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CEBMW25050

SHOP MANUAL KOMALU

WA5004

WHEEL LOADER MACHINE

MODEL

WA500-1 LC

SERIAL NUMBERS

A60001

and up

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

AUG 93

PRODUCT PUBLICATIONS

INFORMATION

VARIOUS PRODUCT PARTS & SERVICE PUBLICATIONS ARE AVAILABLE TO ALL KOMATSU CONSTRUCTION EQUIPMENT OWNERS, INCLUDING OPERATION & MAINTENANCE MANUALS, PARTS BOOKS AND SHOP MANUALS.

SPECIAL PUBLICATIONS SUCH AS SERVICETOOL, AIR CONDITIONING, ANDTURBOCHARGER SHOP MANUALS ARE ALSO AVAILABLE AS WELL AS SELECTED OPERATION & MAINTENANCE AND SHOP MANUALS IN FOREIGN LANGUAGES.

THE PUBLICATIONS

LISTED BELOW ARE AVAILABLE

FOR THIS PARTICULAR MACHINE(S).

DESCRIPTION

FORM NUMBER

PARTS BOOK - PAPER: Engine and Chassis

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

BEPBW25050

PARTS BOOK - MICROFICHE: Engine and Chassis

OPERATION Chassis

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

& MAINTENANCE

BEPMW25050

MANUAL:

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

CEAMW25050

SHOP MANUAL: Chassis

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

CEBMW25050

Engine: Service Manual ............................................. Trouble Shooting & Repair ....................................

SAFETYMANUAL

3379076 3810298

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

PARTSAND SERVICE PUBLICATIONS CAN ONLYBE ACQUIRED BYAUTHORIZED USING THE KDC PARTS INVENTORY PROCESSING SYSTEM (PIPS).

1085 883 R3

KOMATSU DISTRIBUTORS,

IF THE PIPS SYSTEM IS NOT AVAILABLE AT THE DISTRIBUTOR LOCATION, THEN THE FOLLOWING REQUISITION FOR LITERATURE FORM CAN BE USED: FORM KDC-EPS-05, SHOWN ON THE REVERSE SIDE OF THIS PAGE.

PUBINFO.KOM

100791

REQUISITION

FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS

COMPLETE FORM

Komatsu America International Company 440 North Fairway Drive

AND RETURN TO -

Vernon Hills, IL 60061-8112 U.S.A. At&n:Technical Publications Fax No. (847) 970-4186 Tel No. (847) 9706887 COMPANY NAME

SHIP TO

All-N.

TYPE or PRINT ONLY

STREET ADDRESS CITY, STATE, ZIP CODE COUNTRY

PHONE NO.

FAX NO.

DISTR/B!=WNCH CODE

SHIPPING METHOD

IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLlCATION(S), SERIAL NUMBER MUST BE SHOWN.

THE MODEL NUMBER AND MACHINE

MODEL NUMBER

KDC91 D 081696

CURRENT PRICES WILL BE CHARGED

SERIAL NUMBER

CONTENTS No. of page

10 ENGINE 12 TESTING AND ADJUSTING .................................................. 13 DISASSEMBLY AND ASSEMBLY ..............................................

12-1 13-l

20 POWER TRAIN 21 STRUCTURE AND FUNCTION ................................................ 22 TESTING AND ADJUSTING .................................................. 23 DISASSEMBLY AND ASSEMBLY .............................................. 24 MAINTENANCE STANDARD .................................................

40 STEERING

21-l 22-l 23-l 24-l

SYSTEM

41 STRUCTURE AND FUNCTION ................................................ 42 TESTING AND ADJUSTING .................................................. 43 DISASSEMBLY AND ASSEMBLY .............................................. 44 MAINTENANCE STANDARD .................................................

41-l 42-l 43-l 44-l

50 BRAKE AND AIR SYSTEM 51 STRUCTURE AND FUNCTION ................................................ 52 TESTING AND ADJUSTING .................................................. 53 DISASSEMBLY AND ASSEMBLY .............................................. 54 MAINTENANCE STANDARD .................................................

60 WORK EQUIPMENT

SYSTEM

61 STRUCTURE AND FUNCTION ................................................ 62 TESTING AND ADJUSTING .................................................. 63 DISASSEMBLY AND ASSEMBLY .............................................. 64 MAINTENANCE STANDARD .................................................

80 ELECTRIC

51-l 52-l 53-1 54-1

AND ELECTRONIC

61-l 62-l 63-l 64-l

SYSTEM

81 STRUCTURE AND FUNCTION ................................................

81-1

82 TESTING AND ADJUSTING .................................................. ..............................................

82-l 83-l

STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . _ . . . . . . . . . DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . GEAR PUMP METRlCCONVEdSlbNiABii’:::::::::::::::::::::::::::::::::::::::::::::::

91-l 93-1 97-l 99-l

DISASSEMBLY

AND ASSEMBLY

90 OTHERS 91 93 97 99

00-l

SAFETY

WARNING!

IMPORTANT

SAFETY NOTICE

Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended and described in this manual are both effective and safe methods of operation. Some of these operations require the use of tools specially designed for the purpose.

To prevent injury to workers, the symbol shown 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.

SAFETY PREPARATIONS

GENERAL

Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.

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.

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.

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.

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.

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, glasses, cap and other clothes suited for welding work.

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.

Keep all tools in good condition correct way to use them.

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.

00-2

FOR WORK

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.

and learn the

SAFETY

13. Before starting work, remove the leads from the battery. Always remove the lead from the negative (-) terminal first.

19.

Be sure to assemble all parts again in their original places. Replace any damaged part 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. l

use a hoist or 14. When raising heavy components, 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.

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.

be careful not to 16. When removing components, break or damage the wiring, Damaged wiring may cause electrical fires.

22.

When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.

17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires.

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.

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.

18. As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts.

00-3

FOREWORD 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 chapters for each main group of components; these chapters are further divided into the following sections. STRUCTURE

AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. TESTING

AND ADJUSTING

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

AND ASSEMBLY

This section explains the order to be followed when removing, installing, disassembling assembling each component, as well as precautions to be taken for these operations. MAINTENANCE

STANDARD

This section gives the judgement

00-4

standards

when inspecting

disassembled

parts.

HOW TO READ THE SHOP MANUAL

HOW TO READ THE SERVICE MANUAL

VOLUMES

REVISIONS

Service manuals are issued as a guide to carrying out repairs. They are two manuals for each machine, Chassis volume and Engine volume.

Revised pages are shown at the LIST OF REVISED PAGES on the between the title page and SAFETY page.

These volumes are designed to avoid duplication of information. Therefore to deal with all repairs for any model, both chassis and engine volumes are needed.

SYMBOLS

DISTRIBUTION

AND UPDATING

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

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

Item

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:

Special safety precautions are necessary when performing the work Safety

A 4

Example 1 (Chassis volume): Caution

Weight

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

Tightening torque

Places that require special attention for tightening torque during assembly.

K&z

Coat

Places to be coated with adhesives and lubricants etc.

ti 1

Oil, water

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

Drain

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

Consecutive page number for each item

Example 2 (Engine volume): Refer to the pertinent engine manual. 3. Additional pages: Additional pages are indicated by a hyphen (-) and numbered after the page number. File as in the example. Example: 21-4 21-4-l Added pages 21-4-2 21-5 REVISED EDITION

MARK ([l]

Extra special safety precautions are necessary when performing the work because it is under internal pressure. Special technical precautions or other precautions for preserving standards are necessary when performing the work.

a-3 Item number (21. Structure and Function)

Remarks

[2] [3] ....)

When a manual is revised, an edition mark is recorded on the bottom outside corner of the pages.

00-5

HOISTING INSTRUCTIONS

HOISTING

INSTRUCTIONS

Hooks have maximum portion.

Heavy parts (25 kg or more) must be

strength at the middle

lifted with a hoist etc. In the Disassembly and Assembly section, every part weighing 25 kg or more is indicated clearly with the symbol loo%

1. If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 0

Check for removal of all bolts fastening part to the relative parts.

the

Check for existence of another part causing interface with the part to be removed.

79%

88%

71%

41%

Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load.

Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.

2. Wire ropes 4) 1)

Use adequate ropes depending on the weight of parts to be hoisted, referring to the table

below:

(Standard

Wire ropes “2” or “S” twist ropes without

galvaniz-

ing) Rope diameter (mm) 10.0 11.2 12.5 14.0 16.0 18.0 20.0 22.4 30.0 40.0 50.0 60.0

1 Allowable

load (tons)

1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0

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 (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight becomes 1000 kg when two ropes make a 120” hanging angle. On the other hand, two ropes are subject to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150”.

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

2) Sling wire ropes from the middle

portion

the hook.

30"

Lifting angle

90"

120"

150'

: cI FSOO66

Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result.

00-6

STANDARD

TIGHTENING

TORQUE

STANDARD TIGHTENING 1. STANDARD TIGHTENING The following “Disassembly

TORQUE OF BOLTS AND NUTS

charts give the standard and Assembly”.

Thread diameter of bolt (mm)

TORQUE

tightening

torques

Width across flat (mm)

of bolts and nuts. Exceptions

are given in sections

@ km

1.35kO.15 3.2kO.3 6.720.7

13.221.4 31.4k2.9 65.7k6.8

10 12

13 17 19

11.5kl.O la.ot2.0

112k9.8 177+19

16 ia 20 22 24

24 27 30 32 36

28.523 39+4 561-6 7628 94.5210

279?29 383+39 549+58 745+78 927+98

27 30 33 36 39

41 46 50 55 60

135+15 175r20 225225 280230 335k35

1320r140 172Ok190 2210t240 2750t290 32802340

This torque table does not apply to the bolts with which nylon packings or other non-ferrous to be used, or which require tightening to otherwise specified torque. t Nm (newton

2. TIGHTENING

metal washers are

meter): 1Nm + 0.1 kgm

TORQUE OF SPLIT FLANGE BOLTS

Use these torques for split flange bolts.

Tightening

torque

Thread diameter of bolt (mm)

Width across flats (mm)

kgm

10 12 16

14 17 22

6.720.7 11.5+1 28.523

65.7k6.8 1 i2r9.a 279229

00-7

STANDARD

TIGHTENING

3. TIGHTENING

TORQUE

TORQUE FOR NUTS OF FLARED FITTINGS

Use these torques for nut part of flared.

Thread diameter of nut part

Width across flats of nut part

Tighteni

(mm)

kgm

14 18 22 24 30 33 36 42

19 24 27 32 36 41 46 55

2.5+0.5 522 822 1423 18?3 2025 2525 3025

24.524.9 49k19.6 78.5 ? 19.6 137.3 ? 29.4 176.5k29.4

COATING The recommended

coating

Adhesives

Liquid gasket

Antifriction compound (Lubricant including molvbdenum disulfide) Grease (Lithium grease) Vaseline

in the shop manuals are listea oerow.

materials prescribed

Applications

LT-IA

Used to apply rubber pads, rubber gaskets, and cork plugs.

LT-1 B

Used to apply resin, rubber, metallic and non-metallic fast, strong seal is needed.

LT-2”

Preventing

LT-3

Provides an airtight, electrically Used for aluminum surfaces.

LG-1

Used with gaskets and packings to increase sealing effect.

LG-3

Heat-resistant oioina.

bolts, nuts, and plugs from loosening insulating

gasket for precombustion

parts when a

and leaking oil.

seal.

chambers

and exhaust

LG-4

1 Used by itself on mounting surfaces on the final drive and transmission cases. (Thickness after tiahtenina: 0.07 - 0.08 mm).

LG-5

Used by itself to seal grease fittings, tapered screw fittings and tapered screw fittings in hydraulic circuits of less than 50 mm in diameter.

LM-P

G2-LI _--

Applied to bearings and taper shafts to facilitate prevent sticking, burning or rusting.

press-fitting

and to

Applied to bearings, sliding parts and oils seals for lubrication, prevention and facilitation of assembling work. Used for protecting

*LT-2 is also called LOCTITE

00-8

196.1249 245.2?49 294.2&49

MATERIALS

Code

Nomenclature

I toraue

battery electrode terminals in the shop manuals.

from corrosion.

rust

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:

05WB indicates a cable having a nominal number 05 and white coating with black stripe.

CLASSIFICATION BY THICKNESS Nominal number 0.85 (Ol)* 2 (02)* 5 (05)* 15 40 60 100 *

Copper wire Number Dia. of strands Cross section (mm*) strands (mm) 6.88 ’ b.32 11 2.09 0.32 26 5.23 0.32 65 13.36 0.45 84 42.73 0.80 85 1 0.80 63.84 127 1 0.80 109.1 217

CaFi$.D’

1 Curre$)rating

2.4 3.1 4.6 7.0 11.4 13.6

12 20 37 59 135 178

17.6

230

Applicable circuit

Starting, lighting, signal etc. Lighting, signal etc. Charging and signal Starting (Glow plug) Startino Starting Startina

Old numbers

CLASSIFICATION BY COLOR AND CODE

Fiizt) 1

r Classification Primary

Circuits Code Color Code

Starting B Black BW

Charging W White WR

Lighting R Red

Signal G Green GW

Instrument Y Yellow YR

Other L Blue LW

00-9

GENERAL

WEIGHT TABLE

This weight table is a guide for use when transporting or handling components. Unit: k

00-l 0

GENERAL

LUBRICANTS,

FUEL AND COOLANT

PROPER SELECTION

RESERVOIR

FLUID TYPE

-22 -30

TABLE

AMBIENT TEMPERATURE (Top line “F, Bottom line “C) -4 14 32 50 68 86 104 -20 -10 0 10 20 30 40

CAPACITY Specified

Refill

42 4

36 Q

70 Q

62 Q

SAE 1OW

260 Q

150 Q

122 50

SAE 2OW-40 or 2OW-50

Engine with filter

Engine oil See NOTE 1

SAE 15W-40,15W-50

I I

SAE 1 OW-30

Synthetic SAE 5W-20 or 5W-3.0

Torque converter Transmission & Service brakes

Hydraulic

SAE 30W

I Engine oil See NOTE 2

.: .SAE 1OW

system

Drive axles Front & rear

Axle oil

See NOTE 3

78 Q each

All lubrication fittings

Grease

See NOTE 4

Fill as instrutted

Fuel tank

Diesel fuel

See NOTE 5

430 Q

Cooling system

Coolant

See NOTE 6

81 4

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. API: American Petroleum Institute ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers SAE 15W-40 multi-viscosity oil meeting the American Petroleum Institute (API) Classification of CE/SF is recommended. CD/SF oil may be used in areas where CE/SF oil is not available.

NOTES: 1. ENGINE OIL Normal Operation Oil performance

recommendations

are as follows:

The use of a quality engine lubricating oil combined with appropriate oil and filter change intervals are critical factors in maintaining engine performance and durability.

A sulfated ash limit of 1.O mass percent is suggested for optimum valve and piston deposit and oil consumption control. The sulfated ash must not exceed 1.85 mass percent. The sulfated ash limit of 1.85 mass percent has been placed on all engine lubricating oils recommended for use in the engine. Higher ash oils can cause valve and/or piston damage and lead to excessive oil consumption.

00-l1

The API service symbol displays the following information. The upper half of the symbol displays the appropriate oil categories; the lower half may contain words to describe oil energy conserving features. The center section identifies the SAE oil viscosity grade.

2. ENGINE OIL Use API classification CE engine oil. If API classification CD is used, reduce the oil change interval to half. 3. AXLE OIL

Oil viscosity

recommendations

are as follows:

The use of a multi-graded lubricating oil has been found to improve oil consumption control and improve engine cranking in cold temperatures while maintaining lubrication at high operating temperatures. While SAE 15W-40 multi-viscosity oil is recommended for most operating climates, refer to the previous chart for oil viscosity recommendations for extreme climates. Limited use of low viscosity oils, such as SAE 1OW30 may be used for easier starting and providing sufficient oil flow at ambient temperatures below +23”F (-5°C). However, continuous use of low viscosity oils can decrease engine life due to wear. Do not use special “break-in” lubricating oils for a new or rebuilt engine. Use the same type of oil during the “break-in” as specified for normal operation.

Arctic Operation If an engine is operated in ambient temperatures consistently below -10°F (-23°C) and there are no provisions to keep the engine warm when it is not in operation, use a synthetic CE/SF or CD/SF engine oil with adequate low temperature properties such as SAE 5W-20 or 5W-30. The oil supplier the performance

must be responsible

for meeting

service specifications.

IMPORTANT: The use of a synthetic base oil does not justify extended oil change intervals. Extended oil change intervals can decrease engine life due to factors such as; corrosion, deposits and wear. Additional information regarding lubricating oil availability throughout the world is available in the “E.M.A. Lubricating Oils Data Book for Heavy Duty Automotive and Industrial Engines.” The data book may be ordered from the Engine Manufacturers Association, One Illinois Center, 111 East Wacker Drive, Chicago, IL U.S.A. 60601. The telephone number is (312) 644-6610.

For axle oil, use only the recommended follows:

oil as

SHELL: DONAX lT or TD RPM TRACTOR HYDRAULIC FLUID CALTEX: CHEVRON: TRACTOR HYDRAULIC FLUID TEXACO: TDH OIL MOBIL: MOBIL AND SUPER UNIVERSAL * It is possible to substitute engine oil SAE 30W API classification CD for axle oil. If noise comes from the brake, it is no problem of durability. 4. GREASE The recommended lubricating grease is No. 2 multipurpose lithium grease with 3% molybdenum disulfide. 5. DIESEL FUEL

Do not mix gasoline or alcohol with diesel fuel. This mixture can cause an explosion. WARNING!

IMPORTANT: Due to the precise tolerances of diesel injection systems, it is extremely important that the fuel be kept clean and free of dirt or water. Dirt or water in the system can cause severe damage to both the injection pump and nozzles. The use of ASTM No. 2-D diesel fuel with a minimum Cetane number of 40 is recommended. The use of No. 2-D diesel fuel will result in optimum engine performance under most operating conditions. Fuels with Cetane numbers higher than 40 may be needed in high altitudes or extremely low ambient temperatures to prevent misfires and excessive smoke. At operating temperatures below t32"F (O’C), acceptable performance can be obtained by using a blend of No. 2-D and No. 1-D fuels. The use of lighter fuels can reduce fuel economy. Use a low sulfur content fuel having a cloud point that is at least 10 degrees below the lowest expected fuel temperature. Cloud point is the temperature at which crystals begin to form in the fuel. The viscosity of the fuel must be kept above 1.3 cSt to provide adequate fuel system lubrication.

00-l 2

Total Hardness - Not to exceed 170 parts per

6. COOLANT Heavy duty diesel engines require a balanced coolant mixture of water, antifreeze, and supplemental coolant additives. Supplemental coolant additive recommendations are included in the section entitled “CHANGE THE COOLANT AND FLUSH THE COOLING SYSTEM”. The coolant should be changed at the specified service interval shown in the “MAINTENANCE TABLE”. DCA4 is recommended cooling system.

to inhibit

corrosion

in the

million (10 grains/gallon maximum) to prevent scale deposits. Water containing dissolved magnesium and calcium (the usual reason for water hardness) above the specified amount will cause scale deposits to develop in the engine. Chlorides - Not to exceed 40 parts per million (2.5 grains/gallon maximum) to prevent corrosion.

Sulfites - Not to exceed (5.8 grains/gallon sion.

In climates where the temperature is above -34°F (-37”C), use a coolant mixture that contains 50 percent antifreeze. Antifreeze is essential in any climate. It broadens the operating temperature range by lowering the coolant freezing point and by raising its boiling point. Do not use more than 50 percent antifreeze in the mixture unless additional freeze protection is required. Never use more than 68 percent antifreeze under any condition. Low silicate ethylene glycol antifreeze is recommended. The antifreeze should contain no more than 0.1% anhydrous alkali metasilicate. Low silicate antifreeze is recommended to avoid the formation of silica-gel (hydro-gel). This gel formation can occur when the cooling system contains an over concentration of high silicate antifreeze and/or supplemental coolant additive. DO NOT use methanol or alcohol as an antifreeze because of its low boiling point.

100 parts per million maximum) to prevent corro-

Dissolved Solids - Not to exceed 340 parts per million (20 grains/gallon maximum) to minimize sludge deposits, scale deposits, corrosion or a combination of these. If any of the above requirements cannot be met, use distilled, de-ionized, or de-mineralized water. To determine if local water supplies meet these standards, water samples can be tested by water treatment laboratories. “Softened” water that is prepared using common salt (sodium chloride) contains excessive amounts of chlorides and should not be used. NOTE:

Never use water alone in the cooling system because corrosion will occur.

Maintain supplemental coolant additive levels at 1 unit DCA4 per 1 U.S. gal (3.8 liters) of coolant.

for more must be

Use antifreeze during all seasons to protect the cooling system from corrosion as well as freezing damage.

Antifreeze propylene system.

formulated with methoxy propanol, or glycol, is not recommended for this

NOTE:

Do not mix types of antifreeze solutions. Mixed solutions make it impossible to determine the protection against freezing. Antifreeze containing sealer or anti-leak additives should NOT be used in this system. Sealer or anti-leak additives will cause plugging problems in the cooling system.

A mixture of 50% water and 50% ethylene glycol base antifreeze is required for operation of the engine in temperature environments above -34.6” F (-37” C). A mixture of 40% water and 60% antifreeze is recommended for temperatures below -34.6” F (37°C).

Antifreeze may retain its freeze protection than one season but coolant conditioners added to maintain corrosion protection.

In tropical climates where antifreeze availability may be limited, use a corrosion inhibitor (Cummins liquid DCA), or an equivalent to protect the engine cooling system. Do not operate the engine without

a thermostat.

Check the solution periodically and at normal operating temperature, to be sure the cooling system has sufficient protection against freezing.

Use water which has a low mineral content. Water used in conjunction with antifreeze, coolant filters and inhibited water must meet the following standards:

00-13

GENERAL

MEMORANDA

00-l 4

ENGINE 12

TESTING

AND ADJUSTING

STANDARDVALUETABLE .......................................................... FOR ENGINE ON TEST BENCH .................................................... FOR ENGINE ON CHASSIS .......................................................

2 2 3

TOOLLlSTFORENGlNE

. . . . . . . . . . . . . . . . . . . . .._....................................

MEASURING ENGINE STALL SPEED .................................................. Measuring torque converter stall .................................................... Measuring hydraulic stall ......................................................... Measuring full stall ..............................................................

5 5 6 6

VALVE CLEARANCE

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

VALVE AND FIXED INJECTORS BLOW-BYPRESSURE

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

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

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

ALTERNATORFANBELT

. . . . . . . . . . . . . . . . . . . . . . . . . . .._.............................

EXHAUSTGASCOLOR

. . . . . . . . . . . . . . . . . . . . . . . . . . . .._.............................

OILPRESSURE

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

OILTEMPERATURE.......................................................:......

ACCELERATOR PEDAL ........................................................... OPERATING ANGLE...........: ................................................ OPERATING FORCE ...........................................................

15 15 16

The following precautions are necessary when using the Standard Value Tables to make judgements troubleshooting or during testing and adjusting. 1. 2.

during

The values in these tables are based on the values for new machines leaving the plant, so they should be used as target values when repairing or when estimating wear after a period of use. The standard values in these tables for judgement when troubleshooting are estimated values based on the standard values for the machine when shipped from the plant, and on the results of various tests. Therefore, they should be used as reference in combination with repair and operating records when making judgements. These standard value tables must not be used for standard values when judging claims. In addition, do not use these values alone to make simple judgements.

12-1

TESTING AND ADJUSTING

STANDARD

VALUE TABLE

STANDARD VALUE TABLE l

FOR ENGINE ON TEST BENCH Engine item

Cummins Condition

NTA 855C

Unit

Standard value

Permissible value 2200 - 2400 725 - 825

Engine speed

High idling speed Low idling speed

rpm

2300 + 100 775 k.50

Necessary

0°C -20°C (with ether starting aid)

rpm

Min. 150 Min. 120 Max. 635 (;;rt)

starting speed

Intake resistance

At all speeds

mmH,O

Intake pressure Exhaust pressure 0 Turbine inlet pressure Exhaust temperature l Turbine inlet temp.

At rated output

mmhg

Max. 380 (clean) Min. 914

At rated output All speeds l Intake air temp:

mmHg

Min. 838

813

“C

Max. 510

650

Bosch scale

Max. 6.0 Max. 1.5 Max. 2.0

Max. 6.0 Max. 1.5 Max. 2.5

0.28 0.58

mmH20

Max. 305 (New limit)

kg/cm2

3.1 - 3.9 Min. 1.05

All speeds (oil in oil pan)

“C

80-110

120

At continuous rated output (ratio of fuel consumption)

0.5

1.0

kg/cm2

0.28 0.58

0.10 - 0.36 0.46 - 0.71 Max. 100

Exhaust gas color

20°C

Quick acceleration 0 Low idling - High idling At rated output At high idling

Valve clearance l When engine is cold

Intake valve Exhaust valve

Blow-by pressure 0 SAE 15W-40 oil

At rated output l Water temperature:

Oil pressure 0 Oil temp:

At rated output (SAE 15W-40 oil) At low idling (SAE 15W-40 oil)

Min80”C

Oil temperature Oil consumption

Fuel injection

ratio

pressure

Valves and fixed timed injectors adjustment

Min. 70°C

Nozzle tester Top stop injector preload in.lb. l Intake valve l Exhaust valve

= 5 - 6

Coolant temperature

All speeds (at engine outlet)

“C

80 - 90

Valve cracking temperature Full opening temperature Full opening lift

“C “C mm

N/A

Thermostat

Radiator pressure valve function

Opening pressure (differential pressure)

kg/cm2

0.7 kO.15

Fan speed

At rated engine speed

rpm

1575

Belt tension gauge

N(Ibf)

620 (140)

Alternator

12-2

function

belt tension

460 (used engine over 3600 hours)

94 :;A

270 - 490 60 - 110

TESTING AND ADJUSTING

STANDARD

VALUE TABLE

FOR ENGINE ON CHASSIS Engine Check items

Cummins Conditions

NTA 85%

Unit

Standard value

Permissible value

Engine speed

High idling speed Low idling speed

rpm

2300 + 100 690 - 800

2300 2 100 2150-2360

Exhaust gas color

At abrupt acceleration At high idling

Bosch index

Max. 4.5 Max. 1.5

Valve clearance

Intake valve Exhaust valve mmH,O

Max. 305 (New limit)

Max. 460 (Worn limit)

(cold engine)

Blow-by pressure 0 Turbo and air compressor connected

Water temperature inside operatino range At-high-idling (SAE 15W-40 oil)

Oil pressure 0 SAE 15W-40 oil, temperature: Min. 80” C.

Water temperature ing range At rated speed At low idling

Oil temperature

Whole speed range (oil inside oil Dan)

Fan belt tension

Belt tension gauge

Valves and fixed timed injectors adjustment

Top stop injector preload in.lb 0 Intake valve 0 Exhaust valve

inside operat-

120

270 - 490 (60 - 110) = 5 -6 0.10 - 0.36 0.46 - 0.71

12-3

TESTING AND ADJUSTING

TOOL LIST

TOOL LIST FOR ENGINE No. 1.

Check item Engine speed

Tool

Part number

Multi-tachometer

799-203-8000

Tachometer

799-l 01-6000

kit

Remarks Digital display

L: 60 - 20,OOOrpm H: 60 - 19,999rpm

Water, oil, and intake temperature

799-l 01-I 500

-99.9 thru 1200°C

Lubricant

pressure

790-261-l 201

25. 60. 400, 600 ka/cm2

Blow-by

pressure

799-201-l 504

0 - 500 mmAa (mmH,0)

Valve clearance

Feeler gauge

795-l 25-l 210

Intake valve: 0.43mm Exhaust valve: 0.80mm

Smoke detector

799-201-9000

Exhaust gas color Smoke checker

Commercially available

Discoloration dard color (Discoloration index)

Blow-bv

checker

Fuel injection pressure Nozzle iniection condition

Nozzle tester

Commercially available

Alternator

Belt tension awe

ST-l 138 (Cummins)

Fan belt tension

Belt tension gauge

3823138 (Cummins)

Injector timing tool

3375522 (Cummins)

10.

A A 12-4

belt tension

Fuel injection

timing

When carrying out testing, adjusting or troubleshooting, stop machine on level ground, insert the safety pins and block the tracks. When working in groups, use agreed signals and do not allow unauthorized persons near the machine.

0 -70% with stan% x l/10=

Bosch

0 - 300kg/cm2

When checking the water level in the radiator wait for the water to cool. Do not remove the radiator cap while the water is hot. Boiling water may spurt out. Be careful parts.

not to get caught

in rotating

TESTING AND ADJUSTING

MEASURING * l l

MEASURING ENGINE STALL SPEED

ENGINE STALL SPEED

Measurement condition Coolant temperature: Inside operating range Hydraulic temperature: 45 - 55°C Torque converter oil temperature: 60 - 80°C

Special tools

+ t

Check that the idling speeds are at the standard value: Low - 775 ?50rpm High - 2300 -tlOOrpm Before measuring the rpm at each stall, install tool set tachometer (A) and adapter (a) on output port (1) of tachometer. Check that the engine speeds are the standard value. If any item is outside the permitted range, check for any looseness for play in the linkage.

WARNING! Block the wheels.

1. Measuring torque converter stall

1). Start the engine and run at low idle. 2). Put the directional

lever in FORWARD or REVERSE, and speed control lever in the highest speed range.

Using the brake, stop the machine and measure the engine speed when the engine when the accelerator pedal is fully depressed. * Turn the transmission cut-off selector switch (1) to the OFF position, and use the left brake. (Check that the pilot lamp is OFF). t Do not run at stall speed for more than 20 seconds, and do not let the torque converter oil temperature raise above 120°C. t Turn the parking brake switch OFF (release).

12-5

TESTING AND ADJUSTING

2. Measuring hydraulic stall 1)

Start engine and run at high idle.

Operate the dump or lift control lever to move the cylinder to the end of its stroke and actuate the relief valve of the main control valve.

Measure the engine at this point. Do not run the engine at stall speed for more than 20 seconds, and operate the control lever quickly.

3. Measuring full stall

1) Measure the engine

speed when the torque converter stall and hydraulic stall are reached at the same time. + Measure full stall when both the torque converter and hydraulic stall speeds are normal. If either stall speed is abnormal, correct and measure the stall speed again.

12-6

MEASURING ENGINE STALL SPEED

VALVE CLEARANCE

TESTING AND ADJUSTING

VALVE CLEARANCE + +

Condition: Engine is cold. Adjust clearance between valve and rocker lever as follows. Unit: mm

Cold

Intake valve

Exhaust valve

.28

.58

Part Name

QtY

Special tool Part No. 795-125-1210

Feeler gauge

Remove cylinder

head cover (1).

Adjust valve clearance. For details, see the “Engine Operation and Maintenance Manual” (NT 855 Engine Series)

12-7

TESTING

AND ADJUSTING

VALVE AND FIXED TIME INJECTORS

VALVE AND FIXED INJECTORS + t

Measurement condition: Engine is cold Adjust clearance between the crosshead and rocker lever as follows:

Special tool

Part number

795-l 251210

Part name Feeler gauge

cm 1

II I

Unit : mm Fuel system

Top stop injectoe preload: 5 - 6 inlb l Intake valve l Exhaust valve

Standard value

Permissible value

0.28 0.58

0.10 - 0.36 0.46 - 0.71

Remove cylinder

Adjust valve and fixed time injectors For details, see the “Engine Operation and Maintenance Manual” (NT 855 Engine Series).

12-8

head cover (1).

TESTING

AND ADJUSTING

BLOW-BY PRESSURE

BLOW-BY PRESSURE + Measurement condition l l

0 l

Coolant temperature: Inside operating range Engine valve clearance : Standard value Engine oil temperature: Min. 60°C Engine: Rated output Unit: mmH,O

Item I II IIBlow-bv pressure I

New limit

Worn limit

Max. 305

460

Special tool

L12ZZ133

WARNING! When taking measurements, be careful not to touch the exhaust manifold or muffler,or to get caught in rotating parts. 1. Procedure for measuring Blow-by 1) When measuring the blow-by, warm the engine up thoroughly. Stop engine and install plug (1) in the engine 2) crankcase breather vent. 3) Replace the oil filler cap with blow-by checking tool (B). 4) Connect adapter and tool (A) (0 to 500mmHsO) with hose. 5) Measuring blow-by pressure (for details For details, see the “Engine Operation and Maintenance Manual” (NT 855 Engine Series).

PI222134

2. Precautions when measuring blow-by pressure * Blow-by may vary greatly according to the condition of the engine, so if there is any abnormality in the reading, check for any problem related to defective blow-by, such as excessive oil consumption, defective exhaust gas color, or early deterioration or contamination of the oil.

12-9

TESTING AND ADJUSTING

ALTERNATOR BELT TENSION

ALTERNATOR

FAN BELT

CHART Unit:

I New tension

Belt tension

620 (140)

N(Ibfl

Used tension

270 - 490 (60 - 110)

Special Tool Part number (Cummins) IAl

o l l

ST 1138

LOBAR

Part name 1 Belt tension gauge

Testing alternator belt tension. Belts will loosen during use. They must be adjusted to the values listed in the Belt Tension Chart. A belt is considered used if it has been in operation for 10 minutes or longer.

Use the belt tension the belt tension. l

gauge, Part No. ST-l 138. Check

To adjust the alternator belt tension, see the “Engine Operation and Maintenance Manual” (NT 855 Engine Series).

12-10

FAN BELT

LOZAM014

TESTING

AND ADJUSTING

EXHAUST

GAS COLOR

EXHAUST GAS COLOR t

Measurement condition Coolant temperature: Inside operating Valve clearance: Standard value

l l

range

Soecial tools: No.

Part No.

A-l

A-2

Part Name

QtY

799-201-9000

Handy smoke checker

Commercially available

Smoke checker

For tests in the field where there is no air or electricity available, use A-l; for tests in a repair shop, use A-2.

Measuring with A-l WARNING! When measuring the exhaust color, be careful not to touch the exhaust pipe.

When measuring the exhaust color, warm engine up thoroughly (oil temperature 60” C).

the

Fit the filter paper in tool A-l. Insert the exhaust gas suction port into the exhaust pipe, accelerate the engine suddenly, and operate the handle to catch the exhaust gas on the filter paper. Remove the filter paper and compare it with the scale provided to judge the condition.

Measuring with A-2

WARNING! When measuring the exhaust color, be careful not to touch the exhaust pipe.

When measuring the exhaust color, warm engine up thoroughly (oil temperature SO’C).

Insert probe (A) in outlet of exhaust pipe (1) and secure to exhaust pipe with clip. Connect probe hose, connector hose of accelerator switch plug and air hose to tool A-2. * The pressure of the air supply should be under 15 kg/cm*. Connect power cord to AC 100 V socket. * Check that the power switch is OFF before connecting the cord.

the

12-11

TESTING

5. 6.

AND ADJUSTING

Loosen cap nut of suction pump and insert filter paper. Fit the filter paper securely so that the exhaust t gas does not leak. Turn power switch ON. Accelerate engine suddenly. At the same time,depress accelerator pedal, operate relief valve and catch exhaust gas color on filter paper. Lay filter paper used to catch exhaust gas color on top of unused filter papers (10 sheets or more) inside filter paper holder, and read indicated value.

12-12

EXHAUSTGASCOLOR

TESTING

AND ADJUSTING

OIL PRESSURE

AND TEMPERATURE

ENGINE OIL PRESSURE * l

Measurement condition Coolant temperature: Inside operating

range.

Unit: kg/en I Item

Oil pressure 0 rated soeed Low idlina

Permissible value

Standard value

3.1 - 3.9 I

Min. 1.05

Soecial tool IrEannurnber A

A A

790-261-l 201

Part name Hydraulic

WARNING! When measuring, get caught in rotating parts.

I Qtv

tester

be careful not to

WARNING! Install and remove the plug and oil pressure gauge with the engine stopped.

Measure the engine oil pressure when the temperature is at the specified temperature.

Remove plug (1).

Install oil pressure gauge “A” (25 kg/cm2).

Start the engine and measure the oil pressure.

For details, see the “Engine Troubleshooting Repair Manual” (NT 855 Series Engine)

oil

and

12-13

TESTING

AND ADJUSTING

OIL PRESSURE

ENGINE OIL TEMPERATURE +

Measurement condition Coolant temperature: Inside operating

range.

Unit: Item temoerature IIOil~~

Standard value I

80 - 110

“C

Permissible value I

120

Special tools

Part number

Part name

QtY

799-l 01-l 500

Digital thermometer

IIB I 79A-262-1920

I 1 II

Remove dipstick

Insert sensor “B” into the dipstick guide, then connect it to the digital thermometer “A” and measure the temperature of the oil inside the oil pan.

12-14

(1).

AND TEMPERATURE

TESTING AND ADJUSTING

ACCELERATOR OPERATING

ACCELERATOR

PEDAL

ANGLE

Item

a, Operating angle

Unit

I Standard II

degree mm

Stopper height

30 1 40 - 50

Snecial tool

II I A

PEDAL

Part number

Part name

QtY

Angle gauge

Commercially available

_I I

1. Measuring procedure 1. Stop the engine. 2.

Put angle gauge “A” in contact with the accelerator pedal, then measure the operating angle from low idling to high idling, and calculate operating angle a = a, - a2

2. Adjusting

procedure

Remove the cover under the cab, and open the inspection cover on the right side of the engine.

Loosen nut (1) and adjust bolt (2) so that mounting height “L” of the accelerator pedal stopper is within a range of 45 +5mm.

Loosen locknut (4) and adjust length of cable (3) so that the fuel pump lever contacts the high idling stopper when the accelerator pedal is fully depressed (high idling). * Check that the P.T. pump governor lever is in contact with the low idling stopper when the accelerator pedal is released (low idling). + Adjust the travel of the governor lever with joint of cable (3). + After completing the above adjustments, measure each part again to check that it is within the standard values.

BVO45

12-15

TESTING

ACCELERATOR

AND ADJUSTING

OPERATING

FORCE

Special tool

Part number

Part name

QtY

7AO-262-0020

Push-pull scale

1. Measuring procedure 1) Put push-pull scale “A” in contact with the accelerator pedal at point 150mm from pedal fulcrum “a“. + The center of push-pull scale o must be in contact with a point 150 mm from the pedal fulcrum.

2) Start the engine, push the pedal in the direction

of operation and measure the maximum value when pushing from idling to the end of the pedal travel (high idling).

2. Testing and adjusting 1) Stop the engine. 2)

Disconnect cable (1) at the bottom of the accelerator pedal, and check that plate (2) at the bottom of the pedal moves smoothly.

Connect the cable at the bottom of the pedal, then disconnect at the connection for the injection pump, and check that cable (3) moves smoothly. t When performing this inspection, adjust or replace parts as necessary. Measure the operating force again and check that all measurements are within the standard values.

12-16

PEDAL

ENGINE 13

DISASSEMBLY

AND ASSEMBLY

STARTING MOTOR ASSEMBLY. ........................ REMOVAL ..................................... INSTALLATION .................................. ALTERNATOR ASSEMBLY ............................ REMOVAL ..................................... INSTALLATION ..................................

Iii

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

. . . . . . . . . . .

. .. . .. .

. . . . . . . .

. .. . . . . .

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

4 ... 4 ... 4

3 3 3

OIL COOLER ASSEMBLY ............................. REMOVAL ..................................... INSTALLATION .................................. FUELPUMPASSEMBLY.. ............................ REMOVAL ..................................... INSTALLATION ..................................

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

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

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

. . . . . . . . . .

. . . . . . . . .

WATER PUMP ASSEMBLY ............................ REMOVAL ..................................... INSTALLATION ..................................

. , . .. . . . . . , . .

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

. . .

. . . . .

. .. . . . .

. . .

INJECTOR ASSEMBLY ............................... REMOVAL ..................................... INSTALLATION ..................................

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

. . . . . . . . . . .

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

. . . . . . . . .

8 8 8

TURBOCHARGER ASSEMBLY .......................... REMOVAL ..................................... INSTALLATION .........................................

. . . . .

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

. . . . .

9 9 9

. .

10 10

AFTERCOOLER ASSEMBLY .................................. REMOVAL ............................................ INSTALLATION.. ....................................... AIR COMPRESSOR ASSEMBLY ........................ REMOVAL ..................................... INSTALLATION ..................................

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

CYLINDERHEADASSEMBLY ................................. REMOVAL ............................................ INSTALLATION ......................................... RADIATOR ASSEMBLY ............................... REMOVAL ..................................... INSTALLATION ..................................

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

6 6 6

7 ... 7 ... 7

.. .. . ..

. . . . . . . . . . .

. . . .

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

. . . . . . . . . . .

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

. .

12 12 13

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

. . . . . . . . . ..

. . . . . . . . . , . . . . .

. . . .

14 14 16

. . . . . . . . .

. . . . . ..

. . . . . . , , . .

. . . .

19 19 22

13-1

........................................................................ ENGINE.. REMOVAL ..................................................................... INSTALLATION ..................................................................

25 25 31

................................................................ DAMPER ASSEMBLY REMOVAL ..................................................................... INSTALLATION .................................................................. ............................................................. DISASSEMBLYOF.. .................................................................. ASSEMBLYOF

38 38 42 46 49

.............................................................. FUELTANKASSEMBLY REMOVAL ..................................................................... INSTALLATION ..................................................................

53 53 55

To maintain the performance of the machine and to prevent failures, it is particularly important to pay attention to the degree of cleanliness of the oil in the hydraulic circuits. When adding oil or changing the oil, or when replacing the filters, check that the oil container and area around the filler of the hydraulic tank are clean. If any internal part of the hydraulic equipment breaks, disassemble and clean all the hydraulic equipment and circuits to remove any dirt or pieces from the circuit. If any parts of the hydraulic circuits are disassembled and assembled, also carry out thorough flushing of the hydraulic circuits. After replacing or flushing the hydraulic tank oil, filter element, or strainer, or when removing and installing any hydraulic cylinder, hydraulic pump or any other hydraulic equipment or work equipment piping, always bleed the air as follows after completion of installation. Air bleeding procedure 1) Run the engine at low idling, and extend and retract the steering, bucket, and lift arm cylinders 4 - 5 times without going to the end of this stroke. (Stop approx. 100 mm before the end of the stroke.) 2) Operate the steering, bucket, and lift arm cylinders 3 - 4 times to the end of the stroke, then stop the engine and bleed the air from the plugs at the top of the hydraulic tank filter. 3) Raise the engine speed and repeat Step 2, to bleed the air. Repeat this procedure until no more air comes out from the plug. 4) After completing bleeding the air, tighten the plugs. Plug: 1.15k.15 5)

13-2

kgm

Check The level of the oil inside the hydraulic tank, add oil if necessary, then tighten the oil filler cap. * Before loosening the oil filler cap, close the pressurizing valve; after adding oil, tighten the oil filler cap, then open the pressurizing valve. After repair or long storage, follow the same procedure.

DISASSEMBLY

AND ASSEMBLY

STARTING

MOTOR ASSEMBLY

STARTING

MOTOR

REMOVAL

A A

from

the

1. Remove catch, open side cover, then remove two side covers. 2. Disconnect connector (1) and wire (2). connection (3), then remove 3. Remove ground starting motor assembly (4). 4. For details, see Cummins Engine “Troubleshooting and repair manual” (NT 855 Series Engine).

INSTALLATION 1. Fit gasket and install starting

2. 3. 4. 5.

motor assembly (4), then tighten together with ground connection (3). Connect wire (2) and connector (1). Install cover, close two side covers, then lock with catch. Connect cable to negative (-) terminal of battery. For details, see Cummins Engine “Troubleshooting and repair manual” (NT 855 Series Engine).

13-3

DISASSEMBLY

AND ASSEMBLY

ALTERNATOR

ASSEMBLY

REMOVAL

A A

from

the

1. Remove catch, then open side cover. 2. Disconnect wires (1, 2 and 3). 3. Remove bolt (4) of adjustment plate, then loosen mounting bolt and nut (5). 4. Remove adjustment plate (6). 5. Move alternator assembly towards lower position to loosen belt tension, then remove belt (7). bolt and nut, then remove 6. Remove mounting alternator assembly. 7. For details, see Cummins Engine “Troubleshooting and repair manual” (NT 855 Series Engine).

INSTALLATION 1. Install alternator assembly (8), then partially tighten mounting bolt and nut (5). 2. Fit belt (7) in pulley groove and install. 3. Install adjustment plate (6), and partially tighten bolt (4) of adjustment plate. 4. Insert a bar between the alternator assembly and cylinder block, raise the alternator and adjust the belt tension. + The belt should deflect about 15mm when pushed with a finger pressure of 6kg at a point midway between the alternator and the fan pulley. 5. Tighten the adjustment plate bolt, and the alternator assembly bolt and nut. 6. Connect wires (3, 2 and 1). 7. Close cover, then lock with catch. 8. Connect cable to negative (-) terminal of battery 9. For details, see Cummins Engine “Troubleshooting and repair manual” (NT 855 Series Engine).

13-4

DISASSEMBLY

AND ASSEMBLY

OIL COOLER

OIL COOLER ASSEMBLY REMOVAL

1. Remove catch, then open left engine side cover. 2. Loosen drain valve (l), and drain the cooling water. t If the coolant contains antifreeze, dispose of it correctly. oil supply tube (3) and 3. Remove the turbocharger the by-pass filter return tube (4). 4. Remove the cover and the water transfer tube (2). 5. Remove the full flow and by-pass filters (5). 6. Remove the oil cooler assembly, then remove the remaining bolts from the support. 7. For details, see Cummins Engine “Troubleshooting and repair manual” (NT 855 Series Engine).

INSTALLATION Install the oil cooler support. Install the oil cooler assembly (6). Install the cover and the water transfer tube (2). Install the turbocharger oil supply tube (3), and the by-pass filter return tube (4). 5. Install the full flow and by-pass filters (5). 6. For details, see Cummins Engine ‘Troubleshooting and repair manual” (NT 855 Series Engine).

1. 2. 3. 4.

13-5

DISASSEMBLY

AND ASSEMBLY

FUEL PUMP ASSEMBLY REMOVAL

1. Remove the three engine side covers on the left side. 2. Disconnect wire (1) to the fuel shut-off valve. 3. Remove control rod (2). 4. Disconnect the fuel inlet hose (3) and the air supply hose (4). 5. Remove fuel tubing (5, 6, and 7). 6. Remove fuel pump (8). 7. For details, see Cummins Engine “Troubleshooting and repair manual” (NT 855 Series Engine).

INSTALLATION 1. Install fuel pump (8), then install the drive spider coupling. 2. Install fuel tubing (5, 6, and 7). 3. Connect the fuel inlet hose (3) and air supply hose (4). 4. Connect fuel shut-off valve wire (1). 5. Install control rod (2). 6. Install the three engine side covers, then lock with catch. 7. For details, see Cummins Engine ‘Troubleshooting and repair manual” (NT 855 Series Engine).

13-6

FUEL INJECTION

PUMP

DISASSEMBLY

AND ASSEMBLY

WATER PUMP

WATER PUMP ASSEMBLY REMOVAL

1. Remove radiator assembly (see removal of radiator page 13-l 6) 2. Remove water pump belt (1). 3. Remove fan hub (2), and the water pump idler pulley assembly (3). 4. Remove fan hub support bracket (4). 5. Remove air compressor coolant outlet tube (5). 6. Remove thermostat by-pass tube (6). 7. Remove coolant inlet transfer connection (7) from the water pump. 8. Remove water pump assembly (8). 9. For details, see Cummins Engine “Troubleshooting and repair manual” (NT 855 Series Engine).

INSTALLATION 1. Install water pump assembly (8) with a new gasket. (7) with a 2. Install coolant inlet transfer connection new gasket. 3 Install coolant outlet tube (5), and the thermostat by-pass tube (6). 4. Install fan hub support bracket (4). 5. Install fan hub (2), and the water pump idler pulley (3). 6. Install water pump belt (1). 7. For details, see Cummins Engine “Troubleshooting and repair manual” (NT 855 Series Engine).

13-7

DISASSEMBLY

AND ASSEMBLY

INJECTOR ASSEMBLY REMOVAL

Preparatory work -Remove engine side covers, hood, and exhaust pipe. t Remove cylinder head assembly, injector assembly, muffler, intake connector, and air cleaner assembly, then disconnect all injectors. 1. Remove mounting bolt (1) of the head cover, then remove head cover (2). 2. Loosen adjusting screw locknut (3) and move the injector push rod to the side. 3. Remove the injector link. 4. Remove injector hold down clamp (4). 5. Using injector puller (Cummins part #3376497), remove injectors (5). 6. For details, see Cummins Engine “Troubleshooting and repair manual” (NT 855 Series Engine).

INSTALLATION 0

Replace the three o-rings on each injector.

1. Install injectors (5) in the cylinder head injector bore. 2. Install injector hold down clamp (4). 3. Install the injector link in each injector. 4. Align the push rod with the injector rocker lever, turn the adjusting screw, and tighten locknut (3). 5. Install rocker lever head cover (2), and mounting bolts (1). 6. For details, see Cummins Engine “Troubleshooting and repair manual” (NT 855 Series Engine).

13-8

NOZZLE HOLDER

DISASSEMBLY

AND ASSEMBLY

TURBOCHARGER

ASSEMBLY

REMOVAL

Preparatory work 0 -Remove hood, engine side covers, and exhaust muffler. t To remove exhaust muffler and air cleaner assembly (see pg 13-12). 1. Disconnect inlet connector (1). 2. Disconnect oil supply tube (2), and drain tube (3). 3. Remove mount bolts (4), and remove turbocharger assembly (5).

INSTALLATION l

Replace gaskets and o-rings with new.

1. Fit new gasket and install turbocharger assembly (5), then tighten turbocharger mounting bolts (4). 2. Fit new gasket, connect drain tube (2), and supply tube (3). 3. Fit new o-ring and gasket, install inlet connector (1). 4. Install exhaust muffler, hood, and side covers.

13-9

DISASSEMBLY

AFTERCOOLER

AND ASSEMBLY

AFTERCOOLER

ASSEMBLY

REMOVAL

A 1.

Hood and engine side covers. 1) 2)

Remove exhaust pipe (l), sling hood (2), then lift off. Remove left and right hand engine side covers.

2. Ether injector. 1) Remove ether injector

(3), and bracket (4).

3. Draining water. 1) Open radiator drain valve (5), and drain coolant. 2) Open aftercooler drain valve (S), and drain coolant. + If the coolant contains antifreeze, dispose of it properly. 4. Crossover connection. 1) Remove air crossover

connection

(7).

5. Hoses and hose clamps. 1) Loosen hose clamps (8). 2) Remove aftercooler inlet hose (9) and outlet hose (10). 3) Remove air compressor air inlet tube (1 l), and aftercooler signal tube (12). 4) Remove any other hoses which are attached to the aftercooler assembly. 6. Aftercooler assembly. 1) Remove aftercooler ing bolts.

assembly

(13), and mount-

7. For details, see Cummins Engine “Troubleshooting and repair manual” (NT 855 Series Engine).

13-10

L13AH057

DISASSEMBLY

AND ASSEMBLY

AFTERCOOLER

INSTALLATION 1. Aftercooler assembly. 1) Install the guide studs (14) in the cylinder head, then install the aftercooler assembly (13). 2. Hoses and clamos. 1) Install aftercooler inlet hose (9), and outlet hose (lo), and tighten the hose clamps (8). Install air compressor air inlet tube (ll), and 2) aftercooler signal tube (12). 3) Remove any other hoses which are attached to the aftercooler assembly. 3. Crossover connection. 1) Install air crossover

connection

4. Ether injector. 1) Install ether injector

(3) and bracket (4).

(7).

5. Refilling coolant. 1) Close radiator drain valve (5), and aftercooler drain valve (6) 2) Add coolant through the radiator filler neck to the specified level. * Run the engine to circulate the coolant through the system. Then check the coolant level again.

Coolant:

81 P

6. Hood and engine side covers. 1) Install left and right hand engine side covers. 2) Install hood (2), and exhaust pipe (1). 7. For details, see Cummins Engine “Troubleshooting and repair manual” (NT 8.55 Series Engine).

079

DISASSEMBLY

AND ASSEMBLY

AIR COMPRESSOR

ASSEMBLY

REMOVAL

1. Remove the fuel pump assembly (see pg 13-6). 2. Open the right engine side cover. 3. Open the radiator drain valve, and drain the coolant. t If the coolant contains antifreeze, dispose of it properly. 4. Remove hoses (1) and clamps (2). 5. Remove air compressor coolant tube (3). 6. Remove air inlet hose (4), and outlet hose (5). 7. Remove air compressor mounting bolts (6), and the air compressor assembly (7). 8. For details, see Cummins Engine “Troubleshooting and repair manual” (NT 855 Series Engine).

13-12

AIR COMPRESSOR

DISASSEMBLY

AND ASSEMBLY

AIR COMPRESSOR

INSTALLATION

1. Position

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

the timing mark on the air compressor crank shaft, and accessory drive shaft dowel pin. Install the splined coupling on the accessory drive. Install a new gasket, then install the air compressor assembly (7) and mounting bolts (6). Install air inlet hose (4), and outlet hose (5). Install coolant hose (3). Install hoses (l), and clamps (2). Remove the fuel pump assembly (see pg 13-6). Close the radiator drain valve, add coolant through the radiator filler neck to the specified level. * Run the engine to circulate the coolant through the system. Then check the coolant level again.

Coolant:

814

9. Close the right side engine side cover, then lock with catch. 10. For details, see Cummins Engine “Troubleshooting and repair manual” (NT 855 Series Engine).

13-13

DISASSEMBLY

AND ASSEMBLY

CYLINDER

HEAD

CYLINDER HEAD ASSEMBLY REMOVAL

L13AHO57

1. Engine hood and side covers. 1) Remove exhaust pipe (l), sling hood (2), then lift off 2) Remove left and right hand engine side covers. 2. Draining

coolant.

1) Open radiator drain valve (3), and drain coolant. + If the coolant contains antifreeze, dispose of it properly. 3. Bracket. 1) Disconnect

fuel control

cable bracket (4)

4. Drain tube. 1) Remove muffler drain tube (5).

5. Muffler. 1) Remove exhaust pipe (6), then loosen the pipe clamps. 2) Disconnect aspirator pipe (i’), then remove clamp (8). 3) Sling muffler (9), then lift off. LlZAZ023

13-14

DISASSEMBLY AND ASSEMBLY

CYLINDER HEAD

6. Intake connector assembly

1) Disconnect aspirator intermediate hose (10). 2) Remove mounting bolts (1 l), loosen connector clamp (13) then remove intake connector

(12).

L12AZ025

L12AZ026

7. Air cleaner assembly. 1) Remove air cleaner mounting band. 2) Remove intake connector bracket

mounting bolts (14). 3) Sling air cleaner assembly (15), then remove air cleaner and intake connector as one unit.

Air cleaner assembly:

35 kg

L12A2027

8. Cylinder heads. Remove aftercooler 10).

assembly

(16) (see pg 13-

2) Remove turbocharger

assembly (17) (see pg 13-9). 3) Remove exhaust manifold (18). 4) Remove water manifold (19). 5) For details, see Cummins Engine ‘Troubleshooting and repair manual” (NT 855 Series Engine).

13-15

DISASSEMBLY

AND ASSEMBLY

INSTALLATION 1. Cylinder head assembly. 1) Install new head gaskets on the dowel pins in the cylinder block. + Make sure the side of the gasket marked ‘TOP” is facing up. 2) For details, see Cummins Engine “Troubleshooting and repair manual” (NT 855 Series Engine).

3) Install water manifold (19). 4) Install exhaust manifold (18). 5) Install turbocharger assembly (17), see page 13-9. 6) Install aftercooler assembly (16), see pg. 13-11.

13-16

CYLINDER

HEAD

DISASSEMBLY

CYLINDER

AND ASSEMBLY

HEAD

2. Air cleaner assembly. 1) Sling air cleaner assembly and intake connector as one unit, then install the air cleaner assembly (15).

2) Tighten the intake connector

bracket mounting bolts (14). 3) Secure the air cleaner mounting band.

3. Intake connector assembly. 1) Install a new gasket, then install the air intake connector (12), tighten mounting bolts (1 l), and install connector clamp (13). 2) Connect aspirator intermediate hose (10).

L12AZ025

LlZAZ026

4. Muffler. 1) Sling the muffler assembly (9) then install. 2) Connect aspirator pipe (7), then install clamp (8). 3) Install exhaust pipe (6), then tighten the pipe clamps.

13-17

CYLINDER HEAD

DISASSEMBLY AND ASSEMBLY

5. Drain tube. 1) Connect the muffler drain tube (5).

6. Bracket. 1) Connect fuel control

cable bracket (4).

Ll2BVO42

7. Refilling coolant. 1)

2) t

Close radiator drain valve (5), and aftercooler drain valve (6) Add coolant through the radiator filler neck to the specified level. Run the engine to circulate the coolant through the system. Then check the coolant level again.

Coolant:

81 P L06AH080

8. Hood and engine side covers. 1) Install left and right hand engine side covers. 2) Install hood (2), and exhaust pipe (1).

13-18

DISASSEMBLY

AND ASSEMBLY

RADIATOR

RADIATOR ASSEMBLY REMOVAL

A s

0 0

Loosen the oil 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.

Remove cover (1). Loosen plugs (2) and (3) at the top of the hydraulic tank filter to prevent the oil inside the tank from flowing out.

1. Draining

coolant.

1) Open radiator drain valve (4), and drain coolant. + If the coolant contains antifreeze, dispose of it properly.

Coolant:

81 Q

2. Engine hood and side hoods. 1) Sling side hoods (5) remove mounting bolts, then lift off side hoods. + Disconnect the stopper from the engine hood. * When slinging, be sure that the center of gravity is balanced, then lift off. Side hood:

25 kg

2) Sling engine hood (6), remove mounting

bolts, then lift off engine hood. * When slinging, be sure that the center of gravity is balanced, then lift off. Engine hood:

64 kg

13-19

DISASSEMBLY

AND ASSEMBLY

RADIATOR

3. Radiator guard. 1) Remove radiator grille (7), and cover (8). 2) Sling radiator guard (9), remove mounting bolts, then lift off radiator guard. t Disconnect the wiring from the connector. * Be careful not to hit the radiator when lifting off the radiator guard.

Radiator guard:

140 kg.

4. Fan guard and radiator supports. 1) Remove radiator supports (10). 2) Remove fan guard (11) from the radiator. t Remove the clamp of hose (12).

5. Radiator hoses. 1) Disconnect radiator hoses (13), (14), and (15) at the engine end. t Loosen radiator and clamp at engine end, and remove tubes (16) and (17) when removing the radiator.

L06AH063

13-20

DISASSEMBLY

AND ASSEMBLY

RADIATOR

6. Cooler oWna. 1) Disconnect hydraulic oil cooler hoses (18) and (19) from the radiator. Disconnect torque converter hoses (20) and 2) (21) from the radiator.

L&AH084

7. Radiator assembly. 1) Sling radiator assembly (22), remove the mounting bolts, then lift off the radiator assembly. * Sling the radiator assembly, and lift off while moving radiator to the rear. t Be careful, and make sure the cooling fan does not interfere with the radiator core.

Radiator assembly:

295 kg

13-21

DISASSEMBLY

RADIATOR

AND ASSEMBLY

INSTALLATION 1. Radiator assembly. 1) Raise the radiator assembly (22), set in mounting position and install mounting bolts. + Check that the lower hose and upper hose are set in their mounting positions. t Tighten the mounting bolts temporarily, then tighten them fully after installing the supports.

[ Mounting

bolt:

L06AM025

56 +-6.0 kgm

2. Cooler piping. 1) Connect torque converter hoses (20) and (21) to the radiator. 2) Connect hydraulic oil cooler hoses (18) and (19) to the radiator.

Cooler hose : 2Ok5.0 kgm (Width across flats: 41 mm) &6AH064

3. Radiator hoses. 1) Connect radiator hoses (13), (14), and (15) to the engine. + Install hose clamps properly. + Set tube (16) and hose (17) in position, then tighten hose clamp.

13-22

L06AH063

DISASSEMBLY

AND ASSEMBLY

RADIATOR

4. Fan guard and radiator supports. 1) Install fan guard (11) to the radiator. + Install so that the clearances between the fan and fan guard at the left and right, and the top and bottom are the same. t Install hose clamp (12). 2) Install radiator supports (10) to the radiator. t Tighten the radiator mounting bolts.

5. Radiator guard. 1) Set radiator guard (9) into mounting position, then tighten the mounting bolts. * Install the radiator guard without interference, so that the clearances between the radiator guard and the radiator at the left and right are the same. * Connect wiring connector. 2) Install the radiator grille (7) and cover (8).

T4251054

6. Engine hood and side hoods. 1) Set engine hood (6) into the mounting position, then tighten mounting bolts 2) Set side hoods (5) into the mounting position, then tighten the mounting bolts. * Install the stopper to the engine hood.

13-23

DISASSEMBLY

AND ASSEMBLY

RADIATOR

7. Refilling coolant. 1) Close radiator drain valve (4) 2) Add coolant through the radiator filler neck to the specified level.

Coolant:

81 P

L06AH061

8. Refilling hydraulic and transmission oil. 1) Tighten plugs (2) and (3) at the top of the hydraulic tank filter, then add hydraulic oil through the oil filler to the specified level.

1 Plugs at the top of the hydraulic tank filter: 1.2 20.1 kg Ll2ZZO92

2) Install cover (1).

I 3) Add transmission oil through the oil filler to the specified level. t Run the engine to circulate the oil and coolant through the system. t Recheck oil and coolant levels again.

13-24

I Ill I

LO6ZZO16

TRANSMISSION

OIL FILLER

DISASSEMBLY AND ASSEMBLY

ENGINE

ENGINE REMOVAL

WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. Loosen the oil 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.

I).

AY 4

0 0

Remove cover (1). Loosen plugs (2) and (3) at the top of the hydraulic tank filter to prevent the oil inside the tank from flowing out.

1. Draining coolant. 1) Open radiator drain valve (4), and drain coolant. t If the coolant contains antifreeze, dispose of it properly. Coolant:

81 P

2. Side covers. 1) Remove engine side covers (A), (B), and (C). *Remove the left and right side covers. 3. Engine hood and side hoods. 1) Sling side hoods (5), remove mounting bolts, then lift off side hoods. + Disconnect the stopper from the engine hood. t When slinging, be sure that the center of gravity is balanced, then lift off. Side hood:

25 kg

Remove the left and right supports

and bars of the side cover mount. 2) Sling engine hood (6), remove mounting bolts, then lift off engine hood. + When slinging, be sure that the center of gravity is balanced, then lift off. Engine hood:

64 kg

13-25

DISASSEMBLY

AND ASSEMBLY

ENGINE

4. Radiator guard. 1) Remove radiator grille (7) and cover (8). 2) Sling radiator guard (9), remove mounting bolts, then lift off radiator guard. t Disconnect the wiring from the connector. * Be careful not to hit the radiator when lifting off the radiator guard.

Radiator guard:

140 kg.

5. Fan guard and radiator supports. 1) Remove radiator supports (10). 2) Remove fan guard (11) from the radiator. t Remove the clamp of hose (12).

6. Radiator hoses. 1) Disconnect radiator hoses (13), (14), and (15) at the engine end. t Loosen radiator and clamp at engine end, and remove tubes (16) and (17) when removing the radiator.

L06AH063

13-26

DISASSEMBLY

AND ASSEMBLY

ENGINE

Cooler piping.

1) Disconnect

hydraulic oil cooler hoses (18) and (19) from the radiator. 2) Disconnect torque converter hoses (20) and (21) from the radiator.

Radiator assembly. 1) Sling radiator assembly (22), remove the moun-

L66AHO84

ting bolts, then lift off the radiator assembly. * Sling the radiator assembly, and lift off while moving radiator to the rear. + Be careful, and make sure the cooling fan does not interfere with the radiator core.

Radiator assembly:

295 kg

9. Wiring.

1) Disconnect

starting motor wiring (23) and the ground connector (24). 2) Disconnect the engine wiring harness (24). 3) Disconnect the main breaker wiring harness (28). + After removing the wiring, mark with tags to distinguish when installing.

10. Fuel line hoses. 1) Disconnect the following

hoses from the fuel tank end. a) Hose (27) between the fuel tank and the fuel filter. b) Hose (28) Between the fuel pump and the fuel tank.’

L08AD138

L08AD135

13-27

ENGINE

DISASSEMBLY AND ASSEMBLY

11. Fuel control cable. 1) Disconnect fuel control cable (29) from the fuel pump lever (30), then remove together with bracket (31) from the engine. + After removing, move the cable towards the front.

12. Air piping. 1) Disconnect

air piping tube (32), hose (33), and

clamp (34).

LO3BHOOZ

13. Engine oil drain lines. 1) Disconnect the engine oil drain tube (35) at the fuel tank end. 2) Disconnect the enaine block oil drain hose (35A) from the fuel tank.

14. Muffler. 1) Sling muffler (36) and remove it.

15. Air cleaner assembly 1) Remove covers (37), (38), and (39).

13-28

L12AZ028

DISASSEMBLY

AND ASSEMBLY

2) Disconnect

dust indicator

ENGINE

hose (40) at the air

cleaner end.

3) Remove hose (41), then disconnect air intake port (42). 4) Disconnect the intake connector (43), then sling the air cleaner assembly (44) and remove it.

L12AV020

16. Engine

assembly. 1) Disconnect the grease hose (45) from damper assembly,

at the damper end.

2) Disconnect drive shaft (46) from the engine assembly. t Make match marks before disconnecting the coupling.

LlZAR044

DISASSEMBLY

AND ASSEMBLY

ENGINE

3) Sling the engine assembly, then remove the front mounting bolts (47), and rear mounting bolt (48).

LlZAOO80

4) Lift off the engine assembly (49). t Raise the engine, then slowly move towards the rear, and lift off. * When slinging, be sure that the center of gravity is balanced, then lift off.

Engine assembly:

13-30

1287 kg

DISASSEMBLY

AND ASSEMBLY

ENGINE

INSTALLATION 1. Engine assembly. 1) Raise the engine assembly mounting position.

(49), and set in

2) Tighten the front mounting bolts (47), and rear mounting bolt (48). t Tighten the mounting bolts fully to give clearance ‘a’ between the engine damper and the trunnion support.

I Front mounting

bolts:

76 t8.5

kgm

I Rear mounting

bolt:

76 k8.5 kgm

Front

Rear L12AD082

3) Align match marks and install the drive shaft (46) to the engine.

] Mounting

bolts:

11.5 k1.0 kgm

When connecting the drive shaft, clean the contact surfaces of the spider and the coupling.

13-31

DISASSEMBLY

AND ASSEMBLY

ENGINE

4) Connect the grease hose (45) to the damper assembly, at the damper end. it Connect the hose without twisting.

2. Air cleaner assembly. 1) Sling the air cleaner assembly (44) and set into mounting position, then tighten the mounting bolts. + Connect the intake connector (43). 2) Connect the air intake port (42), then connect hose (41).

L12AVOXl

3) Connect dust indicator hose (40) to the air cleaner end. + Connect the hose without twisting.

LlZAR044

4) lnstall covers (37), (38), and (39).

13-32

ENGINE

DISASSEMBLY AND ASSEMBLY

3. Muffler. 1) Sling muffler (36), set into mounting then tighten mounting bolts.

position,

4. Engine oil drain lines. 1) Connect the engine oil drain tube (35) to the fuel tank. 2) Connect the engine block oil drain hose (35A) to the fuel tank.

LlZAZO28

5. Air piping. 1) Connect

air piping tube (32), hose (33), and clamp (34). + Check for air leaks at the tubing and hose connections.

6. Fuel control cable. 1) Install the fuel control cable (29) with bracket to the engine, connect the cable to the fuel pump lever (30) with locknut (31). 1 Locknut

(31): 5 20.5 kgm

For details, on the adjustment of the fuel control cable, see Cummins Engine “Testing and adjusting section in the engine repair manual” (NT 855 Series Engine).

7. Fuel line hoses. 1) connect the following hoses to the fuel tank, install the hose clamps: a) Hose (27) between the fuel tank and the fuel filter. b) Hose (28) Between the fuel pump and the fuel tank.

13-33

DISASSEMBLY

AND ASSEMBLY

ENGINE

8. Wirina.

1) &nect

starting motor wiring (23) and the ground connector (24). 2) Connect the engine wiring harness (24). 3) Connect the main breaker wiring harness (26). + Make sure to tie down and clamp all connectors and wiring where required.

L08AD138

LOBAD

9. Radiator assembly. 1) Raise the radiator assembly (22), set in mounting position and install mounting bolts. + Check that the lower hose and upper hose are set in their mounting positions. A Tighten the mounting bolts temporarily, then tighten them fully after installing the supports.

Mounting

bolt:

56 +6.0 kgm

10. Cooler piping. 1) Connect torque converter hoses (20) and (21) to the radiator. 2) Connect hydraulic oil cooler hoses (18) and (19) to the radiator.

1 Cooler hose : 20 25.0 kgm (Width across flats: 41 mm) &AH084

13-34

DISASSEMBLY

AND ASSEMBLY

ENGINE

11. Radiator hoses. 1) Connect radiator hoses (13), (14), and (15) to the engine. * Install hose clamps properly. * Set tube (16) and hose (17) in position, then tighten hose clamp.

L06AHO63

12. Fan guard and radiator supports. 1) Install fan guard (11) to the radiator. + Install so that the clearances between the fan and fan guard at the left and right, and the top and bottom are the same. + Install hose clamp (12). 2) Install radiator supports (10) to the radiator. + Tighten the radiator mounting bolts.

13. Radiator guard. 1) Set radiator guard (9) into mounting position, then tighten the mounting bolts. + Install the radiator guard without interference, so that the clearances between the radiator guard and the radiator at the left and right are the same. * Connect wiring connector. 2) Install the radiator grille (7) and cover (8).

13-35

DISASSEMBLY

AND ASSEMBLY

14. Engine hood and side hoods. 1) Set engine hood (6) into the mounting position, then tighten mounting bolts 2) Set side hoods (5) into the mounting position, then tighten the mounting bolts. * Install the stopper to the engine hood. t Install the left and right supports and bars of the side cover mount.

15. Side covers. 1) Install engine side covers (A), (B), and (C).

13-36

ENGINE

DISASSEMBLY

AND ASSEMBLY

ENGINE

16. Refilling coolant. 1) Close radiator drain valve (4) 2)

Add coolant through the specified level.

Coolant:

the radiator filler neck to

81 P

17. Refilling hydraulic and transmission oil. 1) Tighten plugs (2) and (3) at the top of the hydraulic tank filter, then add hydraulic oil through the oil filler to the specified level.

Plugs at the top of the hydraulic tank filter: 1.2 +O.l kg

2) Install cover (1).

3) Add transmission oil through the oil filler to the specified level. + Run the engine to circulate the oil and coolant through the system. + Recheck oil and coolant levels again.

TRANSMISSION

OIL FILLER

13-37

DAMPER

DISASSEMBLY AND ASSEMBLY

DAMPER ASSEMBLY REMOVAL

A Y

l l

A 4

Loosen the oil 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.

Remove cover (1). Loosen plugs (2) and (3) at the top of the hydraulic tank filter to prevent the oil inside the tank from flowing out.

1. Draining hydraulic oil.

1) Remove plug (4), then open valve (5) and drain the hydraulic oil.

I Hydraulic

oil:

1504

2. Side covers. 1) Remove engine side covers (6), (7), and (8). *Remove the left and right side covers, 3. Engine hood and side hoods. 1) Sling side hoods (9), remove mounting bolts, then lift off side hoods. + Disconnect the stopper from the engine hood. + When slinging, be sure that the center of gravity is balanced, then lift off.

Side hood:

25 kg

Remove the left and right supports and bars of the side cover mount. 2) Sling engine hood (lo), remove mounting bolts, then lift off engine hood. + When slinging, be sure that the center of gravity is balanced, then lift off. Engine hood:

64 kg 113AH062

13-38

DISASSEMBLY

AND ASSEMBLY

4. Bulkhead. 1) Disconnect dust indicator cleaner end.

DAMPER

11 hose (11) at the air

2) Remove covers (12), (13), and (14).

3) Remove plate (15).

4) Loosen bracket mounting bolts (16). t Do not remove the bracket.

113AH064

13-39

DISASSEMBLY AND ASSEMBLY

DAMPER

5) Sling bulkhead (17), then remove the mounting bolts and lift off. + Disconnect the clamp for the fuel control cable from the bulkhead. + The bulkhead passes close to the cab glass, so be careful when lifting. Bulkhead:

135 kg.

If the machine is equipped with air conditioning, disconnect the air conditioner hose and the condenser wiring harness, then disconnect the clamp for the heater hose from the bulkhead. (See REMOVAL OF AIR CONDENSER AND DRY RECEIVER).

5. Hydraulic pump assemblies.

li Remove tubes (18) and (19), then the remove torque converter charging Torque 13 kg.

pump assembly (20).

converter

charging

pump:

2) Remove tube (21), and disconnect

hoses (22) and (23) from pump end, then remove the steering and PPC pump assembly (24). Steering and PPC pump:

20 kg.

3) Remove tubes (25) and (26), then remove the switch pump assembly (27). Switch pump:

13-40

14 kg.

DISASSEMBLY

AND ASSEMBLY

DAMPER

4) Disconnect block (28) and tube (29) from the pump end, then remove the hydraulic pump assembly (30). Hydraulic

+ +

pump:

14 kg.

After removing the hydraulic pump assembly, remove the tube. Remove the o-rings from all pump mounting surfaces.

6. Drive shaft. 1) Disconnect drive shaft (31) from the damper assembly. + Make match marks before disconnecting the coupling. Drive shaft:

18 kg.

7. Damoer assemblv. 1) disconnect the grease line hose (32) for the damper assembly at the damper. + Remove coupling (33). Temporarily sling cover (34) and remove moun2) ting bolts, then using forcing screws, lift off. Cover:

32 kg.

sling the damper assembly (35) 3) Temporarily with eye-bolt, then remove mounting bolts and lift the damper assembly. Damper assembly:

60 kg.

13-41

DISASSEMBLY AND ASSEMBLY

DAMPER

INSTALLATION 1. Damper assembly.

1) Sling damper assembly (35), set in mounting position, then tighten the mounting bolts.

I Mounting bolts: 11.25 -t 1.25 kgm Shaft spline: Molybdenum disulphide dry lubricant (After coating with lubricant, leave set for 2 - 3 minutes). +

Brand name: Juko lubricant low-cold dry spray or equivalent.

2) Sling cover (34), set in mounting position, then tighten the mounting bolts.

&?_,

Cover contact surface: sealant (LG-4).

Gasket

3) Connect the grease line hose (32) for the damper assembly to the damper. * Install coupling (33). fi

Shaft spline: Molybdenum disulphide dry lubricant (After coating with lubricant, leave set for 2 - 3 minutes). Brand name: Juko lubricant low-cold dry spray or equivalent.

2. Drive shaft. 1) Align match marks and install the drive shaft (31) to the engine. Mounting bolts: 11.5 f 1.O kgm

13-42

When connecting the drive shaft, clean the contact surfaces of the spider and the coupling.

DISASSEMBLY

AND ASSEMBLY

DAMPER

3. Hydraulic pumps. 1) Install hydraulic pump (30), and connect block (28) and tube (29). t Install the tube before installing the pump

2) Install switch pump (27), then install tubes (25) and (26).

3) Install steering and PPC pump (24) and connect hoses (22) and (23), then install tube (21).

4) Install torque converter charging pump (20), then install tubes (18) and (19). + When installing each pump, assemble securely so that the O-ring is not caught in the mating surface. 20 18’

74251013

13-43

DISASSEMBLY

AND ASSEMBLY

DAMPER

4. Bulkhead. 1) Set bulkhead (17) in mounting position, then tighten the mounting bolts. t The bulkhead passes close to the cab glass, so be careful when installing. t Connect the fuel control cable clamp to the bulkhead.

2) Tighten the mounting

bolts for bracket (16).

3) Install plate (15). I

4) Install covers (12), (13), and (14).

14251012

5) Connect dust indicator hose (11) to the air cleaner assembly. + If the machine is equipped with air conditioning, connect the clamp for the heater hose to the bulkhead, then connect the air conditioner hose and the condenser wiring harness. (See INSTALLATION OF AIR CONDENSER-AND DRY RECEIVER).

113AH064

I-r

\\\\

74251056

13-44

DISASSEMBLY

DAMPER

AND ASSEMBLY

5. Engine hood and side hoods. 1) Set engine hood (10) into the mounting position, then tighten mounting bolts 2) Set side hoods (9) into the mounting position, then tighten the mounting bolts. sr Install the stopper to the engine hood. + Install the left and right supports and bars of the side cover mount.

L13AH062

6. Side covers. 1) Install engine side covers (6), (7), and (8).

7. Refilling hydraulic oil. 1) Install plug (4), and tighten valve (5). 2) Tighten plugs (2) and (3) at the top of the hydraulic tank filter, then add hydraulic oil through the oil filler to the specified level. Plugs at the top of the hydraulic tank filter: 1.2 20.1 kg

1 I

Hydraulic

oil:

15OP

3) Install cover (1). * Run the engine to circulate the through the system, then recheck level again.

oil oil 14251011

13-45

DISASSEMBLY

AND ASSEMBLY

DISASSEMBLY

DAMPER

1. Cover assembly. 1) Remove elbows (1) and (2).

2) Remove

mounting bolts, then using forcing screws, remove cover (3). t Tighten the 2 forcing screws uniformly.

LlZAF005

3) Remove oil seal (4) and o-ring (5) from cover (3). 4) Turn over cover (6), then pull out shaft (7). Cover:

29 kg.

6) Remove snap rings (8), and bearing shaft (7).

(9) from LlZAF006

LlZAF008

13-46

LlZAF007

DISASSEMBLY

DAMPER

AND ASSEMBLY

6) Remove snap rings (10) and (1 l), and oil seal (12) from cover (6).

LlZAFOlO

2. Damper assembly. 1) Remove flange (13) using forcing screws. + Tighten the 2 forcing screws uniformly. + Do not remove spacer (14) unless neces=W.

74251159

LlZAF009

2) Remove inner body (15) and rubber (16). 3) Remove snap ring (17) and oil seal (18) from the inner body.

13-47

DISASSEMBLY AND ASSEMBLY

4) Remove flange (20) from outer body (19). + Screw in the mounting bolts, then tap with a hammer to remove.

13-48

DAMPER

DISASSEMBLY

AND ASSEMBLY

ASSEMBLY

DAMPER

1. Damper assembly. 1) Install flange (20) at bottom of outer body (19).

Contact surface of flange and outer body: Gasket sealant (LG-4).

2) Press fit oil seal (18) in the inner body (15), then assemble snap ring (17). * Fit the snap ring securely in the groove. t Set the oil seal with the sleeve on the snap ring side, and fit it close in contact with the snap ring. Inside surface portion (hatched portion) of inner body (15): Lithium base molybdenum disulphide extreme pressure grease.

/(r\7

Fill the grease.

circumference

uniformly

with 18

Lip of oil seal: Lithium base molybdenum disulphide extreme pressure grease.

Brand of Lithium base molybdenum disulphide extreme pressure grease. l Kyodo Oil Molylex No.2 or equivalent. l Showa Shell Sunlight TB-2 or equivalent. l Nippon Sekiyu Molytex No.2 or equivalent.

\I/

1 112AFOll

13-49

DISASSEMBLY

AND ASSEMBLY

DAMPER

3) Assemble inner body (15) in outer body (19), then assemble rubber (16).

Whole surface of rubber: (G2-LI)

Grease

Outer surface Grease (G2-LI)

inner

body:

inner surface Grease (G2-LI)

outer

body:

Between inner Grease (G2-LI)

body

and rubber:

Fill clearance “b” at four 2709 of grease.

places

4) Install flange (13) and tighten

/iT\7

evenly

mounting

with

bolts.

Contact surface of flange and outer body: Gasket sealant (LG-4).

1 Mounting

bolts:

6.8 +0.7 kgm

2. Cover assembly. 1) Fit snap ring (ll), then fit snap ring (10) after press fitting the oil seal (12) in cover (6). + Press fit the oil seal with the lip face on the bearing side.

13-50

DISASSEMBLY

AND ASSEMBLY

2) Assemble shaft (7).

snap

rings

DAMPER

(8) and bearing

(9) to

Bearing portion “c” (hatched portion): Lithium base molybdenum disulphide extreme pressure grease. * +

Do not leave any space when filling with grease. Brand of Lithium base molybdenum disulphide extreme pressure grease. l Kyodo Oil Molylex No.2 or equivalent. l Showa Shell Sunlight TB-2 or equivalent. l Nippon Sekiyu Molytex No.2 or equivalent.

6 \

3) Press fit shaft (7) into cover (6). 4) Press fit oil seal (4) into cover (3) then install oring (5).

/c-\7

+ t

Bearing portion “c” (hatched portion): Lithium base molybdenum disulphide extreme pressure grease. Do not leave any space when filling with grease. Brand of Lithium base molybdenum disulphide extreme pressure grease. l Kyodo Oil Molylex No.2 or equivalent. l Showa Shell Sunlight TB-2 or equivalent. l Nippon Sekiyu Molytex No.2 or equivalent.

LlZAF006

13-51

DISASSEMBLY

AND ASSEMBLY

DAMPER

5) Set cover (3) on mounting position, and tighten the mounting bolts.

6) Install elbows (1) and (2). fi

Elbow (1) and (2): Thread tightener (LT-2).

) Elbow (1): 0.4 20.1 kgm

Be careful of the direction

of elbow (2).

L12AF020

3. Greasing. 1) Assemble damper to the engine, and connect the grease hose, then fill the inside of the damper with grease (310g) from portion “e”. Damper portion “e” (hatched portion): Lithium base molybdenum disulphide extreme pressure grease.

Brand of Lithium base molybdenum disulphide extreme pressure grease. l Kyodo Oil Molylex No.2 or equivalent. l Showa Shell Sunlight TB-2 or equivalent. l Nippon Sekiyu Molytex No.2 or equivalent.

LlZAF021

13-52

DISASSEMBLY

AND ASSEMBLY

FUEL TANK

FUEL TANK ASSEMBLY REMOVAL

1. Draining the fuel tank. 1) Loosen the drain valve (1) and drain the fuel. Fuel: 435 P

2. Engine oil drain lines. 1) Disconnect the engine oil drain tube (2) at the fuel tank end. 2) Disconnect the engine block oil drain hose (2A) from the fuel tank.

3. Fuel line hoses. 1) Disconnect the following hoses from the fuel tank end. a) Hose (3) between the fuel tank and the fuel filter. b) Hose (4) Between the fuel pump and the fuel tank.

Ll2BH035

4. Electrical wiring. 1) Disconnect wiring (5) for fuel sensor from the connector. t Remove the clamp for the engine drain hose from the fuel tank.

T4251050

13-53

FUEL TANK

DISASSEMBLY AND ASSEMBLY

5. Fuel tank assembly.

1) Sling the fuel tank (7), remove mounting bolts, then lift off the fuel tank. t Lay a pallet below the fuel tank, keep the tank balanced and lower slowly. Fuel tank assembly: 295 kg

2) Remove breather tube (8), then pull the fuel tank from under the machine. + There is a limitation on height so be careful that the fuel tank does not interfere with the frame.

13-54

7--

c!a -

L12BD029

DISASSEMBLY

AND ASSEMBLY

FUEL TANK

4. Engine oil drain lines. 1) Connect the engine oil drain tube (2) at the fuel tank end. 2) Connect the engine block oil drain hose (2A) from the fuel tank.

T425lO49

5. Refilling with fuel. 1) Tighten the fuel tank drain valve (l), and add fuel through the fuel tank filler.

Fuel:

13-56

4358

ENGINE 14

MAINTENANCE

STANDARD

ENGINE MOUNT.................................................................

14-I

MAINTENANCE

STANDARD

ENGINE MOUNT

Q e

LlZAD066

Unit: mm Check item

No. 1

14-2

Clearance

between engine mounting

bracket and adjusting

bolt

Criteria

Remedy

3.0 - 7.0

Adjust

POWER TRAIN 21

STRUCTURE

AND FUNCTION

GENERAL ...................................................................... HYDRAULIC CIRCUIT FOR POWER TRAIN ............................................ HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN ....................................

3 5 6

DAMPER

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

TORQUE CONVERTER AND TRANSMISSION RADIATOR AND OIL COOLER

PIPING

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

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

TORQUE CONVERTER AND PTO ....................................................

TORQUE CONVERTER OIL FILTER ..................................................

TRANSMISSION ................................................................. TRANSMISSION foldout # 1 ......................................................

14 15

TRANSMISSION CONTROL VALVE ................................................... UPPERVALVE ................................................................ LOWERVALVE ................................................................

19 20 21

TRANSMISSION SOLENOID VALVE .................................................. TRANSMISSION SOLENOID VALVE ................................................ EMERGENCY MANUAL SPOOL ...................................................

22 23 24 25 27 28 31 33 34 35 36 37

FORWARDlst ................................................................ PRIORITYVALVE .............................................................. MODULATING VALVE AND QUICK RETURN VALVE

ACCUMULATORVALVE ..................... .................................... PILOTREDUCINGVALVE ........................................................ MAIN RELIEFVALVE ........................................................... REDUCINGVALVE ............................................................. TORQUECONVERTERRELlEFVALVE .............................................. LUBRICATION BY-PASSVALVE ................................................... TRANSMISSION PILOT OIL FILTER TRANSFER DRIVESHAFT

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

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

CENTER SUPPORT

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

38 39 40 41

21-1

AXLES ........................................................................ FRONT ..................................................................... REAR .......................................................................

42 42 43

DIFFERENTIAL ................................................................. FRONT ..................................................................... REAR ....................................................................... TORQUE PROPORTIONING DIFFERENTIAL ..........................................

44 44 45 47

FINALDRIVE

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

AXLE MOUNT

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

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

TIREANDWHEEL

21-2

STRUCTUREANDFUNCTION

GENERAL

421F003A

OUTLINE 0

The power from engine (1) is transmitted from the flywheel to damper (2) through the ring gear. The damper alleviates the torsional vibration caused by the variation of the engine torque and transmits the power to torque converter (4) through drive shaft (3). The torque converter converts the delivered torque according to the variation in load on the oil used as the medium, and transmits the power to the input shaft of transmission (10). Then, the engine power is transmitted to PPC pumps (7) and steering pump (6) hydraulic pump (5), switch pump (9) and torque converter charging pump (8) through the pump driving gear in torque converter (4), thereby driving the pumps.

The output shaft of transmission (10) transmits the power to the output shaft of transfer (11) through the gears. The power from the output shaft of the transfer is transmitted to both the front axle and the rear axle.

The power transmitted to front axle and rear axle is reduced through pinion and ring gears in differential (16) and (21), and is transmitted to the axle shafts.

The power from the axle shafts is reduced through final drive (17) and (22) and transmitted to tires (19) and (24) through the planetary carrier.

In transmission (lo), the six hydraulically-operated clutches are operated by the forward-reverse spool and the speed change spools in the transmission valves, which are themselves activated by solenoid valves. Thus, the desired travel speed can be selected from among the 4 forward and 4 reverse gear speeds.

21-3

STRUCTURE AND FUNCTION

GENERAL

425F006A

1. Engine

Switch

pump

17.

Front

final drive

Damper

10.

Transmission

18.

Front

brake

Upper drive shaft

11.

Transfer

19.

Front tire

Torque

Rear drive shaft

Hydraulic

7. 8.

converter

12.

Center

drive shaft

20.

13.

Center

support

21.

Rear differential

14.

Front

drive shaft

22.

Rear final

PPC pump

15.

Parking

brake

23.

Rear brake

Torque

converter

16.

Front differential

24.

Rear tire

charging

pump

6. Steering

21-4

(S6D140)

pump pump

drive

STRUCTURE AND FUNCTION

GENERAL

HYDRAULIC CIRCUIT FOR POWER TRAIN

21-5

STRUCTURE AND FUNCTION

GENERAL

HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN 27 ;19’--L’ - --; ,A- T T I--, I LJ I + I ‘& I

22.3kg/cm2

I P - 28

Min.

20kg/cm2

7 M

-1

F425M 1004

1. Transmission case 2. Strainer 3. Torque converter charging pump 4. Oil Filter 5. Priorlty valve 6. Modulating valve 7. Quick return valve 8. Pilot oil filter 9. Pilot reducing valve 10. Main relief valve 11. Torque converter reliefvalve 12. Torque converter

21-6

13. Oil cooler (water cooled) 14. Oil cooler (air cooled) 15. Transmission lubrication relief valve 16. Transmission lubrication 17. Lubrication by-pass valve 18. Reducing valve 19. Reverse spool 20. Forward spool 21. 4th spool 22. 3rd spool 23. 2nd spool 24. 1st spool

25. Emergency manual spool 26. Solenoid valve 27. Reverse clutch 28. Forward clutch 29. 4th clutch 30. 3rd clutch 31. 2nd clutch 32. 1st clutch 33. Accumulator valve

STRUCTURE

AND FUNCTION

DAMPER

L07EZOO3

1. Coupling 2. Output shaft 3. Cover 4. Bearing

5. 6. 7. 8.

Bearing Outer body Rubber cushion Inner body

FUNCTION l

The damper reduces the twisting and vibration caused by the variations in engine torque, and acts to protect the engine and other parts from such twisting and vibration.

21-7

STRUCTURE

DAMPER

AND FUNCTION

Engine torque

No load applied

Engine torque

Path of power transmission

applied

421FOlO

OPERATION

The engine power is transmitted to the flywheel and outer body (6) and rubber cushion (7) absorbs the twisting and vibration of the engine. The engine power is then transmitted through inner body (8) to output shaft (2). From here, the engine power is transmitted through the coupling to the torque converter drive shaft.

21-8

T.C. AND TRANS. PIPING

STRUCTURE AND FUNCTION

TORQUE CONVERTER

AND TRANSMISSION

PIPING

5 6

L07BMOlO

1. Transmission 2. Transmission control valve 3. Torque converter 4. Torque converter charging pump

5. 6.

Radiator Oil cooler (air cooled type) 7. Oil cooler (water cooled type) 8. Torque converter oil filter

21-9

STRUCTURE AND FUNCTION

RADIATOR AND OIL COOLER

A-A

(R-H) (L-H)

L06AMOl4

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

Radiator Coolant level sensor Fan guard Torque converter oil cooler (water cooled type) Hydraulic oil cooler (water cooled type) Torque converter oil cooler (air cooled type)

A. B. C. D. E. F. G. H.

Coolant inlet port Coolant outlet port Hydraulic oil outlet port Hydraulic oil inlet port Torque converter oil outlet port Torque converter oil inlet port Torque converter oil inlet port Torque converter oil outlet port

21-10

Specifications Radiator core type: G7 type

OUTLINE 0 The oil leaving the torque converter is at high temperature. this oil enters port F of the water cooled oil cooler and is cooled by the engine cooling water. It is then discharged from port E, and enters port G of the air cooled oil cooler. From port H, it lubricated the transmission and returns to the transmission case. 0 The oil returning from the steering cylinder enters port D of the water cooled oil cooler. It is cooled by the engine cooling water, and then returns from port C to the hydraulic tank.

STRUCTURE AND FUNCTION

TORQUE CONVERTER

TORQUE CONVERTER AND PTO

AND PTO

LO7AZO78

1. 2. 3. :: 7. 8. 9. 10. 11. 12. 13.

Mount of switch pump Mount of PPC and steering pump Mount of torque converter charging pump Torque converter outlet pressure pick-up PTO driven gear Drive case Turbine Housing Pump Stator Transmission input shaft PTO gear (drive)

A. B.

Inlet port Outlet port

Specification8 Model: TCA40-1 B Type: 3-element, single stage, signal phase

LO7AZO79

21-11

STRUCTURE AND FUNCTION

TORQUE CONVERTER

AND PTO

8 Flow of motive force

k=!

The torque converter is installed between the damper and transmission. The motive force from the damper passes through the drive shaft and enters drive case (7). Drive case (7), pump (10) and PTO gear (drive) (13) are fixed with bolts. They are rotated directly by the rotation of the engine. The motive force of pump (10) uses oil to rotate turbine (8). This transmits motive force to transmission input shaft (12). The motive force of drive case (7) passes through PTO gear (drive) (13) and is also used as the motive force to drive the gear pump.

425FO1108

Flow of oil l

The oil pressure is adjusted by the torque converter relief valve and then enters inlet port A, passes through the oil passage in housing (9) and flows to pump (10). In pump (10) centrifugal force is applied. The oil enters turbine (8) and the energy of the oil is transmitted to the turbine.

,lO

Turbine (8) is fixed to transmission input shaft (12) so the motive force is transmitted to the transmission input shaft (12).

-11

The oil from turbine (8) is sent to stator (11) and again enters the pump. However, part of the oil passes from the stator through outlet port B and is sent to the cooler.

-12

425FOl

21-12

109

STRUCTURE AND FUNCTION

TORQUE CONVERTER

OIL FILTER

TORQUE CONVERTER OIL FILTER

1. 2. 3. 4.

Relief valve Element Center bolt Drain plug

Filtration area: Relief pressure:

8,900 cm* 3.25 kg/cm*

Section A - A

425FO13 To transmission

control valve

OPERATION l

The oil from the torque converter charging pump (5) enters the filter inlet port A and passes from the outside of element (2) to the inside. It then flows to the outlet port B.

423FOlO

To transmission control valve

If the element (2) is clogged with dirt, or the oil temperature is low, the pressure at the inlet port A rises. When this happens, the oil from the inlet port A opens relief valve (1) and flows directly to the outlet port B. This prevents damage to the pump or element (2).

423FOll

21-13

STRUCTURE AND FUNCTION

TRANSMISSION

View Z

Section

C - C

Section

B -

Section

D -

425FOlllO

1. Oil filler

21-14

Transmission

Transfer

Transmission

Lubrication

Strainer

input shaft

output

coupling

control

valve

bypass valve

STRUCTUREANDFUNCTION

TRANSMISSION

foldout # 7

See foldout # 7 for transmission drawing.

21-15

STRUCTURE

TRANSMISSION

AND FUNCTION

OUTLINE l

The transmission consists of a 4-FORWARD, 4REVERSE speed planetary gear transmission, transfer, and transmission control valve. In the transmission, the motive force of the input shaft is changed by the combination of No. 1 or No. 2 clutch with No. 3,4, 5 and 6 clutch to give FORWARD 1 - 4 or REVERSE 1 - 4 speed, and is transmitted to the output shaft.

Speed range

Clutch combination

No.2. No.6

No.2. No.4

No.2. No.5

No.2. No.3

No.1. No.6

No.1, No.4

No.1, No.5

No.1, No.3

i OPERATION 0

OF CLUTCH

/”

Engaged The oil sent from the transmission

control valve passes through the oil passage inside the transmission. When it reaches the rear of piston (2), it moves the piston (2). When the piston (2) moves, disc (4) and plate (5) are pressed together. Ring gear (6) is meshed with disc (4), so the rotation is stopped.

423F018A

423F019A

Disengaged

When the supply of oil from the transmission control valve is shut off, the pressure of the oil acting on the rear of piston (2) is reduced. The piston is then pushed back to the right by return spring (3), and disc (4) and plate (5) are separated. Ring gear (6) then rotates freely, and no motive force is transmitted.

21-16

STRUCTURE AND FUNCTION

TRANSMISSION

FORWARD 1ST

425FO1112

In 1st FORWARD, No. 2 clutch (15) and No. 6 clutch (28) are engaged. The motive force transmitted from the torque converter by input shaft (2) is transmitted to output shaft (32). No. 2 clutch (15) is actuated by the hydraulic pressure applied to the clutch piston, and it locks ring gear (16) in position. No. 6 clutch (28) is actuated by the hydraulic pressure applied to the clutch piston and holds gear (29) in position.

The motive force from the torque converter is transmitted to the input shaft (2). The rotation of the input shaft (2) is transmitted to planetary gear (17) through sun gear (14). Ring gear (16) is held in position by No. 2 clutch so the rotation of planetary gear (17) rotates carrier (34), which is on the inside ring gear (16). This carrier (34) rotates carrier (35) through ring gear (21). Ring gear (29) is held by 1st clutch (28) so the rotation of sun gear (31) is transmitted to carrier (36) through planetary gear (30) and rotate output shaft (32).

21-17

STRUCTURE

AND FUNCTION

TRANSMISSION

REVERSElST

425FO1113

In 1st REVERSE, No. 1 clutch (11) and No. 6 clutch (28) are engaged. The motive force transmitted from the torque converter by input shaft (2) is transmitted to output shaft (32). No. 1 clutch is actuated by the hydraulic pressure applied to the clutch piston, and it locks ring gear (12) in position. No. 6 (28) clutch is actuated by the hydraulic pressure applied to the clutch piston and hold ring gear (29) in position.

21-18

The motive force from the torque converter is transmitted to the’input shaft (2). The rotation of the input shaft is transmitted to planetary gear (10) through sun gear (9). Ring gear (12) is held in position by No. 1 clutch (11) so the rotation of planetary gear (10) rotates the carrier (33). Carrier (33) rotates in the opposite direction from the input shaft (2).

STRUCTURE AND FUNCTION

TRANSMISSION CONTROL VALVE

1. Lower valve 2. Upper valve 3. Main relief valve 4. Transmission solenoid valve 5. Emergency manual spool 6. Connector a. Pilot reducing pick-up b. Torque converter relief pressure pick-up c. Transmission lubricating pressure pick-up d. Priority pressure pick-up e. Main relief pressure pick-up f. Modulating pressure pick-up g. Accumulator pressure pick-up h. Reducing pick-up

6 View 2

425FO1114

21-19

STRUCTURE AND FUNCTION

TRANSMISSION CONTROL VALVE

UPPER VALVE

1. Reducing valve 2. Quick return valve 3. Modulating valve 4. Priority valve 5. Housing 6. Torque converter relief valve 7. Piston 8. Main relief valve 9. 1st spool 10. 2nd spool 11. Accumulator (for 2nd) 12. Pilot filter 13. Forward spool 14. Pilot reducing valve 15. Lubrication relief valve 16. Reverse spool 17. 4th spool 18. 3rd spool

Section

C - C 425F027A

21-20

TRANSMISSION CONTROL VALVE

STRUCTURE AND FUNCTION

LOWER VALVE 425FOll 15

Section

OUTLINE l The oil from the torque converter charging pump enters port A, and passes through the priority valve (4) via main relief valve (8). It is then divided into three lines: one to the clutch pistons, one to the pilot reducing valve (14), and the other to the main relief valve. The priority valve (4) acts to control the three lines so that the pilot reducing valve (14) is the priority circuit. The oil flowing to the pilot reducing valve (14) conl trols the pilot pressure used to actuate the directional and speed spools. The oil regulated by the pilot reducing valve (14) presses through the orifice in each spool and fills the spool.

B-

425FO1115

The other oil line flows to the modulating valve (3) and quick return valve (2). The action of the modulating valve (3) and quick return valve (2) raises the clutch pressure smoothly. This reduces the shock when actuating the FORWARD, REVERSEand 1st, 2nd, 3rd, and 4th speed clutches to change gear. The accumulator valve (11) controls the oil flow at the 2nd clutch and reduces the filling time when shifting from 2nd to 1st or 3rd gear. The lubrication relief valve (15) controls the lubrication oil inside the transmission.

21-21

STRUCTURE

AND FUNCTION

TRANSMISSION

SOLENOID

VALVE

SOLENOID VALVE

Reverse Forward

3rd 2nd

A’ 1. Connector 2. 1st solenoid valve 3. 2nd solenoid valve 4. 3rd solenoid valve 5. 4th solenoid valve

Section

6. 7. 8. 9.

Forward solenoid valve Reverse solenoid valve Body Emergency manual spool

STRUCTURE l

The transmission solenoid valve is installed to the transmission together with the transmission valve. When the directional lever or speed control lever are operated, the solenoid valve is actuated and moves the spool inside the transmission valve.

21-22

A - A

425FO1116

Actuation and clutch

table for solenoid

valve

STRUCTURE

AND FUNCTION

TRANSMISSION

SOLENOID

TRANSMISSION

SOLENOID

VALVE

Function

There is one solenoid valve installed for each directional and speed spool in the transmission valve. When the directional lever and speed control levers in the operator’s compartment are operated, the solenoid valve is actuated, and oil is drained to actuate the directional and speed spools.

Operation

1) Solenoid valve OFF

From quick return valve

The oil of spool (1) enters port A. However, valve (2) shuts off the oil, so directional and speed spool (1) does not move.

From pilot reducing valve

+ ‘.S,! klz

\ 2

423FO31

Solenoid valve ON When the directional and gear shift lever are operated, the solenoid valve is pulled up. The oil from directional and speed spool (1) ent port A and flows from port B to the drain circuit. Therefore, port A becomes the low pressure circuit, and directional and speed spool (1) is actuated.

423FO32

21-23

TRANSMISSION SOLENOID VALVE

STRUCTUREANDFUNCTION

EMERGENCY

MANUAL SPOOL

Function l

If there is any failure in the electrical circuit of the transmission control system, and the solenoid valve does not work, the emergency manual spool is used. This spool is attached to each directional and speed spool and is used to operate the transmission valve mechanically. (It is used to drive the machine to a place where it can be repaired.) t

Particular attention must be paid when using this spool.

Operation 1. When solenoid valve is normal: (Emergency manual spool is at normal position) When the solenoid valve is working normally, the spool is maintained in this position. Oil from directional and speed spool (1) enters port A, but it is shut off by solenoid valve (2).

From pil reducing valve 423FO44

When solenoid valve is abnormal: a. Clutch in disengaged position (Emergency manual spool is pushed to the left) Emergency manual spool (3) is pushed to left, and the oil at port A is shut off regardless of the action of solenoid valve (2). The oil cannot flow to port B, so the clutch is not actuated.

From pil reducing valve 423fO45

From

b. Clutch in engaged position (Emergency manual spool is pulled to the right) When emergency manual spool (3) is pulled to the right , the oil at port A is drained to port B regardless of the operation of solenoid valve (2). As a result, the clutch is actuated.

21-24

From reducing

valve

quick

STRUCTURE

AND FUNCTION

FORWARD

1st

TRANSMISSION

Forward

SOLENOID

VALVE

1 St

1. Solenoid valve 2. Solenoid valve 3. Oil filter 4. Prioriiy valve 5. 1st spool 6. FORWARD spool 7. Spring 8. Spring 9. Piston

10. Quick return valve 11. Pilot reducing valve 12. Piston 13. Main relief valve F425M1005

21-25

STRUCTURE AND FUNCTION

TRANSMISSION SOLENOID VALVE

Operation When the directional and speed control levers are moved to FORWARD lst, solenoid valves (1) and (2) are opened. The oil from the pump is divided into 3 lines, but when the gears are being changed, the oil flows mainly to each clutch. In one of the three lines, the oil passes from main relief valve (13) through the torque converter. It then lubricates the transmission and returns to the transmission case. One of the two oil lines flows from the pilot reducing valve through the orifice of each speed spool to the solenoid valve. However, solenoid valves (1) and (2) of FORWARD spool (6) and 1st spool (5) are open, so the oil passing through the orifice flows to the drain circuit. As a result, a difference in pressure is created between port A and port B, and this overcomes the force of springs (7) and (8). The port to the clutch is then connected.

21-26

The other oil line flows from priority valve (4) to quick return valve (10). It then flows through orifice “a”, and directional and speeds spools (5) and (6), and flows to the FORWARD clutch and 1st clutch. When it starts to flow to the clutch, it passes through oriiice “a” and creates a difference in pressure port C and port D. Quick return valve (10) moves to the right, and the oil at the rear of modulating valve piston (9) flows to drain circuit E. When each clutch is filled with oil, the difference in pressure between port C and port D disappears. The valve is pushed back to the left by the difference in area of the valves, and drain circuit E is closed. At this point each clutch is filled with oil, but the oil has not reached the specified pressure. The oil at port D flows through orifice “b” and reaches the back of modulating piston (9). The piston (12) moves to the right and the clutch pressure rises slowly. When the modulating piston reaches the end of its stroke, the clutch pressure reaches the specified level, and the clutch is completely engaged.

STRUCTURE AND FUNCTION

TRANSMISSION SOLENOID VALVE

PRIORITY VALVE Function 0

The priority valve (1) controls the minimum pressure of the pilot reducing valve (2). In addition, the priority valve (1) gives the oil flow to the pilot reducing valve (2) priority over the other circuit.

Operation l

The Oil from the pump flows to port A Of priority To modulating valve (1) and port B of pilot reducing valve (2). iIt

valve

To each transmission fi

spool 1

To main relief valve

425FO35

The oil entering port A flows from orifice “a” of priorii valve (1) to port D. The hydraulic pressure and force of poppet spring (3) push back spring (4) and move priority valve (1) to the right. When this happens, port A and port C are connected, and the -8-0mG&&%ing Valve oil flows from port C to the clutch spool.

-FQ&&I wxw&Sssion

21-27

STRUCTURE AND FUNCTION

MODULATING

TRANSMISSION SOLENOID VALVE

VALVE AND QUICK RETURN VALVE (Wari)

Function

40-

C Shifting

gear

The modulating valve and quick return valve act together to raise the transmission clutch pressure slowly. In this way, they reduce the shock when shifting gears, and prevent the generation of peak torque in the power train. As a result, operator fatigue is reduced, and at the same time, operator comfort and the durability of the power train are increased. 0

Time

Kiec) 425F175

1) Immediately after shifting gear (Point A on Fig. 425F175)

To solenoid valve

Operation l

The oil sent from the pump flows from priority valve (1) through port A, passes through modulating valve (2) and enters port B of quick return valve (3). The oil passes through orifice “a” of quick return valve (3) and flows to the clutch piston, which has been actuated. However when it passes through orifice “a” it creates a difference in pressure between port

21-28

425F037

B and port C. The quick return valve moves to the right and the oil flows to clutch (5). In addition, when quick return valve (3) moves to the right, drain port D is opened, and the pressurized oil at the rear of piston (4) flows to the drain circuit.

STRUCTURE

AND FUNCTION

TRANSMISSION

SOLENOID

VALVE

Clutch pressure rising (Point B on Fig. 425F175)

To solenoid valve

valve

425FQ38

Operation l

As the pressure at the clutch piston rises, the pressure at port C also rises. Quick return valve (3) is pushed back to the left and drain port D is closed. The oil from the pump flows from port C to the clutch piston, and at the same time it flows from orifice “b” through quick return valve (3) and enters port E.

At the same time, pressurized oil also passes through the orifice and enters poppet (7) of modulating valve (2). It moves modulating valve (2) to the left and some of the oil at port A flows to port G.

The oil at port E acts on the modulating piston (4). It pushes back spring (6) and moves piston (4) to the right.

21-29

STRUCTURE AND FUNCTION

TRANSMISSION SOLENOID VALVE

Completion of rise in clutch pressure (Point C on Fig 425F175)

To solenoid valve

425FO39

Operation l

The oil entering port E continues to push piston (4). When the piston reaches the end of its stroke, the rise in pressure stops. When this happens, the pressure reaches the set pressure of the modulating valve. In addition, port F and port G are closed by piston (4).

21-30

STRUCTURE

AND FUNCTION

ACCUMULATOR

TRANSMISSION

SOLENOID

VALVE

Function l

The accumulator valve acts to reduce the filling time when shifting gears by allowing the oil at the 2nd clutch piston to escape slowly when shifting from 2nd to 1st. This allows the clutch to be engaged smoothly when shifting from 2nd to 1st.

Shifting to 2nd l

When shifting to 2nd gear, the oil from the pump passes through the reducing valve and enters port A of the 2nd spool (5). When the 2nd spool moves, port A and port B are con-

nected and the oil flows to port C. The oil at port C flows from check valve (2) and orifice “a” to port D.

425FO1119

21-31

STRUCTURE

AND FUNCTION

TRANSMISSION

reducing

valve

2nd clutch

reducing

21-32

valve

Shifting from 2nd 0

VALVE

As the pressure of the oil entering port D rises, the oil continues to push piston (3) to the left until it stops. At the same time, oil is sent to the clutch piston and actuates 2nd clutch (4). From

SOLENOID

The oil from the clutch piston of 2nd clutch (4) enters port D and acts on the rear of the check valve (2). The oil from port D passes through orifice “a” and flows to the drain circuit. In this way the shock when shifting gears can be reduced.

425FO1120

STRUCTURE

AND FUNCTION

PILOT REDUCING

TRANSMISSION

SOLENOID

VALVE

Function l

The pilot reducing valve acts to control the pressure needed to actuate the transmission spools.

Operation 0

The oil from the pump passes through the pilot filter and enters port A of pilot reducing valve (1). The oil passes through port B and enters through the orifice of transmission spool (2) to fill the inside of port c.

relief valve

425 F033

When the pressure inside port C rises, pressurized oil flows from orifice ‘a” of pilot reducing valve (1) and goes to port D. As a result, pilot reducing valve (1) moves to the right, and ports A and B are shut off, so the pressurized oil at port C is maintained at the same pressure.

BE&TO main relief valve

425FO34

21-33

STRUCTURE

AND FUNCTION

TRANSMISSION

MAIN RELIEF VALVE

Quick return spool speedspool

The main relief valve acts to supply the necessary oil to the clutch when shifting gears. When the gears are not being shifted, it sends all of the oil directly to the torque converter.

Pilot reducing

Solenoid valve

SPOOI

Speed spool

I Torque converter Oil cooler

Relief valve

III

VALVE

Clutch

. Priority spool

Function l

SOLENOID

’

II) 425FO30

Operation l

The oil from the pump passes through the oil filter and enters port A of main relief valve (1).

Until the specified pressure is reached, the oil flows to the priority valve.

425FO31

When the pressure goes above the specified level, oil passes through the orifice in relief valve (l), pushes poppet (2), and moves relief valve (1) to the left. The oil is relieved to the torque converter, so the specified pressure is maintained. +

Specified pressure: 27 kg/cm2

Oi; filter

t!B 425FO32

21-34

STRUCTUREANDFUNCTION

REDUCING

TRANSMISSION

SOLENOID

VALVE

Function l

The reducing valve is in the circuit between the quick return valve and the 2nd spool. It reduces the pressure applied to the 2nd clutch, and in this way acts to protect the 2nd clutch. The maximum pressure in the main circuit is kept to the specified level by the main relief pressure.

Operation l

The oil from the quick return valve enters port A and then flows from port B to 2nd spool (2). return valve

From pilot reducing valve

425FO1117

When the circuit to the 2nd clutch is filled with oil and the hydraulic pressure rises, the oil from port B which flows through orifice “a” to port C pushes poppet (3). The reaction to this compresses spring (4) and moves reducing spool (1) to the left. As a result, port A and port B are closed, and the oil stops flowing.

The hydraulic pressure at this point is 20 kg/cm”.

\ a -...

c(“‘._,,

return valve

From pilot reducing valve 425FO1118

21-35

STRUCTURE

AND FUNCTION

TORQUE CONVERTER

TRANSMISSION

SOLENOID

VALVE

RELIEF VALVE

Function l

The torque converter relief valve acts to maintain the pressure of the oil entering the torque converter at a constant pressure. It drains the oil if it goes above the specified pressure

To each transmission

spool

Operation l

The oil from the pump passes through main relief valve (1). It then enters port A and flows to the torque converter. oil filter

To transmission lubrication

425FO42

To each transmission

spool

If the oil at port A goes above the specified pressure, it passes through orifice “a” of torque converter relief valve (2) and enters port B. It then moves torque converter relief valve (2) to the left. As a result, the oil from port A is drained, and the oil flowing to the torque converter is maintained at the specified pressure.

oil filter

TO transmission lubrication

425FO43

21-36

STRUCTURE AND FUNCTION

LUBRICATION

TRANSMISSION SOLENOID VALVE

BY-PASS VALVE

Function l

When traveling in 4th gear, the transmission gears are rotating at high speed. Because of this, the churning resistance of the transmission lubrication oil increases. To reduce this power loss, only enough oil to lubricate the gears at 4th speed is kept. All the rest of the oil is by-passed to the transmission case. From quick return valve .$j.

OPberation (4th clutch not being operated) a

When the 4th clutch is not being operated, there is no hydraulic pressure at port “a” of spool (1). As a result, spool (1) is pushed to the left by the spring. The oil from the torque converter is stopped by spool (l), so all the oil is used for lubricating the transmission. From pilot reducing valve

425F 176

From quick return valve 2 -9

Operation (4th clutch being operated) l

Torque

When oil flows to the 4th clutch, pressure oil flows from 4th spool (2) to port “a” of spool (1). When pressure oil enters port “a”, it pushes back the spring and moves spool (1) to the right. The oil from the torque converter flows to the transmission lubrication system and drain port “b”.

425F177

21-37

TRANSMISSION PILOT OIL FILTER

STRUCTURE AND FUNCTION

TRANSMISSION PILOT OIL FILTER

OUT

Section

A - A

2----3-------

1. Oil filter head 2. Element 3. Case Specification: Filtration area: 370 cm*

21-38

TRANSFER

STRUCTUREANDFUNCTION

TRANSFER

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

Outline l

Transmission output shaft Transfer input gear (teeth 40) Transfer idler gear (teeth 57) Output gear (teeth 55) Output shaft Rear coupling Front coupling

425FO1123

The transfer is installed at the power output end of the transmission and is secured to the transmission case by bolts.

Transmission path l

Output shaft (1) of the transmission is coupled to transfer input gear (2) by a spline. The motive force is transmitted to output gear (4) through idler gear (3) and output shaft (5). Part of the power transmitted to the output shaft is transmitted to the front axle through the center drive shaft and front drive shaft. The rest of the power is transmitted to the rear axle through the rear drive shaft. 425FO1124

21-39

STRUCTURE AND FUNCTION

DRIVE SHAFT

DRIVE SHAFT Outline l

The motive force from the engine passes through the damper, upper drive shaft (5), torque converter, transmission and transfer. Part of this motive force passes through rear drive shaft (4) and goes to the rear axle: the rest of the motive force passes through center drive shaft (3). center support (2) and front drive shaft (1) and is sent to the front axle. In addition to transmitting the motive force, the drive shafts have the following purposes.

When the body is articulated, or when there is shock from the road surface during traveling, or when there is shock during operations, the axle in front and behind the engine and transmission change position. To allow the motive force to be transmitted without damage to parts of the machine when there is shock or when the components move position, the drive shafts have a universal joint and a sliding joint. This allows them to handle changes in angle and length.

425FO50

1. 2. 3. 4. 5.

21-40

Front drive shaft Center support Center drive shaft Rear drive shaft Upper drive shaft

STRUCTURE AND FUNCTION

CENTERSUPPORT

CENTER SUPPORT

425FO51

Function

1. Front coupling 2. Case 3. Grease fiiing 4. Rear coupling

The center support is installed to the front frame between the center driie shaft and the front drive shaft.

With the articulating frame, this part is constantly twisting from side to side, so there is liable to be a large amount of stress on the drive shafts. Therefore, the center support is used to transmit the power smoothly, to reduce the stress on the drive shafts, and improve the durability of the drive shafts.

21-41

AXLES

STRUCTURE AND FUNCTION

AXLES Outline l

The motive force from the engine passes through

Inside the axles, the motive force passes from the bevel pinion to the bevel gear and is sent at angles. At the same time, the speed is reduced and passes through the front differential (1) to the axle shaft. The motive force of the axle shaft is further reduced by a planetary gear type final drive (5) and is sent to the wheels

the damper, torque converter, transmission, transfer, and the drive shafts, and then sent to the front and rear axles

FRONT

1. Front differential 2. Filler 3. Front axle 4. Level plug 5. Final drive 6. Front brake 7. Parking brake 8. Drain plug

21-42

8 View Z

425FO1125

STRUCTURE AND FUNCTION

AXLES

REAR

1. Level plug

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

Filler Rear axle Rear differential Final drive Rear brake Drain plug 425FO1126

21-43

STRUCTUREANDFUNCTION

DIFFERENTIAL

DIFFERENTIAL FRONT

1. Side gear (18 Teeth) 2. Bevel gear (37 Teeth) 3. Shaft 4. Pinion (10 Teeth) 5. Bevel pinion (9 Teeth)

21-44

\ Section

A - A

425FO1127

STRUCTUREANDFUNCTION

DIFFERENTIAL

REAR

i l-0 I

Section

1. Bevel gear (37 Teeth) 2. Bevel pinion (9 Teeth) 3. shaft 4. Pinion (10 Teeth) 5. Side gear (18 Teeth)

A -

425FOll28

21-45

STRUCTURE

AND FUNCTION

DIFFERENTIAL

OUTLINE l

The motive force from the drive shaft passes through bevel pinion (1) and is transmitted to the bevel gear (5). The bevel gear changes the direction of the motive force by 90”, and at the same time reduces the speed. It then transmits the motive force through the differential (4) to the sun gear shaft (2).

423F059A

When driving straight forward l

When the machine is driven straight forward, the rotating speed of the left and right wheels is the same, so the pinion gear (4) inside the differential assembly (6) is sent through the pinion gear (4) and the side gear (3) and is transmitted equally to the left and right sun gear shafts (2).

423F060A

When turning l

When turning, the rotating speed of the left and right wheels is different, so the pinion gear (4) and side gear (3) inside the differential assembly rotate in accordance with difference between the rotating speed of the left and right wheels. The motive force of the carrier (6) is then transmitted to the sun gear shafts (2).

423F061A

21-46

DIFFERENTIAL

STRUCTURE AND FUNCTION 0 TORQUE PROPORTIONING DIFFERENTIAL FUNCTION 0

Because of the nature of their work, 4-wheeldrive loaders have to work in places where the road surface is bad. In such places, if the tires slip, the ability to work as a loader is reduced, and also the life of the tire is reduced. The torque proportioning differential is installed to overcome this problem.

In structure it resembles the differential of an automobile, but the differential pinion gear (4) has an odd number of teeth. Because of the difference in the resistance from the road surface, the position of meshing of the pinion gear (4) and side gear (3A), (38) changes, and this changes the traction of the left and right tires.

Therefore when the ratio of the distances to “a” and “b” is less than 1 : 1.38 (that is, the difference between the resistance from the road surface to the left and right tires is less than 38%), the pinion gear will not rotate freely, so drive force will be given to both side gears, and the tires will not slip. Because of this effect, the tire life can be increased by 20 - 30%, and at the same time the operating efficiency is also increased.

3 3B

OPERATION

423FO63

When traveling straight (equal resistance from road surface to left and right tires) l

If the resistance from the road surfaces to the left and right wheels is the same, the distance between the pinion gear and the meshing point “a” of the left side gear is the same as the distance between the pinion gear and meshing point “b” of right side gear (38).

Therefore the left side traction TL and the right side traction TR are balanced.

Direction

of spider

rotation

When traveling on soft ground (resistance from road surface to left and right tires is different) On soft ground, if the tire on one side slips, the side gear of the tire on the side which has least resis-

423FO64

tance from the road surface tires to rotate forward. Because of this rotation, the meshing of the pinion gear and side gear changes. If left side gear (3A) rotates slightly forward, the distance between the pinion gear and the meshing point “a” of the left side gear becomes longer than the distance between the pinion gear and the meshing port “b” of the right side gear. The position is balanced as follows: axTL

Direction

spider

rotation

= bxTR

The ratio between the distances to “a” and “b” can change to 1 : 1.38.

423FO65

21-47

FINAL DRIVE

STRUCTURE AND FUNCTION

FINAL DRIVE

425FOl129

1. Axle shaft 2. Planetary gear (29 Teeth) 3. Ring gear (78 Teeth) 4. Planetary carrier 5. Sun Gear (18 Teeth) 6. Wheel

21-48

Outline l

To gain a large drive force, the final drive uses a planetary gear system to reduce speed and send drive force to the tires.

FINAL DRIVE

STRUCTURE AND FUNCTION

Operation l

The motive force transmitted from the differential through axle shall (1) to sun gear (5) is transmitted to planetary gear (2). The planetary gear rotates around the inside of a fixed ring gear (3) and in this way transmits rotation at a reduced speed to the planetary carrier (4). This motive force is then sent to the wheels (6) which are installed to the planetary carriers (4). r

425FO1130

21-49

STRUCTUREANDFUNCTION

AXLE MOUNT

Section A - A

21-50

Section B -

B 425FOll31

STRUCTURE

AXLE MOUNT

AND FUNCTION

View

View Z

425FOll32

1. Front axle 2. Rear axle 3. Front frame 4. Rear frame 5. Axle mounting bolts

Front axle l

The front axle (1) receives the force directly during operations, so it is fixed directly to the front frame (3) by axle mounting bolts (5).

Rear axle l

The rear axle (2) 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.

21-51

STRUCTURE

AND FUNCTION

TIRE AND WHEEL

TIRE AND WHEEL l

The tire acts 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 Various types of tires are available to suit the purpose. Therefore it is very important to select the correct tires for the type of work and bucket capacity-

Specifications 0

Tire type: 26.5 x 25, 20PR

TRA code: L3

Nominal size of wheel: 22.00 x 25VVTB

Nominal inflation pressure: 3.5 kg/cm*

425FO60 1. Tire 2. Rim 3. Air valve 4. Lock ring 5. Side ring

21-52

POWER TRAIN 22

TESTING

STANDARDVALUETABLE

AND ADJUSTING

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

TOOL LIST FOR TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION . . . . . . . . . . . . . . . . . . .

MEASURINGSHIFTLEVER

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

METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TIREANDWHEEL

. . . . . . . . . . . . . . . . .._............................................

TROUBLESHOOTING ............................................................. PRECAUTIONS WHEN TROUBLESHOOTING METHOD OF READING TROUBLESHOOTING TABLES’ : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : PREVENTING RECURRENCE OF TROUBLE .......................................... JUDGEMENT ON POWER TRAIN .................................................. TROUBLESHOOTINGTABLE ..................................................... Machinedoesnotmove ........................................................ Machine lacks power or speed. .................................................. Excessive time lag when starting machine or shifting gear. .............................. Torque converter oil temperature too high. ..........................................

12 14 16 17 19 19 21 22 23

+ The following precautions are necessary when using the Standard Value Tables to make judgements during troubleshooting or during testing and adjusting. 1.

The values in these tables are based on the values for new machines leaving the plant, so they should be used as target values when repairing or when estimating wear after a period of use.

The standard values in these tables for judgement when troubleshooting are estimated values based on the standard values for the machine when shipped from the plant, and on the results of various tests. Therefore, they should be used as reference in combination with repair and operating records when making judgements.

These standard value tables must not be used for stand values when judging claims. In addition, do not use these values alone to make simple judgements.

22-1

TESTING

AND ADJUSTING

STANDARD

VALUE TABLE

STANDARD VALUE TABLE Testing and measuring item

Measurement condition

Shift lever operating force and stroke

Torque converter oil temperature: 60-80” C

Directional lever operating force N-F N-R Speed lever operating force 1st -2nd 2nd - 3rd 3rd - 4th Directional lever travel N-F N-R Speed lever 1st - 2nd -3rd -4th

Engine speed: Low idling

Engine stall speed 0 Low idling 0 High idling 0 Torque converter stall 0 Hydraulic stall 0 Full stall

Oil pressure of torque converter and transmission. l Torque converter outlet pressure 0 Pilot reducing pressure 0 Modulating pressure (except F2, R2) 0 Lubrication pressure 0 Reducing pressure (for F2, R2) 0 Torque converter inlet pressure Tire and wheel 0 Fitting of wheel lock

Coolant temperature: inside operating range Torque converter temperature: 60-80” C Hydraulic temperature: 45-55” C

Unit

Standard value

Permissible value

0.3 - 0.9 0.3 - 0.9

Max. 1.4 Max. 1.4

0.3 - 0.9 0.3 - 0.9 0.3 - 0.9

Max. 1.4 Max. 1.4 Max. 1.4

32 - 42 32 - 42

27 - 47 27 - 47

32 - 42

27 - 47

rpm

690 - 800 2150 - 2350 2085 - 2185 2100 - 2200 1465 - 1665

690 - 800 2150 - 2400 1935 - 2335 1950 - 2350 1265 - 1865

3-5 9.8 - 11.8

27 - 30 2-4

19 - 22

19-22

9.5 - 10.5

Torque converter oil temperature: 60-80” C

kg/cm2

Tire inflation pressure l

Specified

pressure

ring

Max. 2.5 Max. 4.0

(4 l

Clearance of whg\ lock ring (C)

mm 2 - 10 O-ring

423F309A

22-2

TOOL LIST FOR TESTING AND ADJUSTING

TESTING AND ADJUSTING

TOOL LIST FOR TESTING AND ADJUSTING No.

Testing & measuring item

Engine speed

Tachometer

799-203-8000

Digital display 60-19999 rpm

Oil temperature

Thermistor kit

799-l 01-6000

o-1000” c

Oil pressure

Hydraulic tester

799-l 01-5000

O-25 kg/cm2 O-50 kg/cm2

Push-pull gauge

79A-262-0020

O-25 kg

Feeler gauge

Commercially available

0.1-3.0 mm

Tool name

Remark

Part number

When carrying out testing, adjusting or troubleshooting, stop the machine on level ground, install the safety bar on the frame, lower the bucket to the ground, and stop the engine. Then apply the parking brake and block the tires.

Do not allow unauthorized persons near the machine.

When measuring the engine speed, one worker should measure the engine speed while the other sits in the operator’s seat to operate the controls. Always check that the operation is safe, and use agreed signals.

Be careful not to get caught in rotating parts.

22-3

TESTING AND ADJUSTING

+ l l l

TORQUE CONVERTER

AND TRANSMISSION

Measurement conditions Coolant temperature: Inside operating range. Torque converter oil temperature: 50 - 80°C Engine speed: High idling

Apply the parking brake and block the tires.

Special tool Part number

QtY

Part name

A 1 799-101-5000 1 Hvdraulic tester

Measuring procedure * The following preparatory work is necessary before measuring any oil pressure. l Remove plate (2) at the rear of the cab. l Turn the transmission cut-off selector switch (1) to OFF and use the left brake. (Check that the pilot lamp is OFF). l Remove the plug from the measuring port of the transmission valve. l Install hydraulic tester A to the measuring port, pull the gauge to the operator’s compartment, then start the engine and measure the pressure. LO722138

Check that there is no leakage of oil from any joints.

22-4

TESTING AND ADJUSTING

TORQUE CONVERTER AND TRANSMISSION

1. Measuring pilot reducing pressure 1) Measuring port (P5). 2) Put the directional lever in neutral, and measure the pressure when the speed control lever is operated (9.8 - 11.8 kg/cm2). 2.

Measuring modulating pressure 1) Measuring port (Pl). 2) Put the directional lever in neutral, and measure the pressure when the speed control lever is operated (27 - 30 kg/cm2).

Torque converter inlet port oil pressure 1) Measuring port (P8). 2) Start the engine and measure the pressure at high idling (9.5 - 10.5 kg/cm2).

Measuring lubrication valve pressure 1) Measuring port (P9). 2) Start the engine and measure the pressure at high idling (2 - 4 kg/cm2).

Measuring reducing valve pressure 1) Measuring port (P3). 2) Start the engine and measure the pressure at high idling and low idling (19 - 22 kg/cm2).

Measuring torque converter outlet port pressure 1) Measuring port (3) (PT l/8). 2) Measure the pressure with engine at high idling (3 - 5 kg/cm2).

,P3

425F203

22-5

TESTING AND ADJUSTING

MEASURING SHIFT LEVER

MEASURING SHIFT LWER Measuring conditions l Engine speed: Stop Unit: kg Item F-R lever Operating force

Speed lever

F-R lever

Travel

Standard value

Permissible value

Neutral-Forward

0.3 - 0.9

Max 1.4

Neutral-Reverse

0.3 - 0.9

Max 1.4

1St-end

0.3 - 0.9

Max 1.4

2nd3rd

0.3 - 0.9

Max 1.4

3rd-4th

0.3 - 0.9

Max 1.4

32 - 42 mm

27 - 47 mm

Neutral-Forward

Speed lever

In each range from 1st thru 4th speeds

Special tools

Part number

Part name

Qt y

79A-262-0020

Push-pull scale

Be sure to set chocks firmly against the tires.

1. Measuring the lever operating effort 1) Stop the engine. t Put marks “a” for dimensions A and B of the control levers. l Dimension A (directional lever, N position): 72.5mm. l Dimension B (speed lever, 2 position): 91 mm. 2)

22-6

32 - 42 mm

1 Neutral-Reverse I

Install push-pull scale A or a balance spring to the marked portion “a” of control lever (l), and measure the operating force when the lever is pulled in the direction of operation. + The measurement should be made in each speed range.

32 - 42 mm

27 - 47 mm 27 - 47 mm

TESTING AND ADJUSTING

Measuring

MEASURING

SHIFT LEVER

the lever travel

1) Stop the engine. 2) Measure the travel when marked portion “a” of control lever (1) is moved in the direction of operation.

22-7

EMERGENCY

TESTING AND ADJUSTING

MANUAL SPOOL

MEI-HOD FOR OPERATION OF EMERGENCY MANUAL SPOOL OUTLINE l

The transmission valve is controlled electrically. Therefore, the emergency manual spool (2) is installed to enable the machine to be moved if there is any failure in the electrical system, or in the solenoid valve and spool.

The emergency manual spool is for use when failure in the transmission control prevents the machine from being moved. It allows the machine to be moved from a dangerous place, to a place where repairs can be carried out safely. The emergency manual spool must never be used except when the transmission control has broken down. When operating the emergency manual spool, follow the correct order of operation exactly, and pay full attention to safety when moving the machine.

To prevent the machine from moving, lower the bucket to the ground, apply the parking brake, and block the wheels. Check that the pressure inside the air tank is above the specified pressure.

1. Remove cover (1) at the rear of the cab.

A 2.

Always stop the engine before operating the spool. Remove lock plate (3) of the emergency manual spool of the transmission valve. *

22-8

Simply loosen the mounting bolts to remove the lock plate.

Reverse

Forward

4th

SW01

rpool

wool

so001 42!5F204

TESTING AND ADJUSTING

EMERGENCY MANUAL SPOOL

Decide the direction to move the machine (forward or in reverse), then move the emergency manual spool to the operating position. FORWARD:

Rotate FORWARD clutch spool and 1st spool counterclockwise, and pull out approx. 10 mm to the ON position.

REVERSE:

Rotate REVERSE clutch spool and 1st spool counterclockwise, and pull out approx. 10 mm to the ON position.

Check that the area around the machine is safe, then remove the blocks from under the wheels.

Sit in the operator’s seat, and depress the left brake pedal fully.

Start the engine, release the parking brake, then release the brake pedal gradually to start the machine.

Approx. 1Omm r

When the engine is started, the transmission is engaged and the MACHINE WILL MOVE !!!!! Therefore, before starting the engine, always check that the direction of travel is safe, and always keep the brake pedal depressed. *

If the machine does not start, turn the 2nd spool, 3rd spool, and 4th spool clockwise, and screw in approx. 10 mm to the OFF position.

After moving the machine, stop the engine, apply the parking brake, and block the wheels.

Return the emergency manual spool to the neutral position, and install the lock plate.

22-9

TIRE AND WHEEL

TESTING AND ADJUSTING

Unit: mm Item

Fiiing of wheel lock rina Clearance of wheel lock ring

NO.

Standard value

Max 2.5

Max 4.5

2 - 10

Permissible value

Measurement condition l Tire inflation pressure: Specified pressure

Wheel

L15AR008

Measuring procedure 1. Fitting of wheel lock ring

Measure distances A and B at four places around the circumference. 2.

Clearance of wheel lock ring Measure dimension C.

22-10

423F309

TROUBLESHOOTING

22-11

PRECAUTIONS WHEN TROUBLESHOOTING

TROUBLESHOOTING

PRECAUTIONS WHEN TROUBLESHOOTING 1. SAFETY

Stop the machine on level ground, and check that the safety pins and parking brake are correctly applied, and that the tires are blocked. When working in groups, use agreed upon signals and do not allow unauthorized persons near machine.

Be careful not to get burned by hot parts or get caught in rotating parts.

a. b.

Always disconnect the cable from the negative (-) terminals of the battery before disconnecting any wiring.

c. d. 3.

Always release the pressure before removing the plugs or caps of any place under hydraulic or air pressure, and connect all measuring tools correctly.

mediately start to disassemble the machine. The machine may be disassembled in such a way that the problem cannot be located, so the cause of the problem will be unknown.

As a result, l

The customer and operator will lose confidence in you. Time will be wasted, and unnecessary costs will be incurred for excess parts and greasing.

To avoid these problems, use the following procedure when troubleshooting. 1. Ask the customer and operator the following questions about the breakdown. a.

Have there been any other problems apart from the one reported? b. Was there anything unusual before the machine broke down? c. Did the breakdown occur suddenly, or had there been signs of trouble before? d. What was the machine doing when break

22-12

Ask the user or operator if the decision

about the failure was made based on measured values, or by comparison, or by feeling. b. Compare extent of failure with standard values. l Check safety before carrying out any check. l Did not make any check or measurement that will make the condition worse.

Just because a failure occurs, do not iml

Check oil level. Check for leakage of oil from piping or hydraulic equipment. Check travel of control levers. Check stroke of spool in control valves.

Reenact the failure and check the condition of the machine (particular conditions at the time of failure). a.

METHODS FOR TROUBLESHOOTING

Check the following items which can be checked simply by visual checks etc.

NY* +

down occurred? Had the machine been repaired before the breakdown? If so, who carried out the repair, and when? Had the same kind of failure occurred before?

Try to locate the possible causes for the failure. The transmission system consists of the transmission itself, the transmission control valve, and the transmission electrical control. In particular, when trouble occurs in the transmission system, the probable location of the failure can be divided as follows; l Transmission itself, or transmission control valve. l Transmission electric control. To decide which of the two is the location of the failure, go to page 22 - 18, (JUDGMENT ON POWER TRAIN).

PRECAUTIONS

TROUBLESHOOTING

Carry out troubleshooting shooting charts.

If part cannot be removed even when the nuts and bolts have been removed, do not use excessive force to remove it. Check the part to see if there is any problem with it and remove the problem before trying to disassemble the part.

When installing or assembling, clean off all dust and dirt and repair any scratches or dents. Remove all grease or oil before coating with gasket sealant.

using the trouble-

There are the following two types of troubleshooting charts. 1. TROUBLESHOOTING TABLE 22 POWER TRAIN 42 STEERING SYSTEM 52 BRAKE AND AIR SYSTEM 62 WORK EQUIPMENT SYSTEM 2.

WHEN TROUBLESHOOTING

TROUBLESHOOTING FLOW CHART 82 ELECTRIC AND ELECTRONIC SYSTEM

The troubleshooting charts consist of: 1) Items which can be checked easily. Items which are likely to be the cause of such failures.

Follow theses charts to carry out troubleshooting. At the same time, do not forget the following points. l l

Check related items. Check that there are no other failures or breakdowns.

For details of troubleshooting page 22-l 4.

6. Investigate l

tables, see

causes of breakdown

Even if the breakdown is repaired, if the original cause of the problem is not removed, the same breakdown will occur again. To investigate and remove the original cause, see “Actions to take to prevent failures from occurring again”.

PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR ASSEMBLING PARTS DURING TROUBLESHOOTING l

Carry out the various testing and adjusting while observing the items on quality control given in “Testing and Adjusting”.

When removing parts, check their condition of mounting, and distinguish between front and rear, left and right, and top and bottom.

Check the match marks, or make match marks to prevent mistakes when installing.

22-13

METHOD

TROUBLESHOOTING

METHOD OF READING TROUBLESHOOTING TABLES DESCRIPTION OF SYMBOLS SHOOTING TABLES

USED IN TROUBLE-

The following symbols are used in the “Remedy” column to indicate the method of eliminating the cause of a fault. X: Replace A: Adjusting

A: Repair C: Clean

METHOD OF READING TROUBLESHOOTING

TABLE

The symbol o in the table is inserted only for causes which can be diagnosed. If a cause cannot be diagnosed, the corresponding box is left blank.

If the result of problem 1 using the troubleshooting table shown at right is abnormal, the cause of the trouble can be assumed to lie between “a” and “d”. Because it is not passible to make a problem regarding “e”, it is necessary to perform the next problem (owing to the possibility of a multiple fault). If the result of problem 1 is normal, the cause of the fault does not lie between “a” and “d”. In such a case, before diagnosing the causes as “e”, however, carry out a check by means of problem 2 or 5.

If now the result of problem 1 is abnormal and the result of problem 2 normal, the cause is one of “a”, “b” or “d”. In addition, if the result of problem 3 is abnormal, the cause will be narrowed down to one of “b” or “d”. To determine which of “b” or “d” is the actual cause, perform problem 4.

If the result of problem is abnormal, blacken out the corresponding o in the table and then perform the next problem on these causes in order to narrow the likely causes.

Example 1: Problem 1 - Abnormal Problem 2 - Normal Problem 3 - Abnormal Problem 4 - Normal

From the table of example 1, the cause of the fault is “b”.

Example 2: Problem 1 - Normal Problem 2 - Abnormal +

22-14

From the table of example 2, the cause of the fault is “e”.

In example 2, it is evident that the cause is “e” without carrying out problem 2, however problem 2 is performed by way of an additional check.

OF READING TABLES

METHOD OF READING TABLES

TROUBLESHOOTING

Example 3: Problem 1

Abnormal

Problem 2

Abnormal

From the table of example 3, the cause is one of “a”, “c” and

Problem 3

Normal

“e”*

Examole 3

///I//

3 4 5

0 0

Continue problems

Example 3-l

Problem 4

Normal

Problem 5

Normal

From table of example 3-1, the cause is “c”.

Example 4: Problem 1

Abnormal

Problem 2

Normal

From table of example 4, the cause is one of “a”, ‘II”, or “d”.

Continue problems

Problem 3

Abnormal

Problem 4

Abnormal

Problem 5

Normal

From table of example 4-1, the cause is “a” or “d”.

As can be seen from the above examples, it is not necessary to perform all the problems. Also, looking at a particular cause, no matter how many l marks there are in the column corresponding to that cause, it will cause to be an actual cause if there is even one o mark in the same column.

Example 4-l

22-15

PREVENTING

TROUBLESHOOTING

RECURRENCE

OF TROUBLE

PREVENTING RECURRENCE OF TROUBLE l

The troubleshooting table is used to establish the direct cause of damage or breakdown of a part or piece of equipment. It is not able to establish the root cause of the damage or failure, however.

Also, this table only describes the action to be taken with the particular part or piece of equipment. It does not mention what action should be taken to prevent a recurrence of the root cause.

In order to remove the root cause of a fault so as to prevent a recurrence, carefully investigate the real cause while referring to the following items.

Reoarding the method of checking and adjusting each part or piece of equipment, refer to “Testing and Adhsting’ in the Shop Manual. -

HYDRAULIC

EQUIPMENT

Oil checks

The fundamental cause of almost all faults occurring in hydraulic equipment is the inclusion of water, air or other foreign matter in the oil. Accordingly, it is necessary to check the oil to see whether or not it contains any of the above substances, and then take appropriate action.

Rubber: Cylinder packing, etc. Metal: Wear or damage to hydraulic equipment such as pump and motor, as well as transmission and torque converter, etc.

1) Oil checks l

Check for water contamination. Check the oil for possible water contamination by means of a diesel engine oil checker or a hot plate. Check for contamination of other foreign matter. Remove the drain plug and filter, then check the bottom of the tank and also the filter to see if any foreign matter has collected there. Check the degree of contamination by means of a contamination checker. Viscosity check Check the viscosity of the oil using a viscometer in order to confirm whether or not the oil is satisfactory. Check of contamination point If, as a result of the above checks, it is discovered that the oil is contaminated by water or other foreign matter, it is necessary to find out where the contamination is occurring and also to take steps to prevent it. Water: Oil storage tank, breather, etc. Sand: Oil replenishing or replacing method, etc.

22-16

Oil cleaning and replacement

If a large amount of metal particles or other foreign matter is discovered in the oil, either wash the oil using an oil refresher or replace it. +

If the oil is contaminated by water, it is not possible to remove the water by means of an oil refresher.

When washing the oil, also wash or replace the strainer and replace the filter.

Cleaning

If a part becomes damaged, fragments may pass into the oil line. It is thus necessary to wash the oil.

In addition, disassemble and wash such parts as valves and cylinders which are liable to collect metal fragments and other foreign matter, thus helping to prevent a recurrence of faults due to such fragments becoming lodged in various parts of the engine or hydraulic equipment.

fragments

of damaged

parts

TROUBLESHOOTING

JUDGEMENT ON POWER TRAIN

Use the following method to judge if the abnormality in the power train is in the electrical system of the transmission, or in the power train itself. If the abnormality in the electrical system, go to troubleshooting items E-8; if the abnormality is not in the electrical system, go to troubleshooting items T-l - T-4. Judgement flow

YES Carry out test for problem transmission solenoid. Is condition normal?

When emergency screw of spool of problem speed range is loosened, does machine move?

YES

tDefective solenoid

tGo

to troubleshooting for transmission T-l - T-4

to troubleshooting for electrical system, E--8

FGo

transmission valve

transmission L02zz010

Testing and inspection of transmission solenoid

Stop the machine on level ground blocks under the tires.

and

put

Air tank at specified

pressure

Install a T-adapter (or socket adapter) to connector CN75, and check the voltage between the con-

nector pin and the chassis ground. 2.

Turn the starting switch ON. +

Do not start the engine.

Turn the parking brake switch ON - OFF (release).

Result of inspection

When depressing the foot brake, depress the R.H. brake so that the transmission is not cut off.

Normal

Checking directional solenoid circuit Standard

condition

Lever position

Connector pin

Go to T-l

- T-4

0 (continuous) at two places Go to troubleshooting E-8 (d) No o (continuous) Go to troubleshooting

E-8 (b), (c)

No l (battery voltage) Go to troubleshooting

E-8 (a)

0: 0 - 0.5V (continuous) 0: 20 - 30V(battery voltage)

22-17

JUDGEMENT ON POWER TRAIN

TROUBLESHOOTING

Checking speed solenoid circuit Standard condition

1-pin

2-pin

3-pin

4-pin

7-pin (Power source)

1st

2nd

3rd

4th

Lever position

Connector pin

0: 0 - 0.W (continuous) 0: 20 - 30V (battery voltage)

Result of inspection: Normal

Go to T-l - T-4

0 (continuous) at two places or more Go to troubleshooting E-8 (9 No o (continuous) Go to troubleshooting

E-8 (e)

No l (battery voltage) Go to troubleshooting E-8 (e)

22-18

TROUBLESHOOTING

TROUBLESHOOTING TABLE

TROUBLESHOOTING TABLE T-l.

Machine does not move. Ask the operator the following points. Did the machine suddenly stop moving? l Yes = Component seized or damaged. 0 Was there anv abnormal noise when the machine stopped moving? Yes = Component broken. Checks before troubleshooting. 0 Is oil level in transmission case correct? Is voltage of solenoid valve correct? l Is monitor display normal? l Is drive shaft broken? l

Transmesion

Transmission

Note 1:

Note 2:

If the solenoid valve and hydraulic pressure are normal, the “I” in the Causes column indicates that the valve spool does not work. If the transmission clutch pressure is low, but the cause cannot be found in the above table, a possible cause is cracks in the valve or transmission.

22-19

TROUBLESHOOTING

TROUBLESHOOTING TABLE

The following symbols are used to indicate the action to be taken when a cause of failure is located: X: Replace A: Adjust

22-20

A: Repair C: Clean

TROUBLESHOOTING

T-2.

TROUBLESHOOTING TABLE

Machine lacks power or speed. Checks before troubleshooting. 0 Is oil level in transmission case correct? l Is there any leakage of oil from joints of piping or valves? 0 Is parking brake or brake locked? 0 Is operation of electric circuit correct? Checking for abnormalities. l Engine high idling speed l Torque converter stall speed l Machine travel speed l Transmission clutch pressure 0 Pressure at outlet port of pump 0 Pilot reducing pressure l Tire inflation pressure

No.

Problems I noise from between pump and filter.

Abnormal

Torque converter

Torque converter stall speed too low

stall speed too high

IAl

Transmission

1 Modulat’ mg pressure drops when oil temperature

rises.

I I I

III

The following symbols are used to indicate the action to be taken when a cause of failure is located: X: Replace A: Repair A: Adjust C: Clean

22-21

TROUBLESHOOTING

T-3.

Excessive time lag when starting machine or shifting gear. Checks before troubleshooting. 0 Is oil level in transmission case correct? l Is there any leakage of oil from joints of piping or valves? 0 Is operation of control valve normal? Checking for abnormalities. 0 Check STANDARD VALUE TABLE to confirm that time lag is actually excessive.

abcdefg

I A

No.

Abnormal

notse from between

pump and falter

2 lExcesswe time lag I” every speed range 3

Machme

moves

normally

in certain

speed ranges

Transmlsslon modulating In every weed ranae

pressure

too low

As an Item 4. Indicator

Torque range.

converter

fluctuates

011temperature

vtolently IS above operatmg

xA A

I I I

lololololol 0 0000

0 0

The following symbols are used to indicate the action to be taken when a cause of failure is located: x: &pktCe A: kqX3ir A: Adjust C: Clean

22-22

TABLE

TROUBLESHOOTING TABLE

TROUBLESHOOTING

T-4.

Torque converter oil temperature too high. Ask the operator the following points. l Does not torque converter oil temperature go up during torque converter stall, and down when the torque converter is not stalled? Yes = Normal (Incorrect selection of gear speed) Checking before troubleshooting. l Is oil level in transmission and steering case correct? 0 Is filter clogged? Checking for abnormalities. l Check STANDARD VALUE TABLE to confirm that torque converter oil temperature is actually high. + If oil temperature is normal but the oil temperature gauge is outside the operating range, the oil temperature gauge is defective.

Problems 1 2

Pump makes abnormal Norse when 011temperature 1 High Idl on g and low Idling speeds are too low.

Hydraulic pressure at inlet port of torque converter too low

Transmtsslon

modulatmg

pressure too low

is low.

loI

0 0

The following symbols are used to indicate the action to be taken when a cause of failure is located: X: Replace A: Repair A: Adjust C: Clean

22-23

TROUBLESHOOTING

MEMORANDA

22-24

TROUBLESHOOTING

TABLE

POWER TRAIN 23

DISASSEMBLY

AND ASSEMBLY

TORQUE CONVERTER CHARGING AND PPC PUMP . . . . . . . . . . . . . . . . . . _ . . . . . . _ . . . . . . . . . _ . . REMOVAL . . . . . . . ............................................................. INSTALLATION . . . . .............................................................

3 3 3

. . . .. . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 TORQUE CONVERTER AND TRANSMISSION 4 REMOVAL . . . . . . . ............................................................. 12 INSTALLATION . . . . ............................................................ . .. . . . . . . .. . . . . .. .. . . . .. .. . . . . . . . . . . . . . . . . . . . . . . . . TORQUE CONVERTER ASSEMBLY DISASSEMBLY OF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PTO ASSEMBLY . ............................................................ Disassembly of ............................................................ ............................................................ ASSEMBLY OF PTO ASSEMBCV : ............................................................ Assembly of . . ............................................................

22 22 24 24 26 26 26

TRANSMISSION ASSEMBLY ....................................................... DISASSEMBLYOF.. ........................................................... ASSEMBLYOF ...............................................................

31 31 41

TRANSFERCASEASSEMBLY ...................................................... DISASSEMBLYOF ............................................................. ASSEMBLYOF ...............................................................

53 53 58

TRANSMISSION CONTROL VALVE ................................................... REMOVALOF ................................................................ INSTALLATION OF.. ........................................................... LOWERVALVEASSEMBLY ...................................................... DISASSEMBLYOF ........................................................... ASSEMBLYOF .............................................................. UPPERVALVEASSEMBLY ....................................................... DISASSEMBLYOF ........................................................... ASSEMBLYOF.. ............................................................ MAIN RELlEFVALVEASSEMBLY .................................................. DISASSEMBLYOF ........................................................... ASSEMBLYOF ..............................................................

64 64 65 66 67 67 68 69 69 70 70 70

CENTER SUPPORT .............................................................. REMOVALOF ................................................................ INSTALLATIONOF ............................................................. DISASSEMBLYOF ............................................................. ASSEMBLYOF ...............................................................

71 71 72 73 75

23-1

DRIVESHAFT .................................................................. DISASSEMBLYOF ............................................................. ASSEMBLYOF ...............................................................

77 77 79

FRONT AXLE.. ................................................................. REMOVALOF ................................................................ INSTALLATION OF.. ...........................................................

81 81 83

FRONT DIFFERENTIAL ........................................................... REMOVALOF ................................................................ INSTALLATION OF.. ...........................................................

85 85 88

REAR AXLE .................................................................... REMOVALOF ................................................................ INSTALLATION OF.. ...........................................................

91 91 95

REAR DIFFERENTIAL ............................................................. REMOVALOF ................................................................ INSTALLATION OF.. ...........................................................

99 99 100

DIFFERENTIALGEARASSEMBLY ................................................... DISASSEMBLYOF ............................................................. FINE DISASSEMBLY OF PINION ASSEMBLY ........................................ FINE DISASSEMBLY OF DIFFERENTIAL GEAR CASE ASSEMBLY ........................ ASSEMBLY OF FlNEASSEMBLY’~iDlFfERENji~iGEkk’ASSiMBLY:::::::::::::::::::::::::::::::: FINE ASSEMBLY OF PINION ASSEMBLY ..........................................

102 102 104 105 106 106 107 108 108

AssEMBiVoFDljiiRENii~iASSiMBiY::::::::::::::::::::::::::::::::::::::::::: FINALDRIVE ................................................................... DISASSEMBLYOF............................................................. ASSEMBLYOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..__......_....__

113 113 116

To maintain the performance of the machine and to prevent failures, it is particularly important to pay attention to the degree of cleanliness of the oil in the hydraulic circuits. When adding oil or changing the oil, or when replacing the filters, check that the oil container and area around the filler of the hydraulic tank are clean. If any internal part of the hydraulic equipment breaks, disassemble and clean all the hydraulic equipment and circuits to remove any dirt or pieces from the circuit. If any parts of the hydraulic circuits are disassembled and assembled, also carry out thorough flushing of the hydraulic circuits. After replacing or flushing the hydraulic tank oil, filter element, or strainer, or when removing and installing any hydraulic cylinder, hydraulic pump or any other hydraulic equipment or work equipment piping, always bleed the air as follows after completion of installation. l Air bleeding procedure 1) Run the engine at low idling, extend and retract the steering, bucket, and lift arm cylinders 4 - 5 times without going to the end of this stroke. (Stop approx. 100 mm before the end of the stroke.) 2) Operate the steering, bucket, and lift arm cylinders 3 - 4 times to the end of the stroke, then stop the engine and bleed the air from the plugs at the top of the hydraulic tank filter. 3) Raise the engine speed and repeat Step 2) to bleed the air. Repeat this procedure until no more air comes out from the plug. 4) After completing bleeding the air, tighten the plugs. m

Plug: 1.15kO.15

kgm

+ If the engine is run at high speed from the start, or the cylinders are operated to the end of this stroke, the air inside the cylinder will cause damage to the piston packing. 5) Check the level of the oil inside the hydraulic tank, add oil if necessary, then tighten the oil filler cap. t Before loosening the oil filler cap, close the pressurizing valve; after adding oil, tighten the oil filler cap, then open the pressurizing valve. * After repair or long storage, follow the same procedure.

CHARGING PUMP

DISASSEMBLY AND ASSEMBLY

TORQUE CONVERTER AND PPC PUMP

CHARGING

REMOVAL

WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Then operate the steering wheel and the control levers several times to release the remaining pressure in the hydraulic piping.

1. Cover.

1) Remove cover (1) and plate (2). 2) Remove bracket (3). 2. Torque converter charging pump. 1) Disconnect tube (4) between transmission and pump at pump end. 2) Disconnect hose (5) between pump and filter at pump end. 3) Remove charging pump (6).

113AH066

Charging pump: 13 kg

INSTALLATION 1. Torque converter charging pump. 1) Set charging pump (6) in mounting position, then tighten the bolts. 2) Connect hose (5) between pump and filter to the pump. 3) Connect tube (4) between transmission and pump to the pump.

T4251017

2. Cover. 1) Install bracket (3). 2) Install cover (1) and plate (2). 3. Refilling with oil. 1) Add transmission oil to the specified level. t Run the engine to circulate the oil through the system. Then check the oil level.

23-3

DISASSEMBLY

AND ASSEMBLY

TORQUE CONVERTER MISSION

TORQUE

CONVERTER

AND TRANSMISSION

AND TRANS-

REMOVAL

A a

Loosen the oil 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.

Remove cover (1). Loosen plugs (2) and (3) at the top of the hydraulic tank filter to prevent the oil inside the tank from flowing out.

oil. 1. Draining hydraulic 1) Remove plug (4) then open valve (5) and drain the hydraulic oil.

Hydraulic

oil:

15OP

2. Side covers. 1) Remove engine side covers (6) (7) and (8). *Remove the left and right side covers. 2) Remove covers (9) and (10).

23-4

74251055

DISASSEMBLY

TORQUE CONVERTER

AND ASSEMBLY

3) Remove cover (11) and remove plate (13).

bracket

AND TRANSMISSION

(12), then

L13AH06

3. Fuel control cable. 1) Disconnect fuel control cable (15) from the fuel pump lever (14), then remove together with bracket (16) from the engine. t After removing, move the cable towards the front.

4. Ladder floor. 1) Remove covers (17), (18), (19), (20), and (23). 2) Sling ladder floor (24), then remove the mounting bolts and lift off.

Ladder floor:

56 kg

UBBUOl

23-5

DISASSEMBLY

TORQUE CONVERTER

AND ASSEMBLY

5. Electrical wiring. 1) Disconnect the following wiring from the connector. 0 Wiring (25) and (26) for transmission. 0 Wiring (27), (28), (29) and (30) for rear frame. 0 Wiring (31) and (32) for front frame. 0 Wiring (33) for power source. t When disconnecting, mark all the wires with tags to distinguish them.

AND TRANSMISSION

30 27 31

6. PPC piping. 1) Disconnect the following hydraulic piping from the PPC valve. l Hose (34) between PPC pump and PPC valve. l Hose (35) between PPC valve and hydraulic tank. l Hoses P2 (36) and P3 (37) for lift spool. l Hoses Pl (38) and P4 (39) for dump spool. t When disconnecting, mark all the hoses with tags to distinguish them. 74251168

LlOAK036

7. Air piping. 1) Disconnect the following air piping from the air tank. l Hoses (40) and (41) between air tank and letI brake valve. + When disconnecting, mark all the hoses with tags to distinguish them. l Hoses (42) and (43) between air tank and right brake valve. * When disconnecting, mark all the hoses with tags to distinguish them.

23-6

14251020

DISASSEMBLY AND ASSEMBLY

TORQUE CONVERTER AND TRANSMISSION

8. Cab, floor frame. 1) Disconnect rod (44) of follow-up linkage. 2) Sling cab and floor frame (45), then remove mounting bolts (46) and lift off. + Disconnect the front end from under support (47). t Check that there is no interference with any hose or electrical wiring, and lift off slowly. + If the machine is equipped with an air conditioner, disconnect the air conditioner and heater hoses.

Cab:

750 kg

L13CH012

L13CH013

9. Air component box. 1) Disconnect the following hoses: l Hydraulic hose (48) between brake chamber and rear slack adjuster. l Air hose (49) between wet tank and dry tank. l Air hose (50) between dry tank and parking brake. l Hydraulic hose (51) between brake chamber and front slack adjuster.

23-7

DISASSEMBLY AND ASSEMBLY

TORQUE CONVERTER AND TRANSMISSION

2) Disconnect hose (52) between torque converter

charging pump and oil filter from tube. 3) Disconnect hose (53) between oil filter and transmission from tube.

4) Sling air component box (54), then remove mounting bolts and lift off. Air component box: 145 kg

10. Hydraulic tank. 1) Disconnect hose (55) between main control valve and hydraulic tank, and hose (56) between PPC valve and hydraulic tank. 2) Disconnect cooler hose (57) from tube.

3) Remove tube (58), and loosen clamp (59).

T4251026

23-8

TORQUE CONVERTER AND TRANSMISSION

DISASSEMBLY AND ASSEMBLY

4) Sling hydraulic tank (60), then remove mounting bolts and lift off.

Hydraulic

tank:

230 kg

11. Accumulator. 1) Disconnect hoses (61), (62) and (63) from tube. 2) Remove accumulator (64) together with bracket.

12. Torque converter charging pump. 1) Remove hose (65) and tube (66), then remove torque converter charging pump (67). it Remove the O-ring from the pump mounting face.

el kg

Torque 13 kg

converter

charging

pump:

13. Steering and PPC pump. 1) Remove tube (66), disconnect

hose (69), then remove steering and PPC pump (70). + Remove the O-ring from the pump mounting face.

el kg

Steering and PPC pump:

20 kg

23-9

DISASSEMBLY AND ASSEMBLY

14. Upper drive shaft. 1) Remove upper drive shaft (71), then remove coupling (72) at damper end. * Make match marks before disconnecting the coupling.

15. Switch pump. 1) Remove tubes (73) and (74), then remove switch pump (75). * Remove the O-ring from the pump mounting face. Switch pump: 14 kg

16. Hydraulic pump. 1) Remove block (76) and tube (77), then remove hydraulic pump (78). * Remove the O-ring from the pump mounting face.

Hydraulic pump: 14 kg

17. Torque converter hoses. 1) Disconnect the following hoses: l Hose (79) between torque converter and torque converter cooler. 0 Hose (80) between torque converter cooler and transmission. * After disconnecting the hoses, move them towards the rear of the machine.

23-10

TORQUE CONVERTER AND TRANSMISSION

.72 71-

TORQUE CONVERTER AND TRANSMISSION

DISASSEMBLY AND ASSEMBLY

18. Center and rear drive shafts. 1) Disconnect center drive shaft (81) from the transmission.

Center drive shaft:

2) Disconnect mission.

31 kg

rear drive shaft (82) from the trans-

Rear drive shaft:

39 kg

19. Toraue converter and transmission.

1) Sling torque

converter and transmission, then remove the mounting bolts. When raised about lOmm, remove trunnion (83). * Disconnect the grease hose. * Be careful not to lose the shims inserted between the trunnion and the frame.

Trunnion:

25 kg

2) Remove

mounting bracket (84) on the front side. * Remove pin (85) inserted in the bracket and transmission by tapping lightly with a plastic hammer.

3) Lift out torque converter and transmission (86). + When removing the torque converter and transmission, carefully move to rear of the machine. t Since there is only a narrow space for the steering wiring, check interference and lift

-Shim

frame

Out.

el kg

Torque converter and transmission: 1173 kg

23-11

DISASSEMBLY

TORQUE CONVERTER

AND ASSEMBLY

AND TRANSMISSION

INSTALLATION 1. Torque converter and transmission. 1) Set torque converter and transmission 100mm in front of mounting position.

(86),

2) Install front mounting bracket (84). + Align pin (85) To holes correctly.

Mounting

bolts:

28 +3.0 kgm

3) Lower transmission further, and when it is about 1Omm from the trunnion, set trunnion (83) in mounting position. + Connect grease hose. * Insert desired thickness of shims between trunnion and frame. * After adjusting the position, remove the lifting tool.

2. Adjusting with shims. 1) Assemble desired amount of shims between trunnion (83) and frame, and between front bracket (84) and frame, then tighten mounting bolts to the specified torque. Mounting

bolts:

76 ~8.5 kgm

2) Install dial gauge “1” to input coupling

of torque converter, and put probe in contact with damper output shaft. Rotate input coupling of torque converter and adjust position. + Runout: Within 2mm. t Measure both radial and face runout. 3) After adjusting position, tighten front and rear mounting bolts fully. Front bracket mounting 76 28.5 kgm

Trunnion mounting 76 k8.5 kgm

23-12

bolts:

bolts: 74251172

DISASSEMBLY

TORQUE

AND ASSEMBLY

CONVERTER

AND TRANSMISSION

3. Center and rear drive shafts. 1) Connect center drive shaft (81)to transmission. Mounting

2) Connect

bolts:

11 f 1.O kgm

rear drive shaft (82) to transmission.

Mounting

bolts:

11 + 1.O kgm

14251170

(

14251067

4. Torque converter hoses. 1) Connect the following hoses: l Hose (79) between torque converter and torque converter cooler. l Hose (80) between torque converter cooler and transmission.

1 Cooler hose : 20 t5.0 kgm (Width across flats: 41 mm)

5. Hydraulic pump. 1) Install pump tube (77).

(78), then install block

(76) and

6. Switch pump. 1) Install switch pump (75), then install tubes (73) and (74).

23-13

DISASSEMBLY AND ASSEMBLY

TORQUE CONVERTER AND TRANSMISSION

7. Upper drive shaft.

1) Fit coupling (72) to damper and install upper drive shaft (71). 1 Mounting bolts: 11.5 k1.0 kgm

T425116E

8. Steering and PPC pump. 1) Install steering and PPC pump (70) then connect hose (69) and tube (68).

9. Torque converter charging pump. 1) Install torque converter charging pump (67), then connect tube (66) and hose (65).

10. Accumulator.

1) Install accumulator (64) with bracket. 2) Connect hoses (61), (62), and (63) to tube.

23-14

DISASSEMBLY

TORQUE CONVERTER

AND ASSEMBLY

11. Hydraulic tank. li Set hydraulic tank (60) in mounting then tighten

mounting

bolts.

1 Mounting

bolts:

AND TRANSMISSION

position,

28.5 +3.0 kgm

2) Tighten t

clamp (59), and install tube (58). Set the clamps at 180” to each other.

3) Connect

cooler hose (57) to tube. 59

T4251026

4) Connect hose (55) between main control valve and hydraulic tank, and hose (56) between PPC valve and hydraulic tank.

12. Air comoonent box. 1) Set air component box (54) in mounting tion, and tighten mounting bolts.

posi-

mzzoia

23-15

DISASSEMBLY

AND ASSEMBLY

TORQUE CONVERTER

AND TRANSMISSION

2) Disconnect

hose (53) between oil filter and transmission from tube. 3) Disconnect hose (52) between torque converter charging pump and oil filter from tube. 4) Connect the following hoses: l Hydraulic hose (48) between brake chamber and rear slack adjuster. l Air hose (49) between wet tank and dry tank. l Air hose (50) between dry tank and parking brake. 0 Hydraulic hose (51) between brake chamber and front slack adjuster.

14251023

j Tube (50): 4.5 kO.5 kgm

[ Tubes (48), (49), (51): 8.25 k1.25 kgm

74251022

13. Cab, floor frame. 1) Set cab and floor frame (45) in mounting position, and tighten mounting bolts (46). + Mounting bolts (Width across flats: 30mm). * Tighten until dimension “b” is reached. Dimension “b”: 42mm. t Be extremely careful not to tighten the bolts too far. + Check that there is no interference with any of the hoses or electrical wiring. L13CH013

11 If

23-16

LlXH014

L13CH012

DISASSEMBLY

AND ASSEMBLY

Connect

rod of follow-up

Locknut:

TORQUE CONVERTER

AND TRANSMISSION

linkage.

12.5 f 1.O kgm

If the machine is equipped with an air conditioner, connect the air conditioner and heater hoses.

14. Air piping. 1) Connect the following air piping. l Hoses (40) and (41) between air tank and left brake valve. l Hoses (42) and (43) between air tank and right brake valve. Tube:

8.25 k1.25 kgm

14251020

w?F==--

15. PPC piping. 1) Connect the following hydraulic piping to the PPC valve. l Hose (34) between PPC pump and PPC valve. l Hose (35) between PPC valve and hydraulic tank. l Hoses P2 (36) and P3 (37) for lift spool. 0 Hoses Pl (38) and P4 (39) for dump spool.

74251168

LlOAK036

23-17

DISASSEMBLY

AND ASSEMBLY

TORQUE CONVERTER

16. Electrical wiring. 1) Connect the following wiring from the connector. 0 Wiring (25) and (26) for transmission. 0 Wiring (27) (28), (29), and (30) for rear frame. 0 Wiring (31) and (32) for front frame. 0 Wiring (33) for power source.

17. Ladder floor. 1) Set ladder floor (24) in mounting tighten the mounting bolts.

AND TRANSMISSION

27 31

position, then

2) Install covers (17), (18), (19), (20), and (23).

LlBBUOl:

18. Fuel control cable. 1) With fuel control cable (15) installed to bracket (16), install bracket to engine, and connect fuel control cable to fuel injection pump lever (14). Locknut:

23-18

1.35 kO.15 kgm

Adjust the length of the cable.

DISASSEMBLY

TORQUE CONVERTER

AND ASSEMBLY

19. Side covers. 1) Install plate (13), then bracket (12).

Install

cover

AND TRANSMISSION

(11) and

2) Install covers (9) and (10).

3) Install side covers (6), (7), and (8).

23-19

DISASSEMBLY

TORQUE CONVERTER

AND ASSEMBLY

AND TRANSMISSION

20. Refilling hydraulic and transmission oil. 1) Install plug (4), and tighten valve (5).

2) Tighten

plugs (2) and (3) at the top of the hydraulic tank filter, then add hydraulic oil through the oil filler to the specified level. 1 Plugs at the top of the hydraulic tank filter: 1.2 20.1 kg

Hydraulic

oil:

1508

3) Install cover (1). +

Run the engine to circulate the through the system, then recheck level again.

oil oil

3 2b

Hydraulic

4) Add transmission

oil through the oil filler to the specified level. * Run the engine to circulate the oil through the system. +- Recheck oil level again. TRANSMISSION OIL FILLER

23-20

DISASSEMBLY

AND ASSEMBLY

TORQUE CONVERTER

AND TRANSMISSION

21. Bleeding air from brakes. 1) Bleed the air from the brake lines. t For details, see BLEEDING THE BRAKES in the TESTING AND ADJUSTING SECTION.

23-21

DISASSEMBLY

AND ASSEMBLY

TORQUE CONVERTER DISASSEMBLY

TORQUE

CONVERTER

ASSEMBLY

Soecial tools Part number

Part name

QtY

790-501-5000

Unit repair stand

790-901-2110

Bracket

793-31 o-21 60

Plate 74251173

Preparatory work. Remove torque converter assembly from the transmission assembly. For details see DISASSEMBLY OF TRANSMISSION ASSEMBLY.

1. PTO assemblv.

1) Set torqueconverter

assembly (1) in tool “A”. Remove holder (2) and coupling (3). 2)

14251174

3) Using eye-bolts “ail (Thread dia. = 16mm, Pitch = 2.0mm), sling PTO assembly. 4) Screw in forcing screws “b” and remove PTO assembly (4).

2. Turbine and case assembly. 1) Remove mounting belts(5) of pump, leaving 2 bolts on opposite sides. Set with case at top and remove 2 remaining 2) mounting bolts. 3) Lii off turbine and case assembly (6).

23-22

74251177

DISASSEMBLY

TORQUE CONVERTER

AND ASSEMBLY

ASSEMBLY

4) Disassemble the turbine and case assembly as

follows: a) Remove pilot (7) and gear (8). b) Remove snap ring (9), then remove spacer (10).

T4251179

c) Using forcing screws “6 (Thread dia. = lOmm, Pitch = 1.25mm), remove turbine (11). + Pull out from bearing inner race side.

\I----

T4251M

3. Stator. 1) Remove snap ring (12). 2) Remove stator (13).

4. Stator shaft and pump assembly. 1) Remove 8 mounting bolts (14). 2) Remove stator shaft and pump assembly (15).

23-23

DISASSEMBLY AND ASSEMBLY

TORQUE CONVERTER ASSEMBLY

3) Disassemble stator shaft and pump assembly as follows: 4 Remove 2 plugs (16) at stator shaft end.

\ \\

7425 illE

b) Knock out inner race of bearing through

the holes of the removed plugs, then remove pump (17). c) Remove bolts, then remove collar (18), pump (17), and cage (19).

425F26;

18 1425118t

PTO ASSEMBLY Disassembly of 5. Cover. 1) Remove cover (20). 6. Bearing. 1) Remove bearing (21).

14251

23-24

DISASSEMBLY AND ASSEMBLY

Nut. 1) Remove nut (22). + Tool kii: 790-l 01-2300 (push-puller).

TORQUE CONVERTER ASSEMBLY

c\ d

8. Gear and bearing. 1) Using puller “d”, pull out gear (23). + The gear is in contact with the outer race, so it can not be removed. 2) Remove bearing (24).

9. Outer race and spacer. 1) Remove snap ring (25) and spacer (26).

425F263

2) Using gear puller “e”, pull out outer race (27) about 10mm. 3) Remove gear (23), outer race (27), and spacer (26).

425F264

23-25

TORQUE CONVERTER ASSEMBLY

DISASSEMBLY AND ASSEMBLY

TORQUE CONVERTER ASSEMBLY

ASSEMBLY

PTO ASSEMBLY Assembly of

23 24

1. Gear and bearing. 1) Install bearing (24) (inside diameter: 50mm) on gear (23). 2) Set gear (23) in PTO case (29).

2. Outer race and spacer. 1) Install outer race (27) (outside dia.: 90mm). t Be careful to install the outer race facing the correct direction.

2) Install spacer (28).

3) Install outer race (27) (outside dia.: 90mm). t Be careful to install the outer race facing the correct direction.

3. Bearing. 1) Using puller “P’ install bearing (24) (inside dia.: 50mm).

425F266

23-26

DISASSEMBLY AND ASSEMBLY

TORQUE CONVERTER ASSEMBLY

4. Spacer and snap ring.

1) Install spacer (25). 2) Install snap ring (26).

5. Nut.

1) Tighten nut (22). Nut: 42.5 +2.5 kg +

Check to make sure that the gear rotates smoothly.

74251201

6. Bearing. 1) Install bearing (21) (outside diameter: 130mm).

14251203

7. Cover and oil seal. 1) Install oil seal (30 into cover (2). * Be careful not to deform the oil seal. /(r\cJ

Oil seal lip: Grease (G2-Ll).

2) Install cover (20).

23-27

TORQUE CONVERTER ASSEMBLY

DISASSEMBLY AND ASSEMBLY

8. Statot shaft and pump assembly. 1) Assembly stator shaft and pump assembly as follows: 4 Install bearing (31) (outside diameter: 130mm) to cage (19).

31 0

a, P

b) Fit cage (19) to pump (17) then tighten bolts.

Bolts: 6.75 20.75 kgm

14251188

install seal ring (33) to stator shaft (32). + Coat the seal ring with grease, and make the protrusion from shaft uniform.

Install pump (17) to shaft (32).

Install 2 plugs (16).

Plug: 0.45 20.15 kgm

14251210

23-28

J-L

1425120

DISASSEMBLY AND ASSEMBLY

TORQUE CONVERTER ASSEMBLY

2) Set torque converter case (34) in tool A, A,, and A2 Special tools Part number

Part name

QtY

790-501-5000

Unit repair stand

790-901-2110

Bracket

793-310-2160

Plate

3) Install stator shaft and pump assembly (15). Bolt: 6.7 20.7 kgm

Bolt: Thread tightener (LT-2).

9. Stator and snap ring. 1) Install stator (13). 2) Install snap ring (12).

10. Turbine and case assembly. 1) Assemble turbine and case assembly as follows: a) Install bearing (37) to case (36).

36 14251213

Install turbine (11) to case (36). + Support the inner race of the bearing in the case, and push in the turbine.

23-29

DISASSEMBLY

c) d) e)

AND ASSEMBLY

TORQUE CONVERTER

ASSEMBLY

Install spacer (10) and snap ring (9). Install inner race (38) to pilot (7). Install gear (8) and pilot (7). Bolt:

/(r\7

6.7 50.7 kgm

Bolt: Thread tightener (LT-2).

2) Fit guide

bolt (Thread dia. = lOmm, Pitch = 15mm), using two eye-bolts “g” (Thread dia. = 12mm, Pitch = 1.75mm), sling turbine and case assembly (6) and then install it. Bolt:

6.5 r0.5

kgm

Bolt:

Thread tightener

12 A

(LT-2).

14251178

11. PTO assembly. 1) Fit O-ring, using eye-bolts “h” (Thread dia. = 14mm, Pitch - 2.0mm), sling PTO assembly (4) and then install it.

14251211

2) Assemble O-ring, and install coupling holder (2). 1 Bolt:

23-30

11.5 +l.O kgm

(3) and

TORQUE CONVERTER ASSEMBLY

DISASSEMBLY AND ASSEMBLY

TRANSMISSION DISASSEMBLY

ASSEMBLY

Special tool II

Part number

II A I

799-301-l 500

Part name

1 Qtv

Leak tester

I 1

Preparatory work Sling torque converter assembly (1) and remove bolts (2) from the transmission assembly.

1. Pilot filter assembly. Remove pilot filter assembly (3) with tube.

2. Control valve assembly. Remove control valve assembly (5).

3. Plate. Remove plate (6).

4. Sleeve. Using eye-bolts “a” (Thread dia. = 16mm, Pitch = 2mm), remove sleeves (7).

23-31

TRANSMISSION ASSEMBLY

DISASSEMBLY AND ASSEMBLY

5. Transfer assemblv. 1) Set with the tr&sfer at the bottom. 2) Using 3 eye-bolts “b” (Thread dia. = 12mm, Pitch = 1.75mm), sling transmission assembly 3) Screw in forcing screws “c” (Thread dia. = 12mm, Pitch = 1.75mm), and lift off the transmission assembly.

”

1072204:

6. Tie bolts. Remove 15 unmarked tie bolts (9). + Using tool A, check operating condition of piston before disassembling. t Leave two marked tie bolts, so the transmission assembly can be removed from the transfer case.

L072204;

7. Input shaft and carrier assembly. Using eye-bolts “d” (Thread dia. = 14mm, Pitch = 2.0mm), lift input shaft and carrier assembly (10). + Disassemble input shaft and carrier assembly according to the following steps: 1) Remove snap ring (11). 2) Support housing and push the input shaft out with a press and remove.

1072204:

23-32

L072204

LO72204

DISASSEMBLY AND ASSEMBLY

TRANSMISSION ASSEMBLY

3) Remove snap ring (12). 4) Support housing and push out carrier assembly (13) with press and remove.

1072204

5) Remove pins, then remove planetary gears (14), bearings (15) and thrust washers (16) from carrier case. 1

a. Spring. Remove springs (17) and (18). + Springs (18) are inserted between each plate.

9. Discs and plates.

Remove discs (19) and plates (20). 10. Ring gear.

Remove ring gear (21). 1072204

1072204

23-33

DISASSEMBLY

TRANSMISSION

AND ASSEMBLY

ASSEMBLY

11. No. 1 piston, housing.

Using eye-bolts “e” (Thread dia. = 16 mm, Pitch 2.0mm), lift out piston and housing (22). + Remove piston (24) from housing (23).

12. Spring.

Remove springs (25) and (26). t Springs (26) are inserted between each plate.

13. Discs and plates. Remove discs (27) from plates (28).

14. Guide pin. Remove guide pin (29).

1072205

LO72205’

23-34

LO72205~

DISASSEMBLY AND ASSEMBLY

TRANSMISSION ASSEMBLY

15. No.2 piston, housing. Lii out piston and housing (30). 16. Drum carrier assembly. Using eye-bolts “e” (Thread dia. = 16mm, Pitch = 2.0mm), lift out No.2 piston and housing (30) and drum carrier assembly (31) as one unit.

31 to722ost

Disassemble drum and carrier assembly according to the following steps: 1) Remove snap ring (32), then remove drum (33). 2) Remove bearing (35) from carrier case (34). 3) Remove pins, then remove planetary gears (36), bearing (37) and thrust washers (38) from carrier case.

L0722057

17. Sun gear. Remove sun gear (39).

18. Swina. Remoie springs (40) and (41). + Springs (41) are inserted between each plate. JJ

L07Z2058

36 37 39

33 i

.40

(I5

41 LO722059

23-35

TRANSMISSION ASSEMBLY

DISASSEMBLY AND ASSEMBLY

19. Discs and plates. Remove discs (42) and plates (43).

20. No.3 piston, housing. Using eye-bolts “e” (thread dia. = 16 mm, Pitch = 2.0 mm), lift out piston and housing assembly (44).

21. Sun gear. Remove sun gear (45). 22. Sleeve. Remove sleeve (46). 23. Rotating clutch assembly. Using eye-bolts “e” (Thread dia. = 16mm, Pitch = 2.0mm), lift off rotating clutch assembly (47) and housing (48) as one unit. * Disassemble clutch assembly according to following steps: 1) Using puller “f”, remove gear assembly (49).

23-36

L07ZZ065

DISASSEMBLY

TRANSMISSION

AND ASSEMBLY

ASSEMBLY

2) Remove pin, then remove planetary gear (50), bearing (51) and thrust washers (52) from

carrier case.

3) Remove snap ring (53), then using bar “g”

remove rotating clutch assembly housing (48).

(47) from

4) Remove bolts (54), then remove case (55).

5) Remove discs (56), springs (57) and plates (58). 6) Remove inner gear (59). 7) Remove bearing (50) from inner gear.

LO7ZZO61

23-37

DISASSEMBLY AND ASSEMBLY

TRANSMISSION

ASSEMBLY

8) Using press fit kit “h” (1 60mm inner diameter) compress belleville spring and remove snap ring (61). t Belleville spring mounting load: 218 kg 9) Remove 3 belleville springs (62).

10722071

10) Using puller “j”, remove housing (64) from shaft (63).

11) Remove thrust plate (65) and sun gear (66). 12) Remove snap ring (67) and take out shaft from ring gear (68). 13) Remove snap ring (69), then remove gear (70). 14) Remove snap ring, then remove bearing (71). 15) Remove snap ring (72), then remove bearing (73) from housing.

LO72207

23-38

DISASSEMBLY AND ASSEMBLY

TRANSMISSION ASSEMBLY

24. Springs. Remove springs (74) and (75). + Springs (75) are inserted between each plate.

25. Discs and plates. Remove discs (76) and plates (77).

26. No.4 piston and housing. Using eye-bolts “e” (Thread dia. = 16mm, Pitch = 2.0mm), lift off piston and housing (78).

27. Springs. Remove springs (79) and (80). * Springs (80) are inserted between each plate.

28. Guide pins. Remove guide pins (81).

23-39

TRANSMISSION ASSEMBLY

DISASSEMBLY AND ASSEMBLY

29. Discs and plates. Remove discs (82) and plates (83).

30. No.5 ring gear. Remove ring gear (84).

31. No.5 piston and housing. Using eye-bolts “e” (Thread dia. = 1 6 mm, Pitch = 2.0 mm), lift off piston and housing (85).

23-40

TRANSMISSION ASSEMBLY

DISASSEMBLY AND ASSEMBLY

TRANSMISSION ASSEMBLY

ASSEMBLY

Special tool

A 1.

Part number

Part name

Qty

799-301-l 500

Leak tester

No.5 piston and housing. 1) install seal ring to piston, then install housing. 2) Using eye-bolts (e) (Thread dia. = 1 6 mm, Pitch = 2.0 mm), lift off piston and housing (85).

2. No.5 ring gear. Install ring gear (84).

3. Guide pins. Install guide pins (81).

4. Discs and plates. Install plates (83) and discs (82).

LO72

23-41

DISASSEMBLY AND ASSEMBLY

TRANSMISSION ASSEMBLY

5. Springs. install springs (79) and (30). + Springs (60) are inserted between each plate.

6. No.4 piston and housing. 1) Install seal ring to piston, then install housing. 2) Using eye-bolts “e” (Thread dia. = 16mm, Pitch = 2.0mm), lift off piston and housing (78).

122078

7. Ring gear and shaft assembly. 1) Install bearing (71) on gear. 2) Install gear (70) to ring gear (63) and secure with snap ring (69).

LO722074

3) Press fit shaft (66) to ring gear and secure with snap ring (67).

LO722006

23-42

DISASSEMBLY

AND ASSEMBLY

TRANSMISSION

ASSEMBLY

4) Align teeth of carrier and ring gear, then install ring gear and shaft assembly (87).

8. Discs and plates. Install plates (77) and discs (76).

9. Springs. Install springs (75) and (74). + Springs (75) are inserted between each plate. 10.

Sun gear. Install sun gear (66) and thrust plate (65).

11. Housing. 1) Install bearing (73) to housing snap ring (72).

and secure with

LO72207'

23-43

DISASSEMBLY

AND ASSEMBLY

TRANSMISSION

ASSEMBLY

2) Install thrust washers (52) bearing (51) and planetary gear (50) to gear case, insert shaft and tap in pin.

Eli

L0722090

3) Using press, press fit gear assembly (49) to

housing.

Using eye-bolts “e” (Thread dia. = 16mm, Pitch = 2.0mm), install housing (48).

12. Rotating clutch assembly. * Disassemble clutch assembly according to following steps: 1) Install 3 belleville springs (62). 2) Using press fit kit “h” (160mm inner diameter) compress belleville spring and install snap ring (61). t Belleville spring mounting load: 218 kg A Check that snap ring is completely inserted into ring groove.

62 \

LO7ZZOi

23-44

DISASSEMBLY

TRANSMISSION

AND ASSEMBLY

3) Install bearing (60) to inner gear and secure with snap ring.

ASSEMBLY

4) Install inner gear (59) to drum.

5) Install plates (58), springs

(57), and discs (56).

-57

L072206!

6) Install case (55) and tighten

bolts (54).

7) Fit seal rings and install clutch assembly

(47).

8) Install snap ring (53).

LO72206

23-45

DISASSEMBLY AND ASSEMBLY

13. Sleeve. Fii Seal ring and install sleeve (46). 14. Sun gear. Install sun gear (45),

15. No.3 piston and housing. Using eye-bolts “e” (Thread dia. = 16mm, Pitch = 2.0mm), sling and install piston and housing assembly (44).

16. Guide pin. Install guide pin (29). 17. Discs and plates. Install plates (43) and discs (42). 18. Springs. Install springs (41) and (40). + Insert springs (41) between each plate.

23-46

TRANSMISSION ASSEMBLY

DISASSEMBLY AND ASSEMBLY

TRANSMISSION ASSEMBLY

19. No.2 piston and housing. Sling No.2 piston and housing (30) and install.

20. Ring gear. Install ring gear (29).

21. Discs and plates. Install plates (28) and discs (27). 22. Spring. Install springs (26) and (25). + Insert springs (26) between each plate. 23. Drum and carrier assembly. Assemble drum and carrier according to following steps: 1) Install thrust washers (38), bearing (37) and planetary gear (36) to gear case, insert shaft and tap in pin.

LDlZZlOO

23-47

DISASSEMBLY

2) 3) 4)

5) 6)

AND ASSEMBLY

Install bearing (35) to carrier case (34). Fit snap ring (33A) to drum (33) then install drum. Align with roll pin, and assemble plate (32) then secure with snap ring (32A). t Check that the snap ring installed to the drum is securely set between the plate and carrier.

Install sun gear (30). Using eye-bolts “k” (Thread dia. = lOmm, Pitch = 1.5mm), sling and install drum and carrier assembly (31). * Align teeth face of planetary gear and ring gear and install.

24. No.1 piston and housing. Install piston (24) to housing (23). + Using eye-bolts “e’ (Thread dia. = 16mm, Pitch = 2.0mm), sling and install piston and housing (22) *

25. Ring gear. Install ring gear (21).

23-48

TRANSMISSION

32A

ASSEMBLY

33A

TRANSMISSION ASSEMBLY

DISASSEMBLY AND ASSEMBLY

26. Discs and plates. Install plates (20) and discs (19).

27. Springs. Install springs (18) and (17). t Insert springs (18) between each plate.

28. Input shaft and carrier assembly. Assemble input shaft and carrier assembly according to followina stetx: 1) Install -thrust washers (16) bearing (15), and planetary gear (14) to gear case, insert shaft and secure with pin.

LO722041

15 1

16 i

1072204:

2) Install bearing to housing. 3) 4)

Support carrier assembly (13) and press fit housing. Install snap ring (12). + Check that snap ring is completely inserted in ring groove.

‘2204

23-49

DISASSEMBLY AND ASSEMBLY

Support housing and press fit shaft (89).

Install snap ring (11).

TRANSMISSION

ASSEMBLY

722105

Using eye-bolts “d” (Thread dia. = 14mm, Pitch = 2.0mm), sling and install input shaft and carrier assembly (10). + Align teeth face of planetary gear and ring gear and install.

29. Tie bolt. Tighten tie bolt (9). Tie bolt: 17 tl.O kgm

23-50

TRANSMISSION ASSEMBLY

DISASSEMBLY AND ASSEMBLY

30. Checking operation of piston. Using tool A, check operation and stroke of pistons. Air pressure: 3 - 5 kg/cm*. Piston stroke: mm: II Stroke Piston No. 1

4.0

No. 2

4.0

No. 3

4.0

No. 5

4.2

31. Transmission case. 1) Using eye-bolts “b” (Thread dia. = 12mm, Pitch = 1.75mm), sling transmission case (8). 2) Fit O-ring and install transmission case.

LO722107

32. Sleeve. Fit O-ring and install sleeve (7).

33. Plate. Fii O-ring and install plate (6).

23-51

DISASSEMBLY

AND ASSEMBLY

TRANSMISSION ASSEMBLY

34. Transmission control valve assembly. Fii O-ring and install transmission control assembly (5).

valve

35. Filter assembly. Fit O-ring and install filter assembly

(3).

I 36. Torque converter assembly. Fit O-ring, sling torque converter assembly (1) connect to transmission assembly, and tighten mounting bolts (2).

37. Adjusting speedometer sensor. 1) Screw in sensor (86) until it contacts outside surface of gear (87). t Before installing the sensor, check that the gear is at the outside surface compared with the mounting surface. 2) After sensor (86) contacts gear (87), turn it back 3/4 - 1 turn and secure with locknut (88). + Be careful that the outlet direction of the sensor harness is not the opposite direction to the sensor connector clamp. A

Sensor thread: Adhesive

1 Sensor locknut:

23-52

(LT-2)

4 +/- 1 kgm

LD7zzo3;

DISASSEMBLY AND ASSEMBLY

TRANSMISSION ASSEMBLY

TRANSFER CASE ASSEMBLY DISASSEMBLY 1.

Transmission assembly. Remove transmission assembly from transfer case.

2. Input shaft cage. Using forcing screw “A”, remove input shaft cage (1).

3. Input gear assembly. 1) Remove input gear assembly (2). 2) Remove bearings (3) and (4) from gear (5).

LOlEV006

4. Outer race. Remove outer race (6) and O-ring from cage assembly (1).

L07EVO07

Coupling. Remove holder (7), then remove coupling (8).

LO7EVOOB

23-53

DISASSEMBLY

AND ASSEMBLY

TRANSFER

ASSEMBLY

6. Cage. 1) Remove cage (9). 2) Remove oil seal (10) from cage (9).

L07EV009

7. Input shaft cover. 1) Turn over transfer case. 2) Remove cover (11). 3) Using forcing screws, remove cage (12), then remove shim (13). t Check the number and thickness of the shims and keep in a safe place.

4) Remove outer race (14) and O-ring from cover (12).

8. Intermediate shaft cage assembly. 1) Remove intermediate shaft cage assembly (15), then remove shim (16). + Check the number and thickness of the shims and keep in a safe place. 2) Remove outer race (45) from cage assembly (1%

23-54

TRANSFER ASSEMBLY

DISASSEMBLY AND ASSEMBLY

9. Intermediate shaft gear assembly.

1) Remove intermediate shaft gear assembly (17). 2) Remove 2 bearings (19) from intermediate shaft gear (18).

LO7EVO14

10. Output shaft coupling cage assembly. 1) Remove holder (20) then remove shaft assembly (21). t When removing the shaft assembly from below, put wooden blocks underneath to prevent damage to the shaft assembly. 2) Remove bearing (23) from shaft (22).

23 107EVOlf

Remove mounting bolts, then using forcing screws “B” (Thread dia. = 12mm, Pitch = 1.75mm), remove coupling cage assembly (24).

4) Disassembly of coupling cage assembly. a) Remove mounting bolts, then using push tool (outside diameter: 94mm), remove coupling and bearing assembly (25), and shim (26) from cage assembly (27). t Check the number and thickness of the shims, and keep in a safe place.

Push

‘26

23-55

DISASSEMBLY

AND ASSEMBLY

b) Remove

collar (28) and outer from cage (30).

TRANSFER ASSEMBLY

race (29)

LO7EVOl

c) Using push tool (outside diameter: 94mm), remove coupling

(31).

4 Remove bearings

(32) and (33), and outer race (34), then remove oil seal (35) from cage (36).

LO7EVOI

11. output

shaft gear and collar. Remove output shaft gear (37) and collar (38) from transfer case.

12. Strainer. 1) Remove cover (39), then remove spring (40).

LOlEV02

23-56

DISASSEMBLY

AND ASSEMBLY

TRANSFER

ASSEMBLY

2) Take out strainer (41) and remove case (42).

LO?EVOZ,

13. Outer race. 1) Remove outer race (43) at intermediate shaft case end. 2) Remove outer race (44) at output shaft case end.

LOlEVOZ:

23-57

TRANSFER ASSEMBLY

DISASSEMBLY AND ASSEMBLY

TRANSFER CASE ASSEMBLY ASSEMBLY

SDecial tool

Part number

Part name

796-730-2140

Wrench

1. Outer race.

1) Using push tool (outside diameter: 150mm), install intermediate shaft outer race (43) to transfer case. 2) Using push tool (outside diameter: 130mm), install outer race (44) at front of output shaft to transfer case. 2. Strainer. 1) Fit O-ring and install case (42). 2) Install strainer (41).

3) Assemble spring (40), then fit O-ring and install cover (39).

L07EV021

3. Cover (input shaft end). 1) Using push tool (outside diameter: 170 mm), install outer race (14) to cover (12), then assemble O-ring.

i2 L07EVOIl

23-58

TRANSFER ASSEMBLY

DISASSEMBLY AND ASSEMBLY

2) Assemble shim (13), and install cover (12) to transfer case. l Standard shim thickness: 1.6mm.

df’

L07EVO24

4. Input shaft gear assembly. 1) Using push tool (inside diameter: IlOmm), install bearings (4) and (3) to gear (5). 2) Turn over transfer case, and assemble input shaft gear assembly (2).

L07EV006

5. Cage assembly. 1) Using push tool (outside diameter: 170mm), install outer race (6) to cage (1) and assemble O-ring.

L07EV007

2) Install cage assembly (1) to transfer case.

Seat surface of mounting bolt: Grease (G2-LI)

L07EVOZ:

23-59

DISASSEMBLY AND ASSEMBLY

TRANSFER ASSEMBLY

6. Adjusting preload of input shaft bearing. Set tool A to input shaft gear, then using torque wrench, measure preload. * Standard value of preload: 0.03 -0.1 kgm + If it is not within the standard value, adjust with shim (13).

.Torque wrench

L07EVO2f

7. Intermediate shaft gear assembly. 1) Using push tool (outside diameter : 150 mm), install 2 bearings (19) to gear (18). 2) Assemble gear assembly (17) to transfer case.

L07EV014

8. Intermediate shaft cage assembly. 1) Using push tool (outside diameter: 150mm), install outer race (45) to cage assembly (15), and assemble O-ring. 4 Install shim (16), then install cage assembly (15). sr Standard shim thickness: 2.0mm.

9. Adjusting preload of intermediate shaft bearing. 1) After installing intermediate shaft gear and cage assembly, sei tool A to input shaft gear assembly, then using torque wrench, measure preload. * Standard value of preload: Adjustment value for input shaft preload to.03 -0.1 kgm. * If it is not within the standard value, adjust with shim (1 6). 2) After adjusting preload of bearing, remove cage assembly (15), shim (16), and intermediate shaft gear assembly (17).

23-60

Input

Torque

DISASSEMBLY

TRANSFER

AND ASSEMBLY

ASSEMBLY

10. Cover.

install input shaft cover (11).

1=1

L07EVOZE

11. Shaft assemblv. 1) Turn over transfer case and set in position. 2) install bearing (23) to shaft (22). + Inside diameter of bearing: 76mm.

3) Using push tool (outside diameter: 130mm),

install outer race (44) to transfer case. 4) Assemble output shaft gear (37) inside transfer case, and set collar (38) on top of gear (37). 5) Install shaft assembly (21).

8 10

6) Assemble oil seal (10) and O-ring to cage (9),

and install to transfer case.

37 21

Lip of oil seal: Grease (G2-LI)

L07EV031

7) Install coupling (8) and holder (7) and secure shaft assembly. /(r\7

Mounting bolt: Thread tightener (LT-2)

Mounting bolt: 76.0 k8.0 kgm

8) Turn over transfer case.

23-61

DISASSEMBLY

AND ASSEMBLY

12. Coupling

and cage assembly.

TRANSFER

Push

1) Assemble coupling and cage assembly a follows: a) Using push tool (outside diameter: 145mm) install oil seal (35) to cage (36). &

Press-fitting surface of oil seal: Gasket sealant (Three Bond 11OB)

Lip of oil seal: Grease (G2-LI)

Push Press

Push

tool

fit

2) Adjusting preload of bearing. a) Pii O-ring and assemble cage assembly (36) in cage assembly (27).

30 29 32 26 33

30 34

36 I

26 /

O-ring: Grease (G2-LI)

b) With cage assembly (36) set naturally on top of cage assembly (27), measure clearance ‘s’ with a feeler gauge. + When holding down with the bolt, be careful not to tighten the cage. + Measure at 2 - 3 places and calculate the average. c) Install shim (26). + Adjust with shims to give a value of measured dimension ‘s’: 0 - 0.05mm.

3) Using push tool (outside diameter: 95mm), press fii coupling (31) to cage assembly.

23-62

tool

Coat the oil seal press-fitting surface at the cage end thinly with gasket sealant, and wipe off any gasket sealant that comes out. b) Using push tool (outside diameter: 170mm), press fit outer race (34) in cage (30). c) Assemble bearing (33) collar (28) and bearing (32), then using push tool (outside diameter: 170mm), press fit outer race (29) in cage (30).

ASSEMBLY

107Ev03:

DISASSEMBLY AND ASSEMBLY

TRANSFER ASSEMBLY

4) Fit O-ring and install cage and coupling assembly (24) to transfer case. /ir\7

O-ring: Grease (G2-Ll)

Tri

5) Fii O-ring and install holder (20). fi

O-ring: Grease (G2-LI)

Holder mounting bolt: Thread tightener (LT-2) 16 j Holder mounting bolt: 76.0 28.0 kgm

13. Intermediate shaft gear assembly. Assemble intermediate shaft gear assembly (17) in transfer case, and install shim (16) and cage assembly (15). + Assemble shim (16) adjusted in Step 9.

14. Adjusting speedometer sensor. 1) Screw in sensor (IA) until it contacts outside surface of gear (1B). t Before installing the sensor, check that the gear is at the outside surface compared with the mounting surface. 2) After sensor (1A) contacts gear (lB), turn it back 3/4 - 1 turn and secure with locknut (1C). + Be careful that the outlet direction of the sensor harness is not the opposite direction to the sensor connector clamp. &

Transmission

case

Sensor thread: Adhesive (LT-2)

Sensor locknut: 4.0 f 1.O kgm

23-63

TRANSMISSION CONTROL VALVE

DISASSEMBLY AND ASSEMBLY

TRANSMISSION REMOVAL

A A

CONTROL VALVE

1. Filter box. 1) Remove bracket (l), then remove plate (2). 2) Remove cover (3), then remove washer tanks (4) and air conditioner filter (5).

3) Remove filter box (6). 2. Transmission valve. 1) Disconnect electrical wiring (7) from transmission valve. 2) Remove eye-bolts (8) and breather (9). 3) Using eye-bolts, lift off transmission valve (10). + The removal work must be carried out by two workers, and the transmission valve must be raised horizontally. Transmission valve: 65 kg

17EYOB

23-64

DISASSEMBLY AND ASSEMBLY

TRANSMISSION

CONTROL

VALVE

INSTALLATION OF 1. Transmission

valve.

1) Set transmission valve (10) in mounting posi-

tion, and tighten mounting bolts. + Position the gasket holes at the matching surface correctly. + Tighten the mounting bolts on opposite sides in turn to prevent the valve the gasket from becoming deformed. Mounting bolts: 5.0 +0.5 kgm

2) Install eye-bolts (8) and breather (9).

3) Connect wiring (7) to transmission valve con-

nector. + When installing the connector, be careful not to deform the thread case.

2. Filter box. 1) Install filter box (6). 2) Install washer tanks (4) air conditioner filter (5), then install cover (3). 3) Install plate (2), then install bracket (1).

23-65

DISASSEMBLY

AND ASSEMBLY

TRANSMISSION

CONTROL

VALVE

LOWER VALVE ASSEMBLY

L07EMOB:

23-66

DISASSEMBLY

AND ASSEMBLY

DISASSEMBLY

TRANSMISSION

1. Remove solenoid

valve assembly

2. Remove stopper

(2) spring (3), and valve (4).

CONTROL

VALVE

(1).

3. Remove valves (5) and (6). 4. Remove spring (8), then remove shim (9), then remove valves (ll), (12) and (13), and spring (14) as a set. 5. Remove covers (15) and (16). 6. Remove spacer (17). 7. Remove spring (18) and valve (19). 8. Remove plug spring (22).

ASSEMBLY

(20), then

remove

collar

(21) and

1. Assemble spring (22) in collar (21), install in body (23), then fit O-ring and install plug (20). 2. Assemble

spring (18) in valve (19) and install.

3. Install spacer (17). 4. Fii gasket and install covers (16) and (15). 5. Assemble valve (12), spring (14), valve (13), shim (9) and spring (8) in valve (11) and install in body. 6. Install valve (6). 7. Install valve (5). 8. Install valve (4), spring (3) and stopper (2). 9. Fit gasket and install solenoid

valve assembly

(1).

23-67

TRANSMISSION DISASSEMBLY

CONTROL

VALVE

AND ASSEMBLY

UPPER VALVE ASSEMBLY

@Q, /l

@aI@

494b\ 0

/ 30 b

fa I 29

L07EM065

23-68

DISASSEMBLY

AND ASSEMBLY

DISASSEMBLY

TRANSMISSION

ASSEMBLY

1. Remove cover (1) and (2). 2. Remove guide (3), then remove spring (4), shim (5), valves (6), (7) and (9) and spring (8) as a set. 3. Remove valves (lo), as a set. 4. Remove stopper valve (15).

(12) and (13) and spring (11)

(14), then

remove

quick

return

CONTROL

VALVE

1. Assemble spring (35), valves (36), (34), (33) shim (32) and spring (31), fit washer (30) and O-ring, then tighten plug (29).

1 Plug: 11.0 21.5 kgm

2. Assemble shim (26) and springs (27) and (28) in valve (25) and install in valve body. + Standard shim width: 3mm

5. Remove spacer (16). 6. Remove cover (17).

3. Assemble valve (22) to valve (21) then assemble spring (23), valve (24) shim (20), and spring (19) in valve body and install guide (18).

7. Remove guide (18), spring (19), shim (20), valves (21) (22) and (24) and spring (23) as a set.

4. Fit O-ring and install cover (17).

8. Remove valve (25) shim (26) and springs (27) and

5. Install spacer (16).

(28). 9. Remove plug (29) washer (30) then remove spring (31), shim (32), valves (33), (34) (36), and spring (35) as a set.

6. Assemble quick return valve install stopper (14).

(15), fit O-ring,

and

7. Assemble valve (12), spring ( ll), and valve (10) in valve (13) and install in valve body. 8. Assemble valves (9) and (7), spring (8), shim (5) and spring (4), and install guide (3). 9. Fit O-ring and gasket and install covers (2) and (1).

23-69

DISASSEMBLY

AND ASSEMBLY

TRANSMISSION

CONTROL

VALVE

MAIN RELIEF VALVE ASSEMBLY

b/ 1

425F27i

DISASSEMBLY

ASSEMBLY

1. Remove plug (1) then remove springs (2) and (3). 2. Remove shims (4), valves and valve (8).

(5) and (6) spring

(7)

1. Assemble and install valve (8), spring (7) valves (6) and (5), then install shims (4) in to valve body (9). t Standard shim width: 1Smm. 2. Assemble springs

(3) and (2) in valve body (9).

3. Fit O-ring and tighten

23-70

plug (1).

DISASSEMBLY

CENTER SUPPORT

AND ASSEMBLY

CENTER SUPPORT REMOVAL

1. Drive shaft. 1) Disconnect the center drive shaft (1) from center support. + Set block under drive shaft and remove.

& ke

Center drive shaft: 31 kg

2) Sling front drive shaft (2) and disconnect

from

center support. Front drive shaft: 43 kg

L07ER030

2. Center support. 1) Disconnect grease tube port.

(3) from center sup-

L07ER03:

2) Sling center support (4), remove mounting bolts and lift off. * In case shims are inserted between center support and frame, check number of shims according to standard used when assembling. Center support:

43 kg

L07ER03:

23-71

CENTER SUPPORT

DISASSEMBLY AND ASSEMBLY

INSTALLATION

1. Center support.

1) Set center support (4) in mounting position and tighten mounting bolts. + Adjust shims so matching surface of center pin and coupling are parallel.

I Mounting

bolt: 56.0 +6.0 (Width across flats: 30 mm)

kgm

2) Connect grease tube (3) to center support.

2. Drive shaft. 1) Connect front drive shaft (2) to center support. Mounting bolt: 11.5 4 1.0 kgm

L07ER03D

2) Connect center drive shaft (1) to center support. + Clean mounting surface of coupling with a clean cloth. Mounting bolt: 11.5 21.0 kgm

23-72

DISASSEMBLY

CENTER SUPPORT

AND ASSEMBLY

CENTER SUPPORT DISASSEMBLY

Coupling. Remove center bolt (l), then remove retainer (2) Oring (3) and coupling (4).

2. Retainer. Remove mounting bolts (5) of retainer. t Remove all mounting bolts while rotating coupling.

3. Shaft. 1) Set shaft case assembly (6) on press stand. 2) Push out shaft (7) with press. t Be careful because the shaft will fall out suddenly.

L07ER03!

3) Remove spacer (8), bearing retainer (5) from shaft.

cone

(9), and

L07ER03

23-73

DISASSEMBLY AND ASSEMBLY

CENTER SUPPORT

4. Oil seal. 1) Remove oil seal (10) and O-ring (11) from retainer.

2) Remove oil seal (12) from case.

5. Case.

Remove bearing cone (13), and bearing outer race (14) and (15).

23-74

425F27

DISASSEMBLY AND ASSEMBLY

ASSEMBLY

CENTERSUPPORT

1. Bearing outer race. Assemble bearing (14) and (15) in case (16).

2. Oil seal. Assemble oil seal (10) in retainer (5). /(T-\7

Outer circumference of oil seal: Grease (G2-LI)

425F27i

3. Bearing cone. Assemble retainer (5) to shaft, and press fit bearing cone (9). t After assembling bearing, check that there is no clearance at tip-of shaft: t Assemble spacers. fi

Lip of seal: Grease (G2-LI)

Inner circumference Grease (G2-LI)

bearing: LOYER03;

Case. 1) Assemble O-ring (11) in retainer. l Insert O-ring completely in groove.

L07ER03

23-75

DISASSEMBLY

CENTERSUPPORT

AND ASSEMBLY

2) Stand shaft and insert case (16). t Fill “a” and “b” of case and inner circumference of oil seal completely with grease. 5. Retainer. Secure retainer (5) in case. + Be careful that O-ring when installing. Mounting

bolt:

does

not get caught b

6.7 20.7 kgm

L07EA03f

6. Bearing cone and seal. 1) Press fit bearing cone (14) to shaft. 2) Assemble oil seal (12) in case. + Dimension of seal press fit and outer edge of case: 0.5mm. A

Seal: Grease (G2-LI)

7. Coupling. Assemble coupling (4), install O-ring (3) and retainer (2), and secure center bolt (1).

L07ER03r

1 Center bolt: 95 f 10 kgm (width across flats: 36 mm)

8. Inspection of end play. Check that end play is within specified range. + End play: Less than 0.22mm. + If end play is “O”, with the seal and bearing coated with grease, check that the free rotating torque is less than 0.4 kgm. L07ERO4l

L07ER0411

23-76

L07ER03

DISASSEMBLY

AND ASSEMBLY

DRIVE SHAFT

DRIVE SHAFT DISASSEMBLY

1. Shaft.

Front

and

rear

drive

shaft

1) Remove shaft (2). t Make match marks “a” before removing to ensure that the direction of the spider assembly does not change. t Cover (1)and (1A) is caulked with a punch at four places, so it must not be removed unless necessary. + When removing cover (1) and (1A) be extremely careful not to damage cover (1) and (lA), and yoke (3). + When removing the caulking, raise the caulking with a screwdriver.

a L07EA042

Centsr Front

and

Rstainsr

roar

drive

shaft

Caulking

Center

drive

shaft

Caulking

L07ER043

L07ER046

2) Remove mounting bolts (4) then remove spider assembly (5). + Make match marks on yoke and spider.

LO?ER044

3) Remove bearing caps (6) from spider assembly. t Remove strap (7) of cap.

107ER045

23-77

DISASSEMBLY

DRIVE SHAFT

AND ASSEMBLY

4) When replacing bearing (8), seal (9), and Derling washer (10) from bearing cap (6), replace whole cap assembly.

0, 0

10 L07ERO4i

2. Yoke. 1) Remove mounting bolts (11) from yoke (3) then remove spider assembly (12). + Stamp match marks on the yoke and spider.

1-I

I 2) Remove bearing

LO7ERO4L

caps (13) from spider assem-

bly.

107ER04!

3) When replacing bearing (14), seal (15), and Derling washer (16) from bearing cap (13), replace whole cap assembly.

23-78

107ERDX

DISASSEMBLY

AND ASSEMBLY

ASSEMBLY

DRIVE SHAFT

1. Yoke. 1) Install

bearing

(14), and seal (15) to bearing

cap (13). &&

Bearing, seal: Grease (G2-LI)

LO1ERO51

2) Assemble Derling washer (16), and bearing cap (13) to spider assembly (12). + Be careful not to damage bearing with heat when welding strap. /(T-\7

Bearing cap: Grease (G2-LI) 0

i 16 L07ER052

3) Assemble spider assembly (12) to yoke (3). + Carefully align match marks. * Clean the mounting face of the bearing cap by wiping with a clean cloth. I

Mounting

bolt:

14.5 2 1.O kgm

LOTEROS

2. Shaft. 1) Assemble

bearing

(8) and seal (9) in bearing

cap (6). A

Bearing seal: Grease (G2-LI) 8

107ER047

23-79

DISASSEMBLY

DRIVE SHAFT

AND ASSEMBLY

2) Assemble Derling washer (10) and bearing cap

(6) to spider assembly (5). + Be careful not to damage bearing with heat when welding strap. A

Bearing cap: Grease (G2-LI)

3) Assemble spider assembly (5) to shaft (2). + Carefully align match marks. + Clean the mounting face of the bearing cap by wiping with a clean cloth. Mounting bolt: 14.5 + 1.O kgm

4) Align match marks “a”, then install shaft (2) to yoke (3). + Check that the direction of the spider assembly is the same. * If the spline is worn, replace the whole drive shaft assembly. L07ER055

Spline: Grease (G2-LI) Front

and

rear

drive

5) If cover (1) and (1A) has been removed, do as follows: l Front and rear drive shaft Insert seal and retainer to cover (1) and shaft (2), assemble cover (l), then caulk with a punch on diagonally opposite sides. l Center drive shaft Insert shaft (2) to cover (1A), assemble cover (lA), then caulk with a punch on diagonally opposite sides.

shaft

a L07ER042

front

and

Retainer

rear

drive

shaft

Caulking

Center

drive

Center

shaft

drive

shaft

23-80

L07ER046

L07ER043

DISASSEMBLY

AND ASSEMBLY

FRONT AXLE

FRONT AXLE REMOVAL

l l

Put blocks under the rear wheels to prevent the machine from moving, and apply the parking brake securely. Insert block (A) between frame (2) and the top surface of rear axle housing (1). Jack up the machine, and put blocks (B) under the front frame on the left and right sides.

L07FM022

1. Tires and wheels.

Sling left and right wheels (3), remove mounting nuts, then lift off. Tires and wheels: 660 kg

2. Drive shaft. Disconnect drive shaft (4) at differential end. + Align match marks on the coupling of drive shaft before assembling of drive shaft.

23-81

DISASSEMBLY AND ASSEMBLY

FRONT AXLE

3. Brake tubes. 1) Disconnect brake tube (5) from slack adjuster. 2) Disconnect brake tubes (6) and (7). t After disconnecting the piping, cover to prevent dust or dirt from entering.

4. Air piping. Disconnect air hose (8) from spring cylinder. + Loosen drain valve and drain air.

5. Front axle assembly. 1) Sling front axle housing (9) on one side, and fit garage jack under other side. 2) Fit garage jack under bottom of differential case. t Be careful not to damage the side face of the parking brake cover.

3) Remove mounting bolts, then using hoist and jack to maintain balance, lower front axle. t Be careful not to allow the parking brake caliper bracket interfere with frame. it Be careful not to allow the slack adjuster on the top surface of the axle housing hit against the frame. Front axle: 2100 kg

I 4) Pull the front axle out from under the machine.

23-82

to7ndoza

DISASSEMBLY

FRONT AXLE

AND ASSEMBLY

INSTALLATION

1. Front axle. 1) Pull front axle under machine body. 2) Fit lifting tool to front axle (9) set garage jack under differential case and maintain balance while setting in mounting position. 3) Tighten mounting bolts of front axle. 1 Mounting bolt: 280 240 kgm (Width across flats: 55 mm)

2. Air piping. Connect air hose (8) to spring cylinder.

L07FM026

3. Brake tube. 1) Install brake tubes (6) and (7). 2) Connect brake tube (5) to slack adjuster. + Wipe the connection with a clean cloth.

LO7FUO25

4. Drive shaft. Connect front drive shaft (4) at differential Mounting

bolts:

end.

11.5 f 1.O kgm

:MO24

23-83

DISASSEMBLY AND ASSEMBLY

FRONT AXLE

5. Tires and wheels. 1) Set left and right wheels (3) in mounting position, then install mounting nuts. Mounting nut: 48 +5 kgm (Width across flats: 30 mm)

4 Jack up machine, then remove block (B) from

under front frame. 3) Remove block (A) from between frame (2) and top surface of rear axle housing (1).

LO7FM022

6. Bleeding air from brakes. Bleed air from brakes, then check operation. * For details of bleeding air, see TESTING AND ADJUSTING.

23-84

DISASSEMBLY AND ASSEMBLY

FRONT DIFFERENTIAL

FRONT DIFFERENTIAL REMOVAL

Special tools

1. Draining oil. Remove drain plugs (1) and (2), then drain oil from axle assembly. Axle assembly: Approx. 75 4

2. Tires and wheels. 1) Using lift arm, raise front axle, the put stand under left housing and put block under front frame. 2) Sling left tire and wheel (3) remove mounting bolts, then lift off. Tires and wheels: 660 kg

LO7FVO17

3. Covers. Remove left and right covers (4).

23-85

DISASSEMBLY

FRONT DIFFERENTIAL

AND ASSEMBLY

4. Axle shaft. Using forcing screw, pull out axle shaft (5) and sun gear (6) about 200mm. + Forcing screw: “A” (Thread dia. = 12mm, Pitch = 1.75mm).

LO7FVOlB

5. Drive shaft. Disconnect front drive shaft (7). + Sling drive shaft and lower carefully. + Remove disc cover (8).

6. Spring cylinder. 1) Remove linkage pin (9) and air hose (10). 2) Remove spring cylinder (11).

7. Parking brake caliper. Remove plate (12) then remove parking caliper (13). + Remove pad. t Use two people to remove caliper. Parking brake caliper:

brake

32 kg

'VOZi

23-86

DISASSEMBLY

AND ASSEMBLY

FRONT DIFFERENTIAL

8. Differential. 1) Remove 2 mounting bolts of differential (14), then remove guide bolt (M20 x 55mm). t Screw the thread of the guide bolts in fully. + After screwing in the guide bolts, remove the remaining mounting bolts. Fit lever block (B) to differential case (15). 2) + Fit both edges of lever block to inspection window.

3) Pull out differential (14) along guide bolts about 20mm from axle housing (16). + Be careful not to damage the differential Oring.

4) Install tools A and B to garage jack, then insert between differential and axle housing, and install tool A to differential. 5) Adjust height of lifting tool and garage jack, and remove differential (14) carefully. Differential:

282 kg

L07FV02:

6) Operate garage jack and pull differential out from under the machine body. 7) Remove O-ring (17).

(14)

23-87

DISASSEMBLY

AND ASSEMBLY

INSTALLATION

FRONT DIFFERENTIAL

1. Differential.

1) Install tools A and B to garage jack, then install differential (14) in tool A.

4 Fii O-ring (17) to differential.

3) Operate garage jack and push differential in

under machine body.

4) When clearance between differential (14) and

axle housing is about 40mm. Install guide bolts (M20 x 55mm) in axle housing. 5) Fit lever block (B) to differential case (15). + Fit both edges of lifting tool to inspection window.

107FV02

6) Adjust height of lilting tool and garage jack, and

assemble differential along guide bolts. + Fit O-ring (17) securely in the groove and make sure that it is not caught when installing.

7) When clearance between axle housing (16) and differential (14) is about 20mm, remove tool A

and tighten mounting bolts uniformly. 8) Remove guide bolts and install mounting bolts.

/(r\7

Mounting bolt: Thread tightener (LT-2) Mounting bolt: 56 +6 kgm (Width across flats: 30 mm)

23-88

FRONT DIFFERENTIAL

DISASSEMBLY AND ASSEMBLY

IA. *

Adjusting shaft shim. Adjust the shaft shim when the differential assembly or axle housing have been replaced. 1) Tighten the mounting bolts of shaft (18) uniformly, and measure clearance ‘a’ between the axle housing and shaft. + Do not assembly any shim.

Axle

housing

Mounting bolt: 0.4 20.1 kgm (When measuring clearance)

425F53!

2) Select a shim of 0.1 i0.05mm larger than the measured value of clearance ‘a’, then assemble the shim. it Shim thickness: clearance ‘a’ + (0.1 +.05 mm) Mounting bolt: 11.5 + /- 1.O kgm

2. Parking brake caliper. Set parking brake caliper (13) in mounting position, insert plate (12) in groove of caliper and tighten mounting bolts. * Insert plate in caliper groove completely. + Check assembly of pad. n

Mounting bolt: Thread tightener (LT-2)

j Mounting bolt: 95 +lO kgm (Width across flats: 36mm)

L07FV02;

3. Spring cylinder. 1) Set spring cylinder (11) in mounting position and install. Mounting bolt: 28.5 23.0 kgm

2) Install air hose (10) and linkage pin (9).

LOlFVOZ

23-89

DISASSEMBLY

AND ASSEMBLY

FRONT DIFFERENTIAL

4. Drive shaft.

1) Install front drive shaft (7). 2) Install disc cover (8). * When connecting the drive shaft, clean the contact surface of the spider and coupling. Mounting bolt: 11.5 r 1.O kgm

Axle shaft. Push in axle shaft (5) together with sun gear (6).

6. Covers.

Fii O-rings in grooves left and right sides. +

of covers (4) and install on

Fit the O-ring securely in the groove and make sure that it is not caught when installing.

7. Tires and wheels.

1) Raise tire and wheel (3), set in mounting position, then install mounting nuts. Mounting nut: 48.0 +5.0 kgm (Width across flats: 30 mm) 2) Remove the stand. 8. Refilling axle assembly with oil. Remove level plug and add oil through oil filler to the specified level. Axle N-l oil: 75 Q

9. Bleeding air from brakes. Bleed air from brakes, then check operation. + For details of bleeding air, see TESTING AND AlIlllSTING~

23-90

107FV02

DISASSEMBLY

REAR AXLE

AND ASSEMBLY

REAR AXLE REMOVAL

A 0

Put blocks under the front wheels to prevent the machine from moving, and apply the parking brake securely. Jack up the machine, and put blocks (A) under the rear frame, and put two stands (8) under the counterweight.

LO7FR015

1. Tires and wheels.

Sling left and right wheels (l), remove mounting nuts, then lift off. Tires and wheels: 660 kg

2. Drive shaft. Disconnect rear drive shaft (2) from rear axle assembly. Rear drive shaft: 39 kg

1425103

3. Brake piping. 1) Disconnect tube (3) between

brake chamber and slack adjuster from slack adjuster. 2) Remove tubes (4) and (5) between slack adjuster and right and left wheel cylinders.

When lifting off the axle, there is danger that the brake tube may be damaged, so always remove it.

23-91

REAR AXLE

DISASSEMBLY AND ASSEMBLY

4. Grease tubes. 1) Disconnect grease tubes (6) and (7) from rear axle support.

2) Disconnect grease tube (8) from front axle support. t Remove clamp of electric wiring from support.

LO?FROl

5. Rear axle and support assembly. 1) Secure axle support and rear axle with chains.

2) Remove mounting bolts, then using hoist and garage jack to maintain balance, lower rear axle and support. Rear axle and support: 2050 kg 3) Pull rear axle and support (10) out from under the machine. + Support both ends of the axle with jacks.

23-92

DISASSEMBLY

AND ASSEMBLY

REAR AXLE

6. Front support.

1) Remove front support (11) from rear axle. + Be careful not to damage the packing. Front support: 95 kg

2) Remove packing (12) and (13) from front support.

L07FR023

3) Remove bushing (14) from front support. t Remove all dirt or grease from the mounting surface of the bushing inside the front support.

11--

L07FR024

7. Rear support. 1) Sling rear support, remove thrust cap (15).

23-93

REAR AXLE

DISASSEMBLY AND ASSEMBLY

L07FR026

2) Remove thrust washer (16), thrust plate (17) and thrust washer (18) from rear axle.

3) Lift off rear support (19). Rear support:

115 kg

4) Remove packing (20) from rear support.

107FR029

5) Remove bushing (21) from rear support. * Remove all dirt or grease from the mounting surface of the bushing inside the rear support.

23-94

L07FR030

DISASSEMBLY

AND ASSEMBLY

INSTALLATION

REAR AXLE

1. Rear support. 1) install bushing (21) on rear support (19). + Soak a cloth with primer for Loctite prism adhesive, then wipe the adhesion surface at the bushing end.

Q” \

&J 9 Q %

& + +

Adhesion surface at rear support end: Instant adhesive Loctite prism 411 (approx. 3 9) Install the bushing within 5 minutes of coating it with primer. Do not mix the primer with adhesive when using it.

0 %

8” 19 LO?FR029

2) Install packing (20) on rear support. it Be sure to assemble the packing facing in the correct direction. /(T\1

Packing lip: Grease (G2-LI)

3) Raise rear support (19) and set in position on rear axle mount. A

107FR030

Rear axle mount: Grease (G2-LI)

4) Install thrust washer (18) and thrust plate (17). /?-\?

Thrust washer: Grease (G2-LI)

Mounting bolt: 28.5 23.0 kgm

23-95

DISASSEMBLY

AND ASSEMBLY

REAR AXLE

5) Install thrust washer (16) and thrust cap (15). A

Thrust washer:

Grease (G2-LI)

Mounting

28.5 k3.0 kgm

bolt:

2. Front support. 1) Install bushing (14) on front support. + Soak a cloth with primer for Loctite prism adhesive, then wipe the adhesion surface at the bushing end. /(r\7

Adhesion surface at front support end: Instant adhesive Loctite prism 411 + +

(approx. 3 g) Install the bushing within 5 minutes of coating it with primer. Do not mix the primer with adhesive when using it.

LD7FR023

2) Install packing (12) and (13) on front support. t Be sure to assemble the packing facing in the correct direction. A

Packing lip:

Grease (G2-LI)

LOlFRD24

3) Raise front support (1 l), and set in position on rear axle mount, t Be careful not to damage packing with coupling. A

23-96

Rear axle mount:

Grease (G2-LI)

REAR AXLE

DISASSEMBLY AND ASSEMBLY

3. Rear axle and support. 1) Pull rear axle and support assembly (10) to underside of the machine. + Secure rear axle and axle support with chains.

2) Using hoist and garage jack to maintain balance, set in mounting position, and tighten mounting bolts of axle support. t Tighten the mounting bolts of the front support on opposite sides in turn. 1 Mounting bolt:

160 ~20 kgm (Width across flats: 46 mm)

4. Grease tubes. 1) Connect grease tube (8) to front axle support. t Install clamp of electric wiring to axle support.

LO7FRO1

2) Connect grease tubes (6) and (7) to rear axle support.

23-97

DISASSEMBLY AND ASSEMBLY

REAR AXLE

5. Brake piping. 1) Install tubes (5) and (4) between slack adjuster and right and left wheel cylinders. 2) Connect hose (3) between brake chamber and slack adjuster to slack adjuster. 1 Tubes (4) and (5): 7.0 k1.0 kgm

6. Drive shaft. Connect rear drive shaft (2) at rear axle end. * When connecting the drive shaft, wipe the contact surface when installing. 1 Mounting bolt: 11.5 f 1.0 kgm

14251031

7. Tires and wheels. 1) Set left and right wheels (1) in mounting position, then tighten mounting nuts. Mounting nut: 48 +5 kgm (Width across flats: 30 mm)

8. Bleeding air from brakes. Bleed air from brakes, then check operation. * For details of bleeding air, see TESTING AND ADJUSTING.

23-98

DISASSEMBLY

AND ASSEMBLY

REAR DIFFERENTIAL

REAR DIFFERENTIAL REMOVAL

’

Rear

Put blocks under the front wheels to prevent the machine from moving, and apply the parking brake securely.

axle

LO7fZ014

1. Rear axle. Remove rear axle. l For details, see REMOVAL OF REAR AXLE. t Do not remove the rear support from the rear axle.

2. Draining oil. Remove drain plug (1) and drain oil from axle assembly. Rear axle oil: 22 P 3. Axle shaft. 1) Remove cover (2). 2) Pull out axle shaft (3). + Pull out axle shaft about 200mm. 4. Rear differential. Using forcing screw, lift off rear differential (4). & kg

Rear differential: 282 kg

LO17FZD16

Remove 0-rina from contact surface.

23-99

DISASSEMBLY AND ASSEMBLY

INSTALLATION

1. Rear differential.

Raise differential (4), set in mounting position, then tighten mounting bolts. + Install the differential raising it horizontally. * Check that there is an O-ring fitted to the mounting face of the differential. A

Mounting bolt: Thread tightener (LT-2)

Mounting bolt: 56 25 kgm (Width across flats: 30 mm)

2. Adjusting shaft shim. Adjust the shaft shim when the differential t assembly or axle housing have been replaced.

1) Tighten the mounting bolts of shaft (5) uniform-

ly, and measure clearance ‘a’ between the axle housing and shaft. t Do not assembly any shim. 0.4 kO.1 kgm Mounting bolt: (When measuring clearance)

4 Select a shim of 0.1 +O.O5mm larger than the

measured value of clearance ‘a’, then assemble the shim. * Shim thickness = clearance ‘a’ t (0.1 +O.O5mm) 1 Mounting bolt: 11.5 +-1.0 kgm

3. Axle shaft. 1) Push in axle shaft (3). t If the axle shaft cannot be inserted, rotate the differential coupling lightly. Never try to force the shaft in.

23-100

REAR DIFFERENTIAL

DISASSEMBLY AND ASSEMBLY

REAR DIFFERENTIAL

2) Fii O-ring on cover (2) and install cover. + Make sure that the O-ring is not caught when installing.

Rear axle. install rear axle. * For details, AXLE.

see INSTALLATION OF REAR

Ra BT

...,o(“c”” Rear

axle

Refilling axle assembly with oil. Tighten plug and add oil through oil filler to the specified level. Axle

6. Bleeding air from brakes. Bleed air from brakes, then check operation. t For details of bleeding air, see TESTING AND ADJUSTING.

23-101

DIFFERENTIAL GEAR ASSEMBLY

DISASSEMBLY AND ASSEMBLY

DIFFERENTIAL DISASSEMBLY

GEAR ASSEMBLY OF

SDecial tools

Part number

Part name

Qty ~

790-501-5000

Unit repair stand

790-901-4110

Bracket

79331 o-2180

Plate

Preparatory work. Set differential assembly (1) on special tools A, A,, and A,. Differential assembly: 230 kg

10722111

1. Pinion assembly. 1) Remove case (2). 2) Remove oil seal (3) and dust seal (3A) from case.

Front

Rear

3A 3

2 ?!I

I 3) Screw in forcing screw “a” (Thread dia. = 18mm, Pitch = 1.75mm), and lift out pinion assembly (4). t Check number of shims (5).

23-102

LO7ZZ112

DISASSEMBLY

AND ASSEMBLY

DIFFERENTIAL

GEAR ASSEMBLY

2. Differential gear case assembly. 1) Remove left and right locks (6), and with a bar, turn nut (7) until it becomes loose.

2) Remove mounting

bolts (9) of cap (8).

LO1ZZllS

3) Remove nut and litI out differential assembly (10).

gear case

23-103

DIFFERENTIAL GEAR ASSEMBLY

DISASSEMBLY AND ASSEMBLY

FINE DISASSEMBLY OF PINION ASSEMBLY 3. Bearing, collar, and cage. 1) Support cage (ll), push shaft with press and take out pinion.

2) Remove bearing (12) and collar from cage.

LO7ZZil

3) Remove outer races (13) and (14) from cage (11).

4. Pinion bearings. 1) Remove snap ring (15), then remove bearing (1% 2) Remove bearing (17).

LO72212

23-104

DIFFERENTIAL GEAR ASSEMBLY

DISASSEMBLY AND ASSEMBLY

FINE DISASSEMBLY OF DIFFERENTIAL GEAR CASE ASSEMBLY 5.

Bevel gear (large). Remove mounting bolts, using eye-bolts “b” (Thread dia. = 16mm, Pitch = 2.0mm)Jft off bevel gear (18).

LO722121

6. Bevel gear (small). Remove thrust plate (19) and bevel gear (20). 7. Pinion gear and cross shaft. Remove pinion gear (21), cross shaft (22), and washer (23) as one unit.

8. Bevel gear (small). Remove bevel gear (24) and thrust plate. 9. Bearing. Remove bearing (26) from case (25).

23-105

DIFFERENTIAL GEAR ASSEMBLY

DISASSEMBLY AND ASSEMBLY

DIFFERENTIAL ASSEMBLY

GEAR ASSEMBLY

Soecial tools

LO722124

FINE ASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY 1.

Bearina. Using ire&fit kit “b” (120mm inner diameter), press fit bearing (26) to case (25).

2. Bevel gear (small). install thrust and small bevel gear (24) in case. + Align thrust with dowel pin and install. 3. Pinion gear and cross shaft. Assemble pinion gear (21) and washer (23) with cross shaft (22). + Align washer groove with dowel pin of case and install.

4. Bevel gear (small). Install bevel gear (20) and thrust (19).

23-106

LOlZZ12!

DISASSEMBLY

AND ASSEMBLY

DIFFERENTIAL

GEAR ASSEMBLY

5. Bevel gear (large).

Using eye-bolts “b” (Thread dia. = 16mm, Pitch 2.0mm), lift and install bevel gear (18). + Align pin hole of thrust and dowel pin on case side and install.

LO722121

FINE ASSEMBLY

OF PINION ASSEMBLY

6. Bearing. 1) Using press fit kit “d” (26mm inner diameter), install pinion bearing (17). 2) Using press fit kit “e” (55mm inner diameter), install bearing (16). /(r\7

Rotating surface of bearing: Engine oil (E030-CD)

3) Install snap ring (15).

7. Cage. 1) Install outer races (14) and (13). 2) Install cage (11) to pinion assembly. 8. Collar. Install collar (27). 9. Bearing. Using press fit kit “d” (76mm inner diameter), install

bearing (12).

23-107

DISASSEMBLY

DIFFERENTIAL

AND ASSEMBLY

GEAR ASSEMBLY

ASSEMBLY OF DIFFERENTIAL ASSEMBLY t Set differential case on special tools A, A,, and A,. 10. Pinion assembly. 1) Assemble shims (5) removed when disassembled. + Standard shim thickness: 2.lmm 2) Using eye-bolts “f’ (Thread dia. = 12mm, Pitch = 1.75mm), install pinion assembly (4). 3) Remove oil seal (3) and dust seal (3A) to case. Lit> A of oil seal: Grease (G2-LI)

LO7ZZ130

Lip A

of dust seal: Grease (G2-LI)

Front

’

Rear

Unit: mm LD?ZZ131

4) Fit O-ring to case, and install case (2). A

Mounting bolt: Thread tightener (LT-2)

Mounting bolt: 2.8 23.0 kgm

5) Install coupling holder. /(r\7

(28) fit O-ring and tighten

Mounting bolt: Thread tightener (LT-2)

[ Mounting bolt: 94 ? 10 kgm

Fit the balancer “g” to bolt hole of coupling, and measure the rotating torque. + Rotating torque: Max. 5.1 kg 11. Differential gear assembly. Sling differential gear assembly (10) and install case.

23-108

1072213

DISASSEMBLY

AND ASSEMBLY

DIFFERENTIAL

GEAR ASSEMBLY

12. Nut and cap.

1) Align nut (7) with differential case groove and install.

2) Install cap (8) and tighten bolt (9). A

Mounting bolt: Thread tightener (LT-2)

[ Mounting bolt: 95 2 10 kgm

t * +

Check match marks on bearing cup before installing. Rotate bevel gear 20 - 30 times to settle in, then tighten bolt. Bearing pre-load adjustment steps are as follows: 1) Install tool B, to cap on both sides. 2) Measure clearance “a” between tool 8, with tool B.

425F290

3) Add 0.26 i0.07mm to measurement dimension and set scale on tool B. + The added dimension becomes the amount of bending of the case, given before preload and given after pre-load. 4) Tighten adjusting nut with bar until increased amount becomes 0.26 ?O.O7mm.

23-109

DISASSEMBLY AND ASSEMBLY

DIFFERENTIAL GEAR ASSEMBLY

Caution for preload adjustment. When adjusting nut is over tightened, in case the amount of increased bending surpasses the standard measurement, return adjusting nut to position before adjusting. Then, while rotating bevel gear, lightly tap bearing cap and bevel gear with plastic hammer, and check that there is no clearance in portion “b”. No clearance

425f29

13. Adjusting tooth contact and backlash. Adjust the backlash, and at the same time adjust tooth contact. 1) Adjust backlash as follows: 4 Movement of bevel gear is done with adjusting nut (7). At this time, so as not to change pre-load pressurization of bearing, turn nuts on both sides, the same amount each, in same direction. b) Put dial gauge “h” in vertical contact with forward and reverse sides of outer edge of bevel gear tooth face, and while turning adjusting nut, adjust until gauge meter fluctuation becomes 0.3 - 0.4mm. + Measure at 3 or 4 places, and keep the pinion gear fixed when measuring. 2) Adjust tooth contact as follows: a) Adjust bevel pinion by adjusting shims between differential case and bearing cage. b) Adjusting tooth contact For details, see ADJUSTING TOOTH CONTACT.

23-110

DISASSEMBLY

AND ASSEMBLY

DIFFERENTIAL

GEAR ASSEMBLY

14. Adjusting tooth contact Coat face of 7 or 8 teeth of bevel pinion lightly with red lead (minimum). Hold the bevel gear by hand to act as a brake, rotate the pinion gear forward and backward and inspect the pattern left on the teeth. Tooth contact

20BF514

Cause

Procedure

for adjustment

The tooth contact pattern should start from about 5 mm from the toe of the bevel gear and cover about 50% of the length of the tooth. It should be in the center of the tooth height.

Adjust the pinion gear by adjusting the shims at the cage. Adjust the bevel gear in the same way as when adjusting backlash.

Bevel pinion gear is too far from bevel gear.

1. Reduce shims at pinion gear to bring closer to bevel gear. 2. Move bevel gear further away from pinion gear and adjust backlash correctly.

Bevel pinion gear is too close to bevel gear.

1. Increase shims at pinion

2OBF515 gear to move away from bevel gear. 2. Move bevel gear closer to pinion gear and adjust backlash correctly.

c 20BF520

20BF516 Bevel gear is too close to pinion gear.

II +

1. Reduce shims at pinion gear to bring closer to bevel gear. 2. Move bevel gear further away from pinion gear and adjust backlash correctly. f

20BF519

20BF517 Bevel gear is too far from pinion gear.

+ 1

1. Increase shims at pinion gear to move away from bevel gear. 2. Move bevel gear closer to pinion gear and adjust backlash correctly. P

20BF511 +

2OBF520

+ 1

When adjusting the driven gear, do not change the pre-load of the bearing. Turn the left and right adjusting the same amount each (check by the number of notches), in the same direction.

nut,

23-111

DISASSEMBLY AND ASSEMBLY

14. Lock. After adjusting tooth contact and backlash, install lock (6). A

23-112

Mounting bolt: Thread tightener (LT-2)

DIFFERENTIAL GEAR ASSEMBLY

DISASSEMBLY

AND ASSEMBLY

FINAL DRIVE

FINAL DRIVE DISASSEMBLY

Sbecial tool

II Part number II A I 795-520-l 910 1.

Part name

Fixture

1 Qtv

L07HH003

Tire and wheel assembly. Loosen wheel nuts, raise machine with equipment tools, insert stand under axle, sling tire assembly, remove wheel nuts, then remove tire assembly (1). Tire and wheel assembly: 600 kg

2. Draining oil. Remove drain plug (2) and drain oil. + Set the drain plug at the bottom.

L07HH004

Axle oil: Approx. 20 0

3. Cover. Remove mounting bolts (3), then remove final drive case cover (4). 4. Axle shaft. Screw in bolt “a” (Thread dia. = 12mm, Pitch 1.75mm) to axle shaft and lift out axle shaft assembly (6). 5. Planetary carrier. Remove mounting bolts (6), and using eye-bolts “b” (Thread dia. = 12mm, Pitch = 1.75mm), lift out planetary carrier assembly (7). + Because balance is bad, adjust the center of gravity with a bar and remove. Planetary assembly: 90 kg

23-113

DISASSEMBLY

AND ASSEMBLY

FINAL DRIVE

6. Ring gear. 1) Using tool A, hold wheel hub (9) and brake housing (8) in position. + install tool A to points on opposite sides, and use washers to adjust clearance.

2) Remove mounting bolts (lo), then remove retainer (11) and ring gear assembly (12). + There are shims inside the retainer, so check the number and thickness of the shims, and use for reference when installing. Ring gear: 50 kg

7. Disassembly of planetary carrier. Using a press, pull out shaft (13) and remove pinion gear (14). + There is a lock ball (15) on the shaft, so be careful not to lose the ball. + Write a number on the case and keep all the removed parts separate in sets. + The bearing and other parts have settled in together, so mark the parts and keep them in sets. 14

L07HHOlO

23-114

L07HH009

L07HHOli

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE

8. Disassembly of ring gear. 1) Remove lock plates (18) from ring gear hub (17), then remove ring gear (19). 2) Pull out bearing (20) from ring gear hub (17).

23-115

DISASSEMBLY

FINAL DRIVE

AND ASSEMBLY

Special tool I

Part number

1 795-520-l 910

Part name

QtY

Fixture

1. Assembly of ring gear. 1) Press fit bearing (20) on ring gear hub (17). + After press fitting the bearing, check that there is no clearance between the rib and bearing. 2) Set ring gear hub (17) on ring gear (19), then install lock plates (18). Install the lock plates with the wider ones t on the inside. Remove all grease and oil from the bolts. t Mounting bolts: Thread tightener (LT-2)

L07HHOlZ

Mounting bolt: 3.2 to.3 kgm

2. Assembly of planetary carrier. Set pinion gear (14) in carrier case, insert ball (15) in shaft (13), then press fit. * Press fii so that the hole for the lock ball is on the outside circumference, then stop with the hole at the front and align the holes. t After press fitting the shaft, check that the gear rotates smoothly.

L07HHOlO

LO7HHO11

23-116

L07HH009

DISASSEMBLY

FINAL DRIVE

AND ASSEMBLY

425F293 3. Adjusting

method of wheel . bearing. . .

1) Insert ring gear assembly (12) in axle housing,

fit retainer (11) tighten temporarily with mounting bolts (lo), and remove tool A. + When removing, secure wheel hub (9) and brake housing (8). + Measure thickness “b” of retainer before installing. + Do not insert shims in the retainer when tightening temporarily. + Rotate the wheel hub 20 - 30 times and tighten the bolts to a uniform torque. Mounting bolt: 8 20.5 kgm

2) Using a depth micrometer or dial gauge, insert

through measuring hole of retainer (21) and measure clearance ‘a’ from retainer to face of housing. + Measure at 2 places and take the average. + 0.3mm added to measured value difference C = a - b, becomes shim thickness. t Use the smallest number of shims which gives the required thickness.

3) After installing tool A to brake housing and

wheel hub, remove retainer, insert the required number of shims and retainer, then tighten mounting bolts. t When assembling shims, after installing tool A, always tighten the mounting bolts uniformly to the specified tightening torque. r(r\7

Mounting bolt: (LT-2)

Thread tightener

Mounting bolt: 28.5 +3 kgm

23-117

DISASSEMBLY

FINAL DRIVE

AND ASSEMBLY

4. Planetary carrier.

Fii O-ring, using eye bolts “b” (Thread dia. = 12mm, Pitch = 1.75mm) sling planetary carrier assembly (7), set in mounting position and tighten mounting bolts (6). + Because balance is bad, adjust the center of gravity with a bar and install.

Axle shaft. Screw in bolt “a” (Thread dia. = 12mm, Pitch 1.75mm) in axle shaft and insert axle shaft assembly (6). * If the position of the sun gear does not match, rotate the wheel hub to align.

6. Cover.

Fit O-ring, install final drive cover (4), then tighten mounting bolts (3). Mounting bolt: 7 k1.0 kgm

7. Refilling with oil.

Tighten drain plug (2), then remove level plug (22), and add oil through oil filler to specified level. * Set the machine so that the level plug of the final drive is at the bottom when refilling with oil. fi Axte oil: Approx. 20 P

23-118

T4251033

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE

8. Tire and wheel assembly. Sling tire and wheel assembly (l),set wheel hub, and after temporarily tightening wheel nuts, raise the machine with garage jack and remove support from under axle. Then lower the machine to the ground, and tighten wheel nuts to the specified torque. I Wheel nut: 48 ?5 kgm

(Width across flats: 30mm)

23-119

DISASSEMBLY

MEMORANDA

23-120

AND ASSEMBLY

FINAL DRIVE

POWER TRAIN 24

TRANSMISSION

MAINTENANCE

MOUNT

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

TORQUE CONVERTER CHARGING DAMPER

STANDARD

PUMP

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

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

2 3 4

TORQUE CONVERTER AND PTO .....................................................

TRANSMISSION

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

12 12 14 16

TRANSFER

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

DIFFERENTIAL

...........

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

FINALDRIVE

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

DRIVE SHAFT

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

CENTER SUPPORT AXLE MOUNT

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

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

24-1

MAINTENANCE STANDARD

Section

/ m

28.25

TRANSMISSION MOUNT

A - A

.25kgm r-l

Section

B -

425FO1212

Unit: mr No

24-2

Check item

Criteria

Thickness of shim for mounting

Shim thickness: 0.5mm (Decide the shim thickness so that the misalignment between the damper output shaft and input shaft is less than 2.0mm).

Clearance between stopper and bracket

There must be a clearance of at least 2mm between the stopper and bracket around the whole circumference.

Remedy

Adjust

MAINTENANCE

STANDARD

TORQUE CONVERTER

CHARGING

PUMP

TORQUE CONVERTER CHARGING PUMP

28.25i3.5

\ kgm

A - A

Section

425F134A

Unit: mr No

Check item

Clearance between gear case and side plate, gear

Criteria Standard clearance

Insertion depth of pin

Rotating torque of spline shaft Discharge Oil: EOl O-CD Temperature: 4565°C

Clearance limit

0.10 - 0.15

0.19 Replace

Clearance between inside diameter of plain bearing and outside diameter of gear shaft

Remedy

0.06 - 0.149

0.20

14 +0/G

0.7 - 1.2 kam Revolution (rpm)

Pressure (kg/cm?

Standard discharge (P/min)

Repair limit discharge @/min)

2500

192

176

24-3

MAINTENANCE STANDARD

DAMPER

Section

A - A

8 425FO1213

24-4

MAINTENANCE STANDARD

DAMPER

Unit: mm NO

Check item

Clearance between bearing and shaft.

Standard size

Toierance

Remedv Standard clearance

Clearance limit

Shaft

Hole

-0.009 -0.034

0 -0.012

-0.003 -0.034

0.05

Clearance between bearing and housing.

0 -0.013

0 -0.030

-0.03 -0.013

0.035

Clearance between bearing and shaft.

+0.012 -0.007

0 -0.015

-0.027 -0.007

0.025

Clearance between bearing and cover.

130

0 -0.018

+.018 -.007

0.007 0.036

0.05

Clearance between retainer and cover.

135

-0.014 -0.054

+0.04 0

0.014 0.094

0.13

Standard size

Tolerance

Repair limit

0 -0.087

-0.12

105

0 -0.087

-0.12

Criteria

Wear of surface in coupling and oil seal.

Wear of surface in shaft and seal.

Backlash of spline (shaft, coupling, and body).

Replace

0.071 - 0.177

24-5

MAINTENANCE STANDARD

TORQUE CONVERTER

TORQUE CONVERTER AND PTO

AND PTO m ,5.5 k0.5kqm

sa/ 42.5f2.5kp

A6.75

irO.i?3qm

6.75 i0.75kq.m

d-y

425FO1214

Unit: mm No 1

Check item

Criteria Tolerance

120

+ 0.035 0

120.5

+ 0.025 0

65.1

Width

3.95

0 -0.1

3.55

Thickness

4.6

20.1

4.14

Inside diameter of seal ring surface of sleeve

Width and thickness of seal ring

24-6

Repair limit

Standard size

inside diameter of seal ring surface of retainer

Remedy

Backlash of PTO gear (Drive gear)

0.18 - 0.49

Repair chrome plating or . replace

Replace

MAINTENANCE STANDARD

TORQUE CONVERTER AND PTO

MEMORANDA

24-7

MAINTENANCE

STANDARD

TRANSMISSION

425FO1215

24-8

MAINTENANCE STANDARD

TRANSMISSION

Unit: mn No

Check item

Criteria

Remedy

Standard size 1

No. 1 clutch springs (12 pieces)

Repair limit

Free Length

Installation length

Installation load

Free Length

Installation load

14.9 kg

13.0 kg

No. 2 clutch springs (12 pieces)

8 kg

7.0 kg

No. 3 clutch springs (12 pieces)

12 kg

10 kg

No. 5 and No. 6 clutch springs (24 pieces)

8.6 kg

7 kg

Replace

Thickness of 1 disc

-0.006 17

Outside diameter of output shaft bearing

120

+0.016 -0.006

+ 0.022

Outside diameter of output shaft bearing

130

+0.018 -0.007

r 0.026

24-9

MAINTENANCE STANDARD

TRANSMISSION

Unit: ml Standard size

Tolerance

Repair limit

3.0

-0.01 -0.03

2.6

Thickness

3.5

kO.1

3.35

Width

4.0

-0.01 -0.03

3.5

Thickness

5.1

. 20.12

4.95

Width

5.0

-0.01 -0.03

4.7

Thickness

6.0

+0.15

5.82

Width 19

24-10

Wear of seal ring for input shaft

Wear of seal ring for output shaft

Wear of seal ring for 2nd clutch

Remedy

Replace

MAINTENANCE STANDARD

TRANSMISSION

425FO1216

Unit: ml No

Criteria

Check item

Remedy

Backlash between No. 1 sun gear and planetary gear

0.13 - 0.31

Backlash between No. 1 planetary gear and ring gear

0.15 - 0.38

Backlash between No. 2 sun gear and planetary gear

0.14 - 0.35

Backlash between No. 2 planetary gear and ring gear

0.15 - 0.39

5 6

Backlash between No. 3 sun gear and planetary gear Backlash between No. 3 planetary gear and ring gear

0.15 - 0.39

Backlash between No. 5 sun gear and planetary gear

0.14 - 0.35

Backlash between No. 5 planetary gear and ring gear

0.15 - 0.39

Backlash between No. 6 sun gear and planetary gear

0.14 - 0.35

Backlash between No. 6 planetary aear and rina aear

0.15 - 0.39

0.14 - 0.35

Replace

24-11

MAINTENANCE

STANDARD

TRANSMISSION l

TRANSMISSION

CONTROL

CONTROL VALVE

UPPER VALVE

\_I______----

4.25tO.75

kgm

14 8 2

16 425F139A

425F140

24-12

VALVE

MAINTENANCE STANDARD

TRANSMISSION CONTROL VALVE Unit: mrn

Check item

Criteria Standard size

Clearance between reducing valve and body

Tolerance

Remedy Standard clearance

Clearance limit

Shaft

Hole

-.035 -.045

+0.013 0

0.035 0.058

0.08

Clearance between torque converter relief valve spool and body

-0.035 -0.045

+0.013 0

0.035 0.058

0.08

Clearance between priority valve spool and body

-0.035 -0.045

+0.013 0

0.035 0.058

0.08

Clearance between quick valve spool and body

-0.035 -0.045

+0.013 0

0.035 0.058

0.08

Clearance between modulating valve spool and body

-0.035 -0.045

+0.013 0

0.035 0.058

0.08

Clearance between main relief valve spool and body

-0.035 -0.045

+0.013 0

0.035 0.058

0.08

Repair limit

Standard size 7

Priority valve spring

Replace

Free length

Installation length

l nstallation load

37.7

22.1 kg

59.6

19.9 kg

Free length

Installation load

Torque converter relief valve spring

12.8 kg

60.6

11.5 kg

Modulating valve spring (inner)

118

110

5.55 kg

117

5.3 kg

Modulating valve spring (outer)

145.7

144

1.69 kg

141

1.60 kg

Main relief valve spring (inner)

108

83.5

30.8 kg

105

29.3 kg

Main relief valve spring (outer)

122

83.5

37.9 kg

118

36.0 kg

Thickness of shim for reducing valve

3.0 mm (pressure per 1 piece: 0.65 kg/cm2)

Thickness of shim for modulating valve

3.0 mm (pressure per 1 piece: 0.20 kg/cm2)

Thickness of shim for priority valve

2.0 mm (pressure per 1 piece: 0.26 kg/cm9

Thickness of shim for torque converter relief valve

4.0 mm (pressure per 1 piece: 0.26 kg/cm2)

Thickness of shim for main relief valve

1.5 mm (pressure per 1 piece: 0.39 kg/cm2)

Adjust

24-13

MAINTENANCE STANDARD

TRANSMISSION CONTROL VALVE

LOWER VALVE

Section

6 -

425FO1218

24-14

MAINTENANCE

STANDARD

TRANSMISSION

CONTROL

VALVE

Unit: mn No

Check item

Clearance between FORWARD-REVERSE spool and body

Clearance between 1st speed spool and body

Clearance between 2nd speed spool and body

Criteria Standard size

Tolerance Shaft

Hole

Remedy Standard clearance

Clearance limit Replace

-0.035 -0.045

+0.013 0

0.035 0.058

0.08

Clearance between 3rd

FORWARD-REVERSE, No. 1, No. 2, No. 3 and

24-15

MAINTENANCE STANDARD

SOLENOID

TRANSMISSION CONTROL VALVE

VALVE

Reverse Forward 4th 3rd 2nd 1st

0.07 + 0.01 kgm

0.075+0.005kyr

ILU

6.7 i0.7kp

~0.165i0.015kp

0.165k0.015kgm

i-u

Ill

0.07 i 0.01 b

I Section

A -

425FO1219

24-16

MAINTENANCE STANDARD

TRANSMISSION CONTROL VALVE

MEMORANDA

24-17

MAINTENANCE STANDARD

TRANSFER -

TRANSFER

------2

37618kgm

‘JO

‘7

‘12

425FO1217

24-18

MAINTENANCE STANDARD

TRANSFER

Unit: mr No

Check item

Criteria

Remedy

Standard size

Tolerance

Repair limit

Outside diameter of idler shaft (Rear)

+ 0.039 + 0.020

70.011

Outside diameter of idler shaft (Front)

+ 0.039

70.011

+0.020 3

Inside diameter of input shaft

170

0 -0.040

130

-0.012 -0.052

170/012

diameter of idler shaft bearing Inside diameter of output shaft (Rear)

Outside diameter of output shaft

+ 0.045

Replace 95.013

+0.023 7

Output diameter of output shaft bearing and housing

170

-0.012

Outside diameter of output shaft

+ 0.039 + 0.020

75.011

Oil seal sliding surface of output shaft coupling (Rear)

0 -0.087

94.82

Oil seal sliding surface of output shaft coupling (Front)

-0.052

-0.087

Standard size

Repair limit

Clearance between input cover and case

2 (Shims)

Preload 0.01 - 0.1 kgm

Clearance between output cover and case

2 (Shims)

Max. 0.05 (with shims)

2 (Shims)

Preload 0.01 - 0.1 kgm

13 14

Clearance between idler cover and case

1 Backlash between input gear and idler

I 1

0.22 - 0.53

war 15

Backlash between output gear and idler

0.22 - 0.53

Adjust

I I

Replace

24-19

DIFFERENTIAL

MAINTENANCE STANDARD

DIFFERENTIAL

13 14 15

1 Section

A - A

425FO1222

24-20

MAINTENANCE STANDARD

DIFFERENTIAL

Unit: mr

Clearance of pinion shaft bearing (inner race)

24-21

DIFFERENTIAL

MAINTENANCE STANDARD

92.5 + 12.5k?“’

28.25 + 3;25kp

2p.25 i 3.okp

I 28.25 + 3.0 kqm

1st step: 0.4 f 0.1 kgm (when measuring 2nd step: 11.5 + 1 .O kgm (shim installed)

24-22

clearance

(no shim))

425FO1223

DIFFERENTIAL

MAINTENANCE STANDARD

Unit: mi No.

Criteria

Check item

Remedy

Standard size

Tolerance

Repair limit

+0.05 -0.05 +0.09

3.8

Thickness of side gear washer

Thickness of pinion gear washer

1.5

1.35

Replace

-0.01 3

Wear of oil seal surface

100

0 -0.087

24-23

MAINTENANCE STANDARD

FINAL DRIVE

48+5kgm

1 Sec.:8f0.5k~m 2 Sec.: 28.25i3.25kpm

425FO1224

Unit: _ . ..__mn

Check item

Criteria Standard size

1 2

Clearance between planetary shaft and bearing

Clearance between ring gear hub and bearing

180

Thickness of spacer

Backlash between planet gear and sun gear Backlash between planet gear and ring

Tolerance

Remedy Standard clearance

Shaft

Hole

+0.015 + 0.002

0 -0.015

-0.002 -0.030

+0.033 +0.004

0 -0.030

-0.004 -0.063

24-24

Thickness of shim for wheel hub

Replace

Standard size

Tolerance

Repair limit

+O.l / -0.1

21.5

0.18 - 0.43 0.18 - 0.54

gear 6

Clearance limit

2.0

Replace

DRIVE SHAFT

MAINTENANCE STANDARD

425FO1220

11.25+ 1.29q.m

-1

1.25+ 1.25kg.m

m 14.65+ 1.25+

-14.6511.25 View X

View

425FO1221

24-25

MAINTENANCE STANDARD

CENTERSUPPORT 6

CENTER SUPPORT

95+10

I I

kgm

6.7i0.7

kgm

425F143A

No.

Check item

Criteria Standard size

Tolerance Shaft

Hole

Standard clearance

Clearance limit

Clearance between case and bearing

0 -0.018

-0.036 -0.061

-0.018 -0.061

-0.015

Clearance between case and bearing Clearance between cou-

130

0 -0.018 +0.051

-0.036 0

-0.018 -0.061 0.032

-0.015

. -0.061

+ 0.032

-0.015

0.066

+0.051 +0.032

0 -0.015

0.032 0.066

pling shaft and bearing 4

Clearance between coupling shaft and bearing

Standard size

Tolerance

0.029

Repair limit

Wear of oil seal surface

0 -0.087

-0.18

Wear of oil seal surface

105

0 -0.087

-0.18

End play of coupling shaft

Preload max. 0.4 kgm

Replace

0.029

24-26

Remedy

Unit:

Repair chrome plating or replace Replace

MAINTENANCE STANDARD

CENTER SUPPORT

MEMORANDA

24-27

MAINTENANCE STANDARD

AXLE MOUNT

28.25 +3.25b

5 2 w

24-28

28.25 k 3.25kgm

425FO1225

MAINTENANCE

STANDARD

AXLE MOUNT

Unit: mr No.

Check item

Criteria Standard size

Tolerance

’ Standard ’

Shaft

Hole

Clearance of shaft and hole front support side (after press fiiing bushing)

310

-0.056 -0.137

+0.489 0

Clearance of shaft and hole front support side (before installing bushing) Clearance of shaft and hole rear support side (after

320.2

+ 2.300 -0.800

+ 0.086 0

260

-0.056 -0.137

+0.481 -0.008

270.2

+ 2.300 +0.800

+0.081 0

Remedy clearance

Clearance limit

0.056 0.626

1.6

0.048 0.618

1.6

. Replace

(see note)

press fiiing bushing) 4

Clearance of shaft and hole rear support side (before installing bushing)

Standard size

Tolerance

Thickness of wear plate

-0.10 -0.25

Thickness of wear plate

+O.l -0.3

Thickness of rear bushing

20.1

Thickness of front bushing

20.1

* Note:

Repair limit

Replace

The bushings must be in contact with the support at both the front and rear.

24-29

MAINTENANCE

STANDARD

MEMORANDA

24-30

AXLE MOUNT

STEERING 41

STRUCTURE

SYSTEM

AND FUNCTION

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

STEERING PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STEERING CIRCUIT DIAGRAM

CENTERHINGEPIN

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

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

STEERING COLUMN AND GEAR BOX STEERING LINKAGE

...................................................... STEERING,CONTROLSYSTEM .............................................................. STEERINGVALVE ROTOR SEAL .................................................................. ....................................................... STEERING RELIEFVALVE SAFETY VALVE (WITH SUCTION VALVE) ............................................ OPERATION OF DEMAND SPOOL ................................................. OPERATION OF THE STEERING VALVE .............................................

7 7 9 10 11 13 16

TWO-WAYRESTRICTORVALVE

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

41-1

CENTER HINGE PIN

STRUCTURE AND FUNCTION

CENTER HINGE PIN

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

Front axle Rear axle Front frame Rear frame Upper hinge pin Lower hinge pin

41-2

OUTLINE l

Section A - A

Section B -

The front frame (3) and rear frame (4) are connected through a bearing by the center hinge pin (5) and (6). The steering cylinders are connected to the left and right 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.

STRUCTURE AND FUNCTION

STEERING

STEERING PIPING

PIPING

425FO1135

1. Steering cylinder (R.H.) 2. Hydraulic tank 3. Steering pump and PPC pump 4. Oil cooler 5. Hydraulic pump 6. Switch pump 7. Steering valve 8. Steering cylinder (L.H.)

41-3

STRUCTURE AND FUNCTION

STEERING

CIRCUIT

STEERING CIRCUIT DIAGRAM

DIAGRAM To main cuntrol

valve

k5-

To PPC valve

425FO1136

1. Hydraulic pump 2. Switch pump 3. Steering pump 4. PPC pump 5. Check valve 6. Demand valve 7. Main relief valve 8. Steering valve 9. Safety valve (with suction)

41-4

10. Two-way restrictor valve 11. Steering cylinder (L.H.) 12. Steering cylinder (R.H.) 13. Oil cooler 14. Hydraulic tank 15. Breather 16. Emergency pump 17. Diverter valve 18. Warning lamp switch

STRUCTURE AND FUNCTION

STEERING COLUMN AND GEAR BOX

STEERING COLUMN AND GEAR BOX f-

Section

B -

Section

C - C

A -

425FO1137

OUTLINE I. Steering wheel 2. Center shaft 3. Steering column 4. Gear box 5. Ball nut 6. Ball 7. Worm

8. Tilt lever

The steering gear is recirculating ball type gear. In this type of gear there is round bottomed thread cut in the steering shaft. There several balls (6) between the nuts which slide in this thread. Ball nut (5) moves up and down in accordance with the rotation of the steering shaft, and turns worm (7). Balls (6) move in the nut groove of the shaft together with the rotating of the steering wheel. They pass from the end of the nut through the passage on the outside, and return to the nut to be recirculated.

41-5

STRUCTURE AND FUNCTION

STEERING

STEERING LINKAGE

LINKAGE

Section

A - A

View

1. Link 2. Link 3. Gear box 4. Pitman arm 5. Link 6. Steering valve

41-6

425FO1138

STRUCTURE AND FUNCTION

STEERING CONTROL SYSTEM

STEERING CONTROL SYSTEM STEERING

VALVE

I I

425FO64

A. To steering cylinder B. To hydraulic circuit C. To steering cylinder D. From hydraulic pump

E. From steering pump F. From switch pump G. To hydraulic tank

41-7

STRUCTURE

STEERING

AND FUNCTION

CONTROL

SYSTEM

Section A - A

Section B -

425FO65

Section C - C

1. 2.

Demand valve Check valve

41-8

3. 4.

Orifice Steering spool

5. 6.

Lever Relief valve

7. 8.

Valve body Safety valve (with suction)

STRUCTURE

STEERING

AND FUNCTION

CONTROL

SYSTEM

ROTOR SEAL

section A -

Section

B -

B 421 F044

1. 2.

3. 4.

Shaft Lever Body Steering spool

41-9

STEERING CONTROL SYSTEM

STRUCTURE AND FUNCTION

STEERING

RELIEF VALVE

1. Main valve 2. Valve seat 3. Pilot poppet 4. Spring 5. Adjustment screw

56OBFO69

Function l

The steering relief valve is inside the steering valve. When the steering cylinder reaches the end of its stroke and abnormal pressure is generated, the oil sent from the pump is relieved through this valve. This prevents damage to the pump or circuit. (The relief valve sets the maximum pressure of the circuit.)

I 56OBFO70

Operation l

Port A is connected to the pump circuit, and port C is connected to the drain circuit. The oil passes through the orifice in the main valve (1) and fills port E Pilot poppet (3) is in contact with valve seat (2).

560BF07

When the pressure inside port A and B reaches the pressure set by the poppet spring (set pressure), pilot poppet (3) opens and the hydraulic pressure at port B escapes from port D to port C. This lowers the pressure at port B. When the pressure at port B drops, the orifice of main valve (1) generates a difference in pressure between port A and port B. Main valve (1) is opened by the pressure at port A and the oil at port A is relieved.

41-10

56OBFO72

STEERING CONTROL SYSTEM

STRUCTUREANDFUNCTION

SAFETY VALVE WITH

SUCTION

VALVE)

1. Suction valve 2. Main valve 3. Main valve spring 4. Pilot piston 5. Suction valve spring 6. Valve body

421FO45

Function l

The safety valve (with suction valve) is in the main valve. If shock causes any abnormally high pressure in the cylinder when the main valve is at neutral the safety valve (with suction valve) releases the abnormal pressure and protects the cylinder from damage.

Operation As a safety valve Port A is the cylinder circuit and port B is the drain l circuit. The pressure oil in port A flows to port D through a hole in the pilot piston. It also flows to port C through an orifice consisting of the main valve (2) and the pilot piston (4). The pilot piston is secured to the safety valve by a lock nut. The diameter of the cross section gives a relationship of d >d, >ds>d,. 9l oil pressure occurs in port A, the If abnormally hrg l suction valve (1) is not actuated because of the relationship ds>d,. However, because of the relationship ds>d, in port A and port C, the hydraulic pressure on the main valve (2) is equivalent to the area difference between d, and d,. If this pressure goes up to the poppet spring force (set pressure), the poppet is actuated, and the oil in port A flows into port B.

421 F046

421 FO4J

41-11

STRUCTURE AND FUNCTION

As a suction valve 0 If negative pressure is generated in port A, port D also has negative pressure, because port D and port A are connected with each other. The tank pressure in port B is applied to port E. Hydraulic pressure “a” equivalent to the area difference between d, and d, is applied to the safety valve because of the tank pressure in port E. Therefore, hydraulic pressure “e” acts to open the valve and hydraulic pressure “a” acts to close the suction valve (1). l If the pressure in port A drops, (approaching negative pressure) hydraulic pressure “a’ becomes smaller than oil pressure “e”. When oil pressure “e’ becomes larger than oil pressure “a” + valve spring (5) force, the suction valve (1) opens, causing the oil to flow from port B into port A. This prevents negative pressure from building up in port A.

41-12

STEERING CONTROL SYSTEM

421 F048

STRUCTURE AND FUNCTION

OPERATION

STEERING CONTROL SYSTEM

OF DEMAND SPOOL

Engine running at idling when turning to the left

425FO1139

The oil from the steering pump flows into port A and the oil from the switch pump flows into port B. The oil from the hydraulic pump pushes check valve (1) open because the circuit is closed. Then, the oil flows into port B and merges with the oil delivered from the switch pump. The merged oil then flows into port A and merges with the oil delivered from the steering pump. Then, the merged oil flows into port C through orifice “a” in demand spool (2).

As its flow increases, the oil pressure at port C rises because of orifice “b” in port A, and exceeds the force of spring (4A). Then, demand spool (2) moves in the direction marked --+. For this reason, some of the oil from hydraulic pump flows into the work equipment circuit through port D. Thus, all the oil delivered from the steering pump and the switch pump plus some of the oil delivered from the hydraulic pump flow into the steering cylinder.

41-13

STRUCTURE AND FUNCTION

STEERING CONTROL SYSTEM

Engine running at medium speed when turning to the left From steering cylinder

To steering cylinder

ltrol valve

425FO1140

The oil from the steering pump flows into port A and the oil from the switch pump flows into port B. The pressure of the oil from the hydraulic pump increases because the circuit is closed and pushes check valve (1) open, overcoming the spring force in the valve. Thus, the oil flows into port B and merges with the oil delivered from the switch pump. The merged oil then flows into port A and merges with the oil delivered from the steering pump. Then, the merged oil flows into port C through orifice “a” in demand spool (2).

41-14

As the oil flow has increased more than that when the engine is running at low speed, the oil pressure at port C rises because of orifice “b” in port A, and exceeds the force of spring (4A). Then demand

spool (2) moves in the direction marked +. For this reason, all the oil from the hydraulic pump plus some of the oil from the switch pump flows into the work equipment circuit through port D. All the oil delivered from the steering pump and some of the oil delivered from the switch pump flow into the steering cylinder.

STRUCTUREANDFUNCTION

STEERING CONTROL SYSTEM

Engine running at high speed when turning to the left From steering cylinder

To steering cylinder

To main coni

425FO1141

The oil from the steering pump flows into port A and the oil from the switch pump flows into port B. The pressure of the oil from the hydraulic pump increases because the circuit is closed and pushes check valve (1) open, overcoming the spring force in the valve.. Thus, the oil flows into port B and merges with the oil delivered from the switch pump. The merged oil then flows into port A and merges with the oil delivered from the steering pump. Then, the merged oil flows into port C through orifice “a” in demand spool (2).

As the oil flow has increased more than that when the engine is running at medium speed, the oil pressure at port C rises because of oriiice “b” in port A, and exceeds the force of spring (4A). Therefore, the demand spool (2) is further moved in

the direction marked +. For this reason, the circuit is closed. Thus, all the oil from the switch pump and that from the hydraulic pump flows into the work equipment circuit through port D. All the oil delivered from the steering pump (4) flows into the steering cylinder.

41-15

STRUCTURE

OPERATION

AND FUNCTION

OF THE STEERING

STEERING

CONTROL

To main

valve

SYSTEM

VALVE

Not operated steering wheel

control

425FO1142

l l

In neutral, the steering wheel is not operated. Therefore, steering spool (3) does not move. The oil from the steering pump flows into port A and the oil from the switch pump flows into port B. Some of the oil from the hydraulic pump flows into the work equipment circuit and the rest of the oil pushes check valve (1) open to flow into port B and merges with oil from the switch pump. (The motion

41-16

of demand spool (2) indicates that the engine is running at low speed.) The merged oil further flows into port A and merges with the oil from the steering pump. The merged oil flows to steering spool (3). However, since the steering valve is in neutral, the oil does not flow into the cylinder, but into the drain through port Y”.

STEERING CONTROL SYSTEM

STRUCTURE AND FUNCTION

Turning right

-I)

To main

425FO1143

When the steering wheel is turned to the right, steering spool (3) moves to the left through the activated control linkage. Some of the oil from the work equipment switch pump flows into port B and port A through the demand valve and merges with the oil from the steering pump.

The merged oil to steering spool (3). Then, the oil flows into the bottom of the L.H. cylinder and the sides of the R.H. cylinder rod through port C in the spool, making a R.H. turn. The oil from the L.H. and R.H. cylinders is drained from two-way restrictor valve (5) through port D in the steering spool.

41-17

STRUCTURE AND FUNCTION

STEERING CONTROL SYSTEM

Turning left

To main contl -001valve

425FOll44

When the steering wheel is turned to the left, steering spool (3) moves to the left through the activated control linkage. Some of the oil from the work equipment switch pump flows into port B and port A through the demand spool (2) and merges with the oil from the steering pump. The merged oil flows to steering spool (3). Then, the oil flows from

41-18

two-way restrictor valve (5) into the side of the L.H. cylinder rod and into the bottom of the R.H. cylinder through port D in the spool, Making a L.H. turn. The oil from the L.H. and R.H. cylinders is drained from two-way restrictor valve (6) through port C in steering spool (3).

TWO-WAY RESTRICTOR VALVE

STRUCTURE AND FUNCTION

TWO-WAY RESTRICTOR VALVE

1. Body 2. Spring 3. Poppet

3 425FO70

Function 0

To reduce the shock caused by the inertia of the machine when the steering is operated, an orifice is installed in the oil line of the return circuit from the cylinder. This applies pressure to the returning oil, and regulates the movement of the cylinder piston.

Operation l

When the oil is flowing to arrow +, it pushes spring (2) and flows through the orifice, and between poppet (3) and the poppet seat.

425FO71

When the oil is flowing to arrow +, the oil flows only from orifice “a” inside poppet (3), so the flow is controlled.

Form cylinder *

425FO72

41-19

STRUCTURE AND FUNCTION

MEMORANDA

41-20

TWO-WAY RESTRICTOR VALVE

STEERING 42

TESTING

STANDARDVALUETABLE

SYSTEM

AND ADJUSTING

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

TOOL LIST FOR TESTING AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MEASURINGSTEERINGWHEELPLAY.................................................

MEASURING OPERATING FORCE OF STEERING WHEEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATING TIME OF STEERING WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STEERINGOILPRESSURE

STEERINGLINKAGE

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

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

TROUBLESHOOTINGTABLES ...................................................... 1. Steering wheel does not turn. ................................................. 2. Steering wheel is sluggish. .................................................... 3. Steering wheel moves unsteadily or is subject to large shock. .......................... 4. Machine tends to turn naturally in one particular direction when traveling. ................. 5. Left and right turning radii are different. ..........................................

8 11 12 13 14 14 14

42-1

STANDARD VALUE TABLE AND TOOL LIST

TESTING AND ADJUSTING

STANDARD VALUE TABLE Testing and measuring item

Measurement condition

Steering wheel l Steering wheel play l Steering wheel operating force 0 Operating time of steering wheel (Low idling) (High idling)

Road surface: Flat, horizontal, dry, paved surface: 0 Hydraulic temperature: 45 - 55°C 0 Machine posture: Facing straight

Clearance between front and rear frame

Engine speed: 1200 rpm

Steering oil pressure l Main relief oil pressure

Hydraulic temperature: 45 - 55°C Engine speed: High idling

Unit

Standard value

Permissible value

mm kg

20 - 70 1.o-2.2

20-l 00 Max. 3.0

Sec. Sec.

3.8 - 4.3 2.8 - 3.1

Max. 6.5 Max. 4.7

25 +2

kg/cm2

210 +5

210 210

TOOL LIST FOR TESTING AND ADJUSTMENT No

A A

Testina and measurina item

Tool name

Part number

Remark 0 - 25 kg

Steering wheel operating force

Push-pull scale

79A-262-0020

Steering wheel operating play

Convex scale

Commercially available

Steering wheel operating time

Stop watch

79A-262-0550

Clearance between front frame and rear frame

Convex scale

Commercially available

Steering oil pressure

Hydraulic tester

799-l 01-5000

When installing or removing gauges, 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. When taking measurements, do not allow unauthorized persons near the machine.

The oil in the circuit is hot, so be careful not to get burnt.

42-2

0 - 250 kg/cm2

When carrying out testing, adjusting or troubleshooting, stop the machine on level ground, install the safety bar on the frame, lower the bucket to the ground, and stop engine. Then apply the parking brake and block the tires.

1/lO second

TESTING AND ADJUSTING

MEASURING

+ l l

MEASURING

STEERING

WHEEL PLAY

STEERING WHEEL PLAY

Measurement condition Engine speed: Stop Machine posture: Facing straight Unit: mm Item

Steering wheel play

v 20_701

HOW TO MEASURE 1. Turn the steering wheel lightly clockwise and counterclockwise two or three times and confirm the neutral position of the steering mechanism. Put mark “a” on the outer frame of the vehicle monitor. 2.

Turn the steering wheel clockwise. Align the position where the tires begin to move with mark (l), then put mark (2) on the steering wheel.

Turn the steering wheel counterclockwise. Align the position where the tires begin to move with mark (1) then put mark (3) on the steering wheel. Measure the distance of a straight line between mark (3) and mark (2).

419F302

TESTING AND ADJUSTING +

Inspect the steering linkage (4) and (5) for looseness and free play. If any, adjust the linkage. 1. Loosen lock nut (6) on the steering gear box. 2. Then, adjust by turning adjustment screw (7) in or out. +

I.-

-1

.L_

L05AD002

To decrease the free play, turn adjustment screw (7) in. To increase the free play, turn the adjustment screw out.

LOSAHQO2

42-3

MEASURING OPERATING FORCE OF STEERING WHEEL

TESTING AND ADJUSTING

MEASURING t l l l l l

OPERATING

FORCE OF STEERING WHEEL

Measurement condition Read surface: Flat, horizontal, dry, paved surface. Coolant temperature: Inside operating range. Hydraulic oil temperature: 45 - 55°C Tire inflation pressure: Specified pressure. Engine speed: Low idling (bucket unload).

Special tool Part number

Part name

Qty

79A-262-0020

PUSh-DUII scale

Measuring

procedure

Hook push-pull scale A to the center of the steering wheel knob.

Start the engine. + After starting the engine, raise the bucket about 400 mm and remove the safety bar.

Set push-pull scale A at a tangent, and read the valve when the steering wheel is moving smoothly. + Do not read the value at the time the steering wheel starts to move. Unit: ka

IF-~

1 Sta;ed Operating force

42-4

1.0 - 2.2

1 Pem$sssble )I

Max. 3.0

OPERATING TIME OF STEERING WHEEL

TESTING AND ADJUSTING

OPERATING t l l l l l

TIME OF STEERING WHEEL

Measurement condition Road surface: Flat, horizontal, dry, paved surface. Coolant temperature: Inside operating range. Hydraulic oil temperature: 45 - 55°C Tire inflation pressure: Specified pressure. Engine speed: Low idling and high idling.

Soecial tool Part number

Part name

Qtv

79A-2626550

Stoo watch

Measuring procedure 1. Start engine. + After starting the engine, raise the bucket about 400 mm and remove the safety bar. 2.

Turn the steering wheel so that the machine is turned fully to the left or fully to the right.

Measure the time taken for the steering wheel to be turned to the left (right) to the full lock position. + Turn the steering wheel as fast as possible without forcing it. + Measure at low idling and high idling, and when turning to the right and to the left. Unit: Sec.

Operating time: Low idle High idle

3.8 - 4.3 2.8 - 3.1

Max. 6.5 Max. 4.7

42-5

STEERING OIL PRESSURE

TESTING AND ADJUSTING

STEERING OIL PRESSURE + l l

Measurement condition Hydraulic temperature: 45 - 55°C Engine speed: High idling

Soecial tool Inumber

Part name

~~101-5000

1 Hvdraulic tester 1

I Qtv

Procedure for measuring main relief pressure

Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Then operate the steering wheel several times to release the remaining pressure in the hydraulic piping.

Fii safety bar (1) on the frame.

Remove plug (2) for measuring the right turn steering circuit.

Install hydraulic tester A to the measuring port.

Start the engine and run at high idling. Turn the steering wheel to the right and measure the pressure when the relief valve is actuated. t When removing plug (3) for the left turn steering circuit, turn the steering wheel to the left and measure. Unit: kg/cm*

42-6

frame Front

STEERING

TESTING AND ADJUSTING

OIL PRESSURE

Testing and adjusting

Always stop the engine before adjusting the hydraulic pressure.

1. Stop the engine. 2.

Remove bolts (4), loosen bolt (5), and rotate cover (6) slowly clock wise. + Rotate the cover using bolt (5) as the pivot. + The working space is confined, so be extremely careful when performing this operation.

Remove cap nut (7) of the relief valve.

Loosen lock nut (8) then turn adjustment screw (9 to adjust. Amount of adjustment for 1 turn of adjustment t screw. 1 turn: Approx. 24.8 kg/cm2 Adjust the set pressure as follows; t To INCREASE pressure, TIGHTEN screw. To DECREASE pressure, LOOSEN screw. + If the relief pressure cannot be measured accurately, DO NOT tty to adjust the pressure. I

8 423F315B

42-7

TESTING

STEERING * l l l l l

0 +

STEERING

AND ADJUSTING

LINKAGE

Measurement condition Hydraulic temperature: 45 - 55°C Engine speed: 1200 rpm Road surface: Flat, horizontal, dry, paved surface Tire inflation pressure: Specified pressure Center Lever: Square with machine center line Pitman arm: Perpendicular to the machine rear frame Remove the cover under the cab.

Measuring

procedure

Start the engine and operate the steering wheel to set the front and rear frames in a straight line.

Loosen linkage mounting bolt (1) and nuts (2), and check the play of ball joints (3), rods (4) and (5), and center lever bearing (6).

Check that the center line of center lever (7) is at right angles to the center line of the chassis. t The steering spool should be at neutral.

I 4.

LINKAGE

Check that the pitman arm (8) is perpendicular.

Center

Start the engine and turn the steering wheel to the left and right to the full lock position. Check that clearance “a” between the front and rear frame stoppers is the standard value. 0 Clearance “a”: 25 ?2 mm.

42-8

line

tear ,ancel LCEADMZ

TESTING AND ADJUSTING

+ t

STEERING LINKAGE

When measuring the clearance to the right, adjustment screw (9) should be in contact with the pitman arm (8). When measuring the clearance to the left, adjustment screw (10) should be in contact with the pitman arm (8).

When measuring the clearance, adjustment screws (11) and (12) do not come in contact with center lever (7) respectively.

L05AD014I

LOCiADO i

Adjustment procedure 1. Set the machine facing straight to the front, and install the safety bar. 2.

Disconnect steering linkage (4) from the pitman arm.

Adjust linkage (5) so that the center line of center lever (7) is at right angles to the center line of the chassis when valve lever (13) is at neutral.

In the condition in “Step 3”, operate the steering valve lever to the end of its travel, and when center lever (7) contacts adjustment screws (11) and (12), turn back l/2 turn and lock in position with the nut. + Always adjust the center lever first.

r LO5ADO17

42-9

TESTING

AND ADJUSTING

Adjust the length of steering linkage (4) so that pitman arm (8) is perpendicular to the front frame, then connect steering linkage (4) to pitman arm (8).

Remove the safety bar.

STEERING

LINKAGE

-a

L05AD018

!L .--._ _l!.._K_.._. --

LO!3

Start the engine, then turn the steering wheel fully to the left and right, and adjust so that pitman arm (8) contacts stopper bolts (9) and (10) when clearance “a” between the front and rear frame stoppers is 25mm. Then lock in position with the nut. + After making the above adjustment, check again that the value is standard. learancel LO5AD013

42-10

TROUBLESHOOTING

TROUBLESHOOTING TABLE

Before carrying out the troubleshooting in this section, read “PRECAUTIONS WHEN TROUBLESHOOTING”, “METHOD OF READING TROUBLESHOOTING TABLE”, and “PREVENTING RECURRENCE OF TROUBLE” in SECTION 22.

42-l 1

TROUBLESHOOTING

TROUBLESHOOTING TABLE

TROUBLESHOOTING TABLE 1. Steering wheel does not turn. Ask the operator the following questions. l Did the steering wheel suddenly cease to turn? - Damage to equipment in steering circuit. l Did steering wheel show signs of being sluggish for some time? - Worn parts in steering circuit or faulty seal. Checks before troubleshooting. l Is oil in hydraulic tank and type of oil satisfactory? l Is there any damage to the steering gear box or the steering linkage? 0 Has the safety bar been removed from the frame? l Is the steering linkage properly adjusted?

Fault of item 1 and also work equipment operate normally.

does not

Steering wheel can only turn to either left or right.

Steering wheel is sluggish and does not turn properly.

Oil pressure in steering circuit does not rise at all

Because the steering circuit and the work equipment circuit are intimately related to each other, check the operation of the work equipment if the steering behaves abnormally.

The following symbols are used to indicate the action to be taken when a cause of failure is located. X: Replace A: Adiust

42-12

A: Repair C: Clean

TROUBLESHOOTING

TROUBLESHOOTING TABLE

Steering wheel is sluggish. Ask the operator the following questions. 0 Did the steering wheel suddenly become sluggish? Damage to equipment in steering circuit. 0 Did the steering wheel show signs of being sluggish for some time? - Worn parts in steering circuit or faulty seal. Checks before troubleshooting. l Is oil level in hydraulic tank and type oil satisfactory? l Is there any abnormality in the steering gear box mounting part, steering column, or linkage? l Is the adjustment of the steering valve control lever correct? l Is there any oil leakage from the oil pressure hose, valves, cylinders, etc.? l Is there any seizure between the pin, pin bearing and bushing of the center hinge and the steering cylinder pin and bushing? o Check tire inflation pressure. Fault check. l Measure the operating force of the steering wheel and also the time required to turn the machine when the steering is operated, then check the results against the judgement criterion table to see whether or not there is any abnormality.

Problems 1

Steering wheel is sluggish in both left and right directions.

Steering wheel is sluggish in one of left and right directions.

Steering wheel is particularly

Boom lifting speed is insufficient throttle.

Steering wheel is sluggish and jerky.

Hydraulic

Steering Circuit pressure is low.

sluggish at low engine speed. when engine is at full

0 0 0

oil overheats.

4 8

oil pressure in return side piping of steering cylinder

rises.

The following symbols are used to indicate the action to be taken when a cause of failure is located. X: Replace A: Adiust

A: Repair C: Clean

42-13

TROUBLESHOOTING

TROUBLESHOOTING TABLE

Steering wheel moves unsteadily or is subject to large shock. Checks before troubleshooting; l Is oil level in hydraulic tank and also oil type satisfactory? l Is there any damage to the steering gear box mounting parts, steering column, or linkage? l Is there any play in the center pin hinge bearing or steering cylinder pin bushing? l Does tire inflation pressure fluctuate? FauR check Operate the wheel loader in a safe place and check the conditions under which the steering wheel becomes unsteady. t If, in addition to the steering wheel being unsteady, there are other faults such as sluggishness, etc., refer to item 2 “Steering wheel is sluggish”.

Machine body is unsteady when traveling on bumpy road surface.

Steering wheel becomes unsteady when working or traveling.

Machine body becomes unsteady when traveling at high speed.

Machine

if suddenly

turned

body becomes unsteady during engine starting.

Machine tends to turn naturally in one particular direction when traveling. Cause:

Faulty steering valve 0 Incorrect positioning of spool l Faulty safety valve 0 Oil leakage in steering cylinder l Does tire air pressure fluctuate?

Left and right turning radii are different. Cause:

42-14

Incorrectly adjusted steering linkage. Left and right steering balance, lock position of stopper. (Valve relief noise can be heard upon completion of turning.)

The following symbols are used to indicate the action to be taken when a

STEERING 43

DISASSEMBLY

SYSTEM

AND ASSEMBLY

STEERING GEAR.. ............................................................... REMOVALOF ................................................................. INSTALLATION OF.. ............................................................

3 3 5

STEERING GEAR BOX.. ........................................................... DISASSEMBLYOF .............................................................. ASSEMBLYOF ................................................................

6 6 7

STEERING AND PPCPUMP

10 10 11

STEERINGVALVE ............................................................... REMOVALOF ................................................................ INSTALLATION OF.. ........................................................... DISASSEMBLYOF ............................................................. ASSEMBLYOF ...............................................................

12 12 14 16 17

STEERING CYLINDER ............................................................ REMOVALOF ................................................................ INSTALLATION OF.. ........................................................... DISASSEMBLYOF.. ........................................................... ASSEMBLYOF ...............................................................

18 18 20 22 24

CENTERHINGEPIN ............................................................. REMOVALOF ................................................................ INSTALLATION OF.. ...........................................................

27 27 34

........................................................ REMOVALOF ................................................................ INSTALLATIONOF .............................................................

To maintain the performance of the machine and to prevent failures, it is particularly important to pay attention to the degree of cleanliness of the oil in the hydraulic circuits. When adding oil or changing the oil, or when replacing the filters, check that the oil container and area around the filler of the hydraulic tank are clean. If any internal part of the hydraulic equipment breaks, disassemble and clean all the hydraulic equipment and circuits to remove any dirt or pieces from the circuit. If any parts of the hydraulic circuits are disassembled and assembled, also carry out thorough flushing of the hydraulic circuits. + After replacing or flushing the hydraulic tank oil, filter element, or strainer, or when removing and installing any hydraulic cylinder, hydraulic pump or any other hydraulic equipment or work equipment piping, always bleed the air as follows after completion of installation. l Air bleeding procedure 1) Run the engine at low idling, and extend and retract the steering, bucket, and lift arm cylinders 4 - 5 times without going to the end of this stroke. (Stop approx. 100 mm before the end of the stroke.) 2) Operate the steering, bucket, and lift arm cylinders 3 - 4 times to the end of the stroke, then stop the

43-1

3) 4) a

engine and bleed the air from the plugs at the top of the hydraulic tank filter. Raise the engine speed and repeat Step 2) to bleed the air. Repeat this procedure until no more air comes out from the plug. After completing bleeding the air, tighten the plugs. Plug: 1.15 20.15 kgm

t If the engine is run at high speed from the start, or the cylinders are operated to the end of this stroke, the air inside the cylinder will cause damage to the piston packing. 5) Check the level of the oil inside the hydraulic tank, add oil if necessary, then tighten the oil filler cap. t Before loosening the oil filler cap, close the pressurizing valve; after adding oil, tighten the oil filler cap, then open the pressurizing valve. + After repair or long storage, follow the same procedure.

DISASSEMBLY

AND ASSEMBLY

STEERING

GEAR

STEERING GEAR REMOVAL

A *

WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the work equipment to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving.

After stopping the engine, operate the steering wheel 2 or 3 times to the left and right and set the steering valve in neutral. 1. Covers

Remove covers (1) and (2) under cab. 2. Steering linkage

Disconnect steering linkage (3) from pitman arm (4).

3. Column joint

1) Remove 2 bracket mounting bolts (5) on opposite sides, then install 2 bolts A. * Prepare 2 bolts A (Ml2 x P1.75, length below head: 100 mm). t Tighten bolts A securely. 2) Leaving bolts A in position, remove remaining mounting bolts (5). * Remove the mounting bolts carefully. + Remove the clamps of the electrical wiring. 3) Remove lock bolts (6), then remove column joint (7) from steering gear shaft. + Make match marks on the joint and steering gear shaft. + After removing the column joint, secure the column joint with wire to prevent it from falling. + If it falls out, it cannot be installed as it is, so be extremely careful not to let it fall. t The working space is confined, so carry out the work carefully.

Secure

floor

frame

L05AHOll

43-3

DISASSEMBLY

AND ASSEMBLY

STEERING

GEAR

4. Steering gear

1) Remove bolts A, then remove steering gear (8) together with bracket (9).

el kg

Steering gear, bracket: 20 kg

2) Remove bracket (9), and mounting nut (10) of

pitman arm (4), then use a puller to remove pitman arm from steering gear (8). t Before removing, make match marks on the pitman arm and steering gear sector shaft.

43-4

L07GROOl

DISASSEMBLY

AND ASSEMBLY

STEERING

GEAR

STEERING GEAR INSTALLATION

1. Steering gear 1) Align match marks, fit pitman arm (4) to steering gear (8), then tighten with mounting nut (lo), and install bracket (9). w

Mounting nut (10): 19 rt3 kgm (Width across flats: 32 mm) Bracket, steering gear mounting bolt: 11.5 k1.0 kgm

2) Set steering gear (8) in mounting position, and install with bolts A. + Install 2 bolts A (Ml2 x Pl.75, length below head: 100mm) on opposite sides. + Tighten bolts A securely. 2. Column joint

1) Align match marks of column joint (7) and steering gear shaft, then insert joint, and tighten lock bolt (6). Lock bolt (6): 5.7 20.7 kgm

LOSAM

2) Install bracket mounting bolts (5). 3) Remove bolts A, and install mounting bolts (5). 3. Steering linkage

Connect steering linkage (3) to pitman arm (4). Mounting nut: 12.5 + 1.O kgm

4. Covers

Install covers (1) and (2) under cab. 5. Inspecting steering linkage

After completion of assembly, inspect linkage, and adjust if necessary. + For details of inspection and adjustment procedure, see SECTION 42, TESTING AND ADJUSTING.

43-5

STEERING GEAR BOX

DISASSEMBLY AND ASSEMBLY

STEERING DISASSEMBLY

GEAR BOX OF

1. Side cover

1) Loosen lock nut (3) of adjustment screw (2), then remove mounting bolts (4) of cover.

LOSAHIJ03

2) Hold side cover so that it cannot rotate, and tighten adjustment screw to remove side cover (1).

LOSAH004

2. Sector shaft Turn steering gear shaft (5) so that sector shaft is in vertical position, and remove sector shaft (6). + Be careful not to damage the thread and bushing of sector gear when removing.

L05AH005

3. Rear cover, shaft, ball nut assembly Remove rear cover (7) then remove shaft and ball nut assembly (8).

L05AH006

43-6

DISASSEMBLY AND ASSEMBLY

STEERING

GEAR BOX

ASSEMBLY

STEERING GEAR BOX

1. Bearing outer race

1) Press fit bearing outer race (10) on gear box (9) and rear cover (7).

105AH007

2) Press fit oil seals (11) and (12) on gear box and rear cover. + If bushing (13) of the gear box is badly worn, replace the gear box. .13 e

Lip of oil seal: Grease (G2-Ll)

LOSAH008

2. Shaft, ball nut assembly, rear cover Assemble shaft and ball nut assembly box, then install rear cover (7). Shaft, ball nut assembly, Grease (G2-Ll)

(8) in gear

bearing

(14):

L05AH009

If there is any problem with shaft (16) or ball nut (15) of the shaft and ball nut assembly, replace the whole shaft and ball nut assembly.

LOSAHOlO

43-7

DISASSEMBLY AND ASSEMBLY

STEERING GEAR BOX

3. Adjusting shim Select shim thickness so that starting torque of shaft is within standard range. + First assemble a larger thickness than necessary, then reduce the thickness to adjust. + Measure the starting torque with torque wrench A. + Standard range for starting torque: 3.5 - 6.5 kgm Mounting bolt (4) of rear cover: 4.5 + 1 kgm 4. Sector shaft, side cover Assemble so that sector gear is meshed at center of ball nut. + If bushing of the side cover (3) is badly worn, replace the assembly. aMounting

bolt: 4.5 +1 kgm

L OSAHOIZ

5. Adjusting adjustment screw 1) Temporarily install pitman arm (17), move arm lightly and tighten adjustment screw (2) so that backlash is “0”.

LOSAH013

2) Turn adjustment screw so that starting torque of shaft is within standard range, then tighten lock nut. t Standard range for starting torque: 3.5 - 7

kgm Lock nut: 2.5 ~0.5 kgm

L05AH014

43-8

DISASSEMBLY

STEERING

AND ASSEMBLY

6. Plug, dust cover Pump in grease through plug mount, install plugs (18) and (19), then install dust cover (20).

GEAR BOX

43-9

DISASSEMBLY AND ASSEMBLY

STEERING AND PPC PUMP

STEERING AND PPC PUMP REMOVAL

A A

WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Then operate the steering wheel and steerina lever several times to the left and right to release the remaining pressure in the hydraulic piping.

Remove cover (1).

Loosen plugs (2) and (3) at the top of the hydraulic tank filter, to prevent the oil inside the tank from flowing out.

1. Cover 1) Remove covers (4), (5) and (6). , 1425100t

2) Remove plate (7) and bracket (8).

1425106;

2. Hydraulic Dibna 1) Disconnect Tube (9) between steering pump and hydraulic tank at steering pump end. 2) Disconnect hose (10) between steering pump and steering valve at steering pump end. 3) Disconnect tube (11) between PPC pump and PPC strainer at PPC pump end. 3. Steering pump and PPC pump Remove steering pump and PPC pump (12). Steering pump and PPC pump: 20 kg

43-I 0

DISASSEMBLY

AND ASSEMBLY

STEERING

AND PPC PUMP

STEERING AND PPC PUMP INSTALLATION OF

1. Steering pump and PPC pump

Set Steering pump and PPC pump (12) in mounting position, then tighten mounting bolt. t Fit the O-ring securely in the groove and make sure that it is not caught when installing.

2. Hydraulic piping

1) Connect tube (11) between PPC pump and PPC strainer at PPC pump end. 2) Connect hose (10) between steering pump and steering valve at steering pump end. 3) Connect tube (9) between steering pump and hydraulic tank at steering pump end.

3. Cover

1) Install plate (7) and bracket (8). 2) Install covers (4), (5) and (6).

4. Refilling with oil Tighten plugs at top of hydraulic tank filter, then add hydraulic oil through oil filler to the specified level.

Hydraulic

Plug at top of filter: 1.2 kO.1 kgm

Run the engine to circulate the oil through the system. Then check the oil level again. 14251069

43-11

DISASSEMBLY

AND ASSEMBLY

STEERING VALVE REMOVAL

A *

Y A 4

Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Then operate the steering wheel and steering lever several times to the left and right to release the remaining pressure in the hydraulic piping.

Remove cover (1).

Loosen plugs (2) and (3) at the top of the hydraulic tank filter, to prevent the oil inside the tank from flowing out.

1. Steering linkage

1) Remove cover (4). 2) Disconnect steering linkage (5) from steering valve. + Move the steering linkage towards the rear frame.

2. Hydraulic piping 1) Remove bolts (6), then loosen bolt (7), and turn cover (8) to the right slowly. A Use bolt (7) as a pivot when turning the cover. + Working space is confined, so be extremely careful when carrying out the operation.

43-12

STEERING

VALVE

DISASSEMBLY

AND ASSEMBLY

STEERING

VALVE

2) Disconnect the following hydraulic piping from steering valve. Tube (9) between switch pump and steering valve. Tube (10) between hydraulic pump and steering valve. Tube (11) between steering pump and steering valve. Tube (12) between steering valve and main control valve. Tubes (13) and (14) between steering valve and steering cylinder. t Remove elbow (15). Tube (16) between steering valve and cooler

3. Steering valve 1) Install eye-bolt to steering valve (17). 2) Sling steering valve (17), then remove mounting bolts, and raise slowly. + When installing the lifting tool, make sure that the center of gravity of the steering valve is balanced. sr The space between the front frame and the cab is confined, so be extremely careful when lifting off. Steering valve: 45 kg Lo5zzooI

43-13

DISASSEMBLY AND ASSEMBLY

STEERING VALVE INSTALLATION

1. Steering valve 1) Set steering valve (17) in mounting position, and tighten mounting bolts. + The space between the front frame and the cab is confined, so be extremely careful when installing. 2) Remove eye-bolts from steering valve (17).

2. Hydraulic piping 1) Connect the following hydraulic piping to the steering valve. Tube (16) between steering valve and cooler. Tubes (13) and (14) between steering valve and steering cylinder. + Install elbow (15). + Set the arrow on the check valve facing in the direction of the tube. Tube (12) between steering valve and main control valve. Tube (11) between steering pump and steering valve. Tube (10) between hydraulic pump and steering valve. Tube (9) between switch pump and steering valve.

43-14

STEERING VALVE

DISASSEMBLY

AND ASSEMBLY

STEERING

VALVE

2) Set cover (8) in mounting position, and tighten

bolts (6) and (7). + The working space is confined, so be extremely careful when carrying out the operation.

3. Steering linkage

1) Connect steering linkage (5) to steering valve. Mounting nut: 12.25 + 1.25 kgm 2)Remove cover (4).

4. Refilling with oil

Tighten plugs at top of hydraulic tank filter, then add hydraulic oil through oil filler to the specified level. Plug at top of filter: 1.2 to.1 kgm

Run the engine to circulate the oil through the system. Then check the oil level again.

5. Inspection of steering linkage

After completion of the assembly operation, inspect the linkage, and adjust if necessary. For details of the method of inspecting

and adjust-

ing, see TESTING AND ADJUSTING.

43-15

DISASSEMBLY AND ASSEMBLY

STEERING

VALVE

STEERING VALVE DISASSEMBLY

425F294

1. Remove tube (1). 2. Remove main relief valve assembly (2). 3. Remove safety valve (with suction valve) assembly (3). 4. Remove case assembly (4). + Disassembly and assembly of case assembly. 1) Remove covers (5 and 6). 2) Remove dust seal (7). 3) Loosen bolt (9) of lever (8) then remove shaft (10). 4) Remove oil seal (11) and bearings (12 and 13). 5. Remove case (14), then remove spool assembly (15). + Disassembly and assembly of spool assembly. 1) Remove bolt (16) then remove retainer (17) spring (18) and retainer (19) from spool (20). + Loosen bolt (16) with the spool assembled in the body.

43-16

Remove plate (21), then remove orifices (22 and 23).

Remove cover (24), then remove spring washer (26) and spool (27).

Remove plate (28), then remove seat (29), spring (30) and poppet (31).

(25),

Steering demand valve assembly: 55 kg

DISASSEMBLY

STEERING

AND ASSEMBLY

VALVE

STEERING VALVE SSEMBLY

1I.

Assemble poppet (31) and spring (30) in valve body

(32). 2. Fit O-ring and backup ring to seat (29) in valve body, then fit O-ring and install plate (28). 3. Assemble spool (27) washer (26) and spring (25) in valve body, then fit O-ring and install cover (24). 4. Assemble orifices (23) and (22) in valve body, then fit O-ring and install plate (21 ). Assembly of spool assembly. * 1) Assemble retainer (19) spring (18) and retainer (17) in spool (20) and tighten bolt (16). Tighten bolt (1 6) with the spool assembled in the body. 5. Assemble spool assembly (15) in body, fit O-ring and install case (14). t Assembly of case assembly 1) Install bearings (13) and (12) and oil seal (11) in case. e

Oil seal:

2) Assemble lever (8) in case, then fit key, install shaft (lo), and tighten bolt (9). 3) Install dust seal (7). 4) Fit O-ring and install covers (6) and (5). 6. Fit O-ring and install case assembly (4). 7. Fit O-ring and install safety valve assembly (3) with suction valve. Safety valve:

4.5 kO.5 kgm

8. Fit O-ring and install main relief valve assembly Main relief valve:

(2).

8.5 + 1.5 kgm

9. Fit O-ring and install tube (1).

Grease (G2-LI)

43-17

DISASSEMBLY

AND ASSEMBLY

STEERING

CYLINDER

STEERING CYLINDER REMOVAL

WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Then operate the steering wheel and steering lever several times to the left and right to release the remaining pressure in the hydraulic piping.

* A

14251036

Cover Remove bolts (l), then loosen bolt (2), and turn cover (3) over to rear of chassis. * Use bolt (2) as pivot when turning the cover. * The working space is confined, so be extremely careful when carrying out the operation.

2. Hydraulic piping Disconnect hoses (4) and (5) from cylinder.

3. Steering cylinder 1) Remove mounting

bolts, and pull out rod pin

(6). t Check the number and thickness of the shims, and keep a record to act as a guideline when assembling.

7425103

43-18

DISASSEMBLY AND ASSEMBLY

STEERING CYLINDER

2) Remove grease tube (7), then remove mounting bolts, and pull out bottom pin (8). + Check the number and thickness of the shims, and keep a record to act as a guideline when assembling. 3) Using receiver block, lift off steering cylinder (8). * The removal of the cylinder must be carried out by two workers. t Be careful not to damage the cylinder rod. Steering cylinder: 47 kg

43-19

STEERING CYLINDER

AND ASSEMBLY

DISASSEMBLY

STEERING CYLINDER INSTALLATION 1.

Steerina cvlinder

1) Usi&iever mounting

block, set steering position.

cylinder

(9) in

2) Install bottom pin (8), then install mounting

bolt and grease tube (7). WARNING! Use a bar to align the pin holes. Never use your fingers. a +

Adjust shim so that clearance standard value. Clearance a + b = Max. l.Omm

becomes

142510X

3) install rod pin (6), then install mounting

A +

bolt. WARNING! Use a bar to align the pin holes. Never use your fingers.

Adjust shim so that clearance becomes standard value. Clearance a + b = Max. 1.Omm

2. Hydraulic piping Connect hoses (4) and (5) to cylinder. Hose nut: 14 +3 kgm (width across flats 32mm)

43-20

DISASSEMBLY AND ASSEMBLY

STEERING CYLINDER

3. Cover Set cover (3) in mounting position, and tighten bolts (1) and (2). + The working space is confined, so be extremely careful when carrying out the operation.

4. Greasing Grease cylinder pins well. * Wipe off excess grease.

43-21

DISASSEMBLY

AND ASSEMBLY

STEERING

CYLINDER

STEERING CYLINDER DISASSEMBLY

SDecial tools Part number A

Part name

790-502-l 003

Stand

790-l 02-2301

Wrench

790-330-l 100

grench

B assemblv

1 LlOZZObl

1. Set cylinder

assembly

(1) in tool A.

2. Raise lock of cylinder head (2), then using tool B, remove cylinder head (2) from cylinder. 3. Pull cylinder head and piston rod assembly (3) out from cylinder (4) then lift off. + Oil will come out when the piston rod assembly is removed from the cylinder, so catch it in a container. 4. Remove cylinder

(4) from tool A.

5. Set cylinder head and piston rod assembly in tool A, and using power wrench “a” and socket “b”, loosen nut (5). + Power wrench: x 16 + Socket (2) - Width across flats: 55mm

6. Remove nut (5), then remove piston assembly and cylinder head assembly (7) from rod (8).

43-22

(6)

STEERING CYLINDER

DISASSEMBLY AND ASSEMBLY

7. Disassembly of piston assembly 1) Remove wear ring (9). 2) Remove piston ring (10) from piston (11). 8. Disassembly of cylinder head assembly 1) Remove snap ring (16), then remove dust seal (17). -

CT3

L1022041

2) Remove rod packing (18), retainer (14) and snap ring (15). Remove bushing (19) from cylinder head (20). 3)

4) Remove O-ring (21) and backup ring (22).

L102204;

43-23

DISASSEMBLY AND ASSEMBLY

STEERING CYLINDER

STEERING CYLINDER ASSEMBLY Special

tools Part number

Part name

QtY

A 1

790-502-1003

1 Repair stand

790-720-l 000

Expander

796-720-l 660

Ring

18 \

Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. Be careful not to damage the rod packings, dust seals, or O-rings when assembling. 1. Assembly of cylinder head 1) Using push tool, press fit bushing (19) on cylinder head (20). * Be careful not to deform the bushing when press fitting. 2) Assemble rod packing (18), retainer (14), and snap ring (15). * Be careful to install the rod packing facing in the correct direction. 3) Using push tool, install dust seal (17) to cylinder head. 4) Install snap ring (16).

ZOXF130

LlOZZO4!

5) Install backup ring (22) first, then O-ring (21). + Do not try to force the backup ring into position. Warm it in warm water (50 to 6O“C) before fitting it.

43-24

DISASSEMBLY

AND ASSEMBLY

STEERING

2. Assembly of piston 1) Using tool C, expand piston ring (10). + Set the piston ring on the expander (tool C) and turn the handle 8 to 10 times to expand the ring. 2) Remove piston ring (10) from tool C and assemble on piston (11).

CYLINDER

3) Fit tool D on piston ring, then using clamp “c”, contact piston ring. + Clamp Part No.: 07281-01159 4) Assemble wear ring (9) on piston.

3. Set piston rod (8) in tool A. 5

4. Assemble cylinder head assembly (7) and piston assembly (6) no rod, then fit nut (5).

5. Using power wrench

“a” and socket “b”, tighten nut

(5). Piston nut:

Power of power wrench

x 16

Width across flats of nut (5)

55mm

Tightening

torque of nut

1 145 ‘14.5

kgm

43-25

DISASSEMBLY

STEERING

AND ASSEMBLY

CYLINDER

6. Remove piston rod and head assembly from tool A. 7. Set cylinder

(4) in tool A.

8. Raise piston rod and head assemble in cylinder (4).

assembly

(3), and

I 9. Using tool B, tighten Cylinder

cylinder

head nut (2).

head nut:

10. Bend lock into notch on cylinder 11. Remove cylinder

95 +9.5 kgm

side.

assembly from tool A.

\, 3 L102204

f-3

43-26

DISASSEMBLY AND ASSEMBLY

CENTER HINGE PIN

CENTER HINGE PIN REMOVAL

Soecial tool Part number B +

790-l 01-2102

A 4

Puller

QtY 1

Before starting work , remove the bucket. For details, see REMOVAL OF WORK EQUIPMENT.

Part name

WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Then operate the steering wheel and control levers several times to release the remaining pressure in the hydraulic piping.

Remove cover (1). Loosen plugs (2) and (3) at the top of the hydraulic tank filter, to prevent the oil inside the tank from flowing out. Loosen drain valve (4) and drain air from air tank.

1. Draining oil Remove plug (5), loosen valve (6), and drain hydraulic oil. t Drain the oil from the hydraulic tank until the level of oil is the bottom level of each pipe. Hydraulic oil: Approx. 130 Q (Bottom level of pipe) 2. Cover Remove cab bottom covers (7) and (8).

L092200:

43-27

DISASSEMBLY

AND ASSEMBLY

CENTER

HINGE PIN

3. Steering cylinder pin Remove left and right steering cylinder pins (9). + Check the number of shims inserted between the frame, and the steering cylinder. 4. Center drive shaft Remove guard (lo), then remove center drive shaft (11). 6 kg

Center drive shaft:

31 kg

5. Steering hose Disconnect hose (12) between steering pump and steering valve from tube connectors. t After disconnecting hose, move to front frame. 6. Air, brake hoses 1) Disconnect air hose (13) from tube connectors. 2) Disconnect brake hose (14) from tube connectors. t After disconnecting each hose, move to front frame,

7. PPC hoses Disconnect the following hoses from the PPC valve: l Hoses P2 (15) and P3 (16) for lift spool. l Hoses P4 (17) and PI (18) for dump spool. + Attach tags on hoses to be able to identify them when installing. + Remove the clamps at the rear frame end and under the floor. + After disconnecting each hose, move to front frame.

74251045

Front of machine

L0922006

43-28

DISASSEMBLY AND ASSEMBLY

CENTER HINGE PIN

8. Electrical wiring Disconnect the following connectors from the floor wiring harness: 0 12-pole connector (19) for front frame wiring harness. 0 4-pole connector (20) for front frame wiring harness. * Remove the clamps for the front frame wiring harness under the floor.

9. Hydraulic hoses Disconnect the following hoses from the tube: Hose (21) between main control valve and hydraulic tank. * Remove the rear frame clamp. Hose (22) between steering valve and cooler. Hose (23) between main control valve and hydraulic tank. Hose (24) between switch pump and steering valve. Hose (25) between steering pump and steering valve. 14251024

After disconnecting each hose, move it towards the front frame. Move the electrical wiring towards the front frame.

74251046

10. Steering linkages Disconnect steering linkages (26) and (27), and remove steering linkage bracket (28).

14251041

43-29

DISASSEMBLY AND ASSEMBLY

11. Frame support 1) Using’hydraulic jack on rear frame, insert block “a” while adjusting height. + Insert the hydraulic jacks and blocks under the left and right frames.

2) Insert support stand “b” under counterweight.

3) Using garage jack under front frame, insert block “c”.

12. Lower hinge pin 1) Remove mounting bolts, then remove retainer (29). + There are shims between the retainer and frame, so check the number and thickness of the shims, and keep in a safe place. 2) Pull out lower hinge pin (30) while adjusting height. t Adjust the height carefully until it is possible to easily remove the pin by hand. 3) Remove spacer (31).

43-30

CENTER HINGE PIN

DISASSEMBLY

CENTER

AND ASSEMBLY

HINGE PIN

13. Upper hinge pin 1) Remove

mounting

bolt, then remove

(32). 2) Using puller A, remove and spacer (34).

upper

hinge

retainer pin (33)

14. Disconnecting frame Remove safety bar, pull out front frame to front and disconnect frame. t Be careful not to let the spacer at the top of the lower hinge bite into the rear frame. + Be careful to maintain the balance when carrying out the operation. + Move the frame about 100mm at a time.

14251048

Front frame frame

15. Lower hinge 1) Remove mounting

bolts, then remove retainer

(35). t There are shims between the retainer and frame, so check the number and thickness of the shims, and keep in a safe place.

43-31

DISASSEMBLY

CENTER

AND ASSEMBLY

HINGE PIN

2) Remove dust seal (36) from retainer (35). 36

Lo9zzo15

I 3) Remove spacer front frame.

(37) and dust seal (38) from

L0922016

4) Remove bearing (39).

16. Upper hinge 1) Remove retainer (40). + There are shims between the retainer and frame, so check the number and thickness of the shims, and keep in a safe place.

43-32

DISASSEMBLY AND ASSEMBLY

2) Remove dust seal (41) from retainer. t Remove dust seal (42) from frame.

CENTER HINGE PIN

Y----l&

L0922019

3) Remove bearing (43).

43-33

DISASSEMBLY

AND ASSEMBLY

CENTER HINGE PIN

CENTER HINGE PIN INSTALLATION

Special tools Part number

Part name

1. Upper hinge 1) Assemble tools A, B, C, D,, and D, at top of front frame upper hinge, and set bearing (43) in tool D. Set the upper hinge on from top and press ffi. t When press fitting, use tool D, as a guide. sr Be careful not to fit the bearing at an angle. + Fill the inside of the bearing with grease. + When assembling the bearing, do not forget to assemble spacer (44). + The clearance of the bearing and spacer (44) is adjusted, so do not change the combination. When replacing the bearing and spacer, replace as a set.

-To II 43 44

L09z7n7

43-34

LO9ZZO2

DISASSEMBLY

CENTER

AND ASSEMBLY

HINGE PIN

2) Press fit dust seal (41) on retainer. t When press fitting the dust seal, fit with the lip on the outside. Seal lip:

Grease (G2-LI)

3) Tighten retainer (40) with 3 mounting bolts, measure clearance “a” of retainer and hinge at 4 locations on circumference, and select shims so the measured value is less than 0.08 - 0.18 mm. + After selecting the shims, assemble retainer to specified torque. Mounting bolt (when shims): 6.0 kO.6 kgm Mounting

bolt:

adjusting

18 t2 kgm

I 1092203

4) Install seal (41) to bottom of front frame. t When press fitting the dust seal, fit with the lip on the outside. Seal lip:

Grease (G2-LI)

43-35

DISASSEMBLY

CENTER HINGE PIN

AND ASSEMBLY

2. Lower hinge 1) Using tools A, B, D, ~4, and ~5, press fit bearing (39) and spacer (38) on front frame. + When press fitting, use tool D, as a guide. + Be cfareful not to fit the bearing at an angle. t Fill the inside of the bearing with grease. + When assembling the bearing, do not forget to assemble the spacer (38). + The clearance of the bearing and spacer (38) is adjusted, so do not change the combination. When replacing the bearing or spacer, replace as a set.

L092202

2) Press fit dust seal (36) on retainer (35). t When press fitting the dust seal, fit with the lip on the outside. e

Seal lip:

Grease (G2-LI)

3) Tighten retainer (35) with 5 mounting bolts, measure clearance “a” of retainer and hinge at 4 locations on circumference, and select shims so the measured values is less than 0.08 -0.18 mm. it After selecting the shims, assemble retainer to specified torque.

To A(

:k L092202

0 Mounting bolt (when shim): 10 +l kgm

35a Mounting

bolt:

adjusting

36 0

18 22 kgm 0

0 0

0 LO9ZZOlf

43-36

DISASSEMBLY

CENTER HINGE PIN

AND ASSEMBLY

4) Press fit dust seal (38) and install spacer (37) on frame. t When press fitting the dust seal, fit with the lip on the outside. * Assemble spacer (37) so that the side with the large chamfer is on the bearing side. Seal lip: Grease (G2-LI) Inside circumference Grease (G2-LI)

of spacer: LO9ZZO3

3. Connecting frame Move front frame towards rear frame and align pin holes.

a t

Use a bar to align the pin holes. Never use your fingers.

WARNING!

Align the pin holes correctly.

LO9ZZO13

4. Upper hinge pin 1) Assemble spacer (34), insert upper hinge pin (33), tap lightly 3 times with a copper hammer until it settles in. + Tap lightly with copper hammer, do not tap hard. t Absolutely, do not coat spacer (34) with grease. e

otu er circumference of hinge pin: Grease (G2-LI)

2) Assemble retainer (32). Mounting bolt (46): Thread tightener (Loctite 262) Mounting bolt (46): 18 +2 kgm

Mounting bolt (47): 18 -c2 kgm +

If the torque of the mounting bolts (46) and (47) do not reach the specified torque, there may be grease on spacer (34), so remove it and tighten the mounting bolts again.

43-37

DISASSEMBLY

AND ASSEMBLY

CENTER

5. Lower hinge pin 1) insert lower hinge pin (30) and assemble spacer (31). 6

Outer circumference Grease (G2-LI)

hinge

pin:

2) Install retainer (29) to lower hinge pin, and after it settles in fully, measure clearance “c” between retainer and frame at 4 locations on circumference, and select shims so the measured value is less than 0.08 - 0.18 mm.

When adjusting the shims, tighten the retainer mounting bolts temporarily to prevent them from turning. Tighten the retainer mounting bolts to the specified tightening torque, then tighten the pin mounting bolts, After selecting the shims, install the retainer with the specified torque. Completely remove grease on the mounting bolts and mounting bolts.

0 \ i+

Mounting bolts (48) and (49): Thread tightener (Loctite 262) Mounting bolt (48): 28.5 23.0 kgm (When adjusting shim) Mounting

bolt (48): 28.5 +3 kgm

Mounting

bolt (49): 39 23.5 kgm

3) Lock safety bar.

43-38

HINGE PIN

DISASSEMBLY

CENTER

AND ASSEMBLY

HINGE PIN

6. Frame support 1) Remove block “c” from front frame.

2) Remove support beam “b” from counterweight. 3) Jack up rear frame and remove block “a”.

b a

7. Steering linkages Install steering linkage bracket (28), and connect steering linkages (26) and (27). Mounting et (28): #262)

bolt of steering linkage brackThread tightener (Loctite

Mounting bolt of steering linkage bracket (28): 18.0 +2.0 kgm Mounting nut of steering linkages (26),(27): 12.5 k1.0 kgm

14251041

8. Hydraulic

hoses Connect the following hoses to the tube: l l

0 l

Hose (25) between steering pump and steering valve. Hose (24) between switch pump and steering valve. Hose (23) between main control valve and hydraulic tank. Hose (22) between steering valve and cooler.

742S1046

43-39

CENTER HINGE PIN

DISASSEMBLY AND ASSEMBLY

Hose (21) between main control valve and hydraulic tank Install the clamps.

Electrical wiring Connect the following connectors to the floor wiring harness. 0 12-pole connector (19) for front frame wiring harness. 0 4-pole connector (20) for front frame wiring harness. t Install the wiring clamps.

10. PPC hoses Connect the following hoses to the PPC valve: l Hoses P2 (15) and P3 (16) for lift spool. l Hoses P4 (17) and Pl (18) for dump spool. 11. Air, brake hoses 1) Connect brake hose (14) to tube. Tube nut: 8.25 k1.25 kgm 2) Connect air hose (13) to tube. Tube nut: 4.5 +.5 kgm

L0922006

43-40

DISASSEMBLY AND ASSEMBLY

CENTER HINGE PIN

12. Steering hose Connect hose (12) between steering pump and steering valve to tube. 13. Steering cylinder pin Fii center drive shaft (11) and install guard (10). Mounting bolt: 11.5 t 1 kgm

14. Steering cylinder pin Install left and right steering cylinder pins (9).

a *

WARNING! Use a bar to align the pin holes. Never use your fingers.

Adjust shims so clearance become specified value. Clearance a + b = Max. 1mm

B t

LO922038

15. Cover Install covers (7) and (8) at bottom of cab.

1092200

16. Refilling with oil 1) Tighten plugs (5) and (6).

CENTER HINGE PIN

DISASSEMBLY AND ASSEMBLY

2) Tighten plugs at top of hydraulic filter cover, then add hydraulic oil through oil filler to the specified level. Plug at the top of filter: 1.2 +O.l Hydraulic oil: Approx. 130 4 t

Run the engine to circulate the oil through the system. Then check the oil level again.

17. Bleeding air

Bleed air from brake system. + For details of bleeding air, see TESTING AND ADJUSTING.

18. inspecting steering linkage After completion of assembly, inspect linkage and adjust if necessary. t For details, see TESTING AND ADJUSTING.

43-42

Hydraulic

STEERING 44

MAINTENANCE

CENTERHINGEPIN

STANDARD

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

STEERING LINKAGE AND STEERING COLUMN STEERING GEAR BOX.. STEERING PUMP

SYSTEM

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

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

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

STEERING CYLlNDER

MOUNT .......................................................

2 4

6 7

44-1

MAINTENANCE

CENTER

STANDARD

CENTER HINGE PIN

[Final

value3

2 13 12

-1021

-1822 [Final

kgmlWhen

kgm value3 m

26.25:

3.25

[Whenadjusting Q~128.25’-3.25 (Final

44-2

kgm shim1 kgm value3

39.25z4.25

Section

B-B

kgm

HINGE PIN

MAINTENANCE

STANDARD

CENTER HINGE PIN

Unit: No.

Check item

Criteria Standard size

Remedy

Tolerance

Standard clearance

Shaft

Hole

Clearance between lower hinge pin and rear frame

100

-0.036 -0.058

+0.054 0

0.036 0.112

Clearance between lower hinge pin and spacer (small)

100

-0.036 -0.058

+ 0.054 0

0.036 0.112

Clearance between lower hinge pin and bearing

100

-0.036 -0.058

0 -0.020

0.016 0.058

Clearance between lower hinge pin and spacer (large)

100

-0.036 -0.058

t 0.054 0

0.036 0.112

Clearance between rear frame and spacer (large)

130

-0.043 -0.106

to.063 0

0.043 0.169

Clearance between front frame and upper hinge bearing

155

0 0.025

-0.048 -0.088

-0.023 -0.088

Clearance between upper hinge pin and rear frame

100

-0.036 -0.058

t 0.054 0

0.036 0.112

Clearance between upper hinge pin and bearing

100

-0.036 -0.058

0 -0.020

0.016 0.058

Clearance between front frame and lower hinge bearing

160

0 -0.025

-0.050 -0.090

-0.025 -0.090

135

to.310 to.210

t 0.063 0

-0.147 -0.31

Replace

Clearance between rear frame and bushing

1: j ~~.iRJyf-~~f Clearance

at press fitted part of

Standard size 13

Height of lower hinge spacer (small)

Height of lower hinge spacer

101.5

Tolerance I

+O.l 20.1

(large) 15

Shim thickness and retainer

for lower hinge

2.3

Shim thickness and retainer

for lower hinge

1.6

Shim thickness and retainer

for upper hinge

Adjust

1.6 I

44-3

MAINTENANCE

STANDARD

STEERING

LINKAGE AND STEERING COLUMN

LINKAGE

-28.25:

Section A-A

Liz3

Section

-6.75

0.75 kgm

Section

28.25 Coat

‘3.25 kgm locktite

B-B

C-C

AND

COLUMN

3.25

kgm

MAINTENANCE

STEERING

STANDARD

LINKAGE AND COLUMN

Unit: No.

Criteria

Check item Standard size

Remedy

Tolerance Shaft

Hole

Standard Clearance

Clearance between steering shaft and column bushing

0 -0.080

+0.150 + 0.050

0.05 0.23

Interference of press fitting part of center lever bearing

0 -0.013

-0.021 -0.051

-0.008 -0.051

Clearance between shaft and inner race of center lever bearing

-0.020 -0.053

0 -0.010

0.010 0.053

Clearance oer

Distance between center of holes in steering linkage

714

Distance between center of holes in steerina linkaae

254

of articulation

stop-

25 + 2 (at engine speed:

Replace

1200 rpm)

Adjust

44-5

MAINTENANCE

STEERING

STANDARD

GEAR BOX

STEERING GEAR BOX

Section

A-A

Unit: No.

Criteria

Check item

Remedy

Standard size

44-6

Clearance between sector shaft and bushing

Clearance between sector shaft and bushina

-0.009 -0.034

t 0.025 0

0.009 0.059

-0.007 -0.028

co.021 0

0.007 0.049

Replace bushing

MAINTENANCE

STANDARD

STEERING

PUMP

STEERING

PUMP

iAR(3)-80

‘Li=7

6.7 20.7kgm

425F15OA

Unit: No.

Criteria

Check item

Remedy Clearance

Standard clearance 1

Clearance between gear case and side elate, aear

0.10 - 0.15

0.19

Clearance between inside diameter of plain bearing and outside diameter of gear shaft

0.06 - 0.149

0.20

Insertion

depth of pin

14 +o/-0.5

Rotating torque of spline shaft

0.7 - 1.2 kgm

Discharge E01 O-CD 45” - 55”

Revolution (RPM) 2500

Discharge pressure

limit

Replace

(kg/cm*)

Standard discharge (@/min.)

Repair limit discharge (r!/min.)

210

184

170

44-7

MAINTENANCE

STANDARD

STEERING

CYLINDER MOUNT

STEERING

Section

A-A

CYLINDER

MOUNT

425F154

Unit: No.

Criteria

Check item Standard size

Remedy Standard clearance

Tolerance Hole] Shaft

Clearance between mounting pin and bushing connection of steering cylinder rod and frame

0 -0.074

+0.174 +O.lOO

0.100 0.248

Clearance between mounting pin and bushing at connection of steering cylinder bottom and frame

0 -0.074

+0.174 +O.lOO

0.100 0.248

Width of boss

Width of hinge

Standard clearance (Clearance a + b)

70 +0.8 0

74 +2

1.2 - 6.0

70 +0.8 0

74 *2

Replace

Connection of steering cylinder and front frame

Connection of steering cylinder and rear frame

44-8

1.2 - 6.0 -

Max. 1.0 after adjusting shim

BRAKE AND AIR SYSTEM 51

STRUCTURE

AND FUNCTION

GENERAL ...................................................................... AIRSYSTEM .................................................................. BRAKECIRCUIT ................................................................

2 2 2

BRAKE AND AIR PIPING

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

BRAKE AND AIR CIRCUIT SYSTEM

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

AIRTANK ...................................................................... WETTANK .................................................................... DRYTANK(UPPER) ............................................................. DRYTANK(LOWER) ............................................................

5 5 5 6

SAFETYVALVE

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

BRAKEVALVE ................................................................... BRAKE ACTUATED .............................................................. OPERATING IN BALANCE ....................................................... BRAKERELEASED .............................................................

8 9 10

AIR GOVERNOR

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

TWO-WAY VALVE

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

BRAKE CHAMBER

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

SLACK ADJUSTER

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

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

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

CHECK VALVE BRAKE

PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PARKING BRAKESOLENOIDVALVE

SPRING CYLINDER BRAKE CALIPER

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

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

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

26 27

51-1

STRUCTURE AND FUNCTION

GENERAL AIR SYSTEM l

The air compressed by the air compressor enters the wet tank and the moisture is removed, and it then goes to the top and bottom dry tanks. The air in the top dry tank flows to the left and right brake valves, and goes to the rear brake circuit. The air in the bottom dry tank flows to the left and right brake valves, and goes to the front brake circuit. At the same time the air also flows to the parking brake solenoid valve.

The air generated by the air compressor fills the circuit, and when the air pressure inside the wet tank reaches the maximum set pressure of the air governor, the air governor acts to open the unloader valve of the air compressor. This places the compressor in an unloaded condition, so no air is compressed. in addition, the air is used so that when the pressure inside the tank drops to the minimum set pressure of the air governor, the air governor acts to close the compressor unloader valve and actuates the air compressor. Furthermore, if the air governor does not work properly, when the pressure inside the tank reaches the maximum pressure, a safety valve is actuated to protect the air circuit by releasing the air pressure to the atmosphere.

BRAKE CIRCUIT l

When the brake valve is actuated, the in the dry tank flows to the brake chamber and increases the pressure of the brake oil in the master cylinder. The pressurized oil passes through the slack adjuster, and pushes the wheel piston to actuate the brake.

The parking brake (14) is applied mechanically by the spring in the spring cylinder (1). It is designed to be released by air pressure. Therefore, if the air pressure is less than the force of the spring in the spring cylinder (l), the brake is kept applied. When the air pressure rises and the parking brake release is reached, a solenoid valve is actuated to supply air to the spring cylinder (1). This releases the parking brake (14).

51-2

GENERAL

STRUCTUREANDFUNCTION

BRAKE AND AIR PIPING

BRAKE AND AIR PIPING See foldout #2 for brake and air piping drawing (LOSZZOOS)

51-3

STRUCTURE AND FUNCTION

BRAKE AND AIR CIRCUIT SYSTEM See foldout #3 for brake and air circuit system (LO3i5!007)

51-4

BRAKE AND AIR CIRCUIT SYSTEM

STRUCTURE

AND FUNCTION

AIR TANK

ipecifications

AIR TANK l

The air tanks consist of one wet tank and two dry tanks. The air from the compressor first enters the wet tank and the moisture is removed. It is then divided and sent to the upper and lower dry tanks.

Name

Capacity (0

Maximum pressure

Wet tank

9.5 kg/cm*

Dry tank (upper)

9.5 kg/cm*

Dry tank (lower)

9.5 kg/cm*

WET TANK

Lo3zzolo

To dry air tank (PT i/2) From air compressor (PT l/2) Plug mount (PT l/2) Air pressure sensor, Emergency To air governor (PT l/2)

brake sensor

F. Plug mount (PT l/8) G. Plug mount (PT l/4) H. To drain valve (PT 3/4) I. Safety valve mount (PT l/8) J. Plug mount (PT 3/4)

)RY TANK (UPPER)

A. From wet tank (PT l/2) B. To brake valve, rear brake line (PT l/2) C. Plug mount (PT l/8)

D. Plug mount (PT l/8) E. Plug mount (PT l/8) F. To drain valve

51-5

STRUCTURE AND FUNCTION

AIR TANK

DRY TANK (LOWER) I

Lo3zzolo

A. From wet air tank (PT l/2) Plug mount (PT l/2) ; Plug mount (PT i/2) D. To brake valve, front brake line (PT l/2) E. Plug mount (PT l/2)

51-6

F. Plug mount (PT l/8) G. To parking brake solenoid valve (PT l/4) H. Plug mount (PT 3/4) I. Plug mount (PT l/8) J. To drain valve (PT 3/4)

STRUCTURE AND FUNCTION

SAFETY VALVE

1. Cover 2. Lock nut 3. Spring seat 4. Ball 5. Wire 6. Lock terminal 7. Lock plate 8. Adjustment screw 9. Spring 10. Valve body 11. Valve seat

7’ Lo3Bzoo4

Function l

The safety valve is installed in the wet tank, and acts as a safety device for the air circuit.

Operation l

If the air governor does not work properly and the pressure inside the tank rises above the set pressure, ball (4) is pushed up and the air escapes to the atmosphere.

Specification Setting pressure:

9.7 + 0.2 kg/cm*

51-7

STRUCTURE AND FUNCTION

BRAKE VALVE

6’ 423Fo97

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

Brake pedal Plunger Piston Inlet valve Piston Inlet valve Rubber spring

A. From air tank B. From air tank C. To rear brake chamber D. To front brake chamber

Outline l

There are two brake valves installed in parallel at

the bottom of the operator’s compartment. These are operated by depressing the pedal.

51-8

When the right pedal is depressed, air is sent to the brake chamber and the brake is actuated. When the left pedal is depressed, the brake is actuated in the same way as with the right pedal, but at the same time, the transmission solenoid valve is actuated electrically, and the transmission is put in neutral.

STRUCTURE AND FUNCTION

BRAKE VALVE

BRAKEACTUATED

Upperpad l

When pedal (1) is depressed, the operating force passes through plunger (2) and rubber spring (7), and is transmitted to piston (3). When piston (3) moves down, exhaust port (9) is closed, and at the time inlet valve (4) is moved down and air from the air tank (11) flows from port A to port C. This actuates the rear brake chamber (12).

+To front adjustor

slack

Lower part l

When pedal (1) is depressed, the operating force passes through plunger (2) and rubber spring (7) and is transmitted to piston (3). When piston (3) moves down, inlet valve (4) is moved down, and air from the air tank flows from port B to port D. This actuates the front brake chamber.

wettank

Operation of brake when lower valve fails l

Even if there is leakage of air in the lower piping, the upper part will operate normally. The brake for the lower circuit will not operate.

51-9

STRUCTURE AND FUNCTION

Operation of brake when upper valve fails 0 Even if there is leakage of air in the upper piping, if pedal(l) is depressed, piston (5) will be pushed down mechanically and the upper part will operate normally. The brake for the upper circuit will not operate.

OPERATING

IN BALANCE

Upperpad l

When the pressure in the space below piston (3) and the air pressure from the brake chamber becomes high, the pressure pushes rubber spring (7), and piston (3) moves up to close inlet valve (4). When this happens, exhaust port (9) stays closed. The air pressure entering the brake chamber is retained and the brake is kept applied.

Lower part l Upper piston (3) moves up, and inlet valve (4) closes. Piston (3) is pulled up by an amount equal to the amount of movement and inlet valve (6) closes. The exhaust valve is closed, so the air pressure is maintained and the brake is kept applied. The air pressure in the space at the upper part balances the operating force of the pedal. The pressure in the space at the lower part balances the pressure in the space at the upper part. When pistons (3) and (5) move to the end of their stroke, inlet valves (4) and (6) are fully opened. The spaces in the upper and lower parts, and the air pressure in the left and right brake chambers become equal to the air pressure in the tank. Therefore the braking effect can be adjusted by the amount the brake pedal is depressed. When the pistons move down to the end of their stroke, the brake is applied fully.

51-10

BRAKE VALVE

STRUCTURE

AND FUNCTION

BRAKE VALVE

BRAKE RELEASED UPPH pati 0 When the pedal (1) is released and the operating

pressure is removed from the top of the piston, the air at the bottom of the piston, and the piston return spring move the piston up. Exhaust port (9) is opened and the air pressure in the brake chamber is released to the atmosphere.

Lower part l

When the pedal is released and the air at the top of piston (5) is let out, the air at the bottom of piston (5) and spring (13) pull the piston up. Exhaust port (10) opens at the air pressure in brake chamber is released to the atmosphere.

,+Frqn mar slack adpster

Frqm front slack adJuster

51-11

AIR GOVERNOR

STRUCTURE AND FUNCTION

AIR GOVERNOR

1. 2. 3. 4.

Spring Exhaust port Piston Unloader port

5. 6. 7. 8.

Exhaust stem Inlet valve Tank port Filter

Specifications

Cut-out pressure: Cut-in pressure:

8.4 +0.35 kgm/cmz 7.0 +0 / -0.35 kgm/cm2

L03BV005

Function l

The air governor maintains the pressure in the air circuit to the specified range.

OPERATION Compressor working The air pressure irk the wet tank (9) passes from the tank port (7) through the filter (8) and acts on the bottom of the piston (3). When the air pressure in the tank (9) is below the specified pressure (cut-out pressure) the piston (3) is pushed down by the spring (1). When this happens, the air at the unloader port (4) passes through the exhaust stem (5) to the atmosphere and the compressor is actuated.

Check

Compressor

51-12

loaded

valve

L03ADOlQ

STRUCTURE

AIR GOVERNOR

AND FUNCTION

Compressor stopped When the pressure in the wet tank (9) rises, and reaches the set pressure (cut-out pressure), the piston (3) is pushed up against the spring (1). When the piston (3) is pushed up, the exhaust stem (5) is closed and the inlet valve (6) opens. The pressure from the tank passes through the inlet valve (6) and unloader port (4), and acts on the unloader valve of the compressor. When the air pressure inside the tank drops, the piston (3) is pushed down by the spring (1). When the pressure drops below the specified pressure (cut-in pressure), the inlet valve (6) closes and the exhaust stem (5) opens. The pressure at the unloader port (4) passes through the exhaust stem (5) and is released in the atmosphere, so the compressor starts to work again.

I-

Compressor

no-load

L03AD020

51-13

TWO-WAY VALVE

STRUCTURE AND FUNCTION

TWO-WAY VALVE Function l The two-way valve is installed between the two brake valves. It acts to prevent the air pressure from escaping from one brake valve when the other brake valve is depressed. Operation The air circuit of the left and right valves is connectl ed so that the brakes on all four wheels are actuated when either of the pedals is depressed. The air pressure entering from port A of the twoway valve moves seat (2) and shuts off the circuit to port B. Therefore, the air pressure flows only to port C and actuates the brake chamber (5).

I 1. 2. 3.

‘3

Body seat Plug

4. 5.

423F103

Cap Brake chamber

423FlO4

51-14

BRAKE CHAMBER

STRUCTURE AND FUNCTION

BRAKE CHAMBER

View Z

1. Air cylinder 2. Air Piston :* Eg 5: Breather 6. Piston 7. Master cylinder 8. Piston valve 9. Body 10. Sensor

Specifications Air cylinder Cylinder bore Stroke Cylinder capacity

180 mm 133.5 mm 2,380 cc

Master cylinder Cylinder bore Stroke Deliverv

68mm 132.5 mm 472 cc

51-15

STRUCTURE

AND FUNCTION

BRAKE CHAMBER

Brake operated l When the brake pedal is depressed, compressed air is supplied from the brake valve to the brake chamber. Air piston (2) moves rod (4) and pushes piston (6) of master cylinder (7) to the right. Brake oil is sent by piston (6) to the brake piston to actuate the brake.

Brake held in position l

When the brake pedal is kept depressed at a constant force, the hydraulic pressure is kept constant, so the brake is kept applied.

To slack adjuster 0

425F0.37

Brake released l

When the operating force on the brake pedal is partly released, the compressed air supplied to the back of piston (2) of the brake chamber is released from the brake valve, and the hydraulic pressure inside master cylinder (7) drops. If the brake pedal is released further, the brake oil sent to the piston of the brake is sent back to the inside of master cylinder (7) by the force of the brake return spring.

From slack adjustor a

425FOBll

51-16

STRUCTURE

AND FUNCTION

SLACK ADJUSTER

1. 2. 3. 4. 5.

Bleeder Cylinder Check valve Piston Spring

A. B.

Inlet port Outlet port

Function

Specification

The slack adjuster is installed in the brake oil line from the brake chamber to the brake piston. It acts to keep the clearance between the brake piston and discs constant even when the brake discs are worn. In this way it acts to keep a constant time lag when the brake is operated.

Check valve cracking pressure: 9.5 kO.5 kg/cm*. Check valve closing pressure:925X6fHl.5 kg/cm*.

51-17

STRUCTURE AND FUNCTION

SLACK ADJUSTER

OPERATION 1.

Brake txdal demessed

LO322012

When the brake pedal is depressed, the oil discharged from chamber (6) enters port P of the slack adjuster.

It is then divided and enters left and right cylinders (2), and moves left and right pistons (4) to the left and right by a distance equal to the total travel S.

Because of this, an amount of oil equal to travel S flows from port C to brake cylinder (7). When this happens, The clearance between brake piston (8)

and the plate becomes 0, but no braking force is generated.

51-18

STRUCTURE AND FUNCTION

SLACK ADJUSTER

LO3ZZOl4

If the brake pedal is depressed further, and the oil pressure inside brake-chamber (6) goes above the specified pressure, check valve (3) opens and the oil flows to ports P and C and brake cylinder (7).

The discs and plates are then pushed together tightly by brake piston (8), and this acts as the braking force.

I. Brake pedal released

LO3ZZO15

When the brake pedal is released, the force of brake spring (9) causes brake piston (8) to return, and the oil equal to travel S returns piston (4) to its original position to release the brake.

In addition, the amount of oil returning from brake cylinder (7) is only equal to the amount of travel S of piston (4) so travel T of brake piston (8) does not change. In other words, the brake diaphragm is always constant regardless of the wear of the brake discs.

51-19

STRUCTURE AND FUNCTION

CHECK VALVE

-A-A

L03BZ005

1. Valve case 2. spring 3. Valve 4. cup

51-20

Function l The check valves are installed to the air suction side of the air tanks (wet and dry), and act to prevent the air pressure of the air tanks from flowing back.

STRUCTURE AND FUNCTION

BRAKE

BRAKE Function l

The brakes are wet-type multiple disc brakes, and are fiied to all four wheels.

1. Guide pin Return spring 3. Brake piston 4. Outer gear (164 Teeth)

5. 6. 7.

Inner gear (112 Teeth) Plate Disc

51-21

STRUCTURE

AND FUNCTION

BRAKE

Operation 0 When the brake pedal is depressed, pressure is applied to the brake oil by the master cylinder of the brake chamber. Brake piston (3) is moved to the right, and disc (7) is kept in close contact with plate (6). Disc (7) rotates together with wheel, so when it is held, the rotation is stopped and the brakes are applied to stop the machine.

L--

---

LO4ZZO13

-ill----

-_-

LO4ZZO14

When the brake pedal is released, the pressure on the rear of brake piston (3) is released. The piston is then moved to the left by the force of return spring (2) and the brake is released.

51-22

STRUCTURE AND FUNCTION

PARKING BRAKE

Outline l l

The parking brake is a disc type and is installed on the front axle. The force of the spring inside the spring cylinder (2) is used to apply the brake mechanically; it is released by air pressure. The parking brake caliper is fixed to the front differential case. The disc is installed to the differential yoke and rotates together with the coupling.

1. Parking brake disc 2. Spring cylinder

51-23

STRUCTURE AND FUNCTION

PARKING BRAKE

Parking brake actuated When the parking brake switch in the operator’s compartment is turned ON (actuated), the solenoid valve is turned OFF (no current flows), so plunger (8) is moved down by spring (2). The air from the tank enters port “c”, but valve (7) is seated, so no air flows. In addition, the air from the spring cylinder enters port “A’, then enters port “B* from seat (4) and is released Therefore, the parking brake is actuated by the force of the spring in the spring cylinder.

0 To brake

valve

LO4ZZOll

Parking brake released When the parking brake switch in the operator’s compartment is turned OFF (released), the solenoid valve is turned ON (current flows), and plunger (8) moves up. Valve (7) that is connected by a rod also moves up at the same time, and exhaust port “B” is shut off by seat (4) and valve (7). The air from the tank passes from port “c” around valve (7), enters port “A”, sends air to spring cylinder, and releases the parking brake.

To brake

valve

LO4ZZO12

51-24

STRUCTURE AND FUNCTION

PARKING BRAKE SOLENOID VALVE

L04zz010

Function l The parking brake solenoid valve is a valve to switch air to the parking brake spring cylinder. It is controlled and actuated by a switch in the operator’s compartment.

1. 2. 3. 4. 5.

Core Spring Body Seat Filter

6. Filter 7. Valve 8. Plunger 9. Coil 10. Connector

A. Outlet valve B. Exhaust port C. Inlet port

51-25

STRUCTURE AND FUNCTION

SPRING CYLINDER

1. Piston 2. Spring 3. Cylinder 4. Boot 5. Rod

51-26

Outline l The air pressure from the parking brake solenoid valve pushes the spring and compresses it to release the parking brake. Usually the parking brake is kept applied by spring (2), so the machine is prevented from moving.

BRAKE CALIPER

STRUCTURE AND FUNCTION

BRAKE CALIPER

_L 6

425Fo95

Section A .i A

1. Caliper 2. Pad

3. Piston 4. Piston shaft

5. Lever 6. Adjustment bolt

Outline The caliper body consists of inner caliper (3) and outer caliper (l), and is connected by bolts. There is a piston guide provided on the inner caliper. Piston (4) and piston shaft (5) are fitted in this, and the rotation of the piston shaft makes the piston move in an axial direction to press against pad (2). Lever (6) is connected by a spline to the split-red end of the piston shaft. Pad (2) is held in the caliper body by the pad pin, and at one end it is fitted in a groove of the outer caliper pad, and at the other end it is fitted in the groove of the caliper mount support.

Using sleeve (9) as a guide, the caliper body moves according to the wear of the pad and slides in the axial direction. The sleeve is installed by bolts to the caliper mount support. Adjustment bolt (8) of lever (6) is used to adjust the clearance between the pad and disc. Wiih the lever kept stationary, the adjustment bolt is turned to adjust the clearance.

To INCREASE clearance,

turn COUNTERCLOCKWISE.

To DECREASE clearance,

turn CLOCKWISE.

51-27

STRUCTURE AND FUNCTION

MEMORANDA

51-28

BRAKE CALIPER

BRAKE AND AIR SYSTEM 52

TESTING AND ADJUSTING

STANDARDVALUETABLE TOOLLlST

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

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

MEASURING BRAKE PEDAL

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

MEASURINGAIRPRESSURE

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

BRAKE PERFORMANCE

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

CHECKING BRAKEOILPRESSURE

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

MEASURINGWEAROFBRAKEDISC

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

AIR BLEEDING FROM BRAKE LINE

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

PARKING BRAKE PERFORMANCE

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

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

12 13

CHECKING AND ADJUSTING PARKING BRAKE ................................................................

TROUBLESHOOTING ............................................................. TROUBLESHOOTINGTABLE ..................................................... Air pressure does not rise at all. ................................................ 1. Air pressure does not rise to the specified range. ................................... Brake is ineffective or not very effective. .......................................... X: Brake does not release, or drags. .............................................. 4. Parking brake does not release, or drags. (Applies to machine equipped with air parking brake.) 5.

17 18 18 19 20 21 22

+ The following precautions are necessary when using the Standard Value Tables to make judgements troubleshooting or during testing and adjusting.

during

The values in these tables are based on the values for new machines leaving the plant, so they should be used as target values when repairing or when estimating wear after a period of use.

The standard values in these tables for judgement when troubleshooting are estimated values based on the standard values for the machine when shipped from the plant, and on the results of various tests. repair and operating records when Therefore, they should be used as reference in combination’with making judgements.

52-1

These standard value tables must not be used for stand values when judging claims. In addition, do not use these values alone to make simple judgements.

52-2

STANDARD VALUE TABLE

TESTING AND ADJUSTING

STANDARD VALUE TABLE Measurement condition

Testing and measuring item Brake pedal 0 Operating force 0 Operating angle 0 Plav Air system pressure l Air governor cut-in l Air governor cut-off l Safety valve actuating Warning buzzer pressure l Actuating starting l Actuating stopping

l l l

Coolant temperature: Inside operating range

kg/cm*

6.0 20.1 6.0 +0.4 0

6.0 lt:O.l 6.0 +0.4 0

Road surface: Flat, horizontal, dry, paved surface Speed when applying brakes: 20 km/h Time lag when pressing the pedal: 0.1 sec. Air pressure: 6 kg/cm* Brake pedal operating force: 38 kg Tire inflation pressure: Specified pressure

Max. 5

kg/cm*

Max. 5

2.2-5.5

Max. a.0

0 l

Coolant temperature: Inside operating range Test pressure: 53 kg/cm*/5 min.

Piston stroke

Tire inflation pressure: Specified pressure Road surface: Flat, dry, paved surface with l/5 (1l“20’) gradi ent Machine: In operating condition

0 Clearance between disc and pad

Max. 60 Max. 27 Max. 10 7.0 0 -0.35 a.4 -co.35 9.7 kO.2

Drop in brake oil pressure

Thickness of pad

16.5-20.5 4-6

7.0 0 -0.35 a.4 +0.35 9.7 +0.2

3947

degree

kg/cm*

Parking brake performance

Permissible valve

Coolant temperature: Inside operating range

Wear of brake disc

Standard valve

Brake performance

Engine speed: Low idling Air pressure: 7 kg/cm* Hydraulic temperature: 4555°C

Unit

l l

Machine stopped

With back plate Total of both side

31.7

12.7

1.06+0.18

Max. 2.3

52-3

TESTING AND ADJUSTING

TOOL LIST

TOOL LIST FOR TESTING AND ADJUSTING No

Testing and measuring

item

Tool name

Remark

Part number

Brake pedal operating force

Push gauge

799-101-1001

0-110kg

Brake oil pressure

Brake test kii

793-520-l 302

0 - 100 kg/cm*

Wear of brake disc

Vernier calipers

Brake distance

Tape measure

Clearance of pad

Feeler gauge

6-l

150 - 200 mm Commercially able

avail-

Hydraulic tester

799-l 0 l-5000

6-2

Nipple

790-301-l 190

6-3

Connector

20PF Commercially available

Measuring

air

30 m .l-3mm 0 - 25 kg/cm* 0 - 50 kg/cm* __

A A

52-4

do not allow unauthorized

persons near the machine.

MEASURING BRAKE PEDAL

TESTING AND ADJUSTING

MEASURING

BRAKE PEDAL

+ Measurement condition 0 Coolant temperature: Inside operating range. 0 Engine speed: Low idling 0 Air pressure: 7 kg/cm* Item

Standard value I

Operating force Brake pedal

39-47 kg

Operating angle

16.5 20.5”

Play

4-6”

PermissiMe value I MaX 55 kg

Special tool Part number

Part name

Q’ty

799-101-1001

Push aauae

Measuring operating force of pedal 1) Fii push gauge A to the operator’s foot. + Align the center of the push gauge with the center of the pedal. 2) Start the engine and run at low idling, then depress the pedal and measure the operating force.

Measuring travel of pedal 1) Fit push gauge A to the operator’s foot. * Align the center of the push gauge with the center of the pedal. 2) Start the engine and run at low idling, then depress the pedal with an operating force of 43 kg and measure the travel L of the pedal with an angle meter.

Measuring play of pedal 1) Start the engine. 2) Push the brake pedal in lightly by hand, and use an angle meter to measure the travel L of the pedal to the point where it starts to become heavy.

425w61

52-5

TESTING AND ADJUSTING

MEASURING AIR PRESSURE

MEASURING AIR PRESSURE + Measurement condition 0 Coolant temperature: Inside operating range. Special tools Part number

Part name

IQtv

799-l 01-5000

Hydraulic tester

790301-l 190

Nioole

20PF Commercially available

Connector

+ When measuring, connect nipple B, connector C to gauge A, then insert in the tire inflation coupler on the machine. 1.

Measuring set pressure of air governor Air governor cut-in pressure: 7.0 -0.35/O kg/cm*. 0 Air governor cut-off pressure: 8.4 kO.35.

1) Open the drain valve and drain air from the tank.

2) Start the engine and raise the pressure inside

the tank. Measure the pressure at which the air governor is actuated and the air compressor is cutoff (no-load rotation). 3) With the engine at low idling, use the brake pedal to lower the air pressure. Measure the pressure at which the air compressor cuts in (start of operation).

52-6

TESTING AND ADJUSTING

MEASURING AIR PRESSURE

Adjusting 1) - Stop the engine. 2) Loosen lock nut (l), and turn adjustment screw (2) to adjust. * Turn the adjustment screw as follows. To DECREASE set pressure, TIGHTEN screw. To INCREASE set pressure, LOOSEN screw. * Amount of adjustment for 1 turn of screw. Approx 1.4 kg/cm2

After adjusting as above, measure again and check that all values are standard.

Measuring cut-off pressure of air pressure alarm buzzer 1) Start the engine and run at low idling. Use the brake pedal to lower the air pressure, and measure the pressure at which the buzzer starts to sound. 2) Lower the pressure further, then increase the engine speed and measure the pressure at which the buzzer stops sounding. + If the pressure is not standard value, check the switch. If necessary, replace the switch. t After replacing the switch, measure the pressures again.

’

425F206

52-7

TESTING AND ADJUSTING

Measuring safety valve Safety valve actuating pressure: 9.7 20.2

Loosen the adjustment screw of the air governor and set the actuating pressure of the air governor above the actuating pressure of the safety valve. Start the engine and measure the pressure when air comes out of the safety valve.

t After measuring, do not forget to return the air governor to the specified pressure. t If the safety valve is defect-we, replace the valve assembly. Do not try to adjust it. t Hook the tool on part “a” when tightening or removing. Never use part “b” when tightening. * Check port “c” from direction “X”, mark the cover, and install so that exhaust port “c” is facing down.

52-8

MEASURING

AIR PRESSURE

BRAKE PERFORMANCE

TESTING AND ADJUSTING

BRAKE PERFORMANCE t Measurement condition 0 Time lag when pressing the pedal: 0.1 sec. 0 Pedal force: 38 kg 0 Road surface: Flat, horizontal, straight, dry, paved surface 0 Machine speed: Speed when applying brakes: 20 km/h 0 Tire inflation pressure: Specified pressure

Item

Standard value

Permissible value

Brake performance

Max. 5 m

Special tool

Measuringprocedure

Part number

Part name

Start the engine and then start the machine. Place the speed control lever in the highest speed range and drive the machine.

Tape measure

Commercially available

When the machine is traveling at 20 km/h, depress the left brake pedal with the specified operating force. Decide the run-up road and point to apply the brakes, then apply the brakes when the braking point is reached. Turn transmission cut-off selector switch ON.

t 4. +

Measure the distance from the braking point to the point where the machine stops. Carry out the test three times and take the average value.

Brake take effect

Stopbing point Brake

distance

Brake Run-up

road

423F319

52-9

TESTING AND ADJUSTING

CHECKING BRAKE OIL PRESSURE

CHECKING BRAKE OIL PRESSURE + Measurement condition a Coolant temperature: Inside operating range 0 Test pressure: 53 kg/cm2 - 5 min. 0 Air pressure: Inside operating range Soecial tool

I Part number A

793-520-l 802

Part name Brake test kii

A Block the tires securely Measuring procedure 1.

Remove bleeder screw (I), then install tool A in bleeder screw mount.

Start the engine and bleed the air. * *

Two workers are needed for this ooeration: one depresses the pedal and the other bleeds the air from the bleeder screw (2). For details of the procedure for bleeding the air from the brake oil, see AIR BLEEDING FROM BRAKE UNE (page 52-12).

Depress the left brake. When the gauge reading is 53 kg/cm’, leave for 5 minutes and check how much the pressure drops.

After measuring, stop the engine, and loosen the bleeder screw. Lower the pressure, then remove tool A. +

52-10

After completing operation, bleed the air from the brake circuit again.

TESTING AND ADJUSTING

MEASURING DISC

MEASURING WEAR OF BRAKE DISC

WEAR

BRAKE

+ Measurement condition l Coolant temperature: Inside operating range l Air pressure: Inside operating range a Piston stroke: 2.2 - 5.5 mm

Part number

Part name

Cty

Commercially available

Vernier calipers

b Stop the machine on level ground and block the A tires. 1.

Remove plug (1).

Depress the brake pedal to the end of its travel.

Measure depth “b” from the end face of the housing to the spring guide. + Keep the brake pedal depressed when measuring.

Install a vinyl hose to bleeder (2), loosen the bleeder and bleed the air brake oil. t After bleeding the brake oil, check that the brake piston has returned to the end of its stroke.

Measure depth “a” from the end face of the housing to the spring guide.

Calculating piston stroke S = b-a S = Max. 8.0 mm a

52-11

TESTING AND ADJUSTING

AIR BLEEDING FROM BRAKE LINE

A Block the tires securely Order of operation 1.

Remove cap (1) of the bleeder screw, insert vinyl hose into the screw and put the other end in a container.

Start the engine.

Depress the brake pedal, loosen the bleeder screw and bleed the air. Then tighten the bleeder screw and slowly release the brake pedal.

* * *

Two workers are needed for this operation: one depresses the pedal and the other bleeds the air from the bleeder screw. Depress the left brake pedal. Keep adding brake oil so that the oil circuit is always full. Repeat this operation until no more bubbles come out from the hose. Then depress the pedal fully and tighten the bleeder screw while oil is flowing out.

Follow the same procedure to bleed the air from each cylinder. After bleeding all the cylinders, check the level of the oil tank and add oil. To bleed the air completely, bleed the air first from the cylinder furthest from the master cylinder. After completely bleeding the air from each cylinder, remove cover (3), and check if over stroke sensor rod (5) of brake chamber (4) has come out. If it has come out, push it into the end face of the brake chamber body.

LO4ZZO20

52-12

TESTING AND ADJUSTING

PARKING BRAKE PERFORMANCE

PARKING BRAKE PERFORMANCE + Measurement condition 0 Tire inffation pressure: Specified pressure 0 Road surface: Flat, dry, paved surface with l/5 (1l“20’) gradient. 0 Machine: In operation condition Item Parking brake performance

Standard value

Permissible value

Keeps machine on l/5 (11’ 20’) gradient

423F321

Measuring procedure 1.

Start the engine and drive the machine straight up a l/5 gradient with bucket unloaded.

Depress the brake,place the F-R lever in neutral, then stop the engine.

Turn the parking brake switch ON, then slowly release the brake pedal and the machine must not move at all. 0

423F322

The measurement must be made with the machine facing either up or down the slope.

52-13

TESTING AND ADJUSTING

CHECKING

CHECKING AND ADJUSTING PARKING BRAKE + Measurement condition 0

Air pressure: Maximum set pressure Unit: mm Item

Standard value

Permissible value

AND ADJUSTING

PARKING

BRAKE

\h I \ \,i

\ (

Thickness

of oad

31.7

12.7

A Block the tire securely. 0

Remove front frame inspection

cover (1).

Method for measuring 1.

Turn the main switch ON, and turn the parking switch OFF to release the brake. t Operate the parking brake switch slowly. If it is not operated slowly, it may be impossible to release the brake. Measure the thickness of pad (3). + When the main switch is turned OFF, the parking brake is applied, so be careful not to turn it OFF. t For details of removing the pad, see DISASSEMBLY AND ASSEMBLY section 53. t Measure 2 pads. * If the thickness is not within the standard value, replace the 2 pads as one set. + For details of replacement, see DISASSEMBLY AND ASSEMBLY section 53.

Measuring clearance Unit: mm Item

Standard value

Permissible value

Clearance between disc and pad

1.06 kO.18

Max. 2.3

Measurement procedure 1. Turn the parking brake switch OFF to release 2. +

52-I 4

brake. Insert thickness gauge between disc (4) and pad (3), then measure the clearances. The clearance value mentioned above indicates the total value of both sides (a + b).

TESTING AND ADJUSTING

CHECKING

AND ADJUSTING

PARKING BRAKE

Adjustment + If the value is not within the standard range, adjust as follows. 0 Remove inspection cover (1) of front frame. 1. +

Turn the starting switch ON, then turn the parking brake switch OFF to release the brake. If the starting switch is turned OFF, the parking brake will be actuated, so be careful not to switch it off.

Turn adjustment bolt (2) at the caliper lever clockwise until pad (3) is lightly in contact with disc (4). t If the adjustment bolt is tightened too much and pad (3) and disc (4) are brought strongly into contact, it may cause the brake to squeak or the discs to overheat.

Turn adjustment bolt 130” f 30” (3 or 4 notch) counterclockwise. This will adjust the total

clearance (a + b) on the left and right between pad (3) and disc (4) to 0.33 - 1.24 mm. t

When replacing the pad, always replace in sets of two pads.

+ After adjusting, measure the brake performance

again and check that it is within the standard value.

425F208

52-15

TESTING AND ADJUSTING

MEMORANDA

52-16

CHECKING

AND ADJUSTING

PARKING BRAKE

TROUBLESHOOTING

52-17

TROUBLESHOOTING TABLE

TROUBLESHOOTING

TROUBLESHOOTING TABLE 1.

Air pressure does not rise at all. Ask the operator the following questions. l Dii the air pressure suddenly cease to rise? - Damage in air circuit or equipment. l Was the air pressure difficult to raise for some time? -. Air leakage, performance drop in air equipment. Check before troubleshooting. l Damaged air hose or tube, external damage to equipment associated with air system. a Is the drain valve completely closed? Fault check. l Check the air pressure by air gauge. l If the pointer of the air gauge on the instrument surized, the gauge is faulty.

ComPressOr does not start to build up pressure &spite he circuit between the air governor and the

The following

symbols are used to indicate the action

to be taken when a cause of failure is located.

52-I 8

Replace

A: Repair

Adjust

C: Clean

TROUBLESHOOTING

TROUBLESHOOTING TABLE

Air pressure does not rise to the specified range.

Checks before troubleshooting 0 Check for possible air leakage from air hose, tube and air equipment. e Is the drain cock completely closed? 0 Check for deformation of compressor or air intake hose. Fault check 0 Install a pressure gauge in the air circuit and measure the air pressure, then compare the measured value with the judgement criterion table to see whether or not it deviates from the specified value.

Air discharge from compressor discharge pipe is weak when engine is running.

Compressor starts to build up pressure when circuit between air governor and unloader is disconnected.

Air comes out of discharge pipe of compressor when engine is running but pressure does not build up.

0 0

The following

symbols are used to indicate the action

to be taken when a cause of failure is located. A: Repair X: Replace C: Clean A: Adjust

52-19

TROUBLESHOOTING

TROUBLESHOOTING TABLE

Brake is ineffective or not very effective.

Ask the operator the following questions. l

Did the brake suddenly ceases to be effective? - Damage in air or brake equipment. Did brake gradually deteriorate? - Deterioration of seal or packing, wear of lining.

Checks before troubleshooting l

Is kind of brake oil correct? (SAElOW-CD). Is air pressure and brake oil quantity satisfactory? Is there any leakage of air or brake fluid when the brake is operated? Is there any external damage to air or brake piping or equipment? Check residual thickness of brake lining. Check tire pressure and tire tread. Measure the pressure in the air circuit. If there is an abnormality, refer to item 1 “Air pressure is completely ineffective” and item 2 “Air pressure does not rise to the specified range”. If the measured value is normal, move on to the following problems.

0 0 0 0 l

Fault check 0 Check it against the valve in the judgement criterion table to see whether or not braking performance is bad. The left and right wheels at both front and rear.

No.

Air leaks from brake valve when a certain brake pedal is depressed. Braking action is action when other brake oedal is deoressed.

When pressing the brake pedal, air leaks from the brake chamber relay valve.

When brake is applied, abnormal brake area.

Sufficient air is not available from the pipe when the tube at the air inlet of the brake chamber is disconnected and the brake pedal depressed.

Air leaks from the indicator of the brake chamber when the brake pedal is depressed.

Excessive metal particles in axle oil.

Leakage of brake oil inside axle more than specified.

When the machine is raised using a 4-wheel jack, the wheel axles placed on a stand and the brake operated with the engine in the forward 1st speed position, however a particular turns fast.

noise is heard from axle 0

0 0 0 0

0000

The following

symbols are used to indicate the action

to be taken when a cause of failure is located.

52-20

TROUBLESHOOTING

TABLE

Brake does not release, or drags.

Checks before troubleshooting l

Does brake pedal return completely? Does parking brake completely disengage?

Fault check 0 Abnormal heat generation in brake. 0 Inertial travel on flat ground.

Air comes out and brake disengaged if brake chamber air input is disconnected when brake pedal is released.

Circuit pressure fails off and brake disengages if oil is bled from air bleeder when brake pedal is released.

A particular wheel rotates sluggishly when the machine is raised with a 4-wheel jack, the wheel axles placed on a stand, the engine shut down and the tires rotated by hand with the parking brake released.

The following

symbols are used to indicate the action

to be taken when a cause of failure is located.

52-21

TROUBLESHOOTING TABLE

TROUBLESHOOTING

Parking brake does not release, or drags. (Applies to machine equipped with air parking brake.)

Checks before troubleshooting 0 Is the pressure in the air circuitwithin the speciIf the air circuit pressure is 4.0 fied range? ( kg/cm2 or less, the parking brake solenoid valve will automatically operate to engage the parking brake.)

When-parking brake switch turned to OFF, air leaks front spring cylinder, and cylinder rod does not return fully.

Parking brake not released even when parking brake switch is turned OFF.

The spring cylinder operates normally return, however the brake drags.

0 0

and the rod and lever 0

The following

symbols are used to indicate the action

to be taken when a cause of failure is located. X : Repalce a: Repair A :

52-22

Adjust

Clean

BRAKE AND AIR SYSTEM 53

DISASSEMBLY

AND ASSEMBLY

BRAKEVALVE ................................................................... REMOVALOF ................................................................. INSTALLATION OF.. ............................................................ DISASSEMBLYOF .............................................................. ASSEMBLYOF . . .. . .. . .. .. .. .. .. .. .. .. .. ... .. .. .. .. . .. .. .. . .. .. . .. . .. .. . .. .. .

3 3 5 7 9

BRAKECHAMBER ............................................................... REMOVALOF ................................................................ INSTALLATION OF.. ........................................................... DISASSEMBLYOF ............................................................. ASSEMBLYOF ...............................................................

11 11 13 14 17

SLACKADJUSTER ............................................................... REMOVALOF ................................................................ INSTALLATIONOF ............................................................. DISASSEMBLYOF ............................................................. ASSEMBLYOF ...............................................................

20 20 20 21 22

BRAKE ASSEMBLY .............................................................. REMOVALOF ................................................................ INSTALLATION OF.. ........................................................... DISASSEMBLY OF (FRONT OR REAR) .............................................. ASSEMBLY OF (FRONT OR REAR) .................................................

23 23 25 29 32

SPRlNGCYLlNDER .............................................................. REMOVALOF ................................................................ INSTALLATION OF.. ...........................................................

36 36 37

PARKING BRAKE.. .............................................................. REMOVALOF ................................................................ INSTALLATION OF.. ...........................................................

38 38 41

PARKING BRAKE PAD ............................................................ REMOVALOF ................................................................ INSTALLATIONOF.............................................................

44 44 44

53-I

Run the engine at low idling, and extend and retract the steering, bucket, and lift arm cylinders 4 - 5 times without going to the end of this stroke. (Stop approx. 100 mm before the end of the stroke.)

Operate the steering, bucket, and lift arm cylinders 3 - 4 times to the end of the stroke, then stop the engine and bleed the air from the plugs at the top of the hydraulic tank filter.

Raise the engine speed and repeat Step 2) to bleed the air. Repeat this procedure comes out from the plug.

After completing

%==l

until no more air

bleeding the air, tighten the plugs.

Plug: 1.15 +O.l5kgm

+ If the engine is run at high speed from the start, or the cylinders are operated to the end of this stroke, the air inside the cylinder will cause damage to the piston packing. 5)

Check the level of the oil inside the hydraulic tank, add oil if necessary, then tighten the oil filler cap. + Before loosening the oil filler cap, close the pressurizing valve; after adding oil, tighten the oil filler cap, then open the pressurizing valve.

* After repair or long storage, follow the same procedure.

DISASSEMBLY

AND ASSEMBLY

BRAKE VALVE

BRAKE VALVE REMOVAL OF

LC4AR015

1. Draining air Open drain valve (1) and drain air from air tanks. 2. Covers Remove covers (2) and (3) under cab.

3. Air piping Disconnect the following air piping from the brake valve. l Tube (4) between front dry tank and brake valve. o Tube (5) between rear dry tank and brake valve. l Tubes (6), (7), (8), and (9) between left brake valve and right brake valve. + Disconnect electric wiring (10) from the connector, then remove the clamp. + Disconnect the brake valve piping on the right side in the same way.

LO4ARO17

53-3

DISASSEMBLY

AND ASSEMBLY

BRAKE VALVE

4. Pedal Pull out cotter pin of pin (1 l), then pull out pin, and remove pedal (12). t Remove the floor mat.

LOAAROIE

5. Brake valve 1) Remove mounting bolts (13). + Loosen bolts (14). 2) Remove bolts (14) and disconnect valve body (15) and mount flange (16). t Valve body (15) will fall when bolts (14) are removed, so be very careful when removing the bolts. * Pull out plunger (17) from mount flange.

L04AROl E

53-4

LO4AR020

DISASSEMBLY

BRAKE VALVE

AND ASSEMBLY

INSTALLATION OF 1. Brake valve 1) Assemble plunger (17) to mount flange (16). Plunger:

Brake oil

2) Set valve body (15) in mounting position, and tighten mount flange (16) and bolts (14).

L04ARO2(

‘15

LO4ARO21

3) Tighten mounting

bolts (13) to lock valve.

LO4AROlS

2. Pedal Set pedal (12) in mounting position, insert pin (ll), then align hole of stopper on left side of pin and install right side cotter pin. * Bend the cotter pin securely. + Check that the spacer is assembled.

LO4AROl E

53-5

DISASSEMBLY AND ASSEMBLY

BRAKE VALVE

3. Air piping Connect the following air piping to the brake valve. 0 Tube (4) between front dry tank and brake valve. 0 Tube (5) between rear dry tank and brake valve. 0 Tubes (6), (7) (8), and (9) between left brake valve and right brake valve. + Connect electric wiring (10) with the connector, then install the clamp. Tube (4) and (5): 8.25 + 1.25 kgm

Tube (6), (7), (8), and (9): 7.0 21.0

kgm

6 LO4AR017

4. Checking for air leakage 1) Start engine and check for leakage of air. 2) Check operation of brakes. 5. Covers

Install covers (2) and (3) under cab.

53-6

DISASSEMBLY

AND ASSEMBLY

DISASSEMBLY

BRAKE VALVE

1. Body assembly 1) Make match mark “a” on upper body and lower body.

a L04ARO2Z

2) Loosen mounting bolts (l), remove upper body (2) and lower body (3), then disconnect them.

2. Upper valve assembly 1) Hold slot-head screwdriver “A” in vice “B” and fit into the slot in the stem inside exhaust passage of relay piston.

L04AR024 2) Loosen nut (4), then remove washer (5), plain washer (6), spring seat (7), rubber spring (8) upper piston (9), return spring (lo), relay piston spring (1 l), relay piston (12), and stem assembly (13).

When loosening the nut, the piston may fly out under the force of the return spring, so hold the piston by hand when loosening the nut.

LO4ARO25

53-7

DISASSEMBLY

AND ASSEMBLY

BRAKE VALVE

3) Remove snap ring (14) then remove primary

valve (1 5) from upper body.

LO4AR02Z

4) Remove snap

ring (16), then disassemble primary valve into washer (17), O-ring retainer (18), O-rings (19) and (20), upper valve spring (21) valve retainer (22), and upper valve (23).

1918

L04AR02i

3. Lower valve assembly 1) Remove exhaust _ cover (24), then remove secondary valve assembly (25). 2) Remove O-ring from lower body.

LO4AR02E

3) Remove snap

ring (27), then disassemble secondary valve assembly into washer (28) O-ring retainer (29), O-rings (30) and (31), lower valve spring (32) valve retainer (33), and lower valve (34).

LCklAR02!

53-8

BRAKE VALVE

DISASSEMBLY AND ASSEMBLY

ASSEMBLY OF 1. Lower valve assembly 1) Set lower valve (34) with valve seat at bottom,

assemble valve retainer (33), lower valve spring (32), O-ring retainer (29) and washer (28), then secure with snap ring (27). Assemble 0-rinas (30) and (31) on the Oring retainer firs:

LO4AR03C

2) Assemble secondary valve assembly (25) in lower body, then install exhaust cover (24).

2. Upper valve assembly 1) Set upper valve (23) with valve seat at bottom, assemble valve retainer (22) upper valve spring (21), O-ring retainer (18) and washer (17), then secure with snap ring (16). + Assemble O-rings (19) and (20) on the Oring retainer first.

19 18

L04ARO2i

2) Assemble primary valve assembly (15) in upper body, then secure with snap ring (14).

L04AR02t

DISASSEMBLY

AND ASSEMBLY

BRAKE VALVE

“A” in vice “B”, 3) Hold slot-head screwdriver assemble relay piston spring (ll), relay piston (12), and stem assembly (13) in bottom of upper body, then set with screwdriver. + Do Not forget to fit an O-ring on the relay piston.

@b$yjyh

LOAARfb2A

4) Assemble return spring (lo), upper piston (9), rubber spring (8), spring seat (7), and washers (5)and (6) from top of upper body, then tighten with nut (4). + Do Not forget to fit an O-ring on the upper piston. The piston may fly out under the *& force of the return spring, so hold 4 the piston by hand when assembling.

I Nut:

0.55 20.15 kgm

3. Body assembly 1) Install O-ring (35) on lower body (3).

LO4ARMl

2) Align match marks “a” on upper body (2) and lower body (3) assemble and tighten mounting bolts (1).

L04AR032

53-10

DISASSEMBLY

AND ASSEMBLY

BRAKE CHAMBER

REMOVAL OF

WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the around and stop the enaine. Then apply the parking brake and put bl&ks under the wheels to prevent the machine from moving.

1. Drain air Open drain valve (1) and drain air from air tanks.

LO4AR015

2. Cover Remove covers (2), (3), (4) and (5).

3. Electric wiring Disconnect electric wiring (6) from connector.

53-11

DISASSEMBLY

BRAKE CHAMBER

AND ASSEMBLY

4. Brake piping 1) Disconnect hose (7) between brake chamber and brake oil tank at brake chamber end. + The oil will come out of the tank, so catch the oil in a container. 2) Disconnect tube (8) between slack adjuster and brake chamber at brake chamber end.

5. Air piping 1) Disconnect tubes (9) and (10). 2) Disconnect tube (11) between brake valve and brake chamber at brake chamber end. I

6. Front brake chamber Remove front brake chamber (12). Brake chamber:

53-12

20 kg

When removing the rear brake chamber, follow the same procedure as for the front brake chamber.

Rear brake chamber

BRAKE CHAMBER

DISASSEMBLY AND ASSEMBLY

INSTALLATION

1. Front brake chamber install front brake chamber (12). t Check that the breather is at the top of the brake chamber.

2. Air piping 1) Connect tube (11) between brake valve and brake chamber at brake chamber end. Tube:

8.25 +1.25 kgm

2) Connect tubes (9) and (10). ] Tube (9): 8.25 21.25 kgm

Tube (10): 2.0 20.4 kgm

3. Brake piping 1) Connect tube (8) between brake chamber and slack adjuster at brake chamber end. Tube:

8.25 + 1.25 kgm

2) Connect hose (7) between brake oil tank and brake chamber at brake chamber end.

4. Electric wiring Connect connector

(6) of electric wiring.

5. Cover Install covers (2), (3), (4) and (5).

6. Air bleeder of brake system Fill brake oil tank with oil, then bleed air from the brake system. + Always keep the brake oil tank full. t For details of air bleeding, see TESTING AND ADJUSTING. * Push in caution sensor rod of brake line.

T4251041

DISASSEMBLY AND ASSEMBLY

DISASSEMBLY

BRAKE CHAMBER

1. Accessories Remove breather (l), bleeder (2) and sensor (3).

2. Cylinder Loosen lock nut (4), then remove cylinder (5). + There is a O-ring fitted on the thread of the cylinder, so remove it.

LO3CHOO7

3. Piston assembly 1) Move retainer (6) to right, remove pin (7), then remove piston assembly (8). + Use a guide pin (Outer dia. = 2.5 mm, length = 50 mm) to remove the pin. 2) Remove rod (9), then remove O-ring.

423F446

LO3CHOO8

L03CHOOS

1. Disassembly of piston assembly

1) Remove snap ring (lo), then remove seat (ll), spring (12) and valve (13). + Spring (12) is small, so be careful not to lose it. 2) Remove packing (15) from piston (14).

L03CHOlO

53-14

DISASSEMBLY

BRAKE CHAMBER

AND ASSEMBLY

5. Body Hold body (16) with hand, remove mounting bolt, then remove body. The tension of the spring on the body %& is 25 kg, so be careful when removing 4 it.

Remove the O-ring from the contact surfaces of the body and air cylinder.

LO3CHOl 1

6. Disassembly of body 1) Remove snap ring (17), then remove ring (18), packing (19), seat (20), and packing (21).

LO3CHOl:

2) Remove snap ring (22), then remove ring (23) and seal (24).

L03CHOl:

7. Air piston 1) Remove spring (27) and piston assembly from air cylinder (25).

(26)

L03CH014

53-15

DISASSEMBLY

AND ASSEMBLY

BRAKE CHAMBER

2) Remove nut, then remove piston (28) and rod (29) * 3) Remove packing (30) and ring (31) from piston (28) -

L03CH015

4) Remove O-ring (32) and washer (33) from rod.

53-16

L03CH016

DISASSEMBLY AND ASSEMBLY

BRAKE CHAMBER

ASSEMBLY OF 1. Assembly of piston assembly

1) Install washer (33) and O-ring (32) on rod (29). + When fitting the O-ring, wind tape around the threads of the rod to prevent damage to the O-ring. O-ring:

Brake oil

2) Assemble packing (30) and ring (31) on piston (28) Packing:

LO3CHOl7

L03CHOl9

Grease (G2-LI)

3) Insert rod (29) in mount of piston (28), then secure with nut. + After tightening the nut, check that there is no clearance between the stepped part of the rod and the piston. Piston mounting (G2-LI)

Nut:

hole:

Grease

14 22 kgm

2. Assembly of body 1) Install seal (24) and ring (23) in body (16), then secure with snap ring (22). + Install the seal with the lip facing the outside. t Check that the snap ring is fitted securely in the groove.

Seal:

Brake oil

423F449

53-17

DISASSEMBLY AND ASSEMBLY

BRAKE CHAMBER

(!o BQ 2120

423F450

2) Turn over body, assemble packing (21), seat (20), and packing (19) insert ring (18), then secure with snap ring (17). + Install the seal with the lip facing the outside. + Check that the snap ring is fitted securely in the groove. Packing:

Brake oil

3. Piston assembly Insert piston assembly (27) in air cylinder (25). t Coat inside of air cylinder with grease. + When inserting the piston assembly, tilt at an angle of about 30”, insert about l/3, then lay the air cylinder on its side and insert the piston fully. + Check that the piston assembly moves smooth-

L03CHO2:

ly-

4. Body assembly Insert spring (26) in mount of air cylinder, fit O-ring (34) in body assembly (16), then install in air cylinder. + Push in the body by hand, install 2 mounting bolts in diametrically opposite positions, then tighten together with bracket (35).

Mounting

bolt:

L03CH02:

4.4 +0.6 kgm

5. Assembly of piston 1) Insert valve (13), spring (12) and seat (11) in piston (14), then secure with snap ring (10). + Be careful to insert the spring facing in the correct direction. + Check that the snap ring is fitted securely in the groove. L03CHO2r

53-18

DISASSEMBLY AND ASSEMBLY

BRAKE CHAMBER

2) Assemble packing (15) on piston. t

Install the packing outside.

with the lip facing the

Packing:

Grease (G2-LI)

6. Piston assembly Blow air into air cylinder and blowout rod. Set piston assembly (8) in mounting position, then connect with pin (7). * The pin hole is hidden by the retainer, so move the retainer to the right and insert the pin. + After inserting the pin, check that the retainer has moved back to its original place and the pin is hidden.

7. Cylinder Install nut (4) and O-ring (36) on cylinder (5), screw into mount, then secure with nut. + Screw the cylinder in fully, then turn back until the breather and bleeder are in a straight line. Inside surface of cylinder: Brake oil

Nut:

14 t3 kgm LO3CHO27

8. Sensor Fii O-rings on rod (9) and sensor (3), then install in mounting position. t Insert the rod until it is level with the body.

Sensor:

5.6 +0.6 kgm

9. Accessories Install breather (1) and bleeder (2).

Bleeder: 0.95 +0.25 kgm LO3CH028

53-19

DISASSEMBLY

AND ASSEMBLY

SLACK ADJUSTER

SLACK ADJUSTER REMOVAL OF

1. Brake piping 1) Remove cover (1). 2) Disconnect tube (2) between slack adjuster and brake chamber at slack adjuster end. 3) Disconnect tubes (3) between slack adjuster and left and right brake piston at slack adjuster end.

L04AR033

2. Slack adjuster

Remove mounting bolts, then remove slack adjuster (4). * There, is little space, so be careful when working.

INSTALLATION

I MARMA

1. Slack adjuster Set slack adjuster

(4) in mounting position, then tighten mounting bolts. * Tighten the mounting bolts partially, then tighten fully after connecting the piping.

2. Brake piping 1) Connect tubes (3) between slack adjuster and

left and right brake pistons at slack adjuster end.

I 2)

Tube:

7 21 kgm

Connect tube (2) between slack adjuster and brake chamber at slack adjuster end.

Tube:

8.25 21.25 kgm

3) Install cover (1).

3. Bleeding air

Bleed air from brake system, and check that there is no leakage of oil from connections. t For details of bleeding air, see TESTING AND ADJUSTING. t Bleed the air from the brake end and slack adjuster end.

53-20

LO4AR035

DISASSEMBLY

AND ASSEMBLY

DISASSEMBLY

SLACK ADJUSTER

1. Bleeder Remove bleeder (2) from body (1).

2. Cylinder Remove mounting bolts, then disconnect body (1) and cylinder (4) together with bracket (3). There is spring tension inside the cylinSLY der, so hold the contact surfaces and 4 be careful when removing.

3. Piston 1) Remove spring (5) and O-ring (6). 2) Remove piston (7), then remove O-ring. + Use a rod of 10 mm diameter and push out the piston slowly. + Be careful not to damage the thread with the rod.

6 5

4. Poppet 1) Remove cover (8) from cylinder (4), then remove plug (9), spring (lo), and poppet (11). + When removing the poppet, blow in air from the oil hole in the cylinder. t Hold the oil port of the cylinder by hand, and do not pump in air suddenly. + Be careful not to change the combination of poppet (11) and cylinder (4). + When replacing, replace the poppet and cylinder as an assembly. 2) Remove O-ring (12) from poppet.

L&iAROX

53-21

DISASSEMBLY

AND ASSEMBLY

ASSEMBLY

SLACK ADJUSTER

1. Poppet 1) Fii O-ring (12) on poppet (11). 2) install poppet (ll), spring (lo), plug (9) and cover (8), then assemble cylinder (4).

00ld

12 amJ

LO4ARO4t

2. Piston 1) install O-ring (13) on piston (7). 2) Insert piston (7) in cylinder (4). + Check that the piston moves smoothly.

LO4ARO4

3. Cylinder 1) Install O-ring (6) and spring (5) in cylinder. + Installed road of spring: 4.4 kg 2) Install body (1) and cylinder (4) together with bracket (3).

4. Bleeder Install bleeder (2).

1 OAAROA:

L04ARO44

53-22

LO4AFKM

DISASSEMBLY

BRAKE ASSEMBLY

AND ASSEMBLY

BRAKE ASSEMBLY REMOVAL OF Special tool

Part number

Part name

QtY

793-520-l 910

Fixture

1’

L07HH003

1. Tires and wheels Jack up axle, put stand under axle, then lift off tire and wheel (1). Tire and wheel:

600 kg

2. Draining oil Remove drain plugs (2) and (3), and drain oil from axle assembly. t Set with the drain plug at the bottom. Axle assembly:

3. Cover Remove mounting cover (5).

304

bolts (4), then remove final case

4. Axle shaft assembly Using forcing screw “a” (Thread dia. = 12 mm, Pitch = 1.75 mm), pull out axle shaft assembly (6).

5. Mounting bolts Remove mounting bolts (7), and using eye-bolts “b” (Thread dia. = 12 mm, Pitch = 1.75 mm), lift off planetary carrier assembly (8). + Since the balance is bad, adjust center of gravity with a bar and remove. Planetary carrier:

90 kg

53-23

DISASSEMBLY

BRAKE ASSEMBLY

AND ASSEMBLY

6. Ring gear assembly Using tool A, hold wheel hub (9) and brake (10) in position. t Install tool A to points on opposite sides, and use washers to adjust clearance.

7. Mounting bolts Remove mounting bolts (11) of retainer (12), then remove ring gear assembly (13). t There are shims between the retainer and axle housing, so check the number and thickness of the shims, and use for reference when installing. Ring gear assembly:

50 kg

8. Remove brake tube (14).

9. Sling brake and wheel hub assembly (16), remove mounting bolts (15), then lift off assembly. Brake and wheel hub assembly: 280 kg

10. Axle housing Remove bearing housing (17).

(18) and retainer (19) from axle

L07HH023

53-24

iii-’

LO7HH02

L07HH022

DISASSEMBLY AND ASSEMBLY

INSTALLATION

BRAKE ASSEMBLY

Special tool

Part number

Part name

QtY

793-520-l 910

Fixture

1. Axle housing Press fii retainer (19) and bearing (18) on axle housing (17). + After press fiiing the retainer and housing, and the retainer and bearing, check that there is no clearance at any point.

2. Brake, wheel hub assembly Use tool A to hold brake assembly and wheel hub in position. t As far as possible, install tool A to points at diametrically opposite positions and adjust clearance using with washer.

3. Raise brake and wheel hub assembly (16), set in position on axle housing mount, then tighten mounting bolts (15). t Be careful of the center of gravity, and sling horizontally, then install it.

Mounting (LT-2)

bolt:

Thread tightener

Mounting

bolt:

56 26 kgm

L07HHO22

L07HH021

4. Install brake tube (14).

Brake tube:

7 +l kgm

53-25

DISASSEMBLY

BRAKE ASSEMBLY

AND ASSEMBLY

5. Wheel bearing adjusting method 1) Raise ring gear assembly (13), then insert in axle housing and, tighten retainer (12) temporarily with 3 bolts, then remove tool A. + Measure thickness “b” of retainer first. t Do not insert shims in the retainer when tightening temporarily. l Rotate the wheel hub to settle the bearing, then tighten to a uniform torque.

Retainer mounting kgm

bolt:

8 ~~0.5 425F293

2) Insert a depth micrometer

through measuring hole of retainer (20), and measure clearance “a” between end face of housing and end face of retainer. t Measure at 2 places and take the average. + 0.3 mm added to measured value difference c = a - b, becomes shim thickness. (Round off fraction to next highest decimal 0.1 mm.) + Use the smallest number of shims which gives the required thickness.

3) Install tool A to brake assembly and wheel hub, and remove retainer. Install required thickness of shims, then install retainer again. Always install tool A before-assembling the * shims. Rotate the wheel hub and tighten the mou* nting bolts uniformly to the specified tightening torque. Mounting bolt: Thread tightener (LT-2) II

Mounting bolt: +3.25 kgm

L07HH025

28.25

425F297

53-26

BRAKE ASSEMBLY

AND ASSEMBLY

DISASSEMBLY

6. Planetary carrier assembly Fii O-ring, and using eye-bolts “b” (Thread dia. 12 mm, Pitch = 1.75 mm) sling planetary carrier assembly (8) and set in mounting position, then tighten mounting bolts (7). + Since the balance is bad, adjust the center of gravity with a bar and install.

7. Axle shaft assembly Install bolt “a’ to axle shaft and install axle shaft assembly (6). t If the position of the sun gear does not match, rotate the wheel hub to align.

a. Cover Fit O-ring in groove in cover, then install cover (5) with bolt (4). I

Mounting

bolt: 11.25 t 1.25 kgm

9. Tighten drain plugs (3) and (2), then remove level plug (21), and add oil through oil filler to specified level. + Set the machine so that the drain plug of the final drive is at the bottom when refilling with oil.

Axle assembly:

Approx. 3OP

I lk-kll I

LWIJ

\ LO7HBO27

53-27

DISASSEMBLY

AND ASSEMBLY

BRAKE ASSEMBLY

10. Raise tire and wheel assembly (1) and set to wheel hub. After tightening with wheel nuts temporarily, raise machine with work equipment, remove support from under axle, then lower machine to ground and tighten wheel nuts to specified torque. I

Mounting nut: 48 45 kgm (Width across flats: 30 mm)

L07HH003

il.

Bleeding from brakes t For details of bleeding air, see TESTING AND

ADJUSTING.

53-28

DISASSEMBLY

DISASSEMBLY Special

BRAKE ASSEMBLY

AND ASSEMBLY

OF (FRONT OR REAR)

tool Part number

Part name

Qty

793-520-l 910

Fixture

1. Cylinder

Using eye-bolts “a” (Thread dia. = 16 mm, Pitch = 2.0 mm), lift out cylinder (1).

Disassemble cylinder with following steps: 1) Screw in eye-bolts “a” (Thread dia. = 16 mm, Pitch = 2.0 mm), push in spring with bar “b”, then pull out pin (2). 2) Remove spring (3) and shaft (4).

3) Remove piston (5).

53-29

DISASSEMBLY

AND ASSEMBLY

BRAKE ASSEMBLY

2. Plate, disc 1) Remove plate (6).

2) Remove disc (7). + When removing the disc and plates, put match marks on the inner gear and disc, and outer gear and plate before removing. t The discs are made of soft material, so be careful not to damage them when removing. * Remove discs and plates alternately.

3. Outer drum + Remove toot A.

LO4AVO21 1) Using eye-bolts “c” (Thread dia. = 12 mm, Pitch = 1.75 mm), lift out outer drum (8).

53-30

DISASSEMBLY

AND ASSEMBLY

BRAKE ASSEMBLY

2) Remove outer race (9). 3) Remove retainer (10).

4) Remove floating seal (11).

LO4AVO24

5) Remove oil seal (12). 6) Remove floating seal (13).

LO4AVO25

53-31

DISASSEMBLY

AND ASSEMBLY

BRAKE ASSEMBLY

ASSEMBLY OF (FRONT OR REAR) Sbecial tool

792-530-l 600

Push puller

1. Outer drum 1) Using tools B and B, install floating seal (13) to hub.

Seal contact face: (E030-CD)

Engine oil

Assemble O-ring (13A) to floating seal. Using alcohol, remove all the white powder from the O-ring surface. Remove all the grease from the floating seal and O-ring contact surface of the hub. Tighten tool B, uniformly so that there is no twisting of the O-ring of the floating seal. After press fitting, measure height t at four places around the circumference, and check that the difference between the measurements is within 1 mm.

LO4AVO26

I CUAVO7fi

2) Install oil seal (12).

Seal contact face: Ll)

Grease (G2-

Mating surface of oil seal and hub: Thread tightener (Loctite #rW

53-32

DISASSEMBLY

ll_

BRAKE ASSEMBLY

AND ASSEMBLY

11A

EF J

3) Using tools B and B,, install floating seal (11) in retainer (10). Seal contact face: (E030-CD) + + t

Engine oil

11A

Assemble O-ring (11A) to floating seal. Using alcohol, remove all the white powder from the O-ring surface. Remove all the grease from the floating seal and O-ring contact surface of the retainer. Tighten tool B, uniformly so that there is no twisting of the O-ring of the floating seal. After press fiiing, measure height ‘Y” at four places around the circumference, and check that the difference between the measurements is within 1 mm.

4) Match retainer (10) with dowel pin and install retainer. 5) Install outer race (9).

LWAVO23

6) Using eye-bolts “c” (Tread dia. = 12 mm, Pitch = 1.75 mm), lift and install outer drum (8).

53-33

DISASSEMBLY

AND ASSEMBLY

BRAKE ASSEMBLY

Install tool A.

LO4AVO21

2. Disc, plate 1) Install disc (7).

2) Install plate (6). t Align notched portion of outer teeth of plate and assemble. t Align the match marks on the disc and inner gear, and plate and outer gear, then assemble the plates and discs in turn.

3. Cylinder Assemble cylinder with following t 1) Set piston (5) at bottom.

steps:

LO6AVOl8

53-34

DISASSEMBLY

AND ASSEMBLY

BRAKE ASSEMBLY

2) Install shaft (4) and spring (3). 3) Screw in eye-bolts “a” (Thread dia. = 1 6 mm, Pitch = 2.0 mm), push in spring with bar “b”, then install pin (2).

4) Fit O-ring and using eye-bolts “a” (Thread dia. = 16 mm, Pitch = 2.0 mm), match with guide bolt “d” and lift and install cylinder assembly (1). Mounting bolt: Thread tightener (LT-2)

Mounting kgm

bolt:

18 22

LO4AVO3C

53-35

DISASSEMBLY

AND ASSEMBLY

SPRING CYLINDER

SPRING CYLINDER REMOVAL OF

1. Cover Remove cover (1) at front of front frame.

L04AR033

2. Linkage 1) Turn adjusting bolt (2) in counter clockwise direction and check that there is play in the linkage (3). 2) Remove pin (4) and disconnect linkage (3) from adjuster (5).

/ 3. Air piping Disconnect air piping (6) of spring cylinder. + Drain the air. t After removing, cover to prevent dust or dirt from engine.

4. Spring cylinder Remove mounting (7).

53-36

nut, then remove spring cylinder

LO4BFOOl

DISASSEMBLY

AND ASSEMBLY

INSTALLATION

SPRING CYLINDER

1. Spring cylinder Set spring install.

cylinder

(7) in mounting

Mounting

nut:

position,

and

28.5 +3 kgm

2. Air piping Connect air piping (6) to spring cylinder.

Linkage 1) Connect linkage (3) to adjuster (5) with pin (4). 2) Turn adjusting bolt (2) in clockwise direction, and at point adjusting bolt cannot be tightened further, turn back 180” or 3 or 4 notches. t For details of adjusting the linkage, see TESTING AND ADJUSTING. t Check the operation of the parking brake.

\ / 4. Cover Install cover (1) at front of front frame.

LO4BFOOl 4

L04AR03d

53-37

DISASSEMBLY

AND ASSEMBLY

PARKING BRAKE

PARKING BRAKE REMOVAL OF

WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the around and stop the enaine. Then apply the p&king brake and put blocks under the wheels to prevent the machine from moving.

1. Drive shaft Disconnect front drive shaft (1) from differential, and remove disc cover (2). Drive shaft:

2. Air hose Disconnect

44 kg

air hose (3) from spring cylinder.

3. Linkage Remove pin (4) and disconnect linkage. + For details on adjusting screw, see TES TING AND ADJUSTING section. / 4. Spring cylinder Remove nut, then remove spring cylinder (5).

5. Caliper 1) Remove plate (6). + Remove pad.

53-38

L04BH017

DISASSEMBLY AND ASSEMBLY

PARKING BRAKE

2) Remove caliper (7). Use two men to remove caliper. * Caliper:

32 kg

6. Disc Remove disc (8).

7. Disassembly of caliper 1) Remove snap ring (9) and pull out adjuster (10).

’ ‘WBHOt

2) Remove washers (11) and (12) and seal (13).

11 LOABHOZ: 3) Remove bolt, then gasket (15).

remove

caliper

(14) and

53-39

PARKING BRAKE

DISASSEMBLY AND ASSEMBLY

4) Remove piston shaft (16) and thrust bearing (17) from piston.

L04BH02r

6) Remove piston (19) and piston seal (20) from caliper (18).

18 /

53-40

f“9 I

L04BH025

DISASSEMBLY

AND ASSEMBLY

PARKING BRAKE

INSTALLATION OF

1. Assembly of caliper 1) Install piston seal (10) in caliper (18), then insert piston (19).

Piston and seal: Grease (G2-LI)

L04BH025 2) Screw in piston shaft (16) into piston, then install thrust bearing (17). + Be careful of direction of thrust bearing, then install. Thrust bearing:

Grease (G2-LI)

LOdBHO24

3) Fii gasket (15), then install cap (14). I

Mounting

bolt:

18 +2 kgm

4) Install seal (13) and washers (11) and (12). * Insert seal in groove completely.

Seal: Grease (G2-LI)

11 L04BHO22

53-41

DISASSEMBLY

AND ASSEMBLY

5) Assemble ring (9).

adjuster

PARKING BRAKE

(10) and secure with snap

2. Disc Install disc (8).

Mounting (LT-2)

bolt:

Thread tightener

Mounting

bolt:

28.5 ?3 kgm

3. Caliper 1) Set caliper (7) in mounting position. + Check that pad is assembled. 2) Install plate (6). * Raise the caliper slightly and align the caliper and the groove of the pad, then assemble. t Insert the pin of the plate completely. Mounting (LT-2)

53-42

Thread tightener

Mounting bolt: 95 + 10 kgm (Width across flats: 36 mm)

4. Spring cylinder Set spring cylinder tighten nut. I

bolt:

(5) in mounting

Nut:

28.5 23 kgm

position

and

DISASSEMBLY

AND ASSEMBLY

PARKING BRAKE

5. Linkage Assemble pin (4) and connect linkage. + For details, see TESTING AND ADJUSTING. 6. Air hose Connect air hose (3) to spring cylinder.

L04BH017

7. Drive shaft Connect from drive shaft (1) to differential and install cover (2). + When connecting drive shaft, clean connecting faces of spider and coupling, then install.

Mounting

bolt:

11.5 + 1 kgm

L04BH016

53-43

DISASSEMBLY

AND ASSEMBLY

PARKING BRAKE PAD

PARKING BRAKE PAD REMOVAL OF

Release the parking brake.

Turn the adjusting bolt (1) in a counter clockwise direction, and increase the clearance between the pad and the disc. Remove cover (2) then remove plate (3). t Remove either the right or left plate (3). Raise the parking brake caliper slightly and remove pad (4).

INSTALLATION

1. Insert pad (4) between caliper and disc. * Since the pad is new, turn the adjusting bolt further in a counter clockwise direction to increase the clearance. + Lii the caliper up slightly and the pad will be able to be smoothly inserted. 2. Fit plate (3) and install cover (2). + Align the caliper and groove of the pad completely with the left and right plates. Mounting (LT-2)

bolt:

Thread tightener

Mounting bolt of plate: 95 210 kgm (Width across flats: 36 mm)

3. Turn the adjusting bolt (1) clockwise and adjust pad clearance. + For details of adjusting, see TESTING AND ADJUSTING.

53-44

BRAKE AND AIR SYSTEM MAINTENANCE

BRAKEVALVE

STANDARD

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

BRAKE CHAMBER ................................................................

SUI\CKADJUSTER

BRAKE

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

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

PARKING BRAKE..

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

SPRINGCYLINDER

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

54-1

MAINTENANCE STANDARD

BRAKE VALVE

54-2

BRAKE VALVE

MAINTENANCE STANDARD

BRAKE VALVE

Unit: mm No

Check item

Clearance between pedal mounting pin and mount plate

2 3

Clearance between rofler and pin

Clearance between primary piston and upper bodv Clearance between relay piston and lower body

Outside diameter of roller

-0.015 -0.050

0.015 1 -0.050 I

+ 0.036 0 1 I

+0.058 0

1 I

0.086 0.015

Pin: 9.85 Hole: 10.1

0.015 0.108

1 Hole: 10.1

Pin:

9.85

Clearance between mount plate and plunaer

Remedv

Criteria

60 66.5

Free height of rubber spring

Piston return spring

Free length

+0.150 + 0.050

+0.401 + 0.325

0.175 0.351

0 -0.10

+0.76 +0.10

0.10 0.86

Replace

Standard size

Tolerance

Repair limit

26.2

+O.l 0.1

26.0

14.4

+0.2 0.2

12.0

Standard Size

Reoair limit

Installation I Installation I length 1 load I I

Free length

I Installation I load I

65.3 9

Primary vaive spring

41.3

Inner stem spring

35.6

Outer stem sorina

41.o

16.0

4.0 ka

12 13 14

54-3

MAINTENANCE

STANDARD

BRAKE CHAMBER

425M57A

Unit: m m No.

Check item

Standard size 1

Clearance between cylinder and piston

Outside diameter of oil seal

69.6

Air piston stroke

54-4

Remedy

Criteria

Tolerance

Standard clearance

Clearance limit 0.15

Shaft

Hole

-0.030 -0.076

+0.046 0

0.030

+ 0.500 -0.300

+ 0.046 0

0.346 0.500

0.122

Min. 133.5 (Normal pressure: Max. 9.5 kg/cm*)

Replace 1.0

MAINTENANCE

STANDARD

SLACK ADJUSTER

5.7 t0.7kgm

6.7 -'O.'lkgm

42!5Fl5oA

Unit: Criteria

Check item

No.

Standard size 1

Clearance between body and piston

Tolerance

Remedy Standard . clearance

Shaft

Hole

4.030 -0.076

to.074

0.030

0.150

Spring

Clearance Limit 0.25

Repair limit

Standard size

Free length

install length

Install load

Free length

198

4.4 kg

39.2

6.8 kg

Replace

Install length

54-5

MAINTENANCE

STANDARD

BRAKE

-18f2kp

-18f2kgm

’

‘9

Detail P

425FO1230

54-6

MAINTENANCE

BRAKE

STANDARD

Unit: mt No.

Check item

Criteria

1 Remedv

Repair limit

Standard size

Return spring

Free length

length

Install load

Free length

Install load

96.9

81.4

70.4 kg

95.4

63.4kg

Install

Standard size

Tolerance

Repair limit

Thickness of plate

2.4

+O.l -0.1

2.0

Thickness of disc

5.1

+O.l -0.1

4.6

Total thickness of plate and disc

39.9

+l.l -1.1

35.0

Wear of contact surface of seal

430

Wear of surface in contact with piston seal

420

+ 0.097 0

Wear of surface in contact with oiston seal

465

+ 0.097 0

Deformation of friction surface of plate and disc

Replace

-0.:55

Repair limit

Standard size Max. 0.4

Backlash between outer gear and plate

0.28 - 0.61

Backlash between inner aear and disc

0.16 - 0.52

54-7

MAINTENANCE

STANDARD

PARKING BRAKE

94.5

View

tlO.Skgm 425F16OP

54-a

MAINTENANCE

STANDARD

PARKING BRAKE

Unit: ml No.

Check item Remaining thickness of friction material

Wear of pad including backing plate

Criteria Tolerance

Standard size

3.7

31.7

12.7

0.8

Face runout of disc

0.4

Wear of rod connecting pin

-0.10 -0.17

Wear of disc

Repair limit

22.7

Remedv

I I

20mm and above

22.0

kO.5

(Thickness of disc plate) 5

Clearance between pad and disc (Total of both sides)

1.06

to.18

Clearance between brake body and elate

1.25

+0.85

Replace

Less than 20mm

Rebuild

Replace

2.3 Adjust

54-9

MAINTENANCE

SPRING CYLINDER

STANDARD

;PRING CYLINDER

Unit: mm No

Standard size 1

Clearance between cylinder and piston

Clearance between piston insert and center boss

Tolerance Shaft

Hole

0.35

Hole: 38.8 Shaft: 38.04

0.76

Free length

Piston spring

260 4

Play of rod in axial direction

installed dimension of rod

54-10

Standard clearance

Hole: 159 Shaft: 158.65

Clearance limit

Replace

Repair limit

Standard size

Remedy

Criteria

Check item

Installation length

Installation load

Free length

Installation load

560 250 Adjust

2.1

WORK EQUIPMENT SYSTEM 61

GENERAL

STRUCTURE

AND FUNCTION

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

HYDRAULlCPlPlNG

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

HYDRAULIC CIRCUIT. ............................................................. SCHEMATICS ................................................................. DIAGRAM ....................................................................

4 4 4

HYDRAULlCTANK ............................................................... OILFILTER By-passVALVE ....................................................... BREATHER ...................................................................

5 6 7

PROPORTIONAL PRESSURE CONTROL VALVE (PPC VALVE) ................................ OPERATIONOFPPCVALVE ..................................................... PPCRELlEFVALVE ............................................................

8 10 14

MAINCONTROLVALVE ........................................................... RELIEFVALVE.. .............................................................. SAFETYVALVE(withsuctionvalve) ................................................ SUCTION VALVE .............................................................. FLOATSELECTORVALVEAND UNLOADERVALVE ....................................

15 18 19 20 21

ACCUMULATOR

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

OPERATION OF MAIN CONTROL VALVE .............................................. LIFT AND DUMP SPOOLS AT “HOLD” ............................................... LIFT SPOOL AT “RAISE” ......................................................... UFTSPOOLAT”LOWER’........................................................ LlFTSPOOLAT”FLOAT” ........................................................ DUMP SPOOL AT “DUMP” ....................................................... DUMP SPOOL AT “TILT BACK” ....................................................

24 24 25 26 27 28 29

BUCKET UNKAGE

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

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

BUCKET

BUCKET POSITIONER AND BOOM KICK-OUT .......................................... Bucket positioner .............................................................. Boom kick-out ................................................................

33 34 34

61-1

WORK EQUIPMENT LEVER LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STRUCTURE AND FUNCTION

GENERAL

GENERAL Outline

The work equipment system consists of the hydraulic circuit and steering circuit. The hydraulic circuit controls the operation of the bucket and attachment. The oil in the hydraulic tank (3) is sent by hydraulic pump (8) to the main control valve (1). When the dump and lift spools of the main control valve are at “HOLD”, the oil passes through the drain circuit of the main control valve. It is then filtered by the filter in the hydraulic tank, and returns to the tank. The dump or lift spool PPC valve is activated by operating the work equipment control lever, causing each spool in the work equipment valve to be hydraulically activated. Thereby, the oil is allowed to flow from the work equipment valve to the lift cylinder (11) or dump cylinder (2), thus operating the lift arm or the bucket. The maximum pressure of the hydraulic circuit is regulated by the relief valve inside the main control valve. There are two safety valves (with suction valve) and an unloader valve in the dump cylinder circuit to protect the circuit. Even when the engine is at rest, the lift arm can be lowered to the ground because a accumulator (6) is provided in the circuit. The hydraulic tank (3) is a pressurized, sealed type unit and has a breather with a relief valve. This acts to pressurize the tank and at the same time prevents negative pressure. This protects the pump form cavitation.

61-3

STRUCTURE

AND FUNCTION

HYDRAULIC PIPING SEE FOLDOUT # 8 AT END OF BOOK.

HYDRAULIC CIRCUIT SCHEMATICS SEE FOLDOUT #9 AT END OF BOOK.

HYDRAULIC CIRCUIT DIAGRAM SEE FOLDOUT #lO AT END OF BOOK

61-4

HYDRAULIC

PIPING

STRUCTUREANDFUNCTION

HYDRAULIC

TANK

HYDRAULIC TANK Outline l

The oil from the hydraulic tank is sent from the pump through the control valve to the cylinders. In the return circuit, the oil from various parts merges. A part of oil is cooled in the oil cooler, passes through the hydraulic filter (2) and returns to the tank (5).

The hydraulic filter (2) filters all the oil in the circuit. If the hydraulic filter (2) becomes clogged, a by pass valve (1) acts to allow the oil to return directly to the tank (5). This prevents damage to the filter (2). The by-pass valve (1) is also actuated when negative pressure is generated in the circuit.

1. Filter by-pass valve Hydraulic filter Oil level sight gauge Breather Hydraulic tank Drain valve

2. 3. 4. 5. 6.

A. Hydraulic cooler return port Main return port : Main suction port D: Ground driven steering suction port E. Ground driven steering return port

.._ !!

‘\

2’

425FO1164

Section A - A

61-5 View Z

HYDRAULIC TANK

STRUCTURE AND FUNCTION

OIL FILTER By-pass VALVE When the filter is clogged By-pass valve (1) opens and the oil returns directly to the tank without passing through the filter. By-pass valve set pressure : 1.27 kg/cm2

From main control

u TO hydraulic tank

425FO1165

To main control valve

When negative pressure is formed in the return circuit. Valve (2) moves up and acts as a check valve. Check valve set pressure: 0.26 kg/cm’

From hydraulic tank 425FO1166

61-6

STRUCTURE AND FUNCTION

HYDRAULIC TANK

BREATHER Preventing negative pressure inside the tank. The tank is a pressurized, sealed type, so negative pressure is formed inside the hydraulic tank when the oil level drops during operations. When this happens, the difference in pressure opens the poppet (3), and air from the outside is let into the tank to prevent negative pressure.

Preventing rise in pressure inside the tank. When the hydraulic cylinders are being used, the oil level in the hydraulic circuit changes and the temperature rises. If the hydraulic pressure rises above the set pressure, sleeve (4) is actuated to release the hydraulic pressure inside the tank.

1. 2. 3. 4.

Body Filter element Poppet Sleeve

423F133

61-7

STRUCTURE

AND FUNCTION

PROPORTIONAL

PPC VALVE

PRESSURE CONTROL VALVE (PPC VALVE)

From PPC pump

To bucket cylinder bottom

To boom cylinder head

To boom cylinder bottom

To bucket cylinder heed

Drain

I lOqzO40

61-8

PPC VALVE

STRUCTURE AND FUNCTION

,. ..,. 2 :.

::,.:::;

:‘f:,;:;y,.?;

1..

,j,:.;

,:..

:. :::

:: <::/i.,,‘:,

“,: ::>I:,.‘:. / ‘,;.

Section

B - B

Section

1. Bolt 2. Piston 3. Plate

Section

C - C

4. Collar 5. Retainer

A - A

D - D

6. Center 7. Spring 6. Valve 9. Body

spring

LlOAZ041

61-9

STRUCTURE AND FUNCTION

OPERATION

PPC VALVE

OF PPC VALVE

Accumulator

425FO1169

Function l

The ppc valve supplies pressure oil from the charging pump to the side face of the spool of each control valve according to the amount of travel of the control lever. This pressure oil actuates the spool.

61-10

Operation 1. Control lever at “neutral”. The oil from PPC pump (10) flows through filter (11) and check valve (12) and enters port “P” of the PPC valve. The circuit is closed by valve (8) so the oil entering port “P” is drained from relief valve (13). Ports “PAI, P,, PB,, and P,” are connected to drain chamber ‘D” through fine control hole (9 in valve (8).

STRUCTURE

AND FUNCTION

PPC VALVE

Control lever operated slightly (fine control)

PPC valve

425FO1170

When piston (2) starts to be pushed by plate (14) retainer (5) is pushed. Valve (8) is also pushed by spring (7) and moves down. When this happens, fine control hole (9 is shut off from drain chamber “D”. At almost the same time it is connected to pump pressure chamber “Pp”, and the pilot pressure of the control valve is sent through fine control hole (9 to port “P,“. When the pressure at port ‘P,” rises, valve (8) is pushed back. Fine control hole (9 is shut off from pump pressure chamber “Pp”. At almost the same time it is connected to drain chamber “D”, so the pressure at port “P;l escapes to drain chamber “D”.

Valve (8) moves up and down until the force of spring (7) is balanced with the pressure of port “P,“. The position of valve (8) and body (9) (when fine control hole (9 is midway between drain chamber “D” and pump pressure chamber “Pp”) does not change until the head of valve (8) contacts the bottom of piston (2). Therefore, spring (7) is compressed in proportion to the travel of the control lever, so the pressure at port “P; also rises in proportion to the travel of the control lever. The spool of the control valve moves to a position where the pressure of port “PA,” (same as pressure at port “PA4”) and the force of the return spring of the control valve are balanced.

61-11

PPC VALVE

STRUCTURE AND FUNCTION

Control lever moved back from slightly operated position to neutral (Fine control).

Accumulator PPC valve

I -

I I

425FO1171

When plate (14) starts to be pushed back, piston (2) is pushed up by a force corresponding to the force of centering spring (6) and the pressure at port “Pi’. At the same time, fine control hole (9 of valve (8) IS connected to drain chamber “D”, so the oil at port “P ” escapes. If &e pressure at port “P/ drops too far, valve (8) is pushed down by spring (7). Fine control hole (9 is shut off from drain chamber “D”, and at almost the same time it is connected to pump pressure chamber “Pp”. The pump pressure is supplied until the pressure at port “PA,” returns to a pressure equivalent to the position of the lever. When the spool of the control valve returns, the oil in drain chamber “D” flows in from fine control hole (f’) of the valve which has not moved. The extra oil then flows through port “P,” to chamber “PB,“.

61-12

STRUCTURE AND FUNCTION

PPC VALVE

4. Control lever operated to end of travel.

Accumulator PPC valve

425FO1172

Plate (14) pushes piston (2) down, and piston (2) forcibly pushes in valve (8). Fine control hole (9 is shut off from drain chamber “D”, and is connected to pump pressure chamber “Pp”. Therefore, pressure oil from the PPC pump passes through fine control hole (9, and flows from port “P,ll to chamber “PA,” to push the spool of the control valve. The oil returning from chamber “PB,” flows from port “P,” through fine control hole (f’) to drain chamber 3”.

61-13

PPC VALVE

STRUCTURE AND FUNCTION

PPC RELIEF VALVE 1

1. 2. 3. 4. 5.

Main valve Valve seat Pilot poppet Spring Adjustment screw Set pressure: 38 kg/cm*. I

421FO71

Function l

The PPC relief valve is between the PPC pump and the PPC valve. When the PPC valve is not being actuated, or when abnormal pressure is generated, the oil sent from the pump is relieved through this valve to protect the pump and circuit from damage. (Sets maximum pressure in the circuit) Fig. 1 421FO72

Operation

Port A is connected to the pump circuit, and port C is connected to the drain circuit. The oil passes through the orifice of main valve (1) and fills port B. Pilot poppet (3) is in close contact with valve seat (2). (Fig. 1) If the pressure at ports A and B reach the pressure set by the poppet spring, pilot poppet (3) opens and the pressure oil at port B flows through port D to port C. As a result, the pressure at port B drops. (Fig. 2) If the pressure at port B drops, a pressure difference is generated between ports A and B due to the orifice in main valve (1). Main valve (1) is pushed open by the pressure at port A, and the oil port A is relieved. (Fig. 3)

Fig. 2

Fig. 3

61-14

421FO73

421FO74

STRUCTURE AND FUNCTION

MAIN CONTROL VALVE PA2

PAI

MAIN CONTROL VALVE

L-B

PB;

‘PBn 425FO1173

PA1: .

K; PB2: P: Pl: P2:

From P4 of PPC valve From P2 of PPC valve From Pl of PPC valve From P3 of PPC valve Pump port From P2 of PPC valve From P3 of PPC valve

Al:

A2: Bl: B2: Dl: D2: T:

To bucket cylinder bottom To lift cylinder bottom To bucket cylinder head To lift cylinder head Drain port Drain port Drain port

61-15

STRUCTURE AND FUNCTION

MAIN CONTROL VALVE

7’

Section A - A

iq=y Section B - 0

9 8 I

Section E -

Section C - C

1. Main relief 2. Dump

valve

spool

Lift

spool

Lift

spool

5. Dump

return

spring

spool

6. Body 7. Suction

Section D - D 425FO1174

61-16

valve

Unloader

Float

10. Safety

valve

selector valve

valve (with

suction)

STRUCTURE

AND FUNCTION

MAIN CONTROL

VALVE

Outline l

The main control valve controls the actuation of the attachments and the bucket in the hydraulic system. It has a tandem circuit which gives priority to the bucket circuit.

The oil from the pump enters port P. The maximum pressure is set by the main relief valve. The oil passes through the by-pass circuit of dump spool (5) and lift spool (4). It then flows from port T to the drain circuit, passes through the filter and returns to the tank. If the dump and lift spools are actuated, the oil flows to the dump and Iit3 cylinders.

However, the circuit gives priority to the bucket, so when the dump spool is being operated, even if the lift spool is operated, the lift arm will not move. l

There are two safety valves (with suction valves) (10) to protect the circuit if abnormal pressure is generated in the bucket circuit. If one of the two safety valves is acting as a relief valve, the other valve acts as a suction valve to make up for any lack of oil.

61-17

STRUCTURE AND FUNCTION

MAIN CONTROL VALVE

RELIEF VALVE

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

Function l

Main valve Valve seat Pilot poppet Pilot poppet spring Adjustment screw Lock nut

421FO80

The relief valve is installed at the inlet of the main control valve. When the oil goes above the set pressure, the relief valve drains the oil to the tank. In this way, it sets the maximum pressure in the hydraulic circuit and protects the circuit.

Operation

Fig. I

421F081

Fig. 2

421FO82

Fig. 3

'421FO83

Port “A” is connected to the pump circuit and port “c” is connected to the drain circuit. The oil passes through the orifice of the main valve (1) and flows to port “B”. Pilot poppet (3) is in close contact with valve seat (2) (Fig. 1) When the hydraulic pressure in the circuit inside port “A” and port “B” reaches the set pressure of the pilot poppet spring (4), pilot poppet (3) opens, and the pressurized oil from port “B” flows from port “D” to port “c”, so the pressure at port “B” drops. (Fig. 2) When the pressure at port “B” drops, the orifice effect of main valve (1) generates a difference in pressure between port “A” and port “B”. The main valve is pushed open and the oil from port “A” passes through port “c” and flows to the drain circuit to release the abnormal pressure. (Fig. 3) The set pressure can be varied by changing the tension of pilot poppet spring (4). To change the set pressure, remove cap nut, loosen lock nut (6) and turn adjustment screw (5) as outlined in Section 62.

61-18

STRUCTURE AND FUNCTION

MAIN CONTROL VALVE

SAFETY VALVE (with suction valve)

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

Suction valve Main valve Main valve spring Pilot piston Suction valve spring Valve body

421FO45

Function l The safety valve (with suction valve) is in the dump cylinder circuit in the main valve. If shock causes any abnormally high pressure in the cylinder when the main valve is at neutral, the safety valve (with suction valve) releases the abnormal pressure and protects the cylinder from damage.

Operation As a safety valve 0 Port A is the cylinder circuit and port B is the drain circuit. The pressure oil in port A flows to port D through a hole in the pilot piston (4). It also flows to port C through an orifice consisting of the main valve and the pilot piston (4).

Fig. 1

421FO46

The pilot piston (4) is secured to the suction valve by lock nut. The diameter of the cross section (cross-sectional area) gives a relationship of d,>d, >ds>d,. (Fig. 1) If abnormally high oil pressure occurs in port A, the suction valve (1) is not actuated because of the relationship ds>d,. However, because of the relationship d,>d, in port A and C, the hydraulic pressure on the main valve (2) is equivalent to the area difference between d, and d,. If this pressure goes up to the main valve spring force (set pressure), the main valve (2) is actuated, and the oil in port A flows into port B. (Fig. 2)

Fig. 2

421FO47

61-19

MAIN CONTROL VALVE

STRUCTURE AND FUNCTION

As a suction valve If negative pressure is generated in port A, port D l also has negative pressure, because port D and A are connected with each other. The tank pressure in port B is applied to port E. Hydraulic pressure “a” equivalent to the area difference between d and d, is applied to the safety valve because oPthe tank pressure in port E. Therefore, hydraulic pressure “e” acts to open the valve and hydraulic pressure “a” acts to close the suction valve (1).

If the pressure in port A drops, (approaching negative pressure) hydraulic pressure “a’ becomes smaller than oil pressure “e”.

421 FO48

When oil pressure “e” becomes larger than oil pressure “a” + valve spring (5) force, the suction valve (1) opens, causing the oil to flow from port B into port A. This prevents negative pressure from building up in port A.

SUCTION VALVE

1. Main poppet 2. Sleeve 3. Spring

421 F088

Operation l If negative pressure is generated in port A (lift cylinder rod end) (ii the pressure is lower than in port B in the tank circuit), the main poppet (1) opens because oil then flows from port B at the tank end to port A at the cylinder port end. 421 F089

61-20

MAIN CONTROL VALVE

STRUCTURE AND FUNCTION

FLOAT SELECTOR VALVE AND UNLOADER VALVE Function l

The float selector valve and unloader valve are installed inside the main control valve. When the lift control lever is placed in “FLOAT”, the float selector valve detects pressure oil from the PPC valve and acts to actuate the unloader valve, which places the lift spool in the “FLOAT” position.

TO PPC VALVE

FROM

FROM STEERING VALVE

Ll OBH038

Operation

When the lift lever is placed at “FLOAT”, the PPC valve is set to LOWER. Port A becomes high pressure, and port B becomes low pressure. The oil from the steering valve fills chambers E and F.

61-21

STRUCTURE AND FUNCTION

MAIN CONTROL VALVE

LIFT LEVER AT “FLOAT

TO PPC VP

FROM

FROM STEERING VALVE

Operation

l-If the difference in pressure between port A and port B exceeds the standard pressure, flow selector valve (2) is moved to the right, and port C and port D are connected. l

Port D is open, so the hydraulic pressure at port E drops and unloader valve (4) moves to ’ t” and the oil flows from the steering valve to the drain circuit. At the same time, the oil also flows to the rod end of the lift cylinder, and the oil at the bottom end is connected to the drain circuit, so the lift arm is set at “FLOAT”.

61-22

Ll OBH039

STRUCTURE

ACCUMULATOR

AND FUNCTION

ACCUMULATOR Before operation

After

operation

Function l

The accumulator is installed between the hydraulic pump and the PPC valve. When the lift arm is left raised, and the control levers are operated with the engine stopped, the pressure of the compressed nitrogen gas inside the accumulator sends pilot pressure to the control valve to actuate it and allow the lift arm and bucket to come down under their own weight.

Operation l

After the engine is stopped, and the PPC valve is at neutral, bladder chamber A is compressed by the hydraulic pressure in chamber B.

If the PPC valve is operated, the hydraulic pressure in chamber B goes below 38 kg/cmz, and the pressure of the nitrogen gas in chamber A expands the bladder. As a result, the oil in chamber B becomes the pilot pressure and actuates the control valve.

425FO1167

425FOll68

Soecification Type of gas

Nitrogen gas (N,)

Volume of gas

480 cc

Max. actuating pressure

38 kg/cm*

Min. actuating pressure

12 kg/cm*

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

Cap Core Guard rubber Ring Lid Bladder Shell

421 FO1029

61-23

HYDRAULIC

STRUCTURE AND FUNCTION

OPERATION VALVE

MAIN

CIRCUIT OPERATION

CONTROL

LIFT AND DUMP SPOOLS AT “HOLD”

Accumulaf(

425FO1175

Operation l l

The oil from the pump enters port A and the maximum pressure is set by the relief valve (11). Dump spool (1) is at HOLD, so the by-pass circuit is open. The oil in chamber A passes around the spool and flows to port B. Lii spool (2) is also at HOLD, so the by-pass circuit is open. The oil in chamber B passes around the spool and flows to chamber C in the drain circuit. From here it passes through the filter and returns to the tank.

61-24

The oil from the PPC pump passes through check valve (13) and enters port L of the PPC valve. However, the lift and dump levers are at the HOLD position, so the oil returns from PPC relief valve (12) to the hydraulic tank.

STRUCTURE

AND FUNCTION

HYDRAULIC

CIRCUIT OPERATION

LIFT SPOOL

425FOll 76

Operation l

When the lift lever (3) is pulled, pressure oil from port L of the PPC valve flows to ports N and S. The oil in port T passes through port M and flows to the drain circuit. The pressure oil in port S pushes the push piston against the force of the spring and moves lift spool (2) to the RAISE position.

is closed by the spool, so the oil pushes up check valve (10). The oil then flows from port H to port I, and goes to the bottom end of the cylinder. At the same time, the oil at the rod end of the cylinder flows from port K to drain port C, and

returns to the tank. Therefore, the lift arm rises.

The oil flows from the pump through the by-pass circuit of the dump spool, and then flows to the bypass circuit of lift spool (2). The by-pass circuit

61-25

STRUCTURE AND FUNCTION

HYDRAULIC

CIRCUIT OPERATION

LIFT SPOOL AT “LOWER”

425FO1177

Operation l

When the lift lever (3) is pushed, pressure oil from port L of the PPC valve flows to ports M and T. The

oil in chamber S is connected to the drain circuit. The pressure oil in chamber T pushes the push piston against the force of the spring and moves lift spool (2) to the LOWER position The oil flows from the pump through the by-pass circuit of lift spool (2). The by-pass circuit is closed

61-26

by the spool, so the oil pushes up check valve (10). The oil then flows from port J to port K, and goes to the rod end of the cylinder. At the same time, the oil at the bottom end of the cylinder flows from port I to drain port C, and returns to the tank. Therefore, the lift arm goes down.

STRUCTURE

AND FUNCTION

HYDRAULIC

CIRCUIT OPERATION

LIFT SPOOL AT “FLOAT’

mumulator

425FO1178

Operation When the lift lever (3) is pushed to the FLOAT

position, the spool of the PPC valve moves further from the LOWER position to the FLOAT position. Pressure oil from port M of the PPC valve flows to port M and also to ports T and W. At the same time, pressure oil from port S of the PPC valve flows to port N. The pressure oil in chamber T pushes the push piston against the force of the spring and moves lift spool (2) to the LOWER position. If the pressure difference between port W and port X goes above the specified level, valve (7) moves to

the right and opens ports C, and C to connect them to the drain circuit. When prot C, is connected to the drain circuit, valve (8) moves up, and the oil from the pump flows to the drain circuit. Therefore, the oil at the rod end of the cylinder flows from port J, and then flows from unload valves (8) to the drain circuit. At the same time, the oil at the bottom end of the cylinder flows from port I to port C, and then flows to the drain circuit. Therefore, the lift arm floats.

61-27

HYDRAULIC

STRUCTURE AND FUNCTION

CIRCUIT OPERATION

DUMP SPOOL AT “DUMP”

425FO1179

Operation l

When the dump lever (4) is pushed, pressure oil from port L of the PPC valve flows to port V via port Q. The oil in chamber R is connected to the drain circuit. The pressure oil in port V pushes the push piston against the force of the spring and moves dump spool (1) to the DUMP position. The by-pass circuit is closed by the spool (l), so the oil from port A pushes up check valve (9). The oil from check valve (9) then flows from port F and

61-28

enters port G, and goes to the rod end of the cylinder. At the same time, the oil at the bottom end of the cylinder flows from port D to drain port C, and returns to the tank. Therefore, the bucket is dumped.

STRUCTURE AND FUNCTION

HYDRAULIC

CIRCUIT OPERATION

DUMP SPOOL AT “TILT BACK”

ccumulator

425FO1180

Operation l

When the dump lever (4) is pulled, pressure oil from port L of the PPC valve flows to port R via port P. The oil in port V is connected to the drain circuit. The pressure oil in port R pushes the push piston against the force of the spring and moves dump spool (1) to the TILT position. The by-pass circuit is closed by the spool (l), so the oil from port A pushes up check valve (9). The

oil from port A then flows from port D to port E, and goes to the Bottom end of the cylinder. At the same time, the oil at the rod end of the cylinder flows from port G to drain port C, and returns to the tank. Therefore, the bucket is tilted.

61-29

STRUCTURE AND FUNCTION

BUCKET LINKAGE

F425M

1006

3 /

1. 2. 3.

61-30

Bucket Tilt lever Dump cylinder

4. 5. 6.

Lii cylinder Lii arm Bucket link

E-l

7. 8. 9.

J-i

Bucket hinge pin Cord ring Cord ring

425FO1181

STRUCTURE

BUCKET LINKAGE

AND FUNCTION

7 Section A - A

Section B - B

Section D - D

Section E -

Section H -

9 Section C - C

Section F -

Section J - J

Section G - G

425FO1182

61-31

STRUCTURE AND FUNCTION

BUCKET

BUCKET 1. 2. 3.

Bucket Tooth Corner

Tooth

1’

Section

A-A

At-l

Section

B-B U7CZO~

61-32

STRUCTURE AND FUNCTION

BUCKET POSITIONER

AND BOOM KICK-OUT

-2zD. I ._I_

:‘

II ::

--..

-..

.“T=j View

1. Proximity

switch

#or bucket

2. Proximity

switch

(for boom kick-out)

3. Dump cylinder

.,-

positioner)

rod

4. Lever 5. Plate

Section

A-A LO8ADl6

61-33

STRUCTURE AND FUNCTION

Bucket positioner The bucket positioner is electrically actuated and is l used to automatically obtain the optimum digging angle for the bucket. When the bucket is moved from the DUMP position to the TILT position, and it reaches the desired angle, the dump lever is automatically moved from the TILT position to the neutral. Lever (4) is secured by bolts to dump cylinder rod l (3). A proximity switch (1) is fixed by bolts to the cylinder. When the bucket is moved from the DUMP position l to the TILT position, the dump cylinder rod moves to the left. At the same time, lever (4) also moves to the left. When it reaches the desired position, lever (4) separates from proximity switch, and the bucket lever returns to neutral.

Boom kick-out The boom kick-out is electrically operated and acts to stop the lift arm. When the lift arm reaches the desired position before the maximum height, the lift arm lever is returned to neutral. l Plate (5) is secured to the lift arm. A proximity switch (2) is fixed to the frame. When the lift arm is moved from the LOWER position to the RAISE position, the lift arm rises. When it reaches the desired position, the proximity switch and plate come into contact and the lift arm lever is returned to neutral. l

61-34

BUCKET POSITIONER AND BOOM KICK-OUT

STRUCTURE AND FUNCTION

WORK EQUIPMENT

LEVER LINKAGE

WORK EQUIPMENT LEVER LINKAGE

Kickdown

Lock lever

switch

3. 4.

Lift control lever Dump control lever

Solenoid valve for dump positioner

Solenoid valve for boom kick-out

PPC valve

61-35

STRUCTURE AND FUNCTION

MEMORANDA

61-36

WORK EQUIPMENT

LEVER LINKAGE

WORK EQUIPMENT SiSTEM 62

TESTING AND ADJUSTING

STANDARD VALUETABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TOOLLIST

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

EMERGENCY MANUAL SPOOL ...................................................... METHODFOROPERATION ....................................................... OUTLlNE ................................................................... OPERATION .................................................................

5 5 5 5

DUMP AND LIFT CONTROL LEVERS .................................................. MEASURING .................................................................. ADJUSTING ...................................................................

7 7 8

HYDRAULIC CIRCUIT FLUSHING . . . . . . . . . . . . . . . . . . . _ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PPCRELIEFVALVE

.............................................................. MEASURINGPRESSURE ........................................................ ADJUSTING ..................................................................

13 13 15

WORKEQUIPMENT .............................................................. RELIEFVALVE ................................................................ MEASURINGTIME.. ........................................................... HYDRAULlCDRlFT ............................................................

16 16 18 19

BUCKETPOSITIONER . . . . ..__....................................................

BOOM KICK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING ............................................................. TROUBLESHOOTING TABLE ..................................................... 1. Lift arm does not rise. ....................................................... 2. Lii arm moves slowly or does not have sufficient lifting power. ......................... 3. Lii arm movement becomes slow after it reaches a certain height. ...................... 4. Bucket cannot be held down with lift arm cylinder. .................................. 5. Lift arm has large hydraulic drift. ............................................... 6. Lii arm movement is unsteady during work. ....................................... 7. Lift arm descends momentarily when control lever is shifted from “Hold” to “Raise”. .......... 8. Bucket does not tilt back. .................................................... 9. Bucket moves slowly or has insufficient tilt back power. .............................. 10. Bucket movement becomes slow during tilt back. ...................................

22 22 22 23 24 24 24 24 24 25 26 27 62-1

11. Bucket cannot be held down by the bucket cylinder. .. .. .. . .. ... . .. . .. .. . .. . . .. .. .. . 12. Bucket has large hydraulic drift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . _ . . . . . . . . . . 13. Bucket moves unsteadily when machine travels under load. (Main control valve in “Hold”). . . . . . 14. Bucket dumps momentarily when control lever is shifted from “Hold” to “Tilt back”. . . . . . . . . . . 15. Control levers of lift arm and dump move stiffly and sluggishly. . . . . . . . . . . . . . . . . . . . . . . _ . . t

The following precautions are necessary when using Standard Value Tables to make judgements troubleshooting or during testing and adjusting.

27 27 27 27 28

during

The values in theses tables are based on the values for new machines leaving the plant, so they should be used as target values when repairing or when estimating wear after a period of use.

These standard value tables must not be used for standard values when judging claims. In addition, do not use these values alone to make simple judgements.

Before carrying out the troubleshooting in this section, read “PRECAUTION WHEN TROUBLESHOOTING”, “METHOD OF READING TROUBLESHOOTING TABLE” and “PREVENTING RECURRENCE OF TROUBLE” in Section 22.

TESTING AND ADJUSTING

STANDARD VALUE TABLE

STANDARD VALUE TABLE Measurement condition

Testing and measuring item

Dump and lift control levers l Lift arm control lever operating force Hold -) Raise Raise + Hold Hold + Lower Lower + Hold Lower -) Float float - Hold l

kg Hydraulic temperature: 45-55°C Engine speed: Low idling Coolant temperature: Inside operating range

Dump control lever operating force Hold - Dump . Hold * Tilt Tilt + Hold Lift arm control lever travel Hold - Raise Hold -) Lower Hold + Float

Operating speed l Lift arm lifting time l Lift arm lowering time l Bucket dumping time l Bucket tilt back time (Full stroke) l Bucket tilt back time (Horizontal position of bucket) Hydraulic drift of lift arm and bucket l Retraction of lift cylinder rod Retraction of dump cylinder rod

l l l

Coolant temperature: Inside operating range Hydraulic temperature: 45 - 55°C Engine speed: High idling

kg/cm 2

Coolant temperature: Inside operating range Hydraulic temperature: 45 - 55°C Engine speed: High idling Steering position: Neutral Bucket: un-loaded

Coolant temperature: Inside operating range Hydraulic temperature: 45 - 55’C Stop engine, leave for 5 minutes, then measure for next 15 minutes. Lift arm horizontal Bucket horizontal Bucket: unloaded

Permissible value

Max. 2.5 2-4 Max. 2.5

Max. 3.5 Max. 6 Max. 3.5

2-4 2-4

Max. 6 Max. 6

Max. 2.5 Max. 2.5 2-4

Max. 3.5 Max. 3.5 Max. 6

52 - 82 34 - 64 52 - 82

37 - 97 19-79 37 - 97

45 - 75 45 - 75

30-90 30-90

38-40 210 +5

36 - 42 210 210

6.8 - 7.4 3.0 - 4.0 1.4 - 2.0

Max. 8.9 Max. 4.8 Max. 2.4

1.9 - 2.5

Max. 3.0

1.3 - 1.9

Max. 2.3

Max. 40

Max. 26

Bucket positioner l Clearance of switch Boom kick-out l Clearance of switch

Standard value

Dump control lever travel Hold -) Dump Hold -) Tilt

Relief oil pressure l PPC valve l Main control valve

Unit

3-5 mm 3-5

62-3

TESTING AND ADJUSTING

TOOL LIST

TOOL LIST FOR TESTING AND ADJUSTING No

62-4

Testing and measuring item

Tool name

Part number

Remark

Hydraulic pressure

Hydraulic tester

799-101-5000

O-300 kg/cm2

Oil temperature

Thermistor kit

799-101-6000

O-1000°C

Engine speed

Tachometer

7942636000

60-19999 rpm

Dump lever and lift lever operating force

Push-pull scale

79A-262-0020

O-25 kg

Measuring travel

Convex scale

Commercially available

Measuring operating time of work equipment

Stop watch

Commercially available

WARNING! When carrying out testing, adjusting or troubleshooting, stop the machine on level ground, install the safety bar on the frame, lower the bucket to the ground, and stop the engine. Then apply the parking brake and block the tires.

WARNING! Do not allow unauthorized near the machine.

persons

WARNING! When measuring the engine speed, one worker should measure the engine speed while the other sits in the operator’s seat to operate the controls. Always check that the operation is safe, and use agreed upon signals.

WARNINGI Be careful rotating parts.

to not get caught

l/10

set

TESTING AND ADJUSTING

EMERGENCY

MANUAL

SPOOL

EMERGENCY MANUAL SPOOL METHOD FOR OPERATION OUTLINE l The transmission valve is controlled electrically. Therefore, the emergency manual spool (2) is installed to enable the machine to be moved if there is any failure in the electrical system, or in the solenoid valve and spool.

WARNING! The emergency manual spool is for use when failure in the transmission control prevents the machine from being moved. It allows the machine to be moved from a dangerous place to a place where repairs can be carried out in safety. The emergency manual spool must never be used except when the transmission control has broken down. WARNINGI When operating the emergency manual spool, follow the correct order of operation exactly, and pay full attention to safety when moving the machine.

A A

WARNING! To prevent the machine from moving, lower the bucket to the ground, apply the parking brake, and block the wheels. Check that the pressure inside the air tank is above the specified pressure. WARNING! Always operating the spool

stop

the

engine

L07EM059

before

OPERATION 1. Remove plate (1) at the rear of the cab. 2.

Remove lock plate (3) of the emergency manual spool of the transmission valve. * Simply loosen the mounting bolts to remove the lock plate.

Rev&

Foriard

4;h

3;d

2nd

lit

SPOOI

spool

SpOOl

spool

Decide the direction to move the machine (forward or in reverse), then move the emergency manual spool to the operating position. FORWARD:

REVERSE:

Rotate FORWARD clutch spool and 1st spool counterclockwise, and pull out approx. 10 mm to the operating position. Rotate REVERSE clutch spool and 1st spool counterclockwise, and pull out approx. 10 mm to the operating posi-

tion.

0 0

Approx.

10 mm

Approx.

10 mm

62-5

EMERGENCY

TESTING AND ADJUSTING

Check that the area around the machine remove the blocks from under the wheels.

Sit in the operator’s seat, and depress the left brake pedal fully.

is safe,

WARNING! When the engine is started, the transmission is engaged and the machine will start. Therefore, before starting the engine, always check that the direction 3 travel is safe, and always keep the brake pedal depressed. If the machine does not start, turn the 2nd spool, 3rd spool, and the 4th spool clockwise, and screw in approx. 10 mm to the OFF position.

Start the engine, release the brake pedal gradually to start the machine. After moving the machine, stop the engine, apply the parking brake, and block the wheels. Return the emergency manual spool to the neutral position, and install the lock plate.

62-6

MANUAL

SPOOL

DUMP AND LIFT CONTROL

TESTING AND ADJUSTING

LEVER

DUMP AND LIFT CONTROL LEVERS MEASURING l

Measurement condition Coolant temperature: Inside operating Hydraulic oil temperature: 45 - 55°C Engine speed: Low idling

l l l

range

Soecial tool

Part number

79A-2624020

WARNING!

Part name Push-pull scale

I cw 1

Install the safety bar on the frame.

procedure 1. Operating force of dump and lift control levers

Measuring l

Fit push-pull scale A on dump and lift control levers and measure operating force. + Hook the push-pull scale A on the center of the knob. t Operate at the same speed as normal and measure the minimum force needed to operate the knob.

2. Travel of dump and lift control levers l

Measure the travel of the dump and lift control levers at each position. + Mark the knob of the lever and use a scale to measure.

62-7

TESTING AND ADJUSTING

DUMP AND LIFT CONTROL LEVERS ADJUSTING 1.

Remove cover (1).

Wiih solenoid (6) pulled, secure the solenoid so that the clearance between cam (3) and roller (4) is dimension “a”. Dimension + t

“a”: 0 - 5 mm

Set the bucket lever and lift lever at HOLD. If cam (3), roller (4) or spring (5) are damaged, replace them before carrying out adjustment.

Lift lever Operate the lift lever and adjust the length of rod (2) to give clearance “b” between the notched portions at both ends of cam (3) and roller (4). Dimension

62-8

“b”: 0 - 1 mm

DUMP AND LIFT CONTROL

LEVERS

TESTING AND ADJUSTING

DUMP AND LIFT CONTROL LEVERS

Bucket lever Operate the bucket lever and adjust the length of rod (2) to give clearance “c” between the notched portion of cam (3) and roller (4). Dimension t

“c”: 0 - 1 mm

Operate the bucket lever and lift lever and check that the lever is held at the TILT, DUMP, RAISE, and FLOAT positions.

62-9

TESTING AND ADJUSTING

HYDRAULIC

CIRCUIT

FLUSHING

HYDRAULIC CIRCUIT FLUSHING l

This procedure is to be used if components have broken metal pieces or wear powder can get into the hydraulic circuit.

WARNING! Park the machine on flat level ground, install a safety bar to the frame, lower the bucket to the ground, stop the engine, apply the parking brake, and then put chocks under the tires.

Remove all dirt and debris from around the component that is to be removed. This is prevent dirt from getting into the hydraulic circuit.

At any time that a component is removed from the hydraulic system, all connecting tubes will be properly cleaned and masked with tape to prevent dirt from getting into the system before reassembly is accomplished.

1. BEFORE FLUSHING

Drain the hydraulic

oil.

WARNINGI When draining the oil, turn the oil filler cap slowly to release the remaining pressure.

2) Remove 3)

the troubled obtain a new pump.

pump,

Cleaning the hydraulic

tank.

A. B. C.

62-10

light

When cleaning, take care to completely remove the dirt from the tank bottom.

Remove dirt from the element case bottom. Remove dirt and clean the suction tube in the hydraulic tank. Remove the tubes from the tank to the pump and from pump to valve, then thoroughly clean the tubes inside.

Cleaning the hydraulic A.

repair

Remove and check the filter cover. Clean the tank inside with detergent, oil or kerosene. Blow dry with air to remove dirt. +

D. E.

then

cylinder.

Disassemble the hydraulic cylinder as described in the this manual. Clean with a detergent the inside of the cylinder tube and the inside of the cylinder head.

LlOBV03r

1. 2. 3. 4.

Hydraulic tank Sight gauge Filter element Valve assembly

5. 6. 7.

Cover plate Oil filler cap Breatherassembly

HYDRAULIC

TESTING AND ADJUSTING

CIRCUIT

FLUSHING

On disassembly, if damage is found on cylinder tube inside wall or the piston packing replace with new one.

5) Cleaning the work equipment control valve and the steering valve. A. B. C.

Disassemble per instructions in this manual. Fill a container with detergent. Deposit valve into the container to clean. t

Use a nylon brush to clean the hole and recessed portion on the valve body and spool.

When removing the relief valve and overload relief valve, do them as assemblies. Put them into a detergentfilled container to clean the check valve and poppet inside the assemblies. Do this by manually operating the check valve and poppet and seeing how they operate.

6) Remove the steering tube and work equipment

tube separately and clean with detergent, then blow dry with air.

7) Install the tubes and valves that were removed and cleaned.

8) Replace the breather element on the hydraulic

f A

tank with a new one.

9) Install a new hydraulic t

filter element.

Make sure that the element is seated properly when installing. If the element is not seated properly, no effect can be expected from the element.

10) Add oil to the hydraulic tank up to the specified oil level.

2. WORK STEPS FOR FLUSHING

1) Start the engine and run at low idling for 10 minutes without operating the work equipment and without utilizing the steering.

2) Run the engine at the high idling setting for 10

1. 2. 3. 4.

Hydraulic tank Sight gauge Filter element Valve assembly

5. 6. 7.

Cover plate Oil filler cap Breather assembly

minutes without operating the work equipment and without utilizing the steering. t

Check the oil level at the hydraulic tank. If the oil level became lower, add oil up to the specified fluid level.

62-11

TESTING AND ADJUSTING

A A

HYDRAULIC CIRCUIT FLUSHING

Release air from the bucket cylinder, work equipment and the steering cylinders circuit as follows: WARNING! Operate components only in this sequence to release the air: Boom cylinder, Bucket cylinder and then Steering cylinder. WARNING! Completely release air from the cylinders described above, because if not done so, the air that has mixed in the cylinders can cause a piston packing to brake. A. Run the engine at low idle and slowly operate the cylinder by stopping the cylinder about 100 mm before the stroke end. Repeat extending and retracting the cylinder in this manner for four or five cycles.

WARNINGI Avoid operating the cylinder up to the maximum stroke end at the beginning of this operation. Doing maximum stroke operation will cause mixed air-oil compression and result in damage to the piston packing. 8. Only after completion of item A. above, now am operate the cylinder up to the stroke end, three or four times to release air from the cylinder. +

Measure the hydraulic pressure. l

Check the oil level at the hydraulic tank; if low, service to proper fluid level.

Measure the pressures on the work equipment and the steering system. If pressures are out of specifications, adjust them to with in specifications.

Drain the hydraulic oil, then;

LlOBV034

A. Recheck for dirt at the bottom of the hydraulic tank. If found, remove. B. Remove hydraulic oil filter element, recheck case inside and remove dirt, then install a new filter element. 6)

Add oil to the hydraulic tank up to the required fluid level.

7).

Release air from the hydraulic circuit by repeating the above procedural steps.

8).

Check the oil level at the hydraulic tank. If oil level is low, add oil to the specified fluid level.

62-12

1. Hydraulic tank 2. Sight gauge 3. Filter element 4. Valve assembly

5. 6. 7.

Cover plate Oil filler cap Breather assembly

PPC RELIEF VALVE

TESTING AND ADJUSTING

PPC RELIEF VALVE MEASURING PRESSURE t l l l

Conditions of measurement Engine coolant temperature: Within operating range Hydraulic oil temperature: 45 - 55°C Engine speed: High idling

WARNING! Stop the machine on level ground and install the safety bar on the frame. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving.

Special tool Part number 7w101-5ooo

Part name

Q’ty

Front of machine

Hydraulic tester

1. Measuring

Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.

Operate the control levers slowly to release the pressure in the accumulator completely.

1). Y +

A 4

1) Remove bolts (l),

lossen bolt (2), and rotate cover (3) slowly clockwise. t Rotate the cover using bolt (2) as the pivot. + The working space is confined, so be extremely careful when carrying out this operation.

2) Remove plug (4) for measuring pressure of the dump main control valve.

cylinder

the hydraulic circuit of the

Install hydraulic test kit to the measurement port. t Install a 90” elbow for the hydraulic test kit in the measuring port, then connect the hose. + Check that there is no oil leakage from any joint. + Use a hydraulic hose that is long enough to reach the operator’s compartment.

62-13

TESTING AND ADJUSTING

PPC RELIEF VALVE

Start the engine and raise the arm about 400 mm. Then operate the control lever to tilt the

bucket back and actuate the relief valve. Measure the pressure when the valve is relieved. + Do not suddenly apply pressure to the hydraulic pressure gauge.

When removing the hydraulic pressure gauge, release the pressure in the same way as when installing the gauge.

Front of machine

62-14

TESTING AND ADJUSTING

PPC RELIEF VALVE

ADJUSTING

WARNING! If it is impossible to measure the relief pressure accurately, DO NOT try to adjust the pressure. WARNlNGf Always stop the engine before adjusting the hydraulic pressure.

1) Stop the engine and remove the covers (1). 2) Remove the cap nut (2) of the relief valve. 3)

Loosen the locknut (3), then turn the adjustment screw (4) to adjust. + One turn of the adjustment screw changes the pressure by about 9.8 kg/cmz. t Turn the adjustment screw to adjust as follows: To INCREASE pressure, TIGHTEN screw. To DECREASE pressure, LOOSEN screw.

62-15

TESTING AND ADJUSTING

WORK EQUIPMENT

RELIEF VALVE

Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving.

RELIEF VALVE

Measurement conditions: l Engine coolant temperature; Wiihin operating range l Hydraulic oil temperature; 45 - 55°C l Engine speed; High idling

MEASURING Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.

Operate the control levers several times to release the remaining pressure in the hydraulic piping and confirm that the bucket moves freely.

1) Remove inspection cover (1) of front frame. 2) Remove plug (2) for measuring pressure of oil in dump cylinder circuit. 3)

Install hydraulic test kii in measuring port. + Check that there is no leakage of oil from any joint. + Use a hydraulic hose long enough to reach the operator’s compartment.

4) Start the engine and raise the lift arm about 400 mm. Then operate the control lever to tilt the bucket back and actuate the relief valve. Measure the pressure when the valve is relieved. + Do not suddenly apply pressure to the hydraulic pressure gauge.

62-16

When removing the hydraulic pressure gauge, release the pressure in the same way as when installing the gauge.

\\ \ :\ i: :\1

LlOAZ049’

TESTING AND ADJUSTING

RELIEF VALVE

ADJUSTING

A A

WARNING! If it is impossible to measure the relief pressure exactly, do not try to adjust the pressure. WARNINGI Always stop the engine adjusting the hydraulic pressure.

1) Remove locknut

before

(3) of relief valve.

2) Turn adjustment t

screw (4) to adjust. One turn of the adjustment screw changes the pressure by about 52.9 kg/cm2. Turn the adjustment screw to adjust as follows.

To INCREASE pressure, TIGHTEN screw. To DECREASE pressure, LOOSEN screw.

62-17

TESTING AND ADJUSTING

RELIEF VALVE

WORK EQUIPMENT MEASURING TIME + l l l l

Lifting

time of lift arm

Lowering

time of lift arm

Measurement condition Coolant temperature: Inside operating range Steering position: Neutral Hydraulic temperature: 45 - 55°C Engine speed: High idling Unit: Sec. ltem

Standard value

Permissible value

Y-Y

Bucket tilt back time (From horizontal position of bucket)

1.31.9

Max 2.3

Special tool Part number Commericallv

available

Part name Stoo watch

Q’tY 1

Dumping

time of bucket

Tilt back

time of bucket

Measurino procedure 1. Liftingiime of lift arm Set the bucket near the maximum tilt back position and at the lowest position on the ground. Raise the bucket and measure the time taken for bucket to reach the maximum height of the lift arm. 2.

Lowering time of lift arm Set the bucket horizontal with the lift arm at the maximum height, lower the bucket and measure the time taken for the bucket to reach the lowest position on the ground.

Dumping time of bucket

Raise the litI arm to the maximum height and measure the time taken for the bucket to move from the maximum tilt back position to the maximum dump position. 4. Tilt back time of bucket 1) Raise the lift arm to the maximum height and measure the time taken for the bucket to reach the maximum tilt back position. 2) Set the bucket horizontal and measure the time taken for the bucket to move from the horizontal position to the maximum tilt back position.

62-18

TESTING AND ADJUSTING

HYDRAULIC

DRIFT

WORK EQUIPMENT HYDRAULIC DRIFT + l l l l l l

Measurement condition Coolant temperature: Inside operating range Hydraulic temperature: 45 - 55°C Stop engine, leave for 5 minutes, then measure for next 15 minutes. Lii arm horizontal. Bucket horizontal. Unloaded (operating load) Unit: mm item

Standard value

Permissible value

Retraction of lift cylinder rod

Max40

Retraction of dump cylinder rod

Max20

Special tool Part number Commerciallv

A A

Part name

I Convex scale

available

WARNING!

Q’ty

Fit the safety locks on the control

levers. WARNING!

Do not go under the work equip-

ment.

Measuring

procedure

1) Set the fift arm and bucket horizontal, then stop the engine. 2) Stop the engine, wait for 5 minutes, then start measuring. Measure the amount the lift B and dump A cylinder 3) rods retract during 15 minutes.

A: R&action

of dump oylindr

B: Rotroction

of lift cylindr

rod

62-19

TESTING AND ADJUSTING

BUCKET POSITIONER Testing 1. Check that the clearance between switch (1) and angle (2) with the engine stopped is within the standard value. 2. Start the engine and check the actuating position at high idling. (Measure three times and take the average.) Adjusting 1. Lower the bucket to the ground, operate the bucket to the desired digging angle, then return the lever to the HOLD position and stop the engine. 2. Secure switch protector (3) to the bucket cylinder bracket so that the center of the switch is aligned with the end face of angle (2). 3. Adjust nut (6) of switch (1) so that clearance “a” from the end face of switch protector (3) to the switch response surface is within the standard value, then lock in position. l Clearance ‘a’: 051.0 mm Switch mounting nut: 1.8kO.2 kgm 4. 5.

Remove the cover (4) of switch. Using washer, adjust so that clearance “b” between the response surface of switch (1) and angle (2) is within the specified value, then lock in position. Using washer, adjust the angle so that the clearance between the response surface of the switch and the angle is within the specified value over the whole stroke of the angle, then lock in position. Check that neither the response face of the switch nor the angle are off center before locking in position. After adjusting, operate the bucket lever, check that the positioner is actuated at the desired position, then lock in position. Clearance “b”: 3-5 mm Install cover (4) of the switch.

62-20

BUCKET POSITIONER

BOOM KICK-OUT

TESTING AND ADJUSTING

BOOM KICK-OUT Testing 1. Wiih the engine stopped, check that the clearance

between switch (1) and plate (2) is within the standard value. 2. Start the engine, run at high idling and check the actuating position . (Measure three times and take the average). Adjusting 1. Raise the lift arm to the desired position, then mark

the I’M arm at the position where the center of the switch align with the plate. 2. Lower the lift arm and stop the engine. 3. Alignment marks, adjust the position of the plate, so that the center of the switch (1) is level with the bottom of plate (2) then lock the plate into position. 4. Adjust the switch so that the clearance between the sensing surface of the switch and plate (2) is within standard value. * Clearance “a”: 3-5 mm D

Mounting +

nut of switch: 1.8kO.2 kgm

After adjusting, operate the lift lever, and check that the Iii3 arm stops at the desired position.

UlAJO2:

62-21

TROUBLESHOOTING

TROUBLESHOOTING TABLE

TROUBLESHOOTING TROUBLESHOOTING

TABLE

1. Lift arm does not rise. Ask the operator the following questions. l Did the boom suddenly fail to raise? 4 Seizure or damage to various units. l Was an unusual noise produced? (Where did it emanate from?) l Were there previous signs of the boom slowing down. - Wear of parts or flattening of spring. Checks before troubleshooting. l Is oil level in hydraulic tank correct? l Is stroke of lift control lever and spool correct?

Tank - pump

No.

: I

a x I

x I

Bucket cannot operate and lift arm is unable to ascend.

The machine body can be lifted up by the lift arm however, the lift arm is unable to ascend. Alternatively, the bucket operates but the lift arm is unable to ascend.

The lift arm can ascend under no load but cannot ascend under load.

The hydraulic

pump produces an unusual noise.

Lift cylinder

has large amount of hydraulic drift.

When the engine is at high idling, steering action is light and excessively fast.

When the engine is at high idling, steering action is heavy and slow.

x I

I I

000000

I 0

0 0

0 lol

loI

The following symbols are used to indicate the action to be taken when a cause of failure is located. X: Replace A: &qXiir A: Adjust C: Clean

62-22

TROUBLESHOOTING TABLE

TROUBLESHOOTING

Lift arm moves slowly or does not have sufficient lifting power. Checks before troubleshooting l Is the amount of oil in the hydraulic tank and also the type of oil correct? l Is the stroke of the lift control lever and also the spool of the main control valve correct? l Seizure of bucket linkage bushing. (Does emits unusual noise) Fault check There is a strong relationship between faults involving lifting force and lifting speed. Such faults appear initially in the form of insufficient lifting speed. Measure the lifting speed of the lift arm when loaded and refer to the standard value table to determine whether or not there is a fault.

.“llll”l

,co a

No.

valve

A i

Bucket tilt back force and speed are abnormal lifting speed is low.

and lift arm

Bucket tilt back force and speed are normal but lift arm lifting speed is low.

Same as item 1 except that lift arm lifting speed becomes particularly low when oil temperature rises.

Hydraulic

When the engine is at high idling, steering action is light and excessively fast.

When the engine is at high idling, steering action is heavy and slow.

Cylinder

The relief pressure of relief valve of main control valve.

pump emits unusual noise.

has a large amount of hydraulic

0 0

drift.

The following symbols are used to indicate the action to be taken when a cause of failure is located. A: k?pair X: Replace A: Adjust C: Clean

62-23

TROUBLESHOOTING

Lift arm movement becomes slow after it reaches a certain height.

Visible deformation

of lift cylinder.

Cause l Swollen or internally damaged lift cylinder tube. + Regarding other faults occurring during lift arm ascent, refer to item 2 “Lii arm moves slowly or does not have sufficient lifting power”.

Problem and cause Check the amount of hydraulic drift and whether or not the machine body can be Med up by the lift cylinder. 1. If the amount of hydraulic drift is greater than the standard value, refer to item 5 “Lift arm has large hydraulic drift”. 2. If the machine body can be lifted up by the lift cylinder, refer to item 4 “Bucketcannot be held down with lift cylinder”. 3. If the amount of hydraulic drift is normal and the machine body can be lifted up by the lift cylinder after the lift arm is moved several times to cause the lift cylinder to move through its entire stroke - the trouble is due to the generation of a vacuum in the cylinder. t If a vacuum is generated frequently, faulty suction valve on lift cylinder rod side.

Bucket cannot be held down with lift arm cylinder. If the relief pressure in the circuit at the bottom of the lift cylinder is insufficient, refer to Item 2 ‘Iii arm moves slowly or does not have sufficient lifting power”.

Checks before troubleshooting l l

Is level of oil in the hydraulic tank correct? Is stroke of main control valve and lift spool correct?

Cause l Faulty main control valve or suction valve seat on lift cylinder rod side. l Oil leakage from lift cylinder piston seal. 5.

Lift arm movement is unsteady during work. During excavation or ground leveling when the lift arm control lever is in the “Hold” position, the bucket and lift arm move up and down in accordance with the terrain.

Check before troubleshooting l

TABLE

Lift arm descends momentarily when control lever is shifted from “Hold”to “Raise”.

Lift arm has large hydraulic drift. Ask the operator the following questions l l

Did the hydraulic drift suddenly become large? - Dirt lodged in valve or damaged parts. Did the hydraulic drift gradually become large? - Worn parts.

The lift arm descends momentarily under its own weight when the lift arm control lever is gradually shifted from the “Hold” position to the “Raise” position while the engine is at low idling. When the control lever is put completely into the “Raise” position, the lift arm behaves normally.

Checks before troubleshooting l l

Is the type and temperature of the oil in the hydraulic tank correct? Is the lift arm spool in the neutral position? Seized link bushing, faulty spool detent.

Problem and cause l

62-24

When measuring hydraulic drift, internal of lift cylinder produces oil leak noise - Damaged piston packing.

Cause l

Faulty seating of main control valve or lift arm load check valve.

TROUBLESHOOTING

TABLE

Bucket does not tilt back.

Ask the operator the following questions. l l l

Did the bucket suddenly ceases to move? Seized or damaged equipment. Was any unusual noise emitted (where did it emanate from)? Were there previous signs of the bucket slowing down? - worn parts of flattened spring.

Checks before troubleshooting. l Is amount of oil hydraulic tank satisfactory? l

Is the stroke of the bucket control spool correct?

lever and

Tank - pump

Lift arm cannot operate and bucket is unable to tilt back.

The machine can be lifted up by the bucket but the bucket cannot tilt back. Or, the lift arm operates but the bucket cannot tilt back.

or scoop.

The hydraulic

Bucket cylinder

Steering action is light and excessively fast when the engine is at high idling.

Steering action is heavy and slow when the engine is at high idling.

The bucket can tilt back under no load but cannot excavate

pump produces an unusual noise.

has large hydraulic

0’0

0 0

I 0

I 0i0

drift.

0 0

The following symbols are used to indicate the action to be taken when a cause of failure is located. A: f%?pair X: Replace A: Adjust C: Clean

62-25

TROUBLESHOOTING

TABLE

Bucket moves slowly or has insufficient tilt back power. Check before troubleshooting l l l

Is the oil quantity in the hydraulic tank and the type of oil satisfactory? Is the stroke of the bucket control lever and the main control valve spool correct? Seizure of bushing in bucket linkage. (Does emits unusual noise)

Fault checks l l

Check the amount of deficient tilt force by performing actual work. Measure the operating speed of the bucket and check it against the judgement criterion table to

determine whether or not it is normal.

speed are abnormal.

Phenomena of

The relief pressure of relief valve of main control valve is

The discharge volume of the hydraulic

pump is low.

The following symbols are used to indicate the action to be taken when a cause of failure is located. A: k?pair X: Replace C: Clean A: Adjust

62-26

TROUBLESHOOTING TABLE

TROUBLESHOOTING

10. Bucket movement becomes slow during tilt back.

13. Bucket moves unsteadily when machine travels under load. (Main control valve in “Hold”).

Checks before troubleshooting l

External deformation

Checks before troubleshooting

of dump cylinder

Cause l l

Swollen or internally damaged dump cylinder tube. Regarding other faults which occur when the bucket operates, refer to item 9 “Bucket moves slowly or has insufficient roll back power”.

Cause l l

11. Bucket cannot be held down by the bucket cylinder. Refer to item 9 “Bucket moves slowly or has insufficient tilt back power”.

Is oil level in hydraulic tank and type of oil correct? Excessive play in pin and bushing of work equipment linkage. Was an unusual noise produced?

Faulty piston seal of dump cylinder. Faulty safety valve with suction valve for the bottom side of dump cylinder. If the above symptoms, refer to the problems items corresponding to each fault.

14. Bucket dumps momentarily when control lever is

shifted from “Hold”to “Tilt back”. Check before troubleshooting l

Is oil level in the hydraulic

ry? Is the stroke of the main control dump spool correct?

tank satisfactovalve

Cause l

Faulty seat of safety with suction valve of control valve for the bottom side of dump cylinder.

Oil leakage from seal of dump cylinder piston.

The bucket dumps momentarily under its own weight when the dump control lever is gradually shifted from the “Hold” position to the “Tilt back” position while the engine is at low idling. When the control lever is put completely into the ‘Tilt back” position, the bucket behaves normally.

Cause l

Faulty seating of main control valve dump spool check valve.

12. Bucket has large hydraulic drift. Ask the operator the following questions. l

Did the hydraulic drii suddenly become large? 4 Dirt lodged in valve or damaged paItS.

Did the hydraulic drift gradually large? - Worn parts.

become

Check before troubleshooting l l

Is the type and temperature of the oil in the hydraulic tank correct? Is the dump spool in the neutral position? - Seized link bushing, faulty spool detent.

Fault check l

l l

Use the judgement criterion table to check whether or not the hydraulic drift of the bucket is actually large. If hydraulic drift is large. Cause: Oil leakage in dump cylinder. If hydraulic drift returns to normal. Cause: Faulty seating of overload relief valve or suction valve on rod side. Faulty oil sealing on spool of dump control valve.

62-27

TROUBLESHOOTING

TABLE

15. Control levers of lift arm and dump move stiffly and sluggishly. Fault check Using the judgement criterion table, check whether or not the operating force of the lever is large.

Main control valve

Movement of lift arm and bucket becomes sluggish when load is applied and oil pressure increases.

Movement of lift arm and bucket becomes sluggish along with change in oil temperature.

Movement of lift arm and bucket becomes partially irrespective of oil pressure and temperature.

Movement of lift arm and bucket becomes generally sluggish irrespective of oil pressure and temperature.

Movement of lift arm and bucket does not become light even when the link of the control lever is disconnected at the valve connection part and the lever operated.

sluggish

0 000

The following symbols are used to indicate the action to be taken when a cause of failure is located. A: Repair X: Replace A: Adjust C: Clean

62-28

HYDRAULIC SYSTEM 63

DISASSEMBLY

AND ASSEMBLY

HYDRAULICTANK ................................................................ REMOVAL .................................................................... INSTALLATION .................................................................

3 3 5

HYDRAULICFILTER ............................................................... REMOVAL .................................................................... INSTALLATION .................................................................

7 7 7

WORKEQUIPMENTPUMP .......................................................... REMOVAL .................................................................... INSTALLATION ................................................................

8 8 10

SWlTCH PUMP ................................................................. REMOVAL ................................................................... INSTALLATION ................................................................

11 11 13

PPCVALVEASSEMBLY ........................................................... REMOVAL ................................................................... INSTALLATION ................................................................ DISASSEMBLY ................................................................ ASSEMBLY .................................................................. PPCRELIEFVALVEASSEMBLY ................................................... DISASSEMBLY .............................................................. ASSEMBLY ................................................................

14 14 16 18 18 19 19 19

MAINCONTROLVALVE ........................................................... REMOVAL ................................................................... INSTALLATION ................................................................ DISASSEMBLY ................................................................ ASSEMBLY ..................................................................

20 20 23 28 32

DUMPCYLINDER ............................................................... REMOVAL ................................................................... INSTALLATION ................................................................

35 35 37

LIFTCYLINDER ................................................................. INSTALLATION ................................................................

39 41

LIFT AND DUMP CYLINDERS ....................................................... DISASSEMBLY ................................................................ ASSEMBLY ..................................................................

: 45

63-1

WORKEQUIPMENT .............................................................. REMOVAL ................................................................... INSTALLATION ................................................................

46 46 52

COUNTERWEIGHT .............................................................. REMOVAL ................................................................... INSTALLATION ................................................................

56 56 56

To maintain the performance of the machine and to prevent failures, it is particularly important to pay attention to the degree of cleanliness of the oil in the hydraulic circuits. When adding oil or changing the oil, or when replacing the filters, check that the oil container and area around the filler of the hydraulic tank are clean. If any internal part of the hydraulic equipment breaks, disassemble and clean all the hydraulic equipment and circuits to remove any dirt or pieces from the circuit. If any parts of the hydraulic circuits are disassembled and assembled, also carry out thorough flushing of the hydraulic circuits. After replacing or flushing the hydraulic tank oil, filter element, or strainer, or when removing and installing any hydraulic cylinder, hydraulic pump or any other hydraulic equipment or work equipment piping, always bleed the air as follows after completion of installation. l Air bleeding procedure 1) Run the engine at low idling, and extend and retract the steering, bucket, and lift arm cylinders 4-5 times without going to the end of this stroke. (Stop approx. 100 mm before the end of the stroke.) 2) Operate the steering, bucket, and lift arm cylinders 3 - 4 times to the end of the stroke, then stop the engine and bleed the air from the plugs at the top of the hydraulic tank filter. 3) Raise the engine speed and repeat Step 2) to bleed the air. Repeat this procedure until no more air comes out from the plug. 4) After completing bleeding the air, tighten the plugs. D

Plug: 1.1520.15 kgm + If the engine is run at high speed from the start, or the cylinders are operated to the end of this stroke, the air inside the cylinder will cause damage to the piston packing. 5) Check the level of the oil inside the hydraulic tank, add oil if necessary, then tighten the oil filler cap. + Before loosening the oil filler cap, close the pressurizing valve; after adding oil, tighten the oil filler cap, then open the pressurizing valve. + After repair or long storage, follow the same procedure.

HYDRAULIC TANK

DISASSEMBLY AND ASSEMBLY

HYDRAULIC TANK REMOVAL

Loosen the oil filler cap slowly to release the pressureinside the hydraulic tank. Then operate the control levers several times to + release the remaining pressure in the hydraulic piping. t Before loosening the oil filler cap, close pressurizing valve (1A). 0 Remove cover (1).

9kL

Loosen plugs (2 and 3) at the top of the hydraulic tank filter, to prevent the oil inside the tank from flowing out.

1. Draining oil Remove plug- (4, _. loosen valve (5) and drain hydraulic oii. Hydraulic oil: Approx. 15OP

I lOBVO3:

Ladder floor 1) Remove cover (6). 2) Sling ladder floor (7), and remove mounting bolts then lift off. +

Be careful of the balance of the lifting tool. Ladder: 30 kg

63-3

HYDRAULIC TANK

DISASSEMBLY AND ASSEMBLY

Hydraulic piping 1) Disconnect hose (8) between main control valve and hydraulic tank. 2) Disconnect hose (9) between PPC valve and hydraulic tank.

I 3) Disconnect coder hose (10) from tube. 4) Remove tube (1l), and loosen clamp (12).

.lO

I 4.

Hydraulic tank Sling hydraulic tank (13), remove mounting bolts, then Iii off. Hydraulic tank: 230 kg

63-4

LlOADO7f

DISASSEMBLY AND ASSEMBLY

HYDRAULIC TANK

HYDRAULIC TANK INSTALLATION 1. Hydraulic tank Set hydraulic tank (13) in mounting position, then tighten the mounting bolts. Mounting bolts: 28+3.0 kgm (3 mounting bolts under tank)

Hydraulic piping 1) Tighten clamp (12) and install tube (11). + Set the clamps at 180” to each other. 2) Connect coder hose (10) to tube.

3) Connect hose (8) between the main control valve and the hydraulic tank. 4) Connect hose (9) between the PPC valve and hydraulic tank.

Ladder floor 1) Raise the ladder floor (7) and set it in the mounted position, then tighten the mount bolts.

63-5

DISASSEMBLY

AND ASSEMBLY

Install cover (6).

Refilling with oil

Tighten the drain plug and plug at the top of the hydraulic tank filter, then add hydraulic oil through the oil filler to the specified level. Plug at top of filter: 1.220.1 kgm

%# + +

63-6

Hydraulic oil: 1504 Install cover (1). Run the engine to circulate the oil through the system. Then check the oil level again.

HYDRAULIC

TANK

DISASSEMBLY AND ASSEMBLY

HYDRAULIC FILTER

HYDRAULIC FILTER REMOVAL Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.

cover

1) Remove cover (1). 2) Loosen plug (2) and remove mounting bolts, then remove cover (3). The tension of the spring is pushing the cover, so be careful when removing it.

*L 4 t 2.

Be careful not to damage O-ring (4) at the contact face of the cover and tank.

Filter 1) Remove spring (5) and bypass valve (6). 2) Remove hydraulic filter (7).

INSTALLATION 1.

Fifter 1) Install hydraulic filter (7). l Insert securely into the pilot inside the filter. 2) Install bypass valve (6) to filter, then install spring (5).

Hydraulic

tank

2. cover 1) Assemble O-ring (4) in groove of cover (3) then install cover (3) to tank, and tighten plug (2). t Replace the O-ring with a new part. t Fii the O-ring securely in the groove, and be careful not to get it caught when installing. Plug: 1.2+0.1 kgm 2)

Install cover (1).

63-7

HYDRAULIC PUMP

DISASSEMBLY AND ASSEMBLY

WORK EQUIPMENT

PUMP

REMOVAL

A Y

AY 4

LlOAK034

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.

Remove the cover (1).

Loosen plugs (2 and 3) at the top of the hydraulic tank filter, to prevent the oil inside the tank from flowing out.

1. Draining oil. Remove plug (4) loosen valve (5) and drain the hydraulic oil. Drain the oil from the hydraulic tank until the * level of oil is at the bottom level of all pipes. A

Hydraulic oil: approx. 130P (At the bottom level of pipes) 2. Torque converter charging pump Remove torque converter charging pump. + For details, see REMOVAL OF TORQUE CONVERTER CHARGING PUMP.

4 3.

Hydraulic piping Disconnect hydraulic piping from the pump as follows: l Disconnect tube (6) between the hydraulic pump and the hydraulic tank. l Disconnect hose (7) between the hydraulic pump and the steering valve. t Remove block (8). t Remove the O-ring from the pump mounting surface.

63-8

I lOBV03f

DISASSEMBLY

AND ASSEMBLY

HYDRAULIC

PUMP

Hydraulic pump Remove the hydraulic pump (9).

The working space is restricted, so be careful when working. Hydraulic pump: 14 kg

LlOAVO6~

63-9

DISASSEMBLY AND ASSEMBLY

WORK EQUIPMENT

PUMP

INSTALLATION 1. Hydraulic pump Set hydraulic pump (9) in mounting position and tighten the mounting bolts. + Set O-ring on the housing and be careful not to let it fall when assembling.

Hydraulic piping Connect hydraulic piping as follows: l Connect hose (7) between the hydraulic pump and the steering valve. + Install block (8). l Connect tube (6) between hydraulic tank and the hydraulic pump.

3. Torque converter charging pump Install the torque converter charging pump. + For details, see INSTALLATION OF TORQUE CONVERTER CHARGING PUMP. 4.

Refillina with oil Tigl%en plugs (4 and 5).

Tighten plugs at the top of the hydraulic tank filter, then add hydraulic oil through the oil filler to the specified level. Plug at top of filter: 10.2kO.l kgm Hydraulic oil: Approx. 130P +

63-10

Run the engine to circulate the oil through the system. Then check the oil level again.

HYDRAULIC PUMP

DISASSEMBLY

HYDRAULIC

AND ASSEMBLY

PUMP

SWITCH PUMP REMOVAL

A SY $

WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. 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.

Remove cover (1). Loosen plugs (1 and 2) at the top of the hydraulic tank filter, to prevent the oil inside the tank from flowing out.

Draining the oil

MOAK034

Remove plug (4) loosen valve (5), and drain the hydraulic oil. t Drain the oil from the hydraulic tank until the level of the oil is at the bottom of each pipe. Hydraulic oil: Approx. 1304 (At the bottom level of the pipes) 2.

Steering pump and PPC pump

Remove the steering and PPC pumps. t For details, see REMOVAL OF STEERING PUMP AND PPC PUMP.

4 3.

UOBVO35

Hydraulic piping

Disconnect the hydraulic piping from the pump as follows: l Tube (6) between the switch pump and steering valve. + Remove block (7). l Tube (8) between the hydraulic tank and switch pump. * Remove the O-ring from the pump mounting surface.

63-11

DISASSEMBLY AND ASSEMBLY

HYDRAULIC PUMP

4. Switch pump Remove switch pump (9). + The working space is restricted, so be careful when working.

el kg

Switch pump: 14 kg

63-12

HYDRAULIC PUMP

DISASSEMBLY AND ASSEMBLY

SWITCH PUMP INSTALLATION 1. Switch pump Set switch pump (9) in mounting position and tighten the mount bolts. t Set O-ring the housing and be careful not to let it fall when assembling.

Hydraulic piping Connect the hydraulic piping as follows: l Tube (8) between the hydraulic tank and the switch pump. l Tube (6) between the switch pump and the steering valve. t Install block (7).

3. Steering pump and PPC pump Install the steering and PPC pump. t For details, se INSTALLATION OF STEERING PUMP AND PPC PUMP.

Refilling with oil

1) Tighten plugs (4 and 5).

4’ IlOBVO:

Tighten plugs at the top of the hydraulic tank filter, then add hydraulic oil through the oil filler to the specified level. Plug at top of filter: 1.2kO.l kgm

Hydraulic oil filler

Hydraulic oil: Approx. 1304

Runthe engine to circulate the oil through the system. Then check the oil level again.

63-13

DISASSEMBLY AND ASSEMBLY

PPC VALVE ASSEMBLY

PPC VALVE ASSEMBLY REMOVAL

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. l

Remove cover (1).

Loosen plugs (2 and 3) at he top of the hydraulic tank filter to prevent the oil inside the tank from flowing out.

Cover

g&_

-4

\!I=MOAK034

Remove cover (4) under cab and cover (5) of console box on right side of operator’s seat.

Hydraulic piping

Disconnect the following hydraulic piping from the PPC valve. l Hose (6) between PPC pump and PPC valve. l Hose (7) between PPC valve and hydraulic tank. l Hoses P2 (8) and P3 (9) for lift spool. 0 Hoses P4 (10) and Pl (11) for dump spool. +

After disconnecting the hoses, fii tags to distinguish them for installation.

Front of ‘machine

63-14

DISASSEMBLY AND ASSEMBLY

Linkage 1) Loosen locknut (12).

PPC VALVE ASSEMBLY

Disconnect linkage (13) from PPC valve.

PPC valve Remove mounting bolts, then remove PPC valve (14) from under floor. t The working space is confined, so carry out the work carefully.

63-15

DISASSEMBLY AND ASSEMBLY

PPC VALVE ASSEMBLY

PPC VALVE ASSEMBLY INSTALLATION 1.

PPC valve Set PPC valve (14) in mounting position, and tighten mounting bolts.

Linkage

1) Install linkage (13) to PPC valve. 2) Tighten locknut (12). + Adjust the linkage. For details, see SECTION 52, TESTING AND ADJUSTING.

Hydraulic piping

Connect the following hydraulic piping to the PPC valve. l Hose (6) between PPC pump and PPC valve. l Hose (7) between PPC valve and hydraulic tank. 0 Hoses P2 (8) and P3 (9) for lift spool. l Hoses P4 (10) and Pl (11) for dump spool.

Front of ‘machine

\”

.I6

IlOAH04

DISASSEMBLY AND ASSEMBLY

PPC VALVE ASSEMBLY

4. cover Install cover (4) under cab and console box cover (5) at right side of operator’s seat.

Refilling with oil Tighten drain plug and add engine oil through oil filler to the specified level.

Plug at top for filter: 1.220.1 kgm *

Hydraulic

Run the engine to circulate the oil through the system. Then check the oil level again.

63-17

DISASSEMBLY

AND ASSEMBLY

PPC VALVE ASSEMBLY

PPC VALVE ASSEMBLY DISASSEMBLY 1. 2. 3. 4.

Remove bolt (1). Remove plate (2). Remove seal (3) then remove collar (4). Remove valve assembly and center spring (7) from valve body (10). 5. Remove collar (ll), then remove retainer (6) shim (12), and spring (8) from valve.

1. Push shim (12), spring (8) and retainer (6) into valve (9) and install collar (11). 2. Install center spring (7) and valve assembly to valve body (10). 3. Install spool (5). 4. Fit O-ring and install collar (4). 5. Install seal (3). 6. Fit plate (2) and install bolt (1). Bolt: 4.5 + 0.5 kgm

63-I 8

LlOBH12f

DISASSEMBLY AND ASSEMBLY

PPC VALVE ASSEMBLY

PPC RELIEF VALVE ASSEMBLY DISASSEMBLY +

Before loosening nut (2), measure the protrusion of screw (3) from the end face of the nut.

-3

1. Remove cover (l), then loosen nut (2), and remove screw (3). 2.

Remove holder (4), then remove poppet (5), spring (6), and retainer (7).

Pull out seat (9) spring (lo), and valve (11) from sleeve (8). * If any abnormality is found in the sleeve or valve, replace the assembly.

Remove plug (12) from sleeve (8).

ASSEMBLY 1. Install O-ring and plug (12) to sleeve (8). A

Plug thread: Thread tightener (LT-2)

2. Assemble valve (11) and spring (10) in sleeve (8), then fii O-ring and install to seat (9). 3. Assemble retainer (7) spring (6), and poppet (5) in sleeve (8) then fii O-ring and install sleeve (4). a

Sleeve: 7+1 kgm

Screw adjustment screw (3) into holder (4), adjust so that the protrusion from end face of locknut (2) is the same as at the time of disassembly, secure with locknut (2), then fii O-ring and install cover (1). Cover: 4+0.5 kgm

Y-12 @

0 0

DISASSEMBLY AND ASSEMBLY

MAIN CONTROL VALVE REMOVAL

WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. 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.

YY 4

Remove cover (1). Loosen plugs (2 and 3) at he top of the hydraulic tank filter to prevent the oil inside the tank from flowing out. Cover Remove cover (4).

2) Remove bolts (5), then loosen bolt (6) and turn

cover (7) to the right slowly. + Turn the cover on the right side of the machine to the left. + Use bolt (6) as a pivot when turning the cover. + The working space is confined, so be extremely careful when carrying out the operation.

Dump cylinder 1) Disconnect the electric wiring (7) from its connector. 2) Disconnect the grease tube (8) from the bottom pin. t Remove the clamp of the grease hose. 3) Disconnect hydraulic piping (9 and 10).

63-20

MAIN CONTROL VALVE

DISASSEMBLY AND ASSEMBLY

MAIN CONTROL VALVE

4) Sling cylinder (11) remove pins (12 and 12A), then remove the cylinder. + Be careful to check the center of gravity when attaching the lifting tool. + There are shims at the mounting pins, so check the number and thickness of the shims, and keep then in a safe place. Pin: 25 kg 3.

PPC hose Disconnect the hydraulic piping from the main contrd valve as follows: o Hose (13) between PPC valve and main control valve for dump spool. l Hose (14) between PPC valve and main control valve for lift spool. l Hose (15) between PPC valve and main control valve for dump spool. l Hose (16) between PPC valve and main control valve for lift spool. + Remove the tube clamp. + After disconnecting the tube, move it towards the rear of the machine. + After disconnecting the hoses, mark with a tag to distinguish them when installing.

Hydraulic hose Disconnect the hydraulic piping as follows: 0 Hose (17) between the main control valve and the hydraulic tank. l Tube (18) and hose between the main control valve and dump cylinder. l Tube (19) between main control valve and the lift cylinder. + Disconnect tube (20) from the manifold end. + Remove tube bracket (21).

Front of machine

tlgADg8$j i 63-21

DISASSEMBLY

0 l

AND ASSEMBLY

Hose (22) between main control valve and steering valve at main control valve end. Tube (23) between hydraulic tank and main control valve at main control valve end.

Tube (24) and hose between main control valve and dump cylinder at main control valve end. Tube (25) between main control valve and lift cylinder at main control valve end. t Loosen the tube clamp first.

Main control valve 1) Remove the mount bolts and turn the main control valve (26) 90”.

2) Using eye-boits, lift out main control valve (26). +

el kg

63-22

Be careful of bleeder screw of slack adjuster and remove.

Main control valve: 91 kg

MAIN CONTROL VALVE

DISASSEMBLY

MAIN CONTROL VALVE

AND ASSEMBLY

MAIN CONTROL VALVE INSTALLATION 1. Main control valve 1) Using eye-bolts, set main control valve (26) in mounting position. + When setting in the mounting position, operate the hoist to maintain the balance and to avoid interference with the bleeder screw of the slack adjuster.

2) Turn main control valve (26) 90” and tighten the mount bolts. * The lift cylinder tube will cause interference, so push the tube upward.

\ I

Hydraulic piping

Connect the hydraulic piping as follows: 0 Connect tube (25) between main control valve and lift cylinder, to main control valve. t Tighten the tube clamp. l Install tube (24) together with hose, between main control valve and dump cylinder. t Be careful of the angle of the tube when installing the clamp. l Connect tube (23) between hydraulic tank and main contrd valve, to the main control valve. l Connect hose (22) between the steering valve and main contrd valve, to the main control valve.

63-23

DISASSEMBLY

MAIN CONTROL VALVE

AND ASSEMBLY

Install tube (19) between main control valve and lift cylinder. + Install tube (20) to manifold. + Install tube clamp (21). Install tube (18), together with hose, between main contrd valve and dump cylinder. Connect hose (17) between hydraulic tank and main control valve, to main control valve.

PPC hose

Connect hydraulic piping to main control valve as follows: l Hose (16) between PPC valve and main control valve for lift spool. l Hose (15) between PPC valve and main control valve for dump spool. l Hose (14) between PPC valve and main control valve for lift spool. l Hose (13) between PPC valve and main control valve for dump spool. Front of machine

I 63-24

II~A~WIA_~;

I LlOAH046

DISASSEMBLY

AND ASSEMBLY

MAIN CONTROL VALVE

Dump cylinder 1) Set cylinder (11) in mounting position, align pin

hole, then adjust with shims so that clearance is the same on both left and right, then assemble pins (12 and 12A) and lock.

WARNING! Use a bar to align the pin hole,. Never use you fingers.

+ +

Adjust shims at cylinder bottom end only. Clearancea+b=Max.l.Omm

2) Connect hydraulic piping (10 and 9). 3) Connect grease tube (8) to bottom pin. 4) Connect electrical wiring (7) to connector.

cover Set cover (7) in the mounting position, and tighten bolts (5 and 6). + The working space is confined, so be extremely careful when carrying out the operation. 2) Install inspection cover (4) of front frame. 1)

63-25

DISASSEMBLY AND ASSEMBLY

MAIN CONTROL VALVE

Refilling with oil Tighten plugs at the top of the hydraulic tank filters, then add hydraulic oil through the oil filter to the specified level.

Plug at the top of filters: 1.250.1 kgm

* +

Install cover (1). Run the engine to circulate the oil through the system. Then check the oil level again.

LlOAKO34

63-26

DISASSEMBLY

AND ASSEMBLY

MAIN CONTROL VALVE

This page is blank.

63-27

DISASSEMBLY

AND ASSEMBLY

MAIN CONTROL VALVE ASSEMBLY DISASSEMBLY

63-28

MAIN CONTROL VALVE

DISASSEMBLY AND ASSEMBLY

1. Spool assemblv 1) Remove sleive (l), then remove case (2). 2) Remove spring (3) and retainer (4). 3) Remove spring (5) and retainer (6). 4) Remove piston (7) spring (8) and spacer (9). 5) Remove spool assembly (10). t Disassemble spool assembly. Remove plugs (12 and 13) from spool (11). 2.

Main relief valve 1) Remove main relief valve assembly. t Disassemble main relief valve assembly. 0 Loosen nut (15) and pull out adjustment screw (16) then remove retainer (17) spring (18), spacer (19) and poppet (28). t Before loosen nut (15) measure the protrusion of screw (16) from the end face of the nut. ii) Loosen nut (21), then remove holder (22) seat (23), and backup ring (24). iii) Remove snap ring (25), and spring (28) from sleeve (29). iv) Remove backup ring (30) from sleeve. If there is any abnormality in the t sleeve or valve, replace as an assembly.

Safety valve assembly with suction Remove safety valve assembly (31). + The safety valve cannot be adjusted when it is on the machine, so do not disassemble it.

8 O A7 @

63-29

DISASSEMBLY AND ASSEMBLY

4. Suction valve assembly Remove suction valve assembly (32). + Disassemble suction valve assembly. i) Remove valve (33) together with seal (34). ii) Remove seal (34) from valve (33). ii) Remove spring (35) from sleeve (36). t If there is any abnormality in the sleeve or valve, replace as an assembly.

Selector valve assembly Remove valve assembly (37). + Disassembly of selector valve assembly. 1) Remove sleeve (38) together with seat (39). + Seat (39) is press fiied to sleeve (38) (press fitting load: 120 - 800 kg), so if there is any abnormality replace as an assembly. (The same applies for the sleeve.) 2) Remove nipple @IO),then remove shim (41) spring (42) and piston (43). + Check the number and thickness of the shims, and keep them in a safe place.

Check valve assembly 1) Remove plate (44), then remove spring (45) and check valve (46). 2) Remove flange (47) then remove spring (48), seal (49), and valve (50).

63-30

MAIN CONTROL VALVE

DISASSEMBLY

MAIN CONTROL VALVE

AND ASSEMBLY

This page is blank.

63-31

DISASSEMBLY

AND ASSEMBLY

MAIN CONTROL VALVE

MAIN CONTROL VALVE ASSEMBLY ASSEMBLY

63-32

LlOBH131

MAIN CONTROL VALVE

DISASSEMBLY AND ASSEMBLY

1. Check valve assembly Assembly valve (59) seal (49), and spring (48) in valve body (51), then fii O-ring and install flange (47). Flange surface: Thread tightener (LT-2) Assemble check valve (46) and spring (45) in valve body, then fii O-ring and install plate (44). Plate mounting bolt: 9?1 kgm 2. Selector valve assembly t Assembly selector valve assembly. 1) Assemble piston (43), spring (42), and shim (41) in sleeve (38), then fii O-ring and install nipple (40). a

Nipple: 2.25kO.25 kgm Fii O-ring and install selector valve assembly (37).

Selector valve: 7.O)il kgm

3. Suction valve assembly * Assemble suction valve assembly. 1) Assemble spring (35) in sleeve (36). 2) Assemble seal (34) in valve (33), and install to sleeve (36). 3) Fii O-ring and install suction valve assembly (32). Suction valve assembly: 19.0f 1.O kgm

4. m

Safety valve assembly with suction Fii O-ring and install safety valve assembly (31). Safety valve: 19.02 1.O kgm

39 \ @

MAIN CONTROL VALVE

DISASSEMBLY AND ASSEMBLY

Main relief valve assemblv + Assemble main relief valve 1) install backup ring (39) and O-ring to sleeve (29)* 2) Assemble spring (28) valve (27), and retainer (26) in sleeve (29), and install snap ring (25). 3) Fii backup ring (24) and O-ring, and assemble seat (23) in sleeve. 4) Screw nut (21) into holder (22) then fii O-ring and assemble in sleeve, and tighten nut. Hdder: 421 kgm Nut thread: Thread tightener (LT-2) Nut: 15522.5 kgm 5) Assemble poppet (20), spacer (19), spring (18) and retainer (17) and screw in adjustment screw (16). Adjust protrusion from end face of nut (15) to same dimension as at time of disassembly, then tighten with nut (15). Nut thread: Thread tightener (LT-2) 4+0.5 kgm 6)

Fii O-ring and install main relief valve assembly (14). Main relief valve assembly: 33+4.5 kgm

Spool assemblv Assembly oi spod assembly * 1) Install plugs (13 and 12) to spool (11). Nut thread: Thread tightener (LT-2) Nut: 2.550.5 kgm

2) Assemble spoof assembly (10) in valve body.

3) Assemble spacer (9), spring (8), and piston (7). 4) Assemble retainer (6), spring (5), retainer (4) and spring (3) then fit O-ring and install case (2) and sleeve (1).

63-34

DISASSEMBLY AND ASSEMBLY

DUMP CYLINDER

DUMP CYLINDER REMOVAL

A *L 4

WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Then overate the control levers several times to &ease the remaining pressure in the hydraulic piping.

Bucket positioner wiring Disconnect wiring (1) from connector,

Grease tube Disconnect tube (2) from pin end. * Remove clamp and move tube.

Hydraulic piping 1) Disconnect hose (3) at rod end from cylinder. 2) Disconnect hose (4) of bottom end from cy!inder end.

Rod pin Sling cylinder, remove lock bolt, then remove pin (5). + When raising the cylinder, sling at two places and be careful to maintain the balance.

!lOBqpa5

DISASSEMBLY

AND ASSEMBLY

Dump cylinder 1) Remove lock bolt, then remove pin (6) at bottom end. t There are shims installed, so check the number and thickness of the shims, and keep them in a safe place.

2) +

Remove dump cylinder (7). Be careful not to damage the cylinder rod. Dump cylinder:

63-36

283 kg

DUMP CYLINDER

DISASSEMBLY AND ASSEMBLY

DUMP CYLINDER

DUMP CYLINDER INSTALLATION

WARNING! Use bar to align the pin holed. Never use your fingers.

1. Dump cylinder 1) Raise dump cylinder (7) and set in mounting position. 2) Align pin hole at bottom end, assemble shim so that clearance between cylinder and frame on left and right is within specified range, then install pin (80 and lock with bolt. Clearance a + b = Max. 1.0 mm

Rod pin Align pin hole at rod end, then install pin (5) and

lock with bolt.

A 3.

WARNING! Use bar to align the pin holed. Never use your fingers.

Hydraulic piping 1) Connect hose (4) at bottom end. 2) Connect hose (3) at rod end. * Fii the O-ring securely in the grooves. l Install the hose without twisting or interference.

DISASSEMBLY

AND ASSEMBLY

Grease hose Connect hose (2) to front frame.

Bucket positioner wiring Connect wiring (1) to connector.

63-36

DUMP CYLINDER

\---

DISASSEMBLY

AND ASSEMBLY

LIFT CYLINDER

LIFT CYLINDER REMOVAL

A 1.

Fender Lii off fender (1).

Fender: 46 kg

& kg 2.

Rod pin

1) Sling lift cylinder (2), and remove lock bolt, then remove pin (3).

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.

2) Start engine, and operate control lever to retract cylinder rod on side where pin was removed. * Set a wooden block between the frame and cylinder, and lower the cylinder. 3.

Hydraulic piping

1) Disconnect hose (4) at rod end from connector. 2) Disconnect hose (5) at bottom end from connector.

lift cylinder

1) place lever block under lift cylinder (2) and pull to rear of machine with lever block [l].

2) Using forcing screw (M12x5Omm), remove pin *

(6) of bottom end. There are shims installed, so check the number and thickness of the shims, and keep them in a safe place.

63-39

DISASSEMBLY AND ASSEMBLY

30 Remove lift cylinder (2).

Be careful not to damage the cylinder rod.

Lii cylinder: 280 kg

63-40

LIFT CYLINDER

DISASSEMBLY

AND ASSEMBLY

LIFT CYLINDER INSTALLATION 1. Lift cylinder

1) Raise lift cylinder (2) and set in mounting position.

inder, then align pin hole using lever

WARNING! Use a bar to align the pin holes. Never use your fingers.

3) Assemble shim so that clearance between cylinder and frame on the left and right is within specified range, then install pin (6) and lock wfth bolt. Clearance a + b = Max. 1.0 mm a

Hydraulic piping

1) Connect hose (5) at bottom end. 2) Connect hose (4) at rod end. + Install the hoses without twisting or interference.

LIFT CYLINDER

DISASSEMBLY

AND ASSEMBLY

Rod pin 1) Sling cylinder (2), start engine, then operate

control lever to extend the rod fully and align pin hole.

Use a bar to align the pin holes. Never use your fingers.

WARNING! A

2) Install pin (3), then lock with bolt.

Fender Install fender (1).

63-42

LIFT CYLINDER

LIFT AND DUMP CYLINDERS

DISASSEMBLY AND ASSEMBLY

LIFT AND DUMP CYLINDERS DISASSEMBLY Special tool

Part name

Part number

798-562-l 003

Unit repair I stand

Qtv 1

LlOBROSt

1. Set cylinder assembly (1)on repair stand A.

Remove head cover mounting bolts (2).

Pull cylinder head and piston rod assembly (3) out from cylinder (4), then lift off. t Oil will come out when the piston rod assembly is removed from the cylinder, so catch it in a container.

Remove piston bolts (5), then remove spacer (6), piston assembly (7) and cylinder head assembly (8).

6 5.

5 UOBRO97

Remove O-ring (10) and backup ring (11) from piston rod (9).

63-43

DISASSEMBLY

AND ASSEMBLY

LIFT AND DUMP CYLINDERS

LIFT AND DUMP CYLINDERS ASSEMBLY Specialtools Part number

Part name

790-!502-1003

Unit repair stand

7go-720-loo0

Expander

7S720-1690

Ring (for lift cylinder)

796-720-1720

Ring (for dump cylinder)

Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.

Assembly of cylinder head assembly 1) using push tool [3], press fit bushing (19) on cylinder head (20). + Be careful not to deform the bushing when press fiiing. 2) Assemble rod packing (18). + Be careful to install the rod packing facing in the correct direction.

I lOBR104 I lOBR10, 7 3)

Install backup ring (16) and O-ring (15). + Do not try to force the backup ring into position. Warm it in warm water (50 - 60” C) before fiiing it.

Using push tool [4], install dust seal (17) to cylinder head, then secure with snap ring.

IlOBRlO~

63-45

DISASSEMBLY

AND ASSEMBLY

LIFT AND DUMP CYLINDERS

Assembly of piston assembly 1) Using tool B, expand piston ring (13). + Set the piston ring on the expander and turn the handle 8 - 11 times to expand the ring. 2) Remove piston ring from tool B, and assemble on piston (14). 3) Pii toofs C or C, on piston ring, then using clamp [5], compress piston ring. + Part No. of clamp: 07281-02169 (for lift cylinder) + Part No. of clamp: 0728102429 (for dump cylinder) 4) Assemble wear ring (12) on piston.

3. Assemble O-ring (10) and backup ring (11) on piston rod (9).

4. Assemble cylinder head assembly (8) and piston assembfy (7) on piston rod. * Coat backup ring (11) with grease so that it does not stick out, and assemble carefully. 5. Assemble spacer (6) then tighten piston bolts (5). Iz=]

Piston bolt: 18.0 +2.0 kgm (Width across flats: 22 mm)

Piston bolt: Adhesives (LT-2)

63-46

I \

DISASSEMBLY

AND ASSEMBLY

LIFT AND DUMP CYLINDERS

Set cylinder (4) in tool A, then raise piston rod and head assembly (3), and assemble in cylinder (4).

Tighten cylinder head mounting bolts (2).

Cylinder head mounting bolt: 67.5k7.5 (Dump cylinder)

Remove cylinder assembly (1) from tool A.

63-47

DISASSEMBLY

AND ASSEMBLY

WORK EQUIPMENT REMOVAL

A 1.

Stop the machine on level ground and install the safety bar on the frame. Lower the work equipment to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. WARNING!

Bucket link

1) Remove mounting pin (1)of bucket link. + +

Remove cord ring. Tie the bucket link to the tilt lever with wire.

Mounting pin: 25 kg

2) Remove mounting pin (2) of bucket hinge. *

Remove cord ring.

Use bar to align the pin holes. Never use your fingers.

WARNING! A

el kg

Mounting pin: 25 kg Move machine to rear and disconnect bucket.

Dump cylinder pin Temporarily sling dump cylinder (3), pull pin (4), then disconnect cylinder rod and tilt lever. + Attach lifting tool to dump cylinder and secure in the rear.

Dump cylinder: 266 kg Mounting pin: 36 kg

Lii cylinder pin Attach lever block [l] to lift cylinder (5), pull machine to rear and remove the mounting pin (6). + Secure the other end of the lever block [l] to the hole of the front frame. Lift cylinder: 260 kg Mounting pin : 25 kg

63-48

WORK EQUIPMENT

DISASSEMBLY

AND ASSEMBLY

WORK EQUIPMENT

Tilt lever, bucket link

1) Temf&arily

sling tilt lever (7) and bucket link, remove mounting pin (8) then lift out from lift arm (9). + Remove with the bucket link still fiied. * 3 men should be used for removal of mounting pin operation.

Tilt lever and bucket link: 615 kg Mounting pin: 59 kg

Temporarily sling bucket link (lo), remove mounting pin (1l), then lift out from tilt lever (7). + Remove cord ring. Bucket link: 103 kg Mounting pin: 25 kg + There are shims installed, so check the number of shims for reference when installing. .ll

I i7tYlfhAC

Lift arm

1) Remove boom kick-out switch (13).

2) Temporarily sling lift arm (9) pull out mounting

pin of lift arm, then lift out lift arm. + Shims are installed at connecting point of front frame and lift arm, so check the number of shims.

Lift arm: 2,025 kg Mounting pin : 35 kg

63-49

WORK EQUIPMENT

DISASSEMBLY AND ASSEMBLY

Dust seal, bushing 1) Pull out dust seal (14) and bushing (15) from lift arm (9).

9’

Pull out dust seal (16) and bushing (17) from tilt lever (7). 7

63-60

7cvo54

Pull out dust seal (18) and bushing (19) from bucket link (10).

L17CVO5!

DISASSEMBLY

WORK EQUIPMENT

AND ASSEMBLY

After using for a long time, a worn pin, may be difficult to remove. If this is the case, make a jig such as the one shown below, and use it to remove the pin.

3-l6x2Depth30 Perforation depth 40 (circumference of equal parts)

Dimension of pin hole (For adapter mounting bolt)

U7CVO5J

63-51

DISASSEMBLY

AND ASSEMBLY

WORK EQUIPMENT

WORK EQUIPMENT INSTALLATION

A 1.

WARNING! Use a bar to align the pin holes. Never use your fingers.

Lb w il

Dust seal, bushing Press fii bushings to bucket link, bellcrank, and lift

arm, then assemble the dust seals. a

Bushing

Bushing: Grease (G2-LI) Lift arm

Bushing

Dust seal U7CVO61

Hydraul!c cylinder

Install each dust seal with the seal lip facing the outside.

Dust seal 0.25

- 0.8 mm

Lift arm

1) Sling lift arm (9) and set in mounting position, then assemble mounting pins and lock with bolt. t Align the mount holes on the front frame with the lift arm, insert the shims so that the clearance is the same on both the left and right. + Clearance a + b = Max. 1.0 mm + After installing the pin, set a support under the tip of the lift arm.

Ll7CVO64

63-52

-cry Bushln;

1.2 - 2.75 mm

DISASSEMBLY AND ASSEMBLY

WORK EQUIPMENT

Install boom kiikout switch (13). + For details, see TESTING AND ADJUSTING section.

Tilt lever, bucket link 1) Assemble cord rings on bucket link (lo), align hole of tilt lever (7), assemble mounting pin (11) then lock with bolt. it Secure the bucket link to the tilt lever with wire. t Insert the shims so clearance is the same on both sides. + Clearance c + d = Max. 1.0 mm

+ t

Be careful not to get the cord ring caught. When using the supply cord ring, see Step 8. 2) Align the hose of the tilt lever (7) and lift arm (9), assemble mounting pin (8) then lock it with the bolt. 4.

Lift cylinder pin While adjusting the lever block [l], see lift cylinder (5) is in the mounted position, then assemble the mount pin (6), and lock with the bolt. + Remove the lever block [l].

Il7CVO64

63-53

DISASSEMBLY AND ASSEMBLY

COUNTERWEIGHT

Dump cylinder pin Temporarily sling dump cylinder (3), adjust operating levers, align pin hole, assemble mounting pin (4), then lock with bolt.

IlTCVOAP

Bucket While operating the contrd lever, align the hole of the bucket mount pin (2) and install the cord ring (21). Insert the shims where needed. Remember to have the same clearance on both sides, left and right. Then install the mount pin and lock it with the bolt. + Clearance e + f = Max. 1.0 mm

t *

Be careful not to get the cord ring caught. When using the supply cord ring, see Step 8.

Bucket link 1) Raise bucket link, align hole of the mounting pin (1) and install the cord ring (22). Insert the shims where needed. Remember to have the same clearance on both sides, left and right. Then install the mount pin and lock it with the bolt. + Clearance g + h = Max. 1.0 mm t Be careful not to get the cord ring caught. + When using the supply cord ring, see Step 8.

63-54

DISASSEMBLY AND ASSEMBLY

Supply cord ring Install the supply cord ring as follows: 1) Insert the cord ring in the grove. + Stretch the cord ring slightly while inserting it in the groove. 2) Insert the bolt into the cord ring and secure. t Tighten the bolt enough so that it does not change the shape of the cord ring.

Refilling with oil

COUNTERWEIGHT

Refill each pin with oil or grease.

63-55

DISASSEMBLY AND ASSEMBLY

COUNTERWEIGHT REMOVAL

WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the work equipment to the ground and stop the engine. Then apply the parking brake and put Mocks under the wheels to prevent the machine from moving.

1. Radiator grille Lii off the radiator grille (1). 2.

Counterweight Sling the counterweight (2) remove the mounting bolts, then lift off the counterweight. l When slinging the counterweight, be careful to maintain it’s balance. * When removing the counterweight, be careful not to let it hit the lamps. Counterweight: 1,500 kg

COUNTERWEIGHT INSTALLATION 1. Counterweight Raise counterweight (2) set in mounting position, and tighten mounting bolts. + When installing the counterweight, be careful not to let it hit the lamps. Mounting bolt: 160220 kgm (Wiith across flats: 46 mm) 2.

Radiator guard 1) Raise radiator grille (1) in the mounting position, and tighten the mount bolts.

63-56

COUNTERWEIGHT

BUCKETLINKAGE..

WORK SYSTEM

EQUIPMENT

MAINTENANCE

STANDARD

BUCKET POSITIONER AND BOOM KICK-OUT BUCKET

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

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

4 5

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

64-1

MAINTENANCE

STANDARD

BUCKET LINKAGE

a Section

D-D

b Section

E-E

Section

”

F-F

a’ Section

64-2

G-G

Section

H-H

b Section

J-J

u7cvo43

MAINTENANCE

No.

BUCKET LINKAGE

STANDARD

Criteria

Check item

Standard clearance

Tolerance

Standard size

Remedy

Shaft

Hole

Clearance between pin and bushing at boss ends and bucket link.

110

-0.036 -0.090

+0.307 +0.220

0.256 0.397

Clearance between pin and bushing at joint of lift arm and bucket

110

-0.036 -0.090

+0.307 +0.220

0.256 0.397

Clearance between pin and bushing at joint of lift arm and frame

120

+0.307 +0.220

0.256 0.397

Clearance between pin and bushing at joint of dump cylinder bottom and frame

120

-0.036 -0.096

+0.307 +0.220

0.256 0.397

Clearance between pin and bushing at joint of dump cylinder rod and lever

120

-0.036 -0.090

+0.367 +o.zu

0.256 0.397

Clearance between pin and bushing at joint of tilt lever and lift arm

140

+0.395 +0.295

0.338 0.501

1.0

Z:Z

Clearance between pin and bushing at joint of lift cylinder bottom and frame

120.

-0.036 -0.090

+0.307 +0.220

0.256 0.397

1.0

Clearance between pin and bushing at joint of lift cylinder rod and lift arm

120

-0.036 -0.090

+0.307 +0.220

0.256 0.397

1.0

Width between bosses

Replace, also if other parts are biting into pin.

Wrdth of hinae

Standard clearance lClearance a + b)

140

3.0

Joint of dump cylinder and frame 143

Joint of lift arm and frame

153

150

3.0

Joint of lift arm and bucket

180

176.8

3.2

Joint of bucket link and bucket

145

142

3.0

Joint of tilt lever and bucket link

144

142

2.0

Joint of tilt lever and lift arm

240

237

3.0

Joint of bucket lever and dump cylinder

143

140

3.0

Joint of lift cylinder and lift arm

125

122

3.0

Joint of lift cylinder and frame

123

3.0

shims on both sides to make clearance on both left and right sides less than 1.5mm

64-3

MAINTENANCE

STANDARDS

BUCKET POSITIONER

AND BOOM KICK-OUT

1’

Section

A-A

L17DV004

Unit: mm No

Check item

Criteria

Clearance of bucket positioner switch

Clearance of boom kick-out switch

Tightening torque of mounting bolt for adjuster

9.023.5

Tightening torque of mounting bolt for switch

1.82.2 kgm

Remedy

Adjust

3-5

kgm

1 Retighten

64-4

MAINTENANCE

STANDARD

BUCKET

Section

A-A U7czo25

Check item

Criteria

Remedy

Standard size 1

1 Wear of bucket tooth

I 2

Thickness of shims for tooth (Clearance between tooth and bucket)

Tightening

torque of mounting

bolt for bucket tooth

Tightening

torque of mounting

bolt for corner tooth

I I

Repair limit

Max. 0.5

106 k-16 kgm

Replace Adjust

Retighten

64-5

MAINTENANCE

STANDARD

MEMORANDA

64-6

ELECTRIC ELECTRONIC 81

AND SYSTEM

STRUCTURE AND FUNCTION

ELECTRICAL WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE STARTING CIRCUIT

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

ENGINE STOP CIRCUIT ............................................................ COMBINATION SWITCH .......................................................... TRANSMISSION CUT-OFF SWITCH TRANSMlSSlONCUT-OFFSELECTOR’~~i~~H’:::::::::::::::::::::::::::::::::::::::’ .......................................................... NEUTRALIZERRELAY KICK-DOWN SWITCH ........................................................... KICK-DOWN ELECTRIC CIRCUIT ..................................................

4 6 8 1: 11

12 13

19 ELECTRICAL PARKING BRAKE CONTROL ............................................. 21 ........................................................ PARKING BRAKEVALVE 21 ....................................................... PARKING SAFETYRELAY 21 .......................................................... NEUTRALIZER RELAY 21 EMERGENCYBRAKE SWITCH .................................................... 22 ............................................................... CONDITIONS.. 22 1. STARTING SWITCH OFF ................................................... 23 2. STARTING SWITCH ON .................................................... 23 2-l. When parking brake switch is turned ON before starting switch is turned ON. ........... 24 2-2. Parking brake switch turned OFF (released) before starting switch is turned ON. ........ PARKING BRAKE SWITCH TURNED OFF (Released) AFTER STARTING SWITCH IS TURNED 3. 25 ON. .................................................................. 26 ...................................... 4. PARKING BRAKE SWITCH ON (operated) 27 ............................................... WHENAIRPRESSUREDROPS 5. BUCKET POSITIONER AND BOOM KICK-OUT .......................................... Bucket positioner .............................................................. Boom kick-out ................................................................

29 30 30

............................................................. PROXIMITYSWITCH OPERATION LirtarmRAISE’:::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::: Kick-out ................................................................... ............................................................... BUCKET’TILT”. Hold ...................................................................... Tilt ....................................................................... ................................................................. Positioned

31 31 31 33 34 34 35 36

81-1

AIR GAUGE CIRCUIT DIAGRAM

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

ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS) ................................... INDICATION ON MONITOR PANEL. ................................................ MONITOR WIRING HARNESS .....................................................

38 40 43

SENSORS ..................................................................... ENGINEOILLEVEL ............................................................ BRAKEOILLEVEL ............................................................. COOLANT LEVEL .............................................................. FUELGAUGE ................................................................ ENGINEOILPRESSURE ........................................................ PARKING BRAKE .............................................................. AIR PRESSURE ............................................................... TORQUE CONVERTER OIL TEMPERATURE .......................................... COOLANTTEMPERATURE ....................................................... ROTATIONALSPEED ........................................................... BRAKE LINE FAILURE .......................................................... TRANSMISSION OIL FILTER CLOGGING ............................................

44 44 45 45 46 47 48 49 50 50 51 51 52

STRUCTURE AND FUNCTION

ENGINE STARTING CIRCUIT

Transmission

Altemator

Safety relay

F +---.I-

Function l To ensure safety when starting the engine, the system is equipped with a neutral safety circuit. This makes it impossible for the engine to start if the directional lever is not at the N (Neutral) position.

Operation l When the directional lever is placed at the N (Neutral) position contacts of the directional lever switch are closed. In this condition, if the starting switch is turned to the START position, current flows in the following circuit. [l] Battery (+) - starting switch terminal B - starting switch terminal C - safety relay terminal S safety relay terminal B - directional lever switch terminal N - ground, so the safety relay is closed.

+1.--.

ste Ming ‘rr moIvl -

I 3-l

In addition, current flows from starting switch terminal BR 4 battery relay coil 4 ground, so the battery relay switch is closed. This forms the following circuit. PI Battery (+) - battery relay - starting motor terminal B 4 safety relay terminal B - safety relay terminal C - starting motor terminal C, and the engine starts. If the directional lever is at any position other than N (Neutral), circuit [l] is not formed, and the engine does not start.

ENGINE STARTING CIRCUIT

STRUCTURE AND FUNCTION

a) Safety relay.

Safety

relay

Connector

SAFETY

__I

RELAY CONNECTION CHART

LO8AD14,

81-5

STRUCTURE AND FUNCTION

Operation l When the starting is turned flows in the following circuit.

ENGINE STOP CIRCUIT

ON, electric

current

[l] Battery (+) - starting switch terminal B - starting switch terminal BR - fuel cut solenoid - ground connection. When electric current flows to the fuel cut solenoid, the fuel governor is put in the FREE position by the fuel control linkage.

When the starting switch is turned OFF, circuit [l] is shut off, but the engine is rotating, so there is still voltaae at terminal R of the alternator. For this reas&, the following circuit is formed. [2] Alternator terminal R - battery relay terminal BR - ground connection. The battery relay is maintained, but because of the diode inserted into the circuit, no electric current flows to the fuel cut solenoid, so the engine stops.

Fuel flows to the fuel injection pump and the engine starts.

Fuel cut solenoid

Starting

Alternator

switch [terminal

To starting

motor Battery

LOSAD

81-6

STRUCTURE

AND FUNCTION

ELECTRICAL

ELECTRICAL TRANSMISSION

TRANSMISSION

CONTROL

Kick-down switch (Lift control lewd

Transmission cutoff selector switch

Combinetion switch

FORWARD-REVERSE

Iev

Function 1

Selection of FORWARD, REVERSE and NEUTRAL

FORWARD-REVERSE lever

Selection of travel speed range

Speed control lever

Kick-down switch

When traveling in F2 it is possible to use this switch to shift down to Fl regardless of the position of the speed control lever. lf the directional lever is placed in R or N, the transmission automatically returns to 2nd.

Transmission

cut-off function

Transmission

cut-off selection function

Selects if transmission

returned to neutral when left brake pedal is operated. cutoff

function

is used or not used.

With this function, the left brake pedal can be used to get even better performance than conventional loaders in digging operations or ease of steering when loading on to trailers.

Neutralizer function

To prevent the operator from driving off when the parking brake is still applied and causing seizure of the parking brake, the transmission is returned to neutral when the parking brake is applied.

Neutral safety function

The engine can only be started if the FORWARDRNERSE lever is in neutral. In any other position the engine will not start. This prevents the machine from starting suddenly. (For details, see STARTING CIRCUIT.)

Warning function

When the machine is driven in reverse, a back-up lamp lights up and a backup horn sounds to warn people standing near the machine.

81-7

ELECTRICAL

STRUCTURE AND FUNCTION

COMBINATION

TRANSMISSION

CONTROL

SWITCH

LO8BZOOl

Function 1

FORWARD-REVERSE lever switch

Selecting FORWARD, REVERSE, or NEUTRAL

Speed control lever switch

Selecting machine speed range

Speed control lever stopper

Prevents speed control lever from going into 3rd or 4th speed during operations

Direction indicator lamp

Indicates direction when turning left or right

Self cancel

Returns direction indicator lamp lever to neutral automatically

Lamp switch

Selects clearance lamps, headlamps,

Dimmer switch

Selects travel beam, low beam

Emergency

flasher switch

Makes left and right turn signal lamps operate at the same time

Emergency

flasher pilot lamp

Flashes when emergency

after turning left or right

parking lamps

flasher lamp is ON

Outline l

The FORWARD-REVERSElever has three contacts: the speed control lever switch has four contacts. The switch alone has no detent mechanism. The detent mechanism is in the combination switch itself. Each switch is held at two places by pins. In addition, each switch is secured to the base by three screws.

When the lever is moved to the desired position, the switch, which is connected by a shaft, moves and electric current flows in only that circuit to move the machine.

STRUCTURE AND FUNCTION

TRANSMISSION l

ELECTRICAL

CUT-OFF SWITCH

TRANSMISSION

CONTROL

power supply of the solenoid valve circuit for the FORWARD-REVERSE clutch, and returns the transmission to neutral.

When the left pedal is operated, the switch detects the air pressure in a brake circuit. It shuts off the

/ valve Two-way

valve

Stop lamp switch

Transmission switch

cut-off

From brake oil tank

t -

To front brake From brake oil tank To rear brake

From air tank (upper) From air tank (lower)

Diaphragm To transmission power supply

n. \

I-

To transmission directional circuit

1) Restored Low voltage -

OFF Actuated High voltage

81-9

STRUCTURE AND FUNCTION

TRANSMISSION

To nrehlns nonltor

-1

ELECTRICAL TRANSMISSION CONTROL

CUT-OFF SELECTOR SWITCH

Nwtrrllzer

-[battery

relay powrr source1

To machlne monitor -1

cut-off switch

Forward relay

Neutrallzsr relay [battery power source1

select0 fmrnuall

solenold

award 9I.Y

solenold

To TRC switch

To back-up lamp relay

Trrnsmirslon F-R switch

Safety relay [terminal Bl Yachlne system trrnlnal

monitor neutral

Outline l This is a waterproof toggle switch for two circuits installed in parallel with the transmission cut-off switch at the power source end of the transmission directional circuit. Operation 1. Transmission cut-off selector switch at OFF. l The points of the cut-off selector switch are in contact, and current always flows to the directional clutch solenoid valves from the cut-off selector switch and cut-off switch. l When the left brake pedal is depressed, the points of the cut-off switch are separated by air pressure, and the electric current is shut off. However, electric current still flows to the directional solenoid valve from the cut-off selector switch, so the brake acts normally in the same way as the right brake.

81-10

To TRC relay

Transmlsslon F-R switch

Safety relay [terminal El

Yaehlnr system ternlnal

monitor neutral

2. Transmission cut-off selector switch at ON. l The points of the cut-off selector switch are separated, and current flows to the directional clutch solenoid valves only from the cut-off switch. l When the left brake pedal is depressed, the points of the cut-off switch are separated by air pressure, and the electric current to the directional solenoid valve is shut off. As a result, the brake acts as a normal brake, and at the same time, places the transmission in neutral.

ELECTRICAL

STRUCTURE AND FUNCTION

TRANSMISSION

CONTROL

NEUTRALIZER RELAY Back-up

lamp L stop lamp

Battery

terminal

To machine motor Transmission switch

-2

Transmission cut-off switch [actuated by air pressure1

(manual1

Kick-down switch

P a

Znd-1st selector relay e Back-up relay

Back-up

Iam

horn

Back-up

I I!

I I-cEi

I I?

I Ii

” --!!-!JI I

lamp

Operation 1. When the parking brake is applied (ON), electric current flows from battery relay - parking brake switch terminal (3) - terminal (2) - parking brake safety relay terminal (2) + ground. As a result, the coil of the safety relay is actuated, and terminal (3) and terminal (5) of the safety relay are joined to form this circuit. 2.

_l40 __

Kick-down switch rel ay

When the parking brake switch is turned OFF (brake released), and the engine is started, the circuit in Section 1 is not formed, so the parking brake switch must be turned ON before the engine will start.

When the parking brake is applied, no electric current flows to the coil of the neutralizer relay, so terminal (3) and terminal (5) of the neutralizer relay are separated. As a result, no electric current flows to the transmission directional circuit, so the transmission is kept in neutral while the parking brake is applied.

81-11

STRUCTURE AND FUNCTION

ELECTRICAL TRANSMISSION CONTROL

KICK-DOWN SWITCH

l. switch 2 Washer 3. screw 4. cover 5. Body 6. Cable

Circuit structuc

Operation 0 The kickdown (sh*Ktdown from 2nd to 1st) operates only when the transmission is in FORWARD2. l When traveling in FORWARD2,if it is desired to shift down to 1st without operating the speed control lever, it is possible to shift down to 1st by pushing the kick-down switch at the top of the left lever. l After this, even if the kickdown switch is pressed, the transmission remains in FORWARD 1.

81-12

The kick-down is canceled (or will not operate) under the following conditions. 0 When the directional lever is at N. l When the directional lever is at R. l When the speed control lever is at any position other than 2. l When the parking brake is applied. l When the starting switch is at OFF.

STRUCTUREANDFUNCTION

ELECTRICAL

TRANSMISSION

CONTROL

KICK-DOWN ELECTRIC CIRCUIT Normally ON

Ntsrnrtor termbd R

“I

To machine nonltor

ne monitor

Back-up

horn

Back-up

I,,

lamp

L08AD14!

When directional lever is in FORWARD l If the directional lever is placed at F, current flows

from battery (t) 4 neutralizer relay terminal (3) terminal (5) - FORWARD solenoid relay terminal (6) - terminal (5) - directional switch terminal F ground. As a result, the forward solenoid relay is actuated, and the circuits between terminals (1) and (2), and terminals (3) and (4) are closed. Next, current flows from battery (t) - neutralizer relay terminal (3) - terminal (5) - transmission cutoff switch - FORWARD solenoid - FORWARD solenoid relay terminal (2) - terminal (1) - ground. The FORWARD solenoid is actuated, and the FORWARD clutches are joined.

system

When speed control lever is placed in 2nd. l

When the speed control lever is placed in 2nd, current flows from battery (t) - 2nd solenoid relay terminal (2) - Terminal (1) - speed control lever switch 2nd terminal - ground, and the 2nd solenoid relay is actuated. When the 2nd solenoid relay is actuated, the circuit between terminals (3) - (5) is closed, and current flows from battery (t) - 2nd solenoid - 2nd solenoid relay terminal (5) - terminal (3) - 2nd-1st selector relay terminal (6) - terminal (3) - ground, and the 2nd solenoid is actuated to shift the transmission to 2nd. When the kickdown switch is actuated, the circuit between terminals (3) and (6) of the 2nd-1st selector relay contacts is opened, and the circuit between contact terminals (3) and (5) is closed, so current passes through the 1st solenoid, and the transmission is shifted to 1st.

81-13

ELECTRICAL TRANSMISSION CONTROL

STRUCTURE AND FUNCTION

When kick-down switch is operated. (When operating or traveling with speed control lever at F2)

Back-q

Cmp I stop lamp

-uphorn

Back

Bask-up lamp

When kick-down switch is Dushed ON. When the kickdown switch is pressed, current flows from: battery (+) 4 neutralizer relay terminals (3) - (5) - kick-down switch - FORWARD solenoid relay terminals (4) - (3) - kick-down relay terminals (6) - (5) - speed control lever switch 2nd terminal ground. As a result, the kickdown relay coil is actuated, and the circuit between terminals (1) and (2), and terminal (3) and (4) of the kickdown relay are closed. A circuit is then formed from kickdown relay terminals (2) - (1) - FORWARD solenoid relay terminals (4) - (3) - kick-down relay terminals (6) (5) - speed control lever switch 2nd terminal ground. Following this, even if the kick-down switch is canceled, the kickdown relay continues to be actuated. (Self-hold circuit of kickdown relay). When the kick-down relay is actuated, in the 2ndI st selector relay coil, current flows from battery (+) - neutralizer relay terminals (3) - (5) - kick-down relay terminals (4) - (3) - 2nd-1st selector relay terminals (2) - (1) - ground. The coil of the 2nd-1st 81-14

selector relay is actuated, the circuit between terminals (3) and (6) is opened, and the circuit between terminals (3) and (5) is closed. When the circuit between 2nd-1st selector relay terminals (3) and (6) is opened, electric current stops flowing to the 2nd solenoid. When the circuit between the 2nd-1st selector relay terminals (3) - (5) is closed, the electric current is switched to a circuit from battery (+) - 1st solenoid - 2nd-1st selector relay terminals (5) - (3) - ground, and flows from the 2nd solenoid to the 1st solenoid, so the transmission is shifted down from 2nd to 1st. After the transmission is shifted down, even if the kickdown switch is pressed again, the circuit between kickdown relay terminals (1) and (2) (connected in parallel to both ends of the switch) is closed, so there is no effect on the operation of the kick-down switch when it is being operated.

STRUCTURE AND FUNCTION

Cancellation

ELECTRICAL

TRANSMISSION

CONTROL

of kick-down switch I

(When directional lever is placed at N or R)

switch

(nanuall

-hIlti

If the directional lever is placed at any position except F, the F terminal contacts are OFF, so electric current stops flowing in the circuit from battery (+) - neutralizer relays terminals (3) - (5) FORWARD solenoid relays terminals (6) - (5) directional switch terminal F 4 ground, and the FORWARD solenoid is reset. When this happens, the circuit between FORWARD solenoid relay terminals (3) and (4) is opened, so electric current stops flowing to the circuit between kickdown relay coil terminals (6) and (5). The kickdown relay is then reset, and the self-hold circuit is canceled. When the kickdown relay is reset, the circuit between terminals (3) and (4) of the kick-down relay is opened, so the current stops flowing in the circuit from neutralizer relay terminal (5) - kickdown relay terminals (4) - (3) + 2nd-1st selector relay terminals (2) - (1) - ground. The 2nd-1st selector relay is reset, so the circuit between terminals (3) and (5) is

Znd-1st ssl&or

opened, and the circuit between terminals (3) and (6) is closed. The electric current stops flowing in the circuit from battery (+) - 1st solenoid - 2nd-1st selector relay terminals (5) - (3) - ground, so the kickdown to 1st is canceled. Next, the circuit between terminals (3) and (6) of the 2nd-1st selector relay is closed, so electric current flows to the 2nd solenoid, and the transmission is shifted back to 2nd, the position of the speed control lever. In this way, the operation of the kick-down switch is canceled, and the machine travels at the position indicated by the speed control lever. If the directional lever is shifted to R, the machine will travel in REVERSE2.

81-15

STRUCTURE AND FUNCTION

Cancellation

ELECTRICAL

TRANSMISSION

CONTROL

of kick-down switch II

(When speed control lever is at position other than 2nd)

To machine monitor Transmission cut-off selector switch (manual1

Back-up

horn

Back-up lamp C stop lamp

I 111

Back-up

Kick-down switch

lamp

L08AD14

If the speed control lever is placed at any position except 2, the circuit between the speed control lever 2nd terminal and ground is opened, so electric current stops flowing in the circuit from battery (+) - neutralizer relay terminals (3) - (5) - kickdown relay terminals (2) - (1) - FORWARDsolenoid relay terminals (4) - (3) kick-down relay terminals (6) - (5) - speed control lever switch 2nd terminal 4 ground, and the kickdown relay is reset. When this happens, the circuit between kick-down relay terminals (1) and (2) is opened, and the selfhold circuit is canceled. Therefore, even if the speed control lever is again placed in 2nd, the system will not be returned to the condition where the kickdown switch is actuated. At the same time, the circuit between terminals (3) and (4) of the kick-down relay is opened, so the electric current does not flow in the circuit from neutralizer relay terminal (5) 4 kick-down relay terminals (4) - (3) - 2nd-1st selector relay terminals (2) - (1) - ground.

81-16

As a result, the 2nd-1st selector relay is reset, so the circuit between terminals (3) and (5) is opened. The current then stops flowing to the 1st solenoid, so the kickdown to 1st is canceled, and the transmission is shifted back to the position of the speed control lever. The circuit between speed control lever 2nd terminals and ground is opened, so the 2nd solenoid is reset. As a result, even if the circuit between terminals (3) and (6) of the 2nd-1st selector relay is closed, the circuit between 2nd solenoid terminals (3) and (5) is open, so the 2nd solenoid circuit is also canceled. In this way, the operation of the kick-down switch is canceled, and the machine travels at the position indicated by the speed control lever.

STRUCTURE

AND FUNCTION

Cancellation

of kick-down switch Ill.

ELECTRICAL

TRANSMISSION

CONTROL

(When parking brake is applied)

I-‘

Back-up lamp & stop lap

I*chkm Dmitlw neutral tartid

If the parking brake switch is turned ON (brake applied), electric current stops slowing to the parking brake valve and the parking brake is applied. When this happens, the neutralizer relay is also reset at the same time, so the circuit between neutralizer relay terminals (3) and (5) is opened, and electric current stops flowing to the directional circuit of the transmission. The transmission is set in neutral, the kickdown relay and 2nd-1st selector relay are reset, and the actuation of the kickdown is canceled. When the 2nd-1st selector relay is reset, the circuit between terminals (3) and (5) of the 2nd-1st selector relay is opened, electric current stops flowing to

systa

the 1st solenoid, and the circuit between terminals (3) and (6) is closed, so a circuit is formed from battery (+) - 2nd solenoid - 2nd solenoid relay terminals (5) - (3) - 2nd-1st selector relay terminals (6) - (3) - ground. Current flows to the 2nd solenoid, and the transmission is shifted to 2nd, the position of the speed control lever. In this way, the kickdown operation is canceled when the parking brake is applied. In addition, the directional lever switch is set at neutral, the transmission gear is set to 2nd, and the machine stops.

STRUCTUREANDFUNCTION

ELECTRICAL

TRANSMISSION

Cancellation of kick-down switch IV. (When starting switch is turned OFF)

I--_-Back-up

Alternator

’ terminal R

lamp & stop lamp

switch [manual1

Yachine monitor system neutral terminal A Switch Back-w

horn

Back-up

lamp

When the starting switch is turned OFF, the battery relay is opened, so electric current stops flowing to the directional circuit and speed circuit of the transmission, so the kickdown action is canceled. When the starting switch is at OFF, the kickdown switch cannot be actuated even if the kickdown switch is turned ON (actuated).

81-18

CONTROL

ELECTRICAL

STRUCTURE AND FUNCTION

PARKING BRAKE CONTROL

ELECTRICAL PARKING BRAKE CONTROL Outline l

When electrical current flows to the parking brake valve (solenoid valve), air pressure from the air tank is applied to the spring cylinder and the parking brake is released.

When the electric current is stopped, the sir pressure form the air tank is cut off. The air pressure inside the spring cylinder passes through the parking brake valve and is released. The parking brake is then actuated by the force of the spring.

L08AD15

81-19

ELECTRICAL

STRUCTURE AND FUNCTION

PARKING BRAKE CONTROL

Function 1

Actuation and release of parking brake

Parking brake switch used

Automatic parking brake

Parking brake is automatically applied when engine is stopped (starting switch is turned to OFF). This prevents the machine from running away when the operator leaves his seat.

Emergency brake

The parking brake is automatically applied when it is impossible to maintain braking power because of a drop in the air pressure inside the tank caused by damage to the air circuit. In this way, the parking brake acts as an emergency brake.

Parking brake safety

After the automatic parking brake is actuated, it is dangerous if the parking brake can be released simply by turning the starting switch ON. Therefore, after the starting switch has been turned ON, the parking brake switch must be operated to release the brake. This ensures safety.

Neutralizer

lf the machine is driven with the parking brake still applied, the parking brake will seize up. Therefore, the caution lamp lights up and the caution buzzer sounds to warn the operator of this mistake in operation. At the same time, when the parking brake is applied, the transmission is moved to neutral, so it is impossible for the machine to move. However, when the parking brake is used as an emergency brake, if the transmission is returned to neutral, the braking distance will increase and the machine may stop in a dangerous place (for example, on a railroad crossing). For this reason, the circuit is designed so that the transmission is not returned to neutral when the emergency brake is applied.

Parking brake switch

Large size multi-pin connector (3 pole Mu3 with lock

Connection table

chloride

1 (actuated)

3 d

Water proof O-ring for panel face

81-20

2 View Z

STRUCTUREANDFUNCTION

ELECTRICAL

PARKING BRAKE CONTROL

PARKING BRAKE VALVE

Valve actuationtable hport

No. I

Exhaust Port No: 3

PARKING SAFETY RELAY NEUTRALIZER RELAY 3

Y--Y

eGE* k --,A

Relay comection chart

Relay actuationtable

TerminalNo. 1 TerminalNo. 2 I

TerminalNo. 5

minal No. 3 ~rminal No. 6

iMERGENCY

BRAKE SWITCH

Diaphragm

Contact

81-21

STRUCTURE AND FUNCTION

ELECTRICAL

PARKING BRAKE CONTROL

CONDITIONS 1.

STARTING SWITCH OFF l When the starting switch is turned OFF, the battery relay is opened, so no electricity flows to the parking brake circuit. For this yeason, if the starting switch is OFF, no electricity flows to the parking brake valve regardless of whether the parking brake switch is ON (actuated) or OFF (released). As a result, the parking brake is actuated. (Automatic parking brake).

Parking brake switch (manual1

To transmission speed circuit

81-22

Parking brake safety relay

Emergency brake switch [with wet tank1

Neutralizer

relay

LOSAD 156

STRUCTURE AND FUNCTION

ELECTRICAL

STARTING SWITCH ON

2-l.

When parking brake switch is turned ON before starting switch is turned ON. Electric current is flowing in circuit [l] battery (+) starting switch 4 battery relay coil - ground, so the battery relay is closed. For this reason, the current flows in circuit [2] battery (+) - battery relay parking brake switch terminals (3) - (2) - parking safety relay terminals (2) - (1) - ground. Because of this, the parking safety relay is actuated, and the circuit between terminals (5) and (3) of the safety relay is closed. When this happens, the following circuit [3] is formed: battery (+) - battery relay - parking safety relay terminals (3) - (5) 4 parking safety terminals (2) - (1) - ground, and the parking safety relay remains as circuit [3] until the starting switch is turned OFF.

In this condition, electric current does not flow to the parking brake valve, so the parking brake is applied. Furthermore, in this condition, the circuit between terminals (3) and (5) of the neutralizer relay is opened, so electric current does not flow to the directional circuit of the transmission, and the transmission is placed in neutral.

Parking brake Switch (manual) -OFF

Battery

Startrh

To transmission speed circuit

brake relay

Emergency switch (with wet

brake

Neutralizer

relay

1 BR

Parking safety

relay

1 -,

(\a

PARKING BRAKE CONTROL

Alternator terminal R

To trarL4mission FOWARD-REVERSE . 9. clrcun

valve

yi,y

tank)

81-23

ELECTRICAL PARKING BRAKE CONTROL

STRUCTURE AND FUNCTION

2-2. l

Parking brake switch turned OFF (released) before starting switch is turned ON. Electric current flows as follows. (1) Battery (+) - starting switch - battery relay coil - ground connection, so the battery relay is CLOSED. However, in this case, the parking brake switch is OFF (released), so the parking safety relay is not actuated. For this reason, no electricity flows to the parking brake valve.

Parking brake switch [manual]

Therefore, after the automatic parking brake is actuated, even if the starting switch is turned to ON, the parking brake is not automatically released. In addition, no electric current flows to the FORWARD-REVERSE circuit of the transmission, so the machine does not move.

Parking safety

brake relav __

rr-3

Battery

Starting

speed

Battery

relay

II! ,

switch

circuit [with

81-24

wet

tank1

Neutralizer

relav

STRUCTURE AND FUNCTION

ELECTRICAL

PARKING BRAKE SWITCH TURNED OFF (Released) AFTER STARTING SWITCH IS TURNED ON. If the parking brake switch is moved from ON (applied) to OFF (released), a circuit is formed between terminals (1) and (2) of the parking brake switch. In addition, the parking brake safety relay is actuated, so electric current flows from circuit [l] battery (+) - battery relay 4 parking brake safety relay - parking brake switch to the following circuits [2] and [3].

PARKING BRAKE CONTROL

Circuit [2] is formed from emergency brake switch parking brake valve - ground, and the parking brake is released. Circuit [3] is formed from battery (+) - battery relay neutralizer relay terminals (3) - (5) - Transmission directional circuit, so the machine moves according to the operation of the directional lever.

Parking brake switch [manual]

-c-

Parking brake _-I-I.. __I_._ sarary relay

Neutralizer

relay

OFF

Battery

Starting

relay

switch

To transmission speed circuit

To transmission FORWARD-REVERSE circuit Emergency brake switch [with wet tank1

81-25

ELECTRICAL PARKING BRAKE CONTROL

STRUCTURE AND FUNCTION

4. l

PARKING BRAKE SWITCH ON (operated) After operating with the parking brake switch at OFF (released), if the parking brake switch is turned to ON (operated), the circuit becomes as shown below. No electric current flows to the parking brake valve, so the air pressure from the air tank acting on the spring cylinder is shut off. At the same time, the air pressure inside the spring cylinder passes through the parking brake valve and is released, so the parking brake is actuated by the force of the spring.

Parking brake switch (manual3

Battery

At the same time, the neutralizer relay is also restored, so the circuit between terminals “3” and “5” is OPEN. No electric current flows to the FORWARD-REVERSEcircuit of the transmission, so the transmission is placed in neutral. In this way, when the parking brake is operated, the neutralizer relay shuts off the electric current to the transmission solenoid valve and puts the transmission in neutral. As a result, there will be no seizing of the parking brake caused by the machine being driven with the parking brake still applied.

Parking brake safety relay Neutralizer relay

relay

FFT-‘-j$+-;~

Starting switch

“Irr

1 -Alternator terminal R

To transmission speed circuit

81-26

circuit switch [with wet tank1

STRUCTURE AND FUNCTION

ELECTRICAL PARKING BRAKE CONTROL

5. WHEN AIR PRESSURE DROPS. (Emergency brake actuated) Operation l If the air pressure drops, the emergency brake switch installed to the dry tank is opened. For this reason, the electric current stops flowing to the parking valve, so the air pressure inside the spring cylinder is released, and the parking brake is applied. However, this case is different from when the parking brake switch is turned ON (brake applied), because electric current is flowing to the neutralizer relay coil.

Parking brake switch [manual1 --

Battery

Stmtina switch

For this reason, electric current flows to the FORWARD-REVERSEcircuit of the transmission, and it is possible to connect the transmission clutch. Therefore, when the emergency brake is actuated, the engine also acts as a brake. This makes the braking distance shorter, and at the same time, if the emergency brake is actuated, and it is necessary to move the machine (for example, if the emergency brake was actuated on a railroad crossing), the machine can be driven by operating the transmission lever. Parking safety ----

brake relay

Neutralizer

relay

I-

. ..

‘_

Alternator terminal R

Parking brake valve To transmission speed circuit

Emergency switch (with wet

brake tank1

81-27

STRUCTURE AND FUNCTION

BUCKET POSITIONER

BUCKET POSITIONER AND BOOM KICK-OUT

AND BOOM KICK-OUT

-. -..

. s

. ..

..Lfjlz

‘._

Ld::=

View

1. Proximity

switch

Qor bucket

2. Proximity switch (far boom 3. Dump cylinder rod

positioner) kick-out)

4. Lever 6. Plate

Section

81-28

STRUCTURE

AND FUNCTION

Bucket positioner l

The bucket positioner is electrically actuated and is used to automatically obtain the optimum digging angle for the bucket. When the bucket is moved from the DUMP position to the TILT position, and it reaches the desired angle, the dump lever is automatically moved from the TILT position to the neutral. Lever (4) is secured by bolts to dump cylinder rod (3). A proximity switch (1) is fixed by bolts to the cylinder. When the bucket is moved from the DUMP position to the TILT position, the dump cylinder rod moves to the left. At the same time, lever (4) also moves to the left. When it reaches the desired position, lever (4) separates from proximity switch, and the bucket lever returns to neutral.

Boom kick-out l The boom kick-out is electrically operated and acts

to stop the lift arm. When the lift arm reaches the desired position before the maximum height, the lift arm lever is returned to neutral. Plate (5) is secured to the lift arm. A proximity switch (2) is fiied to the frame. When the lift arm is moved from the LOWER position to the RAISE position, the lift arm rises. When it reaches the desired position, the proximity switch and plate come into contact and the liti arm lever is returned to neutral.

BUCKET POSITIONER

AND BOOM KICK-OUT

STRUCTUREANDFUNCTION

PROXIMITY

SWITCH

PROXIMITY SWITCH Function l

Proximity switches are installed by a support to the lift and dump cylinders. The lift arm RAISE position and the TILT BACK position can be selected to match the operating conditions. When these positions are reached, a pulse is generated from the

OPERATION

switch, the electric current flows to a magnet and the lift or dump lever is returned to the hold position. When this happens, the main control valve is also returned to hold and the movement of the lift arm or bucket stops.

OF PROXIMITY SWITCH

Lift arm RAISE l

When the lift arm is lower than the set position for the boom kick-out, the detection unit (steel plate) is on the sensing surface of the proximity switch. Electricity flows through the proximity switch. The relay switch is at OFF and the electric current of the magnet switch coil is shut off.

Proximity switch boom kick-out

Solenoid for

Proximity

switch

Detection

81-30

unit

for

kick-out

STRUCTURE

PROXIMITY

AND FUNCTION

SWITCH

When the lift control lever is moved to the RAISE position, The lever cam and the cam follower keep the lift spool in the RAISE position, so the lift arm goes up.

Proximity switch boom kick-out

for Battery

Kick-out Solenoid for

arm

Proximity

relay

kick-out

Cam

switch

Roller

\ %

uni

‘\

PPC

Solenoid

valve

81-31

PROXIMITY SWITCH

STRUCTURE AND FUNCTION

Kick-out l When the lift arm goes up and reaches the set position for the kick-out (that is, the detection unit ((steel plate)) is separated from the sensing surface of the proximity switch), the proximity switch and

relay circuit act to send electric current to the magnet coil. This actuates the magnet, the cam is pulled out of the cam detent, and the lift spool is returned to the neutral position by the return spring.

Proximity switch boom kick-out

for Battery

relay

IISolenoid for

kick-out

ift

Proximity

swi ,tch

arm

( \

PPC

valve

LO8CO18.

Movement of proximity switch Position

Sensing surface of magnet switch is in contact with detection unit

Sensing surface of proximity from detection unit

switch separated

OFF

Proximity switch load (relay switch circuit)

Current flows

Current shut off

Relay switch load circuit (Solenoid circuit)

Current flows

Current shut off

Proximity

81-32

switch display

PROXIMITY

STRUCTURE AND FUNCTION

SWITCH

BUCKET “TILT’ Hold l When the bucket is lower than the set position for the bucket leveler, the detection unit (steel plate) is on the sensing surface of the proximity switch. No electricity flows through the proximity switch. The relay switch is at ON and the electric current from the battery flows through the magnet switch coil.

Proximity switch boom kick-out

for -Battery

Positioner Solenoid for

Bucket

Detection

unit

Proximity

lever

relay

bucket

switch

--I

PPC

valve

LOBCDlBi

81-33

STRUCTURE

PROXIMITY

AND FUNCTION

SWITCH

Tilt l

When the bucket control lever is moved to the TILT position, the lever cam and the cam follower keep the dump spool in the TILT position, so the bucket tilts.

Proximity switch for bucket positioner -Battery

Positioner Solenoid for

Bucket

relay

bucket

lever

Detection

&it

\ Proximity

switch

PPC

81-34

valve

10BCDlB:

PROXIMITY SWITCH

STRUCTURE AND FUNCTION

Positioned l When the bucket tilts and reaches the set position for the bucket leveler (that is, the detection unit ((steel plate)) is separated from the sensing surface of the proximity switch), the proximity switch and relay circuit act to send electric current to the magnet coil. This actuates the magnet, the cam is pulled out of the cam detent, and the dump spool is returned to the neutral position by the return spring. Proximity switch for bucket positioner Battery

Positioner

Bucket

relay

lever

‘-i, PPC valve Movement of proximity switch Position

Sensing surface of magnet switch is in contact with detection unit

Sensing surface of proximity from detection unit

switch separated

OFF

Proximity switch load (relay switch circuit)

Current flows

Current shut off

Relay switch load circuit (solenoid circuit)

Current shut off

Current flows

Proximity

switch display

81-35

STRUCTURE AND FUNCTION

AIR GAUGE CIRCUIT DIAGRAM

To air gauge power supply 4

CN327

lo air gauge light

_ 7

0.858

Air pressure gauge (Front)

Air pressure gauge (Rear)

Air pressure sanding unit (Front)

0.85YB\

Air pressure sending unit (Rear)

L0tl0015

81-36

STRUCTURE AND FUNCTION

ELECTRONIC

ELECTRONIC VEHICLE MONITORING

VEHICLE

MONITORING

SYSTEM

SYSTEM (RIMS)

Outline l

The electronic vehicle monitoring system is a system to inform the operator of the condition of the machine. It consists of sensors installed in various parts of the machine, which observe the condition of the machine and process the information speedily, and display the situation on the monitor panel. The electronic vehicle monitoring system consists of the monitor panel, sensors, warning buzzer, warning lamp and power source. The displays can be broadly divided into CHECK items (1) and CAUTION items (2 and 3), which displays’warnings if any abnormality arises in the machine; and gauges (5) speedometer (7), and service meter (9), which always display the condition of the machine.

Warning

lamp

Warning

l l

The monitor consists of the following components. CHECK module (l), CAUTION module (2), CAUTION module (3) gauge module (5), speedometer module (including service meter), the case, and various other components. Each module (excluding the service meter) has its own microcomputer which processes the signals from the sensor and gives a display. CHECK (l), and CAUTION (2 and 3) modules all use common parts. The microcomputer judges which module it is from the wiring harness to which it is connected.

buzzer

@II@ PC ::

Battery

Sensor

81-37

STRUCTURE

AND FUNCTION

ELECTRONIC

VEHICLE

MONITORING

SYSTEM

38 1B 3c 30

3E !ic 3F 48

4c io

View Z

LllAH03

1 Check 1A Brake oil level 1 B Engine oil level 1 C Coolant level 2 Caution (Warning) 2A Battery charge 28 Fuel level 2C Transmission oil filter 2D Steering failure 3 Caution (Emergency warning) 3A Brake line failure

38 Engine oil pressure 3C Coolant level 3D Air pressure 3E Coolant temperature 3F Torque converter oil temperature 4 Pilot indicator 4A Transmission cut-off 48 Parking brake 4C Work lamp 4D Preheat monitor (Not used)

5 Gauge 5A Air pressure 58 Coolant temperature 5C Torque converter oil temperature 5D Fuel level 6 Turn signals 7 Speedometer 8 Head lamp (High beam) g Service meter 10 Service meter indicator

81-38

STRUCTURE

INDICATION

Category

Symbol

Air pressure

(8)

---

Torque converter oil temperature

Above 130°C

Parking brake

When operated

Work lamp

When operated

Transmission cutoff

When operated

Travel speed

0-lOOkm/h

High beam

When operated

CID

Hazard

Below specified pressure

Above 1OB”C

Winkers (right, left)

Description

Indication range

Coolant temperature

81-40

Indication item

Displays when engine is running. Display goes out when normal. Display flashes when abnormal. Display flashes when abnormal; buzzer and lamp actuated.

Displays when starting switch is turned ON. Lights up when operated.

Digital display

Displays when starting switch is turned ON; lights up when operated.

Lights up when operated.

When operated

I Service meter

0 - 99999/h displayed

Actuated when engine oil pressure is normal. Advances 1 for every hour of operation.

Service meter indicator

Flashes when service meter is operating.

Air pressure

One lamp lights up to indicate level.

STRUCTURE AND FUNCTION

Gate. 9orY

Symbol

Indication item

ELECTRONIC VEHICLE MONITORING

Indication range

SYSTEM

Description

108-C

102* 3*c

0 &

S7-C

Coolant temperature

80-C

One lamp lights up to indicate level.

80°C 87’C

Torque converter oil temperature

One lamp lights up to indicate level.

FULL

Fuel level

All lamps light up below indicated level.

81-41

STRUCTURE AND FUNCTION

ELECTRONIC

VEHICLE

MONITORING

SYSTEM

MONITOR WIRING HARNESS

Operation of monitor panel

If the monitor panel is working normally, the lamps on the monitor panel will work as follows: 1) When the starting switch is turned to ON. a) All monitor lamps will light up for 3 seconds. b) The warning buzzer will sound for 1 seconds. 2) CHECK MONITOR GROUP 4 iI monitor lamps will light up for 3 seconds, then if there is any abnormality in any check item, that item will flash. (About 0.8 seconds ON, then 0.8 seconds OFF repeated.) b) If the outside air temperature is low (below about - lO”C), the flashing interval will change slightly, but this is not an abnormality.

81-42

-. .--._

c) The CHECK item lamps will go out when the engine is started. (Judge whether the engine is running by the rise in the engine oil pressure, or see if there is a voltage of over 10 V from the alternator.) 3) CAUTION MONITOR GROUPS a) All monitors are working from the time the ’ engine starts to the time the engine stops and the starting switch is turned to OFF. If there is any abnormality in the machine, the lamp for that item will start to flash (0.8 seconds ON, 0.8 seconds OFF).

STRUCTURE AND FUNCTION

SENSORS

SENSORS Function l l

There are three types of sensors: contact type, resistor type, and solenoid type. Wiih contact type sensors, one end of the wiring is grounded at the chassis end, and the other end sends the signal from the sensor directly to the monitor or sends it through a relay.

If the contact of the sensor that sends the signal directly to the monitor is closed, the monitor judges the signal normal. If the contact of the sensor that sends the signal to the monitor through a relay is opened, the monitor judges the signal to be normal. (The signal is reversed by the relav.)

Sensor actuation table Sensor type

When normal

When abnormal

Engine oil level

Contact

OFF

Brake oil level

Contact

OFF

Coolant level

Contact

Fuel level

Resistor

On -

OFF -

Engine oil pressure

Contact

Coolant temperature

Resistor

OFF -

ON -

Torque converter oil temperature

Resistor

Travel speed

Solenoid

Brake line failure

Contact

OFF

Transmission oil filter clogging

Contact

OFF

Check item

ENGINE OIL LEVEL SENSOR Function l

The engine oil level sensor is installed on the engine oil pan. When the engine oil goes below the specified level the switch is turned OFF. The machine monitor lamp then lights up to indicate the abnormality.

1. 2. 3. 4. 5.

Connector Wire Plug Float Switch

Circuit

structure

81-43

SENSORS

STRUCTURE AND FUNCTION

BRAKE OIL LEVEL SENSOR Function l This is installed to the brake oil tank, and when the brake oil goes below the specified level, the float goes down and turns the switch ON. This actuates the relay and turns the relay output OFF. This machine monitor lamp then flashes to indicate the abnormality.

1. 2. 3. 4.

Cap Tank Float Connector

Circuit

COOLANT

structure

LEVEL SENSOR

Function l The coolant level sensor is installed on the top of the radiator. When the coolant level goes down, the float goes down and the electric current is shut off. The machine monitor lamp then lights up to indicate the abnormality.

1. Connector 2. Wire 3. Plug 4. Float 5. Switch

Circuit

81-44

structure

STRUCTURE

AND FUNCTION

SENSORS

FUEL GAUGE SENSOR Function l The fuel gauge is installed to the fuel tank, and the float moves up and down according to the fuel level. The movement of the float actuates a variable resister through a arm and sends a signal to the machine monitor to indicate the fuel level. If the display on the fuel monitor drops to a specified level, a signal is generated between the modules inside the machine monitor, and the warning lamp flashes.

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

Connector Float Spring Contact Spacer Variable resistor

3 4 5 Section

Circuit

A-A

structure

81-45

STRUCTURE

AND FUNCTION

SENSORS

ENGINE OIL PRESSURE SENSOR Function l The engine oil pressure sensor is installed to the engine. When the engine oil pressure goes below the specified pressure, the machine monitor lamp lights up to indicate the abnormality.

Terminal

C CNormally

Terminal

Connector

81-46

B [Normally

Terminal

Key

Closed1

Open1

A Kommonl

STRUCTURE AND FUNCTION

SENSORS

PARKING BRAKE SENSOR Function l The parking brake sensor is the parking brake solenoid valve. The diaphragm detects the air pressure, and when the parking brake is applied, the switch is turned OFF, and the machine monitor lamp lights up. If any abnormality occurs in the brake air circuit and the air pressure drops below the specified pressure, the switch is turned OFF, and the machine monitor lamp lights up to indicate the abnormality.

Connector

: 0@

Wire Switch Diaphragm Plug

Air

Circuit

structure

81-47

STRUCTURE AND FUNCTION

SENSORS

AIR PRESSURE SENSOR Function l The air pressure sensor is installed to the wet air tank. It acts through a diaphragm to actuate a sliding resistor according to changes in the air pressure. This sends signals to the machine monitor to indicate the air pressure. If the air pressure drops below the specified level, it generates a signal to the module inside the machine monitor, and the warning lamp flashes.

Circuit structure

81-48

Connector

2. 3.

Ventilation tube Wire

4. 5.

Resistor Resistor selector contact

STRUCTURE AND FUNCTION

SENSORS

TORQUE CONVERTER OILTEMPERATURE

SENSOR

Function l

These sensors are installed on the engine thermostat housing and transmission case. They use a thermistor to detect the temperature, and when the temperature goes above the specified temperature, the machine monitor lamp lights up to indicate the abnormality.

5 1.

Connector

2. Wire 3.

0 0

Tube (Yellow: (Black:

@+=D Circuit structure 4. 5.

COOLANT TEMPERATURE

Coolant temperature) Torque converter oil temperature)

Plug Thermistor

SENSOR

Function 0 These sensors are installed on the engine cylinder block. The sensor uses a thermistor to detect the

1. Connector 2. Plug 3. Thermistor

temperature, and when the temperature goes above the specified temperature, the machine monitor lamp lights up to indicate the abnormality. 1

B A

Circuit structure

81-49

SENSORS

STRUCTURE AND FUNCTION

ROTATIONAL

SPEED SENSOR

Function l The rotational speed sensor is installed on the 1.

transmission output gear. A pulse voltage is generated by the rotation of the gear teeth, a signal is then sent to the machine monitor, and this displays the travel speed.

2. 3.

Connector Magnet Case

Section

A-A

Circuit

structure

BRAKE LINE FAILURE SENSOR Function l

1. Ball Shaft 3. Switch 4. Wire 5. Connector

The brake line failure sensor is installed to the brake chamber. When the stroke of the air piston in the brake chamber goes above the specified stroke (over-stroke), the rod installed to the brake chamber pushes the ball and shuts off the electric current. This turns the switch OFF and the machine monitor lamp lights up to indicate the abnormality.

0 Circuit

81-50

structure

SENSORS

STRUCTURE AND FUNCTION

TRANSMISSION

OIL FILTER CLOGGING

SENSOR

Function l

These sensors are installed on the oil filter outlet port. A switch senses when the filter becomes clogged and pressure rises above the specified range, and the machine monitor lamp lights up to warn of an abnormality.

1. 2. 3. 4.

Connector Wire Boot Body

2=#3 Circuit

structure

81-51

STRUCTURE AND FUNCTION

MEMORANDA

81-52

SENSORS

ELECTRIC AND ELECTRONIC SYSTEM 82

TESTING

AND ADJUSTING

STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM ....................

.. . .. . .. . .

. ..

MACHINE MONITOR (SPEEDOMETER MODULE)

. . .. .. . . ..

.. .

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

. . .

. .

11 12 12 14 16 22 22 22 23 23 24 25 26

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

TROUBLESHOOTING.. ........................................... CHECKS BEFORE TROUBLESHOOTING ............................. JUDGMENT ON POWER TRAIN ................................... METHOD OF READING TROUBLESHOOTING TABLE ................... METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART PRECAUTION WHEN HANDLING CONNECTOR ....................... CONNECTOR TERMINAL NUMBERS ............................... ELECTRICAL WIRING DIAGRAM ................................... ELECTRICAL CONNECTOR (CN) DIAGRAM .......................... VEHICLE MONITOR SYSTEM DIAGRAM ............................. ELECTRICAL CIRCUIT SYSTEM ................................... ENGINE STARTING AND STOP CIRCUIT SYSTEM .................... PARKING BRAKESYSTEM ..................................... KICK-DOWN CIRCUIT SYSTEM .................................. ETHER INJECTION CIRCUIT SYSTEM .............................

.........

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

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

TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM . . . . . . . . . .. . .. . . . . .. POSITION OF CONNECTORS FOR TROUBLESHOOTING . .. . .. . . . E-l ENGINE DOES NOTSTART................................................ . .. .. . . . .. .. . .. . .. . . E-2 ENGINE DOES NOT STOP. . . . . . . . . . . . . . . . . . . . . . . E-3 ENGINE STOPS WHEN TRAVELING E-4 PARKING BRAKE DOES NOT WORK : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : . . . . . . . .. E-5 PARKING BRAKE IS APPLIED WHEN TRAVELING . . . . . . . . . . . . . . . . . E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON . . E-7 WHEN PARKING BRAKE IS APPLIED, SHIFT LEVER DOES NOT ENTER NEUTRAL (PARKING BRAKE IS WORKING NORMALLY.) .. . ... . .. .. . . .. . .. . . .. .. . . .. . .. E-8 TRANSMISSION DOES NOT WORK NORMALLY. . . . . . . . . . . . . . . ...... E-9 KICK-DOWN SWITCH DOES NOT WORK . . . . . . . . . . . . . . . . . _ . . . . . . . . ...... E-10 KICK-DOWN ONLY WORKS WHEN KICK-DOWN SWITCH IS ON . . . . . . . . . ...... E-11 KICK-DOWN OPERATION IS NOT CANCELED ...... E-12 KICK-DOWN WORKS BY MISTAKE WHEN TRAkiG’ li ii’ : : : : : : : : : : : ...... E-13 MACHINE DOES NOT TRAVEL WHEN KICK-DOWN SWITCH IS PRESSED . ...... TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM . . . . . POSITION OF CONNECTORS FOR TROUBLESHOOTING . . . . . . . . . . . . . . . . . . _. M-l (BRAKE OIL LEVEL) FLASHES WHEN ENGINE IS STOPPED . . . _ . . . . . . . _ . . M-2 (ENGINE OIL LEVEL) FLASHES WHEN ENGINE IS STOPPED M-3 (RADIATOR WATER LEVEL) FLASHES WHEN ENGINE IS STOPbED : : : : : : : : :

. . . . .

. . . . . .. . . .

27 28

38 39 40 42 44 44 46 68 71 72 74 74

77 78 89 90 91

M-5 (TRANSMISSION OIL FILTER CLOGGING) FLASHES WHEN ENGINE IS RUNNING ........ 93 M-6 (FUEL LEVEL) FLASHES WHEN ENGINE IS RUNNING ............................. 94 M-8 (ENGINE OIL PRESSURE) FLASHES WHEN ENGINE IS RUNNING .................... 96 M-9 (RADIATOR WATER LEVEL) FLASHES WHEN ENGINE IS RUNNING ................... 96 98 M-10 (DROP IN AIR PRESSURE) FLASHES WHEN ENGINE IS RUNNING ................. M-l 1 (ENGINE WATER TEMPERATURE) FLASHES WHEN ENGINE is RUNNING . . . . . . . . . . . . 98 M-12 (TORQUE CONVERTER OIL TEMPERATURE) FLASHES WHEN ENGINE IS RUNNING . . . . 98 M-13 (PARKING BRAKE) LIGHTS UP ABNORMALLY OR DOES NOT LIGHT UP . . . . . . . . . . . . . 100 M-14 (WORKING LAMP) LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP . . . . . . . . . . . . . 102 M-15 (TRANSMISSION CUT-OFF) LIGHTS UP, DOES NOT LIGHT UP . . . . . . . . . . . . . . . . . . . . 104 M-16 TURN SIGNAL HI BEAM LIGHTS UP, OR DOES NOT LIGHT UP . . . . . . . . . . . . . . _ . . _ . . 106 M-l 7 TURN SIGNAL DOES NOT FLASH EVEN WHEN HAZARD SWITCH IS TURNED ON _ . . . . . 111 M-18 SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY . . . . . . . . . . . . . . . . . . . . _ . _ . 112 . . . . . . . . . . . . . . . . . . . . . . . . . . 113 M-19 HOURMETER DISPLAY DOES NOT WORK NORMALLY M-20 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DOES NOT WORK, OR ONLY PARTWORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 M-21 WHEN STARTING SWITCH IS TURNED ON, ALL MONITOR PANEL LIGHTS LIGHT UP, BUTDONOTGOOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 M-22 (BATTERY CHARGE) FLASHES OR (ENGINE OIL PRESSURE) FLASHES WHEN ENGINE IS STOPPED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 M-23 NONE OF THE MACHINE MONITOR PANEL LIGHTING LIGHTS UP, OR PARTS OF IT DOES NOTLIGHTUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 M-24 WHEN THE STARTING SWITCH IS TURNED TO THE ON POSITION (ENGINE STOPPED), AND THE BUZZER DOES NOT SOUND FOR 1 SEC. WITH THE CAUTION ITEM FLASHING BUT THE BUZZER DOES NOT SOUND . . . . . . . . . . . . . . . . . . . . . . . . . . . _ . . . . . . . . . . . . . . . 124 M-25 NO ABNORMALITY IS SHOWN ON THE MONITOR DISPLAY, BUT THE ALARM BUZZER SOUNDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .._......_._....... 124 M-26 WHEN THE STARTING SWITCH IS TURNED TO THE ON POSITION (ENGINE STOPPED), AND THE WARNING LAMP DOES NOT LIGHT UP FOR 2 SEC. THE CAUTION ITEM IS FLASHING BUT THE WARNING LAMP DOES NOT FLASH . . . . . . . . . . . . . . . . . _ . . . . . . . . . . . . _ . 126 M-27 NO ABNORMALITY IS SHOWN ON THE MONITOR DISPLAY, BUT THE WARNING LAMP LIGHTS UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 M-28 ABNORMALITY IN THE FUEL GAUGE SYSTEM 128 M-29 ABNORMALITY IN THE AIR PRESSURE GAUGE &siirvl’ : : : : : : : : : : : : : : : : : : : : : : : : : 130 M-30 ABNORMALITY IN THE ENGINE WATER TEMPERATURE GAUGE SYSTEM . . . . . . . . . . . _ 132 M-31 ABNORMALITY IN THE TORQUE CONVERTER OIL TEMPERATURE GAUGE SYSTEM . . . . 134

The following precautions are necessary when using the Standard Value Tables to make judgements during troubleshooting or during testing and adjusting. 1. The values in these tables are based on the values for new machines leaving the plant, so they should be used as target values when repairing or when estimating wear after a period of use. 2. The standard values in theses tables for judgement when troubleshooting are estimated values based on the standard values for the machine when shipped from the plant, and on the results of various tests. Therefore, they should be used as reference in combination with repair and operating records when making judgements. These standard value tables must not be used for standard values when judging claims. In addition, do 3. not use these values alone to make simple judgement calls.

+ Before carrying out the troubleshooting in this section, read “PRECAUTIONS WHEN TROUBLESHOOTING”, “METHOD OF READING TROUBLESHOOTING TABLE” and “PREVENTING RECURRENCE OF TROUBLE” all in SECTION 22. + When disconnecting or connecting the T-adapter (or socket adapter) or short socket adapter or when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents. + When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNxx ( )). + When disconnecting connectors or connecting T-adapter, return them to the original condition immediately after checking, then go to the next check.

82-3

STANDARD VALUE TABLE

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM Name of component

Connector number

Inspection method

Radiator water level sensor

CN278

Short connector

Judgement

table

Measurement conditions

‘.. k the dondition~is as shown in the table below, the sensor is defective

Starting switch ON

Short connector connected Monitor OFF CN278 disconnected Monitor ON Continuity check

If the condition is as shown in the table below, ,‘the sensor is normal

Starting switch OFF

Oil level, water level normal Continuity Oil level, water level abnormal No continuity Engine oil level sensor

CN96

Connect to chassis ground

If the condition is as shown in the table below, the sensor is defective

Starting switch ON

CN96 (female) grounded Monitor OFF

CN96 disconnected

Monitor ON Continuity check

If the condition is as shown in table below, the sensor is normal

Starting switch OFF

Engine oil level normal -

Engine oil level abnormal No continuity Air pressure sensor

CN92

Measure resistance

‘If condition is as shown in the table below, the sensor is normal

Starting switch OFF

Air pressure 1 kg/cm2 Approx.

Air pressure 5 kg/cm’

1 kn

Approx. 600 n Torque converter oil temperature sensor, engine water temperature sensor

CN84 CNlOl

Measure resistance

If the condition is as shown in the table below, the sensor is normal

Starting switch

OFF

Normal temperature (25°C) Approx. 37 - 50 kn

100°C Approx. 3.5 - 4.0 kn Fuel level sensor

CN266

Measure resistance

If the condition is as shown in the table below, the sensor is normal Full tank Approx.

12 n or less

Empty Approx. 85 - 110 n

82-4

Starting switch OFF

STANDARD VALUE TABLE

TESTING AND ADJUSTING

Name of component

___

Alternator

Transmission sensor

Connector number

filter

CN153

Judgement

Inspection method

Measurement conditions

table

Measure voltage

When engine is running (‘/2 throttle or above): 27.5 - 29.5 ‘/ * If the battery is old, or after starting in cold areas, the voltage may rise for some time.

Start engine

Short connector

If the condition is as shown in the table below, the sensor isdefective

Starting switch ON

Short connector connected Monitor OFF

I CN153 disconnected Monitor ON Continuity

If the condiiion.is

check

I I Starting switch OFF

as shown in the table below, the’

sensor isnormal

Filter normal Continuitv

Filter clogged No continuity Short connector

Ground driven steering actuation

Continuity

check I

If the condition is as shown in the table ‘below, the sensor is defective

Starting switch ON

If the condition is as shown in the tabie below, the sensor isnormal

Starting switch OFF

Ground driven steering stopped Continuitv

actuated I Ground driven steering No-continuity

Brake stroke limit switch

CN87 CN88

I I

If the condition is as shown in the table below, the sensor is defective

Short connector

connected Monitor OFF

Starting switch ON

CN87, 88 disconnected Monitor ON Continuity

If the conditions as shown in the table below, the sensor is normal

check

Starting switch OFF

Brake normal Continuitv Brake abnormal

No continuity

82-5

STANDARD VALUE TABLE

TESTING AND ADJUSTING

Name of component

Connector number

Inspection method

Engine water temperature switch

___

Continuity

Judgement

check

Terminal wiring harness disconnected Monitor OFF Terminal wiring harness grounded Monitor ON

Starting switch ON

Engine started

If the condition is as shown in the table below, the sensor is normal

check

switch

95°C min.

If the condition is. as shown in the table below, the sensor is defective

Connect to chassis ground

Continuity

,. E$;ing

1012 1 “C Continuitv

Deactivation temperature Engine oil pressure sensor

Measurement conditions

If the.condition is as shown in the table below, the : sensor is normal Activation temperature

___

table

Oil pressure above 0.7 kg/cm2 No continuitv Oil pressure below 0.3 kg/cm2 Continuity Parking brake switch

CN36

Starting switch ON

‘If the condition is as shown in the table below, the sensor is defective

Short connector

connected

Monitor c)FF

CN36 disconnected

Continuity

check

Monitor ON

,lf the condition is as shown in the tablebelow, sensor is normal

Starting switch OFF

the

Parking brake OFF Continuitv

Parking brake ON No continuity Brake oil level sensor

CN86

Short connector

If the condition is as shown in the table below, the sensor is defective Short connector

Staring switch ON

connected Monitor OFF

CN86 disconnected

Monitor ON

Continuity

check

‘If the condition is as shown in the table below, the sensor is normal Brake oil level normal Continuity Brake oil level abnormal

82-6

Starting switch OFF

TESTING AND ADJUSTING

MACHINE MONITOR TER MODULE)

(SPEEDOME-

CNPl

CNPZ

MACHINE

MONITOR

CNP4

CNPS

The speedometer on the machine monitor is common for all models, but the input signals for the travel speed . differ according to the model, so it is necessary to adjust to make the speedometer applicable to the model on which it is being used. In addition, the diameter of the tires differs according to the type of tires fitted, so it is necessary to adjust the travel speed to match this. Procedure +

for adjustment

Adjustment OFF.

is to be done when power supply

is Rotary

switch

Turn the starting switch OFF. Remove the machine monitor, and adjust at the adjustment portion at the rear of the speedometer. Remove rubber caps 1 and 2 at the rear of the speedometer. Inside the rubber caps there are rotary switches. Using a fiat-headed screwdriver, turn the switch to adjust as shown in the diagram on the right.

s+!IIIJ

mmp)#

1 +

Switch 3 has no connection with adjustment of the speedometer, so do not touch it.

Switch 1 Tire size

Switch 2 km/h

MPH

26.5-25-20PR

7(or8)

29.5-25-22PR

After completing adjustment, fit the rubber caps securely, and install the machine monitor.

LllAJOlS

Reference

Suitable setting for switch 2

Switch position

Suitable setting

+14

t12

t10

Switch position

Suitable setting

-2

-4

-6

-8

-10

-12

-14

82-7

TESTING AND ADJUSTING

MEMORANDA

82-8

MACHINE

MONITOR

TROUBLESHOOTING

82-9

CHECKS BEFORE TROUBLESHOOTING

TROUBLESHOOTING

CHECKS BEFORE TROUBLESHOOTING xxxxxxxx

xxxxxxxxx

Checks before starting

Lubricating oil, cooling water

Electrical Equipment

Other check items

82-10

Item

Standard value

Remedy

1. Check fuel level 2. Check for dirt or water in fuel 3. Check hydraulic oil level 4. Check hydraulic oil strainer 5. Check brake oil level 6. Check engine oil level 7. Check cooling water level 8. Check condition of dust indicator 9. Check air pressure

__ __ __ ___ __ __ __

Add fuel Clean, drain Add oil Clean, drain Add oil Add oil Add water Clean or replace Refer to troubleshooting

10. Check for loose or corroded battery terminals 11. Check for loose or corroded alternator terminals 12. Check for loose or corroded stating motor terminals

Tighten or replace

Repair Repair Bleed air

23 - 26 V

Replace

Hydraulic mechanical components

13. Check for abnormal noise or smell 14. Check for oil leakage 15. Bleed air from system

Electrical components

16. Check battery voltage (engine stopped) 17. Check level of battery electrolyte 18. Check for discolored, burnt, or bare wires 19. Check for missing wiring clamps, hanging wires 20. Checks for water leaking onto wiring (checks carefully water leakage at connectors and terminals) 21. Check for broken or corroded fuses 22. Check alternator voltage (engine running at over half throttle) 23. Noise when battery relay is operated (switch starting switch from on to off)

Add or replace Replace Repair

Disconnect connector and dry connection

__ 27.5 - 29.5 V

Replace Replace

Replace

JUDGEMENT ON POWER TRAIN

TROUBLESHOOTING

JUDGMENT ON POWER TRAIN Use the following method to judge if the abnormality in the power train is in the electrical system of the transmission, or in the power train itself. If the abnormality is in the electrical system, go to troubleshooting items E-8 through E-l 3; if the abnormality is not in the electrical system, go to troubleshooting items T-l through T-4. Judgement

flow 3 F

YES

particular range?

Are voltage and resistance of solenoid for problem speed range correct?

YES r

When emergency screw of spool of problem speed range is loosened, does machine move?

YES Defective

Set to transmission cut-off

solenoid

valve

NO -

transmission

Go to troubleshooting Items T-l -T-4

for transmission,

speed Go to troubleshooting for transmission electrical system, Items E-8 - E-13

Defective

transmission

Go to troubleshooting Items T-l -T-4

solenoid

valve

for transmission,

Go to troubleshooting for transmission electrical system, Items E-8 - E-l 3 NO

Measuring

voltage

at the transmission

solenoid

inlet

Port 1. 2. 3. 4.

Turn the starting switch OFF. Remove the transmission control valve mounting connector. Turn the starting switch ON. Check that the voltage is 20 - 30V between the chassis ground connection and the wiring end ((for F and R: CN85 (A); for 1st thru 4th: CN85 (B)) of

the disconnected connector (female). Turn the parking brake switch ON 4 OFF (release).

Measuring resistance of transmission 1. 2. 3.

solenoid

Turn the starting switch OFF. Remove the transmission control valve mounting connector (CN85). Measure the resistance of the problem solenoid from the F and R solenoid and 1st thru 4th solenoid at the disconnected connector (male). The resistance should be approx. 60 n for each solenoid.

82-11

METHOD, TROUBLESHOOTING

TROUBLESHOOTING

METHOD OF READING TROUBLESHOOTING

FLOW CHART

TABLE

See Section 22 of this book.

METHOD OF USING YES-NO TROUBLESHOOTING The electrical system can be broadly divided into following 1. 2.

two parts.

Starting system, transmission electrical control system, brake system. ELECTRONIC VEHICLE MONITORING SYSTEM. The charts for these systems are marked as E-xx, and M-xx respectively.

Troubleshooting

Item

chart No.

E-xx

Troubleshooting

of starting system, transmission

electrical control system, brake system.

M-xx

Troubleshooting

of electronic vehicle monitoring

system.

Method for troubleshooting l Check or measure the items inside the rectangle

YES

I H

FLOW CHART

According to the result, follow the YES arrow or the NO arrow and proceed to the next rectangle. (Note: The number given at the top right of the rectangle is a reference number. It does not indicate the order for troubleshooting). l If the result of the check or measurement leads directly to the CAUSE column, note the cause and take the action given in the REMEDY column. l The value for the check and the measurement method is given inside the rectangle. If the value is correct, or the answer is yes, follow the YES arrow; if the value is not correct or the answer is no, follow the NO arrow. l Below the rectangle, there is a list given preparatory work, methods of operating and handling, and judgement values needed for checking and measuring. If the preparatory work is ignored, or the wrong method of operating or handling is used, or the judgement is wrong, this could result in damage to the equipment. Therefore, always read the procedure carefully before starting the check or measurement, and carry out the operation in the order given. Precaution when carrying out troubleshooting The precautions to be followed when carrying out troubleshooting for each failure is marked * under the description of the failure. Always follow these precautions when making measurements. Tools needed for troubleshooting The tools needed for troubleshooting for each problem are listed as follows.

Troubleshooting tools

Prepare these tools before starting troubleshooting. 4.

Place to install connectors, connector pin numbers When troubleshooting some problems, measurements have to be made of continuity, voltage and resistance at each step during the troubleshooting procedures. The location for measurement at each step (location of connector, connector pin number) is shown in a photograph or diagram. For this reason, use these photographs together with the YES-NO type troubleshooting flow charts to carry out troubleshooting quickly and accurately.

82-12

TROUBLESHOOTING

METHOD, TROUBLESHOOTING

FLOW CHART

Example * + +

When disconnecting or connecting the T-adapter (or socket adapter) or short socket adapter, or when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents. When connecting the T-adapter (or socket adapter), connect to the connector specified. Cnxx 0) When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after . checking, then go co the next check. lights

Cause

I3efectw %wtch

transmlwon

Remedy

cut-off

Replace

El Does

cl @

Is there continwty between CNP3 (female1 (1 1) and chassis ground’

YES -

I Short clrcwt

between CN 18 (female) (3) and (4). Turnstartmg swtichON.

goout’

IS there continuity between CN18 (female) (4) and chassis ground’

1) Turn starting switch

OFF.

11 _

21 31

YES

I I

IDefectwe

Ikfectw contact. or cjwzonnectton I” vwrlng harness Ixtween CN18 (female1 (31 ant (:NP3 (female1 (1 1)

Turn NO tra”srnlsslO” cut-off selector switch ON. Connect T-adapter to CNP3 (female) Turn starting swtch OFF

T-adapter

(for DLI)

Replace

panel

I3efectlve contact, or ,ksconnection I” wmng harries! Isetween CN18 :hassls ground

Trouble-

mo”,tor

(female)

(4) ant

After ,“spectIo”, repaIr (clean) or K!pkKF2

After Inspecton, repau (clean) or replace

Tester

shooting tools

POSITION OF CONNECTOR CN18 (Transmission cut-off selector switch) N-SLC connector 4 pins

82-13

PRECAUTION

TROUBLESHOOTING

PRECAUTION CONNECTOR

WHEN

WHEN HANDLING

CONNECTOR

HANDLING

If the connector has a lock, always release the lock before disconnecting the connector.

This must be removed.

When connecting, align this arrow and push in. Be sure to fit rubber cover tightly.

When removing, press this part and pull the connector out.

LO8ZZlOC

LO8ZZ103

Never pull the cord to disconnect

the connector. When connecting, align the wide inside the conriector and push

When removing, press in on both sides and pull the connector out.

LO8ZZ106 LO8ZZ104

If the connector is difficult to disconnect, do not try to pull it out. (If it is difficult to reach by hand, remove the clamp and move the wiring harness.)

82-14

PRECAUTION

TROUBLESHOOTING

After pulling out the connector, cover with a vinyl bag to protect the contacts from dirt or oil.

When cleaning the connector, never use cleaning agents such as trichloroethane or trichloroethylene. If the connector is very dirty, use a neutral cleaning agent. After cleaning wash well and dry completely immediately. (Do not use any connector which has deposits left on it after drying.) Coat with contact restorer. (When drying, be particularly careful to dry the gaps in the rubber.)

When assembling the connector, be sure to fit it correctly. (For connectors with locks, it should be possible to heat the locks clicks s they fit completely into position.)

Correct any protrusion

WHEN HANDLING

CONNECTOR

of the boots.

82-15

CONNECTOR

TROUBLESHOOTING

TERMINAL

NUMBERS

:ONNECTOR TERMINAL NUMBERS

No. of Pins

ECONOSEAL CONNECTOR Female terminal (Socket)

Male terminal (Pin)

142F401A

142F4OOA

142F403A

142F402A

142F405A

142F404A

142F407A

142F406A

142F408A

LO822009

82-16

TROUBLESHOOTING

No. of pins

CONNECTOR

DLI Female terminal

CONNECTOR

(For monitor

NUMBERS

panel)

(Socket)

TERMINAL

Male terminal

(Pin)

142~418

142F419

‘12

142F420

142F421

142F422

142F423

82-17

CONNECTOR

TROUBLESHOOTING

TERMINAL

NUMBERS

N-SLC CONNECTOR No. of Pins

Male terminal (Pin)

Female terminal (Socket)

1 2

I!3

423F349

423F350

3 B

423F351

423F352

4 m 423F354

423F353

1 6

ffz?I 423F355

423F356

8 B

423F357

423F368

LO8ZZOlC

82-18

CONNECTOR

TROUBLESHOOTING

No. of Pins

NUMBERS

MIC CONNECTOR Female terminal (Socket)

Male terminal (Pin)

TERMINAL

?=T 0

142F410

142F411

t42F413

142F412

142F414

I-(

142F415

142F416

423F417

LO8ZZOl’

82-19

TROUBLESHOOTING

CONNECTOR

TERMINAL

NUMBERS

BENDIX CONNECTOR No. of Pins

Female terminal (Socket)

Male terminal (Pin)

10 @

421FO1133

421FO1132

RELAY CONNECTOR

No. of Pins

3 423F348

LO822012

82-20

TROUBLESHOOTING

NO. OF PINS

CONNECTOR

TERMINAL

NUMBERS

METRI-PACK CONNECTOR FEMALE TERMINAL (SOCKET)

B C

NO. OF PINS

METRI-PACK CONNECTOR MALE TERMINAL (PIN)

D C B 4

82-21

ELECTRICAL

TROUBLESHOOTING

ELECTRICAL WIRING DIAGRAM See foldout # 1, 2, 3 and 4 in back of book.

ELECTRICAL CONNECTOR

(CN) DIAGRAM

See foldout # 5 in back of book.

VEHICLE MONITOR SYSTEM DIAGRAM See foldout # 6 in back of book.

82-22

WIRING DIAGRAM

TROUBLESHOOTING

ELECTRICAL

CIRCUIT SYSTEM

ELECTRICAL CIRCUIT SYSTEM ENGINE STARTING AND STOP CIRCUIT SYSTEM

Starting switch CN14 01 -a2 --a3 04

e 0-p c-0

Battery relay Transmission control switch

/ -

Battery

To transmission I solenoid relay

‘i

I Main breaker

Main fuse

To monitor panel

CN64

+CN102

Starting motor

Safety relay

Fuel cut solenoid

CN63

CN97

L08DD140

82-23

TROUBLESHOOTING

ELECTRICAL

CIRCUIT SYSTEM

PARKING BRAKE SYSTEM

Monitor

pane Fuse box 1-2

CNll Parking switch

brake Parking brake safety relay

CN36

Parking brake display switch

Neutralizer relay &

To transmisstion speed circuit

CN34

To transmission FORWARD-REVERSE circuit

Emergency brake switch

LOIDDl42

82-24

TROUBLESHOOTING

KICK-DOWN

ELECTRICAL

CIRCUIT

SYSTEM

CIRCUIT SYSTEM

brake switch

Fuse box II - 1

Parking valve

brake

“26

Ivz Fuse box

I- 2

3anery relay Banery

CN21

Transmission

cut-off

switch

CN245

P d&

Kick-down

FORWARD

solenoid

relay

REVERSE

solenoid

relay

switch ix243

Pnd-1st selector

relay

Back-up lamp relay To CN54

CN53 *$I

Neutralizer

A$1

Parking

relay

brake safety relay

LO8DD141

82-25

ELECTRICAL

TROUBLESHOOTING

ETHER INJECTION Ether injection switch

Startina

switch

CN13

CIRCUIT

CIRCUIT SYSTEM

CN19

/ CN254

CN95

1 2” 1

1 n

Transmission control switch n

+zz;~ ,

To transmission relay

> solenoid

Main breaker -

To fuse box

L I I CN295

Alternator CN300 1

Main fuse

To monitor

panel

f------

Ether injection

solenoid

Safety

Starting

Fuel cut solenoid

CN253 CN97

L08DD143

82-26

SYSTEM

TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM

82-27

POSITION OF CONNECTORS

TROUBLESHOOTING

POSITION OF CONNECTORS TROUBLESHOOTING

FOR

Battery

- CN25

Battery relay

425PO97

Startina switch

CNll (Parking brake switch) N-SLC connector 3 pins

brake

switch

Working lamp switch

l?N13

CN14 (for startina switch) CON&EAL connector 4 pins

a 2

2 L08CD112

82-28

L08CD094

POSITION

TROUBLESHOOTING

OF CONNECTORS

CN16 (Speed lever, directional lever) ECONOSEAL connector 12 pins 9

CN18 (Transmission cutOoff selector switch) I-SLC connector 4 pins

fzl

Transmission selector TH

cut-off

Central

wi,rnilg

DB 4

L08CDll4 lamp Ci17

LO8CO139

CN21 (Transmission cut-off switch) ECONOSEAL connector 2 oins

__ CN35 (Parking brake solenoid valve) ECONOSEAL connector 2 pins

Parking brake solenoid valve,

diSp,ayswitch 425P108

82-29

TROUBLESHOOTING

POSITION

CN39 (Intermediate connector) ECONOSEAL oins ___. ___-. .- connector __.... --.-. 12.- r11

\ u/

OF CONNECTORS

CM62

11 \

L08CDlW

CN148. CM317

CN52 (Parking brake safety relay) CN53 (Neutralizer relay) CN54 (Back-up relay) RELAY connector 5 pins

CN50 CM?2 CM,53 CM334 (Caution IamD \

1OBCI1131

relay1.

CM49 buzzer

CM54

LO8CD132

L08CD117

CN60 (Fuse box l-2) ECONOSEAL12 Dins

L08CD133

82-30

POSITION

TROUBLESHOOTING

OF CONNECTORS

CN63 (Intermediate connector) CN64 (Intermediate connector) CONOSEAL 12 pins

L08CD116

CN75 (Transmission valve intermediate ECONOSEAL 8 Dins

connector)

5 LOBCDll

CN76 (Diode) I-SLC‘connbctor

2 pins

L08CD120

CN85 (For transmission control valve) BENDIX connector 10 pins

_/-&d$ -

L08CD12 LO8Crl135

82-31

POSITION OF CONNECTORS

TROUBLESHOOTING

CN97 (Intermediate connector) ECONOSEAL connector 12 Dins 7

7 -. \ \

01 llln -

4 LOSCDi

CN102 (For safety relay) ECONOSEAL connector 3 pins

CN204 (Emergency brake switch) ECONOSEAL connector 2 pins

CN204

CN92

LOSCDllf

LO8CD136

:N236 (REVERSE solenoid IELAY connector 6 pins

82-32

relay) autian

lamp

relay)

POSITION OF CONNECTORS

TROUBLESHOOTING

CN237 (2nd solenoid relay) CN239 (2nd-1st selector relay) RELAY connector 5 Dins

L08CD158

CN242 (Kick-down switch relav) :ELAY connector 6 pins _’ ?

5 /

L08CD157 Kick-down switc

CN243 (Kick-down switch) N-SLC connector 2 pins 2

i=N243

CN246 (FORWARD solenoid RELAY connector 6 pins

relay)

CN50 CNv2 CN,53 CN334 (Caution \

CN49

L08CD137

lamp relay1

POSITION

TROUBLESHOOTING

OF CONNECTORS

CN254 (For battery relay) CONOSEAL connector 3 pins

I 08CD15Q

CN295 (Fuse box 11-2) :CONO’SEAL connedtor

CN-254

d//

LOBCD196

12 pins

I OSCDlSQ

L08CD13’

Fuel cut solenoid

Fuel cut-off solenoid

82-34

TROUBLESHOOTING

POSITION

OF CONNECTORS

MEMORANDA

82-35

E-l

TROUBLESHOOTING

CHART No. E-l

ENGINE DOES NOT START Failure mode: E-l + When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents. t When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN o A()) + When disconnecting or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check. + If the lights and other electrical equipment are not working properly, go first to 2) inspection of battery - starting switch. 1) Inspection of starting circuit YES

2 ’ Is there continuity between CN102 (3) (female) and chassis?

YES _

YES

1I Disconnect CN102 (starting motor inlet). Place F-R lever at N. Turnstarting switch OFF.

2) 1 is voltage between CN102 11) (female) and chassis 20 3OV? 1)

_ 2)

Disconnect CN102 (starting motor a&y). Turn starting switch ON.

IS there continuit-q betweenCN16 (9) (male) and chassis?

connect T-adapter (socket adapter) to CN16 (F-R lever inlet). Place F-R N. Turn starting switch OFF.

leverat

YES

4 _ Y Is

voltage between CN14 (3) (female) and chassis 20 3ov7

Connect T-adapter (socket adapter) to CN14 (female). Turn starting switch to START.

Inspection

of battery - battery relay - starting switch YES

2n Is

voltage between two thick terminals of battery relay and chassis each 20 3ov7

YES *

1) Turn starting

1 1

2) IS there sound of battery relay being actuated?

switch ON. Measure voltage of each connecting terminal of thick cable.

1) Turnstarting switch OFF.

ON -

YES

3 YES

Isvoltage between NO

YES

CN254 (3) (female) ;;PV;hassis 20 -

voltage between CN14 (2) (female) and chassis 20 3OV?

4 1) Disconnect CN254. 2) Turn starting switch ON.

Is voltage between CN14 (1) (female) and chassis 20 3OV?

_ NO

82-36

Connect T-adapter (socket adapter) to CN14 (female).

1 1)

2) NO

Connect T-adapter (socket adapter) to CN14 (female). Turn starting switch ON.

1 NO

TROUBLESHOOTING

Troubleshooting tools

E-l Remedy

T-adapter or socket adapter (for Econoseal)

Defective starting motor ass’y or safety relay.

Replace

Defective contact, or disconnection in wiring harness between CN102 (3) (female) - CN97 (7) CN64 (9) - CN16 (9) (female).

After inspection, repair (clean) or replace

Defective F-R switch, or defective contact, or disconnection in wiring harness between F-R switch-chassis ground.

Defective contact, or disconnection in wiring harness between CN102 (1) (female) - CN97 (4) CN63 (5) - CN14 (3).

After inspection, repair (clean) or

After inspection, repair (clean) or replace

Defective starting switch.

Defective contact, or disconnection in thick cable between starting motor battery relay.

After inspection, repair (clean) or

Both terminals are NO: Defective contact, or disconnection in wiring harness between battery battery relay. One terminal is NO: Defective battery relay.

After inspection, repair (clean) or replace

Disconnection in wiring harness between CN254 (3) battery relay - chassis ground, or defective battery relay. Defective contact, or disconnection in wiring harness between CN254 (3) (female) - CN95 (1) -(diode) - CN95 (2) - CN63 (2) CN14 (2).

After inspection, repair (clean) or replace

Defective starting switch.

Defective contact, or disconnection in wiring harness between battery relay - CN254 (2) - CN63 (7) CN295 (1) -fuss - CN295 (2) - CN14 (1) (male).

After inspection, repair (clean) or replace

L08DD144

82-37

E-2

TROUBLESHOOTING

CHART No. E-2

ENGINE DOES NOT STOP. Failure mode: E-2 + When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents. t When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN o A()) t When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check.

Cause

Remedy

Defective fuel cut solenoid.

l3eplZl.X

Contact or disconnected wiring between +24V and wiring harness between CN14 (male) (2) - CN63 (2) CN97 (male) (11).

After inspection, repair or replace

Isvoltage terminal of fuel cut solenoid

1) Turn starting switch OFF.

Is voltage between starting switch BR -chassis ar.mrox.

1) Turn starting switch OFF.

Defective

starting switch.

L08DD145

TROUBLESHOOTING

E-3

TROUBLESHOOTING

CHART No. E-3

ENGINE STOPS WHEN TRAVELING Failure mode: E-3 Check if the starting motor rotates. If it does not rotate, check according

to E-l (a) (Engine does not start).

Cause

Disconnection in wiring harness or defective contact between starting switch terminal BR chassis ground CN14 (2) CN63 (2) - CN97 (11) fuel cut solenoid.

1 terminal B and chassis ground

1) Turn starting switch OFF.

After inspection, R?plaCa

Defective fuel cut solenoid.

YES

chassis ground 20 - 30?

1) Turn starting switch ON.

Troubleshooting tools

Remedy

wiring of fuel cut-off solenoid. 2) Turn starting switch OFF. Replace NO Disconnection in wiring harness or defective contact between starting switch terminal B and battery relay.

After inspection, replace

T-adapter or socket adapter (for Econoseal) Tester

LOBDDl46

82-39

E-4

TROUBLESHOOTING

CHART No. E-4

PARKING BRAKE DOES NOT WORK Failure mode: E-4 + When carrying out troubleshooting of the brake system, stop the machine on level ground. * When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents. * When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN o A()) t When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after . checking, then go co the next check. a.

If parking brake does not work when parking brake switch is ON (applied). Cause

Defective

Is problem removed when is disconnected?

CNl1

YES

Is there continuitY between 1 (female) (1) and (Z)?

CNl

1) Disconnect 2) 3) 4)

CNll. Turn starting switch OFF. Disconnect CN53. Disconnect CN52.

3 YES 1

Redace

Contact of wiring harness at CN 11 I1 (female) and (2)

After inspection repair or replace

Defective solenoid

Replace

parking

brake

Is voltage between CN35 (female) (1) and chassis approx. OV?

brake switcl

2 I

parking

Remedy

Connect T-adapter (socket adapter) to CN35. Start enaine. (Charge% pressure) Turn parking barke switch ON.

Contact of wiring harness at CNl 1 11) (female) and (31

After inspection repair or replace

Iefectiveemergency witch

Ieplace

If parking brake does not work when air pressure has dropped. (does not work as emergency brake)

1 Is problem removed when CN204 is disconnected?

Turn starting switch ON. _ Turn parking brake switch ON -OFF.

T-adapter or socket adapter (for Econoseal)

82-40

brake

I I

L 1)

YES

Defective parking solenoid

brake leplace

TROUBLESHOOTING

E-4

MEMORANDA

82-41

E-5

TROUBLESHOOTING

CHART No. E-5

PARKING BRAKE IS APPLIED WHEN TRAVELING Failure mode: E-5 t When carrying out troubleshooting of the brake system, stop the machine on level ground. + When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents. t When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN 0 A()) + When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check.

2 YES Is there continuity between CN35 12) Imale) and chassis?

;;isyct

Turn starting switch OFF. YES

1 Is voltage between CN35 (1) (male) and chassis 20 - 3OV? L 11

Y ES

Isproblem removed

I connect T-adapter (socket adapter) to CN35. Start engine. (Travel) (Charge air

1) Interchange parking brake safety relay (CN52) with backup lamp relay (CN54). 1 2) Start engine. (Charge air presWra)

Is continuity of CNl 1 (1). L2), (3) as shown in Table

1) 2) 3)

Disconnect CNll. Turn starting switch OFF. Turn parking brake switch ON/OFF.

Is problem removed when short connector is connected?

YES

Connect short connector to CN204 (female).

Startengine. (Charge air pressure)

CN52 (3) &male) and chassis 20 -

1) Disconnect CN52. 2) Turn starting switch ON.

T-adapter

or socket adapter

(for Econoseall Short connector

82-42

Is voltage between CNl 1 (2) (female)

Turn starting switch ON.

Turn parking brake switch -OFF.

E-5

TROUBLESHOOTING

Table 1 Operation

Between

terminals

Between

(1) and (2)

Remedy

Cause

terminals

(3) and (2)

Defective

parking

brake

solenoid

18 YES

Is voltage between CN204 (1) (female) ;;dv:hassis 20 -

YES

9 YES 8 Is voltage between CN52 (2) (female) and chassis 20 3ov7

1) 2) 3)

Disconnect CN52. Turn starttng switch ON. Turn parking brake switch ON.

Is there continuity between CN52 (1) (female) and chassis? 1) Disconnect CN52. 21 Turn starting switch OFF.

I NO

1) Disconnect 2) 3) NO

Defective contact, or disconnection in wiring harnes: between CN35 (2) (male) and chassis

After inspection, repair or replace

Defective relay

parking

Replace

Defective switch

emergency

brake safety

brake

Reolace

3efective contact, or disconnection in wiring harness between CN204 (2) (female) CN35 (1) (male).

After inspection, repaw or replace

lefective contact, or disconnection in wiring harness aetween CN204 (1) (female) 3Nl 1 (1) (female).

4fter inspection, ,epair or replace

Defective contact, or disconnection in wiring harness between CN52 I1 (female) chassis

4fter inspection. .epair or replace

Iefective contact, or disconnection in wiring harness oetween CN52 (2) (female) CNl 1 (2.) (female)

4fter inspection, repair or replace

Defective contact, or disconnection in wiring harness between CNl 1 (2) - CN52 (5

After inspection, repair or replace

Defective contact, or disconnection in wiring harness between CN52 (3) (female) CN60 14) - fuse

After inspection, repair or replace

Defective

Fieolace

CN204. Turn starting switch ON. Turn parking brake switch

ON -OFF.

parking

brake switch

82-43

E-6, E-7

TROUBLESHOOTING

CHART No. E-6

Failure mode: E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON + When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents. + When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN o A()) * When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check. Remedy

Cause

Is problem

1) Interchange parking safety relay (CN52) with back-up lamp relay (CN54). 2) Start engine. (Charge air pressure) 3) Turn starting switch ON.

Is problem removed when CNl 1 is disconnected’

1) Disconnect 2)

CNll. Start engine. (Charge air pressure) Turn starting switch ON.

TROUBLESHOOTING Failure mode:

YES

Is there continuity between neutralizer relay CN53 (male) (3) 3 and (5)?

82-44

safety

relay

Replace

Defective

parking

brake switch

Replace

Disconnect neutralizer relay CN53. Turn starting switch OFF.

3 Is there continuity betweenCN52 (3) (female) and (5)~

_ NO

11 Dtsconnect 2)

YES

Contact of wiring harness between CN52 (3) and (5). (2) (female)

After inspection, repair or replace

Contact of wiring harness between CNl 1 (1) and (3) (female)

After inspection. repair or replace

CN52. Turn starting switch OFF.

CHART No. E-7

WHEN PARKING BRAKE IS APPLIED. SHIFT LEVER DOES NOT ENTER NEUTRAL. (PARKING BRAKE IS WORKING NORMALLY.)

E-7

parking

removed YES

Defective

.Irbnormal contact between +24V and wiring harness between CN53 (5) - CN18 (1: (2) - CN75 (8) - CN85 (A).

After inspection, repair or replace

Defective

Replace

neutralizer

relay

TROUBLESHOOTING

E-6, E-7

MEMORANDA

82-45

E-8

TROUBLESHOOTING

CHART No. E-8

TRANSMISSION DOES NOT WORK NORMALLY Failure mode: E-8 When carrying out troubleshooting of the brake system, stop the machine on level ground. When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents. When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN 0 A()) When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check. Testing and inspection

A 1. 2.

solenoid control circuit

Stop the machine on level ground and put blocks under the tires.

Install a T-adapter (or socket adapter) to connector and the chassis ground. Turn the starting switch ON.

A 3. 4.

WARNING!

of transmission

WARNING!

CN75, and check the voltage between the connector

Do not start the engine.

Turn the parking brake switch ON -- OFF (release). When depressing the foot brake, depress the R.H. brake so that the transmission is not cut off. + If the L.H. brake is depressed, the transmission is cut-off, so it is impossible to check. Check the voltage and c ontinuity using Table 1. According to Results Tables 2 and 3, go to the troubleshooting table in the right column according to the results of the check.

CN75 pins

Lever position 1

1st

2nd

3rd

4th

5 F

6 R

Remedy

power source

Normal actuation table 0 : 0 - OSV (continuous) 0 : 20 - 30V (battery voltage)

82-46

E-8

TROUBLESHOOTING

Table 2 Result of insoection

when ooeratina

F-R lever Cause

Result of inspection l

No battery voltage at all

Problem in transmission

No continuous

(F)

Problem in F circuit

E-8-b

NO continuous

(R)

Problem in R circuit

E-8-C

Continuous

Problem in F and R circuit

E-8-d

at two olaces

Table 3 Result of inspection

when operating

cut-off switch, parking brake, neutral relay circuit

Troubleshooting

go to:

E-8-a

speed lever Cause

Result of inspection l

No battery voltage at all

Problem in power circuit

No continuous

Problem in speed circuit

Continuous or more

Contact in speed circuit

Troubleshooting

go to:

E-8-e

at two places

E-8-f

82-47

E-8

TROUBLESHOOTING

Problem in parking brake, transmission

cut-off switch, neutral relay circuit

2 YES Is problem removed when Short cOnnector 1s connected Instead of tra”SmIssIo” cut-off swtch,

Y ‘ES

2) Is problem removed when transmission cut-off switch is turned OFF?

Connect short cO”“ector to CN21 (female) Turn transmission cut-off switch ON. Start engine.

II Startengine. 3 I NO

Ls problem removed when relay is replaced?

7 YI :S 1 Is there continuitv between CN53 Ci) (female) and chassis?

) Interchange neutralizer relay (CN53) with backup lamp relay (CN54). 2) Start engine.

4 I NC

Is problem removed when relay is replaced?

c 6

YES

1) Interchange parking brake safety relay (CN52) with backup lamp relay (CN54). 2) Start engine.

-ii

1I) !)

Is voltage between CN53 (2) (female) and chassis 20 3ov7

I Disconnect

2) 3)

or socket

(for Econoseall Shot-t Connector

82-48

adapter

4 1)

T-adapter

IDisconnect CN53. Turn starting switch OFF.

Is voltage between CN52 (female) (2). (31, (5) andchassis 20 - 3OV?

CNll. Turn starting switch OFF. Turn Darkina brakk wit& ON/OFF.

Disconnect CN52. Turn starting switch ON. Turn parking brake switch (applied).

E-8

TROUBLESHOOTING

Table

Remedy

.~I

Defective

transmission

cut-of

switch

Realace

After inspection, repair or replace

Defectwe

neutralizer

Defective

parking

relay

YES

9 YES -

Is there continuity between CN52 (1) (female) and chaws,

I Disconnect

YES

barke safet)

Replace

Defective contact or disconnection in wiring harnes between CN53 (5) (female) CN21 (1) (female), CN21 (2) (female) - CN85 (A) (female)

After inspection, repair or replace

Defective contact, or drsconnection in wiring harnes between CN53 (1) (female) an chassis

After inspection, repair or replace

Defective contact, or disconnection in wiring harnes between CNl 1 (1 (female1 CN53 (2) (female)

4fter inspection, zpair or replace

Defective contact. or disconnection in wiring harnes between CN52 I1 (female) chassis

lfter inspection, epair or replace

CN52. switch

relay

If incorrect voltage for (3): Defective contact, or disconnection MI wiring harness between CN52 (3) (female1 - CN6D - fuse If incorrect voltage for (2). (5) Defective contact, or disconnection in wirino

OFF.

Defective

parking

brake switcl

After inspection, repair or replace

Replace

82-49

E-8

TROUBLESHOOTING

Defective continuity

in FORWARD solenoid circuit

YES

2 Y,

Isthere continuity between (female)

CN85 (D) and chassis? I

11 Disconnect 2) 3)

CN85.

Turn starting switch OFF. Place F-R lever in FORWARD. Is problem

YES

removed

Is there continuity between CN246 (5) (female) and chassis? t-

Interchange FORWARD so1eno10 relay lCN246) with REVERSE solenoid relay (~~236). Start engine.

and chassis

20 2) 3)

1) Disconnect 2) 3)

CN85. Turn starting switch ON. Turn parking switch ON OFF.

21 3)

Turn parking y;,ch ON -

Is there continuity between CN 16 (male) (1) and (2)?

Place F-R lever in FORWARD. 1)

Disconnect

Turn starting switch OFF. Place F-R lever in FORWARD.

T-adapter

or socket

(for Econoseal)

82-50

adapter

I Disconnect

2) 31

L NO

Disconnect CN246. Turn starting swtch ON. Turn parkina switch ON L. OFF.

! N

CN246. Turn starting switch OFF. Place F-R lever in FORWARD.

TROUBLESHOOTING

E-8

Cause

7 yES -

Is there continuitV between CN246 (1) (female) and chassis?

1) -

Disconnect CN246. Turn starting switch OFF.

YES

Is there continuity - between CN16 (1) NO (female) and chassis?

I I

1 1) 21

Disconnect CN16. Turn starting switch OFF.

Remedy

Defective

FORWARD

solenoid

Defective relay

FORWARD

solenoid

Ieplace

leplace

Defective contact, or disconnection in wiring harness be;e;e;)CN246 (2) (female) -

\fter inspection. epair or replace

Defective contact, or disconnection in wiring harness betweeen CN246 (1) (female) - chassis

lfter inspection, .epair or replace

Defective contact. or disconnection in wiring harness between CN16 (2) (female) CN246 (5)

Mter inspection, repair or replace

Defective contact, or disconnection in wiring harness between CN16 (1) (female) chassis

After inspection. repair or replace

Defective contact. or disconnection in wiring harness between CN246 (61 (female) CN53 (5)

After inspection, repair or replace

Defective

F-R lever switch

Defective contact. or disconnection in wiring harness between CN85 (A) (female) transmission &-off switch CN53 151

Replace

After inspection. repair or replace

82-51

TROUBLESHOOTING

E-8

Defective continuity

in REVERSE solenoid circuit

YES

2 Is there continuity between CN85 (Cl (female) and chassis?

1) 2) 3)

Disconnect CN85. Turn starting switch OFF. Place F-R lever in REVERSE.

Isproblem

CN85 (A) (female) and chassis 20 -

2) 31

1) Disconnect 2) 3)

CN65. Turn starting switch ON. Turn parking switch ON OFF.

removed

YlES 1

Interchange REVERSE relay (CN236) with FORWARD relay (~~246). start engine. Turnqarking switch ON OFF. Place F-R lever in REVERSE.

Is there contwlty between CN16 (male) (1) and (3) 7

N0 ,

I Disconnect

2) 3)

T-adapter

or socket adapter

(for Econoseal)

82-52

Is voltage between CN236 (6) (female) and chassis 20 3ov7

CN16. Turn starting switch OFF. Place F-R lever in REVERSE.

1) Lhsconnect CN236. Turn startmg swtch OFF. 3) Place F-R lever ,n REVERSE. 21

1 1) 2)

Disconnect CN236. Turn startlng watch ON. Turn parklng switch ON OFF

L NC

TROUBLESHOOTING

E-8

Remedy

Cause

Defective

REVERSE

solenoid

Defective

REVERSE

solenoid

relay

Replace

After inspection, repair or replace

Y After inspection, repair or replace

Turn starting switch OFF. 8

YES

Isthere continuity between (female1 chassis’ 1) 2)

CN16 and

Disconnect CN16. Turn starting switch OFF.

(1)

Defective contact, or disconnection in wiring harnes between CN236 (5) (female) CN16 (3)

After inspection, repair or replace

Defective contact, or disconnection in wiring harnes between CN16 (1) (female) chassis

After inspection, repair or replace

Defective contact, or disconnection in wiring harnes between CN236 16) (female) CN60 (fuse1

After inspection, repair or replace

5 Defective

F-R lever switch

Defective contact, or disconnection in wiring harnes between CN85 (A) (female) transmission cut-off switch CN53 (5)

Replace

After inspection. repair or replace

82-53

E-8

TROUBLESHOOTING

Contact in F-R circuit

Continuous location when there is problem with FORWARD

between CN85 (D) (male) and chassis? Is there continuity between chassis and

3 1) 2)

Disconnect CN85. Turn starting switch OFF.

Is there continuity betweenCN85 (D) (female) and connector body?

IO 1)

Disconnect CN85. Disconnect CN75. Turn starting switch OFF.

2) 3)

4 Is there continuity between CN75 (5) (male) and (1). (2). (3). (4). (6)?

CN85. Disconnect CN75. Turn starting switch OFF.

r Is there continuity between CN16 (2) (male1 and (1). (3). (4). 15). (6). (7). (8)?

positions other than specified where there is continuity, and go

2) 3)

YES

1) Disconnect 2)

Connect T-adapter to CN85. Turn starting switch ON. Turn parking ;OY;tyh ON -

YES

Continuous locatior when there is problem with REVERSE

Is there continuity between CN85 (Cl (male) and chassis? - Is there continuity between chassis and $lD, (FL (G). and

1) 2)

Disconnect CN85. Turn starting switch OFF.

10 Is there continuity betweenCN85 K) (female) and connector body?

_ NO

1) 2) 3)

82-54

YES

Disconnect CN85. Disconnect CN75. Turn starting switch OFF.

ToA

Disconnect FORWARD solenoid relay (CN246). Turn starting switch OFF.

I 1) 2) 3)

Disconnect CN16. F-R leverat Nor R position. Turn starting switch OFF.

TROUBLESHOOTING

Remedy

Cause

Defective insulation between CN85 (01 (male) and connector body, or abnormal contact between chassis ground and wiring harness oi CN85 (0) inside control vakt Defective wiring between pins of CN85

Defective insulation between CN85 (0) (female) and connector body Abnormal contact with wiring harness between CN75 (5) (male) - CN85 (0) (female) and wiring harness between CN75 (1). (2). (3). (4). (6) (male) - CN85 (Cl. (E). (F). (G) (H) (female). Abnormal contact with wiring harness between CN75 (5) (female) - CN246 (2) (female: and chassis or ground connection wiring.

1) Disconnect 2) 3)

CN16. Disconnect CN246. Turn starting switch OFF.

Defective switch

transmission

control

Defective switch

transmission

control

T-adapter

or socket

After inspection, repair or replace

Replace

After inspection, repair or replace

Short circuit between terminals (1) and (2) of FORWARD solenoid relay CN246 (male)

Replace

Defective insulation between CN85 (Cl (male) and connector body. or abnormal contact between chassis ground and wiring harness of CN85 (0) inside control valve Defective wiring between pins of CN85

Defective insulation between CN85 (Cl (female) and connector body

inspection, or replace

Abnormal contact with wiring harness between CN16(2) (female) - CN246 (5) (female an chassis or ground connection wiring.

\fter qair

Mter inspection, spair or replace

Mter inspection, repair or replace

adapter

(for Econoseal)

82-55

TROUBLESHOOTING

E-8

YES

1) 21 3)

Disconnect CN85. Disconnect CN75. Turn starting switch OFF.

1:?

IS there continuity between CN75 (6) (female) and chassis?

YES

21 3)

Disconnect CN75. Disconnect CN16. ;$;is;TEct

solenoid relay CN236. Turn starting switch OFF.

i NO

between CN16 (31 (male) and (1). (2). (4). (51. (6). (7). (8)? Disconnect CN16. F-R lever at N R position Turn starting switch OFF.

YES

1I 2)

Disconnect CN16. Turn startino switch OFF. 1) 2) 3)

82-56

Disconnect CN16 Disconnect CN236. Turn starting switch OFF.

E-8

TROUBLESHOOTING

Cause

Remedy

Abnormal contact with wiring harness between CN75 (6) (male) - CN85 (C) (female) ar winng harness between CN75 (1). (2). (3). (4). (5) (male) CN85 (D). (El, (F). (Gl, IHI (female).

After inspection, repair or replace

Abnormal contact with wiring harness beween CN75 (6) (female) - CN236 (2) (female) and chassis or ground connection wring.

After inspection, repair or replace

Defective switch

transmission

control

Replace

Defectwe switch

transmission

control

Reolace

Abnormal contact with wiring harness between CN16 (3) (female) - CN236 (5) (female) and chassis or ground connection wiring.

After inspection, repair or replace

Short circuit between terminals (1) and (2) of REVERSE solenoid relay CN236 (male)

Replace

82-57

TROUBLESHOOTING

E-8

Problem in speed solenoid

circuit YES

3 Is there continuity between CN85 (H) (female) and chassis?

1st

p 1) 2) 3)

Disconnect CN85. Place speed lever in 1 st. Turn starting switch OFF.

YES _

Is there continuity between CN16 (4) (male) and CN16 (8)?

1) 2)

Disconnect CN16. Turn starting switch OFF.

YES

5 ES

Is there continuity between CN85 (G) (female) and chassis?

!nd

So to problem speed range L

1) 2) 3) 4)

ToA

Connect T-adapter (socket adapter) to CN16 (female). Turn starting switch OFF.

1) Disconnect

CN85. Turn starting switch ON. Turn parking switch ON OFF.

NC 1

T-adapter d,P E ‘= a as5 cc

82-58

or socket

(for Econoseal)

adapter

I-

Is problem removed when relay is replaced?

1) Interchange 2nd solenoid relay ICN237l with backup iamp relay (CN54). 2) Start engine. 3) Turn parking switch ON - OFF.

_ NO 1) Interchange 2nd. 1 st selector relay (CN239) with back-up lamp relay (CN54). 2) Start engine. 3) Turn parking switch ON - OFF.

CN85 (8) (female) and chassis 20 -

Disconnect CN85. Place speed lever in 2nd. Turn starting switch ON. Turn parking switch ON OFF.

TROUBLESHOOTING

Remedy

Ccyse

__ __q

Defective

1 st solenoid

Defectwe contact, or disconnection in wirina harness between CN85 (H) (f&ale) CN75 (1) - CN16 (4)

Defective

speed lever switch

Defective

2nd solenoid

Defective

2nd solenoid

Defective

Znd-1 st selector

After inspection, repair or replace

relay

Defective contact, or disconnection in wirtng harness between CN237 (5) (female) CN85 (G)

After inspection, repair or replace

YES

Dlsco”“ect CN237.

-1 1) 1) 2) 3)

Disconnect CN237. Turn starting switch OFF Place speed lever i” 2nd.

12 YES

ISthere continuity - betweenCN16 (5) (male) and CN16 (817

Disconnect CN239. Turn starting swrtch OFF.

Defective contact. or disconnection in wiring harness between CN237 (2) Ifemale) -

After inspection. repair or replace

Defective contact, or disconnection in wring harness between CN237 (3) (female) CN239 (6)

After inspection. repair or replace

Defective contact, or disconnection in wiring harness between CN239 (3) (female) chassis

After inspection, repair or replace

Defective contact, or disconnection in wiring harness between CN237 (1) (female) CN16 (5)

After inspection, repair or replace

Defective contact, or disconnection in wiring harness between CN16 (8) (female) chassis ground

After inspection, repair or replace

1) Disconnect 2) 3)

NO CN16. Turn starting switch OFF. Place speed lever in 2nd

Defective contact. 01 disconnection in wirtng harness between CN85 (B) (female) - CN75 (7) - CN295 (8) -fuse - CN295 171main breaker

After inspection. repair or replace

82-59

TROUBLESHOOTING

E-8

Cause

YES

Defective

13 Is there continuity between CN85 (F) (female) and chassis?

3rd

14 YES

1) Disconnect

2) 3)

CN85. Place speed lever in 3rd. Turn starting switch OFF.

Is there continuitv batweenCN16 (6) and CN16 (8)?

_ NO

1) 2) 3)

Disconnect CN16. Turn starting switch OFF. Place speed lever I” 3rd.

1) Disconnect 2) 3)

82-60

CN16. Turn starting switch OFF. Place speed lever I” 4th.

Defective contact. Or disconnection in wiring harness be~&y-1~CN85 IF) (female) -

After inspection. repair or replace

Defective

speed lever switch

Replace

Defective

4th solenoid

YES

Turn starting switch OFF.

Replace

3rd solenoid

Remedy

Defectwe contact, or disconnection in wiring harness between CN85 (El (female) ant CN16 17).

After inspection, repair or replace

Defective

Replace

speed lever switch

TROUBLESHOOTING

E-8

MEMORANDA

82-61

E-8

TROUBLESHOOTING

Contact in speed circuit

YES

Is there continuity between CN85 (HI (male) and chassis? Is there continuity between W - (G)

Turn starting switch OFF.

YES

1) 2) 3)

Check for lever positions other than

Disconnect CN85.. Disconnect CN75. Turn starting switch OFF.

Is there continuity

1) 2)

Disconnect CN85. Disconnect CN75. Turn starting switch OFF.

YES

Is there continuity YES r1)

2) 3)

connect T-adapter to CN85. Turn starting switch ON. Turn parking switch ON OFF.

2) 31

Disconnect CN75. Disconnect CN16. Turn starting switch OFF.

NO 4-l

Is there continuity between CN75 (11 (female) and (2). (3). (4). (5). (6)? 1) 2)

Disconnect CN75. E;isFnect L NO

I ToA

T-adapter

or socket adapter

(for Econoseal)

82-62

Turn starting switch OFF.

TROUBLESHOOTING

E-8 Remedy

Cause

Defective insulatoin b&veer CN85 (H) and connector body, or abnormal Contact between chassis ground and wiring harness of CN85 (H) inside control valve Defective wiring between pins of CN85

Defective insulation between CN85 (H) (female) and connector body

After inspection. repair or replace

Abnormal contact with wiring harness between CN75 (1) (male) - CN85 (H) (female) and wiring harness between C~75 (2) - (6) (male) CN85 (Cl - (G) (female)

After inspection, repair or replace

Abnormal contact with wring harness between CN75 (1) (female) - CN16 (4) (female) - CN239 (5) (female) and_ chassis wiring harness

After inspection. repair or replace

Abnormal contact with Wiring harness between CN75 (1) (female) - CN16 (4) (female) - CN239 (5) (female) and wiring harness of line betwear CN75

between (female)

1) 2) 3) 4)

CN16 (41 and CNl6

Disconnect CN85. Disconnect CN75. Disconnect CN16. Turn starting switch OFF.

(2) -

Is there continuity between CN16 (41 (male) and (1 I. (2). (3). (5). (6). (7). (8)? 1) 21 3)

YES

Disconnect CN16. Place speed lever h in 2nd. Turn starting switch OFF.

Defective switch

transmission

control

Defective switch

transmission

Control

Defective

2nd-1 st select01

relay

Disconnect 2nd-1st selector relay CN239.

After inspection. repair or replace

(61

Abnormal contact with wiring harness of CN16 (4) (female) and wiring harness of CN16 (5) (female).

YES

&fter inspection. repair or replace

Abnormal contact with wiring harness of CN239 (5) (female) and wiring harness of CN239 (3) (female).

After inspection, repair or replace

Replace

&fter inspection, repair or replace

82-63

TROUBLESHOOTING

E-8

YES

2nd

Isthere continuity between CN85 (G) (male) and chassis. _ Is there continuity between IC). (D). (EL (F), (H) and chassis?

1) 2)

Disconnect CN85. Turn starting switch OFF.

YES

12 Is there continuity between CN85 (G) (female) and connector body?

YES

1) Disconnect 2) 3)

CN85. Disconnect CN75. Turn starting switch OFF.

Is there continuity between CN75 (2) (male) and (1). (3).

1) 21 3) To I3

Disconnect CN85. Disconnect CN75. Turn starting switch OFF.

YES

Is there continuit-j between CN75 (2) (female) and chassis?

YES

4 1) 2) 3)

Disconnect CN75. Disconnect Cyl6. Turn starting switch OFF.

1 NO

between CN75 (2) (female) and (1). (3). (4). (5). (6)? 1) 2) 3) 4)

82-64

Disconnect CN75. Disconnect CN16. Disconnect CN237. Turn starting switch OFF.

L NO

TROUBLESHOOTING

E-8

Cause

Remedy

B Defective insulation betweet CN85 (G) and connector body, or abnormal COntaCt between chassis ground ant wiring harness of CN85 (G) inside control valve Defective wiring between pins of CN85 (male)

After inspection. repair or replace

Defective insulation between CN85 (G) (female) and connector body

After inspection. repair or replace

Abnormal contact with wiring harness between CN75 (2) (male) - CN85 (G) (female) and wiring harness between

After inspection. repair or replace

CN75 (1). (3). (4). (5). (6) (male) - CN85 (C), (D). (E). (F). (H) Abnormal contact with wiring harness between CN75 (2) (female) - CN237 (5) (female and chassis or ground connection wiring Abnormal contact with wiring harness of line between CN75 (2) (female) and wiring hames of line between CN75 (1). (3). (4).

YES

After inspection. repair or replace

(5). (6) (female)

Defective

2nd solenoid

relay

Abnormal contact with wiring harness of CN237 (3) (male) and wiring harnessof CN237

between (3) - (5) of 2nd solenoid relay CN237 (male)?

After inspection, repair or replace

Replace

After inspection, repair or replace

(5) (male)

Isthere continuity

Disconnect CN237. P

YES

between (3) - (5) of 2nd solenoid relay CN237 (male)? 1) 2) 3)

Disconnect CN237. Lxs;y,nect turn skting switch OFF.

Is there continuity between CN16 (5) (male) and (1). (2). (3). (4). (6). (7). (8)? 1) 2) 3)

Disconnect CN16. Place speed lever in 1 st or 2nd. Turn starting switch OFF.

Defective switch

transmission

control

Reolace

Defective switch

transmission

control

Replace

Is there continuity between CN16 15) (male) and chassis?

1) 2)

Disconnect CN16. Turn starting switch OFF.

Abnormal contact with wiring harness between CN237 (1) (male) - CN242 15) (male) CN16 (5) (male) and chassis 01 ground connection wiring

After inspection. repair or replace

82-65

TROUBLESHOOTING

3rd

Is there continuity between CN85 (F) (male) and chassis? Is there continuity between chassis and 0. (D). (El. (G). and (H) ? 1) 2)

Disconnect CN85. Turn starting switch OFF.

between connector

CN85

(F)

body?

Disconnect CN85.

Turnstarting switch OFF.

22 I

h YES

0’1 1) 2)

Disconnect CN85. FIi;ynect P

Turn starting switch OFF.

1) Disconnect 2)

4th

25 I

Is there continuity between CN85 (E) (male) and chassis? Is there continuity between chassis am

1) 2) 3)

Disconnect CN85. Disconnect CN75. Turnstarting switch OFF.

h YES 1) 2)

Disconnect CN85. EXs;pnect

281

r 3)

82-66

Turn starting switch OFF.

CN16. Turn starting switch OFF.

TROUBLESHOOTING

E-8 Remedy

Cause

: l

Defective insulation betwee CN85 IF) (male) and connector body, orabnormz contact between chassis ground and wiring harness c CN85 (F) inside control valv Defective wiring between Dins of CN85 (male)

After inspection, repair or replace

Defective insulation between CN85 (F) (female) and connector body

After inspection. repair or replace

4bnormal contact with wiring narness between CN75 (3) (male) - CN85 IF) (female) ar Niring harness between CN75 Ill, (2), (41, 15). (6) (male) 3N85 (C). (01, (n,(G). (HI [female)

After inspection, repair or replace

Defective switch

transmission

contra

Defective switch

transmission

contra

Abnormal contact with wiring harness between CN16 (6) (female) - CN75 (3) (female) and chassis orground connection wiring.

Defective insulation betwee CN85 (E) (male) and connector body, or abnormi contact between chassis ground and wiring harness c CN85 (El inside control valv

Reolace

After inspection, repair or replace

Defective insulation between CN85 (El (female) and connector body

After inspection, repair or replace

Abnormal contact with wiring larness between CN75 (4) male) - CN85 (El (female) an king harness between CN75 1). (2). (3). (5). (6) (male) :N85 (C), ID), (F), (G). (HI female)

After inspection, repair or replace

Iefective witch

transmission

control

Iefective witch

transmission

control

ibnormal contact with wiring larness between CN16 (7) female) - CN75 (4) (female) lnd chassis or ground :onnection wiring

tfter inspection, epair or replace

82-67

E-9

TROUBLESHOOTING

TROUBLESHOOTING + * +

CHART No. E-9

KICK-DOWN SWITCH DOES NOT WORK (NORMAL Fl - F4 SWITCHES CORRECTLY) When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents. When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN 0 A()) When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check.

Failure mode:

E-9

Is problem removed when relay is replaced?

I1 Interchange kick-down relay (CN242j with REVERSE solenoidrelay KN236). 2) Start engine.

Is problem removed when relay is I

1) lnterchanae FORWARE solenoidrelay (~~246) with REVERSE solenoidrelay (CN236). 2) Start engine.

Is problem removed I\ YES

1) Disconnect CN243. 2) Press kick-down switch. 3) Turn starting switch OFF.

1) Interchange 2nd1st selector relay (CN239) with back-up lamp relay (CN54). 2) Start engine.

1) Disconnect CN239. 2) Turn starting switch OFF.

82-68

1) Disconnect CN239. 2) Turn starting switch OFF. 3) Place speed lever in 1st.

, NO

TROUBLESHOOTING

Remedy

Cause

Defective

kick-down

relay

Replace

Defective relay

FORWARD

solenoid

Replace

/ p;ctive

9 YES -

Is there continuity between CN242 (5) (female) and chassis?

YES 7

Is there continuity between CN239 (2) (female) and CN242 (3) (female)? 1)

Disconnect CN239 and CN242. Turn starting switch OFF.

Is there continuity between CN242 (2). (4) (female) and CN53 (5) (female)?

1) Disconnect 2)

CN242 and CN53. Turn starting switch OFF.

1) Disconnect 2) 3) NO

Rep,ace

YES a

Znd-1 st selector

ToA

CN242. Turn starting switch OFF. Place speed lever in 2nd.

Defective contact, or disconnection in wiring harness between CN242 (5) (female) and CN16 (5) (female).

After inspection, repair or replace

Defective contact, or disconnection in wiring harness between CN242 (2). (4) (female) - CN53 (5) (female).

After inspection, repair or replace

Defective contact, or disconnection in wiring harness bewteen CN239 (2) (female) CN242 (3) (female).

After inspection, repair or replace

After inspection. repair or replace

Defective contact, or disconnection in wiring harness between CN239 (1) (female) chassis.

- Defective

kick-down

switch

After inspection. repair or replace

Replace

82-69

TROUBLESHOOTING

E-9

YEE

12 r

Is there continuity between CN246 14) (female) - CN242 (1) (female)?

I 1)

82-70

Disconnect CN242 and CN246. Turn starting switch OFF.

Remedy

Defective contact, or disconnection in wiring harness between CN243 (2) (female) CN53 (5) (female).

After inspection. repair or replace

Is there continuity between CN242 (1) (female) - CN243 (1) (female)?

Cause

Defective

Disconnect CN242 and CN246. Turn starting switch OFF

contact,

in wiring harness L disconnection between CN242 (1) (female) -

CN243

After inspection, repair or replace

(1) (female).

Defective contact, or disconnection in wiring harness between CN246 (4) (female) CN242 (1) (female).

After inspection. repair or replace

Defective contact, or disconnection in wiring harness between CN242 (6) (female) CN246 (3) (female).

After inspection, repair or replace

TROUBLESHOOTING

E-10

TROUBLESHOOTING Failure mode: t it it

CHART No. E-l 0

E-10

KICK-DOWN ONLY WORKS WHEN KICK-DOWN SWITCH IS ON (KICK-DOWN SWITCH RELAY DOES NOT CARRY OUT SELF-HOLD OPERATION) When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents. When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN o A()) When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check.

I YES

Defective kick-down relay

1 IS problem removed when relay is replaced?

2 YES

1) Interchange

kick-down switch relay (CN242) with REVERSE solenoid relay (~~236). 2) Start engine.

Is there continuity between CN242 I21 (female) and CN53 (5)’ 1) Disconnect CN242 and CN53. 2) Turn starting switch OFF.

Cause

Remedy

F+lWX

Defective contact, or disconnectionin wiring harness After inspection, between CN242 (2) Ifemale) repair or replace CN53 15). Defective contact, or disconnectionin wiring harness between CN7.42 (1) (female) CN243 (1) (female).

After inspection, repair or replace

82-71

E-11

TROUBLESHOOTING

CHART No. E-l 1

KICK-DOWN OPERATION IS NOT CANCELED Failure mode: E-l 1 + When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents. + When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN 0 A()) + When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check. ES

1 Is problem removed when relay is replaced?

Kick-down is not canceled even when F-R lever is moved from F to N or R.

t 1)

Interchange Znd-1 st selector relay (CN239) with back-uo lamp relay (CN54). Start engine.

YES

, Is problem removed when relay is replaced?

-k----1)

1) Disconnect 2)

CN239. Turn starting switch OFF.

Go to problem

location

Kick-down is not canceled even when parking brake is applied.

Interchange FORWARD solenoid relay (CN246) with REVERSE solenoid relay (~~236). Start engine.

YE 4

Does parking work?

brake

I Interchange Znd-1st selector relay (CN239) with back-up lamp relay (CN54). 2) Stan engine.

YES

Kick-down is not canceled even when speed lever is moved from 2nd to other speed range.

Is problem

removed YES

7 1)

Interchange kick-down relay (CN242) wth REVERSE solenoid relay (CN2361. Start engine.

IS there continuity between CN242 (female) (3) and (4)7

iy 1)

2) 31

T-adapter or

socket adapter

(for Econoseal)

82-72

Disconnect CN242. Turn starting switch OFF. Place F-R lever in NEUTRAL.

TROUBLESHOOTING

E-11

Cause

Defective

Remedy

2nd-1 St SeleCtOr

relay

Replace

Contact with wiring harness between CN239 (female) (3) and (5). or contact with wiring harness between CN239 15) (female) and chassis

After inspection, repair or replace

Defective rea ly

FORWARD

solenoid

Replace

Defective

neutralizer

relay

/ ;;tect w!th wing harness between CN72.(female) (3) and

( Replace

“,~~~~~~~~~e

For details, see Troubleshooting “Parking brake does not work”

/ Dectwe

8 -

Is there continuity betweenCN242 (female) (1) and (2)?

1) 2)

Disconnect CN242. Turn starting switch OFF.

YES

kick-down

switch

Contact with wiring harness between CN242 (female) (1) and (2)

Replace

After inspection, repair or replace

Contact with wiring harness between CN242 (female1 (1) NO

and (4)

After inspection, repair or replace

82-73

TROUBLESHOOTING

E-12. E-13

TROUBLESHOOTING

CHART No. E-12

Failure mode: E-12 KICK-DOWN WORKS BY MISTAKE WHEN TRAVELING IN F2 t When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents. + When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN o A()) * When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check.

1 Isthere continuity between (1) and (2) of kick-down relay CN242 (male), and between (3) and (4)? 1) Disconnect kick-down relay CN242. 2) turn starting switch OFF.

YES

2 Is problem removed when relay is replaced?

Interchange Pnd-1st selector relay (CN239) with back-up lamp relay (CN54). Start engine.

YES

3 _ NO

Is there continuity betweenCN243 (1) (male) and CN243 (2))

YES 4

1) Disconnect 2) 3)

CN243. Turn starting switch OFF. Do not press kick-down switch.

Is there continuity between CN243 (1) [f$yle) and CN243

I 1) 2)

Disconnect CN243. Turn starting switch OFF.

‘1 NO

[feyle)

and CN242

I 1 1 Disconnect CN242. 2) Turn starting swtich OFF. 3) Place F-R lever in NEUTRAL.

TROUBLESHOOTING Failure mode:

E-13 1

Is problem removed when relay is replaced?

1) Interchange 2nd. 1st selector relay (CN239) with back-up lamp relay (CN54). 2) Start engine. 3) Place speed lever in 2nd. 4) Place F-R lever in FORWARD.

82-74

CHART No. E-13

MACHINE

YES

DOES NOT TRAVEL WHEN KICK-DOWN

SWITCH IS PRESSED

E-12, E-13

TROUBLESHOOTING

Remedy

Cause

Defective

kick-down

relay

Defective

2nd-1 st selector

relay

Defective

kick-down

switch

Contact with wiring harness between CN243 (female) (1) and (2)

Contact

with wiring harness (female) (1)

between CN242 and (2)

Contact with wiring harness between CN242 (female) (3) and ‘(4)

Defective

2nd-1 st selector

relay

Defective contact, or disconnection in wiring harness between CN85 (H) - CN23g (5) (female)

ReplaCe

Replace

After inspection, repair or replace

Afterinspection, repair or replace

Replace

Afterinspection, repair or replace

82-75

TROUBLESHOOTING

MEMORANDA

82-76

E-12, E-13

TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM

82-77

TROUBLESHOOTING

POSITION

POSITION OF CONNECTORS TROUBLESHOOTING

FOR

COMBINATION SWITCH DIMMER SWITCH

ARTING SWITCH

L08CD12i

BAlTERY

RELAY

7 L08CD12Z

CNPl .I 16 Dins

82-78

OF CONNECTORS

TROUBLESHOOTING

POSITION OF CONNECTORS

CNP2 DLI 8 Dins

1 CNPZ

CNPl

CNP4

CNPS

L08CD1621

CNP3 (CHECK module) DLI 16 pins

CNP4 (CHECK DLI 12 pins I

module)

L08CD164

82-79

TROUBLESHOOTING

CNP5 .I 8 pins

CNPZ

POSITION

OF CONNECTORS

CNPl

CNP4

CNPS

lI!E! 0

oee maoa

0000

000

5’/’

L08CD16

CNP6 MIC 5 Dins

CN12 (Working lamp switch)

N-SLC connector

2 pins

Parking

\ CN17

82-80

brake

switch

POSITION

TROUBLESHOOTING

CN15 (Lamp switch) ECONOSEAL connector

OF CONNECTORS

12 pins

CN17 (Warning lamp) N-SLC connector 2 pins

Transmission

L08CD120

cut-off

CNl8 (Transmission cut-off selector switch) N-SLC connector 4 pins

L08CD16

CN22 (Intermediate connector) ECONOSEAL connector 4 pins

Kzl

L08CD161

. --

CN14il.CN317

82-81

TROUBLESHOOTING

CN25 (Diode) CN26 (Diode) N-SLC connector

POSITION OF CONNECTORS

2 pins

LO8CD120

CN36 (Parking brake display switch) E,CONOSEAL connector 2 pins

Parking display

brake switch

CN35

63 WI : R 11 [D

2 Paiking solenoid

LOSCD115

brake valve

LO8CD145

CN38 (Intermediate connector) :ONOSEAL connector 4 Dins

Ka / i

[Ii

‘CN64

‘1 1

CN38

Lo8CD15

” CN39 (Intermediate connector) ECONOSEAL connector 12 Dins

L08CD17

82-82

CNlr M.CN317

LOBCO140

POSITION OF CONNECTORS

TROUBLESHOOTING

CN40 (Intermediate connector) I SLC‘connector 6 pins

LOSCD161

CN48 (Auto-preheating timer) N-SLC connector 3 pins

I5a 3

2 LOSCD17t

CN60 (Fuse box l-2) ZONOSEAL connector

12 Dins

13 LOSCD17

\N’

LO8CO141

82-83

TROUBLESHOOTING

POSITION

CN62 (Intermediate connector) CN63 (Intermediate connector) CN64 (Intermediate connectorj EC:ONbSEAL connector 12 pi&

L08CD16ei

CN83 (Speedometer sensor) CN84 (Torque converter oil temperature CN86 (Brake oil level sensor) ECONOSEAL connector 2 pins

82-84

sensor)

OF CONNECTORS

POSITION OF CONNECTORS

TROUBLESHOOTING

CN87 (Brake chamber stroke sensor) CN88 (Brake chamber stroke sensor) ECONOSEAL connector 2 pins

LOBCDll

CN91 (Intermediate connector) ECONOSEAL connector 8 pins

L08CD1741

CN92 (Air pressure sensor) ECONOSEAL connector 2 Dins

L08CDll

LO8CD14.9

82-85

POSITION

TROUBLESHOOTING

CN96 (Engine oil level sensor) ECONOSEAL connector 1 pin

Engine oil level se

L08CD17:

CN97 (Intermediate connector) ECONOSEAL connector 12 pins

LOBCD17

CNlOl (Engine coolant temperature ECONOSEAL connector 2 oins

sensor)

L08CDll5

CNl30 (Caution buzzer) Clr5131 (Caution buzzed

CNl

L08CD173

82-86

OF CONNECTORS

POSITION

TROUBLESHOOTING

OF CONNECTORS

CN153 (Transmission oil filter clogged sensor) ECONOSEAL connector 2 Dins

CNlS

LOICDll!

I CN163 (Engine oil pressor sensor) CONNECOTR

B--

L08CD17

CN266 (Fuel level sensor) CN278 (Radiator water level sensor ECONdsEAL connector 2 pins

L08CDll!

LOBCD152

? Radiator water level sensor

82-87

TROUBLESHOOTING

CN295 (Fuse box H-2) ECONOSEAL connecotr

POSITION OF CONNECTORS

12 Dins

LOSCD17

CN334 (Caution lamp relay) CN336 (Engine oil pressure relay) RELAY connecotr 5 pins 2

CN50

CN52

CN53

CN334 [Caution

lam0 relavl

CN49 Warning buzzer CN55, CN236

CN54 L08CDH7

82-88

’

CN246

CNi42

d239

CN237

LO8CO153

TROUBLESHOOTING

M-l

TROUBLESHOOTING

CHART No. M-l

Failure mode: M-l (BRAKE OIL LEVEL) FLASHES WHEN ENGINE IS STOPPED * When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents. * When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN o A()) t When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check. Cause

YES

3efective

Is there continuity between CNP3 (female) (1) and chassis ground? between

Is there continuity between CN86 (male) (1) and (2)? 1

1) Connect Tadapter (socket adapter) to CN86 (male) (brake oil level sensor 1). 2) Turn starting switch OFF.

M-l

CN86

1) connect Tadapter (socket adapter) to CN86 (female), 2) Turn starting switch OFF.

monitor

Remedy

panel

qeplace

Defective contact, or disconnection in wring harness between CNP3 (female) (1) CN64 (11) CN91 (6) - CN86 (1).

&fter inspection, repair (clean) or replace

Defective contact, or disconnection in wiring harness between CN86 [female) (2) - CN91 (5) chassis ground.

After inspectlon. repair (clean) or replace

Defective brake oil level sensor

qeplace

I No

Related electrical circuit drawing

CNP 3 Monitor

CN64

CN91

CN 86 m-l

Brake 011 level sensor 1

panel

425F511

82-89

M-2

TROUBLESHOOTING

CHART No. M-2

Failure mode: M-2 (ENGINE OIL LEVEL) FLASHES WHEN ENGINE IS STOPPED + When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents. + When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN o A()) t When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check. Remedy

Cause

YES

+I 2)

1) Connect CN96 lenaine oil l&l

engine oil level sense

Replace

Defective

monitor

Replace

panel

Defective contact, or disconnection in wiring harness between CN96 (female) - CN97 (5) - CN62 (1) - CNP3 (female) (2).

chassis ground. Turn starting switch ON.

Defective

se”;or).

2) Connect T-adapter to CNP3 (female). 3) Turn starting switch OFF. T-adapter Trouble-

or socket adapter

T-adapter

(for EconoseaU

(for DLI)

shooting tools I

M-2

Short connector

Related electrical

circuit drawing

CNP3

CN62

CN 97

CN 96

425F512

After inspection. repair (clean) or

M-3, M-4

TROUBLESHOOTING

CHART No. M-3

(RADIATOR WATER LEVEL) FLASHES WHEN ENGINE IS STOPPED Failure mode: M-3 + When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents. + When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN o A()) When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after + checking, then go to the next check. Cause Remedy

YES

Defective

radaator water

level

Z”SOr

YES

YE 2

1) Connect short

connector to CN278 (female) (radiator

water levelsensor).

11 Connect Tadapter (socket adapter) to CN278 (female) 2) Turn startmg switch OFF.

TROUBLESHOOTING

Iefective

monitor

panel

Defective contact, or disconnection in wiring harness between CN278 [female) (1) CN326 (1) CN62 (2) - CNP3 (female).

l-l

1) Connect short connector to CN278 (female). 2) Connect T-adapter to CNP3 (female). 3) Turn starting switch OFF.

Is there contmuity between CN278 (female) (2)

2) Turn starting switch ON.

IS there continuity between CNP3 (female) (3) and chassis ground’

FSDlXi3

Defective contact, or disconnection in wiring harness between CN278 Ifemale) (2) - CN326 (2) chassis ground.

After inspection, repair (clean) or replace

CHART NO. M-4

(BATTERY CHARGE) FLASHES WHEN ENGINE IS RUNNING Failure mode: M-4 If light flashes when the engine is stopped, go to M-8. Engine oil pressure abnormal. Note:

2 Is voltage between CNP4 (female) (51 and chassis ground normal’

Is voltage alternator normal’

1) of terminal

R 2)

1) Turn starting

switch ON. Measure voltage between alternator terminal Rand chassis ground. Is reading 20 3OV?

Troubk-

Connect T-adapter to CNP4 (female) Turn starting switch ON. (Start engine.1 Is reading 20 3ov7

YES Defective

panel

Replace

_ Defective contact, or disconnection in wiring harness between alternator terminal R - CN97 (1) CN64 (1) CNP4 (5).

Defective

T-adapter or socket adapter (for Econoseal)

monitor

T-adapter

After inspection. repair (clean) or repb3?

alternator

(for DLI)

shooting tools

Short connector

82-91

M-3, M-4

TROUBLESHOOTING

M-3

Related electrical circuit drawing

CN278

CN326

CN62

CNP3

Radiator water level sensor

Monitor panel

425FO1363

M-4

Related electrical circuit drawing

CNP4

CN 64

CN 97

Monitor panel

425F514

82-92

TROUBLESHOOTING

M-5

TROUBLESHOOTING

CHART No. M-5

Failure mode: M-5 (TRANSMISSION OIL FILTER CLOGGING) FLASHES WHEN ENGINE IS RUNNING * When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents. * When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN o A()) + When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check. Cause

YFS

Defective transmission filter clogging sensor

1 Doesmgoo”v

3 -

1) Connect short connector to CN153 (female) (transmission oil filter clogging

Is there continuity between CNP3 (female)(lO) and chassis ground?

YES

Defective

SWlSCN)

Is there continuity between CN153 (female) (2) and chassis ground?

1) Connect short connector to CN153 (female). 2) Connect Tadapter to CNP3 (female). 3) Turn starting switch OFF.

1) Connect Tadapter (socket adapter) to CN153 (female). 2) Turn starting switch OFF.

monitor

oil

Replace

panel

Defective contact, or disconnection in wiring harness between CN153 (female) II) - CN91 I1 iZN64 (i)‘CNP3 (female)

2-p

2) Turn starting switch ON.

M-5

YES -

Remedy

After inspection, repair (clean) or replace

(101.

Defective contact, or disconnection in wiring harness between CN153 (female) (2) - CN91 (2) chassis ground.

After inspection, repair (clean) or replace

Related electrical drawing

CN64

CNP3

CNl53

CN91

Monitor panel

Transmission filter clogging sensor

425FO1364

T-adapter

Trouble-

or socket adapter

(for Econoseal)

T-adapter

(for DLI)

shooting to&

Short connector

82-93

TROUBLESHOOTING

M-6, M-7

TROUBLESHOOTING

CHART No. M-6

Failure mode: M-6 (FUEL LEVEL) FLASHES WHEN ENGINE IS RUNNING it When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents. * When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN o A()) + When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check. Remedy

Cause

1 Does fuel 9auge display EMPTY?

YES

in fuel

Defective

1) Turn starting swtch

See M-29 (Abnormality level gauge)

monitor

panel

?eplace

ON.

TROUBLESHOOTING

CHART No. M-7

Failure mode: M-7 (BRAKE LINE FAILURE) FLASHES WHEN ENGINE IS RUNNING + Check that there is no abnormality with the chassis.

YES

between

CN87

1 2) Is there continuity

1) Connect Tadapter (socket adapter) to each sensor (male). 2) Turn starting switch OFF. 3) Connector numbers are CN87 and 88.

82-94

1) Connect Tadapter (socket adapter) to CN87 (female). 2) Turn starting switch OFF.

monitor

panel

2 YE

Defective

T-adapter to CNP3 (female) Turn starting switch OFF.

Defective contact, or disconnection in wiring harness between CN87 (female) (1) - CN91 (8) CN64 (12) - CNP3 (female)

After inspection, repair (clean) or replace

(4). Defective contact. or disconnection in wiring harness between CN87 (female) (2) - CN88 (female) (1). or CN88 (female) (2) CN91 (5) - chassis ground

After inspection, repair (clean) or reolace

Non-continuous defective

Replace

sensor is

TROUBLESHOOTING

M-6

M-6, M-7

Related electrical circuit drawing

CNP4

CN64

CN 266

Monitor panel Fuel level sensor

425F516

M-7

Related electrical

circuit drawing

CN87

CNP3 Monitor panel

CN 64

CNSI

Brake stroke sensor

425F517

82-95

TROUBLESHOOTING

M-8, M-9

TROUBLESHOOTING

CHART No. M-8

Failure mode: M-8 (ENGINE OIL PRESSURE) FLASHES WHEN ENGINE IS RUNNING + When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents. t When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN o A()) + When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check. r

3 Is there continuity between CNP3 (female) (9) and chassis ground?

YES

2 1) Disconnect CN163. 2) Turn starting switch ON. 3) Start engine.

jNO

Is voltage between CN163 (C) and chassis normal?

1) Turn starting switch ON. (Start engine.) 2) Is reading 20 - 3OV?

Note)

If m

flashes

when engine

TROUBLESHOOTING Failure mode:

M-9

Defective sensor.

engine

oil pressure

Defective

monitor

panel.

Defective contact, or disconnection in wiring harness between chassis ground - CN289 (3), (6) CNP3 (female) (9), or defective engine oil pressure sensor relay. Contact between chassis ground and wiring harness between CN163 (C) - CN97 (8) - CN64 (6) - CN289 (2).

is stopped,

Remedy

YES

1) Connect T-adapter to CNP3 (female). 2) Turn starting

Cause

Replace

After inspection, repair (clean) or replace

Go to M-23 (Engine oil pressure or battery charge flashes when engine is stopped.)

is defective.

CHART No. M-9

(RADIATOR

WATER LEVEL) FLASHES

WHEN ENGINE IS RUNNING

Remedy

Cause

Defective

radiator water level

Replace

monitor

Replace

S”SOC.

1 Defective Does

go out?

I 1) Connect short connector to radiator water level Sensor CN278 (female). 2) Turn starting switch ON. 3) Start engine.

Troubleshooting tools

82-96

panel.

NC?

Is there continuity between CN278 (female) (2) and chassis ground?

1) Connect T-adaoter (or sock& adapter) to CN278 (female). 2) Turn starting switch OFF.

T-adapter or socket adapter (for Econoseal) Short connector

I I

I 1) Connect short connector to CN278 (female). 2) Connect T-adapter to CNP3 (female). 3) Turn staiing switch OFF.

Defective contact, or disconnection in wiring harness between CN278 (female) (2) CN326 (2) chassis ground.

T-adapter

Defective contact, or disconnection in wiring harness between CN278 (female) (1) - CN326 (1) CN62 (2) - CNP3 (female) (3).

After inspection, repair (clean) or replace

After inspection, repair (clean) or

(for DLI)

L08DD148

TROUBLESHOOTING

M-8

M-8, M-9

Related electrical circuit drawing

Engine oil pressure

Monitor panel

relay

+24V

Service meter

LOSDD149

M-9

Related electrical circuit drawing

CNP3

CN62

CN326

CN278

Radiator water level sensor

425FOl 365

82-97

TROUBLESHOOTING

M-10, M-11, M-12

TROUBLESHOOTING

CHART No. M-l 0

Failure mode: M-10 (DROP IN AIR PRESSURE) FLASHES WHEN ENGINE IS RUNNING + When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents. * When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN o A()) + When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go co the next check. Cause Remedy

1 Is air pressure gauge vilthrn red level’

YES

See M-30 (Abnormality pressure gauge)

Defective 1) Turn startmg swtch ON

momtor

panel

kpl.Xe

TROUBLESHOOTING Failure mode:

in air

M-11

CHART No. M-l 1

(ENGINE WATER TEMPERATURE)

FLASHES WHEN ENGINE IS RUNNING

See M-31

(Abnormality

1 engine water temperature

YES

gauge) Is engine water temperature gauge wlthm red level’

TROUBLESHOOTING Failure mode:

Defective

monitor

ReplaCe

panel

Turn startmg switch ON

M-12

CHART No. M-12

(TORQUE CONVERTER

OIL TEMPERATURE)

FLASHES WHEN ENGINE IS RUNNING

See M-32 (Abnormality torque converter oil temperature gauge)

YES

Is torque converter 011 temperature gauge within red level? Defective 1!

Turn starting switch ON.

I Trouble-

82-98

T-adapter

(for DLI) I

monitor

panel

ReplaCG?

TROUBLESHOOTING

M-l 0

M-10, M-11, M-12

Related electrical circuit drawing

CNP

CN 63

CN92

Monitor panel

425F520

M-l 1

Related electrical circuit drawing

CN 62

CNP4

CN 101

CN 97

Fnnino

L,,J...”

bvl+Pr .._._.

temperature

sensor

425F521

M-12

Related electrical circuit drawing

CNP4

CN 22

CN84

Torque converter oil temperature sensor

Monitor panel

425F522-K

82-99

M-13

TROUBLESHOOTING

CHART No. M-13

M-13 (PARKING BRAKE) LIGHTS UP ABNORMALLY OR DOES NOT LIGHT UP Failure mode: + When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents. * When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN 0 A()) + When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check. Cause

Remedy

If the light stays lighted up.

YES

- cDefective parkmg brake senSor

4 ‘fEs

--c Xefective monitor panel

YE3

r ~Doesmgoout,

Does parking brake work when switch is turned ON-OFF?

between CNP3 (female) (5) and chassis ground?

1) Connect short connector to CN36 (female) (parking brake sensor). 2) Turn startmg switch ON.

c10

r-l

NC)

short

connector to

CN36 (female) (parking brake sensor). 2) Connect Tadapter to CNP3 (female). 3) Turn starting switch OFF.

Is there continuity between CN36 (female) (2) and chassis ground? I

1 1 I Connect Tadapter (socket adapter) to CN36 (female) (parking brake sensor). 2) Turn starting switch OFF.‘

Turn starting switch ON.

1) Connect

1Iefective contact, or in wiring clisconnection larness between CN36 female)(l) - CN38 (4) (:NP3 (fern&J (5).

F.pl.Xe

Cjefective contact, or clisconnection In wiring larness between CN36 female) (2) and chassis cIround.

hfter inspectton. .epaw (clean) or ,eplace

c;eeTroubleshooting NC3

4fterinspectlon. epau (clean) or

for

c hassls

If the light does not light up.

YES

-_[

YESDoes m r

light up?

1) Disconnect connector CN36. 2) Turn starting switch ON.

Does parking brake work when switch is turned ON-OFF?

1 1I

Turn starting sw:*^& nn llL,l “I..

3 Is there continuity between CNP3 (female) (5) and chassisground?

1) Connect Tadapter to CNP3 (female). 2) Disconnect CN36. 3) Turn starting switch OFF.

T-adapter

(for DLI)

shooting

82-100

tools

ReplaCe

Short connector

between chassis and wiring harness CN36 (female) (1) Iwween ,:N38 (4) - CNP3 (female) (5).

tfter inspection, ,epair (clean) or

IIefective

ieplace

!ground

YES

monitor

panel

SeeTroubleshooting ,chassis

for

T-adapter Trouble-

parktng brake sense!

I:ontact

defective

or socket adapter

(for Econoseal)

replaCe

TROUBLESHOOTING

M-13

Related electrical circuit drawing

CNP3 Monitor panel

CN 36

Parking brake sensor

425F523

82-101

M-14

TROUBLESHOOTING

CHART No. M-14

M-14 (WORKING LAMP) LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP Failure mode: * When disconnecting or connecting the T-adapter Note: Even if all the working lamps bulbs are broken, or there is (or socket adapter) or short connector, or when defective contact or a disconnection in the wiring harness disconnecting the connector for checking, turn the for the working lamp. the light will stay on. starting switch OFF to prevent accidents. A- When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN o A()) When disconnecting connectors or connecting Tt adapters, return them to the original condition immediately after checking, then go to the next * check. Cause

Remedy

If the light stays on. YES

Does~goout? 1) Remove CN12. 2) Turn starting switch ON.

between CNP3 (female) (141 and chassis ground WW-llal’

working

lamp

switct

Defectwe

mon,tor

panel

R+Xe

YES Replace

IS voltage

_ NO

1) Connect Tadapter to CNP3 (female). 2) Turn starting switch ON. 3) Remove CN 12. 4) Is reading OlV?

Defective

Contact between +24V and wirmg harness between CN12 Ifemale) (2) - CN40 (1) CN40 (4) - CNP3 (female) :14).

After mspectnn, repair iclean) or repl.Xe

If the light does not come on. 3

between CN 12 (male) (1) and (2) as shown in Table?

voltage

Is between CN60 (male) (1) and chassis ground normal? 1) Connect Tadapter (socket adapter) to CN60 (male). 2) Turn startinti switch ON. 3) Is reading 20 3OV?

82-102

1) Disconnect CN12 (male). 2) Turn starting switch OFF. 3) Turn working lamp switch ON - OFF.

21 3) 4)

Connect T-adapter to CNP-3 (female). Turnstarting switch ON Turn working lamp switch ON. IS reading 20 3ov7

YES Iefective

’

monitor

panel

kPlC2

Defective contact, or disconnection in wiring harness between CN12 (female) (2) - CN40 (1) CN40 (41 - CNP3 (female) (14)orCN12(female)(l)CN60 (male) (2).

Sefectwe

working

lamp

~efect1ve contact, or iisconnection in wiring ?arness between mam waker - CN60 (male)

After Inspecton,

repair (clean1 or replace

switch

3eplaCe

Xfter inspection. epaw (clean) or (1)

TROUBLESHOOTING

M-14

Related electrical circuit drawing

Fuse box

CN 26 CNPI Head lamp switch 15 Monitor panel 16

B-

CN 60

f24V

CN 12

CN25

Ek 2

CN40 0

Service meter

Working lamp switch

Working lamp

CNP 3

Monitor panel

425F524

82-103

M-15

TROUBLESHOOTING

CHART M-l 5

(TRANSMISSION CUT-OFF) LIGHTS UP, DOES NOT LIGHT UP Failure mode: M-15 t When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents. t When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN o A()) * When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check.

Cause a.

‘ES

Is there continuity between CNP3 (female) (1 1 and chassis ground’

Short circutt between CN18 (female1 (31 and (4). Turnstart~ng swtich ON.

1; I Turn between CN18 (female) (4) and chassis ground,

1) Turn starting switch

Remedy

Light lights up

OFF

NO transmission cut-off Selector switch ON. Connect T-adapter to CNP3 (female). Turn starting switch OFF

Defectwe switch

transmlsslon

Defective

monitor

cut-of,

panel

3eplace

?l+_Xe

kfectlve contact, or disconnection in wnng harnes letween CN 18 (female) (31 an :NP3 (female) (1 11

ifter w5pectlon. epa~r (clean) or eplace

Iefective contact. or lisconnectlon I” wnng harnes letween CN18 (female) (41 an :hassls ground

ifter InspectIon, epar (clean) or eplace

Iefectlve witch

kplace

Light does not light up

YES

transmwon

cut-off

Contact between 2 1) 2)

Remove CN18. Turnstarting swtch ON.

Is there continuity between CNP3 (female1 (1 1) and chassis ground?

82-104

Connect T-adapter to CNP3 (female) Turn starting switch OFF

YES

chaws ground and winng harness xtween CN18 (female) (3) ind CNP3 (female1 (1 1

\fter nspectlon. epaw (clean) or eplace

Iefectlve

kolace

monitor

panel

TROUBLESHOOTING

M-15

Related electrical circuit drawing

CNP3

CNl8

Monitor panel Transmission cut-off switch

425F526-K

82-105

M-16

TROUBLESHOOTING

CHART M-16

M-16 TURN SIGNAL HI BEAM LIGHTS UP, OR DOES NOT LIGHT UP Failure mode: * When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents. * When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN o A()) + When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check.

Turn signal (right) pilot display lights up Cause

Does out?

turn signal go

Contact between +24V and wiring harness between CN (female) (31 - right turn signal switch, or between CN15 (female) (51 and turn signal

2 Is voltage between , CN~ 5 (male) (5) and chassis ground normal?

Remedy

YES

After inspection. repair or replace

switch Contact between +24V line and wiring harness between CN15 (male) (5) and CN55 (female) (4).

Connect T-adapter to CN15 (male). Turn starting switch

ON.

Does voltage switch

repeatedly

between

0 -

20 -

After inspection. repair or replace

3DV’

I Remove CN15

1 2)

Turn starting switch ON.

Is voltage between CNPl (female) (7) and chassis ground normal?

2) 3) 4)

T-adapter

Connect T-adapter to CNPl (female). Turn starting switch ON. Turn right turn signal switch ON. Does voltage switch repeatedly between 0 - 20 - 3OV?

(for DLII

- Defecttve

monitor

panel

Replace

’

Contact between +24V and wiring harness between CNPl (female) (7) and CN15 (male) (31

or socket adapter

(for Econoseal)

82-106

YES

After inspection. repair or replace

TROUBLESHOOTING

M-16

Turn signal (left) pilot display lights up Cause

YE S

YES

connect T-adapter to CNl5 (male). Turn starting switch Does voltage switch

Is voltage between CN15 (male1 (5) and chaws ground normal’

Does turn stgnal go out)

1I 2)

Remove CN15. Turn starting switch ON

2) 3)

ON. repeatedly

0 -

Contact between +24V and wiring harness between CN15 (female) (6) - left turn slgnal switch, or between CN15 (female) (5) and turn signal switch

After inspection, repair or replace

Contact between f24V line, and wiring harness between CN15 (male) (5) and CN55 :female) (4).

After inspection, repair or replace

3DV?

YES Defective

monitor

panel

~ N0

L 1)

2) 31 4)

T-adapter Trouble-

between

Remedy

I I connect T-adapter to CNPl (female). Turn starting switch ON. Turn left turn slgnal switch ON. Does voltage switch repeatedly between 0 - 20 - 3ov7

Contact between +24V and wiring harness between CNPl Ifemale) (6) and CN15 (male)

After inspection. repair or replace

(6)

or socket adapter

(for Econoseal)

shooting to&

T-adapter

(for DLI)

82-107

TROUBLESHOOTING

M-16

Cause

Turn signal (right) pilot display does not light up

YES

Defective

Is voltage between CNPl (female) (71 and chassis ground normal? 1)

Do front and rear turn signal lamps work

31 4)

Operate right turn signal. Turn startmg switch ON.

Remedy

Connect T-adaoter to CNPl ‘(female). Turn startino switch ON. Turn turn signal switch ON. Does voltage switch repeatedly between 0 - 20

monftor

panel

)efective contact, or Gsconnection in wiring harnes xtween CNPl (female) (7) ar ZN15 (male) (3)

- Xl”7

:arry out troubleshoot!ng turn s8gnal

e\fter inspection, ‘epalr (clean) or ‘eolace

Turn signal (left) pilot display does not light up

2 Is voltage between CNPl (female) (6) and chassis ground normal?

YES_

Do front and rear turn signal lamps work nom-ually?

YES

2) 3) 4)

Operate left turn signal. Turn starting switch ON.

Connect T-adapter to CNPl (female). Turn starting switch ON. Turn turn signal switch ON. Does voltage switch repeatedly between 0 - 20 - 3OV?

Iefectwe

Trouble-

T-adapter

82-108

(for DLII

leplace

lefective contact. or isconnection m wiring hames ‘etween CNPl (female) (6) an :N15 (male) (61

:arry out troubleshootlng :ur” signal

or socket adapter

(for Econoseal)

panel

I I

monitor

I I

ifter Inspection. apair (clean) or eplace

TROUBLESHOOTING

M-16

Hi beam pilot does not light up If the head lamp does not switch to Hi beam, check the head lamp system.

2 Is voltage between CNPl (female) (51 and chassis ground normals

I L 1)

I Turn starbng

switch ON. Place combmatvx swtch at HEAD Place dunmer switch at LO beam

Connect T-adapter to CNPl (female) Turn starting swtch ON. Place comblnat8on swtch at HEAD Place dimmer switch at Hi beam. IS reading 20 3OV’

Cause

YES

)efectwe

lefective contact, or lisconnection in wiring larness between CNPl female) (5) and CN39 (female)

monitor

panel

Remedy

leplacz

_ ifter inspection. epair (clean) or eplace

1).

%oth head lamp bulbs ILo beam amps) broken? If the Lo beam bulb is broken. he Hi beam pilot will not kght up even if the lamp IS switched :oHi beam.)

aeplace

Defective

+x&xe

Hi beam pilot stays lighted up

Do both left and right front lamps hght up?

1) 2)

monitor

panel

YES

Iefectwe contact. or jisconnection in wiring harries: letwee” CN15 (female) (9) am :ombmation switch

hfter inspection. wpair (clean) or wlace

Defective contact. or disconnection in wiring harries: between CN15 (female) (12) and combination swtch

After nxpection. repair (clean) or reDlace

Turn starting switch ON Place combination switch at HEAD. Place dnmmer switch at Lo beam.

switch at HEAD Place dunmer switch at Hi beam

T-adapter

connect T-adaDter (sock& adapter) to CN15 (male). Turn starting switch OFF

jisconnection in wiring harness Jetwee” CN15 hnale) (12) ant :hassis ground

After inspection, repair (clean) or reDlace

(for DLI)

shootmg

tools

T-adapter

or socket adapter

(for Econoseal)

82-109

TROUBLESHOOTING

M-16

M-16 a, b, c, & d related electrical circuit drawing +24

.. CNPI

CNl5

t Hazard switch

Turn signal unit

425F527-K

M-16

e & f related electrical circuit drawing

CN201

CNP I

CN28

CN27

Right head lamp Lo

Left head lamp Lo 425FO1366

82-110

TROUBLESHOOTING

M-17

TROUBLESHOOTING

CHART M-17

Failure mode: TURN SIGNAL DOES NOT FLASH EVEN WHEN HAZARD SWITCH IS TURNED ON M-17 t When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents. * When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN 0 A()) * When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check. Remedy Cause

2 I

I3efective

See M-l 7 cl. d) Troubleshooting

1 2) 3)

Turn starting Does voltage

switch switch

ON. repeatedly

between

0 -

2) 3)

Connect T-adapter to CNPl (female). Turn hazard switch ON. Is reading 20 3OV’

Replace

of turn Signa

IJefective contact. or in wiring harnes ,jisconnectio” IBetween CNPl (female) (3) ,ZN15 (male) (2)

After inspection. repair (clean) or replace

contact, or IIefective in wiring harnes ,jisconnection between CN15 (female) (1) I and hazard switch, or betweel /CN15 (female) (2) and hazard switch, of defective hazard switch

After inspection, repair (clean) or replace

3 CN15 (female) (2) and chassis ground normal?

YES 41

2) 31

Connect T-adapter to CN15 (female). Turn hazard switch ON. Is reading 20 3OV’

I 1

Is voltage between CN15 (male) (1) and chassis ground normal?

2) 31

T-adapter Trouble-

panel

3OW

CNPl (female) (3) and chassis ground

monitor

Is voltage between CNPl (female) 16). (7) and chassis

IDefective Connect T-adapter to CN15 (male). Turn hazard switch ON. Is reading 20 3ov7

contact. or in wiring harnes between CN 15 (male) (1) and +24V line

Idisconnection

I NO

After inspectlo”. repair (clean) or replace

or socket adapter

(for Econoseal)

shooting to&

M-17

T-adapter

(for DLI)

Related electrical circuit drawing f24

CNl5 I

CNPI Hazard

42%527-K

82-111

TROUBLESHOOTING

M-18

TROUBLESHOOTING

CHART M-18

Failure mode: M-18 SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY it When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents. t When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN o A()) + When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check. Cause

Remedy

YES Defective

monitor

panel

Defectwe

speed sensor mount

l+?pkXe

3 Is resistance between CNPl (female) (9) and (10) 3ODR-1 k0,

2 YE

between CN22 (female) (4) and (3) 300 R - 1 kR?

1) Connect Tadapter (socket adapter) to CN22 (female). 2) Turn starting switch OFF.

Is resistance between CN83 (male) (1) and (2) 300 0 - 1 kR?

Connect T-adapter to CNPl (femaleI. Turn starting swttch OFF.

Defective contact, or disconnection in wiring harness between CNPl (9). (10) (female) - CN22 (3). (4).

After inspection. repair (clean1 Or replace

Defective contact, or disconnection in wiring harness between CN22 (female) (4). (3) - CN83

After Inspectno”, repaIr or replace

Defectwe

T-adapter

(1).

(21.

1) Connect Tadapter (socket adapter) to CN83 (speed sensor) (male). 2) Turn starting watch OFF.

Trouble-

speed sensor

or socket adapter

(for Econoseal)

shooting tools

M-18

T-adapter

(for DLI)

Related electrical circuit drawing

CNPI

CN22

CN83 Speed sensor

425F530-K

82-112

Replace

sensor locknut and turn speed sensor clockwtse. If it contacts the 9ear within one turn. the distance IS within .5 mm.

Replace

M-19

TROUBLESHOOTING

CHART M-l 9

HOURMETER DISPLAY DOES NOT WORK NORMALLY Failure mode: M-19 + When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents. + When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN o A()) t When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check. Cause

1 Does hourmeter work, or does display

2) Turn switch

start,“g ON.

YES

2 1)

Connect T-adapter to CNP3 (female) Turn starting switch OFF.

1 NO

I Turn starting

switch ON. (Start engine.1 Is readrng 20 3ov7

T-adapter or

socket

engine

3efectwe

monitor

011pressure

panel

Fk?DlXX

Replace

Is there conbnuity between CNP6 (female) (41 and

Is voltage between CN163 and chassis ground normal?

I NO

1efectwe sensor

Remedy

adapter

Short

Defectwe contact. or drscon nection in wmng harness between chassis ground CN289 (3). (6) - CNP3 (female) (9). or defective engine oil pressure sensor relay

After inspection, reparr f&an) or replace

Contact between chassis ground and wiring harness between CN163 - CN97 181 - CN64 (6) - CN289 (2)

After inspection, repsrr fclean) or replace

connector

(for Econoseal)

Troubleshooting

T-adapter

tools

M-19

T-adapter

(for DLI)

or socket

adapter

(for MIC)

Related electrical circuit drawing

Engine

oil

pressure

relay

CNP 3 Monitor panel

425F518

82-113

M-20

TROUBLESHOOTING

TROUBLESHOOTING Failure mode: + t t

CHART

M-20

WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DOES NOT WORK, OR ONLY PART WORKS When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents. When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN 0 A()) When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check. T

Cause a.

None of the monitor panel lights light up 2

, Is voltage between CNPl (female1 (11 and (2) 20 - 3OV,

YES -

1 Is voltagebetween CN60 (male) (5) and chassis ground 20 - 3OV? 1) Connect Tadapter to CN60 (male). 2) Turn starting switch ON.

Remedy

Connect T-adapter to CNPl. Turn staning switch ON.

YES

Defectwe

monitor

panel

IGplace

Iefective contact, or lisconnection in wiring ,ar”ess between CN60 (6) :NPl (1). or between CNPl (2: - CN64 (5) - chassis ground

(3lean (defective :ontactl or replac I (

Abnormality I” wiring harness between battery terminal (f) - battery relay - main breaker - CN148 - CN60 (male) (5).

I4fter Inspection. I.epair or replace

Iefective

IGplace

Except for speedometer module, none of the monitor panel lights light up

IS voltage between CNP5 (female) (1) and (7) 10 - 2OV7 Is voltage between (2) and (71 approx. 5V’ -

Connect T-adapter to CNP5 (female) Turn starting switch ON.

T-adapter or Trouble-

socket adapter

(for Econoseal)

shooting tools

82-114

T-adapter

panel

Zlefective contact or disconnection in wrng harness xtween CNP2 (1) - CNPS 1). CNP2 (2) - CNPS (2). :NP2 (7) -CNP5 (7). or jefective monitor panel

NO 1)

monitor

(for DLI)

Tester

( Zlean (defective c:ontactl or replac

M-20, M-21

TROUBLESHOOTING

YES

Is there disconnection in wiring harness between CNP2 (female) and CNP5 (female)!

Remedy

Iefective contact, or lisconnection in wiring harness xtween CNP2 (female) and ZNP5 (female)

:lean (defective ontact) or replace

Iefective

monitor

panel

leplace

Iefective

monitor

panel

)efective

momtor

panel

connect T-adapter toCNP2 and CNP5 4femalel. 21 Turn stamng switch OFF.

Cause None of CAUTION items light up

Some other parts do not light up I

TROUBLESHOOTING Failure mode:

M-21

T-adapter Trouble-

CHART M-21

WHEN STARTING SWITCH IS TURNED ON, ALL MONITOR PANEL LIGHTS LIGHT UP, BUT DO NOT GO OUT

or socket adapter

Tester

(for Econoseal)

T-adapter

(for DLI)

leplace

M-20 & 21 Related electrical circuit drawing Fuse box Main breaker Battery relay

Battery terminal

( +)

Monitor panel

425F531 -K

82-115

M-22

TROUBLESHOOTING

TROUBLESHOOTING Failure mode:

CHART M-22

(BATTERY CHARGE) FLASHES OR (ENGINE OIL PRESSURE) FLASHES WHEN ENGINE IS STOPPED When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents. When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN o A()) When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check.

t + t

M-22

Remedy

(Engine oil pressure) flashes, and alarm buzzer and warning lamp are actuated

Defective alternator.

Defective

engine.)

monitor panel.

Contact between +24V and wiring harness between alternator terminal R CN97 (1) - CN64 (1) CNP4 (female) (5).

1) connect T-adapter to CNP4 (female). 2) Turn starting switch ON. (With wiring at terminal R removed) 3) Is reading 0 - IV?

ReOlYXe

After inspection, repair (clean) or WhX

(Battery charge) flashes, and warning lamp lights up

YES

I 3

YES

III Does

0 III

goout?

YES _

1) Connect CN163 to chassis ground. 2) Turn starting switch ON.

Is voltage between CN163 (C) and chassis normal?

1) Turn starting switch ON. (Start engine.) 2) Remove CN163. 3) Is reading 20 - 3OV?

Troubleshooting tools

82-116

T-adaoter or socket adaoter ‘(for Econoseal) T-adapter

Is voltage between CNP3 (female) (9) and chassis ground normal?

Replace

Defective

Replace

monitor panel.

Contact between chassis wound and wirina harness between CN289 (g), (6) CNP3 (female) 19). or defective engine’&1 pressure sensor relay.

NO 1) Connect T-adapter to CNP3 (female). 2) Turn startina switch ON.

4) Is readin;; 20 -

Defective engine oil pressure sensor.

After inspection, repair (clean) or replace

3OV? Defective contact, or disconnection in wiring harness between CN163 (C) CN97 (8) - CN64 (6) CN289 (2), (1) - +24V line.

I I

Mter inspection, Fpair (clean) or Fplace

(for DLI)

L08DD150

TROUBLESHOOTING

M-22a

M-22

Related electrical circuit drawing

CNP4

CN 97

CN64

Monitor panel

425F514

M-22b

Related electrical circuit drawing

Engine oil pressure

relay

CNP3 CN289

Monitor panel

+24V

t CNPG

+24V CN163

Engine oil pressure sensor

Service meter -fg7

+TI+$

L08DD149

82-117

TROUBLESHOOTING

M-23

TROUBLESHOOTING Failure mode:

CHART M-23

M-23

NONE OF THE MACHINE MONITOR PANEL LIGHTING LIGHTS UP, OR PARTS OF IT DOES NOT LIGHT UP -f When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents. + When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN o A()) -or When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check. a.

Even when combination lamp is placed at SMALL, none of the panel lighting lights up.

YES 5 Is voltage between CNPl Ifemale) (15) and CNP6 (female) W-$ssis ground

il (ES

H1)

Is voltage between CN26 (1) and chassis ground normal?

2) CN15

(male) (4) and

4) 1)

Connect T-adapter (socket adapter) to CN15 (male). Turn starting swtch ON. Is readmg 20 3ov7

T-adapter to CN15. Turn startmg switch ON. Place combination switch at SMALL. Is readmg 20 3ov7

combination switch at SMALL. Measure voltage between CN26 (female) (1) and chassis ground with CN26 still connected. Turn starting switch ON. Is reading 20 3ov7

1) 2)

Disconnect CN15. Turns starting switch OFF.

T-adapter

or socket adapter

(for Econoseal)

ibnormality in momtor panel, 0 III lamp bulbs broken. or lefectwe contact. or lisconnection in wiring harness ,etween CNPl (female) I1 6) amp connector, or between ainp connector, CNP6 (female) 3) - chassis ground

After inspection. repair (clean) or replace

Iefective contact, or Gsconnection in wiring Tarness between CN26 female) (1) - CNPl (female) 15). CNP6 (female) (2).

After inspectlon. repair (clean) or reolace

Defective contact. or jisconnection in wirina harness between CN15 (male) ‘81- CN58 (11 L I1 2) - CN26 ‘fdmale) (2). br ieiective diode 1ss’y.

After inspection. repair (clean) or replace

Usconnection in wiring harness letwee” CN15 (female) (4) lead lamp and parking lamp witch - CN 15 (female) (8)

YES

hfter mspection. ‘apaIr (clean) or wlace

Defective contact of head lamp and parking lamp switch

Defective contact, or disconnection in wiring harness between battery relay output - CN296 (1). (2) CN15 (male) (4).

switch

82-118

FH_

Combinatgon

shooting

Remedy

Table

Troubk-

Connect T-adapter toCNP1 (female) NO and CNP6 (female) Turn starting switch ON. Place combination switch at SMALL. Is readmg 20 - 3OV’

Cause

Continuity

After inspection. repalr (clean) or reolace

TROUBLESHOOTING

M-23

MEMORANDA

82-119

TROUBLESHOOTING

M-23

Even when the working

lamp is switched ON, none of the monitor panel lights light up

s .YES

I Is voltage between CN25 (1) and chaws ground normal?

YE: ;I

I 1

I Turn workmg

1) Is voltage between

1 I

voltage

Is between CN12 (female) (1) and chassis ground normal? 1) Keep CN12 connected. 2) Turn starting switch ON. 3) Is reading 20 3OV?

82-120

1) connected. Keep CN12

2) Turn starting switch ON. 3) Turn working lamp switch ON. 4) Is reading 20 3OV?

Turn working lamp switch ON. Measure voltage between connect T-adapter to CN40 (male) and chassis ground Is reading 3OV?

20 -

3) 1 NO

4) lamp switch ON. Measure voltwe between CN25 NO (female)(l) and chassis ground with CN25 still connected. Is reading 20 - 3OV7

‘L

Connect T-adapter to CNPl (female) NO and CNPG ifemale) Turn starting swtch ON Place comblnaton switch at SMALL. Is reading 20 - 3OV’

M-23

TROUBLESHOOTING

Cause

Abnormality in monitor panel, or all lamp bulbs broken. or defective contact, or disconnection in wiring harness between CNPl (female) (16) - lamp connector (1). or between lamp connector (2). CNP6 (female) (3) -chassis ground Defective contact, or disconnection in wiring

1 harness between CN25 (female) (1) - CNPl (female) (15). CNP6 (female)

Remedy

After inspection, repau (clean) or replace

After inspection, repair (clean) or replace

(2).

Defective contact, or disconnection in wiring harness between CN40 (female) (4) - CN25 (female) (2) or defective diode ass’y.

After inspection, repair (clean) or

After inspection. repair (clean) or replace

Defective contact, or disconnection in wiring harness between CN12 (male) (1) -working lamp switch CN12 (male) (2). or defective working lamp switch.

F%;_ harness

between

battery relay

After inspection, repair Wean) or replace

After inspection, repair Wx~nl or replace

82-121

M-23

TROUBLESHOOTING

Even when starting switch is turned ON, none of the monitor panel lights light up

YES

Is voltage between CNPl (female) (161 and chassis ground normal? 11

2) 31

connect T-adapter to CNPl (female). Turn starting switch ON. Is reading 20 3OV?

Cause

Remedy

\II lamps broken, or defectwe ontact, or disconnection I” wng harneis between CNPl female) (16) - lamp connect< 1). lamp connector (21 -

After nspectlon. repau Iclean) or replace

jefective

panel

Replace

in lamp wring

Replace

monitor

Part of the panel does not light up

. Olsconnectlon

After Inspectnon. repalr (clean) or replace

Troubleshooting tools

82-122

T-adapter

(for DLU

TROUBLESHOOTING

M-23

Related electrical circuit drawing

Fuse box

CN 26 II CNPI Head lamp switch

CN287

Lamp 2

EE CN288

CN 60

CN 289

CN 12

Service

II_-I :N

CNP6

meter

CN40 4,

0 Working switch

lamp

El= I CNP

Working

lamp

~qqq_

425F524A

82-123

M-24, M-25

TROUBLESHOOTING

TROUBLESHOOTING Failure mode:

CHART M-24

M-24

WHEN THE STARTING SWITCH IS TURNED TO THE ON POSITION (ENGINE STOPPED), AND THE BUZZER DOES NOT SOUND FOR i SEC. WITH THE CAUTION ITEM FLASHING BUT THE BUZZER DOES NOT SOUND When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents. When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN o A()) When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the Cause Remedy next check. The buzzer does not sound for charge level and fuel level of CAUTION items. 7

Defective

Connect CNP4 (female) (8) and chassis ground Does alarm buzzer sound’

Defectwe

1) Turn starting 2)

TROUBLESHOOTING Failure mode:

IReplace

(male ,I

(:lean (defectwe or replace

c:ontact)

CN130

1buzzer so,

‘.”

panel

Defective contact, or disconnection in wiring harness between CN130 - CNP4 (female) (8).

YES

Connect T-adapter to CNP4 (female) Connect CNP4 (8) to chassis ground Turn startma switch ON. _I

monitor

alarm buzzer

Defective contact, or disconnection in wiring harness between CN131 (female) - f24V line.

switch ON Is reading 20 3ov7

Iqeplace

I qfter I epair

inspectlon. (cleanl or

I eplace

CHART M-25

M-25

NO ABNORMALITY IS SHOWN ON THE MONITOR DISPLAY, BUT THE ALARM BUZZER SOUNDS The alarm buzzer sounds when the parking brake is applied and the transmission is in any position except NEUTRAL.

s-l

Disconnect CNl30. Does alarm buzzer sound?

YES

1 1 Disconnect CNP4 (female) Does alarm buzzer sound?

1) 2)

Disconnect CNP4 (female). Turn starting switch ON.

1) Disconnect CN130. 2) Turn starting switch ON.

82-124

or socket adapter

(for Econoseal)

T-adapter

(for DLU

alarm buzzer

Contact between chassis ground and wiring harness beetwr CNP4 (female) (8) -

I I

Defectwe

shooting tools

Defective

T-adapter Trouble-

YES

I I

V&ring harness wth crocodile

clip

monitor

panel

Replace

After Inspection, repair (clean1 or replace

Replace

TROUBLESHOOTING

M-24, M-25

Related electrical circuit drawing

+24V CN131 Alarm buzzer

CNP4 Monitor panel

CNl30 425FO1367

82-125

M-26

TROUBLESHOOTING

TROUBLESHOOTING Failure mode:

* + *

CHART M-26

M-26

WHEN THE STARTING SWITCH IS TURNED TO THE ON POSITION (ENGINE STOPPED), AND THE WARNING LAMP DOES NOT LIGHT UP FOR 2 SEC. THE CAUTION ITEM IS FLASHING BUT THE WARNING LAMP DOES NOT FLASH When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting the connector for checking, turn the starting- switch OFF to prevent accidents. When connectina the T-adapter (or socket adapter), connect to the connector specified. (CN 0 A()) When disconneciing connectors‘or connecting’T-adapters, return them to the original condition immediately after checking, then go to the Cause Remedy next check.

‘ES

Does warning

Iefectwe

monnor

panel

Replace

Narnrng lamp bulb broken, or iefecbve contact. or irsconnection in wnng harness cetween CN17 (male1 I1 amp. or CNl 7 (male) (2) -

I-

lamp

After wpectron. reparr (clean) or replace

amp 1)

Connect T-adapter to CNP4 Ifemale). Connect CNP4 (female) (7) to chassis ground. Turn starting switch ON.

Iefectwe contact. or jisconnectron in wnng harness ,etween CN17 (female) (2) :hassis ground

chassis ground? I 1) N

0’ 2) 11

T-adapter

Connect T-adapter to CN17 (female) Connect CNP4 (female) (7) to chassis ground Turn starting switch ON.

Connect T-adapter to CN17 Ifemale). Turn starting switch OFF

Defective contact, or disconnection in wiring harness between CNP4 (female) (7) - CN297 (female) (2). (1) - +24V line, or between CN17 (female) (1) CN297 (female) (3). (5) +24V line, or defective lamp relay.

After mspectron. reparr (clean) or

After rnspection. repair (clean1 or replace

or socket adapter

(for Econoseal)

Troubleshooting tools

M-26

T-adapter

Related electrical

(for DLI)

circuit

drawing

Caution

lamp

relay

Warning Monitor

lamp

panel

425F534-K

82-126

M-27

TROUBLESHOOTING

TROUBLESHOOTING Failure mode: + * +

CHART M-27

M-27

NO ABNORMALITY IS SHOWN ON THE MONITOR DISPLAY, BUT THE WARNING LAMP LIGHTS UP When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents. When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN 0 A()) When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check.

YES

Defective

monitor

Replace

panel

Contact between chassis ground and wiring harness between CNP4 (female) (7) CN297 (female) (2).

Contact between +24V line and wiring harness between

CN17(female)(l)CN297 (female) (3). or defective lamp 2)

Trouble-

After mspectlon, repair (clean1 or replace

After inspection, repar (clean1 or replace

CNP4 Ifemale). Turn starting swtch OFF.

T-adapter

(for DLI)

shootmg tools

M-27

Short ConneCtOr

Related electrical

circuit

drawing

Caution

lam0 relav

mp Monitor panel

425F534-K

82-127

M-28

TROUBLESHOOTING

CHART M-28

ABNORMALITY IN THE FUEL GAUGE SYSTEM M-28 Failure mode: + When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents. t When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN 0 A()) t When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check. Remedv

If nothing is displayed

in the display area

YES 1

Does fuel gauge show FULL?

2 -

1) Connect short connector to CN266 (female) (fuel sensor).

Is there continuity between CNP4 (female) (4) and chassis ground’

L NO

2) Turn starting switch ON.

If indicator

fuel sensor

Reolace

Defectwe

momtor

RePlaCe

YES

1) Connect Tadapter to CNP4 (female). 2) Connect short connector to CN266 (female). 3) Turn starting switch OFF.

Defective

panel

Defective contact, or disconnection in wiring harness between CN266 (female) (2) - CN64 (4) chassis ground, or between CN266 (female) (1) CN64 (3) - CNP4 (female) (4).

4fter mspectjon. .ep.sv (clean) or .eplace

Defective

3ecdace

remains ar FULL

YES

1 Does whole display ary? of fuel gauge go -

1) Disconnect CN266 (fuel sensor). 2) Turn starting switch ON.

2 Is there continuity between CNP4 (female) (41 and chassis ground?

1) Connect Tadapter to CNP4 (female). 2) Remove CN266 3) Turn starting switch OFF.

T-adapter

(for DLII

Troubleshooting tools

82-128

I Short

connector

YES

fuel sensor

Contact between chassis ground and wiring harness between CNP4 (female) (4) CN64 (3) - CN266 (female)

rfter mspectlon. :pair (clean) or splace

(11 -

. Defectwe

monitor

panel

leplace

TROUBLESHOOTING

M-28

Related electrical circuit drawing

CNP4 Mnnitnr . _. . _. \ panel

CN64

CN 266

_I Fuel level sensor I

425F516

82-129

M-29

TROUBLESHOOTING

CHART M-29

ABNORMALITY IN THE AIR PRESSURE GAUGE SYSTEM M-29 Failure mode: When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting t the connector for checking, turn the starting switch OFF to prevent accidents. When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN 0 A()) * When disconnecting connectors or connecting T-adapters, return them t to the original condition immediately after checking, then go to the next check. a.

If nothing is displayed

YES

f Does air pressure gauge show maxlm”m level7

1 1) Connect short connector to CN92 (air pressure sensor) 2) Turn starting switch ON.

If the indicator

Is there continuity between CNPL (female) (1) and chassis ground?

1) Connect Tadapter to CNP4 (female). 2) Connect short connector to CN92 (female) 3) Turn starting switch OFF.

Defective

air pressure

Defective

monitor

I~~~,~

panel

Defective contact, or disconnection in wiring harness between CN92 (female) (1) - CN63 (1) CNP4 (female) (1). or between CN92 (female) (2) - CN62 110) - chassis ground.

After inspection. repair (clean) or replace

)efective

Replace

T-adapter

(for DLI)

shooting Short connector

air pressure

sensor

Contact between chassis ground and wiring harness between CNP4 (female) (1) CN63 (1) - CN92 (female) (1).

Defective 1) Connect Tadapter to CNP4 (female) 2) Disconnect CN92. 3) Turn starting switch OFF.

82-130

Replace

remains at maximum level YES

tools

sensor

YES

Trouble-

Remedy

Cause

in the display area

monitor

panel

After inspection. repair (clean) or replace

TROUBLESHOOTING

M-29

Related electrical circuit drawing

CNP 4

CN 63

CN92

Monitor panel

CN 62

425F520

82-131

M-30

TROUBLESHOOTING

CHART M-30

ABNORMALITY IN THE ENGINE WATER TEMPERATURE GAUGE SYSTEM Failure mode: M-30 + When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents. t When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN 0 A()) * When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check. Cause Remedy a.

If nothing is displayed

in the display area

1 Does engine water temperature gauge show minimum level

1) Disconnect CNlOl (engine water temperature) 2) Turn starting swttch ON.

If the indicator

2 Is there continuity between CNP4 (female) (2) and chassis ground?

YES

1) Connect Tadaoter to CNP4 (female). 2) Disconnect CNlOl. 3) Turn starting switch OFF.

82-132

Aftermspect!on, repaw (clean) or replace

,fectlve monitor

Reolace

panel

fective engme water noerature sensor

2 Is there continuity between CNP4 (female) (2) and chassis ground?

I )

1) Connect Tadaoter to CNP4 (female). 2) Connect short connector to CNlOl (female). 3) Turn startino switch OFF.-

T-adapter

(for DLI)

shooting tools

,ntact between chassis xmd and wiring harness tween CNlOl &male) (1) CN97 13) - CN62 19) IP4 (female) (2)

remains at minimum level

area of engine water temperature gauge

Trouble-

Replace

YES

1) Connect short connector to CNlOl (male). 2) Turn starting switch ON.

:fective engine water nperature sensor

Short connector

YES

fective

monitor

panel

iective contact. or connection in wiring ‘ness between CNP4 nale)(2)-CN62(9)97 (3) - CNlOl (female) or between CNlOl male) (2) - CN97 (2). CN62 I), -chassis ground.

7eplace

4fter Inspection, spav (clean) or xplace

TROUBLESHOOTING

M-30

Related electrical circuit drawing

CNP4

CN 62

CN 97

CNIOI

Engine water temperature sensor

Monitor panel

425F521

82-133

M-31

TROUBLESHOOTING

CHART M-31

ABNORMALITY IN THE TORQUE CONVERTER OIL TEMPERATURE GAUGE SYSTEM Failure mode: M-31 t When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents. + When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN 0 A()) t When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check. a.

If nothing is displayed

in the display area

efective torque converter m-merature sensor

YES

1 Does torque oil temperature gauge show rnmm~~m level?

converter

1) Disconnect CN84 (torque COWeRer oil temperature). 2) Turn starting switch ON.

2 Is there continuity between CNP4 (female) (3) and chassis ground?

YES

jefective

tools

82-134

kfter inspectiOn. .epalr (clean) or ,eplace

monitor

panel

lefective torque converter ?mperature sensor

2 L

I )

Is there continuity betweenCNP4 (male1 (3) and chassis ground? 11 Connect T’ adapter to CNP4 (female). 2) Connect short connector to CN84 (female). 3) Turn starting switch OFF.

T-adapter

Troubleshooting

remains at minimum level

gauge

1) Connect short connector to CN84 (female). 2) Turn starting switch ON.

ontact between chassis round and wiring harness etween CN84 (female) (1) :N22 (1) CNP4 (female) (3).

YES

temperature

oil

1) Connect Tadapter to CNP4 (female). 2) Remove CN84. 3) Turn starting switch OFF.

If the indicator

Remedy

Cause

(for DLI)

r Short connector

YES

Iefective

monitor

oil

panel

Replace

kfective contact, or lisconnection in wiring larness between CNP4 female) (3) - CN22 (1) :N84 (female) (1). or between :N84 (female) (2) - CN22 (2) - chassis ground.

After inspection. repau (clean) or replace

M-31

TROUBLESHOOTING

M-31

Related electrical circuit drawing

CN84_

Torque converter oil temperature sensor

Monitor panel

425F522-K

82-135

TROUBLESHOOTING

MEMORANDA

82-136

M-31

ELECTRIC ELECTRONIC 83

DISASSEMBLY

AND SYSTEM

AND ASSEMBLY

MACHINE MONITOR .............................................................. REMOVAL .................................................................... INSTALLATION .................................................................

2 2 3

83-1

DISASSEMBLY

MACHINE

AND ASSEMBLY

MONITOR

MACHINE MONITOR REMOVAL

A l

Disconnect the cable from the negative (-) terminal of the battery.

1. Covers Remove covers (1 and 2) of the machine monitor. 2. Wiring l l l

0 l

0 l l l

Connector Connector Connector Connector Connector Connector Connector Connector Connector

(3) for CNPl. (4) for CNP2. (5) for CNP3. (6) for CNP4. (7) for CNP5. (8) for CNPG. (9) for CNP7 (Night lighting lamp). (10) for CNP8 (Night lighting lamp). (11) for CNP9 (Night lighting lamp).

After disconnecting the connectors, to distinguish when installing.

3. Machine monitor Remove mounting the machine monitor (12). *

bolts,

mark with a tag

then

remove

the

When removing the machine monitor, be careful not to give it any sudden shock.

83-2

’

LllAH02

DISASSEMBLY AND ASSEMBLY

MACHINE

MONITOR

MACHINE MONITOR INSTALLATION 1. Machine monitor Set the machine monitor (12) in the mounting position and install it. t Be careful not to tighten the screw too much.

LllAHO24

2. Electric wiring Connect the following electrical wires to the machine monitor. 0 Connector (11) for CNP9 (Night lighting lamp). 0 Connector (10) for CNP8 (Night lighting lamp). l Connector (9) for CNP7 (Night lighting lamp). 0 Connector (8) for CNPG. l Connector (7) for CNP5. 0 Connector (6) for CNP4. 0 Connector (5) for CNPB. l Connector (4) for CNP2. l Connector (3) for CNPl. l

LllAH02!

After inserting the connectors, apply the connector lock securely. Assemble so that there is no strain on the wiring.

3. Covers Install covers (1 and 2) of the machine monitor.

LllAHO2~

83-3

DISASSEMBLY

AND ASSEMBLY

MEMORANDA

83-4

MACHINE

MONITOR

AIR CONDITIONER 91

STRUCTURE

AND FUNCTION

GENERAL ...................................................................... 3 BASIC INFORMATION ON AIR CONDITIONERS 3 UNITSRELATEDTOREFRIGERATION ..... . .. .. .. .. .. .. .. .. .. . .. .. . .. . .. .. .. . .. ... 3 Heat ..................................................................... 3 Temperature ............................................................... 3 Pressure .................................................................. 4 Humidity .................................................................. 5 PRINCIPLE OF COOLING ....................................................... 6 Whydocoolerscool? ........................................................ 6 Refrigerator using evaporation latent heat .......................................... 6 Refrigeration method (Vapor compression) ......................................... 6 Refrigerating cycle .......................................................... 7 Heating cycle .............................................................. 9 REFRIGERANTS.. ........................................................... 10 SAFETYPRECAUTIONS ..................................................... 10 REFRIGERATOR OIL (LUBE OIL) ................................................. 11 SPECIFICATIONS ............................................................ 12 PIPINGDIAGRAM

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

ELECTRIC WIRING DIAGRAM .......................................................

COMPRESSOR(CRANKTYPE)

MAGNETICCLUTCH CONDENSER

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

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

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

RECElVERW/SIGHTGlASS

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

18 19 21

AIR CONDITIONER UNIT .......................................................... EXPANSION VALVE ............................................................ EVAPORATOR ................................................................ THERMOSTAT ................................................................ PRESSURE SWITCH ........................................................... HEATER BLOWERurjij:::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::: PIPING ..................................................................... AIR CONTROLSYSTEM .........................................................

23 24 26 26 27 29 29 30 31

CONTROLPANEL ............................................................... BLOWER SWITCH .............................................................

32 32

91-1

AIR CONDITIONER SWITCH ...................................................... TEMPERATURECONTROLLEVER ................................................. AIRSOURCESELECTOR LEVER ..................................................

91-2

32 32 32

GENERAL

STRUCTURE AND FUNCTION

GENERAL BASIC INFORMATION ERS

ON AIR CONDITION-

UNITS RELATED TO REFRIGERATION Heat The kinetic energy of the molecular activity of a substance takes the form of heat. If a substance is given by any other substance, its temperature will rise. If heat is taken away by another body, the temperature will decrease. 1.

Temperature When cooling or warming a substance, the degree of warmth or coolness is measured in units of “C (Centigrade) or “F (Fahrenheit).

1. Scales of temperature.

Quantity of heat. If the heat is transferred from one substance to another, the temperatures of both substances will change. The amount of change in temperature will depend on the quantity of heat transferred. The quantity of heat is indicated in units of calories (Cal) or kilocalories (Kcal). One cal denotes the quantity of heat required to raise the temperature of lg of water by 1 degree. One Kcal denotes the quantity of heat required to raise the temperature of 1 kg of water by 1 degree. Specific heat. The quantity of heat required to raise or lower the temperature of substance varies depending on the type, weight, and amount of change in temperature of the substance. The quantity of heat required to raise the temperature of one unit weight of a substance by 1 degree is called the “specific heat“ of the substance. The unit of the specific heat is “kcal/kg.“C. The specific heat is often indicated with a numerical value without the unit. The larger the specific heat of a substance, the more difficult it is for the substance to warm up and cool down. The specific heat of water is 1, which is the largest value of any solid or liquid.

Substance

The temperature at which water freezes at the standard barometric pressure (1 barometric pressure) (the “freezing point”): Centigrade. . . . . . . . . . . . . . . . 0 degree (“C) Fahrenheit . . . . . . . . . . . . . . . . 32 degrees

Temperature at which water boils at the standard barometric pressure (the “boiling point”): Centigrade . . . . . . . . . . . . . . . 100 degrees

(“F)

6?renheit (“F) l

. . . . . . . . . . . . . . . 212 degrees

On the centigrade scale, the scale is equally divided into 100 graduations ranging from 0 to 100 degrees. One graduation is 1°C. A temperature below the freezing point (a sub-zero temperature) is indicated by -a”C. On the fahrenheit scale, the scale is divided into 180 graduations ranging from 32 to 212 degrees. one graduation is 1” F. A temperature below 0” F is called a sub-zero temperature and indicated by B” F. Centigrade

100°C

Fahrenheit

212O F

= .c I -f

Specific heat (Kcal/kg.“C)

Water

1.0

1 ‘1 I

Alcohol

0.57

l* *S 0

Ice

0.49

Iron

0.11

Copper

0.09

Aluminum

0.21

d -4

Temperature l

scale

Burner FOOACOOl

Relationship between the Centigrade and the Fahrenheit scales: Centigrade and Fahrenheit temperatures can be converted according to the following formulas: Centigrade temperature (“C) = (“F -32) x 5/9 Fahrenheit temperature (“F) = “C x 9/5 + 32

91-3

STRUCTUREANDFUNCTION

GENERAL

2. Absolute temperature (Kelvin scale) At zero degrees on the absolute scale (“absolute zero”), the molecular activity of all substances ceases. Absolute temperature is often used to make theoretical studies, since it is the lowest temperature in the natural world. l Relationships between the absolute temperature scale and the Centigrade and Fahrenheit temperature scales: 0°C is 273” K (on the Kelvin scale) in the absolute temperature system. One degree in the Kelvin scale is equal to one degree in the Centigrade scale. On the Fahrenheit temperature scale, 0" F is equivalent to 460” R (on the Rankine scale). One degree in the Rankine scale is equivalent to one degree on the Fahrenheit scale. Thus, their relationships are as follows: Absolute temperature (“K) = (“C) + 273 0°K = -273°C. Absolute temperature (“R) = (“F) t 460 0”R = -460°F.

Pressure The force acting on a unit area is called “pressure”. Normally, the force acting on a unit area of 1 cm2 is indicated in unit of kg. Unit of pressure: kg/cm2.

Pks I Pressure:

Pkg/cm2

1 cm2 FOOACOOZ

Gauge pressure. The pressure measured with a pressure gauge at zero barometric pressure is called the gauge pressure. This pressure indicates the difference between the absolute pressure and the atmospheric pressure. For a theoretical calculation, the gauge pressure must be converted into the absolute pressure. In most cases, pressure refers to the gauge pressure. The unit gauge pressure is kg/cm2 g, which discriminates it from ordinary pressure.

Atmospheric pressure. This is the pressure of the air. The standard atmospheric pressure is 1.03 kg/cm2 abs. at sea level, which is equivalent to a mercury column of 760 mm (Hg) or to a water column of 10.3 m. The relationship between the absolute pressure and the gauge pressure can be indicated by the following formula: Absolute pressure = Gauge pressure + Atmospheric pressure. Even if the gauge pressure of a gas in a container is zero, thegas is actually subject to a pressure of 1.03 kg/cm abs.

Vacuum and the degree of the vacuum. Normally, a pressure gauge has a red zone on its scale to indicate the pressure below 0 kg/cm2. Any gas pressure indicated in the red zone is below the atmospheric pressure. The term “vacuum” refers to a given space filled with gas at a pressure below the atmospheric pressure. A perfect vacuum refers to a space completely empty of gas pressure (an absolute pressure of 0 kg/cm2 abs.). The degree of vacuum applies to the static pressure below the atmospheric pressure and is indicated in terms of absolute pressure in units of cm Hg. On the gauge scale, the atmospheric pressure is set at zero and the perfect vacuum is set at 76 cm Hg. To convert the reading, h cm Hg, of the vacuum gauge into the absolute pressure P kg/cm2 abs., the following formula is used: P = 1.03x(1 -h/76) In this case, the degree of vacuum is (76-h) cm Hg. [Degree of vacuum1

Absolute pressure. The pressure which is actually imposed on the wall of a vessel by the gas inside is called the absolute pressure. The so-called complete vacuum pressure, in which no molecular activity occurs, is defined as the zero pressure. This absolute pressure is used in the same manner as the absolute temperature when treating problems theoretically. The unit of absolute pressure is kg/cm2 abs. to discriminate it from ordinary pressure.

[Gauge Atmospheric

, Ubsolute

scale1

pressure1 1.03kg/cm2 abs.

pressure ‘; 2 ii 2

Perfect

vacuum

cmHg,

cmHg

+ 0

kg/

II? ass

FoaAcoo~

91-4

STRUCTURE AND FUNCTION

GENERAL

Humidity The amount of steam contained in the air is called the humidity. Humidity is general classified into absolute humidity and relative humidity.

1. Absolute humidity. The absolute humidity is the weight of moisture per kg of dry air contained in the wet air, expressed in units of x kg/kg. Practically, an air diagram is used to indicate the weight of moisture contained in 1 kg of wet air. For example, if 30 g of moisture is contained in 1 kg of wet air, the absolute humidity on the air diagram is indicated as follows: Absolute humidity = 0.03 (kg)/1 (kg) = 0.03 kg/kg2.

Relative humidity. The ratio between the steam partial pressure P (kg/cm2) of the wet air and the max. partial pressure Ps contained in the steam at that humidity (the steam partial pressure of the saturated air) is called the “relative humidity”. That is, Relative humidity

= $C 100 (“h)

Generally, when we speak of humidity, we mean relative humidity. This is the humidity obtained from a home hygrometer or g’wen in the weather forecast.

91-5

GENERAL

STRUCTURE AND FUNCTION

PRINCIPLE OF COOLING 1. Why do coolers cool? We have all experienced the cold feeling when we are sweating and the wind blows, or when we put a liquid like alcohol on our skin. This feeling occurs because water or alcohol have the property of taking heat from the surroundings when evaporating and turning into gas. If we express this another way, if we apply heat to a liquid it turns into gas. This is called evaporation latent heat. In a cooler, freon 12 (R-12) is used instead of alcohol. When the liquid freon 12 turns into gas, it takes latent heat from its surroundings. However, if it is allowed to disperse as a gas, this is uneconomical. We need a devise which uses some method to collect this gas and turn it back into liquid before evaporating it again, and to repeat this cycle continuously. A cooler is such a devise. The fluid which turns into a liquid and then becomes a gas to cool the surroundings is called the refrigerant.

I; ; ! I

Evaporated

1IaicPho’ ; ! /

Principle

cooling FOOAClOl

Fin.

Refrigerant

gas

Refrigerator using evaporation latent heat The liquid refrigerant (freon 12) is sent under high pressure through a valve where it is allowed to expand and is sent to the heat exchanger. The refrigerant takes heat from the air in the room sucked in by low pressure vapor (moist vapor), turns into gas (super heated vapor) and is discharged. The air which has lost its heat is blown into the cooled room. This is the basic principle of the cooler, but using only this device to cool is uneconomical and not very practical

Rlefrigerant \ [High pressure fluid3

Valve

’ FOOAClOZ

Expansion

valve

Refrigeration method (Vapor compression) The refrigerant gas is compressed by a compressor (adiabatic compression) and changes to high temperature and high compression. It is then sent to the condenser and undergoes forced cooling in the condenser to be turned to liquid. If this liquefied refrigerant is expanded suddenly at the expansion valve, it changes into a low temperature and low pressure mist and flows inside the evaporator. The refrigerant, which enters the evaporator as a mist, passes through the fins of the evaporator and takes latent evaporation heat from the surrounding air. This causes it to evaporate and turn to its original gaseous condition. In this way it acts to cool the surrounding air and thereby cool the room.

91-6

A=Low

temperature,

low

B=High

temperature,

high

Compressor

5 5

pressure

liquid

pressure

liquid FOOAC103

GENERAL

STRUCTUREANDFUNCTION

Refrigerating cycle The refrigerating cycle of an air conditioner consists of the compressor, condenser, expansion valve, and evaporator as shown in the diagram. Refrigerant is circulated in this sealed circuit (refrigeration cycle), and heat is transferred from the low temperature source (air inside the operator’s compartment) to the high temperature source (outside air) to give the cooling. This is called the evaporation compression refrigeration system, and at this time is the most widely used form of cooling used for bus coolers, room air conditioners, and small refrigerators. A)

Flow of refrigerant 1) The liquid refrigerant which leaves the receiver is expanded suddenly at the expansion valve. It becomes a low temperature, low pressure mist and flows to the evaporator. 2) The refrigerant mist which flows into the evaporator takes heat from the air (air inside the operator’s compartment) at the surface of the evaporator. It evaporates and is further heated, and is then sucked into the compressor as a gaseous refrigerant. The air inside the operator’s compartment is sucked into the cooling unit by a fan, is cooled on the evaporator surface, and is then sent out into the operator’s compartment again. 3) The gaseous refrigerant evaporated in the evaporator is sucked into the compressor. 4) The gaseous refrigerant is compressed in the compressor, and is then sent to the condenser at high temperature and high pressure. 5) In the condenser, the gaseous refrigerant is cooled. It becomes a liquid refrigerant again and flows to the receiver. By repeating the above steps (1) to (5), the heat is taken from the air at the surface of the evaporator, and heat is dissipated to the air at the surface of the condenser to produce cooling inside the operator’s compartment.

Generally speaking, for a gas to be liquefied, it must be pressurized. However, if it is cooled at the same time as being pressurized, it can be liquefied easily For this reason, compressors and condensers are needed in the present refrigerating systems.

Refrigerating

cycle

FOOAC104

Properties of R-12 Using R-12 (freon 12) as an example, let us explain how the refrigerant can be liquefied. High temperature (7O”C), high pressure (15 kg/cm*) gaseous refrigerant is compressed in the compressor. It then enters the condenser where is is cooled and liquefied. R-12 starts to liquefy at about 62°C at 15 kg/cm*, so the temperature of the refrigerant need only be brought below 62°C. If it

cooled turns \

I \

this amount, to liquid.

60 50 40 30

Note:

The temperature and pressure of the refrigerant vary according to the air flow and temperature of the front surface of the condenser.

In this way, the refrigerant is repeatedly circulated during the refrigeration cycle to carry out the refrigeration action. In refrigerators using the evaporation latent heat of the refrigerant at present used, if the gaseous refrigerant is not liquefied at near normal temperature, it cannot take evaporation latent heat from the surrounding material to carry out refrigeration (cooling).

Gauge pressure fkg/cmZG1 Refrlgerant saturating curve FOOAC106

91-7

GENERAL

STRUCTURE AND FUNCTION

C) Temperature and pressure in the refrigeration cycle

Heat Cooling

Radiation

air f

4444

/ 6

Evaporation [evapoatorl

Compression (compressor1

Condensation Ccondansorl

Overheating

Saturation

*WF

b4 /

0°C

sot

1.3

2.1

[Temperature variation]

- o”c (Pressure

(Pressure

cooling

constant1 kg/cm2

(Pressure variation)

constant) kg/cm2

FOOACO07

1. 2. 3.

Receiver Evaporator Condenser

In the refrigeration cycle, the refrigerant transforms from a liquid to a gas (evaporation) and from a gas to a liquid (condensation). Both the temperature and pressure of the refrigerant vary throughout the refrigeration cycle. The figure above indicates variations of the temperature and pressure in the refrigeration cycle. (The numbers in the diagram are taken from the design values of a standard air conditioner, and are given only for reference. These values vary depending on the conditions for the actual cycle).

91-8

4. 5. 6.

Compressor Blower Expansion valve

GENERAL

STRUCTURE AND FUNCTION

Heating cycle The heating

cycle uses cooling water taken from the engine cooling system. A) The cooling water absorbs the heat from the engine, and its flow is controlled by the water valve to enter the heater core. B) In the heater core, the heat of the cooling water is transferred to the air at the surface of the core. C) The heat is sent by the blower to the operator’s compartment. D) The cooling water which has given up its heat in the heater core returns to the engine.

By repeating the above steps (A) to (B), the inside of the operator’s compartment is heated.

Hot

air

Heater core Water

t Water

1v,+

Engine

FOOAClO6

91-9

STRUCTURE AND FUNCTION

GENERAL

REFRIGERANTS The refrigerant plays the most important role in the refrigeration cycle. Various kinds of refrigerants are available for various types of applications. The most critical characteristic of a refrigerant is the ease with it liquefies and vaporizes at normal or low temperatures. However, only a few kinds of refrigerants are used in air conditioners, depending on various conditions, such as the type of compressor, evaporation temperature (pressure), and condensation temperature (pressure).

Ammonia and Freon type gases, which satisfy the requirements, are widely used. Air conditioners usually use “Freon type” gases because of their safety and the small size of refrigeration system. 1. Freon type gases Components in this system are compatible with Refrigerant 12 (CChF, - Dichlorodifluoromethane). Use of other refrigerants would not achieve performance characteristics, and more importantly, would, in most cases, chemically deteriorate components.

SAFETY PRECAUTIONS The substance used in the air conditioning system, namely R-12, is basically a safe, non-toxic refrigerant. However, when it is exposed to an open flame, it changes to a very highly poisonous and deadly phosgene gas. This phosgene gas will tarnish bright metal surfaces. The liquid refrigerant will boil (or vaporize at -29.8”C (-21.7”F) at atmospheric pressure (or when it is exposed to the air). It also evaporates so rapidly that the gas may displace the oxygen in the area, if it happens to be a small enclosed area. Therefore, whenever the system is worked on, a safe practice would be to work on it in a well ventilated area. The refrigerant, when exposed to the air, is approximately -29°C (-21°F). Upon contact with the skin, the effect is just like frostbite. Treat the same as you would for frostbite. If the refrigerant should contact the eyes, immediately flush the eyes with water and continue to do so until the temperature is above the freezing point. Consult an eye specialist immediately. Blindness could result from an injury of this sort and it is highly recommended that safety goggles be worn whenever servicing the system

Do not add alcohol or other liquid driers to the system to prevent freeze-up. The desiccant in the dryer prefers alcohol to water and will discharge moisture to absorb alcohol. Refrigerant oil is the exception to the rule that water and oil do not mix. If left in an open container it will absorb moisture and may cause freeze-ups at the expansion valve or sludging. Use only refrigerant oil in the compressor.

91-10

If the air conditioning system must be discharged, do it out of doors or in a well ventilated area where no extreme heat or open flame is present. Release the refrigerant slowly as it will suck the oil from the compressor if the system is opened too fast. Always use the correct type of hoses for the air conditioning system. Do not use any hose which is not specified for refrigeration use. Never apply heat of any sort on any of the air conditioning hoses or components of the system while it is charged. The extra heat could cause the pressure of the refrigerant in the system to become excessive and cause dangerous rupture. Be sure the pressurized refrigerant containers are never exposed to or stored in an area where the temperature could exceed 52°C (125” F). Do not discard empty refrigerant containers where they might be subjected to a temperature of 52°C (125°F) or higher.

Remember: 1. Wear safety goggles. 2. Keep refrigerant away from heat. 3. Do not smoke or have an open flame near when discharging refrigerant. 4. Work in a well ventilated area. 5. Avoid physical contact with refrigerant.

STRUCTURE AND FUNCTION

REFRIGERATOR

GENERAL

OIL (LUBE OIL)

The lube oil used in air conditioners is generally called refrigerator oil. The purpose of the lube oil in the compressor is to prevent the excessive wear of the piston, cylinder walls, and other frictional parts like bearings, and to prevent them from seizing by removing the heat created by friction. In addition to this lubricating purpose, the lube oil also serves to prevent leakage of refrigerant by maintaining a uniform thin oil film on the contact surface of parts. Freon type refrigerant dissolves in oil better than ammonia does. When the freon is dissolved in oil, the freezing point of the oil goes down, which causes no hindrance to the use of the oil at low temperatures. The flash point and the ignition point of the refrigerant oil are ordinarily 160” C to 170” C and 200°C to 220“ C, respectively. The lube oil for air conditioners is used with refrigerant. Thus, the viscosity of the oil when mixed with refrigerant is an important factor in the selection of the refrigerant oil. The lube oil used in air conditioners is a mineral oil refined from petroleum. Various types of lube oils are available on the market. The refrigerant has a large effect on the durability of the compressor and therefore, the oil must conform to that specified for each compressor.

Characteristics of SUNISO refrigerator oil (SUNISO is a U.S. specification). 1.

5. 6.

Chemical stability The oil is resistant to chemical reactions with the refrigerant or any other substance in the system. Thermal stability No carbon deposits are formed at high temperatures in the valve and delivery (discharge) portion of the compressor. Low wax content The flocculent material does not separate from the oil-refrigerant mixture in the low-temperature portion of the refrigeration system. Low pour point The oil in the refrigeration system does not freeze because the pour point is lower than the lowest temperature in the system. High insulation resistance Proper viscosity Excessive wear of the compressor is prevented because the proper viscosity is maintained even at high temperatures. Sufficient fluidity of the oil is maintained at low temperatures and a satisfactory oil film is formed at all times. Cleanliness of oil No dust, or foreign matter that accelerate the deterioration of oil are mixed in the oil. Thus, the cylinder liners and bearings will not get flawed and oil grooves will not get clogged.

91-11

STRUCTURE

GENERAL

AND FUNCTION

SPECIFICATIONS

Nippon Denso

Manufacture

DC, 24V

Power source Cooling capacity

(kcal/h)

3,500

Heating capacity

(kWh)

4,000

Compressor l Model l No. of cylinders x 0 bore x stroke l Max. speed (rpm) l (cc/rev.) Delivery Magnetic clutch l Type l Power consumption

Reciprocal type (2M126B) 2 x 050 mm x 32 mm 126 Magnetic, dry disc type (150F) Max. 40 All copper tube, 4-line plate fin type

Condenser Condenser fan l Motor type l Power consumption (W) l (m3/min) Max. air flow 0 Control Receiver dryer l Auxiliary device l Capacity

(cc)

86F 160 23.3 ON * OFF

Fusible plug (Melting point: lOO-105°C at 30 kg/cm*), 580 All aluminum tube, corrugated

Evaporator

desiccant

fin type

Blower l l l l l

Type Power consumption of motor 0 (m3/min) Max. air flow Air flow control Temperature control

Refrigerating

method

Refrigerant l Name of refrigerant l Charging amount Compressor oil l Compressor Protection devise

91-12

oil volume

Sirocco fan 150 Cooling: 7 (heating: 5.3) 3 speeds Full air mix type Evaporation

compression

R-12 1.5 - 1.6 DENS0 OIL 6 or SUNISO 4GS 380 Fusible plug (receiver), pressure switch (air conditioner

unit)

PIPING DIAGRAM

STRUCTURE AND FUNCTION

PIPING DIAGRAM

Hot Water

air

ttt

valve

Heater core ,II Water

IlWater

1 Ic

% Engine

Cooling fan +

uro servlc~

Expansion

valv

valve

Condenser FOOAC107

91-13

STRUCTURE AND FUNCTION

ELECTRIC WIRING DIAGRAM

ELECTRIC WIRING DIAGRAM Condenser

L-_

relay

A/C relay t

A/C

7------7

relay

I-

Condenser --------1

_------___--I

, “1 P

..w...

1 uw ‘U

>“I,CII

-----I

,‘y-yJg$g----

i Thermstat

L.P.S.

H.P.S.

;

Blower

units

L-----J

Blower

switch

I_-----------___--------

_____ A/C

units

FOOAC108

91-14

STRUCTURE AND FUNCTION

COMPRESSOR

(CRANK TYPE)

2. 3. 4. 5. 6. 7. a. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

Service valve (on high side) Valve stopper Discharge valve Valve plate Piston pin Connecting rod Ball bearing Shaft seal Seal plate Service valve (on low side) Core type valve Cylinder head Gasket Suction valve Piston ring Piston Crankcase O-ring Crankshaft Gasket Bottom plate

pressure

Function

Structure

The reason for using a compressor in an evaporation compression type refrigerator is to circulate the refrigerant in the refrigeration cycle so that the refrigerant can be used repeatedly, and to compress the refrigerant to make it easier to liquefy. The compressor functions in the refrigeration cycle to compress the gaseous refrigerant into a high temperature, high pressure type. Thereby, the gaseous refrigerant in the evaporator, which has taken heat from the air in the room, can liquefy by emitting its heat easily, even at an ordinary temperature (for example, at an ambient

The compressor is an important component in the refrigeration system. It can be compared to the heart. Its mechanism consists mainly of “compression mechanism”, “lubrication system”, and “shaft seal section”. The compression mechanism of the straight type compressor servers to convert rotary motion into vertical motion of the piston by means of the crankshaft. The crankshaft has a ball bearing on the front portion and a plain bearing on the rear portion. Each bearing is supported in the crankcase.

outside temperature of 35°C).

The compressor is of a reciprocating type (straight type).

2 cylinder crank

91-15

COMPRESSOR

STRUCTURE AND FUNCTION

OPERATION 1. Compression mechanism Suction valves are secured under the valve plate, and discharge valves and valve stoppers are installed on the top side.

Valve

Valve 1)

Suction stroke When the pressure in a cylinder is lower than that in the suction section (low pressure section) as a result of the lowering piston (in the suction stroke), the refrigerant gas enters the cylinder by forcing the suction valve to open. In this case, the discharge valve comes into close contact with the valve plate closing the discharge port in the valve plate. Therefore, the gas does not flow from the high pressure section back into the cylinder.

2) Compression stroke When the pressure in a cylinder is higher than that in the discharge section (high pressure section), the discharge valve opens, causing the high pressure refrigerant gas to be delivered to a condenser. In this case, the suction valve comes into close contact with the valve plate under the pressure in the cylinder, closing the suction port. Therefore, the gas does not flow back into the suction section (low pressure section).

In this way, the difference between the high and low pressures in the compressor is kept constant and the upward warpage of the discharge valve in the compression stroke is stopped with a valve stopper.

stopper

Discharge

plate

Suction

valve

valve 142F336A

VIIV

142F337A

Discharge

Discharce

Rising

in compression

[discharge)

stroke

142F338

91-16

STRUCTURE AND FUNCTION

COMPRESSOR

Lubrication system This compressor is lubricated at the large end of the connecting rod by a centrifugal splash method.

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

Piston Crankcase Rear shaft Bottom plate Compressor oil Front bearing Shaft seal Crankshaft Piston pin Connecting rod

FOOAC109

Shaft seal section Shaft seals are inserted between the crankshaft and crankcase. This shaft seal section is an important part which keeps the refrigerant and the compressor oil from leaking out of the compressor, whether the compressor is in operation or at rest. Shaft seals are set to seat in a parallel portion of the crankshaft. The seals are fixed in the direction of the crankshaft rotation, allowing the crankshaft and the shaft seals to rotate as one integrated part.

1. 2. 3. 4.

Seal plate O-ring Crankcase Ball bearing

5. 6. 7.

Shaft seal Snap ring Crankshaft

91-17

COMPRESSOR

STRUCTURE AND FUNCTION

MAGNETIC CLUTCH FUNCTION The magnetic clutch is a clutch with a magnet. It operates or stops the compressor as necessary when room temperature reaches, exceeds, or goes below the specified temperature while the engine is in operation.

142F340

1. 2. 3. 4. 5.

6. Key 7. Compressor shaft 8. Plate spring 9. Ball bearing 10. Clutch pulley

Clutch stator Stator coil (magnet) Clutch rotor Snap ring Pressure plate

OPERATION The rotor is set on the compressor crankshaft. When the compressor is at rest, only the pulley runs. When the air conditioner switch is turned ON, the current flows to the coil built in the stator, making the stator a powerful magnet. This magnet strongly attracts the rotor hub, causing the compressor to rotate together with the pulley.

Principle

91-18

of clutch

magnetic 142F341

STRUCTURE AND FUNCTION

CONDENSER

CONDENSER POOACOOl

FUNCTION In a refrigeration system, the condenser converts the high temperature, high pressure gaseous refrigerant compressed in the compressor into a liquid refrigerant. It does this through a forced heat exchange with the outside air by means of two electric cooling fans.

GENERAL DESCRIPTION The condenser acts to take the high temperature, high pressure refrigerant which has been compressed in the compressor, to force it to carry out heat exchange with the outside air using a cooling fan, and to turn the gaseous refrigerant into liquid refrigerant. In the condenser, the quantity of heat to be emitted from the gaseous refrigerant depends on the quantity of heat absorbed from the room air in the evaporator and the work to be done to compress the gas in the compressor. Accordingly, the effect of the heat radiation on the room cooling effect is so large that the forced cooling is performed by two special cooling fans, in addition to the cooling fan for the engine radiator. This independent condenser helps prevent overheating of the engine and does not effect engine performance. 1. 2-Stage control of condenser fan motor The electric fan of the condenser if controlled to two speeds by the pressure of the refrigerant on the pressure side. If the pressure of the refrigerant on the high pressure side rises above 18 kg/cm*,. the pressure switch is turned ON and electncrty at 24V is applied to make the fan motor run at high speed. When the pressure of the refrigerant on the high pressure side drops below 14 kg/cm*, the pressure switch is turned OFF and a resistor reduces the voltage to make the fan motor run at low speed. This extends the life of the fan motor, and also avoids the unnecessary use of electricity.

Plate fin type

FOOACllO

Electric fan Rotor

FOOAClll

Resistor

FOOAC112

91-19

CONDENSER

STRUCTURE AND FUNCTION

Pressure switch This switches ON and OFF according sure of the refrigerant. ON: 14 kg/cm* OFF: 18 kg/cm*

to the pres-

Polnt;Nclosed: 14 kg/cm2 A

v Points open: OFF Operating

18 kg/cm2

pressure

FOOAC113

Pressure switch

POOACO02

Electric fan motor This turns the electric fan and carries out the forced cooling of the condenser. 1)

Fan

Fan motor

POOACO04

91-20

STRUCTURE

RECEIVER

AND FUNCTION

RECEIVER W/SIGHT GLASS (LIQUID TANK)

.Outlet

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

Receiver (liquid tank) tube Receiver (liquid tank) body Sight glass Dryer Silica-gel (contained in cloth bag) Strainer Liquid refrigerant

142F344A

GENERAL DESCRIPTION

The refrigerant liquified in the condenser is temporarily stored in this tank so that the refrigerant can be supplied to the evaporator according to the cooling load. A strainer is provided in the tank and the silica-gel is sealed on the external surface of the strainer. A sight glass and a fusible plug are provided in the top. The purpose of the strainer and silica-gel is to remove dust and water content from inside the refrigeration cycle. If water is contained in the refrigeration cycle, the functional parts will be corroded or the water will freeze in the small port in the expansion valve, thus creating the danger that the flow of the refrigerant will be obstructed.

91-21

STRUCTURE

RECEIVER

AND FUNCTION

1. Fusible plug A fusible plug is also called a melt bolt. It is a bolt in which a hole has been drilled at its center and filled with special solder which melts at 103 to 110” C. If the condenser cannot ventilate properly, making it impossible to thoroughly dissipate the heat, the pressure side in the condenser and receiver will increase excessively and may cause these devices to be damaged. In such a case, the special solder in the fusible plug will melt, emitting the refrigerant to the open air. + When the special solder melts at 103 to 110” C, the pressure of the refrigerant is approx. 30 kg/cm*.

Solder

Fusible plug

2. Sight glass This is a peep window provided to observe the condition of refrigerant flowing through the refrigeration cycle. Generally, if air bubbles can be seen, it indicates that the refrigeration system is lacking refrigerant. When no air bubbles are observed, the proper quantity of refrigerant is in the system. + When there is no refrigerant in the system, no air bubbles will be seen.

,Sight

glass O-Ring

Sight

91-22

FOOAC114

glass

142F346

STRUCTURE

AND FUNCTION

AIR CONDITIONER

UNIT

OUTLINE This air conditioner unit is of a reheat air conditioning type. The air cooled and dehumidified through the evaporator is reheated to the proper temperature through the heater core to provide a comfortable atmosphere in the room. In hot weather, only the evaporator operates and in cold weather, mainly the heater operates. In other seasons, particularly in rainy and humid season, both the heater and the evaporator operate to dehumidify the air and heat the room. POOACO05

91-23

AIR CONDITIONER

STRUCTUREANDFUNCTION

1. EXPANSION

UNIT

VALVE

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

Valve Diaphragm chamber Capillary tube Diaphragm Push rod Pressure spring Adjusting screw Heat sensitizing tube

FOOACTl5

Function This is a temperature actuating expansion valve which has the following functions. 1) The high temperature, high pressure liquid refrigerant passing through the liquid tank is injected through a small orifice. Thereby, the refrigerant is suddenly expanded, resulting in an atomized low temperature, low pressure refrigerant. 2) According to the cooling load, the quantity of refrigerant supplied to the evaporator is controlled depending on the degree that a needle valve has opened.

OUTLINE If evaporation of the refrigerant can be completed at the outlet of the evaporator, regardless of variations in the cooling load in the evaporator and in the speed of the compressor the capability of the refrigerant to circulate in the refrigeration cycle can be utilized to the full, and the air conditioner can be operated with high efficiency. In a temperature actuating expansion valve, the quantity of gaseous refrigerant flowing out of the evaporator as overheated steam (gas) is controlled so that the temper-

ature difference saturated constant.

91-24

(degree of overheating)

steam and the overheated

between the steam remains

The expansion valve consists of a needle valve, heat sensing tube, diaphragm, pressure spring, and adjustment screw. The heat sensing tube contacts with and is secured on the outlet of the evaporator and refrigerant R-12 is sealed inside the tube.

TYPES OF EXPANSION VALVES This type of air conditioner uses an internally equalizing expansion valve. Depending on where the refrigerant pressure (Pe) in the evaporator is sensed, expansion valves are classified into two types, namely, external and internal equalizing valves. In an external type expansion valve, the refrigerant pressure at the evaporator outlet is sensed as indicated by the broken line. In an internal type, the pressure of the refrigerant is sensed immediately after the throttle and expansion through the needle valve.

STRUCTURE

AND FUNCTION

AIR CONDITIONER

UNIT

Diaphragm \

FOOAClW

1) Internal equalizing expansion valve When the evaporation pressure of an air conditioner in operation is stable, the following equation holds: Pf = Pe + Ps Where, Pf: Force applied to the top of the diaphragm by gas pressure sealed in the heat sensing sleeve. Pe: Force applied to the underside of the diaphragm by the evaporation pressure of the refrigerant in evaporator. Ps: Force of screw for adjusting the extent of overheating. I

and pressure in the heat sensing tube are higher, causing the diaphragm to be pushed down. The displacement of this diaphragm will cause the push rod to increase opening of the needle valve. As a result the quantity of refrigerant supplied to the evaporator can be increased. On the other hand, when the cooling load is small, the overheated part “c’ of steam is shorter, causing the pressure in the heat sensing tube to drop. Consequently, the degree of opening of the needle valve is smaller and less refrigerant is supplied. Thus, the quantity of refrigerant is controlled according to the refrigerant load.

Then, the needle valve remains stationary at the same degree of opening and the flow of the refrigerant is kept constant. The refrigerant at outlet L using this expansion valve is always the overheated steam (gas). As the cooling load gets larger (as the temperature of the air taken into the evaporator gets higher), the refrigerant soon evaporates, causing the temperature of the gaseous refrigerant at the evaporator outlet to go up (the overheated part of the steam, L, gets longer). Consequently, the temperature

91-25

STRUCTURE AND FUNCTION

AIR CONDITIONER

UNIT

2. EVAPORATOR The evaporator used is of a flat tube, corrugated fin type as shown. When a forced heat exchange is made with the blower motor between the atomized refrigerant (whose temperature and pressure have been lowered through the expansion valve) and the air in the operator’s room, the refrigerant evaporates, absorbing the heat from the air in the room, and thereby cooling the air. The purpose of the evaporator is to effect such a heat exchange, The air in the room is cooled by making the cooled air circulate in the room. Like the condenser, the evaporator has an extremely simple construction. The capacity of the evaporator depends on the efficiency of heat exchange between the refrigerant and the air. In other words, the shape and material of the fins, together with the space between the fins has a great effect on the capacity of the evaporator. If warm air hits the evaporator fins and is cooled below dew point, the moisture in the air will be condensed and will form drops of water on the evaporator fins. When this happens, if the fins are cooled below 0” C, the drops of water will freeze and change to frost. If frosting occurs, the heat exchange efficiency of the evaporator will drop, so the full cooling capacity cannot be obtained.

POOACO07:

[Gas1

142F400

3. THERMOSTAT FUNCTION

The thermostat is used to prevent the formation of frost on the evaporator. If the temperature of the evaporator fins or the evaporation temperature of the refrigerant goes below 0°C frost will form on the fins or they will freeze, thereby reducing the air supply and deteriorating the cooling capacity. To prevent this problem, the thermostat is used to control the room air temperature to the desired level. OUTLINE

A gas-type thermostat is used. The gas sealed in the heat sensing tube must be very sensitive to temperature variations and must have a large coefficient of expansion. The heat sensing tube is a fin thermostat installed to the evaporator fin. If the air temperature at the air conditioner outlet is higher than the preset level, the gas in the thermostat heat sensing tube will expand to raise the pressure, thereby forcing the diaphragm to move up. Then, the micro-switch will be turned ON, actuating the magnetic clutch to run the compressor. On the other hand, if the air temperature at the 91-26

142F352

AIR CONDITIONER UNIT

STRUCTURE AND FUNCTION

outlet is lower, the gas in the heat sensing tube will contract, causing the pressure to drop. The diaphragm will be pulled down, the magnetic clutch will dis-engage, and the compressor will stop running. Thus, the temperature in the room will be controlled as necessary.

4. PRESSURE SWITCH FUNCTION This switch protects the air conditioner

system.

OUTLINE This switch is used to stop the compressor if an excessively high or low pressure in the refrigeration cycle is detected by the diaphragm. Thereby, the equipment in the refrigeration cycle is protected from damage. Two pressure switches are used in this air conditioner, one for excessively high pressures and one for excessively low pressures.

1) For cutting the high pressure

If the high pressure in the refrigeration cycle, that is, the condensing pressure of the refrigerant, increases excessively because of the clogging or poor cooling of the condenser while the air conditioner is operating, the system break down or be damaged. The high pressure switch is used to prevent such problems.

Pressure

III Fixed

II /---Snap

disc

contact

Pin Terminal

EEx~o:~”

resin)M-Wire

harness

Structure of (for cutting

pressure switch high pressure) FOOAC117

Operating

pressure l42F3S4

A normally-closed type contact is used for the high pressure switch. If the pressure on the high pressure side exceeds 23 kg/cm*, a snap disc will be reversed, a pin will be pushed down, and the internal contact will open. When the contact opens, it will turn OFF the magnetic clutch, causing the compressor to stop.

2) For cutting low pressure If the air conditioner or the compressor is operated when there is little or no refrigerant in the refrigeration cycle, the compressor will not be lubricated properly, and this may cause the compressor to seize up. Before operating the

Pressure

switch for low pressure

cutting l42F356

air conditioner,the switch detects that there is enough refrigerant in the refrigeration cycle. If not, the low pressure switch actuates to prevent the magnetic clutch from engaging.

91-27

AIR CONDITIONER UNIT

STRUCTURE AND FUNCTION

OPERATION

Terminals

A normally open type contact is used for the low pressure switch. If the pressure on the high side exceeds 2.3 kg/cm2, the diaphragm will overcome the spring force, causing the movable contact to close. (Contact

”

point

closed1

OFF

2.3 kg/cm2

(Contact

point

Operating

l-4

Structum of pmssum switch (for cutting low pmssure)

open1

pressure

FOOACll9

FOOAC118

Then, if the drop in the saturation pressure of the refrigerant is detected by the pressure switch OFF signal, the shortage of refrigerant can be detected. In the graph (142F358) indicating the relationship between the residual quantity of refrigerant and its saturation pressure, the detected pressure is 2.1 kg/cm2 when the residual quantity of refrigerant is about 50 g at an outside air temperature of 25°C. This detected pressure is also the saturation pressure at an outside air temperature of O”C, therefore, the pressure switch keeps the compressor from operating, even when there is enough refrigerant. That is, the pressure switch can work as an outside air temperature sensor. A pressure detecting point may be provided on either the high or low pressure side. If it is placed on the low pressure side, the variation in pressure while the air conditioner is operating will cause erroneous action. Therefore, the pressure detecting point is provided between the receiver (liquid tank) and the expansion valve on the high pressure side.

Outside

Detected pressure

When the proper quantity of refrigerant is sealed in the refrigeration cycle before the air conditioner is operated, its saturation pressure is about 6 kg/cm2 at an outside air temperature of 25°C. This pressure does not vary much even if some of the refrigerant has leaked out. However if the refrigerant becomes extremely low, the pressure will drop as shown in the graph (142F358).

.--- I(

Outside

I 100

+Residual

teap.

25’C I*

----

, 0

%gi

air

200 quantity

air

temp.

O°C

300 ‘% of

refrigerant

Relationship between the rrsidule of refrigerant and the pressure

tgl quantity

l42F358

Detects saturation immediately before

pressure oDeration

Expansion

valve

;;

REceiver

> 2

Compressor

Refrigerant

detecting

pressure

point

FOOAC120

91-28

STRUCTURE AND FUNCTION

AIR CONDITIONER UNIT Hot

HEATER

Hot “3

wer

outlet

1) Heater core

The heater using engine cooling water. The heater core consists of fins, tubes, and pipes. If the air of the operator’s room flows through the core fins while hot water is flowing through the heater core, the air will be heated by means of the heat exchange, thereby heating the room.

142F362

2) Water valve This water valve is connected in the engine cooling system circuit (on the heater core inlet side) to control the flow of hot water into the heater core. The valve is opened or closed by means of the heater temperature control knob on the control panel.

O-fling

Spring

Valvaf OUT

FOOACl21

6. BLOWER UNIT This sucks in the air inside the operator’s compartment or air from outside, forces it through the evaporator heater core, and then sends it back into the operator’s compartment.

1) Blower motor The ferrite type blower motor is used to operate a blower which force feeds the air of the operator’s compartment or the fresh outside air through the evaporator. The power consumption of the motor is 15OW,and the motor speed (air flow) is controlled by a resistance.

POOACOl

91-29

STRUCTURE AND FUNCTION

Blower

AIR CONDITIONER

fan

The blower fan is a centrifugal type Sirocco fan. (The air is blown out at right angles to the shaft.)

Sirocco

Centrifugal

fan

type 142F401

Blower

resistor

The blower motor has two resistors built into it so that it can operate at three speeds: LO, ME, and HI.

w LO

FOOAC122

F)auytt; rubber

Stiff

rayon

Inner layer

rubber

braided

yarn

7. PIPING Hoses and tubes are used as piping in the air conditioner system. Hose material is resistance to corrosion by the refrigerant (R-12) and is weather proof.

142F365

Tub

O-rings are used for piping joints, and the sealing ability is ensured by “O-ring + bulge machining”.

Brazed 142F366

91-30

UNIT

STRUCTURE

AIR CONDITIONER

AND FUNCTION

8. AIR CONTROL

UNIT

SYSTEM

FOOAC123

The system can be switched using the air source selector so that the blower motor sucks in inside air or inside + outside air and sends it to the evaporator. The air which passes through the evaporator has its temperature adjusted by the air mix damper and is then blown out through the vents.

1. Defroster vent 2. Face vent 3. Foot vent 4. Air mix chamber 5. Air source selector damper 6. FRESH air filter

7. Blower 8. Evaporator 9. Temperature control damper 10. Heater core 11. Water valve 12. RECIRCULATE air f&r

91-31

STRUCTURE AND FUNCTION

CONTROL PANEL

1. 2. 3. 4.

1. BLOWER SWITCH 1)

91-32

LEVER

SWITCH

Switching when cooling (power for compressor) When the button is pressed, the switch is turned on and the pilot lamp lights up. When the button is pressed again, the switch is turned off and the pilot lamp goes out. I+ If the air conditioner switch is turned on but the blower switch is still off, the air conditioner will not work (the pilot lamp does not light up). + Turn the air conditioner switch on after turning the blower switch on.

CONTROL

This lever controls the temperature during cooling or heating. Move the lever towards (left) the Cool position to lower the temperature; move the lever towards (right) the WARM position to raise the temperature. * If the air conditioner switch and blower switch are turned on, and the lever is moved to the WARM position, the air conditioner will give dehumidifying and heating.

L13FD018

3. TEMPERATURE

This is used for controlling the air flow when cooling or heating, and also acts as the main switch. This switch controls the air flow to three levels: Low - Medium - High * If the knob is turned to the OFF position, the air conditioner will stop.

2. AIR CONDITIONER

Blower switch Air conditioner switch Temperature control lever Air source selector lever

AIR SOURCE SELECTOR

LEVER

This lever switches the source of air during cooling or heating. FRESH (right - outside air is brought in) This is used for normal cooling and heating. Fresh air from the outside is used in addition to the air inside the operator’s compartment. RECIRC (left - inside air is recirculated) This is used for quick cooling and heating. * In this position, only the air inside the operator’s compartment is used. l

AIR CONDITIONER 92

TESTING AND ADJUSTING

SERVICETOOLS ................................................................. GAUGE MANIFOLD ............................................................. GAS LEAKDETECTOR ........................................................... HALIDE TORCH LEAK DETECTOR ................................................ ELECTRICLEAKTESTER ....................................................... VALVE FOR SERVICE CANS .......................................................

3 3 6 6 8

MAINTENANCE PROCEDURE ...................................................... PRECAUTIONS WHEN REMOVING OR INSTALLING PIPING .............................. PROHIBITED WORK .......................................................... OTHER PRECAUTIONS ........................................................ BLEEDING AIR FROM REFRIGERATION CIRCUIT ...................................... PURPOSE ................................................................. CONNECTING GAUGE MANIFOLD ............................................... EVACUATION ............................................................... AIR-TIGHTNESS CHECK ....................................................... GAS-LEAKCHECK ........................................................... EVACUATlON(REPEATING) .................................................... CHARGING THE REFRIGERATION CIRCUIT WITH REFRIGERANT .......................... CHARGING FROM THE HIGH-PRESSURE SIDE. ..................................... CHARGING FROM THE LOW PRESSURE SIDE (REPLENISHING THE REFRIGERATION CIRCUIT) WHEN THE AMBIENT TEMPERATURE IS LOW ...................................... WHEN THE AMBIENT TEMPERATURE IS HIGH ...................................... REPLACING SERVICE CANS ..................................................... CHECKING THE AMOUNT OF REFRIGERANT ......................................... REMOVALOFGAUGE MANIFOLD ................................................. DISCHARGINGTHEREFRIGERANT ................................................ DAILYCHECKS ............................................................... CHECKREFRIGERANTLEVEL .................................................. CLEANINGTHECONDENSER .................................................. CHECKING THE V-BELT ....................................................... CHECKlNG OIL LEVEL.. ........................................................ PROCEDURE FOR CHECKING .................................................. PROCEDURE FOR CHECKING OIL LEVEL ADDING AND REMOVING OIL ......... : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : :‘: : : : : : : : : : ADDING OIL BY EVACUATION ..................................................

10 10 10 10 12 12 12 13 13 13 14 15 15 16 17 ii 18 20 20 21 21 21 21 22 22 22 23 23

TROUBLESHOOTING ............................................................. VISUAL AND ACOUSTICAL CHECKS ............................................... DEFECTIVECOOLING .......................................................... TROUBLESHOOTINGTABLES .................................................... DEFECTIVE HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 24 25 26 28

92-1

TROUBLESHOOTING USING GAUGE MANIFOLD ...................................... PREPARATIONSBEFOREMEASURING ............................................ INSUFFICIENT REFRIGERANT .................................................. EXCESSIVE REFRIGERANT OR INSUFFICIENT COOLING OF CONDENSER AIR INSIDE REFRIGERATION SYSTEM ............................................ MOISTURE IN REFRIGERATING SYSTEM .......................................... REFRIGERANTDOESNOTCIRCULATE ........................................... FAILURE OF EXPANSION VALVE (OPEN TO FAR) .................................... DEFECTIVE MOUNTING OF HEAT SENSING TUBE ................................... DEFECTIVE COMPRESSION BY COMPRESSOR .....................................

92-2

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

29 29 29 30 30 31 32 33 33 33

SERVICE TOOLS

TESTING AND ADJUSTING

SERVICE TOOLS GAUGE MANIFOLD The gauge manifold is used not only for evacuation and charging refrigerant, but also for troubleshooting. The dials on the front of the gauge manifold are used to open and close the valves. LO indicates “Low pressure valve”, and HI indicates “High pressure valve”. Each valve can be opened and closed by turning the respective dial. 1. 2. 3. 4. 5. 6. 7.

Low pressure valve Low pressure gauge High pressure gauge High pressure valve Red hose Green hose Blue hose

1. STRUCTURE AND HANDLING OF GAUGE MANIFOLD The following four circuits (A to D) can be structured by opening or closing the high and low pressure valves.

Gauge manifold

FOOACOlO

To wuw To refriQerrtion cycle

Structure of vahm

Structure 1. 2. 3. 4. 5.

of. gauge manifold

FOOACOll

Low pressure gauge High pressure gauge High pressure valve (HI) Low pressure valve (LO) Built-in valve (Also called schrader valve)

1. 2. 3. 4.

Valve operation knob Valve plate Spring Seat

92-3

TESTING AND ADJUSTING

SERVICE TOOLS

A. When both low pressure valve (LO) and high pressure valve (HI) are closed:

B. When low pressure valve (LO) is open, and high pressure valve (HI) is closed:

C. When low pressure valve (LO) is closed, and high pressure valve (HI) is open:

D. When both low pressure (LO) and high pressure valve (HI) are open:

92-4

TESTING

AND ADJUSTING

CHARGING

SERVICE

TOOLS

HOSES

The three charging hoses are blue, green, and red. The blue one is connected to the low pressure side, the green one to the adapter at the center, and the red one to the high pressure side. When storing the gauge manifold, connect each charging hose to an empty adapter as shown in Fig. FOOACOlO to prevent dust and water from entering the manifold. Since the pin which opens the core type valve is built into the nut on the bent adapter (45”) at the end of the hose, it is not necessary to install an adapter (joint to open the core type valve) when connecting with another core type valve.

WARNlNGf

For the above reason, be sure to connect the straight end to the gauge manifold, and the bent end to the mate side (service valve or charge valve of the compressor).

Charging

Since there is a packing in the nut at the end of the hose, it can be connected to the mate side by tightening it lightly by hand. (It is not necessary to tighten it with pliers.) Although the core type valve can be opened and closed with the pin, the valve cannot be adjusted with a valve plunger as in service valves (a stem type valve opened and closed with a ratchet wrench).

2. 3. 4.

hose [with

built-in

pin1

FOOACOi3

Pin Packing 45 degree swivel Nut

If the needle of the gauge fluctuates, tighten nut (4) a little more.

To gauge manifold

To inside of compressor 1. Charging hose tat bent side1 2. Core type valve [Scharader valve1 3. Pin 4. Nut

Core type

service

valve

FOOAC014

92-5

TESTING AND ADJUSTING

SERVICE TOOLS

GAS LEAK DETECTOR A tester that can detect the leak of refrigerant gas is called a gas leak detector. To find the place from which gas is leaking, look for it patiently. Even if a highly accurate detector is used, a gas leak may be missed if you do not look carefully. Especially, 10 days or so after the gas has been charged, if the operator feels that the

HALIDE TORCH LEAK DETECTOR The main components of the halide torch leak detector are a bin(l), valve (2), intake pipe (3) nozzle (6), torch (7), and combustion cylinder (11).

cooling capacity might have decreased because of a gas leak, check all connections, rotating parts, welded zones (including fusible plug of liquid tank) carefully. There are two types of gas leak detectors: 1.

Halide torch leak detector - it can detect any gas leak which causes a significant drop in

cooling capacity any time during one season. Electric leak tester - can detect l/15 of the amount detect.

of gas that a halide torch type can

1. 2. 3. 4. 5.

Bin Valve Intake pipe and hose Strainer Holder (set screw for combustion cylinder)

6. Nozzle 7. Torch 8. Ignition window 9. Set screw for copper plate 10. Copper plate 11. Combustion cylinder

’

4 RJ

Structure

halide

torch

leak

Spare

detector FOOACO15

92-6

12. Cap 13. Wrench for nozzle 14. Handle 15. Adjustment line for flame length (upper limit) 16. Adjustment line for flame length (lower limit)

17. Core type valve (for bin) 18. Nozzle cleaner 19. Wrench for bin valve

TESTING AND ADJUSTING

SERVICE TOOLS

2) To ignite the gas, insert a match or lighter through the ignition window of the combustion cylinder, and turn the handle counterclockwise. 3) Use the valve to adjust the flame length between the upper limit line (15) and the lower limit line (16). If the flame is too long, it can only overheat the combustion cylinder. It cannot detect slight leaks of the refrigerant. The shorter the flame, the more sensitive the detector. 4) After adjusting the flame length, slowly bring the end of the intake pipe to possible leaking places (connections of the piping) and observe the color of the flame. The relation between the color of the flame and the amount of the leaking refrigerant is shown in the table below. Always keep the detector in the upright position. 5) When the leak detector is not in use, remove the bin. Replace the bin when empty.

When air containing the refrigerant gas is inhaled from the intake pipe, it will contact the heated copper plate (10). Copper halide will be produced to change the color of the flame. A gas leak cab be detected with this change in color of the flame. (see table below)

WARNING!

1. In the halide torch gas leak detector, an open flame is used. Since it can ignite a combustible gas, make sure that there are no flammable substances before using the detector. 2. Do not breathe the vapor coming out of the detector. Although freon gas is not poisonous by itself, it can form poisonous phosgene gas, hydrochloric acid, or fluoride when it contacts the flame. Therefore, never breathe the vapor coming out of the gas leak detector. How to detect gas leak 1) Confirm that propane gas is charged in the bin.

Connect the bin to the valve, and turn the valve fully clockwise. The core type valve (inside valve) of the bin will open, and the gas will be ready to flow out. If the valve handle is turned counterclockwise, the gas will flow out.

Flame of halide torch and amount of leakina of R-12 Amount of leaking gas

Degree of leak

g/month

P/month

0.8

mm3/sec

Color of flame

0.13

Detection is imoossible

4.8

1.85

Sliaht areen

6.8

2.47

Light green

8.4

3.23

Light green

114

22.8

3.78

Greenish purple

163

32.6

3.85

Greenish purple near purple

500

100.0

12.57

Greenish ourole almost ourole

108.0

Purple Decomposition of gas is noticed

1400

280.0

92-7

TESTING AND ADJUSTING

ELECTRIC LEAK TESTER The electric tester utilizes the cations discharged from metals at high temperature. This tester uses a platinum wire as the heating electrode. It is based on the principle that many cations are discharged when halide gas or air containing halides comes into contact with the heated platinum. The detector electrodes are made of double cylinders; the inside positive electrode heated to approximately 800°C and the outside negative electrode. A voltage of 200V is applied between these two electrodes. If air containing halide gas flows between the electrodes, the cation current flows from the positive to the negative electrode. This current is amplified to turn on the lamp and buzzer to indicate a gas leak. The electric leak tester can detect a gas leak as low as 10AmmHg.Q/sec.

WARNING!

The detectors electrode is heated to 8OO”C, which can ignite a combustible gas. Therefore, confirm that there are no combustible substances around the work area.

How to detect gas leak 1) Connect the detector cable to the metal plug socket at the rear of the amplifier. 2) Connect the power cables. a) For HGT-112 model, connect the power cable to an automobile battery (12V), the red clip to the positive (+) terminal, and the black clip to the negative (-) terminal. + If the cables are connected in reverse, the tester will break down. b) For HGT-200 model, connect the power cable to the AC power source (AClOOV, 50/6OHz). 3) Set the “SELECTOR” knob to “STANDBY” and turn the power switch “ON”. Wait for about ten minutes until the electrode heater is warmed up. 4) Set the “SELECTOR” knob to “CHECK”. Using the check leak liquid, check the operation of the buzzer and alarm lamp in a place where there is no halide gas. Unscrew the leak valve of the check leak liquid one turn with a screw driver, and bring the intake pipe of the tester near the leak valve. If the buzzer and alarm lamp operate, the tester is normal. If they do not operate, or readjustment is necessary, set the “ALARM SET” knob to the point where the

92-8

SERVICE TOOLS

buzzer and the alarm lamp start to operate. + If the “ALARM SET” knob is turned by a large angle at one time, its sensitivity is not stable, and will cause misoperation. Wait for about 20 seconds after turning the knob one scale. Set the “SELECTOR” knob to “LEAK TEST-l” 5) (buzzer and alarm lamp operate) or “LEAK TEST-2” (alarm lamp only operate). 6) Slowly bring the end of the intake pipe of the tester to possible leaking places (connections of the piping). When the buzzer or alarm lamp operate at a certain place, gas is leaking from there. 7) When stopping use of the tester for a short time, set the “SELECTOR” knob to “STANDBY”. 8) Although the sensitivity of the electrodes gradually decrease, they long lives. Adjust the sensitivity with the “ALARM SET” knob until adjustment is no longer possible. When adjustment is no longer possible, replace the electrodes with new ones.

WARNING!

1. The electrode of the tester is heated to 800°C while the tester is in use. Never use it in a place where there are combustible gases (city gas, propane gas, thinner, gasoline, etc.). 2. If the tester is used for a long time, the end of the detector (intake pipe and electrode housing) will be heated to approximately 60°C. Never touch it. 3. A highly dense halide gas (gas from a freon gas bin) can damage the electrode of the tester, or deteriorate the performance. Never let it flow into the tester. 4. Note that the tester will not operate correctly if there are halide gases in the ambient air (gasoline, thinner, cigarette smoke, etc.). 5. Be sure to close the leak valve of the check leak liquid after using. 6. When the humidity of the ambient air is very high or water vapor is inhaled, the buzzer may continue to operate even if the “ALARM SET” knob is set to “0”. This is not a failure. After the vapor has cleared, the tester will operate correctly. 7. Always keep the intake pipe and filter clean. A clogged ‘filter can cause insufficient sensitivity, instability, incorrect responses, etc. 8. If the intake pipe is blocked or bent, or the opening of a vent for the fan is blocked, the fan motor will overheat and damage may occur. 9. When the tester is not in use for short periods, set the “SELECTOR” knob to “STANDBY”. When the tester is not in use for long periods of time set the power switch to “OFF”. Note that the detector is heated to 70 to 80°C while in “STANDBY”. 10 Never apply a strong shock to the detector and amplifier.

SERVICE TOOLS

TESTING AND ADJUSTING

VALVE

FOR

SERVICE

CANS

The valve for the service cans is used when charging refrigeratina svstem. Handle it as follows: 1) BeFore using the service can, confirm that a packing can be used on it. Then, turn the handle fully counterclockwise to lift the needle. Lii the disc (circular nut) at this time. 2) Screw the valve into the service can, and tighten the disc. Take care not to tighten it so much that the service can is damaged. 3) Connect the green charging hose of the gauge manifold to the valve. Turn the handle of the valve clockwise to lower 4) the needle and make a hole on the blind cap of the service can. to lift the 5) Turn the handle counterclockwise needle. Then, the refrigerant will flow into the refrigerating system through.the valve. To stop the gas, turn the handle fully clockwise to lower the needle.

WARNING!

0 -2

Never reuse an empty can. Structure

of valve

service

can FOOACOl6

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

Adapter for charging Handle Needle Packing Service can Disc

hose

92-9

TESTING AND ADJUSTING

MAINTENANCE

MAINTENANCE PROCEDURE

PROCEDURE

PRECAUTIONS WHEN INSTALLING PIPING

REMOVING

PROHIBITED WORK The followina operations are prohibited: 1) Never allow moisture, dirt, or air to get into the air conditioner parts. If moisture, dirt, or air does enter into the air conditioner parts, it will become completely impossible for the air conditioner to work properly, so be particularly careful when carrying out operations. For this reason, never work outside, and avoid working on rainy days.

Never let moisture, air, or dirt get into the air conditioner! FOOAC130

not

remove

blind

plugs

2) Never leave the air conditioner parts with the

blind plug removed. To prevent rust and the entry of dust, dirt, or moisture, the air conditioner parts are all carefully dried, and parts such as the compressor are filled with gas and completely sealed with blind plugs. Therefore, do not remove the blind plugs until immediately before connecting the piping, and after removing the plugs, complete the work quickly. In particular, if the receiver is left open, the desiccant (drying agent) inside will completely lose its effect. WARNING!

Never let moisture or dirt get into the parts of the cooler.

WARNING!

Never leave the parts of the cooler with the blind plugs removes.

Never parts

leave the with blind

FOOAC131

Never

run compressor

without

gas!

Don’t run without

gas

Put in gas

Never run the compressor in the refrigeration cycle without any refrigerant. If the compressor is run without any refrigerant, the oil will not lubricate properly and this may lead to seizure.

OTHER PRECAUTIONS 1) When trying to bend a stiff pipe, never heat it with a burner. If a burner is used on the pipe, an oxidized film will be formed inside, and this will cause the same kind of problem as dirt. If it is necessary to clean the inside of the pipe, use freon 11, never use compressed air because it contains moisture.

air conditioner plugs removed!

FOOAC132

Never Never

heat clean

pipes pipes

with with

flame! compressed

air!

FOOAC133

92-10

TESTING AND ADJUSTING

MAINTENANCE PROCEDURE

2) Be careful

not to connect the receiver in reverse. There is an “IN” mark at the refrigerant inlet side of the receiver sight glass, so be careful not to connect the inlet and outlet sides in reverse when connecting the piping. If the ports are connected in reverse, it will lead to such troubles as overcharging with refrigerant and defective cooling. t When removing the piping, replace the receiver.

Do not connect outlet ports in

the inlet and wrong direction! FOOAC134

When connecting the piping, coat with oil. When connecting the piping, coat the O-ring with compressor oil before tightening. Always use two spanner wrenches when tightening. When tightening, turn only the spanner on the flared nut, keep the other nut in position and do not let it turn. Always coat piping and with compressor oil!

O-rings FOOAC135

Tighten the piping connections to the specified tightening torque. When connecting the piping, if the pipe connection nut is tightened too much, damage to the flared part and cause the nut to fall off. With Oring type nuts the seal may be deformed, leading to gas leakage. On the other hand, if the connections are not tight enough, the gas will leak, so always tighten to the standard torques given in the table below.

Too loose

Too tight Do not undertighten or the piping connections!

overtighten FOOAC136

Standard

toraues

for DiDha connection

Type of tightening

nut

tightening

nuts

torque (kgcm)

3/8”, 08 (8 mm)

120 - 150

l/2”

200 - 250

5/8”

300 - 350

92-11

MAINTENANCE

TESTING AND ADJUSTING

BLEEDING CIRCUIT

AIR

FROM

REFRIGERATION

PURPOSE Extreme care should be taken during handling, to prevent moisture from entering the air conditioner. Since the refrigerant (R-12) does not dissolve easily in water, small amounts of water remaining inside the circuit may become frozen in the small orifice of the expansion valve, and cause rusting of the compressor valves. This can impair the operation of the air conditioner in various ways. Thus, it is necessary to remove all moisture from the air conditioner before charging it with refrigerant Evacuation [repeating

PROCEDURE

To remove the moisture from the air conditioner, the water is evaporated by evacuation. To obtain a good vacuum, a high performance vacuum pump must be used. Otherwise, a long time is required for evacuation. Moisture in the air conditioner can be removed by a “repeating vacuum method” in a relatively short period of time.

procedure vacuum method1

‘,y,a;;;tion

iy;;;ation

For approx. 15 minutes

Leave for 5 minutes

$%ghtness

+ fzyyAggauge

Charging conditioner with refrigerant (1

+ %Zak

kg/cm21 Charge conditioner with refrigerant gas to gauge pressure 1 kg/cm2

t750

mmHg

higher1

CONNECTING GAUGE MANIFOLD 1) Close high-pressure (HI) and low-pressure (LO) valves at the gauge manifold. 2) Connect charging hoses (red and blue) to the compressor service valves. Red hose.. . . . . to high pressure side (D side) Blue hose . . . . . to low pressure side (S side)

A 3)

WARNING! The “L” shaped ends of the charging hoses should be connected to the compressor service valves. Otherwise, the valve core will not open. Each charging hose should be connected to the right (high or low pressure) side.

Valve

set

Connect ‘L’

shaped

Lawprsss valv.

With the engine stopped, open the high pressure valve of the gauge manifold and the valve for the service can. Charge approximately 4/5 of the amount of refrigerant specified on page 91-12 SPECIFICATIONS.

Connecting

the gauge manifold FOOAC039

92-12

TESTING AND ADJUSTING

MAINTENANCE

Valve

set

EVACUATION 1) Open both the high-pressure valve (HI) and the low pressure valve (LO) at the gauge manifold. 2) Switch on the vacuum pump and allow it to run for approximately 15 minutes. 3) When the negative pressure (degree of vacuum) reading of the low pressure gauge is 750 mmhg or more, turn off the vacuum pump switch and close the high and low pressure valves.

+ High

AIR-TIGHTNESS CHECK 1) Maintain this vacuum (keep the high and low pressure valves closed) for 5 minutes or more. Then, make sure that the needle of the gauges does not move back to zero. 2) If the needle moves toward the zero mark, it indicates a leak. If this happens, retighten or repair the piping connections and perform the evacuation again until it is confirmed that no air is leaking.

Vacuum

PROCEDURE

pump

[in

LO Close

pressure

operation1

Evacuation

Valve

set

HI Close

I *s”m

fnr

FOOAC040

\ Retightsn

Air tlghtness 4

GAS-LEAK CHECK 1) Reconnect the charging hose (green), which has been connected to the vacuum pump, to a service can. + For method of installing the service can. See VALVE FOR SERVICE CANS on page 92-9. 2) Open the service can valve, keeping the nut on the gauge manifold side of the charging hose (green) in the open position. Thus, the air in the charging hose is bled out under pressure of the refrigerant. (when a “Whoosh” sound is heard, retighten the hose.)

Valve sst LO

connections

FOOACMl

check

Note: If refrigerant out with a ‘whoosh’ tighten flared nut.

leaks sound,

Open service can valve

nrru

Service

can+

from

charging

compressor

Bleeding

air

U R-12

hose FOOAC042

92-13

MAINTENANCE PROCEDURE

TESTING AND ADJUSTING

3) Open the high pressure valve at the gauge manifold and charge with refrigerant until the low pressure gauge reads 1 kg/cm*. After charging, close the high pressure valve. 4) Carefully check the refrigeration circuit for gas leaks, using a gas leak detector. 5) If a leak is detected, retighten or repair it.

sat

Vaivr

LO Close

HI Open

Low pressure gauge readlng 1 kg/cd

. ~0

Class

check

WARNING! Before checking for gas leaks, make sure there are no flammable substances (such as fuel) in the vicinity. If the refrigerant comes into contact with a naked flame, a poisonous gas (phosgene) will be given off.

Charging

with

refrigerant

for

leaks

FOOAC043

ValvesetLow pressure gaugeabove

I LO 1 HI

Open]DpenB+

EVACUATION (REPEATING) 1) Close the service can valve and disconnect the green charging hose from the service can, then connect it to the vacuum pump. + Both the high and low pressure valves at the gauge manifold should be kept closed. 4 Repeat the evacuation procedure described on page 92-13 (2. EVACUATION) until the lowpressure gauge reads 750 mmHg or higher, for 15 minutes or more. 3) After evacuation, close the high and low pressure valves at the gauge manifold.

HI Close

High pressure gauge

WARNING! Evacuation should be repeated at least two times. Particularly in rainy or humid weather.

Vacuum

pump

(in

operation)

Evacuation

92-14

LO Close

[Repeating)

FOOACO44

TESTING AND ADJUSTING

MAINTENANCE

CHARGINGTHE REFRIGERATION WITH REFRIGERANT

CIRCUIT

After evacuation, charge the refrigeration refrigerant in the following manner:

circuit with

Charging

the

rsfrigsratlon

Evreurtlon

cylca For rpproxlnrtely 15 minutes

__t

PROCEDURE

Check f;;kjas

with

Leave air conditioner for 5 ninutss For 15 nlnutss or more at 750 Hg or norm

4 1. 2.

Charge with 1 l/2 cans 00 not operate the air Reralnnish the rsfrlnrrrtlon

I of refrigerant from the high condltlonrr unit while charging cycle from the low pressure

pressurs side. with refrigerant. side. by oDeratIng

the

air

Ll3zzOos

CHARGING FROM THE HIGH-PRESSURE SIDE 1) Disconnect green charging hose from the vacuum pump, then connect it to the service

,, “al”0

sat

2) ?kn

the service can valve, keeping the nut on the gauge manifold side of the charging hose open, to bleed the air out of the charging hose under the pressure of the refrigerant. + When a ‘whoosh” sound is heard, retighten the nut.

To compressor

Bleeding

air

from

charging

hose

FOOAC045

92-15

MAINTENANCE

TESTING AND ADJUSTING

Open the high-pressure valve at the gauge manifold and the service can valve, with the engine stopped. Charge specified amount of refrigerant (see page 91-12 SPECIFICATIONS). WARNING!

Valve

set

Put In 1 l/2 cans Iabout 600 gl

PROCEDURE

“,

DON’TS

A. While charging with refrigerant, do not operate the compressor. If the compressor is operated, the refrigerant will flow back into the service can and hoses, causing them to burst. B. If the compressor is operated without refrigerant in the refrigeration cycle, it will burst or seize up. C. The low pressure valve at the gauge manifold must not be opened (to prevent compression of the liquid refrigerant). 4)

Close both the high pressure valve at the gauge

Charging with refrigerant [with engine stopped1

manifold and the service can valve.

FROM THE LOW PRESSURE SIDE (REPLENISHINGTHEREFRIGERATIONCIRCUIT) 1) Make sure that the high pressure valve at the gauge manifold is closed. 2) Start the engine and open all the doors of the cab. 3) Turn on the air conditioner switch. Thermal control lever. . . . . . set to “COLDEST” Blower switch . . . . . . . . . . . . . . . . set to “HI” 4) Set the engine speed to 1300 - 1500 rpm. CHARGING

WARNING! If valve is opened the service can will be broken off, causing serious injury.

[Gauge

FOOAC048

nanifoldl

Start engine and run 1300 - 1500 rpm

COLDEST COOL

HI . . . @ OFF * Blower

Preparations for the refrigeration

92-16

Thermal control

lever

switch

replenishing circuit

FOOAC047

TESTING AND ADJUSTING

MAINTENANCE PROCEDURE

5) Open the low pressure valve at the gauge

manifold and the service can valve. Then, charge the circuit with refrigerant until air bubbles in the sight glass at the liquid tank disappear.

Contlnus to charge until air bubbles d&appear from sight glass

Valve

sot

Open

Closa

Gauge manifold indications: 0 High pressure side . . . . . 12 to 17 kg/cm2 (ambient temperature 30°C) 0 Low pressure side . . . . . 1.5 to 2 kg/cm2 (ambient temperature 30” C)

6) After charging the refrigeration circuit with

refrigerant, close the low pressure valve at the gauge manifold and the service can valve. Then, stop the engine.

7) Using a gas leak detector, make sure there are no gas leaks.

WARNING!

DON’TS Sarvlea [Da

Keep the service can right side up while charging the air conditioner with refrigerant. (When charging with the engine running). If the service can is turned upside down, the liquid refrigerant will be drawn into the compressor, causing damage to the compressor valves and packing. Set or hold the service can upright and charge the circuit with gaseous refrigerant.

can

not stand

1. Do not open the high pressure valve (HI) at the gauge manifold. If the high pressure valve is open, the gas will flow into the service can and charging hoses, causing them to burst.

[with

Charging refrigerant engine

Valve

set

Open

in operation3

FOOACO48

Continueto charge until air bubbles disappear from slght glass

3. WHEN THE AMBIENT TEMPERATURE IS LOW Where the refrigerant is not flowing into the refrigeration circuit easily, warm the service can in warm (40°C or below) water to raise the pressure in the service can.

WARNING! If the service can is heated in hot water or by direct flame, it will burst. When warming a service can in warm water, make sure the water temperature is not higher than 40°C.

ater

heated

to In

4. WHEN THE AMBIENT TEMPERATURE IS HIGH If the ambient temperature is high, to speed the flow of the refrigerant into the circuit, cool the condenser by using a fan.

At low ambient

operation

temperatures FOOAC049

92-17

TESTING AND ADJUSTING

REPLACING

MAINTENANCE

SERVICE CANS

PROCEDURE

+-Yalve

handle

If the service can is emptied before the circuit is completely charged, replace it with a new can in the following manner:

1) Close the high and low pressure valves at the gauge manifold.

2) Raise the needle and disc of the service can valve.

3) Install the service can valve into a new service can. Service

4) Bleed the air from the charging hose as follows: a) Tighten the service can valve, then loosen it slightly. b) Slightly open the low pressure valve at the gauge manifold. c) When the refrigerant flows out between the service can valve, making a “whoosh” sound, immediately close the service can valve and the low pressure valve at the gauge manifold.

Valve

can

valve

FooAco50

Note: When refrigerant flows with a ‘whoosh’ sound, close the low pressure valve

set

Slightly service

loosen valve

WARNINGI Be careful not to let the refrigerant contact your skin.

5) Screw the service can valve handle into the can to provide a hole and continue charging with refrigerant. Bleeding

air

from

charging

hose FOOAC051

CHECKING ANT

THE AMOUNT

After charging the refrigeration check the amount as follows:

13-15

OF REFRIGER-

kg/c.2

circuit with refrigerant, gh pressure

valve

1) Disconnect

the lead wire to the magnetic clutch and reconnect it so the power is directly from the battery.

2) Open all doors and start the engine.

Run the

engine speed at 1300 to 1500 rpm. 3) Connect the magnetic clutch lead wire directly to the battery. Turn the blower switch to the “HI” position. (Set the thermal control lever coldest position.) 4) Maintain a pressure of 13 to 15 kg/cm* on the high pressure side for approximately 5 minutes, or until the refrigeration circuit is stabilized.

92-18

Stop blower motor and oDerate CORD~~SSO~ only. (EngIna spa& is set td 1300 - 1500 rnpl

I11 Checking

amount

refrigerant

charged FOOAC052

TESTING AND ADJUSTING

5) After the refrigeration circuit is stabilized, turn

off the blower switch, so that only the compressor is running. The pressure on the low pressure side will gradually decrease. If the pressure on the high pressure side is kept between 13 to 15 kg/cm2, the amount of refrigerant charged can be measured in the followina manner: 4 Too little refrigerant charged” At a pressure of 1.01 kg/cm2 or above on the low pressure side, bubbles pass continuously through the sight glass. b) Proper amount of refrigerant charqed. At a pressure of 1.0 to 0.6 kg/cm on the low pressure side, bubbles pass continuously through the sight glass. cl Too much refrigerant char%+ At a pressure of 0.6 kg/cm or less on the low pressure side, bubbles may or may not be observed in the sight glass at all.

MAINTENANCE

Remove

charging

PROCEDURE

hoses The high pressure hose should be left until the gauge reading reaches its miminun. Then disconnect the hose from the compressor

Low pressu valve [clos

igh

pressure

Loosen flared nut,“iu/shing compressor service valve

hose

valve

[close]

6) If there is too little refrigerant, add some from

the low pressure side as described on page 9216 (see 2. CHARGING FROM THE LOW PRESSURE SIDE.)

Valve

onto

the

FOOAC054

7) If there too much refrigerant, discharge some gradually from the low pressure side until the amount is decreased to the proper level. 6) After making sure the refrigeration circuit contains the proper amount of refrigerant, turn on the blower switch and confirm that, at a pressure of 1.01 kg/cm2 or more on the low pressure side, no air bubbles appear in the sight glass. Turn off the blower switch and confirm that, at a pressure of 1.0 to 0.6 kg/cm2, air bubbles pass through the sight glass. Repeat these checks two or three more times.

fitting

set

High

pressure

gauge

High

pressure

valve

[open)

9) Stop the engine, and reconnect the magnetic clutch lead wire as it was before. 10) Disconnect the charging hoses and remove the gauge manifold (SEE REMOVAL OF GAUGE MANIFOLD - page 92-20).

Discharging

refrigerant

FOOAC137

92-19

MAINTENANCE PROCEDURE

TESTING AND ADJUSTING

REMOVAL OF GAUGE MANIFOLD

Remove

charging

hoses

After charging the refrigeration circuit with refrigerant remove the charging hoses from the compressor as follows:

The high pressure hose should be left until the gauge reading reaches its nimimum. Then disconnect the hose from the compressor

1) Push the “L” shaped fitting on the low pressure charging hose (blue) against the compressor service valve to prevent leakage. Then, loosen the flared nut.

4 As soon as the flared nut is removed, disconnect the charging hose from the service valve.

3) Leave the charging unit connected to the refrigeration circuit until the high pressure gauge shows the lowest possible reading (10 kg/cm2).

Low pressu valve [clos

High

pressure

nut.“p&hing Loosen flared compressor service valve

hose

valve

(close1

k BI

4) Disconnect the high pressure hose (red) in the same manner as the low pressure charging hose.

WARNINGI Disconnect charging hoses from compressor as quickly as possible to minimize loss of refrigerant. Particularly on the high pressure side, compressor oil may sometimes gush out together with refrigerant. Therefore, wait for the gauge to drop to its lowest reading and remove the hose quickly.

Valve

WARNING! Be careful not to get any refrigerant on your skin. Use safety goggles to protect your eyes from the refrigerant.

DISCHARGING

fitting

onto

the

FOOAC054

set

EKl

THE REFRIGERANT

High

pressure

gauge

igh

pressure

valve

[aped

If the coolant is discharged during the refrigerating cycle, always use the charging valve and discharge the refrigerant gradually from the high pressure side.

WARNING! If the piping connection is removed immediately, the refrigerant will get in your eyes.

WARNING1 If all the refrigerant is discharged at one time, the compressor oil will leak out, so be sure to discharge the refrigeration circuit gradually.

Discharging

refrigerant

FOOAC137

TESTING AND ADJUSTING

MAINTENANCE

PROCEDURE

DAILY CHECKS When carrying out the daily maintenance checks before operating the machine, also check the following items: 1. CHECK REFRIGERANT LEVEL

Start the enaine and check the followino: 1) Turn theair conditioner switch ON, and run the engine at the standard speed (generally ar 2000 rpm). 2) Run the blower motor at maximum speed. 3) Set the temperature control lever at maximum cooling. 4) Check the sight glass. Look at the sight glass at the top of the receiver and dryer, and check the flow of the refrigerant in the refrigerating cycle. If there are bubbles in the flow as shown in the figure, the refrigerant is low. If there are no bubbles, the refrigerant is at the correct level. However, even if the refrigerant level is too high, there are no bubbles, so in this case, check the temperature of the suction hose (low pressure piping) connected to the compressor. If it is warm, the refrigerant level is too high.

,Sight

glass

cl\ No

refrigerant2

Re Checking

sight

glass FOOAC138

2. CLEANING THE CONDENSER Direct tap water on the condenser installed at the front of the machine to wash off any dirt or mud stuck to the condenser. If the is excessive dirt, use a soft haired brush while applying the water. A hard haired brush may damage or bend the fins, so do not use a hard haired brush. Repair any crushed fins with a screwdriver blade or electrical pliers. 3. CHECKING THE V-BELT If the V-belt is loose, it will slip and cause the compressor speed to drop. As a result, it will be impossible to obtain the specified cooling capacity, and cooling will be defective, so check the V-belt in the following manner. Push the V-belt with a finger midway between the pulleys. The V-belt should deflect about lOmm, but this figures varies according to the machine model. For details of the V-belt tension, see the operating manual for that machine. Do not use any deteriorated V-belt. Replace it with the same size and type of V-belt.

Compresso<

pulley /

1 haft

pulley

v-bit Checking

V-belt FOOAC13S

92-21

MAINTENANCE

TESTING AND ADJUSTING

CHECKING

PROCEDURE

OIL LEVEL

1. PROCEDURE

FOR CHECKING

(Unnecessary if oil is normal) Before checking the oil level, run the refrigerating cycle at low speed (approximately 1000 rpm) for 50 to 6 minutes. This circulates the refrigerant. In addition, the compressor oil which circulates in the refrigeration cycle and remains at each functional part is collected as far as possible in the compressor. Next, discharge the refrigerant inside the refrigerating system. Depending on the type of compressor, it may be impossible to check the oil level. However, for those models where the oil level can be checked, check per PROCEDURE 2. (Only check if there is any abnormality, such as defective cooling or leakage of oil from the refrigeration system.) FOR CHECKING OIL LEVEL Use a dipstick to check the oil level. There are various types of compressors. In some, the end of the oil plug acts as the gauge, and in others, there is only an oil plug. For compressors with only the oil plug, insert a dipstick (9545662020). When doing this, measure with the handle end of the dipstick in close contact with the crankshaft case. Pull out the dipstick and check that the oil level is between the top and bottom lines on the gauge. This range indicates that the oil is at the correct level. If the oil is not between the top and bottom lines, correct the oil level.

2. PROCEDURE

ut in ontact

Checking

with

dipstick FOOAC140

Oil plug [Do not screw in, simply bring into contact1

For compressors with a dipstick built into the oil plug, the procedure for measuring is the same. However, there is already oil on the dipstick, so wipe off that oil before measuring. When doing this, bring the threaded part of the oil plug into contact with the crankcase. Do not screw it in. Range level

for

suit

2. Checking with dipstick FOOAC141

92-22

TESTING AND ADJUSTING

MAINTENANCE

PROCEDURE

3. ADDING AND REMOVING OIL If there is any failure in the functional parts during the operation of the refrigeration system, some compressor oil will remain in the refrigerating system. If trouble had occurred in the evaporator or condenser, and these are replaced with new parts, lt is necessary to add an amount of oil equal to the oil which would have remained in those parts. On the other hand, when replacing the compressor, the oil level inside the new compressor must be the same as the oil level remaining in the failed compressor. (Remove any excess oil.) Amount of compressor

oil to add (when replacing functional

parts).

Replaced part

Amount of oil to add or remove 2MllO

Adding

Removing

Condenser

reolaced as individual

oatt

Evaporator

replaced as individual

part

Receiver replaced as individual Compressor

Series, 2M126 Series 30 cc 60 cc

part

replaced as an individual

10 cc part

Remove enough oil to give the same volume of oil as in the removed compressor

NOTE: The values in the above table show the oil remaining after running for 5 to 6 minutes at an engine speed of 1000 rpm.

4. ADDING OIL BY EVACUATION If the structure of the refrigerating system is kept intact, oil must be added by evacuation. First, use a measuring cylinder to prepare slightly more compressor oil than is needed for adding to the refrigerating system. As shown in the figure, connect the service valve at the high pressure side of the compressor with the valve at the high pressure side of the gauge manifold. Connect a vacuum pump to the connection port at the center of the gauge manifold. Connect a charging hose to the service valve at the low pressure side of the compressor, and put the other end into the compressor oil prepared in the measuring cylinder. When the vacuum pump is started, the oil will be sucked from the low pressure side of the compressor and will go into the compressor. When the specified amount of oil has been sucked into the compressor, stop the vacuum pump.

Must be showing

Compres oil to be

a n

added

Adding

oil

evacuation

FooAC,42

TESTING AND ADJUSTING

TROUBLESHOOTING

TROUBLESHOOTING l

Before the hot season sets in, make a systematic check on each functional part in the refrigeration system. This will make it possible to find those problems which customers are seldom aware of. The early discovery and prompt repair will contribute to a longer service life of the air conditioner system.

VISUAL AND ACOUSTICAL

CHECKS

1. V-belt If the V-belt is too loose, it will be torn off because of slippage. To prevent such problems, keep the belt tight. Replace a torn belt with a new one. 2. Noise around the compressor Check the compressor mounting bolts and the bracket mounting bolts for looseness and tighten as necessary. 3. Noise from inside the compressor This may indicate that either a delivery or suction valve has been damaged, or that the connecting rod has come loose. Dismount the compressor and repair or replace it. 4. Mud and dirt on the condenser fins If the condenser and fins are fouled with mud or dust, the cooling effect of the condenser will decline, and the cooling capacity of the air conditioner will also be reduced. Be sure to wash the mud and dust off the condenser. Use a soft haired brush, if the condenser fins are washed with a hard hair brush, they will be scratched or bent. Therefore, clean them very carefully. 5. Clogged air filter If an air filter is clogged, the air flow will be significantly reduced, deteriorating the cooling capacity. Remove and clean all air filters. 6. Dirty connections and portions with oil The presence of oil indicates that the refrigerant is leaking. The compressor oil contained in the refrigerating gas escapes from the system together with the leaking refrigerant. Consequently, the gas leaking portions get fouled with oil. If any place has gotten dirty with oil, retighten the connections or replace the related parts to prevent gas leakage. Oil stains are frequently found in the compressor gaskets and piping connections, so check these areas carefully.

92-24

7. Noise around the blower Run the blower motor at low (Lo), medium (Med), and high (Hi) speeds. If you notice any abnormal operating noise or unsatisfactory rotation, replace the blower motor. But before replacing the blower motor, check to see if the noise is caused by foreign matter stuck in the motor, or if the motor is running unsatisfactorily because of loose parts. 8. Checking the quantity of refrigerant through the sight glass When many air bubbles are seen through the sight glass, it indicated a lack of refrigerant. Therefore, add refrigerant to its proper level. In this case, see if there are any oil stains (step 6) and confirm that the refrigerant is not leaking from any point. If no air bubbles are seen through the sight glass even when the condenser is cooled with water, it indicates that too much refrigerant has been charged into the condenser. In this case, carefully drain the refrigerant through a low pressure service valve a little at a time, until the proper level is obtained. Otherwise, too much refrigerant will drain out or the compressor oil will spurt out.

TROUBLESHOOTING

TESTING AND ADJUSTING

DEFECTIVE

COOLING at high pres too high

rFrressure ;ure

end

at high pres too low

‘ressura ;ure end

YE at low pros too high

Vessure sure end

-t

Too

much

system refrigerant

Condenser covered dirt or dust Refrigerant

low

;;Ff;;ssor

delivery

Gasket broken Low pressure IcrushedIcloggedl

LP ressure and low too low

at high pressure

[compressor1 piping

valve

open

too

Defective sensing

contact tube

heat

L-Refrigerant

too

much

Refrigerant

not

enough

Frost

Low

pressure

evaporator piping

valve

abnormal

clogged too

much

pressure-Refrigerant ends

not

enough

battery

lnterferance rotor and

far

heat

pressure--Refrigerant ends

$lrop

Abnormality of internal parts conoressor

valve

,-Expansion

t Expansion Pressure at high and low pressure too high

with

Gas leakaga from sensing tube

at low pres too low

‘ressure iure ena

Air

voltage

between stator

Broken/disconnected IO

Failure or adjustment Layer

defective in relay

short

Defective

Disconnected

-Other

Outside air venturlator

entering through to window

Temperature

control

Heater

‘ES

-Filter -Air

near

function

coil

defective

,-Obstruction -Frost

suction

port

evaporator

clogged duct

Blower

coil

ground

clogged & motor

or and

disconnected

efective

switch

Defective

resistor

Battery Blown

parts

voltafle

tow

fuse

B$;cgtive/disconnected t

-Defective ,Blower

system

Contact heater -Deformation

Defective

brush

tightening between case of

of blower

contact blower and

blower

L02zzo66

92-25

TESTING AND ADJUSTING

ROUBLESHOOl

IG TABLES Location

Problem

Suction pressure (pressure at low pressure side) abnormally high (more than apprBximately 3 kg/cm )

TROUBLESHOOTING

Compressor parts

Expansion valve related parts

Delivery pressure (pressure at high pressure side) abnormally high (more than appro imately 20 kg/cm d)

Condition

Possible cause

When compressor is stopped, high and low pressure immediately become the same

Area around low pressure hose, low pressure service valve abnormally cold

1. 2.

Valve open too far Defective contact (disconnection) of heat sensing tube

1. Replace valve 2. Securely fix heat sensing tube

Replace compressor

system re-

Pressure at high pressure side also high; suction pressure drops after forced cooling of condenser

Too much refrigerant in refrigeration system

1. Bleed from compressor shrader valve (high pressure side) to adjust to correct amount

Condenser

related parts

Poor suction of air by condenser cooling fan (insufficient cooling air)

1. 2.

Defective motor Condenser fins clogged with dirt

1. Replace motor 2. Clean fins (wash with water)

Insufficient cooling water, oil Ignition timing incorrect Defective water pump, insufficient capacity Radiator fins clogged with dirt

1. Add to correct level 2. Adjust timing 3. Replace or repair 4. Clean fins (wash with water)

Outside temperature extremely high Source of heat inside machine (heater, etc.)

1. Improve cooling of condenser 2. Turn off heater, etc.

Engine related parts

Engine tends to overheat

Others

Heat load too high

Refrigerating lated parts

system re-

Expansion valve related parts

92-26

Gasket, O-ring broken High, low pressure valve reed broken Dirt or dust stuck in reed valve

Refrigerating lated parts

Suction pressure (pressure at low pressure side) abnormally low (less than apsroximately 0.5 kg/cm )

Remedy

Even when condenser is cooled by water no bubbles are seen in sight glass

Too much refrigerant

Immediately after wmpressor is stopped, pressure drops s$denly about 2 kg/cm

Air in refrigeration system

1. Discharge all refrigerant and evacuate, then refill to correct level

Cooling is poor, many bubbles can be seen in sight glass

Insufficient erant

1. Add to correct level

Receiver and dryer abnormally cold (condensation, etc.)

Receiver and dryer clogged

1. Replace (evacuate completely)

No condensation at valve, piping at low pressure end not cold

Valve clogged (defective adjustment, entry of dirt or dust)

1. Replace valve

refrig-

Bleed from compressor schrader valve (high pressure side) to adjust to correct amount

TESTING AND ADJUSTING

TROUBLESHOOTING

Problem

Location

Condition

Suction pressure (Pressure at low pressure side) abnormally low less than apyoximately 0.5 kg/cm )

Expansion valve related parts

No condensation at valve, piping at low pressure end not cold (may become negative pressure)

Frost on valve

Others

Delivery pressure (pressure at high pressure side) abnormally low (less than ayroximately 10 kg/cm )

;;spressor

Possible cause Gas lost from heat sensing tube Temporary clogging caused by freezing of valve (trouble caused by entry of water)

2. 3.

Valve tends to clog (defective adjustment, or dirt in valve)

1. Replace valve

Wind discharge temperature low, no wind

Frost on evaporator

1. Check, adjust thermostat

Heat load is too low

Outside temperature extremely low

When compressor is stopped, high and low pressure immediately becomes the same

Gasket, O-ring broken High, low pressure valve reed broken Dirt or dust stuck in reed valve

1. Replace compressor

Refrigerating lated parts

No attraction for magnetic clutch

Replace valve After replacing valve and receiver, evacuate completelY

system re-

Cooling is poor, many bubbles can be seen in sight glass

Insufficient erant

refrig-

1. Add to correct level

Expansion valve related pa*

No condensation at valve, piping at low pressure end not cold (may become negative pressure)

Valve clogged (defective adjustment, entry of dirt or dust) Gas lost from heat sensing tube Temporary clogging caused by freezing of valve (trouble caused by entry of water)

1. Replace valve 2. Replace valve 3. After replacing valve and receiver, evacuate complete-

Gas leakage, oil leakage

Remedy

Compressor parts

Area around shaft seal dirty with oil, gas level reduced

Gas leaking from shaft seal

1. Replace shaft seal

Refrigerating lated parts

system re-

Area around piping connections dirty with oil, gas level reduced

Gas leaking from piping connection

1. Tighten connection 2. Replace piping

Cooler switch ON

Disconnection

No attraction even when cooling switch is ON

Defective wiring or connections (ground, fuse)

Reconnect or replace parts

Defective contact, or switch related parts (thermostat, stabilizer relay, cooler switch)

Repair or replace

Excessive clearance between rotor and stator

Repair or replace

Clutch

When switch is turned ON, rotor shows movement and is attracted when pushed

in coil

Replace

92-27

TROUBLESHOOTING

TESTING AND ADJUSTING

Problem Magnetic clutch slips

DEFECTIVE

Possible cause

Remedy

Battery voltage low

Charge battery

Oil on clutch face

Remove oil

Layer short in coil

Replace

Condition

Location

Clutch slips during rotation

Clutch

HEATING

YES

-Water

valve

clogged

.Plping

clogged

hot

water

bent circuit

-Insufficient level cooling water

-Defective

radiator

engine

thermostat

.Obstruction near suction port YE’

Are

blower

Frost

on evaporator

Air duct clogged disconnected

-Blower related

Defective

switch

Defective

resistor

Battery

Blown

S, motor parts

low

voltage

fuse

Defective connected

or diswiring

Defective of brush

contact

Defective of blower

tightening

Blower

system

between Contact and heater case

blower

-t LOZZZO66

92-28

kleformatlon

blower

TESTING AND ADJUSTING

TROUBLESHOOTING FOLD

TROUBLESHOOTING

USING GAUGE MANI-

In this method, the gauge manifold is used to indicate on its gauges the pressure at the high pressure and the low pressure sides of the refrigerating system, to locate problems and to repair them. 1. PREPARATIONS BEFORE MEASURING Precautions 1) Close the valves firmly on the high pressure and low pressure sides of the gauge manifold, then connect the charging hoses (red high side, blue low side) to the service valves of the comoressor. When doina this, alwavs set the valve plunger type service valve at the intermediate seat position (if the indicator moves, this means the back seat) so that measurement can be carried out with the gauge. t When measuring, remove the air inside the charging hoses from the connection port at the gauge manifold end using the pressure of the refrigerant in the air conditioning system. 2) Generally speaking, when the refrigerating system is working normally, (and under the following conditions: Air temperature at cooler suction port: 30” to 35°C; Engine speed : 2000 rpm; Maximum cooling, blower running at maximum speed) the gauge manifold readings are as follows: 0 Low pressure side: approximately 1.5-2.0 kg/cm2. 0 High pressure side: approximately 14.5-l 5 kg/cm2. 3) If the outside temperature is low for machines mounting the EPR, at around 1.8 kg/cm*, the pressure at the low pressure side continuously alternates between’ high pressure and low pressure. 2. INSUFFICIENT REFRIGERANT Conditions 1) Cooling effect is poor. Symptoms in refrigerating system 1) Pressurelow at both low and high pressure ends. 2) Bubbles seen in sight glass. 3) Air coming from cooler vents only slightly cold. Cause 1) Gas leakage somewhere in the refrigerating system. Judgement 1) Insufficient refrigerant in system - refrigerant leaking. Remedy 1) Check for leakage with leak tester, repair. 2) Add refrigerant to correct level.

The gauge manifold readings given in the following diagrams are all for the same conditions (Air temperature at cooler suction port: 30” C to 35”C; Engine speed: 2000 rpm; Maximum cooling: Blower running at maximum speed), but the actual gauge reading will vary slightly according to the surrounding air condi_. trans.

UHlgh

Pressura ga 1.5 kg/cm*

Gauge

manifold

reading

when

operation

normal FOOAC143

essur*

gauge\\

u High pressure 8-9

gaugr

kg/cm2

Gauge manifold readings with insufflclent refrigerant FOOACl44

TESTING AND ADJUSTING

TROUBLESHOOTING

3. EXCESSIVE REFRIGERANT OR INSUFFICIENT COOLING OF CONDENSER Conditions 1) Very little cooling effect Symptoms in refrigerating system 1) Pressure high at both low and high pressure ends.

High

pressure

gauge

20 kg/cm’

Cause 1) There is excessive refrigerant in the system, so the capacity is not being fully displayed. Judgement 1) Excessive refrigerant in system - too much refrigerant. 2) Defective cooling of condenser - clogged condenser fins or loose fan belt. Remedy 1) Clean condenser (with water). 2) Correct tension of fan belt. 3) Replace condenser fan motor. 4) If items l), 2) and 3) are normal, check the amount of refrigerant. * For details, see page 92-21, “Check refrigerant level”. * When discharging the refrigerant, push the shrader valve on the low pressure side of the gauge manifold and discharge the refrigerant gradually.

Gauge manifold r&dings refrigerant

w’ith’ excessive FOOACY15

High 23

prsssurs

gauge

kg/cd

4. AIR INSIDE REFRIGERATION SYSTEM Condition 1) Cooling effect is insufficient. Symptoms in refrigerating system 1) Pressure high at both low and high pressure ends. 2) Piping at low pressure end does not feel cold. Cause 1) Air in refrigerating system. Judgement 1) Air in refrigerating system - incomplete evacuation. Remedy 1) Replace receiver and dryer. 2) Check compressor oil level, check for dirt in compressor oil. 3) Evacuate, then charge with new refrigerant.

92-30

Gauge

manifold

readings

with

The gauge readings show the the refrigerant still charged evacuating after discharging

air

system

condition with and without the system FOOACl46

TROUBLESHOOTING

TESTING AND ADJUSTING

5. MOISTURE IN REFRIGERATING SYSTEM Conditions 1) The cooler repeats a cycle of cooling and noncooling. Symptoms in refrigerating system 1) During operation, the pressure at the low pressure end sometimes changes between negative pressure and normal pressure.

High

prrssurs

7-15

ka/cn*

gauge

Cause 1) The moisture in the refrigerant of the refrigerating system is freezing at the orifice in the expansion valve, so the system is temporarily shut-off. After a short time, the ice melts and the system returns to the normal condition. Judgement 1) The dryer is oversaturated -the moisture in the refrigerating system is freezing at the orifice in the expansion valve and preventing the refrigerant from circulating. Remedy 1) Replace receiver and dryer. 2) To remove the moisture in the system, carry out repeated evacuation of the system. 3) Add new refrigerant to the correct level.

Gauge manifold readings refrigerating system

with

moisture

the FOOACI47

92-31

TROUBLESHOOTING

TESTING AND ADJUSTING

6 REFRIGERANT DOES NOT CIRCULATE Conditions 1) No cooling effect (there may be cooling occasionally). Symptoms in refrigerating system 1) The pressure on the low pressure side indicates negative pressure and the pressure on the high pressure side is extremely low. 2) There is frost or condensation on the piping on both sides of the expansion valve or the receiver and dryer.

High 76

cmHa

readings

‘whsn

pressurs

gauge

6 kg/cm*

Cause 1) Water or dirt in the refrigerating system is freezing or sticking at the orifice of the expansion valve and preventing the flow of refrigerant. 2) Gas leakage from the heat sensing tube of the expansion valve is preventing the flow of refrigerant. Judgement 1) Orifice of the expansion valve is closed - refrigerant does not circulate. Remedy Leave for a short time, then start operation again to judge if the problem is caused by water or by dirt. 1) If the problem is caused by water, carry out the action given in 5 (Moisture in refrigeration system). 2) If the problem is caused by dirt: l Remove the expansion valve and blow out the dirt with compressed air. If the dirt can not be removed, replace the expansion valve. l Replace the receiver and dryer. 0 Evacuate the refrigeration system, then add new refrigerant to the correct level. 3) If the problem is gas leakage from the heat sensing tube, replace the expansion valve.

92-32

Gauge

refkigdrant

not

circulate FOOACl48

TESTING AND ADJUSTING

TROUBLESHOOTING

7. FAILURE OF EXPANSION VALVE (OPEN TO FAR), DEFECTIVE MOUNTING OF HEAT SENSING TUBE 19-20

Conditions 1) Cooling effect is poor.

kg/cm’

Symptoms in refrigerating system 1) Pressure high at both low and high pressure end. 2) Frost or excessive condensation on piping at low pressure end. Cause 1) Failure of expansion valve or defective mounting of heat sensing tube. 2) Flow control is not being carried out properly. Judgement 1) Excessive liquid refrigerant inside piping at low pressure end 4 expansion valve open too far.

Gauge

readings

when

expansion

valve

Remedy 1) Check mounting of heat sensing tube. 2) If there is no abnormality in l), test the expansion valve as an individual part and adjust it. If it can not be adjusted, replace it.

fails FOOACl49

8. DEFECTIVE COMPRESSION BY COMPRESSOR Conditions 1) No cooling.

Hlgh

pressure

7-10

kg/cm2

gauge

Symptoms in refrigeration system 1) Pressure at low pressure end too high. 2) Pressure at high pressure end too low. Cause 1) Leakage inside compressor. Judgement 1) Defective compression by compressor - leakage from valve, damage, damage to sliding parts (piston, cylinder, gasket, connecting rod, etc.). Remedy 1) Replace compressor as assembly.

Gauge manifold compression is

readings defective

when

compressor FOOACl50

TESTING AND ADJUSTING

MEMORANDA

92-34

TROUBLESHOOTING

AIR CONDITIONER 93

SPECIALTOOLS

DISASSEMBLY

AND ASSEMBLY

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

MAGNETICCLUTCH . . ... . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. . .. . .. .. . .. .. .. DISASSEMBLYOF . . ... . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. . .. .. .. . .. . .. .. .. CHECKSBEFOREDISASSEMBLY................................................. REMOVAL OF ROTOR AND STATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL OF CENTER PIECE FROM ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL OF BEARING FROM ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY OF ASSEMBLYOiBi;sRirjc’i~‘ddiok’:::::::::::::::::::::::::::::::::::::::::::::: ASSEMBLY OF CENTER PIECE TO ROTOR ASSEMBLY OF STATOR AND ROTOR TO CO~~d~&k’ : : :: ::: :: :: :: :: :: : : :: :: :: :: : :::

3 3 4 4 5 6 7 7 7 8

AIR CONDITIONER UNIT ........................................................... DISASSEMBLYOF.. ............................................................ CHECKS BEFORE DISASSEMBLY ................................................. REMOVAL OF CONTROL PANEL AND THERMOSTAT ................................. REMOVALOFUNITCOVER .................................................... REMOVALOFWATERVALVE ................................................... REMOVALOFEXPANSIONVALVE ............................................... REMOVALOFEVAPORATOR ................................................... REMOVALOFHEATERCORE ................................................... REMOVALOFPRESSURESWITCHES .............................................

9 9 13 15 15 17 19 19 19

BLOWER UNIT ................................................................. DISASSEMBLYOF.. ........................................................... CHECKS BEFORE DISASSEMBLY. ............................................... REMOVALOF BLOWER RESISTOR ............................................... REMOVAL OF BLOWER MOTOR AND FAN .........................................

CONDENSER .................................................................. DISASSEMBLYOF ............................................................. CHECKSBEFOREDISASSEMBLY ................................................ REMOVAL OF CONDENSER, FAN MOTOR ......................................... REMOVALOFPRESSURESWITCH ............................................... REMOVALOFRESISTOR ......................................................

22 22 22 23 24

20 20 20 21

93-1

DISASSEMBLY AND ASSEMBLY

SPECIAL TOOLS

0a FOOAC151

Soecial tool reauired

Part name

No.

II 1 I Center piece remover II 2 I Bearina driver

I QV

II 1r--11 --I

Bearing driver support

Bearing remover

Clutch bolt remover guide

Snap ring pliers (open type)

Clutch forcing bolt

Center piece driver

93-2

DISASSEMBLY AND ASSEMBLY

MAGNETIC CLUTCH

MAGNETIC CLUTCH DISASSEMBLY

FOOAC152

1. Compressor Magnetic clutch 3. Bolt with washer 4. Dust cover 5. Bolt with washer 6. Rotor assembly 7. Stator 8. Snap ring 9. Hub 10. Snap ring 11. Bali bearing 2

93-3

MAGNETIC CLUTCH

DISASSEMBLY AND ASSEMBLY

ressor

1. Checking rotor assembly Rotate rotor of magnetic clutch by hand, and check that there is no noise or play. + If there is any noise or play, disassembly the clutch and check the ball bearing and other pat-k.

POOACO12

2. Checking stator coil Measure resistance value of stator coil, and check that there is continuity. Standard resistance value: +

11.5 & 0.4 ohms (at 2O’C)

If there is a big difference between the measured value and the standard value, replace the stator. POOAC013

REMOVAL OF ROTOR AND STATOR 1. Clutch lock bolt 1) Remove the dust cover at the front of the magnetic clutch. 2) Using clutch bolt remover guide, secure center piece, then remove clutch lock bolt with 12 mm socket wrench.

Clutch bolt remover guide

12-mm wrench

POOAC063

65Y

Clutch forcing

2. Rotor 1) Install clutch forcing bolt in tap in center of rotor, then screw in this bolt with a wrench

POOAC064

DISASSEMBLY

AND ASSEMBLY

MAGNETIC

CLUTCH

Remove rotor from magnetic clutch.

Clutch rotor

3. Stator Remove 3 stator lock screws, then remove stator from compressor. Clutch stator

REMOVAL OF CENTER PIECE FROM ROTOR 1. Dust cover Remove 3 set screws with screwdriver, then remove the dust cover.

tnol

-Snap

ring pliers (Open type)

Snap ring,

2. Snap ring Using snap ring pliers (open type), remove the snap ring holding bearing.

93-5

MAGNETIC CLUTCH

DISASSEMBLY AND ASSEMBLY

3. Center piece 1) Using 3 bolts supplied, install center piece remover to the rotor.

Assembly bolts (x3

POOACO70

2) Insert a bar into center shaft of the center piece remover, then turn the bar gradually in a clockwise direction. Center piece

3) When the center shaft of center piece remover is turned fully with bar, it is possible to remove the center piece from the rotor as shown in the figure.

POOAC069

POOAC071

REMOVAL OF BEARING FROM ROTOR +

-v

Do not remove except when replacing the beating. Plastic

hammer+

1. Bearing

Set the rotor on top of bearing driver stand, then fit bearing remover to bearing. Tap this with a plastic hammer to remove. +

Id ring

Bearing

Do not reuse the bearing after removal. Bearing support

FOOAC153

DISASSEMBLY

AND ASSEMBLY

ASSEMBLY OF ASSEMBLY

MAGNETIC

CLUTCH

Rubber seal

OF BEARING TO ROTOR

1. Bearina

1) Fii<ealed ring to rotor, then assemble 2 new bearings as follows.

2) Set rotor on top of bearing driver support, the

fit the first bearing on rotor. Set bearing driver and bearing remover on top of the bearing, and ffi into position. t Set the bearing with rubber seal surface at the bottom. Hand press 45 Bearing Bearing

3) 4)

Gradually push down special tool with hand press to assemble bearing. Assemble the second bearing in the same way. t Fit the second bearing with rubber seal surface at the top. t Fit the two bearings so that the rubber seal surfaces are at the top and bottom. Always use the special tool, and be careful not to twist the bearings.

ASSEMBLY

arlng

Bearing support

ring

OF CENTER PIECE TO ROTOR

1. Center piece 1) After completion of assembly of the bearing to

the rotor, fit tip of center piece to the rotor bearing. + Always stand the center piece upright when fitting.

a press Center

piece driver

Center

piece

2) Set rotor on top of the bearing driver support,

then assemble center piece driver the center of center piece. Gradually push this down with a hand press and fit center piece completely to root. t Always push center piece driver down with a hand press. (Never hit directly with a hammer)

93-7

MAGNETIC CLUTCH

DISASSEMBLY AND ASSEMBLY

2. Snap ring Assemble snap ring to the original position to secure the bearing.

liers

Snap

3. Dust cover Using 3 screws, assemble the dust cover to original position.

POOAC073

ASSEMBLY OF STATOR AND ROTOR TO COMPRESSOR 1. Stator Using the same 3 screws, assemble the stator to the compressor. + Check that there is a key assembled to the compressor shaft.

2. Rotor 1) Align with key of the compressor shaft, assemble rotor to the compressor, then tighten clutch lock bolts with clutch bolt remover guide to secure center piece as shown. u

Tightening torque: 2.4 + 0.7 kgm

POOAC076

Torque wrench

2) After completing above assembly, rotate rotor by hand and check that it does not contact stator or pulley. Tiahtenina torwe 2:4 +or- 01.7 kgm POOAC077

3. Dust cover Install dust cover with 6 bolts.

DISASSEMBLY AND ASSEMBLY

AIR CONDITIONER DISASSEMBLY

AIR CONDITIONER UNIT

UNIT

nditioner switch

CHECKS BEFORE DISASSEMBLY 1. Checking air conditioner switch, blower switch 1) Checking air conditioner switch. Check continuity between each terminal, replace if defective.

Blower switch

POOACO14’

FOOAC156

2) Checking blower switch. Check continuity between each terminal, replace if defective.

B-

-----I

HI ME LO -

FOOAC157

93-9

DISASSEMBLY AND ASSEMBLY

AIR CONDITIONER UNIT

2. Checking temDerature control lever 1) Slide- the ‘temperature control lever on the control panel from the HOT side to the COOL side to check that the air mix damper and the water valve work properly.

2) If the lever is extremely heavy, or the water valve does not close completely, adjust with cable clamp (1) wire clamp (2), and damper link (3).

Tehperature

control cable

c POOACOl5

WARNING1 Check with the damper cable set to the MAX HOT position. If the setting is defective, the cooling and heating will be defective.

3. Checking thermostat 1) Apply ice to the tip of the thermostat capillary tube, and measure the temperature at which the thermostat switches ON and OFF. Reference temperatures: l ON temperature: 45°C. 0 OFF temperature: 1.O + 1.5/-0.5”C. 0 Differential: 3.5 + 1.5/-l .O”C. + If there is a big difference between the measured value and the reference temperature, replace the thermostat. 4. Checking pressure switches 1) Check continuity of low pressure switch at atmospheric pressure. There should be no continuity between the terminals at atmospheric pressure.

i :Li

2.1 kg/cm2

POOACOi 6

FOOAC158

ON A

OFF

Operating

93-10

pressure

2.3 kg/cm2

FOOAClSS

If there is continuity at atmospheric pressure, replace the low pressure switch.

POOACO17

;

DISASSEMBLY AND ASSEMBLY

Check continuity of high pressure switch at atmospheric pressure. There should be continuity between the terminals at atmospheric pressure.

27 kg/cm2

A Y

21 kg/cm2 Operating

-B

AIR CONDITIONER UNIT

OFF

pressure

POOACO18

FOOAC160

If there is no continuity at atmospheric pressure, replace the high pressure switch.

5. Checking air conditioner relay POOACO19

FOOAC161

1) Using the following procedure, apply the battery voltage (24V) between the terminals and check for continuitv between D and A. Terminal C

Terminal B

Continuity between D and A

24V

Ground

Yes

I Ground

If defective, replace the air conditioner relay.

93-11

AIR CONDITIONER UNIT

DISASSEMBLY AND ASSEMBLY

6. Checking condenser relay

Condenser relay

FOOAC162

1) Using the following procedure, apply the battery voltage (24V) between the terminals and check for continuity between B and D.

Terminal C

Terminal A

24V

ov +

Ground Ground

Continuity between B and D I

Yes No

If defect-we, replace the condenser relay.

93-12

II I

DISASSEMBLY AND ASSEMBLY

AIR CONDITIONER UNIT

REMOVAL OF CONTROL PANELAND THERMOSTAT 1. Control panel, thermostat 1) Remove coupler (2) of air conditioner switch, air conditioner relay, condenser relay (1) thermostat and blower switch. + Remove clamp (3).

Remove air source selector cable (4) and temperature control cable (5) from control panel.

POOAC022

/ /

3) Remove low pressure switch coupler (6) and high pressure switch coupler (7).

POOAC023

Remove capillary tube (8) of the thermostat from evaporator fin.

POOAC024

93-13

DISASSEMBLY

AND ASSEMBLY

AIR CONDITIONER

5) After removing grommet for the capillary tube, remove 2 screws (9), then remove thermostat (10). + When removing the thermostat, be careful not to use force and bend the capillary tube.

6) Remove 2 control panel lock screws (11).

POOAC026

7) Remove 4 control panel mounting bolts (12).

POOAC027

93-14

Remove control panel (13).

UNIT

DISASSEMBLY AND ASSEMBLY

AIR CONDITIONER UNIT

REMOVAL OF UNIT COVER 1. Unit cover 1) Remove 2 evaporator screws (I) and 4 unit cover mounting bolts (2).

POOAC029

2) After removing grommet (3) for temperature control cable, remove unit cover (4).

POOACO30

Remove 4 bolts (5) then remove side cover (6).

REMOVAL OF WATER VALVE 1. Grommet Remove grommets (2) for high pressure and low pressure tubes. and grommet (1) for heater hose.

POOACO32

93-15

DISASSEMBLY

AND ASSEMBLY

AIR CONDITIONER

2. Heater hose Loosen 2 hose clamps, and remove 2 heater hoses (3) from the heater core.

\ 3. Connecting shaft Remove connecting valve from clamp.

POOACb33

shaft joining damper and water

4. Clamp Remove clamp (4) of high pressure tube.

POOAC035

5. Evaporator assembly Remove evaporator (5) from air conditioner unit together with heater core and damper. t Be careful not to bend the piping, or damage the evaporator or heater core.

93-16

UNIT

DISASSEMBLY AND ASSEMBLY

AIR CONDITIONER UNIT

6. Heater hose Remove heater hose (6) from the air conditioner unit case.

7. Water valve Remove 3 water valve mounting remove water valve (7).

bolts

(8), then

6. Temperature control valve Loosen hose clamp, then remove temperature control cable (10).

hose (9) and

POOAC039

REMOVAL OF EXPANSION VALVE 1. Expansion valve 1)

Remove clamp (1) for high and low pressure tubes.

93-I 7

AIR CONDITIONER UNIT

DISASSEMBLY AND ASSEMBLY

Remove packing and hold clip (2) of expansion valve heat sensing tube. + The packing can not be used again, so replace with new packing. Ex va

Remove low pressure tube (3) using two spanner wrenches. + When tightening or removing the piping always use two spanner wrenches. Tightening torque: 325 + 25 kg/cm.

POOAC042

Remove flared nut at the expansion valve inlet end, then remove high pressure tube (4). Tightening torque: 135 -t 15 kg/cm.

POOAC043

93-i a

Remove flared nut at expansion valve outlet end, then remove expansion valve (5). Tightening torque: 225 + 25 kg/cm.

DISASSEMBLY AND ASSEMBLY

AIR CONDITIONER UNIT

REMOVAL OF EVAPORATOR 1. Evaporator

Pull out evaporator (1) from damper assembly (2). Ne careful not to damage the side packing, tubes, and fins of the evaporator.

REMOVAL OF HEATER CORE 1. Heater core

Pull out heater core (1) from damper assembly (2). Be careful not to damage the packing, tubes, and fins of the heater core.

REMOVAL OF PRESSURE SWITCHES 1. Low pressure switch

Remove low pressure switch (1) from the high pressure tube using two spanner wrenches. B

Tightening torque: 150 f 10 kg/cm.

2. High pressure switch

Remove high pressure switch (2) from the high pressure tube using two spanner wrenches. m

Tightening torque: 150 f 10 kg/cm.

93-19

DISASSEMBLY

AND ASSEMBLY

BLOWER UNIT

BLOWER UNIT DISASSEMBLY CHECKS

Blower motor couder Fesistor

BEFORE DISASSEMBLY

1. Checking

blower motor

Check continuity between terminals A and B. If there is no continuity, rotate the motor shaft slightly, then check again.

-A

POOACO49

FOOAC163

If there is no continuity,

replace the blower motor.

2. Checking blower resistor Check continuity between each terminal.

A[MEDI

BtLOI

C[HII B

4-J

FOOACl64

If the continuity

REMOVAL

is defective, replace the resistor.

OF BLOWER RESISTOR

1. Blower resistor Remove 1 screw, then remove blower resistor (1).

93-20

DISASSEMBLY

REMOVAL

AND ASSEMBLY

BLOWER UNIT

OF BLOWER MOTOR AND FAN

1. Blower motor, fan 1)

Remove air inlet tube (2) of blower motor.

POOAC051

Remove 3 blower motor lock bolts (3).

POOAC052

Pull out blower motor and fan (4) from case.

WOACO53

Remove 1 blower fan mounting remove fan (6).

nut (5), then

93-21

DISASSEMBLY

AND ASSEMBLY

CONDENSER

CONDENSER DISASSEMBLY

CHECKS BEFORE DISASSEMBLY 1. Checking fan motor 1) Check the continuity between terminals A and B. If there is no continuity, rotate the motor shaft slightly, then check again.

FOOACl666 l

If there is no continuity,

replace the fan motor.

2. Checking fan resistor 1) Check the continuity 8.

between terminals A and

/QQk I

FOOACl66

If there is no continuity,

replace the resistor.

3. Checking pressure switch 1) Check that is no continuity between terminals A and B at atmospheric pressure. 14

kg/cm2

ON A

OFF

18 kg/cd

Operating

pressure

‘$

J-j-j

‘B *

FOOAC167

If there is continuity at atmospheric replace the pressure switch.

93-22

pressure,

DISASSEMBLY

AND ASSEMBLY

REMOVAL OF CONDENSER, 1. Condenser,

CONDENSER

FAN MOTOR

fan motor

1) Loosen 2 bolts (1) of fan motor mounting bracket, and remove 3 shroud mounting bolts (2).

POOAC057

Remove 4 fan motor mounting bolts (3), then remove fan motor assembly (4). ,

Remove 1 condenser fan mounting nut (5), then remove fan (6).

WOACO59

4) Remove 3 fan motor mounting bolts (7), then remove motor (8) from the shroud.

93-23

DISASSEMBLY

REMOVAL

AND ASSEMBLY

OF PRESSURE SWITCH

1. Pressure switch Remove pressure tube of condenser

switch (1) from high pressure using two spanner wrenches.

torque:

REMOVAL

Tightening

100 2 10 kg/cm.

OF RESISTOR

1. Resistor Remove 1 resistor lock bolt (l), then remove resistor (2).

93-24

CONDENSER

GEAR PUMP 97

SA SERIES

GENERAL ...................................................................... PRINCIPLEOFOPERATION ....................................................... PRESSURE LOADEDTYPEGEAR PUMP ............................................. FIXEDSIDEPIATETYPEGEARPUMP ...............................................

2 3 6 8

SASERIES ..................................................................... STRUCTURE .................................................................. TESTINGANDADJUSTING ...................................................... DISASSEMBLY ................................................................ ASSEMBLY .................................................................. MAINTENANCESTANDARD ......................................................

9 9 13 16 20 25

97-1

GENERAL

GEAR PUMP

GENERAL The hydraulic pumps used in construction machinery are external gear pumps and are classified as fixed displacement rotary pumps.

The hydraulic pump is a device which receives mechanical energy from a prime mover such as an engine, converts the energy into fluid energy, and functions as the source of energy in a hydraulic system.

External gear pumps employ involute spur gears, and can be structurally classified into the following types.

The fluid energy can be divided into ttie energy of velocity, pressure, and potential. Almost all of the fluid energy used for hydraulic pressure is pressure energy.

The hydraulic pump receives and transmits the energy through the static pressure of a fluid, and easily produces a high pressure since its delivery is determined by the transfer of volumetric displacement enclosed by the fixed walls. Therefore, the pump delivery is not changed significantly with variations in the load.

Pressure loaded type (PAL, PAR, KAL, KAR) Pressure plate type

It follows that the pump itself is a device which makes the oil flow, rather than a device to produce pressure. The pump pressure is generated by the resistance (the load) against the oil flow. Therefore, when there is no resistance, no pressure is produced.

Type of bearing Ball or roller bearing type Plain bearing type

Structurally, hydraulic pumps can be broadly classified into rotary pumps and reciprocating pumps. Functionally, They can be classified into fixed displacement pumps and variable displacement pumps.

Type of side plate adjustment Fixed side plate type (FAL, FAR, GAL, GAR)

Gear pumps installed on installed on the machines are called standard pumps. They are designed as follows: “PAL 160”

PAL 160 I L=

For high pressure: 210 kg/cm*, pressure loaded type

A: Flange type mount section

Counter-clockwise rotation

For high pressure: 175 kg/cm*, (210 kg/cm* for some pumps) pressure loaded type

B: Foot type mount section

Clockwise

For medium pressure: 140 kg/cm* (155 kg/cm* for some pumps) pressure loaded type

For medium pressure: 125 kg/cm*, fixed side plate type

For low pressure: 30 kg/cm*, fixed side plate type

97-2

I 160=

rotation

Theoretical pump delivery at 1,000 rpm (liters/min)

GENERAL

GEAR PUMP

PRINCIPLE OF OPERATION l

MECHANISM FOR DELIVERING OIL The drawing at right shows the operational principle of an external gear pump in which two gears are rotating in mesh.

Suction

Discharge

The oil entering through the suction port is trapped in the space between two gear teeth, and is delivered to the discharge port as the gear rotates. Except for the oil at the bottom of the gear teeth, the oil trapped between the gear teeth is prevented from returning to the suction side with the gears in mesh.

23OF137

Since the gears are constantly delivering oil, the oil delivered to the discharge port is forced out of the port. The amount of discharge increases with the speed of rotation of the gear. If there is no resistance in the oil passage into which the discharged oil flows, the oil merely flows through the passage, producing no increase in pressure.

23OF138

If, however, the oil passage is blocked with some thing like a hydraulic cylinder, there will be no other place for the oil to flow, so the oil pressure will rise. But the pressure which rises in this way will never go higher, once the hydraulic cylinder piston starts moving because of the oil pressure. As described earlier, the pump produces the oil flow, but not the oil pressure. We can therefore conclude that pressure is a consequence of load. In other words, the pressure depends on a counterpart.

23OF139

23OF140

97-3

GEAR PUMP

INTERNAL OIL LEAKAGE

PRINCIPLE

OF OPERATION

placing an overload on the bearings, and resulting in a shortened service life of the bearing or interference of the gear with the case.

Oil leaks from a place under higher pressure to a place under lower pressure, provided that a gap or a clearance exists in between. In the gear pump, small clearances are provided between the gear and the case and between the gear and the side plate to allow the oil to leak out and to serve as a lubricant so that the pump will be protected from seizure and binding. The drawing at right flows

shows how the leaked oil in the pump. As such, there is always oil

leakage in the pump from the discharge side (under higher pressure) to the suction side. The delivery of the pump is reduced by an amount equal to the pump discharge. In addition, the delivery of the pump will also decrease as the amount of oil leakage increases because of expanded radial clearance resulting from the wear of pump parts, the lower oil viscosity resulting from increases in the oil temperature, and the initial use of low viscosity oil. o

23OF141

FORCES ACTING ON THE GEAR The gear, whose outer surface is subjected to oil pressure, receives forces pointing towards its center. Due to the action of the delivery pressure, the oil pressure is higher on the delivery side of the pump, and due to suction pressure, is lower on the suction side. In the intermediate section, the pressure will gradually lower as the position moves from the delivery side to the suction side. This phenomenon is shown in the drawing at right.

:ride

In addition, the gears in mesh will receive interacting forces. These forces pushing the gears toward the suction side are received by the bearings. Since the gears are pressed toward the suction side by theses forces, the radial clearance becomes smaller on the suction side in the case. In some pumps (PAL, PAR, KAL, KAR), the clearance may become zero, thus allowing the gear teeth and the case to come into light contact. For this reason, an excessive increase in the delivery pressure must be avoided, since it will produce a large force which will act on the gears,

97-4

‘Pressure distribUtiMI

23OF142

PRINCIPLE OF OPERATION

GEAR PUMP

TRAPPING”

PHENOMENON

OF THE OIL

When a gear pump is rotating with the gears in mesh as shown in the drawing at right, in some instances two sets of gear teeth are in mesh while in other instances only one set of the gear teeth is in mesh. When two sets of the teeth are in mesh simultaneously, the oil in the space between the meshed gear teeth will be trapped inside - the front and rear exits will be completely shut.

Odivw

Suction side

Trapping starts

This is called the “trapping” phenomenon of oil. The space in which the oil is trapped moves from the suction side to the delivery side as the gears rotate. The volume of the space gradually decreases from the start of trapping until the space reaches the center section, and then gradually increases after leaving the center section until the end of trapping. Since the oil itself is non-shrinkable, a reduction of the volume of space will greatly increase the oil pressure, unless some provision is made to relieve oil pressure. The high pressure oil will cause the pump to make noise and vibrate.

The *ace reaches the minimum

Trapping ends

23OF143

To prevent this, relief notches are provided on the

side plates to release the oil to the delivery side. below, the relief notches are provided in such a way that the oil can be relieved from the trapping space tot he delivery side when the volume of the space is reduced. As shown in the drawing

Relief notches are also provided on the suction side to prevent the formation of a vacuum in the space by allowing the oil to enter the space from the suction side when the space is expanded.

23wl44

23OF145

97-5

GEAR PUMP

PRESSURE LOADED TYPE GEAR PUMP

19 23OF146 GENERAL DESCRIPTION Hydraulic pumps used for the work equipment hydraulic units on construction machinery are pressure loaded type gear pumps. Some gear pumps of this type have a maximum delivery pressure of 210 kg/cm2 or higher. The pressure loaded type gear pump is designed so that the clearance between the gear and the side plate can be automatically adjusted according to the delivery pressure. Therefore, the oil leakage from the side plate is less than in the case of the fixed side plate type under a high discharge pressure. Consequently, no significant reduction of the pump delivery occurs, even when the pump is operated under high pressure.

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

Drive gear Bracket Bushing Gear case Cover Seal plate Collar Bach-up ring Driven gear

GEAR PUMP

PRESSURE LOADED TYPE GEAR PUMP

STRUCTURE AND OPERATION In a pressure loaded type pump, two bushings acting as side plates are inserted into the pump case, and are pressed toward the sides of the gears. The oil leakage from the gear sides is thus minimized. Since the bushings are constantly pressed toward the gears by the oil pressure, there is no fear of an increase on oil leakage, even when the bushings are worn out and the clearances are expanded many hours of operation. The bushings are pushed towards the gears from the cover side by the oil pressure, and they are pushed from the gear side by the pressure of oil trapped between the gear teeth and that which has leaked out from the clearance between the gear and the bushing. Since the oil pressure in the gears is higher on the pump delivery side and is lower on the suction side, provisions are made so that the pressing force acting on the bushings from the cover side is regulated in such a way that the delivery side is pressed harder and the suction side weaker to match the counter pressure. More specifically, the area of the bushing on the discharge side is made larger than that on the suction side by partitioning the area of the bushing subjected to pressure on the cover side, with a back-up ring installed to the seal plate as shown in the drawing at right. When the pump is operated at high speed, the pressure on the suction side is lowered and the distribution of pressure around the periphery of the gear will change into the state shown in the drawing at right below. Pressure balance grooves are therefore provided on the bushings to keep the balance of the force on the cover side against the pressure acting on the bushing from the gear side that varies with the pump rotation and the pressure distribution. Thus the delivery pressure is led as shown in the drawing and the pressure distribution is stabilized at any rotational speed.

with balance groove without balance groove

\ Discharge \

without belence groove (high specdb

05F140

97-7

GEAR PUMP

PRESSURE LOADED TYPE GEAR PUMP

FIXED SIDE PLATE TYPE GEAR PUMP

GENERAL DESCRIPTION

Hydraulic pumps used for the main clutch, transmission, and steering system on bulldozers are fixed side plate type gear pumps which can be classified as follows: pumps generally called FAL or FAR pumps having a maximum delivery pressure of 30 kg/cm’ and pumps generally called GAL or GAR pumps having a maximum delivery pressure of 125 kg/cm2. Since the bracket and the case cover serve as the side plates and the gear teeth bottom land is closer to the outer race of the bearing in the case of the fixed side plate type gear pump, oil leakage is liable to occur at the clearance between the gear and the side plate. However, this is only a small problem, as the pump is used for steering control which is operated at a low service pressure.

97-a

1. 2. 3. 4. 5.

Drive gear Bracket Gear case Cover Driven gear

STRUCTURE

SA SERIES

Side plate

STRUCTURE FEATURES The gear pump is a high quality, reliable product that is specially designed for use in construction equipment which works under severe conditions. 0 The side plate, given surfaces treatment to improve its matching characteristics with the special copper alloy, ensures minimum torque loss and excellent wear resistance. l With the improved hydraulic balance mechanism, the pump offers stable performance and high durability.

ZfXlF132

STRUCTURE 1. Drive gear 2. Driven gear 3. Snap ring 4. Oil seal 5. Plate 6. Bracket 7. O-ring 8. Side plate 9. Back-up ring 10. Seal ring 11. Gear case 12. Side plate 13. Back-up ring 14. Seal ring 15. Cover 16. O-ring 17. Bolt 18. Dowel pin 1

3//////II4

16 12

\ i7 13 14 ZlFO23

97-9

SA SERIES

STRUCTURE

SA-1 Series single pump

222 4-

df -QZ!p,.:

Dclivnv port

LloAvo19

(The drawing above shows a pump of the counter-clockwise rotation type. In a clockwise rotation pump, the positions of the suction and delivery ports are reversed.)

SA-2 Series single pump l

Side port type

Ll oAvo20

(The drawing above shows a pump of the counter-clockwise rotation type. In a clockwise rotation pump, the positions of the suction and delivery ports are reversed.)

97-10

SA SERIES

STRUCTURE

Rear port type

(The drawing above shows a pump of the counter-clockwise rotation type. In a clockwise rotation pump, the positions of the suction and delivery ports are reversed.)

SA-3 Series single pump l Side port type

Delivwy port LlBwd22

(The drawing above shows a pump of the counter-clockwise rotation type. In a clockwise rotation pump, the positions of the suction and delivery ports are reversed.)

97-11

SA SERIES

STRUCTURE

Rear port type

LlBAV023

(The drawing above shows a pump of the counter-clockwise rotation type. In a clockwise rotation pump, the positions of the suction and delivery ports are reversed.)

SA-4 Series single pump

4-G.Dmpth: Dmlivmry

port

Dapth: F -

LlEIV024

(The drawing above shows a pump of the counter-clockwise rotation type. In a clockwise rotation pump, the positions of the suction and delivery ports are reversed.)

NOTE: Dimensions A through H in the drawings vary with pump capacity.

97-12

SA SERIES

STRUCTURE

TESTING AND ADJUSTING Measure the pump delivery with a bench or flow meter kii (790-303-1001). For SA pumps operating at a service pressure of 50 kg/cm2 or less, see the standard and the repair limit in Table No. 2. (Examples: Pumps for power trains and servo-hydraulic pumps for excavators)

Notes on pa!

followir

table 1 &

Check item

Series No

Capacity Code

Delivery pressure (kg/cm2)

The capacity codes rna rked + are for triple pumps. Standard Rotation (rpm)

Delivery (liters/min)

Repair limit Rotation

Delivery

(rpm) O:?

Performance Hydraulic oil: EOlOCD

008 010 012 014 016 020 025

+016 +020 425 028 032 036 040 045 050

Oil temperture: 50°C

420 425 &40 450 056 063 071 080 100 112 125

112 125 140 160 180 200 224 250

25 32 38 47 52 66 83

210

3000

45 55 90 112 129 145 158 184 231

210

140

210

5”: 67 77 88 100 111 121 138

2000

212 236

3500

23 29 34 43 48 61 76

3000

40 50 62 71 82 92 103 111 128

2500

42 51 82 102 119 134 146 170 214

2000

192 213

233 253 2200 287 328 _______________

215 234 266 303

336 373 411 460

310 345 385 425

2000

97-13

SA SERIES

STRUCTURE

Sti ndard No

Check item

Series No

Performance Hydraulic oil: EOl OCD

Oil Tempera -ture: 50°C 2

CaCpaozy

Delivery pressure (kg/cm*)

Rotation (rpm)

Delivery (liters/min)

008 010 012 014 016 020 025

z3’

MO8 416 +020 +025 028 032 036 040 045 050

23 47 59 72 80 92 104 115 126 144

40 48 54 68 86

3000

420 +025 +040 450 056 063 071 080 100 112 125

Rei lir limit Rotation (rpm)

3500

3000

60 96 119 134 151 164 192 241 30

112 125 140 160

2000

2200

217 240

242 264 300 342

2500

2000

2200

Delivery (tftmf$/

25 30 37 44 50 63 79 21 43 53 66 74 84 95 106 115 132 44 55 88 109 123 138 150 176 221 198 220

222 242 275 314

4 180 200 224 250

2000

350 389 434 480

2000

321 257 398 440

For SA pumps operating at a service pressure of 50 kg/cm* or less, see the standard and the repair limit in table, No. 2. (Examples: Pumps for power trains and servo-hydraulic pumps for excavators).

97-14

STRUCTURE

SA SERIES

Note 1.)

If it is impossible to raise the pump speed to the value shown in the table because of limitations of the test bench, calculate the allowance for the delivery from the following formula:

Q = Qo -INo - N) Qth 1000 however, where,

N2 ;:

::I Qth:

1000 rpm RPM of test bench Repair limit for delivery at N rpm (liters/min) RPM in the table Repair limit for delivery in the table (liters/min) Capacity code

Note 2.)

If the test bench allows the pump to raise its delivery pressure above 140 kg/cm2 but not above 210 kg/cm’, use the repair limit for delivery given in Table, No 1

Note 3.)

For pumps whose service pressure exceeds 50 kg/cm2 in operation, use Table, No 1. (do not use Table, No 2)

Note 4.)

The volumetric efficiency of a pump decreases after the pump is reassembled. After reassembly, therefore, perform the following tests with a test bench or flowmeter kii (790-303-1001). (1) Shock test 20 times

TIma

LlOAVO25

(2) Performance test (measurethedelivery)

97-15

SA SERIES

DISASSEMBLY

DISASSEMBLY 1.

Single pump + Cautions before disassembly To avoid confusion in the reassembly, stamp match marks on connecting sections of bracket (6) to gear case (11) and gear case (11) to cover (15). 6

Put the pump assembly on a work bench with the bracket side facing down, and loosen mounting bolts (17) for cover (15).

Use the bracket mounting the pump assembly.

UOAVOSl

bolt holes to secure

LlOAVO32

2) +

Remove cover assembly (15). Place the internal parts in line in the order of removal, taking care not to damage the contacting surfaces or sliding surfaces of the parts. Pull out cover assembly (15) taking care not to damage the hole for the dowel pin. Do not pry the cover.

L10AV033

Remove O-ring (16) from the cover.

UOAVO34

97-16

SA SERIES

DISASSEMBLY

4) Pull out side plate (12) on the cover side.

LiOAVO36

Remove backup ring (13) and seal ring (14).

23OF221

6) * +

Remove drive gear (1) and driven gear (2). Pull out the gears by hand. Do not use a hammer. If the oil seal is not replaced, tape the drive gear and the spline section to protect the oil seal from damage.

7) Remove bracket (6) from gear case (11). + When removing bracket (6) from gear case (11) take care not to let side plate (8) on the bracket side fall down and leave the side plateinstalled as is to the gear case. + Do not hit the side plate surface.

DISASSEMBLY

SA SERIES

Pull outside side plate (8) from gear case (11).

on port

Dis\charga

port LlOAVO39

Remove backup ring (13) and seal ring (14).

10) Remove O-ring (7) from bracket.

UOAVO41

97-18

SA SERIES

DISASSEMBLY

2. Tandem pump 1) Stamp match marks. 2)

Put the pump on a work bench with the front pump bracket surface facing down, and remove the four bolts that connect the front pump to the rear pump.

Match

Disconnect the front pump from the rear pump.

For the disassembly of single pumps, see the section on single pumps.

3. Triple pump Follow the same procedure for tandem pumps.

L10AV055

LiOAVO50

97-19

SA SERIES

ASSEMBLY

1. Single pump t When a used gear case is assembled, remove +

the burrs from the case and make sure that the side plate can be sided smoothly. Make sure that the dowel pin on the case has specified length (9. P + Lenoth of dowel pin 2 15

Put cover (15) on a work bench.

00 0

@ffT!i3 -cB 00°

0 L10AV043

2) + + +

Install side plate (12) into gear case (11) with the seal groove facing outside. Do not install the backup ring and the seal to side plate (12) at this stage. Do not confuse the suction side of the side plate with the delivery side. Do not damage the periphery of the side plate, especially around the seal section.

Discharge port LlOAVO44

Measurement of side clearance Temporarily assemble bracket (6) and gear case (11) as shown in the drawing at right. Place the assembly on a work bench and measure the difference between the stack height including drive gear (l), side plates (8) and (12) and the height of gear case (11). Measure with a depth dial gauge or depth micrometer.

Judgement criteria Confirm that the measurements conform to the standard clearance given in the Maintenance Standard Table.

23OF222

97-20

ASSEMBLY

SA SERIES

3) Install gear case (11) to cover (15) with the match marks aligned. -a

LlOAVO45

4) Install drive gear (1) and driven gear (2).

L10AV046

Install side plate (8) with the backup and seal ring grooves facing upward.

LlOAVO47

6) Install backup ring (9) and seal ring (10). * Install them with care to prevent gaps between *

Discharge port

the ring and the gear case. If it is impossible to eliminate the gap, replace the seal ring and the backup ring.

.Gap

23OF223

97-21

SA SERIES

ASSEMBL V

Apply some hydraulic oil to the shafts of gears (1 and 2) and also to the sliding section of the side plate. Take care to keep gear case free from oil.

LlOAVO48

Install O-ring (7) to bracket (6).

LiOAVO49

9) + +

+ t

Install bracket (6). Align the match marks when installing the bracket. Before installing the bracket, make sure that the seal and backup rings are properly installed according to the precautions in item 6. Make sure O-ring (7) is fit properly. Confirm that the contact surface is free from dirt and dust. LlOAVO50

10) Carefully turn the gear pump assembly upside down so that the bracket side will face downward, and put the gear pump assembly on a work bench. + When turning the pump upside down, take care not to let the contact surfaces open out and not to let the O-ring and seal come off.

LlOAVO51

97-22

ASSEMBLY

SA SERIES

11) Remove the cover (15) and install O-ring (16).

14 Install backup ring and seal ring to side plate

(12) in the manner described in item 6. 13) Install cover (15). * Align the match marks when installing the cover. * Before installing the cover, make sure backup ring and seal ring are properly installed according to the precautions given in item 6. t Make sure O-ring (16) is fit properly.

L10AV035

14) Tighten mounting bolts (17). * Use a torque wrench and tighten the bolts to the specified torque in the order shown in the drawing. For the tightening torque, see the Maintenance Standard Table, this section.

LlOAVO32 Tightening

order LlOAVO26

15) After assembly, check the rotational torque of the pump shaft to see if it conforms to the value given in the table. t After the pump is assembled, carry out the performance test (measure the pump delivery) with a test bench or flow meter kit (790-3031001). Confirm that the performance is with the repair limits.

Rotational torque

1.0 - 1.5 kam

2. Tandem pump 1) For the assembly of individual units of the front and rear pump, follow the same assembly procedure as for the single pump. 2) Put the front pump on a work bench.

97-23

SA SERIES

ASSEMBLY

Install the coupling to the front pump.

4) Fit the O-ring to the rear pump bracket. 5) Put the rear pump on top of the front pump. * Take care not to let the O-ring come off. + Align the match marks.

lightening

O-ring I

order

k3A-d

LlOAVO52

LlOAVO27 6) Tighten four mounting bolts. t Tighten the bolts with a torque wrench to the specified torque in the order shown in the drawing below. Match

After the pump is assembled, carry out the performance test (measure the pump delivery) with a test bench or flow-meter kit (790-3031001). Confirm that the performance is within the repair limits.

3. Triple pump Follow the same assembly procedure as for the tandem pump. UOAVOSB

97-24

MAINTENANCE

SA SERIES

STANDARD

MAINTENANCE STANDARD

LlOAVO28

Check item

Series No

Unit: mm

Criteria Standard clearance

Remedy

Clearance limit

0.19

SAL & SAR = 020 - 080

Clearance between the gear case and the gear plus the side plate

0.19

SAL & SAR 0.13 - 0.18

0.20

0.11 - 0.16

0.19

Too-125

SAL & SAR =

Replace the side plate or the pump assembly

112 - 180 4

SAL & SAR = 200 - 250

0.22

SAL & SAR 0.06 - 0.144

(708 - 014 2

Clearance between the I.D. of the plain bearing and the O.D. of the gear shaft

SAL & SAR 0.06 - 0.119

o=lS-025 0.06 - 0.125

0.22

Replace

0.06 - 0.149

0.06 - 0.140

97-25

MAINTENANCE

SA SERIES

Check item

Series No

Remdy

Tightening torque for the case mounting bolts 15 - 18 kgm

97-26

STANDARD

OTHER 99

METRIC CONVERSIONS

99-1

METRIC

UNIT

CONVERSIONS

MULTIPLY BY

TO GET

w square millimeter

(mm2)

0.001550003

square inch

6.4516

square centimeter

(cm2)

0.1556063

square inch

0.00064516

square meter (m2)

o.OQ2QO304

square meter (m2)

0.8361274

square meter (m2)

25.29285

square meter (m2)

0.00252Q285

square hectometer

645.16 square inch (in2)

square foot (f?) square yard (yd2)

1550.003

square inch

10.76391

square foot

1.195990

square yard

0.03953686

square rod

square rod (rod2)

4646.856

(hm2)

395.3686

square rod

0.0002471054

acre

2.471054

acre

square meter (m2)

0.oooooo3861022

square mile

square kilometer

0.386102175

square mile

square meter (m2)

acre 0.4046856 2589988.0

square hectometer

(hm2)

square mile (mile2) 2.589988

MULTIPLY BY

UNIT

(km2)

TO GET

MULTIPLY BY

TO GET

DENSITY (Mass Density) pound per cubic yard

0.5932763

kilogram

per cubic meter

1.685555

(lb/yd3)

0.06242797

(lb/ft3)

0.03612730

(lb/k?)

8.345406

(lb/US gal)

10.02242

(lb/UK gal)

(kg/m3)

(lb/yd3) pound per cubic foot

16.01846

kilogram

per cubic meter

(kg/m3)

(1b/ft3) pound per cubic inch

27.67990

(lb/in3)

gram per cubic centimeter (g/cm3) ;$j,rarn

per liter

pound per US gallon (lb/US gal)

0.1198264

pound per UK gallon (lb/UK gal)

0.09977633

kilo ram per liter (kgjl)

MULTIPLY BY

TO GET

UNIT

MULTIPLY BY

TO GET

FORCE

pound, pound-force (tbf)

ounce-ounce-force

99-2

(oaf)

4.448222

newton (N)

0.004448222

kilonewton

0.2780139

newton (N)

0224808Q (kN)

224.8089 3.596942

pound-force pound-force ounce force

METRIC CONVERSIONS

UNIT

MULTIPLY BY

TO GET

MULTIPLY BY

TO GET

FORCE PER LENGTH 0.1751268

newton per millimeter

(N/mm)

5.710148

pound-force

per inch

pound, force per inch (Ibf/in)

~;r~fi~-force

per foot)

175.1268

newton per meter (N/m)

0.005710148

pound-force

per inch

14.5939

newton per meter (N/m)

0.06852178

pound-force

per foot

HEAT

British thermal unit

kilojoule per liter (kJ/I)

Btu per gallon (Btu/gal) *Heat flow rate. Also see POWER.

micron Q

(same as micrometer

one for one)

foot (ft)

0.3048

meter (m)

3.280840

(ft)

yard (yd)

0.9144

meter (m)

1.093613

(yd)

1.609344

kilometer

0.6213712

mile

(km)

mile

rod

1609.344

meter (m)

0.0006213712

mile

5.0292

meter (m)

0.1988388

rod

99-3

METRIC

UNIT

CONVERSIONS

MULTIPLY BY

TO GET

MULTIPLY BY

TO GET

MASS (WEIGHT)

ounce

short ton (2666 lb)

megagram

MULTIPLY BY

UNIT

0.7456999 horsepower

(Mg)

TO GET

0.9842664

long ton

MULTIPLY BY

TO GET

kilowatt (kW)

1.341022

(hp)

watt (W)

0.001341022

(hp)

(hp) 745.6999

Btu per hour* (Btu/h)

0.2930711

watt (W)

3.412141

(Btulh)

Btu per minute* (Btu/min)

17.58427

watt (W)

0.05686962

(Btu/min)

lAJso heat flow rate. See HEAT. UNIT

MULTIPLY BY

TO GET

MULTIPLY BY

TO GET

PRESSURE 6.894757

kilopascal

0.606894757

megapascal

0.0703

kilogram force per square pntrmeter (kg/cm 1 inch of mercury

pound force per square Inch (psi)

(in Hg)

inch of water (in H20) bar

99-4

(kPa)

(psi)

145.0377

(psi)

kilogram force er2quare centimeter (kg Pcm )

14.225

(psi)

98.6665

kilopascal

(kPa)

0.01019716

(kg/cm2)

3.37685

kilopascal

(kPa)

0.296134

(in Hg)

0.24884

kilopascal

(kPa)

4.0186

(in H20)

kilopascal

(kPa)

0.01

bar

100.0

(Mpa)

0.1456377

METRIC

UNIT

CONVERSIONS

MULTIPLY BY

TO GET

MULTIPLY BY

TO GET

TEMPERATURE degree Fahrenheit (“F)

(‘F-32) f 1.8

degree Celsius (“C)

UNIT

MULTIPLY BY

(1.8x%)

+ 32

(“F)

MULTIPLY BY

TO GET

TEMPERATURE INTERVAL OR TOLERANCE degree Fahrenheit (‘F)

divide by 1.8

degree Celsius (“C)

UNIT

MULTIPLY BY

TO GET

cubic yard (yd3)

0.7645549

cubic meter (m3)

1.307951

(Yd3)

cubic foot (ft3)

0.02831685

cubic meter (m3)

3531466

(ft3)

16.38796

cubic centimeter (cm3)

0.06102376

(in3,

0.01638796

liter (I)

61.02376

(in3)

3.785412

liter (I)

0.2641726

(US gal)

0.003785412

cubic meter (m3)

US liquid quart (US qt)

0.9463529

liter (I)

US liquid pint (US pt)

0.4731765

cup

1.8

(‘F)

MULTIPLY BY

TO GET

cubic inch (in3)

U&li,“$d a

gallon 264.1729

(US gal)

1956688

(US qt)

liter (I)

2.113376

(US Pt)

0.2365882

liter (I)

4.226753

cup

0.02957353

liter (I)

33.81402

(US fl 02)

29.57353

cubic centimeter (cm3)

0.03381402

(US fl 02)

14.78676

milliliter (ml)

0.06762807

tablespoon

4.928922

milliliter (ml)

0.2028841

teaspoon

4.546092

liter (I)

0.2199692

(UK gal)

0.064546092

cubic meter (m3)

219.9692

(UK gal)

0.02841307

liter (I)

35.19567

(UK fl oz)

US fluid ounce (US fl 02)

tablespoon

teaspoon

LIKKli$d gallon

UK fluid ounce (UK fl oz) cubic centimeter (cm3)

28.41307 I

(UK fl oz)

0.03519597 I

99-5

METRIC

UNIT

MULTIPLY BY

CONVERSIONS

TO GET

MULTIPLY BY

TO GET

TORQUE 1.366818

newton meter (Nom)

0.7376621

(Ibf ft) or (ft lb)

0.1383

kilogram-force meter (kgf*m) or (kg*m)

7.233

(Ibf ft) or (ft lb)

pound-force inch (Ibf in) or (in lb)

0.1129848

newton meter (Nom)

8.860748

(Ibf in) or (in lb)

ounce force inch (ozf in)

0.007061662

newton meter (Nom)

kilogram-force meter (kgf*m) or (kg*m)

9.806660

newton meter (Nom)

pound-force foot (Ibf ft) or (ft lb)

141.6119

(ozf in)

0.1019716

(kgf*m)

39.37008

(in/s)

VELOCITY

foot per minute (ft/min)

inch per second (in/s) meter per second (m/s)

99-6

or (kg*m)

Komatsu America international Company 440 North Fairwav Drive I Vernon Hills, IL 66061-8112 U.S.A. Attn: Technical Publications Fax No. (847) 970-4186

PROPOSAL

FOR MANUAL

REVlslON

FOR INTERNAL USE ONLY -- No. PMR 2

NAME OF COMPANY:

PHONE NO:

: S

DEPARTMENT:

E R

NAME:

MANUAL NAME: MANUAL NO: MACHINE MODEL: S/N IF APPLICABLE: PAGE NO:

PROBLEM:

Attach photo or sketch. If more space is needed, use another sheet.

1 FOR INTERNAL USE ONLY CORRECTIVE ACTION:

PFMRl 081696

LOCATION:

DATE:

FOLDOUT NO. 5 ELECTRICAL WIRING AND CN DIAGRAM

‘CN326

View

\ CN153

c\N2w-

Ether injection switch Working lamp switch Parking brake switch Starting switch Transmission cut-off selector switch 6 Fuse box 7. Front wiper switch 8. Radio 9. Rear wiper switch 10. Condenser relay 11. Air conditioner relay 12. Warning buzzer 13. Head lamp 14. Front combination lamp 15. Front wiper 16. Front working lamp 17. Washer tank 18. Rear wiper 19. Brake oil tank 20. Ether injection solenoid 21. Coolant level sensor 22. Rear working lamp 23. Alternator 24. Rear combination lamp 25. Battery relay 26. Breaker 27. Engine water temperature sensor 28. Engine oil pressure sensor 29. Torque converter oil temperature sensor 30. Transmission oil filter clogging sensor 31. Brake stroke sensor 32. Speedometer sensor 33. Parking brake display switch 34. Parking brake solenoid valve 35. Bucket proximity switch

L08DD138

FOLDOUT NO. 6 VEHICLE MONITOR SYSTEM Engine oil pressure sensor

Fuse box I-2

Fuse box II-2

NLY

relay I

r To turn signal unit COOlant To rear turn signal lamp TO rear turn signal lamp +24V

IPl

CN94CN95

Fuel cut solewad I I I I

I I

I L

I AI I I

‘T

CN36

Parkmg brake lndlcator switch

To start,ng motclr

*To

To F-R lever f

pressure

relay

t $F$+@

-I CNlOl

Working

Water temp. sensor

lamp switc

ml Brake oil- level sensor I

Alternator

CN21

w Transmission cut-off switch

lamp

Ether qectlon solenmd

starting motor

N36

LH. front combination

*Tj.,

TO turn signal unit

Engine oil

CN102

Safety relay

Starting motor

LH. head lamp

L08DD139

FOLDOUT NO. 7 TRANSMISSION

9. No. 1 sun gear (Teeth 30) IO.

No. 1 planetary

11.

No. 1 clutch

gear (Teeth 28)

12.

No. 1 ring gear (Teeth 70)

13. No. 1 idle gear (Teeth 86) 14.

No. 2 sun gear (Teeth 42)

15.

No. 2 clutch

16.

No. 2 ring gear (Teeth 90) 24)

17. No. 2 planetary

gear (Teeth

18. No. 3 planetary

gear (Teeth 24)

19. No. 3 clutch

No. 1 clutch

No. 3 clutch

No. 2 clutch

No.4

No. 5 clutch

clutch

‘REVERSE”

FORWARD

’

2nd

4th Section A -

No. 6 clutch #

)I 3rd

b 1st

A 425FOllll

20.

No. 3 sun gear (Teeth 42)

21.

No. 3 ring gear (Teeth 90).

22.

No. 4 clutch

23.

No. 4 hub

24.

No. 5 clutch

25.

No. 5 ring gear (Teeth 90)

26.

No. 5 planetary

27.

No. 5 sun gear (Teeth50)

28.

No. 6 clutch

gear (Teeth 21)

29.

No. 6 ring gear (Teeth 90)

30.

No. 6 planetary

31.

No. 6 sun gear (Teeth 50)

32.

Output

33.

No. 1 carrier

34.

No. 2, 3 carrier

shaft

35.

No. 5 carrier

36.

No. 6 carrier

gear (Teeth 20)

FOLDOUT NO. 8 HYDRAULIC PIPING

1. Main control valve 2. Dump cylinder 3. Hydraulic tank 4. PPC valve 5. Steering, PPC pump 6. Accumulator 7. Oil cooler 8. Hydraulic pump

9. Switch pump 10. Steering valve 11.

Lift cylinder

12. Steering cylinder

425FO1161

FOLDOUT NO. 9 HYDRAULIC CIRCUIT SYSTEM

26 \I

425FO1162

FOLDOUT NO. 10 HYDRAULIC CIRCUIT DIAGRAM

1. Hydraulic tank 2. Hydraulic filter 3.

Breather

4. Switch pump 5. Torque converter charging pump 6. Hydraulic

pump

7. Steering pump 8. PPC pump 9. Check valve 10. Pilot oil filter 11.

Check valve

12. Accumulator 13.

Relief valve

14. PPC valve 15. PPC valve

16. Main relief valve 17. Service spool 28.

transmissb

10 11 13 d

iL___>j

425FO1163

Safety valve (with suction)

19.

Dump spool

20.

Safety valve (with suction)

21.

Float selector valve

22.

Unloader

23.

Lift spool

24.

Slow return valve

25.

Lift cylinder

26.

Dump cylinder

27.

Service cylinder

28.

Demand valve

29.

Main relief valve

30.

Steering valve

31.

Safety valve (with suction)

32.

Two-way

33.

Steering cylinder

34.

Oil cooler

35.

Emergency pump

restrictor valve

36.

Diverter valve

Warning lamp switch

FOLDOUT NO. 11 AIR PIPING

1. Spring cylinder 2.

Parking brake solenoid valve

3. R.H. brake valve 4.

L.H. brake valve

5. Brake oil tank 6. Air compressor 7. Air governor 8.

Rear brake

Rear slack adjuster

10.

Air tank (wet)

11.

Rear brake chamber

12. Air tank (dry) (lower) 13.

Front brake chamber

14. Air tank (wet) (upper) 15.

Parking brake

16.

Front slack adjuster

17.

Front brake

LO322006

FOLDOUT NO. 12 BRAKE AND AIR CIRCUIT SYSTEM

1. Air compressor 2. Air governor 3. Check valve 4. Air tank (wet)

5. Tire inflation 6. Drain valve 7. Safety valve 8.

Emergency brake sensor

9. Air pressure sensor 10.

Air tank (dry)(Lower)

11. Air tank (dry) (Upper) 12.

Check valve

13.

Drain valve

14.

R.H. brake valve

15.

L.H. brake valve

16. Two-way

valve

17.

Stop lamp switch

18.

Transmission

19.

Front brake chamber

cut-off switch

20.

Rear brake chamber

21.

Brake oil tank

22.

Front slack adjuster

23.

Front brake

24.

Rear slack adjuster

25.

Rear brake

26.

Horn valve

27.

Horn

28.

Parking brake solenoid valve

29.

Parking brake sensor

30.

Spring cylinder

Air circuit Brake oil circuit

Lo3uoo7