleshooting) • Decide action to take
TEW00186
1) Before starting troubleshooting, locate and repair simple failures. • Check before starting items • Other check items 2) See the Troubleshooting Section of the shop manual, select a troubleshooting flowchart that matches the symptoms, and carry out troubleshooting.
TEW00187
Step 6 Re-enacting failure •
Step 4 Go to jobsite
Drive and operate the machine to confirm the condition and judge if there is really a failure.
Step 5 Ask operator questions to confirm details of failure. • • • TEW00189
Was there anything strange about the machine before the failure occurred? Did the failure occur suddenly? Had any repairs been carried out before the failure? TEW00190
WA30-5
20-203 (3)
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and 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 gear oil and hydraulic oil).
1. Points to remember when handling electric equipment 1) Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses. TEW00191
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.
(2) Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.
20-204 (3)
WA30-5
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
(3) Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.
TEW00194
(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. As already said, the connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be shortcircuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it. (5) Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer.  When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins.  If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.
WA30-5
TEW00195
TEW00196
20-205 (3)
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
2) Removing, installing, and drying connectors and wiring harnesses (1) Disconnecting connectors ‡ 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. fl Never pull with one hand. ‡
When removing from clips When removing a connector from a clip, pull the connector in a parallel direction to the clip. fl If the connector is twisted up and down or to the left or right, the housing may break.
‡
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. fl If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.
TEW00198
20-206 (3)
WA30-5
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
(2) Connecting connectors ‡ Check the connector visually. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. Check that there is no damage or breakage to the outside of the connector. fl 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. fl If there is any damage or breakage, replace the connector. ‡
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.
‡
Correct any protrusion of the boot and any misalignment of the wiring harness For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. fl If the connector cannot be corrected easily, remove the clamp and adjust the position.
‡
If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.
(3) Connecting connectors (DT type connector) Sine the DT 8-pole and 12-pole DT type connectors have 2 latches respectively, push them in until they click 2 times. 1. Male connector, 2. Female connector ‡ Normal locking state (Horizontal): a, b, d ‡ Incomplete locking state (Diagonal): c
WA30-5
20-207 (3)
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
(4) Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. ‡ Disconnect the connector and wipe off the water with a dry cloth. fl If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oil and water from the compressed air before blowing with air. ‡
TEW00196
Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. fl Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector.
TEW00202
‡
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. fl After completely drying the connector, blow it with contact restorer and reassemble.
20-208 (3)
WA30-5
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
3) Handling control box (1) The control box contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the control box. (2) Do not open the cover of the control box unless necessary.
TEW00204
(3) Do not place objects on top of the control box. (4) Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. (5) During rainy weather, do not leave the control box in a place where it is exposed to rain.
TEW00205
(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 control box. Fit an arc welding ground close to the welding point.
TEW00206
2. Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connect connectors. 2) Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. fl If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated. 4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. fl If there is any change, there is probably defective contact in that circuit.
WA30-5
20-209 (3)
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
3. Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful. 1) Be careful of the operating environment. Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust. 2) Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to 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. 3) Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out on to the ground, collect it and ask the customer to dispose of it, or take it back with you for disposal.
TEW00207
TEW00208
4) Do not let any dirt or dust get in during refilling operations. Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil 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.
TEW00209
20-210 (3)
WA30-5
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
5) Change hydraulic oil when the temperature is high. When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil. 6) Flushing operations After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.
7) Cleaning operations After repairing the hydraulic equipment (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultrafine (about 3Âľ) particles that the filter built into the hydraulic equipment cannot remove, so it is an extremely effective device.
TEW00211
WA30-5
20-211 (3)
TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
Lubricant, coolant Electrical components
Hydraulic, mechanical components
Checks before starting
Item
Remedy
1. Check fuel level, type of fuel
—
Add fuel
2. Check for dirt or water in fuel
—
Clean, drain
3. Check hydraulic oil level
—
Add oil
4. Check filter (hydraulic, HST)
—
Replace
5. Check brake fluid level
—
Add fluid
6. Check engine oil
—
Add oil
7. Check coolant level
—
Add water
8. Check clogging of dust indicator
—
Clean or check
9. Check for loose or corroded battery terminals or wiring
—
Tighten or replace
10. Check for loose or corroded alternator terminals or wiring
—
Tighten or replace
11. Check for loose or corroded starting motor terminals or wiring
—
Repair or replace
12. Check operation of gauges
—
Repair or replace
13. Check for abnormal noise or smell
—
Repair
14. Check for oil leakage
—
Repair
15. Bleed air from system
—
Bleed air
16. Check effect of brakes
—
Adjust or repair
17. Check effect of parking brake
—
Adjust or repair
18. Check battery voltage (engine stopped) 19. Check battery electrolyte level
24 – 26V
Repair or replace
—
Add electrolyte or replace
Electrical components
Other check items
Judgement standard
20. Check for discolored, burned, or bare wiring
—
Replace
21. Check for missing wiring clamps, hanging wires
—
Repair
22. Check for water on wiring
—
Dry place affected by
(check carefully for water at connectors and terminals)
water
23. Check for broken or corroded fuses
—
Replace
24. Check alternator voltage (engine running at over half throttle)
—
Replace
(If the battery charge is low, it may reach approx. 25 V
28.5 – 29.5V Repair or check
immediately after starting) 25. Noise when battery relay is operated
—
Replace
(turn starting switch ON-OFF)
20-212
WA30-5
TROUBLESHOOTING OF ELECTRICAL SYSTEM E-1. Engine does not start .................................................................................................................... 20-252
WA30-5
20-251 (3)
TROUBLESHOOTING
E-1
E-1 Engine does not start fl When carry out troubleshooting, set the forward/ reveres lever in neutral. fl When measuring the voltage, turn the starting switch ON. When measuring the resistance, turn the starting switch OFF. YES a) Starting motor does not rotate (1/2) 3
YES
Is voltage YES between starting motor terminal C and ground normal? • 10 - 15 V • Starting switch: START
4 Is voltage between S1 (2) NO and ground normal? • 10 - 15 V • Starting switch: START
YES 5
2 NO
YES Does horn sound or does lamp light up?
Is voltage between S1 (1) and ground normal? • 10 - 15 V
NO • Starting switch: ON
15 YES Is voltage YES between starting motor terminal B and ground normal? 14
YES Is voltage
1
between L2 (2) and ground normal?
Are electrolyte specific gravity and battery voltage normal?
• 10 - 15 V
13
• Specific gravity: Min. 1.26 • Voltage: Min. 12 V
Is voltage between starting motor terminal B NO and ground normal?
NO
• 10 - 15 V
16 YES Is resistance between L2 NO (male) (1) and (2) normal? • Max. 1 Ω • Disconnect L2.
NO
• 10 - 15 V
NO
NO
20-252 (3)
WA30-5
TROUBLESHOOTING
E-1
Cause
Defective starting motor
Remedy
Repair or replace
Disconnection or defective Repair or contact in wiring harness replace wiring between S1 (female) (2) - harness starting motor terminal C
8 YES Is voltage
YES between N9 (1) and ground 7 Is voltage
YES between N9 (3) 6 Is voltage between N9 (4) and ground normal? • Max. 2 V • Starting switch: ON
and ground normal? • 10 - 15 V • Starting switch: START
Disconnection or defective • Repair or contact in ground wiring replace wiring harness of safety relay or harness defective safety relay • Replace relay
normal? • 10 - 15 V • Starting switch: START
NO
NO
Go to A
Go to B
Defective alternator
NO
Repair or replace
Disconnection or defective contact in wiring harness Repair or between S1 (female) (1) - replace wiring M15 (female) (1) (up to harness branching point) Defective starting switch
Replace
Disconnection or defective Repair or contact in wiring harness replace wiring between starting switch terminal B - L2 (female) (2) harness Disconnection or defective contact in wiring Repair or harness between L2 replace wiring (female) (1) - starting harness motor terminal B Defective slow-blow fuse
Replace
Disconnection or defective contact in wiring harness Repair or between battery (+) replace wiring terminal - starting motor harness terminal B Lowering of battery capacity
WA30-5
Charge or replace
20-253 (3)
TROUBLESHOOTING
E-1
(2/2)
Cause
YES 10
Remedy
Defective control switch
Replace
Disconnection or defective contact in wiring harness between starting switch terminal C - N4 (female) (1)
Repair or replace wiring harness
Defective starting switch (Between B - C)
Replace
Is voltage
YES between N4 (1) 9 A
Is voltage between N4 (2) and ground normal?
and GND normal?
11 YES
Is voltage between starting switch • 10 - 15 V terminal C and • Starting switch: NO ground normal? START
• 10 - 15 V • Starting switch: START • Forward/Reverse NO lever: Neutral
• 10 - 15 V • Starting switch: START
12 YES B
Is voltage between starting switch terminal ACC and ground normal?
NO • 10 - 15 V • Starting switch: ON
E-1
NO
Disconnection or defective contact in wiring harness Repair or replace between N4 (female) (2) - wiring harness N9 (female) (1) Disconnection or defective contact in wiring harness Repair or replace between starting switch wiring harness terminal ACC - N9 (female) (3) Defective starting switch (Between B and ACC)
Replace
a) Electric circuit diagram of each system
20-254 (3)
WA30-5
TROUBLESHOOTING
E-1
b) Engine stop solenoid does not operate b)–1 Engine stop solenoid does not attract core
Cause
Defective engine stop solenoid
YES
2 Is resistance YES between L6 (female) (3) and ground normal?
1
• 10 - 15 V • For 1 second after starting switch is turned ON
Disconnection or defective Repair or contact in wiring harness replace wiring between R4 (female) - L6 harness (female) (3)
YES 3 Is voltage between R4 and NO ground normal? • 10 - 15 V • For 1 second after starting switch is turned ON
4 YES Is voltage between R3 and NO ground normal?
NO • 10 - 15 V • Starting switch: ON YES
6
A
Is voltage between L13 (2) and ground normal? • 10 - 15 V • For 1 second after starting switch is turned ON
WA30-5
Replace
Disconnection or defective Repair or contact in wiring harness replace wiring between R5 (male) (2) harness N13 (female) (2)
YES 7
• 10 - 15 V • For 1 second after starting switch is turned ON
Disconnection or defective contact in wiring harness Repair or replace wiring between R3 (female) harness starting switch terminal BR
Disconnection or defective Repair or contact in wiring harness replace wiring between R5 (male) (1) - R4 harness (female)
NO • Max. 1 Ω • Disconnect R5 and N13.
Is voltage between R5 (2) NO and ground normal?
Go to A
Defective engine stop relay
Is resistance YES between R5 (female) (1) and N13 (female) (1) normal?
5
Replace
Disconnection or defective Repair or contact in wiring harness replace wiring between L6 (female) (3) harness ground
NO
• Max. 1 Ω • Disconnect L6.
Is voltage between L6 (2) and ground normal?
Remedy
8 YES Is voltage between R5 (4) and ground NO normal?
NO • 10 - 15 V • Starting switch: ON
Defective engine stop timer
Replace
Disconnection or defective Repair or contact in wiring harness replace wiring between starting switch harness terminal BR - R5 (male) (4)
20-255 (3)
TROUBLESHOOTING
E-1
b)–2 Engine stop solenoid attracts core but cannot hold it
Cause
1 YES Is voltage between L6 (1) and ground normal? • 10 - 15 V • Starting switch: ON
NO
Defective engine stop solenoid
Remedy
Replace
Disconnection or defective contact in wiring harness Repair or replace wiring between L6 (female) (1) harness starting switch terminal BR
b)–1, 2 Electric circuit diagram of each system
20-256 (3)
WA30-5
TROUBLESHOOTING OF HYDRAULIC SYSTEM (H MODE) Troubleshooting ...................................................................................................................................... 20-302 Checking machine before troubleshooting .......................................................................................... 20-302 Checking HST before troubleshooting ................................................................................................. 20-303 H-1. Impossible to travel in either direction (FORWARD or REVERSE) ........................................... 20-305 H-2. Impossible to travel in one direction only (either FORWARD or REVERSE) ........................... 20-306 H-3. Lacks speed in both directions (FORWARD and REVERSE) ...................................................... 20-307 H-4. Lacks speed in one direction only (FORWARD or REVERSE) ................................................... 20-308 H-5. Lacks drawbar pull in both directions (FORWARD and REVERSE) .......................................... 20-308 H-6. Lacks drawbar pull in one direction only (FORWARD or REVERSE) ....................................... 20-309 H-7. Engine speed in high when starting in both directions (FORWARD and REVERSE) ............. 20-309 H-8. Engine speed in high when starting in one direction only (FORWARD or REVERSE) .......... 20-309
WA30-5
20-301 (3)
TROUBLESHOOTING
TROUBLESHOOTING • CHECKING MACHINE BEFORE TROUBLESHOOTING
TROUBLESHOOTING 1. Introduction This explanation of troubleshooting gives details of troubleshooting for the hydraulic system of the HST. When carrying out troubleshooting, carry out checks with the machine monitor, and check also for oil leakage and problems with the machine. Next, carry out troubleshooting of the electrical system, and if no problem is detected, start troubleshooting of the HST. 2. Precautions for dirt When disassembling, assembling, or replacing the HST units, it is necessary to pay more attention than usual to prevent dirt from getting into the hydraulic system. For this reason, carry out the work indoors as far as possible. If dirt gets inside the HST system, it may cause defective actuation or damage to internal parts. To prevent such problems, when removing any parts or units for inspection or replacement, wash the area around the replacement parts with flushing oil and take care to prevent the dirt from extending to other parts of the HST unit. 3. Precautions after inspection and replacement 1) If the pump, motor, charge pump, or filter have been inspected or replaced, run at low idling for at least 5 minutes to bleed the air from inside the hydraulic circuit. 2) When checking the HST oil filter, if dirt or metal particles are stuck to the filter, replace the oil filter.
CHECKING MACHINE BEFORE TROUBLESHOOTING 1. Machine itself 1) Stop the machine on level ground. 2) The HST oil must be SAE10W-30CD. 3) The oil in the hydraulic tank must be at the normal level. 4) There must be no air sucked into the hydraulic circuit. 5) The oil must be at the specified oil temperature. 6) The engine speed must be within the specified range. 7) The work equipment must work properly. 8) There must be no external leakage of oil from around the HST unit. 2. Checking electrical system The pilot lamps should give the display shown in the table below. If there is any abnormality in the electrical system, check the sensors and wiring harnesses.
fi ×
Pilot lamp Parking brake switch ON Parking brake Parking brake switch OFF Parking brake Parking switch ON brake caution Parking and buzze brake switch OFF HST oil filter clogging
Lights up or buzzer sounds Lamp goes off Starting Starting switch ON, switch ON, Remarks engine engine stopped running
fi
fi
×
×
×
×
fi
×
fi
fl × (fi)
( ): Actuation when HST filter is clogged
fl If the temperature of the hydraulic oil is low, the lamp may light up when the engine speed is raised. This is not an abnormality.
20-302 (3)
WA30-5
TROUBLESHOOTING
CHECKING HST BEFORE TROUBLESHOOTING
CHECKING HST BEFORE TROUBLESHOOTING 1. Checking linkage of inching valve 1) Check for loose or missing linkage. 2) Check that the valve lever is at the specified position when the brake pedal is OFF.
2. Check directional electrical control system (only when it is impossible to travel) 1) Check from the gearshift lever to the HST solenoid valve. • Remove the connector and check the connector at the wiring harness end. • If there is abnormality in one direction only (FORWARD or REVERSE), it is possible to narrow down the problem by interchanging the connections of connectors A and B. • Check with the starting switch ON (engine stopped). Terminal No.
Cause of failure
Normal condition
2 and chassis (ground)
No continuity when parking brake is ON
Defective parking switch
Continuity when parking brake is OFF
Defective ground
4 and chassis (ground)
No continuity when parking brake is ON
Defective parking switch
1 and 2 (+end) Parking lever OFF
3 and 4 (+end) Parking lever OFF
Defective ground
Continuity when parking brake is OFF Electrical potential difference 12 V when rectional lever is at R Electrical potential difference 0 V when rectional lever is at N or F Electrical potential difference 12 V when rectional lever is at F Electrical potential difference 0 V when rectional lever is at N or R
di-
Defective directional lever, defective power supply circuit
di-
Defective directional lever
di-
Defective directional lever, defective power supply circuit
di-
Defective directional lever
2) Checking directional solenoid valve • Check 2 times each for HST connector terminals 1 and 2 or 3 and 4 as shown in the diagram on the right. • If approx. 5.5 Ω is not shown for both times, there is a short circuit or disconnection, so replace the solenoid.
WA30-5
20-303 (3)
TROUBLESHOOTING
CHECKING HST BEFORE TROUBLESHOOTING
3. Checking HST circuit oil pressure Measurement conditions and judgement standard • Hydraulic oil: 45°C – 55°C (inside tank) • Engine water temperature: Bottom 1/3 of white range of engine water temperature gauge
Unit: MPa {kg/cm2} Travel condition (directional lever position) Engine speed (rpm)
Control oil pressure
Neutral (N) 950 (Low)
2,000 2,700 1,500 (Partial) (Partial) (Rated)
0.39-0.69 0.59-0.98 0.98-1.37 1.57-2.16 {4-7} {6-10} {10-14} {16-22}
Forward (F) Reverse (R)
When necessary (HST relief) Forward (F) Reverse (R)
Full
Full
1.57 - 2.16 {16 - 22} (at 2,700 rpm)
Low-pres1.86 - 2.45 1.47-2.06 1.57-2.16 1.67-2.26 1.86-2.45 sure end High-pres- {15-21} {16-22} {17-23} {19-25} 10.79 - 12.75 sure end 0 - 0.2 Oil pressure When ×3 0 - 0.2 {0 - 2} {0 - 2} neces- inside servo 1.57 - 2.16 sary 0 - 0.2 {0 - 2} ×4 cylinder {16 - 22}
Main circuit oil pressure
20-304 (3)
{19 - 25}
1.77 - 2.35 {18 – 24}
{110 - 130} 33.34 - 37.27 {340 - 380} 1.57 - 2.16 {16 - 22} 0 - 0.2 {0 - 2}
WA30-5
TROUBLESHOOTING
H-1
H-1 Impossible to travel in either direction (FORWARD or REVERSE) [Check oil pressure] Main circuit high pressure
[Cause]
[Inspection location]
[Remedy]
➤
Replace HST motor assembly (or other part of transmission)
Defective operation of
➤
Wash, replace lowpressure relief valve
Defective operation of
➤
Wash, replace DA valve
➤ or motor
Defect inside HST pump
Replace HST pump ➤ or motor assembly
NG
Defective operation ➤ of DA valve
➤
NG
➤ Clogged filter
➤ Wash, replace filter
NG
Clogged inching ➤ orifice
➤ Wash inching orifice
Defect inside HST ➤ pump
➤
Replace HST pump assembly
NG
Defective operation ➤ of directional valve
➤
Wash, replace directional valve
NG
➤ shuttle valve spool
Defective operation of
➤
Wash, replace shuttle valve
➤ Defect inside HST pump or ➤ motor
Replace HST pump ➤ or motor assembly
➤ Clogged drain orifice
➤ Wash drain orifice
OK
Damage inside HST ➤ motor
NG Main circuit low pressure
NG
Check low-pressure relief valve
NG
➤ low-pressure relief valve
NG
➤ DA valve
OK
➤ Check DA valve OK OK
Control oil pressure
NG
Check DA valve
Wash, replace DA valve
OK
➤ Check fail-safe filter OK
➤
OK (Low probability of occurrence)
Check inching orifice OK
x3, x4 oil pressure
NG (Both X3 and X4)
Check directional valve
OK
➤
OK
Check motor shuttle valve spool OK
OK Check pump drain orifice
WA30-5
NG
20-305 (3)
TROUBLESHOOTING
H-2
H-2 Impossible to travel in one direction only (either FORWARD or REVERSE) [Check oil pressure]
NG
Check high-pressure relief valve
NG
Defective operation of
➤ high-pressure relief valve
➤
Main circuit high pressure
[Cause]
[Inspection location]
[Remedy]
NG
➤
Wash, replace highpressure relief valve (Try interchanging F and R)
OK
X3, X4 oil pressure
NG (Both X3 and X4)
Check directional valve
NG
Defective operation ➤ of directional valve
Wash, replace ➤ directional valve
NG
Defective operation ➤ of shuttle valve spool
Wash, replace ➤ shuttle valve
Defect inside HST ➤ pump or motor
Replace HST pump ➤ or motor assembly
OK
➤
OK
Check motor shuttle valve spool OK
➤
20-306 (3)
WA30-5
TROUBLESHOOTING
H-3
H-3 Lacks speed in both directions (FORWARD and REVERSE)
[Check oil pressure]
Main circuit low pressure
[Cause]
[Inspection location]
NG
Check low-pressure relief valve
[Remedy]
Wash, replace lowpressure relief valve
NG
➤ low-pressure relief valve
➤
NG
Defective operation ➤ of DA valve
Wash, replace DA ➤ valve
NG
Defective performance ➤ of charge pump (discharge too small)
Replace charge ➤ pump
Defect inside HST ➤ pump or motor
➤ Replace HST pump or motor assembly
NG
Defective operation ➤ of DA valve
➤ Wash, replace DA valve
NG
➤ Clogged filter
➤ Wash, replace filter
NG
Clogged inching ➤ orifice
➤ Wash inching orifice
Defect inside HST ➤ pump
Replace HST pump ➤ assembly
NG
Defective operation of ➤ directional valve
Wash, replace ➤ directional valve
NG
➤ Clogged filter
➤ Wash, replace filter
NG
➤
Defective operation of
OK
➤ Check DA valve
OK
OK
➤ Check oil filter Check charge pump OK
Control oil pressure
NG
Check DA valve OK
➤ Check fail-safe filter OK
➤
OK (Low probability of occurrence)
Check inching orifice OK
x3, x4 oil pressure
NG (Both X3 and X4)
Check directional valve OK
➤
OK
Check fail-safe filter OK
➤ Check motor shuttle valve spool
Defective operation of shuttle valve spool
➤
Wash, replace shuttle valve
➤
Replace HST pump or motor assembly
OK Defect inside HST ➤ pump or motor
WA30-5
20-307 (3)
TROUBLESHOOTING
H-4, H-5
H-4 Lacks speed in one direction only (FORWARD or REVERSE)
[Check oil pressure]
[Cause]
[Inspection location]
[Remedy]
Control oil pressure
OK
x3, x4 oil pressure
NG
Check directional valve
Wash, replace directional valve
NG
Defective operation ➤ of directional valve
➤
NG
➤ Clogged filter
➤ Wash, replace filter
NG
Defective operation ➤ of shuttle valve spool
➤
Wash, replace shuttle valve
Defect inside of HST ➤ pump or motor
➤
Replace HST motor assembly
OK
➤
OK
Check fail-safe filter of motor
➤
OK
Check motor shuttle valve spool OK
H-5 Lacks drawbar pull in both directions (FORWARD and REVERSE) [Check oil pressure] Main circuit high pressure
[Cause]
[Inspection location]
OK
Check fail-safe filter of motor
[Remedy]
NG
➤ Clogged filter
➤ Wash, replace filter
NG
Defective operation of ➤ shuttle valve spool
➤
Defective operation ➤ of HST motor
Replace HST motor ➤ assembly
OK
➤
NG
Check motor shuttle valve spool
Wash, replace shuttle valve
OK
Carry out same troubleshooting as for "Lacks speed in both directions (FORWARD and REVERSE)"
20-308 (3)
(or other part of transmission)
WA30-5
TROUBLESHOOTING
H-6, H-7, H-8
H-6 Lacks drawbar pull in one direction only (FORWARD or REVERSE) [Check oil pressure] Main circuit high pressure
[Cause]
[Inspection location]
OK
Check fail-safe filter of motor
NG
➤ Clogged filter
NG
➤ shuttle valve spool
[Remedy]
➤ Wash, replace filter
OK
➤
NG
Check motor shuttle valve spool
Defective operation of
➤
Wash, replace shuttle valve
Defective operation of
➤
Replace HST motor assembly
Defective operation of
➤
Wash, replace highpressure relief valve
OK ➤ HST motor
Check high-pressure relief valve
NG
➤ high-pressure relief valve
(Try interchanging F and R)
OK
➤ Carry out same troubleshooting as for "Lacks speed in one direction only (FORWARD or REVERSE)"
H-7 Engine speed is high when starting in both directions (FORWARD and REVERSE) Carry out same troubleshooting as "Lacks speed in both directions (FORWARD and REVERSE)"
H-8 Engine speed is high when starting in one direction only (FORWARD or REVERSE) [Cause]
[Inspection location]
Check for looseness of pump neutral adjustment screw
NG
Incorrect pump neutral
➤ position
[Remedy] Adjust neutral adjust-
➤ ment screw again
OK
➤ Carry out same troubleshooting as for "Lacks speed in one direction only (FORWARD or REVERSE)"
WA30-5
20-309 (3)
DISASSEMBLY AND ASSEMBLY
30 DISASSEMBLY AND ASSEMBLY How to read this manual ............................ 30- 2 Precautions when carrying out operation . 30- 4 Special tools list ........................................... 30- 6 See 68E-88E Series Engine Shop Manual. STARTING MOTOR Removal and installation ALTERNATOR Removal and installation FUEL INJECTION PUMP Removal and installation WATER PUMP Removal and installation NOZZLE HOLDER Removal and installation CYLINDER HEAD Removal and installation FUEL INJECTION PUMP Removal and installation .......................... 30- 6-1 ENGINE Removal and installation .......................... 30- 7 RADIATOR Removal and installation .......................... 30-21 FUEL TANK Removal and installation .......................... 30-25 MAIN PISTON PUMP Removal and installation .......................... 30-26 Disassembly and assembly ...................... 30-35 PISTON MOTOR Removal and installation .......................... 30-41 Disassembly and assembly ...................... 30-45 ENGINE AND TRANSFER Removal and installation .......................... 30-47 TRANSFER Disassembly and assembly ...................... 30-60 DRIVE SHAFT Disassembly and assembly ...................... 30-67
FRONT AXLE Removal and installation ........................ 30- 69 REAR AXLE Removal and installation ........................ 30- 71 DIFFERENTIALS Disassembly and assembly .................... 30- 77 AXLE HOUSINGS Disassembly and assembly .................... 30- 91 CENTER HINGE PIN Removal and installation ........................ 30-102 STEERING VALVE Removal and installation ........................ 30-119 Disassembly and assembly .................... 30-120 STEERING VALVE AND RELIEF VALVE HOUSING SIDE Disassembly and assembly .................... 30-128 STEERING CYLINDER Removal and installation ........................ 30-130 PARKING BRAKE Removal and installation ........................ 30-131 HYDRAULIC TANK Removal and installation ........................ 30-136 WORK EQUIPMENT VALVE Removal and installation ........................ 30-137 DUMP CYLINDER Removal and installation ........................ 30-138 LIFT CYLINDER Removal and installation ........................ 30-139 HYDRAULIC CYLINDER Disassembly and assembly .................... 30-140 WORK EQUIPMENT Removal and installation ........................ 30-144 COUNTERWEIGHT Removal and installation ........................ 30-150 INSTRUMENTS PANEL Removal and installation ........................ 30-151
fl When operating the hydraulic cylinders for the first time after removing and reinstalling hydraulic devices or piping such as hydraulic cylinders, pumps, etc. for repair, be sure to bleed air according to the following procedure. 1. Run the engine at low idling speed. 2. Operate the work equipment control lever to move each hydraulic cylinder 4 - 5 times. At this time, stop the cylinder about 100 mm before each stroke end, however. 3. Then, move each hydraulic cylinder to the stroke end 3 - 4 times. 4. After the above work, run the engine at the normal working speed. fl Perform the above work when starting a vehicle which has been stored long after repaired, too. WA30-5
30-1 1 (3)
HOW TO READ THIS MANUAL
DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL REMOVAL AND INSTALLATION OF ASSEMBLIES Special tools • Special tools that are deemed necessary for removal or installation of parts are listed. • List of the special tools contains the following kind of information. 1) Necessity : Special tools which cannot be substituted, should always be used. ‡: Special tools which are very useful if available, can be substituted with commercially available tools. 2) Distinction of new and existing special tools N: Tools with new part numbers, newly developed for this model. R: Tools with upgraded part numbers, remodeled from already available tools for other models. Blanks: Tools already available for other models, used without any modification. 3) Circle mark ( ) in sketch column: A circle mark means that a sketch of the special tool is presented in the section of Sketches for Special Tools. fl Part No. of special tools starting with 79*T means that they are locally made parts and as such not interchangeable with those made by Komatsu in Japan e.g. 79*T---xxx---xxxx.
Installation • Except where otherwise instructed, install parts is the reverse order of removal. • Instructions and precautions for installing parts are shown with mark in the INSTALLATION Section, identifying which step the instructions are intended for. • Marks shown in the INSTALLATION Section stand for the following. ¤: This mark indicates safety-related precautions which must be followed when doing the work. fl: This mark gives guidance or precautions when doing the procedure. 8: This mark stands for a specific coating agent to be used. : This mark indicates the specified torque. :
This mark indicates an amount of oil or water to be added.
Sketches of special tools • Various special tools are illustrated for the convenience of local manufacture.
Removal • The REMOVAL Section contains procedures, precautions and the amount of oil or water to be drained. • Various symbols used in the REMOVAL Section are explained and listed below. ¤: This mark indicates safety-related precautions which must be followed when doing the work. fl: This mark gives guidance or precautions when doing the procedure. This mark shows that there are instructions or precautions for installing parts. =: This mark shows oil or water to be drained. : Mass of a part or component.
30-2 (3) 1
WA30-5
HOW TO READ THIS MANUAL
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES Special tools • Special tools which are deemed ncessary for disassembly and assembly are listed in this section. • List of the special tools contains the following kind of information. 1) Neccessity : Special tools which cannot be substituted, should always be used. ‡: Special tools which are very useful if available, can be substituted with commercially available tools. 2) Distinction of new and existing special tools N: Tools with new part numbers, newly developed for this model. R: Tools with upgraded part numbers, remodeled from already available tools for other models. Blanks: Tools already available for other models, used without any modification. 3) Circle mark ( ) in sketch column: A circle mark means that a sketch of the special tool is presented in the section of Sketches for Special Tools. fl Part No. of special tools starting with 79*T means that they are locally made parts and as such not interchangeable with those made by Komatsu in Japan e.g. 79*T---xxx---xxxx.
Assembly • Section titled ASSEMBLY contain procedures, precautions and the know-how for the work, as well as the amount of oil or water to be added. • Various symbols used in the ASSEMBLY Section are explained and listed below. ¤: This mark indicates safety-related precautions which must be followed when doing the work. fl: This mark gives guidance or precautions when doing the procedure. 8: This mark stands for a specific coating agent to be used. : This mark indicates the specified torque. :
This mark indicates an amount of oil or water to be added.
Sketches of special tools • Various special tools are illustrated for the convenience of local manufacture.
Disassembly • The DISASSEMBLY Section contains procedures, precautions and the amount of oil or water to be drained. • Various symbols used in the DISASSEMBLY Section are explained and listed below. ¤: This mark indicates safety-related precautions which must be followed when doing the work. fl: This mark gives guidance or precautions when doing the procedure. =: This mark shows oil or water to be drained.
WA30-5
30-3 1 (3)
PRECAUTIONS WHEN CARRYING OUT OPERATION
DISASSEMBLY AND ASSEMBLY
PRECAUTIONS WHEN CARRYING OUT OPERATION [When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] 1. Precautions when carrying out removal work • If the coolant contains antifreeze dispose of it correctly. • After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering. • When draining oil, prepare a container of adequate size to catch the oil. • Confirm the match marks showing the installation position, and make match marks in the 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. Do not pull the wires. • Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. • Check the number of thickness of the shims, and keep in a safe place. • When raising components, be sure to use lifting equipment of ample strength. • When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. • Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. fl Precautions when handling piping during disassembly Fit the following blind plugs into the piping after disconnecting it during disassembly operations. 1) Face seal type hoses and tubes Nominal number
Plug (nut end)
Nut (elbow end)
02 03 04 05 06
07376-70210 07376-70315 07376-70422 07376-70522 07376-70628
02789-00210 02789-00315 02789-00422 02789-00522 02789-00628
2) Split flange type hoses and tubes Nominal number
Flange (hose end)
Sleeve head (tube end)
Split flange
04 05
07379-00400 07379-00500
07378-10400 07378-10500
07371-30400 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used. Nominal number
Part Number
06 08 10 12 14 16 18 20 22 24 27
07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430 07049-02734
30-4 (3) 1
Dimensions (mm) D
d
L
6 8 10 12 14 16 18 20 22 24 27
5 6.5 8.5 10 11.5 13.5 15 17 18.5 20 22.5
8 11 12 15 18 20 22 25 28 30 34
WA30-5
DISASSEMBLY AND ASSEMBLY
PRECAUTIONS WHEN CARRYING OUT OPERATION
2. • • • • •
Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pins and lock plates securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 – 3 drops of adhesive. • When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. • Clean all parts, and correct any damage, dents, burrs, or rust. • Coat rotating parts and sliding parts with engine oil. • When press fitting parts, coat the surface with anti-friction compound (LM-P). • After fitting snap rings, check that the snap ring is fitted securely in the ring groove. • When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. • When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. • When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side. fl 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 the cylinder 100 mm from the end of its stroke. 3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke. fl When using the machine for the first time after repair or long storage, follow the same procedure.
WA30-5
30-5 1 (3)
SPECIAL TOOLS LIST
DISASSEMBLY AND ASSEMBLY
SPECIAL TOOLS LIST Contents of work Symbol Assembly of differential
Pulling out axle shaft bearing
A
Part No.
Part name
Q'ty
1
793-122-1110
Mandrel
1
1
790-101-3100
Puller assembly
1
2
790-101-3110
Puller
3
790-101-3120
Bolt
2
4
790-101-3130
Nut
2
Remarks
Mounting distance
1 set
B
Support of press fitting of axle housing seal
C
1
793-122-1120
Seal support
2
Removal, installation of parking brake assembly
D
1
793-141-1110
Disc support
2
790-502-1003
Cylinder repair stand
1
790-101-1102 or 790-102-1100
Pump Power wrench
790-445-2871
Bracket
1
790-445-3590
Pin
2
2
790-330-1100 or 790-102-2301
Multi-wrench
1
Removal, installation of cylinder head assembly
3
790-720-1000
Expander
1
Expansion of piston ring
796-720-1740
Ring
07281-00809
Clamp
1
Lift cylinder
Clamping of piston
796-720-1630
Ring
1
Dump cylinder
ring
07281-00809
Clamp
1
Steering cylinder
1
Disassembly, assembly of hydraulic cylinder assemblies
E
Locking of disc
1
Dump cylinder
4
30-6 1 1
WA30-5
DISASSEMBLY AND ASSEMBLY
FUEL INJECTION PUMP
REMOVAL OF FUEL INJECTION PUMP ASSEMBLY Serial No. 26001 and up 1. Loosen the fan belt and remove fan (1).
2. Before removing fuel injection pump (2), remove the cover in front of the timing gear case. Using paint, make match marks on the meshing parts of pump drive gear (3) and idle gear (4).
3. Accurately record the relative positions of stamped line (5) of the fuel injection pump body and stamped line (6) of the gear case with markoff lines (7), etc.
4. Remove fuel high pressure injection pipe (8).
5. Disconnect fuel hoses (9) and (10) and engine stop solenoid connector (CN-L6).
WA30-5
30-6-1 (3)
DISASSEMBLY AND ASSEMBLY
FUEL INJECTION PUMP
6. Remove lubrication tube (11) and 3 fuel injection pump mounting nuts (12).
7. Remove nut (13) from the fuel injection pump drive shaft end. fl Take care not to drop the nut in the case. fl Never loosen mounting bolt (14) of pump drive gear (3) and flange. (If the relative positions of the flange and fuel injection pump drive gear change, it becomes very difficult to adjust the fuel injection timing.) 8. Using a puller, push the fuel injection pump drive shaft out of the gear and remove fuel injection pump assembly (2).
INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY Serial No. 26001 and up
fl Carry out installation in the reverse order to removal.
fl For installation of the fuel high-pressure injection pipe, see the illustration at right. Nut at shaft end: 113 – 123 Nm {11.5 – 12.5 kgm}
fl Install the fuel injection pump temporarily and tighten the nut at the shaft end first. fl Adjust the fuel injection angle. For details, see TESTING AND ADJUSTING, Testing and adjusting fuel injection timing.
30-6-2 (3)
WA30-5
DISASSEMBLY AND ASSEMBLY
ENGINE
REMOVAL OF ENGINE ASSEMBLY Serial No. 22005 – 26000
¤ Stop the vehicle on level ground and install the safety bar to the frame, then lower the bucket to the ground. Stop the engine and apply the parking brake and put blocks under the wheels to prevent the vehicle from moving. fl Open the engine hood in advance. fl Disconnect the cable from the negative (–) terminal of the battery.
1. Draining water 1) Loosen radiator cap (1) to release the pressure from the radiator. 2) Loosen drain valve (2) to drain cooling water. fl If antifreeze is in the radiator, handle it as chemical and do not discharge it without treating it. =
Cooling water: 5.5 ¬
2. Electric wiring and sub-tank 1) Remove clamps of electric wire (3) and battery cable (4). fl Leave the protector installed. 2) Disconnect hose (5) connected to sub-tank from radiator, then remove sub-tank (6).
3. Radiator hoses Loosen clamps of radiator hoses (7) and (8) on engine side. fl Pull out the hoses when removing the radiator.
WA30-5
30-7 1 (3)
DISASSEMBLY AND ASSEMBLY
ENGINE
4. Fan guard Remove fan guard (9).  Take care not to damage the radiator fins.
5. Hydraulic piping Disconnect hydraulic pipes (10) and (11) from radiator.
6. Radiator 1) Remove hood lock (12) and bracket (13).
2) Remove mounting bolts (15) of radiator (14), and lift off radiator.  Taking care not to damage the radiator fins, remove the radiator by pulling it backward. Radiator (Including bracket): 14 kg
30-8 (3) 1
WA30-5
DISASSEMBLY
7.
Electric wiring Disconnect following electric wires. Starting motor wiring connectors
l
ENGINE
AND ASSEMBLY
(16) and
(17). Alternator wire (18). Wiring connectors (191, (201, and (21) on right side of engine. Put tags, etc. to the wires for distinction. *
. l
16
. .
l
8.
HST oil temperature sensor terminal HST filter clogging sensor wire (23).
(22).
Wiring connectors (24) and (25) on left side of engine. Remove ground wire (26) on the left side * of the engine from the rear frame.
Fuel control linkage and cable Disconnect cable (28) from fuel control linkage lever (271, then remove cable (28) from support (29) under accelerator pedal. * When removing the cable from the bracket, make match marks on the lock nut for assem bly.
WAX-5
DISASSEMBLY
9.
ENGINE
AND ASSEMBLY
Fuel hose I) Disconnect hose (30) between water separator (31) and feed pump from water separator. 2) Disconnect hose (32) between fuel filter and fuel tank from fuel filter.
I I I
362FO6094
10. Engine oil drain valve Remove engine oil drain valve (33) from rear frame.
11. Muffler and exhaust tube 1) Remove muffler cover (34). 2) Remove nut (36) of exhaust tube (35) from engine, then disconnect tube. 3)
Remove muffler mounting bracket (37) from engine mounting part.
4)
Remove muffler tube assembly (38) without removing exhaust tube (35). j, Remove muffler pipe (39) in advance.
362FO5096
30-10 0
WA30-5
DISASSEMBLY
5) 6)
Remove Remove
ENGINE
AND ASSEMBLY
hydraulic piping clamp (40). clip (41) under engine mount.
362FOE.307
DWW05484
12. Engine hood and air cleaner assembly 1) Sling engine hood (42) by three parts and remove gas spring (43) from hood. * Take care not to damage the rod of the gas spring.
2)
Remove floor mounting end of engine hood (421, then lift it off. * Remove engine hood without removing the operator’s seat, balancing it carefully. r9 kg
3)
Engine
Remove air cleaner connect tachometer
hood (including
seat): 32 kg
assembly (441, then discable (45).
DISASSEMBLY
ENGINE
AND ASSEMBLY
13. Engine 1) Place stand @ under transfer (47). * Adjust the height of stand @ carefully. 2) Sling engine temporarily and remove bolts coupling engine and transfer (47). j, The 2 nuts under the engine flywheel are welded, and stud bolts are used.
m 3)
Remove mounting nut (48) and move engine (49) horizontally backward, then pull out stud bolts (50) under transfer (47). * When pulling out the stud bolts, keep the level of the engine and transfer. Pull out the stud bolts carefully so that * the welded nut will not be removed. * Remove the engine oil drain hose so carefully that it will not be damaged. kg rF?l
14. Disassembly 1) Remove
2)
362FO6099
Engine (including engine mount bracket): 160 kg
of damper damper assembly
oil and
(51) from engine
(49). * Width across flats of hexagon socket: mm Remove boss (52) from removed damper sembly (51). Ir Width across flats of hexagon socket: mm * Disassemble the damper only when quired.
30-12 0
10 as10 re-
WA30-5
DISASSEMBLY AND ASSEMBLY
ENGINE
INSTALLATION OF ENGINE ASSEMBLY Serial No. 22005 – 26000 1. Assembly of damper 1) Drive pin (53) in pin hole of boss (52) to end. 2) Install boss (52), aligning it with hole of rubber (54). fl Apply grease thinly to the aluminum insert of the rubber. fl Degrease the threads of the boss and mounting bolts in advance.
3) Apply adhesive to threads of mounting bolts (55), and lock boss (52) with them. fl Take care of the installing direction of the boss. fl When installing the boss, take care that grease and adhesive will not stick to the rubber. fl After tightening the bolts, check that the rubber is not loosened. 8 Mounting bolt: Adhesive (LOCTITE 262) Mounting bolt: 87.8 ± 4.41 Nm {8.95 ± 0.45 kgm} 4) Install damper assembly (51), matching it to fitting hole of flywheel (56) of engine (49). fl When installing the damper assembly, take care that grease and adhesive will not stick to the rubber. fl Degrease the mounting bolts and tapped holes on the engine side in advance. fl After tightening the bolts, check that the rubber is not loosened. 8 Mounting bolt: Adhesive (LOCTITE 262) Mounting bolt: 87.8 ± 4.41 Nm {8.95 ± 0.45 kgm}
WA30-5
30-13 (3) 1
DISASSEMBLY AND ASSEMBLY
ENGINE
2. Engine 1) Sling and hold engine assembly (49) horizontally and install it to the fitting part of transfer (47). fl Install 2 stud bolts (50) to the bottom of the transfer. fl Apply adhesive after installing the engine assembly to the transfer. fl When coupling the engine with the transfer, adjust their height so that the pump shaft on the transfer side will be inserted smoothly in the spline of the damper on the engine side. fl Take care that stand (1) will not come off. Never couple the engine forcibly. fl Apply grease to the spline of the damper. 8 Spline: Grease (LM-P)
2) Check that joint of engine (49) and transfer (47) is even, then tighten the coupling bolts. fl Clamp the engine wires, hydraulic hoses, and engine control cable together with clips. Mounting bolt: 110.0 ± 12.3 Nm {11.25 ± 1.25 kgm}
3) Degrease engine side of stud bolt (50) and threads of nut (51-1) and apply adhesive to them, then tighten stud bolt (50) permanently. fl Apply adhesive to only the engine side. fl When tightening the nut on the transfer side, take care that the stud will not turn. 8 Stud: Adhesive (LOCTITE 262) Nut: 110.0 ± 12.3 Nm {11.25 ± 1.25 kgm}
4) Remove stand (1) under transfer (47).
30-14 (3) 1
WA30-5
DISASSEMBLY AND ASSEMBLY
ENGINE
5) Install engine mounting nut (48). Mounting nut: 66.2 ± 7.35 Nm {6.75 ± 0.75 kgm}
3. Engine hood and air cleaner assembly 1) Connect tachometer cable (45), then connect hose of air cleaner assembly (44) to turbocharger and secure it with clamp.
2) Install engine hood (42) to floor fitting part and tighten mounting bolts temporarily. fl When slinging the engine hood, take care of its center of gravity. fl After installing the engine hood lock, tighten the mounting bolts permanently. 3) Sling engine hood (42) and install gas spring (43) to hood. 4. Muffler and exhaust tube 1) Install clip (41) to lower part of engine mount.
WA30-5
30-15 (3) 1
DISASSEMBLY AND ASSEMBLY
ENGINE
2) Install hydraulic piping clamp (40).
3) Install muffler tube assembly (38) temporarily without removing exhaust tube (35). fl Install muffler pipe (39).
4) Install muffler mounting bracket (37) to engine. Mounting bolt: 66.2 ± 7.35 Nm {6.75 ± 0.75 kgm} 5) Install exhaust tube (35) to engine with nuts (36). Nut: 30.9 ± 3.43 Nm {3.15 ± 0.35 kgm}
6) Install muffler cover (34).
30-16 (3) 1
WA30-5
DISASSEMBLY AND ASSEMBLY
ENGINE
5. Engine oil drain valve Install engine oil drain valve (33) to rear frame.
6. Fuel hose 1) Connect hose (32) between fuel filter and fuel tank to fuel filter. 2) Connect hose (30) between water separator (31) and feed pump to water separator.
7. Fuel control linkage and cable Connect cable (28) to fuel control linkage lever (27), then install it to support (29) under accelerator pedal. fl When installing, align the match marks made when removed. fl Adjust the revolution of the engine. For details, see TESTING AND ADJUSTING. 8. Electric wiring Connect the following electric wires. • Starting motor wiring connectors (16) and (17). • Alternator wire (18). • Wiring connectors (19), (20), and (21) on right side of engine.
WA30-5
30-17 1 (3)
DISASSEMBLY AND ASSEMBLY
• •
• •
ENGINE
Wiring connectors (24) and (25) on left side of engine Install ground wire (26) on left side of engine to rear frame.
HST filter clogging sensor wire (23). HST oil temperature sensor terminal (22).
9. Radiator 1) Place radiator (14) to the fitting position, and install cushions and spacers, then install mounting bolts (15). 2) Insert upper and lower hoses of radiator in fitting position on engine side. fl Tighten the mounting bolts temporarily first. Tighten them permanently after positioning the radiator. Radiator mounting bolt: 66.2 ± 7.35 Nm {6.75 ± 0.75 kgm} fl Install the radiator so that the clearance between the radiator fins and front side of the fan will be even all round. 3) Install bracket (13) and hood lock (12). fl Pressing in the bracket forward, secure it with the mounting bolt. fl After installing the hood lock, adjust the locking condition and secure with mounting bolts.
30-18 (3) 1
WA30-5
DISASSEMBLY AND ASSEMBLY
ENGINE
10. Hydraulic piping Connect hydraulic pipes (10) and (11) on radiator side. fl Do not twist the hoses.
11. Fan guard Install fan guard (9).
12. Radiator hoses Tighten clamps of radiator hoses (8) and (7) on engine side. fl Tighten these clamps so that the hoses will not be twisted and will not interfere with the other parts.
13. Electric wiring and sub-tank 1) Insert bracket in sub-tank (6) and connect hose (5) to radiator. 2) Install clamps of electric wire (3) and battery cable (4). fl Take care not to bend the protector. fl Connect the cable of the negative (–) terminal of the battery.
WA30-5
30-19 (3) 1
DISASSEMBLY AND ASSEMBLY
ENGINE
14. Refilling with water and oil 1) Tighten drain valve and add water through water filler (1) to specified level. - Cooling water: 5.5 ¬
2) Add hydraulic oil through oil filler (57) to specified level. fl Run the engine to circulate the water and oil through the system. Then, check their levels again. fl Close the engine hood.
30-20 1
WA30-5
DISASSEMBLY AND ASSEMBLY
ENGINE
REMOVAL OF ENGINE ASSEMBLY Serial No. 26001 and up
¤ Stop the vehicle on level ground and install the safety bar to the frame, then lower the bucket to the ground. Stop the engine and apply the parking brake and put blocks under the wheels to prevent the vehicle from moving. fl Open the engine hood in advance. fl Disconnect the cable from the negative (–) terminal of the battery. 1. Cover Remove the cover (vibration damping panel) on the right side of the engine. 2. Draining water 1) Loosen radiator cap (1) to release the pressure from the radiator. 2) Loosen drain valve (2) to drain cooling water. fl If antifreeze is in the radiator, handle it as chemical and do not discharge it without treating it. =
Cooling water: 7.5 ¬
3. Electric wiring and sub-tank 1) Disconnect connector (3) and remove clamp (4) of the wiring harness. fl Put the wiring harness on the front side. 2) Disconnect hose (5) connected to sub-tank from radiator, then remove sub-tank (6).
4. Radiator hoses Loosen clamps of radiator hoses (7) and (8) on engine side. fl Pull out the hoses when removing the radiator.
WA30-5
30-20-1 (3)
DISASSEMBLY AND ASSEMBLY
ENGINE
5. Fan guard Remove fan guard (9). fl Take care not to damage the radiator fins.
6. Hydraulic piping Disconnect hydraulic pipes (10) and (11) from radiator.
7. Radiator 1) Remove hood lock (12) and bracket (13).
30-20-2 (3)
WA30-5
DISASSEMBLY AND ASSEMBLY
ENGINE
2) Remove mounting bolts (15) of radiator (14), and lift off radiator.  Taking care not to damage the radiator fins, remove the radiator by pulling it backward. Radiator (Including bracket): 14 kg
8. Electric wiring 1) Disconnect main wiring harness (16) of the starting motor from the battery and disconnect connector (17) from the fuel pump. 2) Disconnect ground wiring harnesses (18) and (19).
3) Disconnect HST oil temperature sensor terminal (22) and HST filter clogging sensor wire (23).
WA30-5
30-20-3 (3)
DISASSEMBLY AND ASSEMBLY
ENGINE
4) Disconnect connectors (20), (21), (24), and (25) of the wiring harnesses between the chassis and engine.  Remove the clamps from the disconnected wiring harnesses and put the wiring harnesses on the engine side.
9. Fuel control linkage and cable Disconnect cable (28) from fuel control linkage lever (27), then remove cable (28) from support (29) under accelerator pedal.  When removing the cable from the bracket, make match marks on the lock nut for assembly.
10. Fuel hoses 1) Disconnect fuel hoses (30) and (31) from fuel filter.
11. Engine oil drain valve Remove engine oil drain valve (33) from rear frame. 12. Muffler and exhaust tube 1) Remove muffler cover (34).
30-20-4 (3)
WA30-5
DISASSEMBLY AND ASSEMBLY
ENGINE
2) Remove nut (36) of exhaust tube (35) from engine, then disconnect tube.
3) Remove muffler mounting bracket (37) from engine mounting part. 4) Remove muffler tube assembly (38) without removing exhaust tube (35).
fl Remove muffler pipe (39) in advance.
5) Remove hydraulic piping clamp (40).
WA30-5
30-20-5 (3)
DISASSEMBLY AND ASSEMBLY
ENGINE
6) Remove clip (41) under engine mount.
13. Engine hood and air cleaner assembly 1) Sling engine hood (42) by three parts and remove gas spring (43) from hood. fl Take care not to damage the rod of the gas spring.
2) Remove floor mounting end of engine hood (42), then lift it off. fl Remove engine hood without removing the operator’s seat, balancing it carefully. Engine hood (including seat): 32 kg
3) Remove air cleaner assembly (44), then disconnect tachometer cable (45) at panel side. (Put the cable on the engine side.)
30-20-6 (3)
WA30-5
DISASSEMBLY AND ASSEMBLY
ENGINE
14. Engine 1) Place stand (1) under transfer (47). fl Adjust the height of stand (1) carefully. 2) Sling engine temporarily and remove bolts coupling engine and transfer (47). fl The 2 nuts under the engine flywheel are welded, and stud bolts are used.
3) Remove mounting nut (48) and move engine (49) horizontally backward, then pull out stud bolts (50) under transfer (47). fl When pulling out the stud bolts, keep the level of the engine and transfer. fl Pull out the stud bolts carefully so that the welded nut will not be removed. fl Remove the engine oil drain hose so carefully that it will not be damaged. Engine (including engine oil and mount bracket): 160 kg
15. Disassembly of damper 1) Remove damper assembly (51) from engine (49). fl Width across flats of hexagon socket: 10 mm 2) Remove boss (52) from removed damper assembly (51). fl Width across flats of hexagon socket: 10 mm fl Disassemble the damper only when required.
WA30-5
30-20-7 (3)
DISASSEMBLY AND ASSEMBLY
ENGINE
INSTALLATION OF ENGINE ASSEMBLY Serial No. 26001 and up 1. Assembly of damper 1) Drive pin (53) in pin hole of boss (52) to end. 2) Install boss (52), aligning it with hole of rubber (54). fl Apply grease thinly to the aluminum insert of the rubber. fl Degrease the threads of the boss and mounting bolts in advance.
3) Apply adhesive to threads of mounting bolts (55), and lock boss (52) with them. fl Take care of the installing direction of the boss. fl When installing the boss, take care that grease and adhesive will not stick to the rubber. fl After tightening the bolts, check that the rubber is not loosened. 8 Mounting bolt: Adhesive (LOCTITE 262) Mounting bolt: 87.8 ± 4.41 Nm {8.95 ± 0.45 kgm} 4) Install damper assembly (51), matching it to fitting hole of flywheel (56) of engine (49). fl When installing the damper assembly, take care that grease and adhesive will not stick to the rubber. fl Degrease the mounting bolts and tapped holes on the engine side in advance. fl After tightening the bolts, check that the rubber is not loosened. 8 Mounting bolt: Adhesive (LOCTITE 262) Mounting bolt: 87.8 ± 4.41 Nm {8.95 ± 0.45 kgm}
30-20-8 (3)
WA30-5
DISASSEMBLY AND ASSEMBLY
ENGINE
2. Engine 1) Sling and hold engine assembly (49) horizontally and install it to the fitting part of transfer (47). fl Install 2 stud bolts (50) to the bottom of the transfer. fl Apply adhesive after installing the engine assembly to the transfer. fl When coupling the engine with the transfer, adjust their height so that the pump shaft on the transfer side will be inserted smoothly in the spline of the damper on the engine side. fl Take care that stand [1] will not come off. Never couple the engine forcibly. fl Apply grease to the spline of the damper. 8 Spline: Grease (LM-P)
2) Check that joint of engine (49) and transfer (47) is even, then tighten the coupling bolts. fl Clamp the engine wires, hydraulic hoses, and engine control cable together with clips. Mounting bolt: 110.0 ± 12.3 Nm {11.25 ± 1.25 kgm}
3) Degrease engine side of stud bolt (50) and threads of nut (51-1) and apply adhesive to them, then tighten stud bolt (50) permanently. fl Apply adhesive to only the engine side. fl When tightening the nut on the transfer side, take care that the stud will not turn. 8 Stud: Adhesive (LOCTITE 262) Nut: 110.0 ± 12.3 Nm {11.25 ± 1.25 kgm}
4) Remove stand [1] under transfer (47).
WA30-5
30-20-9 (3)
DISASSEMBLY AND ASSEMBLY
ENGINE
5) Install engine mounting nut (48). Mounting nut: 66.2 ± 7.35 Nm {6.75 ± 0.75 kgm}
3. Engine hood and air cleaner assembly 1) Connect tachometer cable (45), then connect hose of air cleaner assembly (44) to turbocharger and secure it with clamp.
2) Install engine hood (42) to floor fitting part and tighten mounting bolts temporarily. fl When slinging the engine hood, take care of its center of gravity. fl After installing the engine hood lock, tighten the mounting bolts permanently.
3) Sling engine hood (42) and install gas spring (43) to hood.
30-20-10 (3)
WA30-5
DISASSEMBLY AND ASSEMBLY
ENGINE
4. Muffler and exhaust tube 1) Install clip (41) to lower part of engine mount.
2) Install hydraulic piping clamp (40).
3) Install muffler tube assembly (38) temporarily without removing exhaust tube (35).
fl Install muffler pipe (39).
WA30-5
30-20-11 (3)
DISASSEMBLY AND ASSEMBLY
ENGINE
4) Install muffler mounting bracket (37) to engine. Mounting bolt: 66.2 ± 7.35 Nm {6.75 ± 0.75 kgm} 5) Install exhaust tube (35) to engine with nuts (36). Nut: 30.9 ± 3.43 Nm {3.15 ± 0.35 kgm}
6) Install muffler cover (34).
5. Engine oil drain valve Install engine oil drain valve (33) to rear frame.
6. Fuel hose Connect fuel hoses (31) and (30) to fuel filter.
30-20-12 (3)
WA30-5
DISASSEMBLY AND ASSEMBLY
ENGINE
7. Fuel control linkage and cable Connect cable (28) to fuel control linkage lever (27), then install it to support (29) under accelerator pedal.  When installing, align the match marks made when removed.  Adjust the revolution of the engine. For details, see TESTING AND ADJUSTING.
8. Electric wiring Connect the following electric wires 1) Connect main wiring harness (16) of the starting motor to the battery and connect connector (17) to the fuel pump. 2) Connect ground wiring harnesses (18) and (19).
3) Connect connectors (25), (24), (21), and (20) of the wiring harnesses between the chassis and engine. 4) Install the wiring harness clamps as they were.
5) Connect HST filter clogging sensor wire (23) and HST oil temperature sensor terminal (22).
WA30-5
30-20-13 (3)
DISASSEMBLY AND ASSEMBLY
ENGINE
9. Radiator 1) Place radiator (14) to the fitting position, and install cushions and spacers, then install mounting bolts (15). 2) Insert upper and lower hoses of radiator in fitting position on engine side. fl Tighten the mounting bolts temporarily first. Tighten them permanently after positioning the radiator. Radiator mounting bolt: 66.2 ± 7.35 Nm {6.75 ± 0.75 kgm} fl Install the radiator so that the clearance between the radiator fins and front side of the fan will be even all round. 3) Install bracket (13) and hood lock (12). fl Pressing in the bracket forward, secure it with the mounting bolt. fl After installing the hood lock, adjust the locking condition and secure with mounting bolts.
10. Hydraulic piping Connect hydraulic pipes (10) and (11) on radiator side. fl Do not twist the hoses.
30-20-14 (3)
WA30-5
DISASSEMBLY AND ASSEMBLY
ENGINE
11. Fan guard Install fan guard (9).
12. Radiator hoses Tighten clamps of radiator hoses (8) and (7) on engine side. fl Tighten these clamps so that the hoses will not be twisted and will not interfere with the other parts.
13. Electric wiring and sub-tank 1) Insert bracket in sub-tank (6) and connect hose (5) to radiator. 2) Connect connector (3) and install wiring harness clamp (4). fl Take care not to bend the protector. fl Connect the cable of the negative (–) terminal of the battery. 14. Cover Install the cover (vibration damping panel) on the right side of the engine.
15. Refilling with water and oil Tighten drain valve and add water through water filler (1) to specified level. Cooling water: 7.5 ¬
WA30-5
30-20-15 (3)
DISASSEMBLY AND ASSEMBLY
ENGINE
2) Add hydraulic oil through oil filler (57) to specified level. fl Run the engine to circulate the water and oil through the system. Then, check their levels again. fl Close the engine hood.
30-20-16 (3)
WA30-5
DISASSEMBLY AND ASSEMBLY
RADIATOR
REMOVAL OF RADIATOR Serial No. 22005 – 26000
¤ Stop the vehicle on level ground and install the safety bar to the frame, then lower the bucket to the ground. Stop the engine and apply the parking brake and put blocks under the wheels to prevent the vehicle from moving. fl Open the engine hood in advance. fl Disconnect the cable from the negative (–) terminal of the battery. 1. Draining water 1) Loosen radiator cap (1) to release the pressure from the radiator. 2) Loosen drain valve (2) to drain cooling water. fl If antifreeze is in the radiator, handle it as chemical and do not discharge it without treating it. = Cooling water: 5.5 ¬
2. Electric wiring and sub-tank 1) Remove clamps of electric wire (3) and battery cable (4). fl Leave the protector installed. 2) Disconnect hose (5) connected to sub-tank from radiator, then remove sub-tank (6).
3. Radiator hoses Loosen clamps of radiator hoses (7) and (8) on engine side. fl Pull out the hoses when removing the radiator.
WA30-5
30-21 (3) 1
DISASSEMBLY AND ASSEMBLY
RADIATOR
4. Fan guard Remove fan guard (9).  Take care not to damage the radiator fins.
5. Hydraulic piping Disconnect hydraulic pipes (10) and (11) from radiator.
6. Radiator 1) Remove hood lock (12) and bracket (13).
2) Remove mounting bolts (15) of radiator (14), and lift off radiator.  Taking care not to damage the radiator fins, remove the radiator by pulling it backward. Radiator (Including bracket): 14 kg
30-22 (3) 1
WA30-5
DISASSEMBLY AND ASSEMBLY
RADIATOR
INSTALLATION OF RADIATOR Serial No. 22005 – 26000 1. Radiator 1) Place radiator (14) to the fitting position, and install cushions and spacers, then install mounting bolts (15). 2) Insert upper and lower hoses of radiator in fitting position on engine side. fl Tighten the mounting bolts temporarily first. Tighten them permanently after positioning the radiator. Radiator mounting bolt: 66.2 ± 7.35 Nm {6.75 ± 0.75 kgm} fl Install the radiator so that the clearance between the radiator fins and front side of the fan will be even all round. 3) Install bracket (13) and hood lock (12). fl Pressing the bracket against the radiator, secure it with the mounting bolt. fl After installing the hood lock, adjust the locking condition and secure with mounting bolts.
2. Hydraulic piping Connect hydraulic pipes (11) and (10) on radiator side. fl Do not twist the hoses.
3. Fan guard Install fan guard (9).
WA30-5
30-23 (3) 1
DISASSEMBLY AND ASSEMBLY
RADIATOR
4. Radiator hoses Tighten clamps of radiator hoses (8) and (7) on engine side. fl Tighten these clamps so that the hoses will not be twisted and will not interfere with the other parts.
5. Electric wiring and sub-tank 1) Insert sub-tank (6) in bracket and connect hose (5) on radiator side. 2) Install clamps of electric wire (3) and battery cable (4). fl Connect the cable of the negative (–) terminal of the battery.
6. Refilling with water and oil 1) Tighten drain valve and add water through water filler (16) to specified level. - Cooling water: 5.5 ¬
2) Add hydraulic oil through oil filler (17) to specified level. fl Run the engine to circulate the water and oil through the system. Then, check their levels again. fl Close the engine hood.
30-24 1
WA30-5
DISASSEMBLY AND ASSEMBLY
RADIATOR
REMOVAL OF RADIATOR Serial No. 26001 and up
¤ Stop the vehicle on level ground and install the safety bar to the frame, then lower the bucket to the ground. Stop the engine and apply the parking brake and put blocks under the wheels to prevent the vehicle from moving. fl Open the engine hood in advance. fl Disconnect the cable from the negative (–) terminal of the battery. 1. Draining water 1) Loosen radiator cap (1) to release the pressure from the radiator. 2) Loosen drain valve (2) to drain cooling water. fl If antifreeze is in the radiator, handle it as chemical and do not discharge it without treating it. = Cooling water: 7.5 ¬
2. Electric wiring and sub-tank 1) Remove the cover. 2) Disconnect connector (3) and remove wiring harness clamp (4). fl Put the wiring harness on the front side. 3) Disconnect hose (5) going to the sub-tank from the radiator and remove sub-tank (6).
3. Radiator hoses Loosen clamps of radiator hoses (7) and (8) on engine side. fl Pull out the hoses when removing the radiator.
WA30-5
30-24-1 (3)
DISASSEMBLY AND ASSEMBLY
RADIATOR
4. Fan guard Remove fan guard (9). fl Take care not to damage the radiator fins.
5. Hydraulic piping Disconnect hydraulic pipes (10) and (11) from radiator.
6. Radiator 1) Remove hood lock (12) and bracket (13).
30-24-2 (3)
WA30-5
DISASSEMBLY AND ASSEMBLY
RADIATOR
2) Remove mounting bolts (15) of radiator (14), and lift off radiator. fl Taking care not to damage the radiator fins, remove the radiator by pulling it backward. Radiator (Including bracket): 14 kg
WA30-5
30-24-3 (3)
DISASSEMBLY AND ASSEMBLY
RADIATOR
INSTALLATION OF RADIATOR Serial No. 26001 and up 1. Radiator 1) Place radiator (14) to the fitting position, and install cushions and spacers, then install mounting bolts (15). 2) Insert upper and lower hoses of radiator in fitting position on engine side. fl Tighten the mounting bolts temporarily first. Tighten them permanently after positioning the radiator. Radiator mounting bolt: 66.2 ± 7.35 Nm {6.75 ± 0.75 kgm} fl Install the radiator so that the clearance between the radiator fins and front side of the fan will be even all round. 3) Install bracket (13) and hood lock (12). fl Pressing the bracket against the radiator, secure it with the mounting bolt. fl After installing the hood lock, adjust the locking condition and secure with mounting bolts.
2. Hydraulic piping Connect hydraulic pipes (11) and (10) on radiator side. fl Do not twist the hoses.
3. Fan guard Install fan guard (9).
30-24-4 (3)
WA30-5
DISASSEMBLY AND ASSEMBLY
RADIATOR
4. Radiator hoses Tighten clamps of radiator hoses (8) and (7) on engine side. fl Tighten these clamps so that the hoses will not be twisted and will not interfere with the other parts.
5. Electric wiring and sub-tank 1) Insert sub-tank (6) in bracket and connect hose (5) on radiator side. 2) Connect the connector (3), then install clamps (4) of electric wire. fl Connect the cable of the negative (–) terminal of the battery.
6. Refilling with water and oil 1) Tighten drain valve and add water through water filler (16) to specified level. Cooling water: 7.5 ¬
2) Add hydraulic oil through oil filler (17) to specified level. fl Run the engine to circulate the water and oil through the system. Then, check their levels again. fl Close the engine hood.
WA30-5
30-24-5 (3)
FUEL TANK
DISASSEMBLY AND ASSEMBLY
REMOVAL
OF FUEL TANK
AStop the vehicle on level ground and install the safety bar to the frame, then lower the bucket to the ground. Stop the engine and apply the parking brake and put blocks under the wheels to prevent the vehicle from moving. Open engine hood (I). l
1.
2.
Plate 1) Remove plate (2) on rear side. 2) Loosen plug (3) to drain fuel.
Fuel tank 1)
2)
3) 4)
5) 6)
m .
*
.
362FOE.336
362F06337
Place block and hand lift truck under fuel tank (41, then disconnect water separator hose (9). Remove mounting bolt (5) of fuel tank (4) and lower hand lift truck. * Take care not to lower the fuel tank too Stop lowering once when the much. clearance between the fuel tank and floor a frame becomes about 60 mm. If the fuel tank is lowered to much, the * wires and hoses will be damaged. Take care. -Disconnect fuel hose (6) from fuel tank. Disconnect fuel unit wire (7) from connector. * Remove this wire without removing the breather hose. Lower fuel tank (4) slowly, balancing it. 1121 Fuel tank (Dry): 22 kg &l Pu�c out fuel tank from left bottom body.
INSTALLATION .
g+FG$
Carry out installation removal.
of vehicle
OF FUEL TANK in the
reverse
order
to
9 362FO6339
‘362FO5340
Lift up fuel tank (4) with the hand lift truck and stop it about 60 mm before the fitting part temporarily.
When lifting and installing the fuel tank, keep it level. Refilling with fuel Tighten the drain valve and supply fuel through fuel filler (8). Q
WAN-5
Fuel: 42 e
M
A
362FOX34:
30-25 0
DISASSEMBLY
AND ASSEMBLY
REMOVAL OF MAIN PUMP ASSEMBLY
MAIN
PISTON
PUMP
PISTON
AStop the vehicle on level ground and install the safety bar to the frame, then lower the bucket to the ground. Stop the engine and apply the parking brake and put blocks under the wheels to prevent the vehicle from moving. Loosen the oil filler cap to release the residual pressure from the hydraulic tank, then operate the steering wheel and work control lever 2 - 3 times to release the residual pressure from the piping. * Disconnect the cable from the negative (-1 terminal of the battery. * Remove the canopy in advance.
A
1.
Floor mat and cover I) Remove floor mat (I) and cover (2). 2) Remove steering column cover (3).
2.
Steering Remove
3.
column bracket steering column
362FO5343
bracket (4).
Frame guard assembly I) Disconnect fuel control cable (5) from front side, then remove it from support (6). * Make match marks on the lock nut for assembly. 2) Remove high-low control cable (7) from rear support (8).
362~05347
30-26 0
WA30-5
DISASSEMBLY
3) 4)
MAIN
AND ASSEMBLY
Remove inching from valve.
6)
Put block (I) at front frame (15) and bring guard assembly (16) down forward. Ir nsert a pad between the front frame and guard assembly. Lift up floor assembly (17) about 100 mm and put block @ under it, then remove wire clamp.
8)
PUMP
Remove parking brake lever cable (9) from floor support (IO). Disconnect parking brake pedal cable (9-I) from lever (II), then remove support (12). Ir Remove the cable without removing it from the support.
5)
7)
PISTON
valve
hoses (13) and (14)
Disconnect following wiring connectors. Water separator (18). . Fuel unit (19). l Stop lamp switch (20). . Parking brake switch (21). * Before disconnecting the connectors, tags to them for assembly. l
WA30-5
put
30-27 0
DISASSEMBLY
9)
MAIN PISTON PUMP
AND ASSEMBLY
Lift off floor assembly (17). Jr When lifting off the floor assembly, take care of its balance and check that the all cables and wires have been disconnected.
4.
Work equipment pump 1)
2) 3) 4)
5.
Remove hydraulic tubes (23) and (24). * Install covers to the holes of the removed tubes and the tube connecting holes of the pump securely to prevent entry of dirt, foreign matter, etc. Remove work equipment pump (25). Remove solenoids (38) and (39). Disconnect solenoid connector (39-I ). Ir Before disconnecting the connector, put a tag to it for assembly. j, Note that the piping of the main piston pump will be changed after the pump is replaced. (*Application of steps 3) and 4) above: Serial Nos. 17840 and up.)
\
I/
HST hvdraulic piping Plug the cbnne&ing *
. . . .
.
. .
holes of the disconnected tubes and hoses securely to prevent entry of dirt, foreign matter, etc. Disconnect hoses (26) and (27) from pump. Disconnect tube (27-l) from pump, without disconnecting hose. Disconnect hose (28) from tube. Disconnect tube (29) from pump. * Disconnect the tube without removing the hose. Remove hose (30) from tube connector (31). * Move the hose aside and hold it with wires, etc. Disconnect hose (32) from pump. Disconnect tube (32-I) from pump.
30-28 0
362FO5354
WA30-5
DISASSEMBLY
. .
.
AND ASSEMBLY
Disconnect tube (33) from pump. Remove hose (34). Disconnect HST control hoses (351 and (36) from pump (37). * Before disconnecting the connectors, put tags to them for assembly.
.
Remove upper side of solenoid R (38) and lower side of solenoid F (39) from pump. * Before removing the solenoids, put tags to them for assembly.
.
Disconnect check valve (40) under pump first from connecting parts of hose (41) and tube. Then, remove check valve (40) from nipple. * Remove the check valve without removing hose (41).
.
MAIN PISTON PUMP
I 6.
362FO6360
Main piston pump assembly 1) Remove upper mounting bolts of main piston pump (421, then install guide pin 0. . M = 16, P = 2.0, I? = 45 mm.
WA30-5
30-29 f??
1
DISASSEMBLY
AND ASSEMBLY
2)
Sling main piston pump (42) temporarily. * When slinging the pump, apply pads to the tubes for protection.
3)
Remove lower mounting bolts to lift off main piston pump (42). * Since the space for removal of the piston pump is narrow, lift it off carefully, taking care not to damage the parts around it. * Fit caps to the hydraulic pipe connecting parts securely. & kg
MAIN PISTON PUMP
Main piston pump (42): 37 kg (Excluding work equipment pump) (Application: Serial Nos. 15001 - 17839) 362FO53633
i&l kg
30-30 0
Main piston pump (42-l): 28 kg (Excluding work equipment pump) (Application: Serial Nos. 17840 and UP)
WA30-5
DISASSEMBLY
MAIN PISTON
AND ASSEMBLY
INSTALLATION OF MAIN TON PUMP ASSEMBLY
PISim834B
iTsiR
1.
Main piston pump assembly 1) Apply grease to the spline of damper (45). & Damper spline: Grease (LM-PI * Take care not to apply too much grease. * Clean the pump fitting faces carefully. t Install guide pin @ to the pump fitting part.
WA30-5
: 15001--17839
WA30-5
: 178402
WA40-3
: 1OOOl~l2550
WA40-3:
12551-
362FO57of
2.
PUMP
2)
Sling main piston pump (42) and install it, aligning it to damper spline, then install it with lower mounting bolts temporarily. * Keep the piston pump on the level to align it with the spline and install it without applying excessive force.
3)
Remove guide pin @ and tighten the mounting bolts. * Tighten the mounting bolts evenly. QEE Mounting bolt: 29 f 3 kgm
362FO5710
HST hydraulic piping . Degrease threads
of check valve (40) and nipple. Apply adhesive to threads of nipple, then install check valve (40). Ir Apply adhesive to threads of nipple. & Threads of nipple:
Liquid adhesive (LOCTITE 262) l
. .
Connect hose (41) to tube. Install lower side of solenoid F (39) and upper side of solenoid R (38) to piston pump. Install HST control hoses (36) and (35) to pump. Ir Connect the hoses so carefully that they will not be twisted and will not interfere with the other parts. * Note that the piping of WA30-5, serial Nos. 17840 and up, needs to be changed after the main piston pump is replaced.
WA30-5
362FO5360
1
DISASSEMBLY
.
Install hose (34). * Connect the hose so carefully that it will not be twisted and will not interfere with the other parts. Fit O-ring to flange of tube (331, and install tube (33). * Fit a new O-ring to the groove and take care that it will not be caught.
.
3.
MAIN PISTON PUMP
AND ASSEMBLY
. . . .
Connect hose (32) to pump. Connect tube (32-I) to pump. Connect hose (30) to tube (31). Fit O-ring to tube (29) connected to hose, then install them to pump. * Take care that the hoses will not be twisted and the O-ring will not be caught.
. . .
Connect hose (28) to tube. Install tube (27-I) to pump. Connect hoses (26) and (27) to pump.
Work equipment pump 1) Connect solenoid connector 2)
(39-I). Install solenoids (39) and (38) to piston pump. * Connect the hoses so carefully that they will not be twisted and will not interfere with the other parts.
2j
3)
4)
30-32 0
362FO5364
Install work equipment pump (25). * Check that collar, joint, and O-ring are fitted. w Mounting bolt: 3.15 f 0.35 kgm Install hydraulic tubes (23) and (24). Ir Fit the O-ring to the groove and take care that it will not be caught. j, Tighten the hydraulic tube flange evenly.
WA30-5
DISASSEMBLY
4.
MAIN
AND ASSEMBLY
Frame guard assembly 1) Install floor assembly ing block 0.
PISTON
PUMP
(17) to top of mount-
2) Connect following Ir
. l
. l
electric wiring connectors. Connect the wiring connectors according to the tags put to them when they were disconnected.
Parking brake switch (21). Stop lamp switch (20). Fuel unit (19). Water separator (18).
3)
Install electric wiring clamp to bottom of floor assembly (17).
4)
Remove block @ and install floor assembly (17) in position. Then, remove block @ from front frame (15) and install guard assembly (16). * Perform this work by two persons very carefully, making signs to each other.
5)
Connect inching valve hoses (14) and (13). * Connect the hoses so that they will not be twisted and will not interfere with the other parts.
6)
Connect parking brake pedal cable (9-I) to lever (II), then install support (12). Install parking brake cazble (9) to floor support (IO). Adjust the parking brake. For details, see * TESTING AND ADJUSTING.
7)
362FO5112
WA30-5
30-33 0
DISASSEMBLY
install high-low
8)
MAIN
AND ASSEMBLY
PISTON
PUMP
control cable (7) to rear sup-
port (8). Connect fuel control cable (5) to front lever, then install support (6). * Installing the cable to support (61, aligning their match marks. * Adjust the cables. For details, see TESTING AND ADJUSTING.
9)
Steering column bracket Install steering
6.
column
bracket
(4).
Floor mat and cover 1) Install steering column cover (311 2) Install cover (2) and floor mat (I).
7.
Refilling with oil Add hydraulic oil through oil filler (46) to the specified level. * Run the engine to circulate the oil through the system. Then, check the oil level again.
*
/ 362FO5335
30-34 0
362FO5343
1
362FO5348
WA30-5
DISASSEMBLY
DISASSEMBLY OF MAIN TON PUMP ASSEMBLY Application:
MAIN PISTON PUMP
AND ASSEMBLY
PISMain
Piston
PUMP assembly Charge-relief
I
15001 - 17839
valve
The following disassembly procedure is for replacement of sealing parts. Accordingly, do not remove the adjustment screws. Before disassembling the pump, be sure to make match marks on its parts for assembly.
Main
relief
/
valve
DWW05489
Oil seal 1) 2)
Remove snap Remove seal * Since the seal case,
ring (I). case (2). oil seal is press fitted replace them together.
to the
362F0636E
I 2.
Gear pump Remove hexagon
WA30-5
hexagon socket head bolts (MIZ) with wrench to remove charge pump (3).
362FO6369
DISASSEMBLY
3.
AND ASSEMBLY
MAIN
PISTON
PUMP
Main relief valve and charge relief valve 1) Remove main relief valve (HP) (4).
2)
Remove
charge
relief valve
(LP) (5).
5
4.
5.
Solenoid Remove hexagon
hexagon socket head bolts (M4) wrench to remove solenoid (6).
Bushing Remove
bushing
with
(7) with spanner.
362FO6370
30-36 0
WA30-5
DISASSEMBLY AND ASSEMBLY
ASSEMBLY OF MAIN PUMP ASSEMBLY Application: 1.
MAIN PISTON PUMP
PISTON
15001 - 17839
Bushing Tighten bushing (7) with spanner. w Bushing: 3.9 kgm
UC 2.
362FO6376
Solenoid install solenoid and tighten hexagon socket head bolt (M4) (6). w Hexagon socket head bolt (M4): 0.4 + 0.05 kgm
362FO6376
3.
Main relief valve and charge relief valve 1) Install charge relief valve (LPI (5). w Charge relief valve (LPI: 6.5 kgm
2)
WA30-5
Install main relief valve (HP) (4). w Main relief valve (HP): 9.1 kgm
DISASSEMBLY
MAIN PISTON PUMP
AND ASSEMBLY
Gear pump install charge pump (3) to pump body (A4V) and secure it with hexagon socket head bolts. w Hexagon socket head bolt (M12):
11.25 ? 1.25 kgm
\
i62 F06379
Oil seal 1) Install seal case (2) to pump body. Ir Apply a little amount of grease to the oil seal lip. 6 Oil seal: Grease (G2-LI)
I/
I
I 2)
362FO6380
Secure seal case with snap ring (I).
/
30-38 0
362F0.5381
WA30-5
DISASSEMBLY
AND
DISASSEMBLY OF MAIN TON PUMP ASSEMBLY Application:
*
*
1.
17840
MAIN
ASSEMBLY
and
PUMP
PIS-
up
The following disassembly procedure is for replacement of sealing parts. Accordingly, do not remove the adjustment screws. Before disassembling the pump, be sure to make match marks on its parts for assembly. Oil seal 1) Remove snap 2) Remove seal * Since the seal case,
ring (I). case (2). oil seal is press fitted replace them together.
to the
2.
Gear pump Remove hexagon socket head bolts (MIO) with hexagon wrench to remove charge pump (3).
3.
Main relief valve and charge relief valve 1) Remove main relief valve (HP) (4). 2)
4.
PISTON
Remove
Solenoid Remove hexagon
WA30-5
charge
relief valve (LP) (5).
m
CEW00238
hexagon socket head bolts (M4) wrench to remove solenoid (6).
with
30-39 a
DISASSEMBLY
AND ASSEMBLY
ASSEMBLY OF MAIN PUMP ASSEMBLY Application:
MAIN PISTON PUMP
PISTON
17840 and up
1. Solenoid Install solenoid and tighten hexagon socket head bolt (M4) (6). w Hexagon socket head bolt (M4): 0.4 _t 0.05 kgm
2.
Main relief valve I) Install charge relief valve (LP) (5). w Charge relief valve (LPI: 8.25 & 0.75 kgm 2)
CEW00239
Install main relief valve (HP) (4). Main relief valve (HP): 9.1 kgm
w 3.
Gear pump Install charge pump (3) to pump body (A4V) and secure it with hexagon socket head bolts. w Hexagon socket head bolt (M10): 6.5 kgm
4.
Oil seal 1) Install seal case (2) to pump body. *
2)
30-40 0
Apply a little amount of grease to the oil seal lip. a Oil seal: Grease (G2-LI)
Secure
m
CEWOO1238
seal case with snap ring (1).
WAX-5
DISASSEMBLY
PISTON
AND ASSEMBLY
MOTOR
REMOVAL OF PISTON MOTOR ASSEMBLY the vehicle A Stop it to the left, then
A
on level ground and articulate lower the bucket to the ground. Stop the engine and apply the parking brake and put blocks under the wheels to prevent the vehicle from moving. Loosen the oil filler cap to release the residual pressure from the hydraulic tank, then operate the steering wheel and work control lever 2 - 3 times to release the residual pressure from the piping. . Disconnect HST oil temperature sensor connector. . Remove the canopy in advance.
1.
Floor mat and cover Remove floor mat (I) and cover (2).
2.
Drive shaft Disconnect drive shaft (3) from transfer. * Make match marks on the drive shaft and transfer for installation.
362FO5382
3.
Hydraulic piping . Disconnect following hydraulic pipes. 1) High-pressure hoses (4) and (5).
362FO6383
2)
Hoses (6) and (7) between and piston motor.
3)
Hose (8) between main piston pump and piston motor. Fit caps to the connecting parts of the disconnected pipes.
*
WAN-5
HST
pump
362FO6384
DISASSEMBLY
PISTON MOTOR
AND ASSEMBLY
4) Loosen
clamp of hose (9) between piston motor and oil cooler, then pull out hose. * Fit caps to the connecting parts of the disconnected pipe.
4.
Piston motor assembly Sling piston motor assembly (IO) temporarily and remove mounting bolts, then lower piston motor assembly slowly. the piston motor, never * When removing stand under it.
*
*
Remove the upper mounting bolts first and fit guide pins in the bolt holes. M12, P = 1.75, e = 45 Since the space for removal of the p,iston motor is narrow, lift it carefully, taking care not to damage the parts around it. &I kg
30-42 0
Piston motor
assembly:
29 kg
WA30-5
DISASSEMBLY
PISTON MOTOR
AND ASSEMBLY
INSTALLATION OF PISTON MOTOR ASSEMBLY 1.
Piston motor assembly
1) Pull piston motor assembly 2)
3)
4)
2.
(IO) into under vehicle body. Stick O-ring (11) to piston motor fitting part with liquid adhesive. & Liquid adhesive: PERMATEX FAM Sling piston motor assembly (IO) and install it in position, matching it to the guide pins. At this time, check that the O-ring is not * caught. Tighten the mounting bolts in the diagonal order. m Mounting bolt: 11.5 f 1.0 kgm
Hydraulic piping I) Connect hose (9) between piston motor and oil cooler. * Take care not to tighten the clamp too much. Connect hose (8) between main piston pump 2) and piston motor. * Fit the O-ring to the groove and take care that it will not be caught. hoses (6) and (7) between HST 3) Connect pump and piston motor. Ir Connect the hoses so carefully that they will not be twisted and will not interfere with the other parts. hoses (4) 4) Fit new O-rings to high-pressure and (51, then connect them straight. * Fit the O-rings to the grooves and take care that they will not be caught.
362FO6393
362FO6391
DISASSEMBLY
AND ASSEMBLY
PISTON
3.
Drive shaft Connect drive shaft (3). * Align the match marks with each other.
4.
Floor mat and cover Install cover (2) and mat (I).
2
5.
362FO5343
MOTOR
362FO5344
Refilling with oil Add hydraulic oil through oil filler (12) to the specified level. * Run the engine to circulate the oil through the system. Then, check the oil level again. . l
30-44 0
Install canopy. Connect HST oil temperature
sensor.
WA3Q-5
DISASSEMBLY
PISTON MOTOR
AND ASSEMBLY
DISASSEMBLY OF PISTON MOTOR ASSEMBLY *
*
The following disassembly procedure is for replacement of sealing parts. Accordingly, do not remove the adjustment screws. Before disassembling the pump, be sure to make match marks on its parts for assembly.
362FO5392
1.
Oil seal 1) Remove
2)
WA30-5
snap ring (I).
Remove seal case (2). * Since the oil seal is press fitted seal case, replace them together.
to the
30-45 m
DISASSEMBLY
ASSEMBLY OF PISTON MOTOR ASSEMBLY 1.
PISTON
AND ASSEMBLY
MOTOR
.
Oil seal 1)
Fit O-ring
(3) to motor
body.
2)
Install seal case (2) to motor body. * Apply a little amount of grease to the oil seal lip. A Oil seal: Grease lG2-LII
362FO6396
3)
Secure
seal case with snap ring (I).
\ 1
30-46 0
362FO5397
WA335
DISASSEMBLY AND ASSEMBLY
ENGINE AND TRANSFER
REMOVAL OF ENGINE AND TRANSFER ASSEMBLIES Serial No. 22005 – 26000
¤ Stop the vehicle on level ground and install the safety bar to the frame, then lower the bucket to the ground. Stop the engine and apply the parking brake and put blocks under the wheels to prevent the vehicle from moving. ¤ Loosen the oil filler cap to release the residual pressure from the hydraulic tank, then operate the steering wheel and work control lever 2 - 3 times to release the residual pressure from the piping. fl Disconnect the cable from the negative (–) terminal of the battery. fl Remove the canopy in advance. 1. Floor mat and cover 1) Remove floor mat (1) and cover (2). 2) Remove steering column cover (3).
2. Electric wiring Disconnect main wiring connector (4) from front frame, then remove bands (5).
3. Drive shaft 1) Disconnect front drive shaft (6). fl Disconnect the drive shaft from the transfer. 2) Remove rear drive shaft (6-1).
WA30-5
30-47 (3) 1
DISASSEMBLY
4.
AND ASSEMBLY
ENGINE
AND TRANSFER
Hydraulic piping and support 1) Disconnect steering hoses (7) and (8). 2)
Disconnect hose (9) between priority valve and work equipment valve from valves, then remove support (IO) from frame.
3)
Remove hose (I 1) between work equipment valve and oil filter from filter.
4)
Remove
tube
(13)
from
work
equipment
pump (12). Ir Install covers to each hose and its connecting hole.
5.
Work equipment pump 1) Remove hydraulic tube (14). * Install covers to the removed tube and its connecting hole on the pump to prevent entry of dirt, foreign matter, etc. 2) Remove work equipment pump (12).
6.
Work equipment control cable 1) Disconnect work equipment (15) from valve.
control
cable
2) Remove
work equipment control cable (15) from front frame without removing it bracket (16). * Remove
30-48 0
the clamp
in the rear frame.
WA30-5
DISASSEMBLY
7.
ENGINE
AND ASSEMBLY
Tachometer cable Disconnect tachometer cable (17). * Disconnect the tachometer cable intermediate connector.
from
AND TRANSFER
the
8.
Air cleaner Loosen clamp of hose (19) on turbocharger side of air cleaner (18), then disconnect hose (19).
9.
Fuel control linkage and cable Disconnect cable (21) from fuel control linkage lever (201, then remove it from bracket (22) under accelerator pedal. * When removing the cable from the bracket, make match marks on it and locknut for assembly.
10. Electric wiring Disconnect the following electric wires Starting motor wiring connectors (23) and l
l
l
WA30-5
(24). Alternator wire (25). Wiring connectors (261, (27), and (28) on right side of engine. * Put tags, etc. to the wires for distinction.
362F05404
3t2F05305
1
DISASSEMBLY
ENGINE
AND ASSEMBLY
11. Radiator assembly * Remove radiator (29). MOVAL OF RADIATOR
For details, ASSEMBLY.
AND TRANSFER
see RE-
12. Floor frame assembly * Remove floor frame assembly (30). For details, see steps 12-1) - 7) of REMOVAL OF CENTER.HINGE PIN.
362FO6405
362FO6406
13. Hydraulic piping 1) Remove oil cooler hose bracket (31) and clip (32) of engine mat. * Remove each hose without removing the bracket. 2)
Disconnect oil cooler hoses (33) and (34). * Install covers to the holes of the removed hoses and their connecting holes securely to prevent entry of dirt, foreign matter, etc.
362FO6407
3)
Remove
main
piston
pump
tubs and hose
(35). 4)
Remove tube (36) between hydraulic tank and main piston pump (37) from main piston pump. * Secure the tube to the frame so that the transfer will not interfere with it when the transfer is removed.
361 FO2088
30-50 0
DISASSEMBLY AND ASSEMBLY
ENGINE AND TRANSFER
14. Engine and transfer assembly 1) Install sling to engine assembly (38), transfer assembly (39), and main piston pump (37), then sling engine and transfer assembly temporarily. fl When installing the sling, take care not to damage the hydraulic tubes and hoses around the main piston pump. fl Take care of the center of gravity extremely.
2) Remove mounting nuts (40) on both sides of transfer assembly (39).
3) Remove mounting nuts (41) on both sides of engine assembly (38).
4) Remove cooler hose clips (43) and (44) of flywheel of engine and transfer assembly (42). fl Wind the engine control cable and engine wiring around the engine. fl After removing each clip, tighten the mounting bolts again. Mounting bolt: 110.0 ± 12.3 Nm {11.25 ± 1.25 kgm}
WA30-5
30-51 (3) 1
DISASSEMBLY AND ASSEMBLY
ENGINE AND TRANSFER
5) Sling engine and transfer assembly (42) slowly and stop when it is lifted about 20 mm. Check that the all parts have been disconnected, then lift off engine and transfer assembly slowly. fl When lifting off the assembly, take care that it will not interfere with the parts around it.
15. Disconnection of engine and transfer assemblies 1) Install engine and transfer assembly (42) to stand, etc. fl Support the stand, etc. sufficiently so that it will not fall down.
2) Remove hoses (45) and (45-1) of filter assembly (46) from transfer assembly (39), then remove filter assembly (46).
3) Sling transfer assembly (39) temporarily and remove connecting bolts and stud bolts of engine assembly (38), then disconnect transfer assembly (39) from engine assembly (38). fl When installing the sling, take care of the center of gravity of the transfer assembly. Remove the connecting bolts and lift off the assembly slowly.
30-52 1
WA30-5
DISASSEMBLY AND ASSEMBLY
ENGINE AND TRANSFER
INSTALLATION OF ENGINE AND TRANSFER ASSEMBLIES Serial No. 22005 – 26000 1. Connection of engine and transfer assemblies 1) Apply grease to splines of engine assembly (38) and damper (47). 8 Damper spline: Grease (LM-P)
2) Set transfer assembly (39) to connecting part of engine assembly (38), then insert spline shaft. fl Before connecting the transfer assembly, install stud bolt (48) to the bottom of the transfer connecting part. fl Degrease the threads on the engine side of the stud bolt. fl Align the spline of the main piston pump with the damper spline on the engine side securely.
3) Assemble transfer assembly (39) and engine assembly (38), and eliminate clearance between their connecting parts, then tighten connecting bolts temporarily. fl Tighten the connecting bolts together with the clips according to the procedure shown below. Connecting bolt: 110.0 ± 12.3 Nm {11.25 ± 1.25 kgm}
4) Apply adhesive to threads of degreased stud bolt (48) and tighten nut (49). 8 Stud bolt: Adhesive (LOCTITE 262) Stud bolt: 110.0 ± 12.3 Nm {11.25 ± 1.25 kgm}
WA30-5
30-53 (3) 1
DISASSEMBLY AND ASSEMBLY
ENGINE AND TRANSFER
5) Connect hoses (45) of filter assembly (46) installed to transfer assembly (39). Filter sub-assembly: 110.0 ± 12.3 Nm {11.25 ± 1.25 kgm}
2. Engine and transfer assembly 1) Sling engine and transfer assembly as it was slung for removal, and install it to rear frame cushion (47). fl Stop lowering the assembly above the rear frame and check that it will not interfere with any other part, then lower it in position. fl When installing the assembly to the cushion, align the cushion pins with the mount bracket pin holes. 2) Install cooler hose clips (43) and (44) to flywheel of engine and transfer assembly (42). Mounting bolt: 110.0 ± 12.3 Nm {11.25 ± 1.25 kgm}
3) Install mounting nuts (41) on both sides of engine assembly (38). Mounting nut: 66.2 ± 7.35 Nm {6.75 ± 0.75 kgm}
30-54 (3) 1
WA30-5
DISASSEMBLY AND ASSEMBLY
ENGINE AND TRANSFER
4) Install mounting nuts (40) on both sides of transfer assembly (39). Mounting nut: 66.2 ± 7.35 Nm {6.75 ± 0.75 kgm}
3. Hydraulic piping 1) Install tube (36) between hydraulic tank and main piston pump (37) to main piston pump (37). fl Take care that the O-rings will not be twisted or caught. 2) Install hose (35) to underside of main piston pump tube. fl Take care that the hose will not interfere with another part and will not be twisted.
3) Connect oil cooler hoses (33) and (34). fl Take care that the hoses will not interfere with another part and will not be twisted. 4) Install oil cooler hose bracket (31) to transfer case, then install hose clip to engine mount.
4. Floor frame assembly fl Install floor frame assembly (30). For details, see steps 5.1) - 8) of INSTALLATION OF CENTER HINGE PIN.
WA30-5
30-55 (3) 1
DISASSEMBLY AND ASSEMBLY
ENGINE AND TRANSFER
5. Radiator assembly fl Install the radiator (29). For details, see INSTALLATION OF RADIATOR ASSEMBLY.
6. Electric wiring Connect the following electric wires • Wiring connectors (26), (27), and (28) on right side of engine. • Terminal of alternator wiring connector (25). • Starting motor wiring connectors (23) and (24). fl Connect the wires according to the tags put to them when they were disconnected.
7. Fuel control linkage and cable Connect cable (21) to fuel control linkage lever (20), then install cable (21) to bracket (22) under accelerator pedal. fl Align the match mark of the cable with that of the bracket.
8. Air cleaner Connect hose (19) on turbocharger side to air compressor, then secure it with clamp. fl Take care that hose will not be twisted.
30-56 1
WA30-5
DISASSEMBLY AND ASSEMBLY
ENGINE AND TRANSFER
9. Tachometer cable Connect tachometer cable (17).
10. Work equipment control cable 1) Connect work equipment control cable (15) to valve spool. 2) Install work equipment control cable (15) together with bracket (16) to front frame. fl Install the lamp in the rear frame.
11. Work equipment pump 1) Install work equipment pump (12). fl Check that the collar, joint, and O-ring are fitted. Mounting bolt: 30.9 ± 3.43 Nm {3.15 ± 0.35 kgm}
2) Install hydraulic tube (14). fl Fit the O-rings to the grooves and take care that they will not be caught. fl Tighten the hydraulic tube flange evenly.
WA30-5
30-57 (3) 1
DISASSEMBLY AND ASSEMBLY
ENGINE AND TRANSFER
12. Hydraulic piping and support 1) Install tube (13) to work equipment pump (12). fl Fit the O-rings to the grooves and take care that they will not be caught. 2) Connect hose (11) between work equipment valve and oil filter (11). fl Take care that the hoses will not interfere with another part and will not be twisted. 3) Connect hose (9) between priority valve and work equipment valve, then install support (10) to the frame. Hose adapter: 78.5 ± 19.6 Nm {8 ± 2 kgm} • Width across flats of hose adapter: 27 mm 4) Connect steering cylinder hoses (7) and (8) on both sides. fl Take care that the hoses will not interfere with another part and will not be twisted.
13. Drive shaft 1) Install front drive shaft (6). 2) Install rear drive shaft (6-1). fl Take care of the direction of the yoke. Fit the socket and spigot securely. Mounting bolt: 30.9 ± 3.43 Nm {3.15 ± 0.35 kgm}
14. Electric wiring Connect main wiring connector (4) of the front frame, then secure it with bands (5).
30-58 (3) 1
WA30-5
DISASSEMBLY
AND ASSEMBLY
ENGINE
AND TRANSFER
15. Floor mat and cover 1) Install steering column cover (3). 2) Install cover (2) of floor mat (1).
16. Refilling with oil Add hydraulic oil through oil filler (50) to the specified level. * Run the engine to circulate the oil through the system. Then, check the oil level again.
t#
WA30-5
Hydraulic
oil: 38 e
30-59 0
DISASSEMBLY AND ASSEMBLY
ENGINE AND TRANSFER
REMOVAL OF ENGINE AND TRANSFER ASSEMBLIES Serial No. 26001 and up
¤ Stop the vehicle on level ground and install the safety bar to the frame, then lower the bucket to the ground. Stop the engine and apply the parking brake and put blocks under the wheels to prevent the vehicle from moving. ¤ Loosen the oil filler cap to release the residual pressure from the hydraulic tank, then operate the steering wheel and work control lever 2 - 3 times to release the residual pressure from the piping. fl Disconnect the cable from the negative (–) terminal of the battery. fl Remove the canopy in advance. 1. Floor mat and cover 1) Remove floor mat (1) and cover (2). 2) Remove steering column cover (3).
2. Electric wiring Disconnect main wiring connector (4) from front frame, then remove bands (5).
3. Drive shaft 1) Disconnect front drive shaft (6). fl Disconnect the drive shaft from the transfer. 2) Remove rear drive shaft (6-1).
30-59-1 (3)
WA30-5
DISASSEMBLY AND ASSEMBLY
ENGINE AND TRANSFER
4. Hydraulic piping and support 1) Disconnect steering hoses (7) and (8). 2) Disconnect hose (9) between priority valve and work equipment valve from valves, then remove support (10) from frame. 3) Remove hose (11) between work equipment valve and oil filter from filter.
4) Remove tube (13) from work equipment pump (12). fl Install covers to each hose and its connecting hole.
5. Work equipment pump 1) Remove hydraulic tube (14). fl Install covers to the removed tube and its connecting hole on the pump to prevent entry of dirt, foreign matter, etc. 2) Remove work equipment pump (12).
6. Work equipment control cable 1) Disconnect work equipment control cable (15) from valve. 2) Remove work equipment control cable (15) from front frame without removing it bracket (16). fl Remove the clamp in the rear frame.
WA30-5
30-59-2 (3)
DISASSEMBLY AND ASSEMBLY
ENGINE AND TRANSFER
7. Tachometer cable Disconnect tachometer cable (17).  Disconnect the tachometer cable at tachometer side.
8. Air cleaner Loosen clamp of hose (19) on turbocharger side of air cleaner (18), then disconnect hose (19).
9. Fuel control linkage and cable Disconnect cable (21) from fuel control linkage lever (20), then remove it from bracket (22) under accelerator pedal.  When removing the cable from the bracket, make match marks on it and locknut for assembly.
10. Electric wiring 1) Disconnect main wiring harness (23) of the starting motor from the battery and disconnect connector (24) from the fuel pump. 2) Disconnect ground wiring harnesses (25) and (26).
30-59-3 (3)
WA30-5
DISASSEMBLY AND ASSEMBLY
ENGINE AND TRANSFER
3) Disconnect connectors (27), (28), (50), and (51) of the wiring harnesses between the chassis and engine. fl Remove the clamps from the disconnected wiring harnesses and put the wiring harnesses on the engine side.
11. Fuel hoses Disconnect fuel hoses (52) and (53) from the filter.
12. Radiator assembly fl Remove radiator (29). For details, see REMOVAL OF RADIATOR ASSEMBLY. 13. Floor frame assembly fl Remove floor frame assembly (30). For details, see steps 12-1) - 7) of REMOVAL OF CENTER HINGE PIN.
14. Hydraulic piping 1) Remove oil cooler hose bracket (31) and clip (32) of engine mat. fl Remove each hose without removing the bracket. 2) Disconnect oil cooler hoses (33) and (34). fl Install covers to the holes of the removed hoses and their connecting holes securely to prevent entry of dirt, foreign matter, etc.
WA30-5
30-59-4 (3)
DISASSEMBLY AND ASSEMBLY
ENGINE AND TRANSFER
3) Remove main piston pump tubs and hose (35). 4) Remove tube (36) between hydraulic tank and main piston pump (37) from main piston pump. fl Secure the tube to the frame so that the transfer will not interfere with it when the transfer is removed.
15. Engine and transfer assembly 1) Install sling to engine assembly (38), transfer assembly (39), and main piston pump (37), then sling engine and transfer assembly temporarily. fl When installing the sling, take care not to damage the hydraulic tubes and hoses around the main piston pump. fl Take care of the center of gravity extremely.
2) Remove mounting nuts (40) on both sides of transfer assembly (39).
30-59-5 (3)
WA30-5
DISASSEMBLY AND ASSEMBLY
ENGINE AND TRANSFER
3) Remove mounting nuts (41) on both sides of engine assembly (38).
4) Remove cooler hose clips (43) and (44) of flywheel of engine and transfer assembly (42). fl Wind the engine control cable and engine wiring around the engine. fl After removing each clip, tighten the mounting bolts again. Mounting bolt: 110.0 ± 12.3 Nm {11.25 ± 1.25 kgm}
5) Sling engine and transfer assembly (42) slowly and stop when it is lifted about 20 mm. Check that the all parts have been disconnected, then lift off engine and transfer assembly slowly. fl When lifting off the assembly, take care that it will not interfere with the parts around it. Engine and transfer assembly: 240 kg
16. Disconnection of engine and transfer assemblies 1) Install engine and transfer assembly (42) to stand, etc. fl Support the stand, etc. sufficiently so that it will not fall down.
WA30-5
30-59-6 (3)
DISASSEMBLY AND ASSEMBLY
ENGINE AND TRANSFER
2) Remove hoses (45) and (45-1) of filter assembly (46) from transfer assembly (39), then remove filter assembly (46).
3) Sling transfer assembly (39) temporarily and remove connecting bolts and stud bolts of engine assembly (38), then disconnect transfer assembly (39) from engine assembly (38).  When installing the sling, take care of the center of gravity of the transfer assembly. Remove the connecting bolts and lift off the assembly slowly.
30-59-7 (3)
WA30-5
DISASSEMBLY AND ASSEMBLY
ENGINE AND TRANSFER
INSTALLATION OF ENGINE AND TRANSFER ASSEMBLIES Serial No. 26001 and up 1. Connection of engine and transfer assemblies 1) Apply grease to splines of engine assembly (38) and damper (47). 8 Damper spline: Grease (LM-P)
2) Set transfer assembly (39) to connecting part of engine assembly (38), then insert spline shaft. fl Before connecting the transfer assembly, install stud bolt (48) to the bottom of the transfer connecting part. fl Degrease the threads on the engine side of the stud bolt. fl Align the spline of the main piston pump with the damper spline on the engine side securely.
3) Assemble transfer assembly (39) and engine assembly (38), and eliminate clearance between their connecting parts, then tighten connecting bolts temporarily. fl Tighten the connecting bolts together with the clips according to the procedure shown below. Connecting bolt: 110.0 ± 12.3 Nm {11.25 ± 1.25 kgm}
4) Apply adhesive to threads of degreased stud bolt (48) and tighten nut (49). 8 Stud bolt: Adhesive (LOCTITE 262) Stud bolt: 110.0 ± 12.3 Nm {11.25 ± 1.25 kgm}
WA30-5
30-59-8 (3)
DISASSEMBLY AND ASSEMBLY
ENGINE AND TRANSFER
5) Connect hoses (45) of filter assembly (46) installed to transfer assembly (39). Filter sub-assembly: 110.0 ± 12.3 Nm {11.25 ± 1.25 kgm}
2. Engine and transfer assembly 1) Sling engine and transfer assembly as it was slung for removal, and install it to rear frame cushion (47). fl Stop lowering the assembly above the rear frame and check that it will not interfere with any other part, then lower it in position. fl When installing the assembly to the cushion, align the cushion pins with the mount bracket pin holes.
2) Install cooler hose clips (43) and (44) to flywheel of engine and transfer assembly (42). Mounting bolt: 110.0 ± 12.3 Nm {11.25 ± 1.25 kgm}
30-59-9 (3)
WA30-5
DISASSEMBLY AND ASSEMBLY
ENGINE AND TRANSFER
3) Install mounting nuts (41) on both sides of engine assembly (38). Mounting nut: 66.2 ± 7.35 Nm {6.75 ± 0.75 kgm}
4) Install mounting nuts (40) on both sides of transfer assembly (39). Mounting nut: 66.2 ± 7.35 Nm {6.75 ± 0.75 kgm}
3. Hydraulic piping 1) Install tube (36) between hydraulic tank and main piston pump (37) to main piston pump (37). fl Take care that the O-rings will not be twisted or caught. 2) Install hose (35) to underside of main piston pump tube. fl Take care that the hose will not interfere with another part and will not be twisted.
3) Connect oil cooler hoses (33) and (34). fl Take care that the hoses will not interfere with another part and will not be twisted. 4) Install oil cooler hose bracket (31) to transfer case, then install hose clip to engine mount.
WA30-5
30-59-10 (3)
DISASSEMBLY AND ASSEMBLY
ENGINE AND TRANSFER
4. Floor frame assembly fl Install floor frame assembly (30). For details, see steps 5.1) - 8) of INSTALLATION OF CENTER HINGE PIN.
5. Radiator assembly fl Install radiator assembly (29). For details, see INSTALLATION OF RADIATOR ASSEMBLY.
6. Fuel hoses Connect fuel hoses (53) and (52) to the filter.
7. Electric wiring 1) Connect connectors (51), (50), (28), and (27) between the chassis and engine.
30-59-11 (3)
WA30-5
DISASSEMBLY AND ASSEMBLY
ENGINE AND TRANSFER
2) Connect ground wiring harnesses (26) and (25). 3) Connect main wiring harness (23) of the starting motor to the battery and connect connector (24) to the fuel pump. fl Install the wiring harness clamps as they were.
8. Fuel control linkage and cable Connect cable (21) to fuel control linkage lever (20), then install cable (21) to bracket (22) under accelerator pedal. fl Align the match mark of the cable with that of the bracket.
9. Air cleaner Connect hose (19) on turbocharger side to air compressor, then secure it with clamp. fl Take care that hose will not be twisted.
10. Tachometer cable Connect tachometer cable (17) to tachometer on the panel.
WA30-5
30-59-12 (3)
DISASSEMBLY AND ASSEMBLY
ENGINE AND TRANSFER
11. Work equipment control cable 1) Connect work equipment control cable (15) to valve spool. 2) Install work equipment control cable (15) together with bracket (16) to front frame. fl Install the lamp in the rear frame.
12. Work equipment pump 1) Install work equipment pump (12). fl Check that the collar, joint, and O-ring are fitted. Mounting bolt: 30.9 ± 3.43 Nm {3.15 ± 0.35 kgm}
2) Install hydraulic tube (14). fl Fit the O-rings to the grooves and take care that they will not be caught. fl Tighten the hydraulic tube flange evenly.
13. Hydraulic piping and support 1) Install tube (13) to work equipment pump (12). fl Fit the O-rings to the grooves and take care that they will not be caught.
30-59-13 (3)
WA30-5
DISASSEMBLY AND ASSEMBLY
ENGINE AND TRANSFER
2) Connect hose (11) between work equipment valve and oil filter (11). fl Take care that the hoses will not interfere with another part and will not be twisted. 3) Connect hose (9) between priority valve and work equipment valve, then install support (10) to the frame. Hose adapter: 78.5 ± 19.6 Nm {8 ± 2 kgm} • Width across flats of hose adapter: 27 mm 4) Connect steering cylinder hoses (7) and (8) on both sides. fl Take care that the hoses will not interfere with another part and will not be twisted.
14. Drive shaft 1) Install front drive shaft (6). 2) Install rear drive shaft (6-1). fl Take care of the direction of the yoke. Fit the socket and spigot securely. Mounting bolt: 30.9 ± 3.43 Nm {3.15 ± 0.35 kgm}
15. Electric wiring Connect main wiring connector (4) of the front frame, then secure it with bands (5).
WA30-5
30-59-14 (3)
DISASSEMBLY AND ASSEMBLY
ENGINE AND TRANSFER
16. Floor mat and cover 1) Install steering column cover (3).
2) Install cover (2) of floor mat (1).
17. Refilling with oil Add hydraulic oil through oil filler (50) to the specified level. fl Run the engine to circulate the oil through the system. Then, check the oil level again. Hydraulic oil: 39 ¬
30-59-15 (3)
WA30-5
DISASSEMBLY
DISASSEMBLY 1.
Hydraulic
OF TRANSFER
piping
1) Install transfer assembly 2) Remove pump
2.
TRANSFER
AND ASSEMBLY
hoses
(4) to stand.
and tubes
of main
piston
(I).
3)
Remove
hoses of piston motor
4)
Remove hose between (I) and oil filter (3).
5)
Remove mounting bracket of oil filter (3) from housing of transfer (4). * Remove the filter assembly without removing the bracket. * Check the connecting angle of each hose for assembly.
main
(2). piston
pump
Main piston pump assembly I) Sling main piston pump (1) by 2 parts. 2)
Remove
mounting
bolts, then
lift off piston
pump (I). * Take care of the center of gravity of the piston pump, then lift it off slowly. &I kg
3.
Main piston pump: 37 kg (Excluding work equipment
pump)
Piston motor assembly 1) Sling piston motor (2) by 2 parts. 2)
Remove mounting bolts, then lift off piston motor (2). * Take care of the center of gravity of the piston motor, then lift it off slowly. l&lkg
30-60 a
Piston motor: 29 kg
WA30-5
DISASSEMBLY
4.
TRANSFER
ASSEMBLY
Parking brake assembly 1) Pull out rear coupling coupling (5). 2)
5.
AND
(6), then remove front
Remove parking brake (7). j, For details, see REMOVAL BRAKE.
OF PARKING
Motor gear and output shaft. 1) Remove plug (8j and pull out pin (9). 2)
Remove motor gear (IO) and retainer (II) together. f Before installing the motor gear and retainer, place cushion under them.
3)
Remove retainer assembly ing bolt.
4)
Remove mounting bolt of plate (13). Turn plate by 180 degrees to move it toward motor gear (I).
5)
Hit bottom of output shaft (14) with copper hammer to drive it out. * Take care not to damage spline and bolt hole.
6)
WA30-5
Remove
(12) by using forc-
362FO5127
362FO6419
II
plate (13).
30-61 0
DISASSEMBLY
7)
TRANSFER
AND ASSEMBLY
Pull bearings (1.5) and (16) out of motor gear (IO) with puller.
16
8)
Pull bearing (17) out of output shaft (14) with puller.
9)
Remove gear ring (20).
(181, bearing
362FO6129
(191, and snap
,
,Elock
DWW05553
30-62 a
WA30-5
DISASSEMBLY
ASSEMBLY SEMBLY 1.
TRANSFER
AND ASSEMBLY
OF TRANSFER AS-
Motor gear and output shaft 1) Install snap ring (20) to shaft (14), then press fit (19). Install the snap ring first. * * When fitting the bearing, apply transfer oil to fitting part of the shaft. * The outside diameter of the bearing on the front side is different from that on the rear side. Take care. A Bearing fitting part of shaft: (EOIO-CD)
2)
Install gear (18) and press fit bearing
362FO642C
(17).
,Block
DWW05553
3)
Press fit bearings
(16) and (15) to motor gear
(IO). * Press fit the bearings securely so that clearance at part “a” will be eliminated.
#
\ a
WA30-5
362FO6421
362FO5131
30-63 m
DISASSEMBLY
TRANSFER
AND ASSEMBLY
4) Install plate (13) to motor gear side. 5) Apply soap water to inside of seal fitting part of retainer (12), then fit oil seal (2 1) and dust seal (22). * Standard value: 3.0 f 0.2 mm 3.OkO.2
362FO5132 *
*
After fitting the oil seal, check that it is not slanted. & Outside of oil seal and dust seal: Soap water Apply grease thinly to oil seal lip. a Seal lip: Grease (G2-LI)
6) Install output shaft (14) and turn plate (13) by 180 degrees. Apply adhesive to mounting bolt, then tighten it. * Degrease the mounting bolt and bolt hole completely. & Mounting bolt: Adhesive (LT-2) QEE Mounting bolt: 3.15 f 0.35 kgm 7)
/
Block
Install O-ring (23) to groove of retainer (12). Apply soap water to retainer fitting part of transfer case (241, and install retainer (12). * Take care not to damage the O-ring. 6 Retainer fitting part: Soap water w Mounting bolt: 11.25 f 1.25 kgm
8) Turn over transfer block.
case (24) and place it on
9) Install motor gear assembly of its direction.
10) Install retainer (II). * When installing pin hole (a).
the
(IO), taking care
retainer,
Block
align
u DWWO5496
the
11) Insert pin (9) and install plug. w Plug: 0.45 f 0.15 kgm
I
30-64 0
362FO5135 1
WA30-5
DISASSEMBLY
AND
ASSEMBLY
2.
Parking brake assembly 1) Install parking brake (7). t For details, see INSTALLATION OF PARKING BRAKE. 2) Insert rear coupling (6), aligning its spline. * Take care that the front and rear couplings will not be deviated in circumferential direction from each other. * Apply grease to the all periphery of the slinger and shaft spline. 6 Periphery of slinger and shaft spline: Grease (LM-GI
3.
Piston motor assembly 1) Install O-ring (25) to fitting part, then sling piston motor by 2 parts and install it in position. * Apply liquid adhesive to the O-ring. 6 O-ring: Liquid adhesive PERMATEX 2) Secure piston pump (1) with mounting bolts. * When installing the piston pump, take care that the O-ring will not be caught. * Tighten the mounting bolts evenly. w Mounting bolt: 11.5 + 1.0 kgm
4.
Main piston pump assembly 1) Sling main piston pump (I) by 2 parts and install it in position. 2) Align bolt holes and install bolts to secure main piston pump (I). * Tighten the mounting bolts evenly.
5.
Hydraulic piping 1) Install oil filter (3) to housing of transfer (4), then install bracket. the Ir Install the filter before installing bracket. m Mounting bolt: 11.25 f 1.25 kgm
TRANSFER
362FO5138
WA30-5
30-65 a
DISASSEMBLY
2)
AND ASSEMBLY
TRANSFER
Install hoses (26) between main piston pump (I) and oil filter (3). * Take care not to install wrong hoses. m Outlet and inlet hoses: 8+2 To filter
kgm
From filter
t
DWW05497
-
3)
4)
Install hoses of piston motor
-
DWW05498
(2).
Install hoses and tubes of main piston pump (1).
* * * *
*
When installing the hoses in steps 3) and 4) above, observe the following items. Install a new O-ring to install each hose. Fit the O-rings to the grooves and take care that they will not be caught. Take care that the hoses will not interfere with another part and will not be twisted. When installing each hose, tighten the split flange evenly.
362FOE.425
i
30-66 0
:05142
WA30-5
DISASSEMBLY
DISASSEMBLY SHAFT 1.
DRIVE SHAFT
AND ASSEMBLY
OF DRIVE
Spiders and bearings 1)
Remove
bearing
caps (1).
41SFO1079
2)
Remove rings (3) of spider (2), then hit bearings (4) lightly to drive them out. * Make match marks on both spiders so that their directions will not be’changed.
U AlQF422B
2.
Cover * Since cover (5) is caulked with a punch (at 4 places), do not remove it unnecessarily. * When removing cover (5), take care not to damage it and tube (6). Ir When opening the caulked parts, pry them up with a screwdriver, etc. * Work on the rear drive shaft similarly to the above.
Caulked
\ Seal DWW05500
362FO5143
WA30-5
30-67 a
DISASSEMBLY
ASSEMBLY 1.
DRIVE SHAFT
AND ASSEMBLY
OF DRIVE SHAFT
Spiders and bearings 1) Install bearings (4) of spider (2) in position, then install rings (3). * Install the bearing so that the grease fittings will be in the same direction. & Work similarly on the front, center, and rear drive shafts.
2)
3 \
Install bearing caps. a Bearing cap: Grease (G2-LII * If a spider and its bearing caps are worn, replace them as an assembly. * Do not weld the strap of the cap, since welding heat can damage the bearing.
416FO1071
2.
Cover * If cover (5) has been removed, install it according to the following procedure. 1) Inset-t seal to cover (5) and tube (61, the install cover (5) and caulk it with punch along the diagonal lines. * Work similarly on the rear drive shaft.
Caulked
Seal
DWW05500
I
30-68 0
362FO5143
WA3Q-5
DISASSEMBLY
REMOVAL
AND
ASSEMBLY
FRONT AXLE
OF FRONT AXLE
AStop the vehicle on level ground and install the safety bar to the frame, then lower the bucket to the ground. Stop the engine and apply the parking brake and put blocks under the wheels to prevent the vehicle from moving. * Remove the inspection cover from the front side of the front frame. 1.
2.
Raising vehicle body Place stands @ under the front frame to jack up vehicle body. * Raise the front frame by operating the bucket, and place stands @ when the tires are lifted up a little above the ground.
VI
362FOE.427
Tire wheels Wind sling belt onto tire wheel (1). Remove the mounting bolts and lift off the tire wheel. &I kg
Tire wheel:
48 kg
362FO5428
3. 4.
Drive shaft Disconnect front drive shaft (2). Axle I) Sling axle (3) temporarily with jack and hoist. Remove mounting bolts (4) and lift off axle (3). Ir Adjust the jacking height the mounting bolts.
2)
Axle: 127 kg &I kg Pull out axle assembly from
and
remove
under vehicle
body. * Use a hoist and a jack to pull out the axle.
WA30-5
30-69 0
DISASSEMBLY
AND
\
ASSEMBLY
FRONT
AXLE
INSTALLATION OF FRONT AXLE 1.
Axle 1) Pull axle into under vehicle body. * Use a hoist and a jack to pull in the axle. 2)
Raise axle (3) with jack and hoist and install it in position, then tighten mounting bolts (4). Ir Bring the axle in position by using the bolts as guides. w Mounting bolt: 28.25 & 3.25 kgm
2.
Drive shaft Connect front drive shaft 12). m Drive shaft: 3.15 t 0.35 kgm
3.
Tire wheels Sling tire wheel (I) and install then tighten the mounting bolts. @
4.
m
Mounting
it in position,
bolt: 45 + 5 kgm (Width across flats: 30 mm)
Lowering vehicle body Take out stands 0 from under front frame, then lower vehicle body. * Raise the front frame a little by operating the bucket, then take out stands 0.
30-70 0
WA30-5
DISASSEMBLY
REMOVAL
REAR AXLE
AND ASSEMBLY
OF REAR AXLE
AStop the vehicle on level ground and install the safety bar to the frame, then lower the bucket to the ground. Stop the engine and apply the parking brake and put blocks under the wheels to prevent the vehicle from moving. . Open engine hood (I).
1.
Raising vehicle body 1) Put block 0 between on each side.
rear axle and rear frame
362FO5144
Place stands @ under rear frame and lift up vehicle body. j, Raise the rear frame with a garage jack. When the tires are lifted up a little, place stands 0.
2)
2.
Tire wheels Wind sling belt onto tire wheel (2). Remove mounting bolts and lift off the tire wheel.
el kg
3.
Tire wheel:
43 kg
Drive shaft Disconnect rear drive shaft (3) from axle. Ir Make match marks for assembly.
WA3Q-5
the 362Fbk433
DISASSEMBLY
4.
REAR AXLE
AND ASSEMBLY
Drain valve Remove port.
engine oil drain valve (4) from rear sup-
362FO5435
5.
Rear support Secure both sides of rear support to axle with wires (4-l), etc. j, Remove the blocks between rear frame and axle.
362FO5436
6.
Axle 1) Remove trunnion cap (5). * When the axle assembly is pulled out backward, the trunnion cap interferes with the muffler. Accordingly, remove the cap in advance. 2)
Place garage jacks on both sides under axle housing of axle (61, and remove mounting bolts (6-I ). * Adjusting the height of the garage jacks, move the axle backward.
3)
If coupling end comes off front axle support (7), lower coupling side first. j, Mask the yoke of the coupling with sealing tape. * When removing the axle, take care since the rear support side lowers. & kg
30-72 0
Rear support
of rear axle: 148 kg
WA305
DISASSEMBLY
4)
Pull out axle assembly *
7.
REAR AXLE
(8) from vehicle body.
After pulling out the axle assembly, remove the wires, etc. used to secure it.
Rear support Sling rear support (9) temporarily and remove mounting bolts. Remove thrust plate (IO), then remove rear support (9). r&lkg
8.
AND ASSEMBLY
Rear support:
Bushing I) Remove O-ring support (9).
2)
24 kg
(I I) and bushing
(12) from
Remove plate (7-11, O-ring (131, and bushing (14) from support (7).
362FO6442
WA30-5
30-73 0
DISASSEMBLY
INSTALLATION 1.
REAR AXLE
AND ASSEMBLY
Bushing 1) Install O-ring
OF REAR AXLE (11) and bushing
(12) to sup-
port (9). * Install the bushing with its chamfered side on the axle housing side. * Install the bushing with its joint on its side. & O-ring and bushing: Grease (LM-G) 2)
DWW05503
Install O-ring (131, bushing (141, and plate (7-I) to support (7). * Install the bushing with its chamfered side on the axle housing side. * Install the bushing with its joint on its side. 6 O-ring and bushing: Grease (LM-G)
-=2FO6442
2.
Rear support 1) Sling rear support (9) temporarily it in position of rear axle. &I kg
Rear support:
and insert
24 kg
362FO5440
362FO5039
*
After applying grease to part “a” of the axle, take care that foreign matter will not stick to it. 6 O-ring and periphery of axle “a”: Grease (LM-GI
2)
Install thrust plate (IO). w Mounting bolt: 11.25 5~ 1.25 kgm * Install the axle assembly before installing the trunnion cap.
30-74 0
I
42AF01199
WA30-5
DISASSEMBLY
3.
REAR AXLE
AND ASSEMBLY
Axle 1)
2)
Lift up both sides of axle (6) with garage jacks and pull it into under rear frame.
Lift up axle diagonally
with rear support (15)
up. 3)
4)
Pull rear support (15) into frame first, and align coupling with fitting part of front support.
Push in axle and align it with front support (7). * When inserting the axle assembly to the front support, take care that the O-ring will not be caught.
5)
Install trunnion cap (5). * When installing the trunnion cap, fill it with grease. & Trunnion cap: Grease (LG-2) w Mounting bolt: 11.25 f 1.25 kgm
4.
Rear support Align the mounting holes of rear support (15) with those of rear frame, install mounting bolts. * Remove wires and put blocks 0. w Mounting bolt: 28.25 ? 3.25 kgm
5.
Drain valve Install engine
oil drain valve (4) to rear support.
362FO5435
WA30-5
362FO5145
DISASSEMBLY
6.
AND ASSEMBLY
REAR AXLE
Drive shaft install rear drive shaft (3). * When installing the drive shaft, fit the socket and spigot securely and take care of the direction of the yoke. w Mounting bolt: 3.15 + 0.35 kgm
362FOEk4
7.
Tire wheels Wind sling belt onto tire wheel CC!). Install it in position and tighten the mounting bolts. w Mounting bolt: 45 + 5 kgm (Width across fiats: 30 mm)
362Fbk433
8.
Lowering vehicle body 1) Take out stands @ from under rear frame, then lower vehicle body. Ir Raise the rear frame a little with garage jacks, then take out stands 0. 2) Remove the blocks @) between rear axle and rear frame on both sides.
362FO5144
30-76 0
WA30-5
DISASSEMBLY
DISASSEMBLY TIALS 1.
DIFFERENTIALS
AND ASSEMBLY
OF DIFFEREN-
Differential cover and axle housing assembly 1) Install differential assembly to stand, etc. and sling axle housing assembly (1) temporarily, then remove shaft. &I kg
2)
Remove
Differential
differential
assembly:
Front: 40 kg Rear: 39 kg
cover (2).
2.
Cage assembly 1) Tighten forcing bolt and remove cage assembly (3)/(3-l) by using guide bolts. * Check the quantity of the shims for assembly. * Loosen the mounting bolts of the coupling to install the coupling temporarily. 2) Remove
O-ring from cage assembly
end
Front
end
(3)/(3-l).
3.
Bearing carrier Tighten forcing bolts evenly to remove bearing carriers (4) and (4-I). -k Check the quantity of the shims for assembly. * Make identification marks on both bearing carriers so that they will not be mixed up.
4.
Differential carrier assembly 1) Remove differential carrier assembly differential housing (5).
WAN-5
Rear
(6) from
30-77 0
DISASSEMBLY
DIFFERENTIALS
AND ASSEMBLY
2)
Remove bevel gear (7) from differential carrier assembly (6), then remove bearing from bevel gear.
3)
Remove thrust washer (91, side gear (IO), and lock pins (II) from differential carrier (8).
4)
5)
5.
Pull out shafts (12) and (131, then pinion gear (13-l).
remove 362FO5450
362FO6449
Remove side gear (14) and turn over carrier (81, then remove bearing. f Remove each bearing with a puller.
Coupling
18
16
15
17
bolt (15), then remove I) Remove mounting holder (16), coupling (17L and O-ring (18).
2) Using press, pull pinion gear (19) out of cage. 3)
Remove spacer (20) and bearing cone (21) from pinion gear (19). * Remove bearing cone (21) with a puller.
4)
Remove oil seal (22). * Remove bearing cone (23).
30-78 0
WA30-5
DISASSEMBLY
DIFFERENTIALS
AND ASSEMBLY
5)
Remove
bearing
cone (21).
6)
Remove bearing cups cages (24) and (24-l).
(25)
and
(26) from
Front cages
Rear cages
I
WA30-5
362FO5150
30-79 0
DISASSEMBLY
ASSEMBLY 1.
DIFFERENTIALS
AND ASSEMBLY
OF DIFFERENTIAL
Pinion gear
1) Press fit bearing
cone (21) to pinion gear (191, then install spacer (20). * Install the spacer to only the rear cage.
2)
Press fit bearing cups (25) and (26) to cages (24) and (24-I). * Check that any clearance is not made among the parts. * Apply oil to the cup fitting parts and outside of the cups. & Bearing cup: Oil (Axle oil) * After press fitting the cups, check that there is not clearance at parts “a”.
362FO5464
a
Front
3)
Install rear cage (24) to pinion gear (191, then press fit bearing cone (23). * Press fit the bearing with the specified load, then rotate the cage to fit the bearing. . Press load: 5 ton 6 Bearing: Oil (Axle oil) * Check that the cage is rotated lightly under the specified load. If the cage does not is not rotated lightly, replace the bearing spacer, etc., then adjust again. f Reference (Adjustment is not necessary) . Pre-load on bearing: 105 kg - 0 kg . End play: 0 - 0.139 mm
30-80 a
ouaoe
‘25
~~~05506
Rear gauge DWW05507
Press
WA30-5
DISASSEMBLY
4)
DIFFERENTIALS
AND ASSEMBLY
Press fit front cage (24-I)
to pinion gear (19-
1). * Press load: 5 ton * Before press fitting bearing cones (23-I) *
5)
6)
7)
Press +
and (21-l), apply oil to them. Install spacer (20-I) to the cage and pinion gear. & Bearing: Oil (Axle oil)
Press fit oil seal (22-I) to cage (24-I). * Press fit the oil seal until it is flush with face “c” of the cage. 6 Press fitting part of oil seal:
DWW05509
Gasket sealant (SEALEND 242) Apply grease to lip “b” of oil seal (22-l). & Oil seal lip: Grease (G2-LI) Install coupling (17-I) to pinion gear (19-l). Keep applying pressure of 3.4 ton to pinion gear and rotate cage sufficiently to fit bearing. * Apply grease to end face “e” of the coupling. 6 End face “e” of coupling:
-1
Grease (LM-GI 8)
Install standard shim 1.3 mm thick to end face of spline of pinion gear (19-11, then apply pressure of 3.4 ton to pinion gear again.
While pressure is applied to pinion gear, measure torque Y and end play at part A of cage (24-I 1. l Torque Y: 0 - 1.8 kg (Including sealing resistance of 0.7 kg) l End play: 0 - 0.05 mm 10) Adjust shim thickness so that torque Y and end play will be in above range. If they cannot be adjusted into above range, repeat steps 81, 91, and IO). t After tightening the mounting bolts, check again that torque Y and end play are in the above range.
362F05155
9)
1
30-81 0
DISASSEMBLY
AND
DIFFERENTIALS
ASSEMBLY
11) install shim (27) selected in step 10) and Oring holder (16-1). Apply adhesive to mounting bolt (15-l), then tighten it. * Take care that the O-ring will not be caught. & Mounting bolt: Adhesive (LT-21 m Mounting bolt: 6.75 f0.75 kgm 12) Check that torque Y is 0 - 1.8 kg (including sealing resistance of 0.7 kg) and end play is 0.05 or less. 13) Press fit cage (3) and oil seal (22). * Press fit the oil seal until it is flush with face “c” of the cage. & Press fitting part of oil seal: Gasket sealant (SEALEND 2421 14) Apply grease to lip “b” of oil seal (22). 6 Oil seal lip: Grease (G2-LI)
A
\\
2.
CouDlina rear coupling (17) to pinion gear (19), I) in&II then install O-rings (18) and (18-l), and holders (16) and (16-I). * Install the O-rings securely so that they will not be projected. -k Apply grease to end face “d” of the coupling. & End face “d” of coupling: Grease (LM-G) Sr When inserting the coupling, take care not to damage the sealing. 2) Degrease the threads of mounting bolts (15) and (15-1) and pinion gear, and apply adhesive to them, then tighten them. 6 Mounting bolt: Adhesive (LT-2) w Mounting bolt: 6.75 20.75 kgm 3) After measuring torque of front cage assembly, check that shim (27) is inserted, then perform step 2).
Rear
m
Is-\
I/
362FO5166
Oi DWW05511
15-t
362FO5160
30-82 a
WA30-5
DISASSEMBLY
3.
DIFFERENTIALS
AND ASSEMBLY
Differential carrier assembly 1) Press fit bevel gear (7), differential carrier (8), and bearings (6) and (6-I). Ir Press fit the bearings to their shoulders and eliminate clearance.
Press
Press stand
Press
siand
Block
DWW05513
I 2) Install side gear (14) to differential 03). 6
12
362FO5455
carrier
Face “f” of side gear: Oil (Axle oil)
3)
Install pinion gear (28) and insert shafts (12) and (131, then align the pin holes and insert lock pin (II). & Each gear and shaft: Oil (Axle oil)
4)
Install side gear (IO) and thrust washer (9). a Sliding faces of thrust washer: Oil (Axle oil)
uw
-362FO5161
0 362FO5456
WA30-5
DISASSEMBLY
5)
DIFFERENTIALS
AND ASSEMBLY
Install bevel gear (7) to differential carrier (81, then tighten mounting bolts (29). * Before installing the bevel gear, check that the lock pin is inserted. k Degrease the bolt holes and mounting bolts, then apply adhesive to them. & Mounting bolt: Adhesive (LT-2) m Mounting bolt: 6.75 + 0.75 kgm
ti/--k8
4.
Adjustment of shim of cage 1) install cage assembly (3)/(3-l) to differential housing (1) without inserting any shim. w Mounting bolt: 11.25 + 1.25 kgm
2)
30-84 0
r
Rear
end
362FO5162
Front
end
Insert measuring tool Al in differential housing (I), then measure distance L between end of bevel pinion gear and measuring tool Al with inside micrometer or cylinder gauge. * Apply oil thinly to measuring tool Al and insert it in the differential housing evenly, taking care not to pry the differential housing.
WAXI-5
DISASSEMBLY
3)
DIFFERENTIALS
AND ASSEMBLY
Selection of shims t = C - (L + D/2) t: Shim thickness C: (A + a) - (B + b) a: Deviation from dimension b: Deviation from dimension L: Measured value D: Diameter of tool Al
A B
Apply the measured diameter as dimension D. Basic dimensions . Dimension A: 95 t- 0.3’mm . Dimension B: 32 * 0.1 mm Shim thickness ‘9” is between 0.36 and 1.67 mm. The following items are recorded on the end face of the pinion gear with an electromagnetic pen. MD
+O.lO I-
r
Dimension
-0.01 F Dimension b
362FO5163
I
14
,4-l
(Unit: mm)
a (Unit: mm)
Combination No. of bevel pinion gear and bevel gear
Be sure to use a bevel pinion gear and a bevel gear having the same No. After adjusting the shim, remove the cage.
5.
Bearing carrier Press fit bearing cups (30) and (30-I) to bearing carriers (4) and (4-l). * Press fit the bearing cups until all clearance at part “g” is eliminated all round. a Press fitting part of bearing cup: Oil (Axle oil)
I 6.
362FO516d
Adjustment of bearing carrier shim 1) Sling differential carrier assembly (6) and install it in position, then install bearing carriers (4) and (4-I) on both sides. * Install the differential carrier assembly so that the bevel gear will be on the left side when seen from the cage mounting side.
WA30-5
30-85 a
DISASSEMBLY
AND
2) Tighten
carrier (4-l) rier side to standard
$
m
DIFFERENTIALS
ASSEMBLY
on the differential torque.
Mounting
car-
r
bolt: 3.15 f 0.65 kgm
362FO6464
3)
Secure bearing carrier (4) on bevel gear side with four mounting bolts. * Turning the bevel gear, apply oil to the bearing. & Bearing: Oil (Axle oil) * Tighten the mounting bolts, turning the bevel gear to fit the all parts. w Mounting bolt: 1.2 kgm
4)
Loosen four mounting bolts on bevel side until bearing has end play.
5)
Tighten CI9
*
four mounting
gear
bolts again evenly.
Mounting bolt: 0.55 kgm m At this time, check that the bearing has end play and tighten the mounting bolts, turning the bevel gear.
6)
Measure clearance tl and t2 in grooves at two places of bearing carrier (4) on bevel gear side with filler gauges.
7)
Selection of shim Shim thickness = (tl + t2)/2 k 0.035 mm j, Make up shims of the obtained thickness by combining the shims of the following thickness. 0.05 mm, 0.20 mm, 0.30 mm, 0.80 mm
30-86 0
WA30-5
DISASSEMBLY
8)
w
Mounting
bolt: 3.15 f 0.65 kgm
Measure pre-load on bevel gear with spring balance to check that it is in the specified range. f Pre-load: 0.3 - 1.9 kg (Target value: 1.9 *
7.
DIFFERENTIALS
Remove bearing carriers (4) on both sides and insert selected shims (32). * Turning the bevel gear, tighten the bearing carrier mounting bolts evenly. $
9)
AND ASSEMBLY
kg) If the pre-load is out of the specified range, adjust it by changing the shim thickness.
Cage 1)
Install O-ring (31) to cage. & O-ring: Grease (G2-LII
2)
Install guide bolts, then install cage assembly (3) together with shim (33) selected in step 4. ‘The shim thickness must be between 0.36 and 1.67 mm. Apply grease thinly to the outside of the O-ring fitting part of the cage so that the O-ring will not be broken. Check that the O-ring is not twisted or caught. m Mounting bolt: 11.5 + 1.0 kgm
WA3Q-5
30-87 0
DISASSEMBLY
8.
DIFFERENTIALS
AND ASSEMBLY
Adjustment of backlash 1) Measure backlash of bevel gear
with dial gauge. * Backlash: 0.13 - 0.23 mm * First, measure the backlash with the all shims inserted on the bevel gear side. Sr Measure backlash at 3 places on the periphen/ of the bevel gear. The dispersion of the measured value must not exceed 0.1 mm.
2)
To adjust backlash into the specified range, move a part of shims on bevel gear side to opposite side. * Do not change the total thickness of the shims on both sides. Ir If the backlash is too large . Move a part of shim B to shim A. * If the backlash is too small . Move a part of shim A to shim B.
/
Shim B
Shim A DWW05515
30-88 0
WA30-5
DISASSEMBLY
9.
DIFFERENTIALS
AND ASSEMBLY
Check of tooth contact Knead red lead in spindle oil, etc., and apply mixture to surface of 7 - 8 teeth of bevel gear. Holding bevel gear with hand to brake it, turn pinion gear forward and backward to check tooth contacts of gears. Check and adjust toot contact by following method. Tooth contact
Cause
Adjustment
method
‘roper tooth contact. Nhen tooth contact is xoper, 50% of all :ooth length is in :ontact around pitch ,ine, leaving toe side sbout 5 mm, toward heal side.
Adjust pinion gear by changing shim thickness of cage. Adjustment of bevel gear is same as that of backlash.
3evel pinion gear too Farfrom gear.
1. Reduce shim of pinion gear to bring pinion gear near bevel gear. 2. Bring bevel gear far from pinion gear, and adjust backlash correctly.
415F247
415F248
415F247
Bevel pinion gear is too near gear.
n
1. Increase shim of pinion gear to bring pinion gear far from bevel gear. 2. Bring bevel gear near pinion gear, and adjust backlash correctly.
2
-
415F248
415F247
Bevel gear is too near pinion gear.
1. Decrease shim of pinion gear to bring pinion gear near bevel gear. 2. Bring bevel gear far from pinion gear, and adjust backlash correctly.
nb ! 2
-
415F248
415F247
Bevel gear is too far from pinion gear.
415F247
* *
1. increase shim of pinion gear to bring pinion gear far from bevel gear. 2. Bring bevel gear near pinion gear, and adjust backlash correctly.
'
2
415F248
If the tooth contact is out of the range, adjust the shim again from measurement When adjusting the position of the bevel gear, do not change the total thickness both sides.
WA30-5
-
L-
t __
in step 4. of the shims on
30-89 0
DISASSEMBLY
AND ASSEMBLY
DIFFERENTIALS
10. Differential cover and axle housing assembly I) install differential cover to housing (5). Ir Degrease the cover fitting face of the housing and the joints of the cover, and dry naturally, then apply gasket sealant to them. * Apply continuous beads of gasket sealant 2 - 3 mm in diameter as shown at right. Take care not to brake the bead line. & Cover fitting face: Gasket sealant (LOCTITE 515) w Mounting bolt: 3.15 f 0.35 kgm 2)
Bead width 2-3mm
DWW05516
Degrease the fitting faces of the differential housing and axle housing (I), and dry naturally, then apply gasket sealant to them. a Fitting face of axle housing: Gasket sealant (LOCTITE 5151
Bead width 2-3mm
I 3)
Insert axle shaft (34) in axle housing assembly (I), and install axle housing assembly (I), matching it to guide pin of differential housing. w Mounting bolt: 11.25 + 1.25 kgm
I 11 Refilling with oil Tighten drain plug and add oil through level gauge (35) to the specified level. I&
DWW05517
’
I
I
362FO5170
oil filler/
Axle oil: 4.5 e Axle assembly
30-90 0
WA30-5
DISASSEMBLY
DISASSEMBLY HOUSINGS 1.
AXLE HOUSINGS
AND ASSEMBLY
OF AXLE
Draining oil Loosen drain plug (1) to drain oil. I&
Axle oil: 4.5 .rZ
362F05039A
T 2.
I
362FO5470
Axle housing assemblies I) Sling axle housing (2) and remove housing mounting bolts. Make match marks on both axle housings * so that they will not be mixed up.
362FO6471
2)
Disconnect
axle housing
and remove
shaft
(3). lf?lkg
Axle housing:
40 kg
362FO5172
3.
Planetary carrier assembly 1) Remove axle shaft mounting bolt, then move planetary carrier assembly (4).
re-
362FO547:
WA30-5
DISASSEMBLY
2)
AND ASSEMBLY
Remove shim (5). * Record the shim thickness
AXLE HOUSINGS
for assembly.
I 4.
Planetary carrier 1) Drive in spring pin (6). * Take care not to drive in the spring too much. 2) Using press, pull out shaft (7).
415F194
pin
I
J
4 I6F273
6
3) 4)
30-92 a
Pull spring pin (8) out of removed shaft (7). Remove pinion gear (IO) from planetary carrier (91, then remove bearing cone (Ilj and spacer (12).
1
362FO5475
362FO5174
362FO5476
362F0647
WA30-5
DISASSEMBLY
5.
AXLE HOUSINGS
AND ASSEMBLY
Housing and shaft
1) Erect housing and shaft assembly, then sling housing
(2).
362FO5173
2) Hit end of axle shaft (13) with copper hammer to drive it out. * When axle shaft (13) is driven out a little, pull out part “a” of oil seal (14) with screwdriver, etc. to protect oil seal from bearing (15).
I * 3)
415FO1066
Remove the bearing according to the following procedure. When removing bearing (15) from shaft (131, press in part “a” of oil seal and sleeve (16) toward flange with screwdriver, etc., evenly all round.
362FO6478
4)
Make clearance “c” between bearing (15) and sleeve (16-I) to apply puller.
Flange
Shaft
WA30-5
DWW05519
30-93 0
DISASSEMBLY
5)
AXLE HOUSINGS
AND ASSEMBLY
install bolt @ (5/8 - 18 UNF, .r?=Approx. 60mm) to part “b” of puller (B2). * Tighten bolt @ to the end.
b
82
6)
Install puller (B2) to clearance “c” between bearing (15) and sleeve (16-11, then assemble bolt (B3) and nut (B4). Sr Install the puller securely.
7)
Insert washer between bolt @ and face of flange, the loosen bolt @to remove bearing
* *
*
(15). Since puller (Bl) is not hooked sufficiently to bearing (15), take care that it will not come. If the threaded part of bolt @ is not long enough, put one or more washers on the face of the flange to adjust the height of bolt @ to pull out bearing (15). Replace the oil seal and sleeve assembly with new ones.
I
415FO1602
I
415FO1603
DWW05520
6.
Ring gear Using puller 0,
remove
up ring gear (17).
I 30-94 0
415F197
362F0547E
WA30-5
DISASSEMBLY
7.
AXLE HOUSING
AND ASSEMBLY
Axle housing Remove bearing housing (2).
cups (18) and (18-I)
from axle
42AF01209
WA30-5
30-95 0
DISASSEMBLY
AND ASSEMBLY
ASSEMBLY
AXLE HOUSING
OF AXLE HOUSING
1. Axle housing Press fit axle housing (2) and bearing cups (18) and (18-I). * After press fitting the cups, check that there is not clearance at parts “a”.
42AF01210
2.
Ring gear Press fit ring gear (19) to axle housing (2), then insert pin (20). * Before press fitting ring gear (19), cool it down with dry ice to about -30°C. * Align the pin holes of the housing and ring gear, then assemble them. j, When press fitting the ring gear, do not slant it but keep it on the level.
3.
Axle shaft 1)
Assemble oil seal and sleeve (16), then press fit them to axle shaft (13). * Take care not to deform the seal and sleeve with a hammer, etc. * Apply axle oil thinly to sleeve contact part “a” of oil seal. 6 Sleeve contact face: Oil (Axle oil)
2)
Install bearing (15) on press stand, then press fit axle shaft (13). j, Do not slant the bearing. 6 Press fitting part of bearing: Oil (Axle oil)
30-96 0
II I ’
DISASSEMBLY
4.
AXLE HOUSING
AND ASSEMBLY
Housing and shaft 1) Erect shaft (13) and install tool Cl to it. * Check that the top of tool Cl is in contact with seal (16). * Take care that tool Cl will not come off.
2)
Aligning housing (2) with oil seal fitting part, lower it slowly. * Insert the housing by utilizing its weight.
3)
Remove
4)
Turning housing (21, press fit bearing cone (21) to shaft (13). * The bearing cone needs to be press fitted to the end of the cup. If it is press fitted with too high pressure, however, it can damage the inside of the cup. Take care of the fitting pressure. & Bearing cone fitting part: Oil (Axle oil) Fitting pressure: 1.5 ton * * After installing the housing, level difference “c� of the seal surface must be within the specified range. If there is clearance b at part a, it must be within the specified range and even. . Standard values Clearance b : 0.85 + 0.7 mm c : 12 f 0.2 mm : 0.28 mm max. Slant
WA30-5
tool Cl.
Press Diameter fittina
of part
Dress 4_9.7mm
+
b
30-97 0
DISASSEMBLY
5.
AXLE HOUSING
AND ASSEMBLY
Planetary carrier 1) Install bearing cone (11) to pinion gear (IO). Aligning shaft holes of planetary carrier (9) and gear, install spacer (12). * Shim does not need to be adjusted. * Reference end play: 0 - 0.158 mm
362FO6477
2)
Aligning shaft with hole of spring pin (6), press fit it. Put spacer (12) in the planetary carrier in * advance. Drive in the shaft with the joint of the * spring pin up. * Aligning shaft (7) with the hole of spring pin (6), drive the spring pin until it is flush with the carrier. Fitting pressure: 2 ton * & Shaft: Oil (Axle oil)
-12
Groove should face upward.
DWW05525
3)
362FO6482
Hit end of shaft (7) and differential side of gear (IO) lightly to press back bearing cone (11) so that gear turns lightly. * Check that the gear turns lightly.
-
30-98 0
362FO6483
DISASSEMBLY
6.
AXLE HOUSING
AND ASSEMBLY
Adjustment of end play of wheel bearing 1) Install housing and shaft assembly (22) under press. 2)
Keep pressure of 2 ton on bearing cone (21) and turn housing (2) by 3 - 4 turns. * Pressure to be kept: 2 ton * After finishing pressing, do not turn the housing.
3)
Remove axle shaft (13) from under press, measure dimension “h” with depth micrometer. * Standard value “h”: 34.03 mm
4)
Install planetary carrier assembly (4) to stand. + Take care not to slant the carrier assembly.
5)
Measure dimension Z of planetary carrier assembly (4) with depth micrometer. * Standard value Z: 35.5 & 0.1 mm
6)
Calculate “clearance y” from value “h” of axle shaft measured in step 3) and value “2” of planetary carrier measured in step 5). y=Z-h Shim t = y + (0 - 0.04) Select shims so that their total thickness will be “t”.
Press +
21
l
l
l
7)
WA30-5
Install selected shims having thickness of t, then install planetary carrier assembly (4) and tighten mounting bolts to the specified torque. * Install the planetary carrier assembly slowly so that it will not give an impact to the bearing. D Mounting bolt: 11.25 ? 1.25 kgm
30-99 0
DISASSEMBLY
8)
9)
7.
Measure the end play and torque with check bar and spring balance respectively, and check that they are within the respective specified ranges. . Standard-end play: 0. - 0.04 mm . Standard torque: 5 kg max. * If either or both of these values are out of the specified ranges, repeat the work from step 3).
Remove
planetary
carrier
assembly
(4).
Measurine
lue
Point
DWW05527
Planetary carrier assembly I) Install shims (5) selected in step 6) to axle shaft end of planetary carrier assembly (41, then install mounting bolt (23). Sr Degrease bolt hole of axle shaft and mounting bolt securely. & Mounting bolt: Adhesive (LT-2) bolt: 11.25 & 1.25 kgm Clean the ends of the shaft and the spline of the planetary carrier before installing them.
e9 *
A
8.
AXLE HOUSING
AND ASSEMBLY
w
Mounting
362FO5485
When installing the planetary carrier, take care not to catch your fingers in the gears, etc.
Axle housing assembly 1) Degrease and clean differential housing fitting face of axle housing, and apply gasket sealant continuously to it. & Joint of housing: Gasket sealant (LOCTITE 5151
LOCTITE 515
DWW05528
30- 100 0
WA30-5
DISASSEMBLY
2)
AND ASSEMBLY
AXLE HOUSING
Sling axle housing (2) horizontally. Aligning spline grooves with holes of pins (241, install axle housing carefully. w Housing mounting bolt: 11.25 Il.25 kgm
j,
3)
9.
If the differential cover has been removed, install it by the following method. Install differential cover (25) to differential housing. J, Apply gasket sealant continuously. e Fitting face of cover: Gasket sealant (LOCTITE 515) m Fitting face of cover: 3.15 F 0.35 kgm
Refilling with oil Tightendrain plug and add oil through level gauge (26) to the specified level.
362FO5487
-
I LOCTITE 515
DWW05529
oil filler/
26
Oil level gauze
-bY -n
Axle assembly DWW05530
fa=a
WA30-5
26 /
DISASSEMBLY
REMOVAL PIN
CENTER
AND ASSEMBLY
PIN
OF CENTER HINGE
AStop the vehicle on level ground and install the safety bar to the frame, then lower the bucket to the ground. Stop the engine and apply the parking brake and put blocks under the wheels to prevent the vehicle from moving. Loosen the oil filler cap to release the residual a pressure from the hydraulic tank, then operate the steering wheel and work control lever 2 - 3 times to release the residual pressure from the piping. * Disconnect the cable from the negative (-1 terminal of the battery. * Remove the canopy in advance. 1.
Floor mat and cover 1) Remove floor mat (I) and cover (2). 2) Remove steering column cover (3).
2.
Electric wiring Disconnect main wiring connector frame, then remove band (5).
3.
HINGE
362FO6344
d
362FO5343
(4) from front
Drive shaft Disconnect front drive shaft (6). * Disconnect the drive shaft from the transfer.
30-l 02 0
WAD5
DISASSEMBLY
4.
CENTER
AND ASSEMBLY
Steering cylinder 1) Disconnect steering
7 cylinder
hoses
(7) and
(8). 2)
5.
Hydraulic piping and support 1) Disconnect hose (IO) between ment valve and oil filter. 2)
6.
Remove lock bolt on bottom side of steering cylinder, then remove pin (9). Remove the hose clamp bracket from the * rear frame. Install covers to the holes of the removed * hoses and their connecting holes.
work
equip-
Disconnect hose (I I) between priority valve and work equipment valve. * After disconnecting the hoses, remove them from the support. Install covers to the holes of the removed * hoses and their connecting holes.
Work equipment control cable Disconnect work equipment control cable 1) (12) from valve. 2) Remove work equipment control cable (12) from front frame without removing it bracket (13).
7.
8.
Air cleaner Loosen clamp of hose (15) on turbocharger of air cleaner (14), then disconnect hose. Tachometer cable Disconnect tachometer
WA30-5
cable (16).
side
8
I
I
HINGE
PIN
DISASSEMBLY
9.
CENTER
AND ASSEMBLY
HINGE
PIN
Radiator bracket 1) Disconnect battery (+) cable (17) from battery, then remove clip (19) of electric wire (18) from bar (20). * Remove the battery cable and wire clip on the rear frame side. * Move the combination lamp wires on both sides to aside and secure them so that they will not bend. 2)
Remove
engine
hood lock (21).
3)
Disconnect sub-tank (22) and hose (23) from tank, then plug hose adapters.
4)
Remove brackets (24) on both sides from radiator (25). * Remove the bar without removing it from the bracket. * After removing the bracket, support the radiator so that it will not fall down.
10. Electric wiring Disconnect the following electric wires . Disconnect terminals of alternator and starting motor wiring connector (26). *
.
Pull slow-blow fuse bracket of the floor.
(26-l)
out
of the
Wires (271, (281, and (29) for right side of engine. Ir Put tags, etc. to the wires for distinction. 362FO5187
30- 104 0
WA30-5
DISASSEMBLY
AND
CENTER
ASSEMBLY
11 Fuel control linkage and cable Disconnect cable (31) from fuel control lever (301, then remove it from bracket der accelerator pedal. or When removing the cable from the make match marks on it and lock assembly.
HINGE
PIN
linkage (32) unbracket, nut for
31 362FO5404
30 362FO5305
12. Floor frame assembly 1) Disconnect parking brake pedal cable (33) from lever (34), then remove support (35).
2)
Disconnect following wiring connectors. . Water separator (36). . Fuel unit (37). . Stop lamp switch (38). . Parking brake switch (39).
*
Before disconnecting the connectors, tags to them for assembly.
put
1
3)
Remove inching valve (42).
4)
Remove clamp (44) of electric right front of floor.
WA30-5
362FO5188
valve hoses (40) and (41) from
wire
(43) under
30-105 0
DISASSEMBLY
AND
CENTER
ASSEMBLY
5)
Disconnect hose (45) between work ment pump and steering valve.
6)
Disconnect hose (46) between steering valve and oil filter. * install covers to the holes of the removed hoses and their connecting holes.
HINGE
PIN
equip-
7) Sling floor frame assembly (47) by 4 parts. Remove mounting bolts and lift up about 50 mm and stop temporarily. Check that the floor frame assembly is disconnected perfectly, then lift it off slowly. * Take care of the center of gravity and check that the cables, hoses, wires, etc. have been disconnected.
13. Raising vehicle bodv I) Adjust height of rear frame
and install jack
0. 2)
Install stand @ under counterweight.
362FO5505
3)
Install frame. *
30-l 06 0
block
@ just
under
center
Adjust the height of the frame carefully.
362FO55OE
of front
extremely
WA30-5
DISASSEMBLY
AND ASSEMBLY
CENTER
14. Center hinge pin 1) Remove lock bolt (48) under center hinge pin. * Since the lock bolt is secured with adhesive, do not remove it forcibly. 2) Remove plate (49). 3) Remove bolts of hinge pin (50) above center hinge. 4) Pull out hinge pin (50). * If the pin cannot be pulled out, adjust the level of the front frame and rear frame. 5) Remove shim (51) from top of hinge, then pull up upper and lower spacers (52) and’ (53) until they are removed from rear frame (54). * Check the quantity sem bly.
WA30-5
of the shims for as-
362FO5506
HINGE
PIN
362FO5509
DISASSEMBLY
CENTER
AND ASSEMBLY
HINGE
PIN
15. Disconnection of frame 1) Remove safety bar (55) and turn both tires to pull out front frame forward. * When disconnecting the front frame, take care that its upper and lower spacers will not be caught in the rear frame. 2) After removing the front frame, remove spacers (52) and (53).
362FO5510
362FO5511
16. Center hinge bearing. 1) Remove upper and lower dust seals (56) and (57) from rear frame (54). * If the dust seals are removed, replace them with new ones. 2)
Remove
Front
upper and lower bearing cones (58). 53
3)
Remove *
upper and lower bearing
_frame
52
cups (59).
When removing the dust seal and bearing cup, take care not to damage the inside of the center hinge of the rear frame.
57
30-108 0
362FO5198
WA30-5
DISASSEMBLY AND ASSEMBLY
INSTALLATION HINGE PIN 1.
CENTER HINGE PIN
OF CENTER
Center hinge bearing I) Press fit bearing cups (59) to top and bottom of rear frame (54). * Clean the bearing cup fitting parts of the center hinge and apply oil to their inside, then press fit the bearing cups. It- Securely press fit the bearing cups to eliminate clearance at parts “a�.
*
2)
3)
a
When press fitting the bearing cups, use jigs so that they will not slant.
Install bearing cones (58) to top and bottom of bearing cup (59). Before installing the baring cones, apply * grease to the outside of the bearings. & Bearing: Grease (G2-LI)
*
Sling and support the bearing cones under the hinge.
*
Degrease the inside of the dust seal fitting parts at the top and bottom of the center hinge.
Press
Apply adhesive to the outside of dust seals (56) and (571, then press fit them. * Press fit both dust seals with their lips
Pad
UD. -r-
* *
WA30-5
When press fitting the dust seals, take care not to slant them. Take care not to damage the seal lips and keep raising the bearing cones. & Outside of dust seal: Adhesive (Bearing mount)
I
DWW05535
30-109 0
DISASSEMBLY
4)
AND ASSEMBLY
CENTER HINGE PIN
Apply grease to all periphery of center hinge “b” of rear frame. & Center hinge “b”: Grease (G2-LI) Grease
I 2.
DWW05536
Connection frames I)
Turn both tires to move front frame toward rear frame, and align their pin holes. Awhen aligning the pin holes, use a bar. Never insert your fingers in the pin holes. * Align the pin holes securely. Ir Aligning the pin holes, install the safety bar.
2)
Install spacers (52) and (53) to the top and bottom of the front frame. *
Insert each spacer with fered side in. &
Outside
its more
cham-
of spacer: Grease (G2-LI)
53
DWW05537
@Y3
30-110 0
DWW05536
WA30-5
DISASSEMBLY
3.
AND
ASSEMBLY
Center hinge pin 1) Aligning pin holes of front frame and rear frame securely, insert lower spacer (53). When aligning the pin holes, use a bar. Never insert your fingers in the pin holes. Sr Align the pin holes securely. *. Insert the spacer slowly so that the dust seal spring will not come off.
a
2)
Install plate (49). j, Check that there is not clearance at part “c� all round and the plate is installed evenly. B Mounting bolt: 6.75 + 0.75 kgm
3)
Aligning pin holes of front frame and rear frame securely, insert upper spacer (52). When aligning the pin holes, use a bar. g Never insert your fingers in the pin holes. Align the pin holes securely. Insert the spacer slowly so that the dust seal spring will not come off. After inserting the upper and lower spacers, check that the dust seal spring has not come off. Apply grease to the dust seal lips. & Dust seal lip: Grease (GZ-LI)
4)
Check that the pin holes are aligned, then install center hinge pin (50) and tighten mounting bolts (60) temporarily. -k To tighten the mounting bolts temporarily means to tighten them to the degree that they can be returned with the fingers.
WA30-5
CENTER
HINGE
PIN
DISASSEMBLY
5)
AND ASSEMBLY
Hit head of center hinge pin (50) 2 - 3 times with copper hammer to fit the contact parts. * When hitting the head of the center hinge pin, apply a pad to it. * Take care not to hit too strongly.
CENTER HINGE PIN
Covper hammer
I
6)
Apply adhesive to threads of lock bolt (48), then tighten it to specified torque. * When reusing the hinge pin, remove the all adhesive from the threaded hole and degrease the threaded hole. * Degrease the threads of the lock bolt. 6 Lock bolt: Adhesive (LOCTITE 262) Qza Lock bolt: 9.0 + 1.0 kgm
7)
Measure clearance “t” between front frame and upper plate of hinge pin (50) with thickness gauges at 4 places, then select shims so that the clearance will be in the specified range. Standard clearance: 0.5 mm max. J, Assemble shims so that their thickness will not exceed t - (0.5) mm. -f Use the minimum clearance measured at the 4 places as value “t”.
DWW05543
l
8)
Insert assembled shims in hinge pin (50), then secure with mounting bolts (60). w Mounting bolt: 6.75 f 0.75 kgm
30-112 a
WA30-5
1
CENTER HINGE PIN
DISASSEMBLY AND ASSEMBLY
4.
Lowering vehicle body 1) Remove block @ from center of front frame.
2)
Remove
3)
Remove jack @I under vehicle body. *
stand @ from counterweight.
Lower the vehicle fully.
rear frame
to lower
body extremely
care-
362FO5505
5.
362FO5506
Floor frame assembly 1) Sling floor frame assembly (47) by 4 parts, and move it to rear frame (54).
2)
Aligning floor frame assembly with guide pins (611, lower it slowly. Stop it about 50 mm before its fitting position and check that it has not caught any part, then install it.
3)
Connect hose and oil filter.
(46) between
steering
valve
4) Connect hose (45) between work equipment pump and steering valve. * Take care that the O-rings will not be twisted or caught. * Take care that the hoses will not interfere with another part and will not be twisted.
i
WA30-5
30-113 0
DISASSEMBLY
CENTER HINGE PIN
AND ASSEMBLY
5)
Install clamp (44) of electric right front of floor.
wire (43) under
6)
Install inching valve hoses (41) and (40) to valve (42). * Take care that the hose will not interfere with another part and will not be twisted.
7)
Connect the following electric wiring connectors. It Connect the wiring connectors according to the tags put to them when they were disconnected. . Parking brake switch (39) . Stop lamp switch (38). . Fuel unit (37) . Water separator (36)
r
’’
8)
6.
362~05189
7
362FO51ti
Connect parking brake pedal cable (33) to lever (341, then install support (35) to underside of floor. * Adjust the parking brake. For details, see TESTING AND ADJUSTING.
Fuel control linkage cable Connect cable (31) to fuel control linkage lever (301, then install cable (31) to bracket (32) under accelerator pedal. Ir Align the match mark of the cable with that of the locknut.
362FO5404
30-114 a
362FO5305
WA30-5
DISASSEMBLY
7.
Electric wiring Connect the following electric wires. . Wires (27), (28), and (29) for right side of engine. * Connect the wires according to the tags put to them when they were disconnected.
l
8.
CENTER
AND ASSEMBLY
Connect terminals of alternator and starting motor wiring connector (26). * Install slow-blow fuse (26-I) to the bracket of the floor.
Radiator bracket 1) Install brackets (24) to both sides of radiator (25), then install radiator rubber mount (62) to floor frame. w Mounting bolt: 6.75 + 0.75 kgm
362FO5212
2)
WA30-5
Remove plug from hose (23), then connect that hose and sub-tank (22) to tank.
HINGE
PIN
DISASSEMBLY
3)
CENTER
AND ASSEMBLY
HINGE
PIN
Install engine hood lock (21). * Close the hood to check its locking condition.
362FO5516
4)
Install battery (+I cable install clamp of electric j, Secure the battery the right side of the
(17) to battery, then wire (18) to bar (20). cable and wires on rear frame with clips
(19).
cable 9. Tachometer Connect tachometer
cable (16).
10. Air cleaner Connect hose (15) on turbocharger side to air cleaner (141, and secure it with clamp. Ir Take care that the hose will not be twisted.
control cable 11. Work equipment 1) Connect work equipment control to valve spool. 2)
cable (12)
Install work equipment control cable (12) together with bracket (13) to front frame.
30-116 0
WA30-5
DISASSEMBLY
AND ASSEMBLY
CENTER
12. Hydraulic piping and support 1) Connect hose (I I) between priority valve and work equipment valve. m Hose adapter: 8 k 2 kgm Width across flats of hose adapter: l
2)
27 mm Connect hose (IO) between work equipment valve and oil filter. m Hose adapter: 8 f 2 kgm . Width across flats of hose adapter: 27 mm Ir Take care that the hose will not interfere with another part and will not be twisted.
13. Steering cylinder 1) Install steering
cylinder
(62) in position.
2)
Adjust clearance “a” at fitting part of bottom. Ir Adjust the total of clearance “a” to specified value with shims. Clearance “a” = 1.0 mm max.
3)
Install pin (9) to bottom side, then install bolt. When aligning the pin holes, use a bar. Never insert your fingers in the pin holes.
A 4)
Connect steering cylinder hoses (7) and (8). * Take care that the hose will not interfere with another part and will not be twisted.
14. Drive shaft Install front drive shaft (6). * When installing the drive shaft, fit the socket and spigot securely and take care of the direction of the yoke. m Mounting bolt: 3.15 * 0.35 kgm
WA30-5
HINGE
PIN
DISASSEMBLY
AND
ASSEMBLY
CENTER
HINGE
PIN
15. Electric wiring Connect main wiring connector (4) of the front frame, then secure it with bands (5).
16. Floor mat and cover 1) Install steering column
2)
cover (3).
Install cover (2) of floor mat (1).
362FO5343
17. Refilling with oil Add hydraulic oil through oil filler (63) to the specified level. * Run the engine to circulate the oil through the system. Then, check the oil level again. Q
Hydraulic
oil: 38 fi
\
\p! w
30-118 a
- __
362FO5344
362FO5335
WA30-5
DISASSEMBLY
REMOVAL VALVE
STEERING VALVE
AND ASSEMBLY
OF STEERING
&top
A
the vehicle on level ground and install the safety bar to the frame, then lower the bucket to the ground. Stop the engine and apply the parking brake and put blocks under the wheels to prevent the vehicle from moving. Loosen the oil filler cap to release the residual pressure.from the hydraulic tank, then operate the steering wheel and work control lever 2 - 3 times to release the residual pressure from the piping.
1.
Cover 1) Remove steering column cover (I), then remove bands of wires and connectors. 2) Remove steering column bracket (3) from guard, then bring it down backward.
2.
Hydraulic piping Disconnect the following hydraulic pipes. a . Hose (5) between steering valve and work equipment valve . Hose (4) between work equipment pump and steering valve . Hydraulic hoses (6) and (7) of steering cylinder . Return hydraulic hose (8) of steering system
3.
If Steering valve Remove mounting bolts (9) to remove steering valve (2). When removing the steering valve, take care * not to catch your fingers in the parts.
INSTALLATION VALVE l
* .
m *
Carry out installation moval.
OF STEERING in the reverse
order to re-
Take care that the hose will not interfere with another part and will not be twisted. Refilling with oil Add hydraulic oil through the oil filler to the specified level. * Run the engine to circulate the oil through the system. Then, check the oil level again. Align the spline of the steering column with that of steering valve, and tighten the mounting bolts in the diagonal order. w Mounting bolt: 6.75 + 0.75 kgm
WA30-5
STEERING VALVE
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY VALVE * fr
j,
Remove dirt and dust from the outside joints of the unit with a wire brush, etc. Perform the following work in a clean place where dirt and dust will not stick to the parts. Hold the steering valve with a vise to disassemble it, as long as possible.
Disassembly 1.
OF STEERING
of rotor side
Hold the mounting flange lightly with vise 0, with rotary side up. *
Apply copper plates, etc. to the vise, and do not clamp too strongly.
2.
Remove
screws (I) to remove
end cap (2).
3.
Remove
O-ring (3) from end cap (2).
4.
Pull out rotor set (41, and remove O-ring (5). * Take care not to drop the star from inside of the rotor set.
5.
Remove
30- 120 0
23EF0
I IO8
23EF0
I 109
I
spacer (6).
WA365
DISASSEMBLY
STEERING VALVE
AND ASSEMBLY
6. Remove
drive (7).
7. Remove
spacer plate (8).
8. Remove
O-ring (9) from
housing
(IO).
23EFOI
Disassembly
of control
I IO
side
9. Remove housing (IO) from vise and place it on clean cloth so that the finished face will not be scratched.
10. Raise end of snap ring (1 I) with screwdriver remove
to
it from housing.
23EFOIIll
11. Turn spool and sleeve
until pin becomes horizontal, then press spool and sleeve with the thumb to remove seal bushing (12) from housing.
I
23EFOI
I I2
I
23EFOI
II3
12. Remove X-ring seal (13) from seal bushing (12). 13. Remove
dust seal (14) from seal bushing (12) with screwdriver. * Take care not to scratch the seal bushing.
WAD5
30-121 0
DISASSEMBLY
ANb ASSEMBLY
STEERING VALVE
14. Remove 2 bearing races (15) and thrust (16) from spool and sleeve.
needle
I 15. Pull spool and sleeve assembly (17) from housing (IO) in direction of arrow. * Pull the spool and sleeve assembly out of the housing, turning it to the right and left slowly so that it will not be caught in the housing. 16. Pull pin (18) out of spool and sleeve
23EFOI
II4
23EFOI
I16
23EFOI
I17
lo-
assembly
(17).
17. Press spool (20) in sleeve (19) forward a little and remove 6 centering springs (21) with hand carefully from spool (20).
18. Turn spool (20) slowly and pull it out from rear of sleeve (19) (in direction of arrow).
19. Remove O-ring
(22) from
20
housing.
20. Remove set screw (23) from housing. * The set screw is coated with adhesive SEALOCK. 21. Tighten screw bar in check seat (24) to pull out the latter.
22. Remove
O-rings
(25) and (26) from
check seat
(24).
23. Remove ball (27) and retainer (28) by hitting housing lightly.
30- 122 0
WA30-5
DISASSEMBLY
STEERING VALVE
AND ASSEMBLY
ASSEMBLY VALVE
OF STEERING
Check the all parts for flaws and burrs. Clean the all metallic parts in clean solvent, then dry them by blowing compressed air against them. Do not file or a part or polish it with coarse sandpaper. Apply clean grease to the O-rings. (New X-ring seals do not need to be greased, however.) Apply a little amount of grease to the O-rings for rotor set. When assembling the disassembled valve, replace the O-rings and seals with new ones.
Assembly
of control
side
1.
Put retainer (28) in housing with tweezers. * Check that the retainer is not slanted.
2.
Put in ball (27).
3.
Fit O-rings (26) and (25) to check seat (241, then push check seat (24) into housing. * Take care of the vertical direction of the check seat. * Take care not to scratch the O-rings.
4.
Install set screw (23). * Check that the set screw head is a little lower than housing end. w Set screw: 1.2 kgm & Set screw: LOCTITE
5.
Install spool (20) and sleeve (19) with their spring grooves on same side. * Install the spool by turning and sliding it. * Check that the spool can be turned easily inside the sleeve by turning its spline with the fingers. * Check the positioning mark of each part, if made.
I
I
23EFOI
Groove spring
for
20
Matins
WA30-5
I I8
marks
OWWO5546
30-123 0
STEERING VALVE
DISASSEMBLY AND ASSEMBLY
6. Align spring
grooves of spool (20) and sleeve (191, and erect them on fiat place, then inset-t springs (21) in spring grooves. * Insert the springs with the cuts at both ends down.
7. insert
pin (18)
in spool
and
sleeve
23EFOI
120
23EFOI
121
assembly
(171.
Insert spool and sleeve assembly (17) in housing (IO) in direction of arrow. 1) Keeping pin horizontally, turn spool and sleeve assembly to right and left little by little to insert it. Ir Take care not to scratch the housing and spool and sleeve assembly with each other. 2) Insert the spool and sleeve assembly until it is flush with the rear end of the housing. Ir If the assembly is inserted more than this level, the pin will fall. 3) Check that spool and sleeve turn lightly inside housing. 9. Install O-ring 10. Fit 2 bearing case (IO).
(22) to housing
I I22
23EFOI
123
(IO).
races (15) and thrust needle
(16) to
I
30- 124 0
23EF0
WA30-5
DISASSEMBLY
AND ASSEMBLY
11. Put dust seal (14) in seal bushing
12. Put X-ring
seal (13) in seal bushing
STEERING VALVE
(12).
(12).
13. Insert seal bushing (12) in spool, turning it. . Press in the seal bushing to the specified position by hitting it with a plastic hammer, etc. . Check that the seal bushing is in contact with the bearing race on the level.
23EF0
I I24
14. Fit snap ring (11) to housing.
Assembly
of rotor side
15. Hold flange of housing * *
lightly with vise. Do not clamp the flange too strongly. Check that the spool and sleeve are a little lower than the end face having 14 holes.
16. Put O-ring
(9) in housing.
126
17. Place spacer plate (8) and align bolt holes with tap holes of housing.
I WA30-5
23EF0
I I27
30-125 0
DISASSEMBLY
STEERING
AND ASSEMBLY
18. Turn spool and sleeve assembly until pin (18) becomes parallel with port surface of housing, then fit yoke of drive (7) to pin. * Draw a line on the end of the spline of the drive with a felt-tip pen to position the spool and sleeve assembly accurately.
19. Fit O-ring
Port
VALVE
surface
Set
Din
and
port
(5) to rotor set (4).
23EF0
20. Set O-ring (5) side of rotor set on spacer plate side, then fit bottom (A) of star of rotor (4) to drive (B). 1) Check that lines A, B, C, and D are in parallel with each other. 2) Align bolt holes of rotor set without removing fitted drive (7). * The above procedures are important for setting of valve timing of the unit.
I I29
Grouves
7
(Make
a
ort
/
Pin
surface
DWW05549
21. Put spacer (6) in rotor set. 22. Place end cap (2) on rotor set, then holes.
align
bolt
23EFOI
30-126 0
131
WA30-5
DISASSEMBLY
AND ASSEMBLY
STEERING VALVE
23. Apply oil to threads
of screw, then tighten end cap. * Install the handle to the spool and check that the spool turns. w Screw: First time: 1.5 kgm
Second time: 2.75 + 0.15 kgm
23EFO
WA30-5
I I32
30-127 a
DISASSEMBLY
STEERING VALVE
AND ASSEMBLY
DISASSEMBLY OF RELIEF VALVE HOUSING SIDE OF STEERING VALVE 1.
Loosen bolts (1) to remove relief valve housing (2) from steering valve assembly.
2.
Remove
3.
Secure housing (2) with vise, etc. * Take care not to clamp the housing strongly.
O-rings
(3).
4.
Remove plug (4), then from that plug.
5.
Remove
remove
O-ring
main relief valve assembly
spring (7). * Do not disassemble
too
(5)
(6) and
the main relief valve.
6.
Loosen locknut (9) of double relief valve (8), then’ remove adjustment screw (10) and Orings (11) and (12).
7.
Remove
8.
Loosen plug (15), then remove retainer pin assembly (16) and ball (17).
9.
Remove
valve cones (13) and spring (14).
assembly
and
(18).
42AF01218
30-128 0
WA305
DISASSEMBLY
AND ASSEMBLY
STEERING VALVF
ASSEMBLY OF RELIEF VALVE HOUSING SIDE OF STEERING VALVE *
Clean the all metallic
1.
Tighten check assembly m Check assembly:
2.
parts.
Install spring housing (2).
6.
Tighten plug (4) together m Plug: 5 kgm
with O-ring
7.
Install O-rings steering valve.
install
8.
Set pressure for double relief valve assembly (81, then tighten locknut (14) permanently.
(7) and valve
assembly
(6) to
(18).
1.0 kgm
Install ball (17) correctly, then put retainer and pin assembly (16). Wind sealing tape onto plug (15) and tighten it. w Plug: 1.3 kgm
3.
Install valve cones (13) and spring (141, then tighten adjustment screw (IO) together with O-rings (12) and (11). * The pressure is changed about 55 kg/cm2 by one turn of the screw.
4.
Tighten
double
5.
relief valve
(31, then
(5).
housing
to
(8) and locknut
(9). l
Tighten these items temporarily at this time. Tighten them permanently after the pressure is set normally. m Locknut (Permanent tightening): 4 kgm
42AF01218
WA30-5
30-129 a
DISASSEMBLY
STEERING VALVE
AND ASSEMBLY
REMOVAL OF STEERING CYLAStop the vehicle on level ground and install the safety bar to the frame, then lower the bucket to the ground. Stop the engine and apply the parking brake and put blocks under the wheels to prevent the vehicle from moving. g Loosen the oil filler cap to release the residual pressure from the hvdraulic tank, then operate the steering wheel and work control lever- 2 - 3 times to release the residual pressure from the piping. . When removing a cylinder, articulate the vehicle body in the direction opposite to it. Remove the front cover of the front frame in advance. l
1. Rod pin 1) Remove rod pin (I) of steering cylinder. m 2) Start engine and operate steering wheel to retract cylinder rod (2) from which pin was removed. * Do not retract the rod to the stroke end, but stop about 20 mm before the stroke end. 2.
3.
Hydraulic piping 1) Disconnect hose (3) on steering cylinder rod. side from adapter of tube (4). 2) Disconnect hose (5) on steering cylinder bottom side from adapter of tube (6).
8,
7, a
Cylinder Remove lock bolt on bottom side, then remove m pin (7) to remove cylinder (8). i Take care not to scratch the plated parts of the rod.
INSTALLATION OF STEERING CYLINDER . Carry out installation in the reverse order
i
>,lF~I
I Bottom
side
to
removal. mfijll Align the pin holes on the bottom side and insert shims so that clearance “a” between the cylinder and frame will be the specified value, then insert pin (7) and lock it with the bolt. AWhen aligning the pin holes, use a bar. Never insert your fingers in the pin holes. Clearance “a”: 1.0 mm max. . Add hydraulic oil through the oil filler to the specified level. * Run the engine to circulate the oil through the system. Then, check the oil level again.
l
30-130 0
WA3Q-5
DISASSEMBLY
AND ASSEMBLY
REMOVAL
PARKING
BRAKE
OF PARKING BRAKE
the vehicle on level ground and install the A Stop safety bar to the frame, then lower the bucket to the ground. Stop the engine and apply the parking brake and put blocks under the wheels to prevent the vehicle from moving. * After putting the blocks under the wheel, release the parking brake. . Drain.oil from the transfer. _
:
Transfer
oil: 1.8 t (EOIOW-30)
1.
Drive shaft and cable I) Disconnect drive shaft (I) from transfer. 2) Disconnect cable (2-I) from parking brake lever (2).
2.
Coupling and spacer Remove mounting bolt to remove holder (31, Oring (41, coupling (51, and spacer (6). * Before removing the front and rear couplings, make match marks on them so that they will not be deviated in circumferential direction from each other.
3.
Parking brake assembly 1) Remove all mounting bolts (71, then install forcing bolts. 2) Tighten forcing bolts to make clearance of 1.3 mm, then insert and secure separator plate holding tool Dl. * Take care not to make clearance wider than 1.3 mm. If too wide clearance is made, the disc plate will be pushed out and removal of parking brake assembly will become difficult.
Disk
v DWWO5551
WAN-5
7’
362FO5216
30-131 0
DISASSEMBLY
3)
Tighten forcing bolts to remove parking brake assembly (8). * Since you must work in a bad position to remove the parking brake assembly, take care extremely. * When removing the parking brake assembly, take care not to bring the oil seal lip in contact with the shaft. & ks
4.
PARKING BRAKE
AND ASSEMBLY
Parking
brake assembly:
3 kg
Disassembly of parking brake assembly 11 Remove tool Dl, then remove plate
(IO), wave spring (I I), and disc (12) from housing (9) in order. * Check that the lever is at the releasing position. Push in pin (13) side of plate (IO) and raise the opposite side to remove the plate. Take care not to damage the sliding surfaces of the plate.
ril
362FO5527
2) Remove piston assembly (14) from lever “e�, then remove 3)
ball (16) from
housing
(9).
Remove bolt (17) from housing (9), then remove lever (18), spacer (191, lever assembly (2), oil seal (201, and bearings (21) and (22). * Width across flats of hexagon socket head bolt: 6 mm Sr Before removing lever assembly (21, check its top and bottom. 362FO5218
362FO521S
30-132 0
3
362FO5528
WA30-5
DISASSEMBLY
INSTALLATION BRAKE 1.
PARKING BRAKE
AND ASSEMBLY
OF PARKING
Assembly of parking brake assembly I) Press fit bearing (22) to housing (9). Ir Press fitting dimension “a”: 1 mm * When press fitting the bearing, take care not to slant it. * Dimension “d” of oil seal and dust seal: 3.0 f 2.0 mm & Oil seal lip: Grease (G2-LI)
t 362FO5i20
2)
Press fit bearing (21) so that its end will be flush with face c of housing (9).
3)
Press fit oil seal (20) and apply grease to its lip. Sr Press fitting dimension “b”: 1.5 mm & Oil seal lip: Grease (G2-LI)
4)
Install lever assembly (2) to housing (9), then install spacer (19) and upper lever (18) in position and secure them with washer and bolt (17).
‘I’ \I 2 * *
5)
0 --___ : , 18 6‘.
362FO5223
Set the lever assembly
and spline of the lever to the center. & Hexagon socket head bolt: Adhesive (LT-2) QEI Hexagon socket head bolt: 3.15 f 0.35 kgm
Fit balls (16) to grooves of housing (9), then install them to lever “e” of piston assembly (14).
362FO5529
WA30-5
30- 133 0
DISASSEMBLY
6)
PARKING
AND ASSEMBLY
Check that the lever is at the releasing position. Insert plates (IO) in pin (13) of housing (91, then install discs (12) and wave springs (11) in order. * Before installing discs (121, soak it in clean transmission oil for at least 2 minutes. * Use 1 spring. Ir Note that’the number of the plates, discs, and wave springs is different from those of WA30-5.
I
BRAKE
362FO5224
362FO5530
7)
2.
Press housing and separator plate with fingers so that they will be flush with each other, then install tool Dl. * Align the splines of the discs in advance.
Parking brake assembly Align shaft spline with disc splines, and install parking brake assembly (81, matching it to dowel pins. * Install the brake assembly carefully so that the disc splines will be aligned. * Fit the gasket in advance. w Bolt: 11.5 + 1.0 kgm
30-134 0
WA30-5
DISASSEMBLY
3.
Fit O-ring (4) to groove, then install mounting bolt of holder (3). w Mounting bolt: 11.25 & 1.25 kgm
Drive shaft and cable I) Connect cable (2-I) (2). w
2)
5.
PARKING BRAKE
Coupling and spacer 1) Insert spacer (6) in shaft, then install coupling (51, aligning it with spline. * Install the coupling, aligning it with the match mark. Take care that the front and rear couplings will not be deviated in circumferential direction from each other. 2)
4.
AND ASSEMBLY
to parking
*
WA30-5
lever
Ball nut: 3.0 + 0.3 kgm
Connect drive shaft (1) to transfer side. * Fit the socket and spigot securely and take care of the direction of the yoke. w Mounting bolt: 3.15 + 0.35 kgm
Refilling with oil Tighten the drain valve and supply oil filler (23) to the specified level. Q
brake
Transfer
oil through
oil: 1.8 t (EOIOW-30)
If necessary, adjust the parking brake cable. For details, see TESTING AND ADJUSTING.
DISASSEMBLY
AND ASSEMBLY
HYDRAULIC TANK
REMOVAL OF HYDRAULIC TANK the vehicle on level ground and install the A Stop safety bar to the frame, then lower the bucket to
A
1.
the ground. Stop the engine and apply the parking brake and put blocks under the wheels to prevent the vehicle from moving. Loosen the oil filler cap to release the residual pressure from the hydraulic tank, then operate the steering wheel and work control lever 2 - 3 times to release the residual pressure from the piping. * Drain hydraulic oil.
Plate 1) Open engine 2)
2.
hood (I). rear plate (2).
Remove
Hydraulic tank I) Set block and hand lift truck under hydraulic tank (3). 2)
3)
Remove mounting bolts (4) of hydraulic tank (31, and lower hand lift truck. * Lowering the hand lift truck, disconnect hoses (5) and (6) from the tank tubes.
Balancing kg IL�7
4)
hydraulic
Hydraulic
tank (31, lower
it.
tank (Dry): 25 kgm
Pull out hydraulic tank (3) from right underside of vehicle body.
Carry out installation removal.
*
.
362FO5534
m
INSTALLATION OF HYDRAULIC TANK l
c-
in the
Lift up the hydraulic install it in position.
tank
reverse
order
horizontally
to
and
Refilling with oil Add hydraulic oil through oil filler (7) to the specified level. * Run the engine to circulate the oil through the system. Then, check the oil level again.
30-136 0
IdY
y
362FO5535
WORK EQUIPMENT VALVE
DISASSEMBLY AND ASSEMBLY
REMOVAL OF WORK EQUIPMENT VALVE the vehicle on level ground and install the A Stop safety bar to the frame, then lower the bucket to
A
1.
the ground. Stop the engine and apply the parking brake and put blocks under the wheels to prevent the vehicle from moving. Loosen the oil filler cap to release the residual pressure from the hydraulic tank, then operate the steering wheel and work control lever 2 - 3 times to release the residual pressure from the piping. Cover I) Install stand 0 2)
2.
3.
4.
Remove
at end of lift arm.
front cover (1) of front frame.
Control linkage Disconnect control
linkages
(2) and (3).
Hydraulic piping . Disconnect the following
hydraulic
pipes. m
1) 2) 3)
Lift cylinder hydraulic tubes (4) and (5). Dump cylinder hydraulic tubes (6) and (7). Work equipment hydraulic hoses (8) and (9). m
4)
Disconnect tor.
bucket positioner
Work equipment valve Remove work equipment
wiring connec-
valve (IO).
INSTALLATION OF WORK EQUIPMENT VALVE .
Carry out installation removal.
*
in the
reverse
order
to
Take care that the hose will not interfere with another part and will not be twisted.
m l
.
Width
across flats of hose adapter:
27 mm
Refilling with oil Add hydraulic oil through oil filler (11) to the specified. level. * Run the engine to circulate the oil through the system. Then, check the oil level again.
WA30-5
362F0554E
DISASSEMBLY
DUMP
AND ASSEMBLY
CYLINDER
REMOVAL OF DUMP CYLINDER
a a
.
Stop the vehicle on level ground and install the safety bar to the frame, then lower the bucket to the ground. Stop the engine and apply the parking brake and put blocks under the wheels to prevent the vehicle from moving. Loosen the oil filler cap to release the residual pressure from the hydraulic tank, then operate the steering wheel and work control lever 2 - 3 times to release the residual pressure from the piping. Disconnect connector (I) of bucket positioner switch.
1.
Rod pin Sling cylinder temporarily and remove lock bolt m to remove pin (2). * Sling the cylinder by 2 parts, taking care of its center of gravity.
2.
Hydraulic piping 1) Disconnect hose (3) on rod side from cylinder. m 2) Disconnect tube (4) on bottom side from adapter of hose (5). m
3.
Dump cylinder 1) Remove lock bolt and remove pin (6) on bottom side. m 2) Lift off dump cylinder (7). * Take care not to damage the cylinder rod. &I kg
Dump
cylinder:
19 kg
INSTALLATION OF DUMP CYLINDER .
m
Carry out installation removal.
A When Never
l%?lK-l -Take
in the
reverse
order
to
aligning the pin holes, use a bar. insert your fingers in the pin holes.
care that the hose will not interfere with another part and will not be twisted.
m &When Never
.
aligning the pin holes, use a bar. insert your fingers in the pin holes.
Bucket positioner * For adjustment of the bucket positioner, TESTING AND ADJUSTING.
30-138 0
see
WA30-5
DISASSEMBLY
REMOVAL
A
g
LIFT CYLINDER
AND ASSEMBLY
OF LIFT CYLINDER
Stop the vehicle on level ground and install the safety bar to the frame, then lower the bucket to the ground with the teeth directed down. Stop the engine and apply the parking brake and put blocks under the wheels to prevent the vehicle from moving. Loosen the oil filler cap to release the residual pressure from the hydraulic tank, then operate the steering wheel and work control lever 2 - 3 times to release the residual pressure from the piping. * Install stand (I) at end of Ii& arm.
1.
Rod pin Sling lift cylinder (1) temporarily and remove m lock bolt to remove pin (2). * Sling the cylinder by 2 parts, taking care of its center of gravity.
2.
Hydraulic piping 1) Disconnect hose (3) on rod side from adapter of hose (4). 2) Disconnect tube (5) on bottom side from m adapter of hose (6). Jr Install covers to the holes of the removed hoses and their connecting holes to prevent entry of foreign matter.
3.
Lift cylinder I) Remove lock bolt and remove pin (7) on m bottom side. 2) Lift off lift cylinder (I). * Lift off the lift cylinder slowly, taking care of its center of gravity. * Take care not to damage the cylinder rod.
4kg Dump
cylinder:
INSTALLATION DER l
m
22 kg
OF LIFT CYLIN-
Carry out installation removal.
in the
reverse
order
to
A
When aligning the pin holes, use a bar. Never insert your fingers in the pin holes.
J,
Take care that the hose will not interfere with another part and will not be twisted.
A
When aligning the pin holes, use a bar. Never
m
-
m insert your fingers
WA305
in the pin holes.
30- 139 0
DISASSEMBLY
HYDRAULIC
AND ASSEMBLY
CYLINDER
DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLIES 1.
Set cylinder
assembly
(I) to tool El.
2.
Using tool E2, loosen cylinder
head (2).
42AF01219
3.
Pull cylinder head and piston rod assembly (3) out of cylinder (41, then lift it off. * Prepare an oil container, since oil flows out when the piston rod assembly is pulled out of the cylinder.
4.
Remove
cylinder
(4) from tool El.
I 5.
42AF01220
Set cylinder head and piston rod assembly to tool El, and loosen nut (5) with wrench 0, etc.
*
Width
mm
across flats
El I WA30-5
1) 2)
3)
I
47
141130
Remove piston assembly (6). Remove retainer (7). * Remove the retainer from only the dump cylinder of WA30. Remove head assembly (2).
42AF01222
30-140 a
WA30-5
DISASSEMBLY
.
Disassembly 1) Remove 2) Remove
AND
HYDRAULIC
ASSEMBLY
of piston assembly wear ring (8). piston ring (9) from
piston (IO).
18
.
CYLINDER
42AF01231
Disassembly of cylinder head assembly 1) Remove snap ring (I I), then remove dust seal (12). 2) Remove rod packing (13). 3) Remove bushing (14) from cylinder head (15). 4) Remove O-ring and backup ring (16).
WA30-5
30-141 0
DISASSEMBLY
AND
HYDRAULIC
ASSEMBLY
CYLINDER
ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLIES Press
*
Apply engine oil to the sliding surfaces of each part. When assembling the rod packing, dust seal, and O-ring, take care not to damage them.
1.
Assembly of cylinder head assembly I) Using push tool 0, press fit bushing (14) to cylinder head (15). * Press fit the bushing very carefully so that it will not be deformed. 2) Install rod packing (13). 3) Using push tool, install dust seal (12) to head 4) 5)
+
-
DWW05561
(15). Install snap ring (II). Install backup ring (16) and O-ring. Sr Do not install the backup ring forcibly, but heat it in water at 50 - 6O’C, then fit it.
16 15 14 12 '11 42AF01234
2.
Assembly of piston assembly 1) Using tool E3, expand piston ring (9). Jr After setting the piston ring to the tool, turn the handle by 8 - 10 turns to expand the piston ring. 2) Remove piston ring (9) from tool E3, then install it to piston (IO).
42AF01227A
I 3)
Set tool E4 to contract
4)
Install wear
ring (8).
42AF01229
piston ring (9). I
42AF01229
30-142 0
A
WA30-5
DISASSEMBLY AND ASSEMBLY
HYDRAULIC CYLINDER
3. Set piston rod to tool El. 4. Install cylinder
head assembly (3), retainer (7), and piston assembly (6) to rod, then install nut (5). -k Install retainer of WA-30.
(7) to only the dump cylinder
5. Using torque wrench 0, tighten & Nut: Adhesive (LT-2)
nut (5).
Piston nut: 42AF01222
Lift cylinder Nut (Width across flats) (mm)
1
Tightening torque of nut (kgm)
Dump cylinder
/
41
63 k 6.3
41
Steering cylinder
/
63 i 6.3
30
25 f 2.5
6. Remove piston rod and head assembly tool El. 7. Set cylinder
(3) from
(4) to tool El.
8. Sling
piston rod and head install it to cylinder (4).
assembly
(31, and
I 9. Using tool E2, tighten D
Cylinder
WA30-5
10. Remove
cylinder
cylinder
42AF0122C
head nut (2).
head nut: Lift cylinder
Dump cylinder
Steering cylinder
50 i 5.0
45 + 4.5
42 f 4.2
assembly
from tool El, I
I
42AF01219
WA30-5
30-143 0
DISASSEMBLY
WORK
AND ASSEMBLY
EQUIPMENT
REMOVAL OF WORK EQUIPMENT g
Stop the vehicle on level ground and install the safety bar to the frame, then lower the bucket to the ground. Stop the engine and apply the parking brake and put blocks under the wheels to prevent the vehicle from moving.
1. Bucket link 1) Remove bucket link mounting pin (I). * Secure the bucket link to the bell crank with wires, etc. 2)
Remove both hinge mounting pins (2) of bucket (21). ANever insert fingers in the pin hole.
3)
Move back vehicle bucket. & kg
2.
to disconnect
Bucket (With B.O.C.): 177 kg
Dump cylinder mounting pin Sling dump cylinder (3) temporarily and pull out pin (4) to disconnect cylinder head and bell crank. Sr Stand the cylinder assembly against the rear and secure it with sling 0. iI+kg
3.
backward
Dump
cylinder:
362FO5550
14 kg
Lii cylinder Sling lift cylinder (5) temporarily and remove mounting pin (6). * Install block @ to the end of the lift arm. * Place block @ on the axle, and lower the cylinder onto it. r%kg
Lift cylinder:
lg.2
kg 362F055E
362FO5553
30-144 0
362FO5554
1
WA30-5
DISASSEMBLY
4.
AND ASSEMBLY
WORK EQUIPMENT
Lift arm, bell crank, and bucket link Install mounting pin (8) to lift arm, bell crank, and bucket link (7). Sling them temporarily and pull out lift arm mounting pin (9) to remove lift arm. Lift arm, bell crank, and bucket link: 317 kg Secure the mounting pin with the bolt. Check the quantity of shims, if inserted.
&I kg * *
5.
Bell crank and bucket link I) Pull out mounting pin (11) of bucket link (IO) to remove bucket link (10) from bell crank (12). Bucket link: 9 kg &I kg Remove wires, etc. used to securing the * bucket link to the bell crank. * If the pin is pulled out, the bell crank jumps up. Accordingly, do not bring your face, etc. near the bell crank.
2)
6.
Sling bell crank (12) temporarily out mounting pin (13) to remove from lift arm (14).
Dust seal and bushing I) Pull dust seal (15) and bushing lift arm (14).
and pull bell crank
(16) out of
.16
415F236
WAD5
li
362FO5559
30-145 0
DISASSEMBLY
2)
AND
WORK EQUIPMENT
ASSEMBLY
Pull dust seal (17) and bushing bell crank (12).
(18) out of
362FO5560
1 3)
Pull dust seal (19) and bushing bucket link (IO).
(20) out
Of
io
362FO5561
415F240
30-146 0
WA30-5
DISASSEMBLY
AND ASSEMBLY
INSTALLATION EQUIPMENT
WORK
OF WORK
A
When aligning
1.
Dust seal and bushing Press fit bushing (16) to bucket link (IO), bell crank (121, and lift arm (14) with press, etc., then install dust seal (15). & Bushing: Grease (G2-LI)
the pin holes, use a bar. Never insert your fingers in the pin holes.
16
4 I6F320
2.
EQUIPMENT
Bell crank and bucket link 1) Align holes of bell crank (12) and lift arm (14), and lock mounting pin (13) with mounting bolt.
2)
Align holes of bucket link (IO) and bell crank (12), and lock mounting pin (11) with mounting bolt. *
WA30-5
Secure the bucket with wires, etc.
link to the bell crank
15
362FO5562
DISASSEMBLY
3.
ASSEMBLY
WORK
EQUIPMENT
Lift arm, bell crank, and bucket link Install lift arm, bell crank, and bucket link (7) to slinging part. Install mounting pin to mounting holes of front frame and lift arm, then lock it with bolt. *
4.
AND
After installing the pin, install a stand to the end of the lift arm.
Lift cylinder Sling lift cylinder (5) temporarily and align cylinder rod with mounting hole of lift arm, then install mounting pin (6) and lock it with mounting bolt. Ir
After installing each block.
the
mounting
pin,
remove
65
5.
Dump cylinder Sling dump cylinder (3) temporarily and operate control levers to align pin holes. Install mounting pin (4) and lock it with bolt. * Pulling sling 0 toward you, lower dump cylinder slowly.
P++-m 362FO5552
6.
1
362FO555/
Bucket 1) Operate control levers to align mounting holes of bucket (21) and mounting pin (21, the install pin and lock it with bolt. AWhen aligning the pin holes, use a bar. Never insert your fingers in the pin holes.
w
il
2 362FO5550
30-148 a
WA30-5
DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT
7. Bucket link 1) Sling bucket link (10) and align its pin hole with hole of mounting pin (1), then lock it with bolt.
WA30-5
30-149 1
DISASSEMBLY AND ASSEMBLY
COUNTERWEIGHT
REMOVAL OF COUNTERWEIGHT ¤ Stop the vehicle on level ground and install the safety bar to the frame, then lower the bucket to the ground. Stop the engine and apply the parking brake and put blocks under the wheels to prevent the vehicle from moving. 1. Counterweight Sling counterweight (1) temporarily, and remove mounting bolts (2). fl If the counterweight is lowered too much it will interfere with the muffler stack. Accordingly, do not lower it too mach. Counter weight: 400 kg
INSTALLATION OF COUNTERWEIGHT •
Carry out installation in the reverse order to removal.
•
Width across flats of mounting bolt: 30 mm 8 Mounting bolt: Adhesive (LOCTITE 262) Mounting bolt: 549.0 ± 58.8 Nm {56 ± 6 kgm}
30-150 (3) 1
WA30-5
DISASSEMBLY
REMOVAL PANEL
INSTRUMENTS
AND ASSEMBLY
PANEL
OF INSTRUMENTS
&stop the vehicle on level ground and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the vehicle from moving. . Disconnect the cable from the negative (-1 terminal of the battery.
1.
Instruments panel 1) Remove and lift up mounting bolts to remove panel assembly (2) from instruments panel guard (I). 2) Disconnect following electric wiring conneca tors. Connectors (3) and (4). Remove the wires from the clamp. * l
2.
Panel 1) Disconnect tachometer cable (6) from housing (5). 2) Remove panel assembly (2). 3) Remove each cage from housing (5).
6
/u
362FO5570
INSTALLATION OF INSTRUMENTS PANEL 362FO5226
.
Carry out installation removal.
in the
reverse
order
to
w *
WA30-5
After connecting the connectors, arrange the wires to install them without applying excessive forces to them.
30-151 a
40
MAINTENANCE STANDARD
Transmission • engine mount...................... 40- 2 Work equipment • steering pump, HST charge pump .................................. 40- 3 Transfer .......................................................... 40- 4 HST inching valve .......................................... 40- 6 Drive shaft ...................................................... 40- 7 Differential (1/2) ............................................. 40- 8 Differential (2/2) ............................................ 40-10 Final drive ..................................................... 40-12 Axle mount .................................................... 40-13 Steering column ........................................... 40-14 Priority valve ................................................. 40-15 Steering cylinder mount .............................. 40-16 Brake ............................................................... 40-17 Hydraulic cylinder ......................................... 40-18 Center hinge pin ........................................... 40-20 Work equipment linkage .............................. 40-22 Bucket positioner .......................................... 40-24 Bucket ............................................................ 40-25
WA30-5
40-1 1 1
MAINTENANCE STANDARD
TRANSMISSION • ENGINE MOUNT
TRANSMISSION • ENGINE MOUNT
40-2 (2) 1
WA30-5
MAINTENANCE STANDARD
WORK EQUIPMENT • STEERING PUMP, HST CHARGE PUMP
WORK EQUIPMENT • STEERING PUMP HST CHARGE PUMP
Unit: mm
No.
Check item
1
Clearance between gear and side plate
2
Clearance between inside diameter of plain bearing and outside of diameter of gear shaft
3
Depth for knocking in pin
4
Rotating torque of spline shaft
WA30-5
Criteria
Remedy
Standard clearance
Clearance limit
0.10 – 0.15
0.19
0.06 – 0.119
0.20
Standard size
Tolerance
10
0 –0.5
Replace
4.0 – 9.8 Nm {0.4 – 1.0 kgm}
40-3 (2) 1
MAINTENANCE STANDARD
TRANSFER
TRANSFER
40-4 1 1
WA30-5
MAINTENANCE
STANDARD
TRANSFER
Unit: mm
No.
1
Check item
Clearance between input gear bearing and housing
Criteria Standard size
Tolerance Shaft
Remedy
Hole
Standard clearance
Clearance limit
80
4.013
+0.018 -0.012
-0.012 +0.031
-
2
Clearance between input gear and bearing
3
Clearance between input gear bearing and housing
80
-0.013 0
+0.018 -0.012
-0.012 +0.031
-
4
Clearance between input gear and bearing
50
+0.013 +0.002
4.012
-0.002 -0.025
-
5
Clearance between output shaft bearing and housing
6
Clearance between output shaft and bearing
7
Clearance between output shaft bearing and housing
8
Clearance between output shaft and bearing
-
Replace
Clearance between rear coupling oil seal and i housina 1 Clearance between front 10 coupling oil seal and housing 9
11
Outside diameter of rear coupling oil seal sliding surface Outside diameter of front co;zE;g oil seal slrdrng
WAN-5
+0.350 +0.150
72
Standard size 55
1
+0.046 0
-0.104 -0.350
Repair limit
Tolerance
54.95
Jo74
Jo74
-
I
40-5 a
MAINTENANCE
HST INCHING VALVE
STANDARD
HST INCHING
VALVE
0 0
0
0////
I
L-liA-T-
SEW02263
Unit: mm
No.
Check item
,
Clearance between inching valve housing and shaft
Model
40-6 0
Remedy
Criteria Standard
clearance
Repair limit Replace
Y120096399
0.006 - 0.028
0.048
WA30-5
MAINTENANCE STANDARD
DRIVE SHAFT
DRIVE SHAFT
WA30-5
40-7 (2) 1
MAINTENANCE STANDARD
DIFFERENTIAL
DIFFERENTIAL (1/2) fl The diagram shows front side
Unit: mm
No.
Check item
1
Bevel gear free rotating torque
2
Preload of differential side bearing
3 4 5
Shim thickness of rear portion of differential side bearing gear Thickness of shim for differential housing and gauge assembly Protrusion of pin
40-8 (2) 1
Criteria
Remedy
0.29–1.77Nm {0.03–0.18kgm} [2.94–18.63N {0.3–1.9kg}] 980–6,178N {100–630kg} 0.65–1.7
Adjust
0.36–1.67 9.5
WA30-5
MAINTENANCE
STANDARD
DIFFERENTIAL
DIFFERENTIAL (2/21
362FO5670
40-10 0
WAS@5
MAINTENANCE STANDARD
DIFFERENTIAL
Unit: mm
No.
1
Check item
Criteria Standard size
Shaft
Hole
Standard clearance
Clearance limit
Fitting of differen- Outer tial side bearing race
75
0 –0.016
–0.021 –0.051
–0.051 – –0.005
—
Inner race
45
+0.033 +0.017
0 –0.012
–0.045 – –0.017
—
80
0 –0.013
–0.021 –0.051
–0.051 – –0.008
—
35
+0.025 +0.009
0 –0.012
–0.037 – –0.009
—
72
0 –0.016
–0.021 –0.051
–0.051 – –0.005
—
30
+0.015 +0.002
0 –0.012
–0.027 – –0.002
—
16
0 –0.018
+0.193 +0.150
+0.150 – +0.211
0.3
Outer
Fitting of bearing race 2 at pinion shaft Inner gear end race
Outer
Fitting of bearing race 3 at pinion shaft Inner coupling end race
4
Tolerance
Remedy
Clearance between pinion gear and spider
Standard size
Tolerance
Repair limit
5
Thickness of side gear washer
2
0 – 0.20
6
Wear of lock pin's outside diameter
6
0 –0.075
7
Height of space between pinion shaft bearings (rear differential)
30.98
8
Outside diameter of axle mount (rear differential)
80.80
0 –0.035
80.40
9
Outside diameter of axle mount (rear differential)
105.80
0 –0.035
105.40
10
±0.025
Rear side
0 – 0.139
Front side
0 – 0.05 ª
Replace (ª Adjust)
1.8 — —
End play of pinion shaft
11
Backlash of bevel gear and pinion shaft
0.190 – 0.340
12
Backlash of side gear and pinion gear
0.130 – 0.250
WA30-5
40-11 1
MAINTENANCE STANDARD
FINAL DRIVE
FINAL DRIVE
Unit: mm
No.
Check item
Criteria Tolerance
Remedy
Standard size
Shaft
Hole
Standard clearance
Clearance limit
181
+0.100 +0.030
+0.100 0
–0.100 – +0.070
—
8.0
–0.080 –0.116
+0.036 0
+0.080 – +0.152
—
Inner race
50
+0.025 +0.009
0 –0.012
–0.037 – –0.009
—
Outer race
90
0 –0.015
–0.024 –0.059
+0.059 – +0.009
—
Inner race
55
+0.039 +0.020
0 –0.015
–0.054 – –0.020
—
Outer race
100
0 –0.015
–0.024 –0.059
–0.059 – –0.009
—
Housing
100
—
+0.054 0
—
—
Shaft
65
0 –0.046
—
—
—
6
Clearance between pinion gear bearing and shaft
17
+0.046 –0.003
0 –0.012
–0.058 – 0.003
—
7
End play of axle shaft
8
Clearance between oil seal and housing
1
Clearance between axle housing and ring gear
2
Clearance at guide pin
3
Clearance at axle housing bearing pressfitted section
Clearance at axle housing bearing pressfitted section
4
Axle shaft seal press-fitted section
5
40-12 1 (2)
Replace
0 – 0.04 0.15 – 1.55
WA30-5
MAINTENANCE STANDARD
AXLE MOUNT
AXLE MOUNT
Unit: mm
No.
Check item
Criteria Tolerance
Standard size 1
Clearance between frust plate
Clearance between hole and 2 shaft at front support end
3 Clearance between hole and shaft at rear support end
WA30-5
0.7 Standard size
Remedy Repair limit
±0.35 Tolerance
—
Shaft
Hole
Standard clearance
Clearance limit
105.8
0 –0.035
—
—
—
80.8
0 –0.035
—
—
—
Replace
40-13 1 (2)
MAINTENANCE STANDARD
STEERING COLUMN
STEERING COLUMN
Unit: mm
No.
Check item
Clearance between 1 steering shaft and column bearing
40-14 1 (2)
Criteria Standard size 20
Tolerance
Remedy
Shaft
Hole
Standard clearance
+0.009 –0.004
0 –0.010
–0.019 – 0.004
Clearance limit Replace —
WA30-5
MAINTENANCE
STANDARD
PRIORITY VALVE
PRIORITY VALVE
SEW02271
Unit: mm
Criteria
Check item
No.
Standard
1
2
Spring
for pushing
Relief valve spring
WA305
Remedy Repair
size
limit
Free length
installed length
Installed load
Free length
Installed load
51
45
31.4N I3.2kg)
-
24.5N 12.5kgI
23
19
84.3N {8.6kg}
-
67.7N {6.9kgI
spool Replace
40-15 a
MAINTENANCE
STEERING
STANDARD
STEERING CYLINDER MOUNT
CYLINDER MOUNT
_-_
---
‘~~-.--:._-.-__-___’
A-A
362FO5675
Unit: mm
No. -
1
Check item Clearance between mounting pin and bushing at connection of steering cylinder rod bottom and frame
Criteria Tolerance
Standard size
Shaft
Hole
35
-0.025 -0.064
+0.142 +0.080
Remedy Standard clearance 0.105 0.206 i
L
2
Connection between steering cylinder and front and rear frame
40-16 0
Width of boss 45 +0.8 0
-I Clearance limit -
Width of hinge
Standard clearance (a+b)
48il .O
1.2 - 4.0
Replace
WA30-5
MAINTENANCE
BRAKE
STANDARD
BRAKE (Also used as parking
brake)
2
I
A-A
SWWO4652
Unit: mm
No,
1
2
WA30-5
Repair limit
Standard size
Tolerance
2.60
f0.06
-
Thickness
4.70
to.08
4.25
Depth of lining groove
4.50
+0.30 0
0.225
Lining thickness
0.75
kO.085
-
Thickness of plate
Brake disc
Remedy
Criteria
Check item
Replace
40-l 7 0
MAINTENANCE
STANDARD
HYDRAULIC Steering
HYDRAULIC CYLINDER
CYLINDER
cylinder
Lift cylinder
ml 41mm) SWW04654
Dump cylinder
SWW04655
40-l 8 0
WA30-5
MAINTENANCE STANDARD
HYDRAULIC CYLINDER
Unit: mm
No.
1
2
3
Check item
Criteria Cylinder Standard name size
Shaft
Steering
30
–0.020 –0.072
+0.133 –0.007
0.013 – 0.205
0.505
Lift
40
–0.025 –0.087
+0.132 +0.006
0.031 – 0.219
0.519
Dump
35
–0.025 –0.087
+0.132 +0.006
0.031 – 0.219
0.519
Steering
35
–0.025 –0.064
+0.142 +0.080
0.105 – 0.206
1.0
Lift
40
—
+0.039 0
—
—
Dump
40
–0.025 –0.064
+0.142 +0.080
0.105 – 0.206
1.0
Steering
35
–0.025 –0.064
+0.142 +0.080
0.105 – 0.206
1.0
Lift
40
–0.025 –0.064
+0.142 +0.080
0.105 – 0.206
1.0
Dump
40
–0.025 –0.064
+0.142 +0.080
0.105 – 0.206
1.0
Clearance between piston rod and bushing
Clearance between piston rod connecting pin and bushing
Clearance between cylinder bottom connecting pin and bushing
WA30-5
Tolerance
Remedy
Hole
Standard Clearance clearance limit
Replace
40-19 1
MAINTENANCE STANDARD
CENTER HINGE PIN
CENTER HINGE PIN
Unit: mm
No.
1
Check item
Clearance between hinge pin and hinge pin spacer
Criteria Tolerance
Remedy
Standard size
Shaft
Hole
Standard clearance
Clearance limit
50
–0.025 –0.050
+0.025 0
0.025 – 0.075
—
2
Clearance between hinge pin spacer and front frame
80
–0.030 –0.060
+0.046 0
0.030 – 0.106
—
3
Clearance between hinge pin and bearing
50
–0.025 –0.050
0 –0.012
0.013 – 0.050
—
4
Clearance of rear frame and bearing
105
0 –0.015
–0.020 –0.080
–0.080 – –0.005
—
5
Wear of hinge pin spacer and oil seal contact surface
6
Clearance at seal pressfitting portion of rear frame hinge
40-20 1 (2)
Standard size
Tolerance
Replace
Repair limit
80
0 –0.074
—
105
+0.170 +0.080
—
WA30-5
MAINTENANCE STANDARD
WORK EQUIPMENT LINKAGE
WORK EQUIPMENT LINKAGE
40-22 1 (2)
WA30-5
MAINTENANCE STANDARD
WORK EQUIPMENT LINKAGE
Unit: mm
No.
1
2 3 4 5
6 7 8 9
Check item
Clearance between pin and bushing at both ends of bucket link Clearance between pin and bushing at end of bucket link bucket Clearance between pin and bushing at connection of boom and bucket Clearance between pin and bushing at connection of boom and frame Clearance between pin and bushing at connection of bucket cylinder bottom and frame Clearance between pin and bushing at connection of bucket cylinder rod and bellcrank Clearance between pin and bushing at connection of bellcrank and boom Clearance between pin and bushing at connection of boom cylinder bottom and frame Clearance between pin and bushing at connection of boom cylinder rod and boom
Criteria Tolerance
Standard size
Shaft
Hole
Standard clearance
Clearance limit
40
–0.025 –0.064
+0.142 +0.080
0.105 – 0.206
1.0
45
–0.025 –0.064
+0.142 +0.080
0.105 – 0.206
1.0
45
–0.025 –0.064
+0.142 +0.080
0.105 – 0.206
1.0
45
–0.025 –0.064
+0.142 +0.080
0.105 – 0.206
1.0
40
–0.025 –0.064
+0.142 +0.080
0.105 – 0.206
1.0
40
–0.025 –0.064
+0.142 +0.080
0.105 – 0.206
1.0
60
–0.030 –0.076
+0.105 +0.075
0.105 – 0.181
1.0
40
–0.025 –0.064
+0.142 +0.080
0.105 – 0.206
1.0
40
–0.025 –0.064
+0.142 +0.080
0.105 – 0.206
1.0
Width of boss 10
Connection of bucket cylinder and frame
Remedy
+0.8
Width of hinge +2.0
50 0
51 0
Standard clearance (Clearance a + b) 0.2 – 3.0
11
Connection of boom and frame
51±1.0
52 0
12
Connection of boom and bucket
51±1.0
53±0.5
13
Connection of bucket link and bucket
50 0
14
Connection of boom cylinder and frame
50 0
15
Connection of bellcrank and bucket link
50 0
53 –0.5
0 – 4.5
16
Connection of bellcrank and boom
105±1.5
107±0.5
0 – 4.0
17
Connection of bucket cylinder and bellcrank
50 0
53 –0.5
18
Connection of boom and boom cylinder
50±1.0
51 0
WA30-5
+2.5
+0.8
+2.5
+0.8
+2.0
53±0.5 +2.0
52 0
+1.5
+1.5
+0.5
Replace (Replace if there is scuffing on pin)
0 – 4.0 0.5 – 3.5 0 – 3.5 1.2 – 4.0
Replace (Insert shims on both sides so that clearance is less than 0.5 mm on both left and right)
1.7 – 4.5 0 – 2.5
40-23 1
MAINTENANCE STANDARD
BUCKET POSITIONER
BUCKET POSITIONER
Unit: mm
No.
Check item
Criteria
1
Clearance between Proximity switch and plate
Min.1
Clearance between Plate and guide
3–5
2
40-24 1 (2)
Remedy
Adjust or repair
WA30-5
MAINTENANCE STANDARD
BUCKET
BUCKET
Unit: mm
No.
1
Check item
Wear of bucket tooth
WA30-5
Criteria
Remedy
Standard size
Tolerance
Repair limit
17.0
—
12.0
Replace
40-25 1 (2)
90
OTHERS
Electric circuit diagram Serial No. 22005 – 26000 ................. 90Electric circuit diagram (1/2) Serial No. 26001 and up .................. 90Electric circuit diagram (2/2) Serial No. 26001 and up .................. 90-
3 5 7
Attachment Backhoe .................................................... 90-101
WA30-5
90-1 (2)
ELECTRIC CIRCUIT DIAGRAM Serial No. 22005 – 26000
WA30-5
90-3 (2)
ELECTRIC CIRCUIT DIAGRAM (1/2) Serial No. 26001 and up
WA30-5
90-5 (2)
ELECTRIC CIRCUIT DIAGRAM (2/2) Serial No. 26001 and up
WA30-5
*1. For hot water type heater spec. *2. For STD spec. *3. For large bucket spec.
90-7 (2)
BACKHOE WA30-5 (PHS030-3E)
BACKHOE MODEL PHS030-3E
SERIAL NUMBER 1471 and up (For WA30-5 21812 and up)
•
WA30-5
This section contains only information related to the backhoe. For other information, see the WA30-5 Shop Manual.
90-101
CONTENTS GENERAL General assembly drawing .................................................................................................................. 90-103 Specifications ......................................................................................................................................... 90-104 Weight table ............................................................................................................................................ 90-106
STRUCTURE AND FUNCTION Valve control ......................................................................................................................................... Hydraulic circuit diagram ...................................................................................................................... Backhoe control valve ........................................................................................................................... Check valve ............................................................................................................................................. Work equipment .................................................................................................................................... Actual electrical wiring diagram ......................................................................................................... Electrical circuit diagram .......................................................................................................................
90-107 90-108 90-109 90-111 90-113 90-114 90-115
TESTING AND ADJUSTING Adjusting backhoe swing ...................................................................................................................... 90-116
90-102
WA30-5
GENERAL
GENERAL ASSEMBLY DRAWING
GENERAL GENERAL ASSEMBLY DRAWING Unit: mm
WA30-5
90-103
GENERAL
SPECIFICATIONS
SPECIFICATIONS BACKHOE Machine model
WA30-5
Serial No.
21812 and up
Backhoe model
PHS030-3E
Backhoe Serial No.
1471 and up
Operating weight
kg
2,970
Backhoe assembly weight
kg
700
3
0.05
Working ranges
Performance
Bucket capacity Max. digging depth
mm
2,535
Max. vertical wall depth
mm
1,465
Max. vertical wall depth (fixed machine)
mm
1,250
Max. digging reach
mm
3,270
Max. digging hight
mm
3,080
Max. reach at ground level
mm
3,245
Max. dumping hight
mm
1,900
Max. dumping hight (bucket cylinder max. stroke)
mm
1,975
Max. dumping reach (bucket cylinder min. stroke)
mm
1,910
Max. dumping reach (bucket cylinder max. stroke)
mm
1,185
Boom swing angle (machine center)
deg.
Left: 90
Right: 90
Slide amount (machine center)
mm
Left: 465
Right: 465
Max. digging force (bucket) Dimention
m
kN {kg}
20 {2,040}
Overall length (front bucket on the ground)
mm
4,410
Overall width (front bucket)
mm
1,575
Overall hight (canopy)
mm
2,820
Bucket width
mm
300
90-104
WA30-5
Control valve
GENERAL
SPECIFICATIONS
Machine model
WA30-5
Serial No.
21812 and up
Backhoe model
PHS030-3E
Backhoe Serial No.
1471 and up
Type x No.
7–spool type x 1
Control method
Direct control type
Boom cylinder
Type
Reciprocating piston
Cylinder (inside diameter)
mm
80
Diameter of piston rod
mm
40
Stroke
mm
440
Max. stroke
mm
1,180
Min. stroke
mm
740 Reciprocating piston
Cylinder (inside diameter)
mm
80
Diameter of piston rod
mm
40
Stroke
mm
440
Max. stroke
mm
1,180
Min. stroke
mm
740
Bucket cylinder
Type Hydraulic cylinder
Hydraulic system
Arm cylinder
Type
Reciprocating piston
Cylinder (inside diameter)
mm
70
Diameter of piston rod
mm
35
Stroke
mm
375
Max. stroke
mm
1,015
Min. stroke
mm
640
Swing cylinder
Type
Reciprocating piston
Cylinder (inside diameter)
mm
80
Diameter of piston rod
mm
45
Stroke
mm
Max. stroke (between pin and rack center)
mm
381
Min. stroke (between pin and rack center)
mm
209
Outrigger cylinder
Type
WA30-5
Left: 86
Right: 86
Reciprocating piston
Cylinder (inside diameter)
mm
50
Diameter of piston rod
mm
30
Stroke
mm
350
Max. stroke
mm
910
Min. stroke
mm
560
90-105
GENERAL
WEIGHT TABLE
WEIGHT TABLE ¤ This weight table is a guide for use when trnsporting or handling component. Unit: kg Machine model
WA30-5
Serial No.
21812 and up
Backhoe model
PHS030-3E
Backhoe Serial No.
1471 and up
Backhoe assembly
700
• Boom
65.7
• Arm
48.3
• Bucket assembly
45.2
• Swing mount
80
• Swing bracket
23.75
• Outrigger frame
125
• Control valve
18
• Boom cylinder assembly
22.5
• Arm cylinder assembly
22.2
• Bucket cylinder assembly
14.8
• Swing cylinder assembly
22.3
• Outrigger cylinder assembly
90-106
13.2 x 2
WA30-5
STRUCTURE AND FUNCTION
VALVE CONTROL
STRUCTURE AND FUNCTION VALVE CONTROL
1. Slide lock lever 2. R.H. work equipment control lever (boom, bucket) 3. R.H. outrigger control lever 4. L.H. outrigger control lever 5. L.H. work equipment control lever (arm, swing) 6. Lock pin removal lever 7. Safety lock lever
Positions of levers and pedals 1 HOLD 2 Boom (RAISE) 3 Boom (LOWER) 4 Bucket (CURL) 5 Bucket (DUMP) 6 HOLD 7 Boom swing (left) 8 Boom swing (right) 9 Arm (OUT) 0 Arm (IN)
WA30-5
A B C D E F G H I J
R.H. outrigger (EXTEND) R.H. outrigger (RETRACT) L.H. outrigger (EXTEND) L.H. outrigger (RETRACT) Work equipment control lever (LOCK) Work equipment control lever (FREE) Slide (LOCK) Slide (RELEASE) Lock pin (REMOVE) Lock pin (INSERT)
90-107
STRUCTURE AND FUNCTION
HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC CIRCUIT DIAGRAM
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.
Hydraulic tank Hydraulic oil filter Hydraulic, steering pump HST charge pump HST main pump Priority valve Steering valve Main control valve Relief valve Suction-safety valve Safety valve Boom swing spool Arm spool L.H. outrigger spool R.H. outrigger spool Bucket spool Boom spool Slide lock spool Boom swing cylinder Arm cylinder L.H. outrigger cylinder R.H. outrigger cylinder Bucket cylinder Boom cylinder Slide lock cylinder Check valve
90-108
WA30-5
STRUCTURE AND FUNCTION
BACKHOE CONTROL VALVE
BACKHOE CONTROL VALVE (1/2)
1. Relief valve 2. Suction-safety valve 3. Safety valve P: T: A1: B1: A2: B2: A3: B3:
From work equipment control valve port C To hydraulic filter To boom swing cylinder lock pin end To boom swing cylinder adjustment bolt end To arm cylinder head To arm cylinder bottom To L.H. outrigger cylinder bottom To L.H. outrigger cylinder head
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A4: B4: A5: B5: A6: B6: A7: B7:
To To To To To To To To
R.H. outrigger cylinder bottom R.H. outrigger cylinder head bucket cylinder head bucket cylinder bottom boom cylinder head boom cylinder bottom check valve check valve
90-109
STRUCTURE AND FUNCTION
BACKHOE CONTROL VALVE
(2/2)
1. 2. 3. 4. 5. 6. 7. 8.
Relief valve Spool (boom swing) Spool (arm) Spool (L.H. outrigger) Spool (R.H. outrigger) Spool (bucket) Spool (boom) Spool (slide lock)
90-110
9. 10. 11. 12. 13. 14. 15.
Suction-safety valve (right boom swing) Suction-safety valve (left boom swing) Safety valve (arm OUT) Suction-safety valve (arm IN) Suction-safety valve (bucket CURL) Safety valve (boom RAISE) Suction-safety valve (boom LOWER)
WA30-5
STRUCTURE AND FUNCTION
CHECK VALVE
CHECK VALVE
1. 2. 3. 4. 5.
Valve body Spring Valve Piston Plug
A: From backhoe control valve port A7 B: From backhoe control valve port B7 C: To slide lock cylinder
WA30-5
90-111
STRUCTURE AND FUNCTION
CHECK VALVE
Operation When slide lock is at LOCK • The pressure oil from the pump enters port A, overcomes the tension of spring (2), and moves valve (3) to the left. • The circuit between port A and port C opens, the pressure oil from the pump flows to the slide lock cylinder, and locks the slide.
When slide lock is at RELEASE • The pressure oil from the pump enters port B, pushes piston (4) to the left and moves valve (3) to the left. • The circuit between port A and port C opens, the pressure oil inside the slide lock cylinder is drained, and the slide is released.
90-112
WA30-5
STRUCTURE AND FUNCTION
WORK EQUIPMENT
WORK EQUIPMENT
1. 2. 3. 4. 5. 6.
Operator's seat Boom Arm cylinder Bucket cylinder Arm Bucket
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7. 8. 9. 10. 11.
Outrigger Swing bracket Swing cylinder Swing mount Slider head
90-113
STRUCTURE AND FUNCTION
ACTUAL ELECTRICAL WIRING DIAGRAM
ACTUAL ELECTRICAL WIRING DIAGRAM
1. Rear combination lamp (R. H.) 2. Rear combination lamp (L. H.)
90-114
WA30-5
STRUCTURE AND FUNCTION
ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM WITH BACKHOE
WA30-5
90-115
TESTING AND ADJUSTING
ADJUSTING BACKHOE SWING
TESTING AND ADJUSTING ADJUSTING BACKHOE SWING fl If there is excessive play in the backhoe swing mechanism, adjust as follows.
¤ Stop
the engine and place the safety lock lever at the LOCK position.
1. Loosen bolt (1).
2. Turn plate portion (2) of the eccentric boss to adjust the backlash. fl Standard clearance: 0.1 mm fl Turn plate portion (2) of the eccentric boss in the following directions to adjust. A: Backlash becomes larger B: Backlash becomes smaller
90-116
WA30-5