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SEBM008002

Shop Manual

.FA!OO= WHEEL LOADER

SERIAL NUMBERS

VVA900-1 - 10001 andUP

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

May 1997

00&l

CONTENTS No. of page

GENERAL . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-l

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY

AND ASSEMBLY

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

30-I

MAINTENANCE

STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .

40-l

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

IO-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-I

z k

OTHERS . . . . . . . . . .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-l

LIST OF REVISED PAGES

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00-2-5 0

SAFETY

NOTICE

SAFETY SAFETY NOTICE IMPORTANT SAFETY NOTICE Proper

service

and

repair

is extremely

service and repair techniques are both effective designed

manual.

for safe machine

by Komatsu

and safe. Some of these techniques

by Komatsu

To prevent

important

recommended

for the specific

injury to workers,

The cautions

fully. If any dangerous take the necessary

situation

require the use of tools specially

is used to mark safety precautions

these symbols

should

arises or may possibly

always

arise, first consider

in operation

carefully

6. Decide

are extremely

BEFORE operating

Manual

the machine.

out any greasing

read all the precautions which

dangerous.

and Maintenance

1. Before carrying

a place

in the repair

workshop

parts. Always

the tools and parts in their correct Always

to keep

places.

keep the work area clean and make

sure that there is no dirt or oil on the floor.

or repairs,

given on the decals

Smoke

only in the areas provided

for smok-

ing. Never smoke while working.

are fixed to the machine.

2. When

carrying

out any operation,

wear safety shoes and helmet. loose work clothes,

always

. Always

wear

or clothes with buttons

safety glasses when

hitting

parts with a hammer. . Always

wear

safety

trained,

glasses

when

welder

welding

gloves,

out the work,

apron,

al-

hand

shield, cap and other clothes suited for welding work.

and

block the wheels

or tracks

the

8. Before

with two

or more workers,

always agree on the oper-

ating procedure

before

starting.

Always

in-

form your fellow workers before starting any Before starting

work,

REPAIR signs on the controls

in the operator’s

compartment.

in good condition

the correct way to use them.

to prevent

from moving. blade,

ripper,

bucket or any other work equipment

starting

work,

to the

If this

lower

equipment

is not possible,

from falling.

and learn

insert

In addition,

the

be sure

to lock all the control levers and hang warning signs on them. 9. When disassembling

out any operation

step of the operation.

repairs,

safety pin or use blocks to prevent the work

ways

carrying

any

on hard, level ground,

carry

out welding

5. Keep all tools

oil or making

ground.

carrying

hang UNDER

adding

park the machine

always have a

work. When wear

grind-

etc.

repairs are needed, experienced

7. Before

machine

ing parts with a grinder, 3. If welding

PREPARATIONS FOR WORK

Do not wear

missing.

4. When

care-

safety, and

keep tools and removed Mistakes

in this

be followed

actions to deal with the situation.

GENERAL PRECAUTIONS

Read the Operation

The

in this manual

purpose.

the symbol A

accompanying

operation.

and described

the

machine

with

before starting 10. Remove

or assembling, blocks,

jacks

support or stands

work.

all mud and oil from the steps or

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

use the handrails,

ladders

steps when

getting

Never

on or off the machine.

jump

impossible

on or off the machine.

to use the handrails,

steps, use a stand to provide

If it is

ladders

safe footing.

00-3

SAFETY

PRECAUTIONS

DURING

19. Be sure to assemble

WORK

original 11. When or

removing

hydraulic

loosen them spurting

the oil filler cap, drain plug pressure

slowly

measuring

to prevent

plugs,

the oil from

disconnecting

nents

of the oil, water the

or removing

pressure

compo-

or air circuits, completely

first

from

the

circuit. 12. The

and

installing

is stopped,

that they will not be damaged

out any work

20. When

installing

sure that

high pressure

they

are

are hot

ful when

installing

circuits.

Also,

to cool

before

on the oil or water

circuits. 13. Before starting work, remove the leads from the battery.

Always

remove

the negative

(-1 terminal

the lead from

14. When raising heavy components,

use a hoist

aligning

or hand.

fingers

caught

lifting

ample

capacity.

Install

the lifting

which

has

places.

Use a hoist to prevent

or crane

and operate

the component

from

hit-

part. Do not work with

any

removing

ternal

pressure

or under

pressure

spring,

always

leave two

bolts in position

sides. Slowly

release the pres-

covers which

are under infrom

sure, then slowly loosen the bolts to remove.

17. When

removing

components,

or damage

removing

be careful not

the wiring.

may cause electrical piping,

Damaged

fires.

stop the fuel or oil

from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. on the floor

Fuel or oil

can cause you to slip, or can

even start fires. 18. As a general

rule, do not use gasoline

wash parts. In particular,

use only the mini-

mum

washing

parts.

00-4

violently

or rotate at

careful

to check

correctly.

Be careful

not to get your

in a hole.

measuring

hydraulic

that the measuring

of gasoline

when

24. Take care when

pressure,

tool is correctly

electrical

removing

tracks of track-type When

removing

rates suddenly,

15. When

wiring

When

parts such as guards,

check assem-

at the correct

part still raised by the hoist or crane.

to break

parts, always torques.

bled before taking any measurements. equipment

slowly

ting any other

23. When

equipment

parts

two holes, never insert your

fingers

use

or installing

vibrate

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

connecting

tightening

be particularly

or crane.

Always

tubes for high pressure

protective

or parts which

22. When

care-

installed.

use the specified

high speed,

Damaged

so be extremely

that they are installed

first.

is be-

hoses, make

not twisted.

check that

21 When assembling installing

on opposite

be sure

by contact

ing operated.

are correctly

for the oil and water

carrying

16. When

parts with new parts.

hoses and wires,

so be careful

oil in the circuits

the engine

not to get burned. Wait

Replace any damaged . When

tubes are dangerous,

water

when

all parts again in their

places.

with other parts when the machine

out.

Before remove

NOTICE

or installing

the

machines.

the track, the track sepaso never let anyone stand at

either end of the track.

GENERAL

FOREWORD

FOREWORD GENERAL This

shop

serviceman

manual

has been

an accurate

prepared

as an aid to improve

understanding

repairs and make judgements.

the quality

of the product and by showing

Make sure you understand

of repairs

by giving

the

him the correct way to perform

the contents

of this manual

and use it to full

information

for operations

performed

in a

into the following

chapters;

these

effect at every opportunity.

This shop manual

mainly

service workshop.

For ease of understanding,

chapters

are further

contains

divided

the necessary

technical

the manual

is divided

into the each main group of components.

STRUCTURE AND FUNCTION This section explains an understanding

the structure

of the structure,

and function

of each component.

but also serves as reference

It serves not only to give

material

for troubleshooting.

TESTING AND ADJUSTING This

section

adjustments

explains

Troubleshooting

DISASSEMBLY

checks

charts correlating

before

and

after

performing

repairs,

as well

of the checks and repairs.

“Problems”

to “Causes” are also included

in this section.

AND ASSEMBLY

This section

explains

assembling

each component,

MAINTENANCE

to be made

to be made at completion

the order to be followed

when

as well as precautions

removing,

installing,

disassembling

to be taken for these operations.

STANDARD

This section gives the judgement

standards

when

inspecting

disassembled

parts.

NOTICE The

specifications

contained

time

and

without

any

with

the

latest

advance

in this notice.

shop

manual

Use the

are subject

specifications

to change given

in the

at any book

date.

00-5

HOW TO READ THE SHOP MANUAL

FOREWORD

HOW TO READ THE SHOP MANUAL VOLUMES

REVISED EDITION MARK

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

When

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

pages.

Electrical volume: Attachments volume:

Each issued as one volume to cover all models

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

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

a manual

(@@@....I

is revised,

is recorded

an edition

on the

bottom

mark of the

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

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

FILING METHOD 1. See the page number

on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume): 10 - 3 Item number (IO. Structure and Function) Consecutive page number for each item. Example

cated

pages:

by a hyphen

page number.

Additional

Remarks

Safety

Special safety precautions are necessary when performing the work.

Caution

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

Weight

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

‘ightening torque

Places that require special attention for the tightening torque during assembly.

Coat

Places to be coated with adhesives and lubricants, etc.

31. water

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

Drain

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

pages are indi-

(-1 and number

after the

File as in the example.

Example: IO-4

12-203

IO-5

12-204

00-6

Item

2 (Engine volume):

Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item.

3. Additional

Symbol

FOREWORD

HOISTING INSTRUCTIONS

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

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

If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for

removal

of all bolts fastening

the part to the relative

2) Check for existence

of another

ing interference

the

with

100%

88%

79%

71%

41%

parts.

sADoo479

part caus-

part to be re-

moved.

3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.

WIRE ROPES 1) Use adequate weight

ropes

depending

of parts to be hoisted,

on the

referring

the table below: 4)

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

Allowable

load

tons

9.8

1.0

11.2

13.7

1.4

12.5

15.7

1.6

21.6

2.2

27.5

35.3

43.1

22.4

54.9

5.6

Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load kN {kg) when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN 11000 kg} vertically, at various hanging angles. When two ropes sling a load vertically,

can be

2.8

suspended.

9.8 kN

3.6

{IO00

4.4

hanging

98.1

10.0

176.5

18.0

274.6

28.0

392.2

40.0

This weight

kg) when angle.

two

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

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

portion

becomes

ropes

make

On the other

ropes are subjected

a 120”

hand, two

to an excessive

force

as large as 39.2 kN (4000 kg1 if they sling a 19.6 kN (2000 kg) load at a lifting angle of 150”.

0 B

rlI:,

$B 16.7

to 19.6 kN (2000 kg) of total weight

~~~ (1400)

9.0 ~10001

z (500)

30 Lifting

60 mole

90 (decree)

120

150 SAD00480

00-7

COATING MATERIALS

FOREWORD

COATING

MATERIALS

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

Categon/

Main applications, features

(omatsu code

u Used to prevent rubber gaskets, rubber

LT-1A

cushions, and cock plug from coming out.

. Used in places requiring an immediately effective, strong adhesive. Used for plastics (except polyethylene, polyprophylene, tetrafluoroethlene and vinyl chloride), rubber, metal and non-metal.

Polyethylene container

LT-1 B

LT-2

0994040030

I I 50 g

Polyethylene container

790-129-9060

* Used as adhesive or sealant for metal, glass and plastic.

(Set of adheLT-3

sive and hardening agent)

LT-4

790-129-9040

Holtz MH 705

790-126-9120~

Adhesives

Features: Resistance to heat and chemicals Used for anti-loosening and sealant purpose for bolts and plugs.

( 250 g I’;;;;?;; Used as sealant for machined holes. l

75 g

Tube

Used as heat-resisting sealant for repairing engine.

9 Quick hardening type adhesive Three bond 1735

790-129-9140

50 g

Polyethylene container

2 g

Polyethylene container

I I

Aron-alpha 201

790-129-9130

Loctite 646-50

79A-129-9110

50 cc

Polyethylene container

LG-1

790-129-9010

200 g

Tube

9 Features: Resistance to heat, chemicals Used at joint portions subject to high temperatures.

b Used as adhesive or sealant for gaskets and packing of power train case, etc.

Gasket LG-3

790-129-9070

1 kg

Can l

00-8

Quick hardening type adhesive Quick cure type (max. strength after 30 minutes) Used mainly for adhesion of rubbers, plastics and metals.

sealant

Cure time: within 5 sec. to 3 min. Used mainly for adhesion of metals, rubbers, plastics and woods.

Features: Resistance to heat Used as sealant for flange surfaces and bolts at high temperature locations, used to prevent seizure. Used as sealant for heat resistance gasket for high temperature locations such as engine precombustion chamber, exhaust pipe, etc.

COATING MATERIALS

FOREWORD

Category

Q’tv

Part No.

Komatsu code

Container

Main applications, features l

LG-4

200 g

790-129-9020

Tube

Features: Resistance to water, oil Used as sealant for flange surface, thread. Also possible to use as sealant for flanges with large clearance. Used as sealant for mating surfaces of final drive case, transmission case.

. Used as sealant for various threads, pipe LG-5

1 kg

790-129-9080

Polyethylene container

joints, flanges. Used as sealant for tapered plugs, elbows, nipples of hydraulic piping.

. Features: Silicon based, resistance to heat, Gasket sealant

LG-6

09940-00011

Tube

250 g

09920-00150

cold Used as sealant for flange surface, tread. . Used as sealant for oil pan, final drive case, etc. l

. Features: Silicon based, quick hardening type Used as sealant for flywheel housing, intake manifold, oil an, thermostat housing, etc.

150 g

Tube

100 g

Tube

Used as heat-resisting sealant for repairing engine.

Can

Used as lubricant for sliding portion (to pre1 vent from squeaking).

Molybde num disulphide lubricant

L”-G

1 ogg40-ooo51 1

6o g

LM-P

09940-00040

200 g

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

General purpose type

G2-LI

SYG2-4OOLI SYG2-350LI SYG2-4OOLI-A Various SYG2-16OLI SYGA-16OCNLI

GP-CA

SYG2-400CA SYG2-350CA SYGP-4OOCA-A Various SYG2-16OCA SYGA-1GOCNCA

Tube

Various

Grease

Molybdenum disulphide lubricant

SYG2-400M

400 g (IO per case)

Various

Used for normal temperature, light load bearing at places in contact with water or steam.

Used for places with heavy load

Belows type

00-9

STANDARD TIGHTENING TORQUE

FOREWORD

STANDARD

TIGHTENING

TORQUE

STANDARD TIGHTENING TORQUES OF BOLTS AND NUTS Use these torques

for metric

bolts and nuts. (Always

use torque

wrench).

Thread diameter of bolt

Width across flats

kgm

6 8 10 12 14

10 13 17 19 22

13.2f 1.4 31f3 6657 113+10 177f19

1.35f0.15 3.2f0.3 6.7f0.7 11.5fl 18f2

16 18 20 22 24

24 27 30 32 36

279530 382?39 549f59 745f83 927+103

28.553 39+4 56+6 76f8.5 94.5+ 10.5

27 30 33 36 39

41 46 50 50"

1320f140 1720+190 2210f240 2750f290 3290f340

135515 175f20 225+25 280+30 335+35

Thread diameter of bolt

Width across flats

k9m

6 8 Iii 12

10 13 14 27

7.85f 1.95 18.6k4.9 40.2f5.9 82.35k7.85

0.820.2 1.9f0.5 4.1f0.6 8.4rtr0.8

TIGHTENING TORQUE OF HOSE NUTS Use these torques Nominal

No.

for hose nuts. Thread

02 03 04 05 06 10 12 14

diameter

Width

Tightening

across flat

torque

kgm

14 18 22 24 30 33 36 42

19 24 27 32 36 41 46 55

24.5f 4.9 49f 19.6 78.5f 19.6 137.3k29.4 176.5k29.4 196.1+49 245.2+ 49 294.2f 49

2.5f0.5 5f2 8f2 14f3 18f3 20f5 25f5 30f5

TIGHTENING TORQUE OF SPLIT FLANGE BOLTS Use these torques Thread

00-10

diameter

for split flange Width

bolts. Tightening

across flat

torque

knm

65.7f 6.8

6.7f0.7

12 16

17 22

112f9.8 279f29

11.5fl 28.5f3

STANDARD TlGHTENlNG TORQUE

FOREWORD

TIGHTENING TORQUE OF O-RING BOSS CONNECTOR Use these torques Nominal

No.

for O-ring Thread

boss connector diameter

Width

mm 02 03.04 05,06 IO,12 14

14 20 24 33 42

Tightening

across flat mm

Varies depending on type of connector.

torque

kgm

34.3f4.9

3.5kO.5 9.5fl 14.5f2 43f6 89.5f 13.5

93.1k9.8 142.1k19.6 421.4k58.8 877.1f 132.3

TIGHTENING TORQUE OF O-RING BOSS CONNECTOR Use these torques

Nominal

No.

for O-ring Thread

08 10 12 14 16 18 20 :o" 33 36 42 52

boss connector diameter

Width

Tighteni

across flat

I torque

kgm

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

14 17 19 22 24 27 30 32 32

7.35k1.47 11.27f 1.47 17.64f1.96 22.54k1.96 29.4rt4.9 39.2f4.9 49f4.9 68.6f9.8 107.8f14.7 127.4k19.6 151.9f24.5 210.7f29.4 323.4k44.1

0.75kO.15 1.15f0.15 1.8a0.2 2.3f 0.2 3f0.5 4f0.5 5f0.5 7+1 llf1.5 13+2 15.5+ 2.5 21.5+3 33i 4.5

36 -

,Sealingsurface

TIGHTENING TORQUES OF FLARE NUT Use these torques

for O-ring boss connector

Thread

Width

diameter mm 14 18 22 24 30 33 36 42

Tightening

across flat mm 19 24 27 32 36 41 46 55

torque

24.5k4.9 49k19.6 78.5f 19.6 137.3f29.4 176.5f29.4 196.lf49 245.2f 49 294.2f49

2.5f0.5 5f2 8f2 14f3 18+3 20f5 25f5 30f5

00-l1

FOREWORD

ELECTRIC WIRE CODE

ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example:

5WB indicates

CLASSIFICATION

a cable

having

a nominal

number

5 and white

coating

with

black

stripe.

BY THICKNESS Copper wire

N;tyaF;sof

(mm)

0.85

Ca;kzjD.

Dia. of strands Cross section 0.32

(mm*) 0.88

Currerirating

I I

2.4

Applicable

circuit

I 12

Starting, lighting, signal etc.

3.1

Lighting,

signal etc.

4.6

Charging

and signal

Starting

(Glow plug)

0.80

42.73

11.4

135

Starting

127

0.80

63.84

13.6

178

Starting

100

217

0.80

109.1

17.6

230

Starting

CLASSIFICATION

0.45

13.36

7.0

BY COLOR AND CODE

Prior itv

Lighting

Instrument

Signal

Other

Code

mary Color

White

Black

Red

Yellow

Green

Blue

Code

pri_

Red &White

Yellow & Red Green &White Blue &White

Yellow & Black Green & Red

Red 81 Black A,&

liary

Code

Color White & Blue

Black & Red Red & YellowfYellow RG

LR Blue & Red

& GreenlGreen & YellowlBlue

& Yellow

Red & Green

RL 6

Color

00-l 2

Red & Blue

Yellow & Blue Green & Black Blue & Black I

Yellow&White

GL I Green & Blue I

CONVERSION

FOREWORD

CONVERSION METHOD details

TABLE

OF USING

The Conversion

TABLE

THE CONVERSION Table

of the method

TABLE

in this section

is provided

of using the Conversion

to enable

simple

conversion

Table, see the example

of figures.

For

given below.

EXAMPLE .

Method

Convert

of using the Conversion

Table to convert

from millimeters

to inches

55 mm into inches.

(I 1 Locate the number 50 in the vertical column at the left side, take this as @, then draw a horizontal line from @. (2) Locate the number

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

line

down from 0. (3) Take the point where the two lines cross as 0. from millimeters 2.

to inches.

Therefore,

This point @ gives the value when converting

55 mm = 2.165 inches.

Convert 550 mm into inches. (I) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to convert it to 55 mm.

(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. (3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

Millimeters

to inches

0 10 20 30 40

1 mm = 0.03937

0 0.394 0.787 1.181 1.575

0.039 0.433 0.827 1.220 1.614

0.079 0.472 0.866 1.260 1.654

0.118 0.512 0.906 1.299 1.693

0.157 0.551 0.945 1.339 1.732

0.197; 0.591; 0.984 i 1.378 i 1.772 i

0.236 0.630 1.024 1.417 1.811

0.276 0.669 1.063 1.457 1.850

0.315 0.709 1.102 1.496 1.890

0.354 0.748 1.142 1.536 1.929

2.205 2.598 2.992 3.386 3.780

2.244 2.638 3.032 3.425 3.819

2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

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

)!!I 2.559

2.953 3.346 3.740

00-13

FOREWORD

CONVERSIONTABLE

Millimeters to Inches 1 mm = 0.03937

0.039

0.079

0.118

0.157

0.197

0.236

0.276

0.315

0.354

0.394

0.433

0.472

0.512

0.551

0.591

0.630

0.669

0.709

0.748

0.787

0.827

0.866

0.906

0.945

0.984

1.024

1.063

1.102

1.142

1.181

1.220

1.260

1.299

1.339

1.378

1.417

1.457

1.496

1.536

1.575

1.614

1.654

1.693

1.732

1.772

1.811

1.850

1.890

1.929

1.969

2.008

2.047

2.087

2.126

2.165

2.205

2.244

2.283

2.323

2.362

2.402

2.441

2.480

2.520

2.559

2.598

2.638

2.677

2.717

2.756

2.795

2.835

2.874

2.913

2.953

2.992

3.032

3.071

3.110

3.150

3.189

3.228

3.268

3.307

3.346

3.386

3.425

3.465

3.504

3.543

3.583

3.622

3.661

3.701

3.740

3.780

3.819

3.858

3.898

Kilogram to Pound

1 kn = 2.2046 lb

T 0

2.20

4.41

6.61

8.82

11.02

13.23

15.43

17.64

19.84

22.05

24.25

26.46

28.66

30.86

33.07

35.27

37.48

39.68

41.89

44.09

46.30

48.50

50.71

51.91

55.12

57.32

59.53

61.73

63.93

66.14

68.34

70.55

72.75

74.96

77.16

79.37

81.57

83.78

85.98

88.18

90.39

92.59

94.80

97.00

99.21

101.41

103.62

105.82

108.03

110.23

112.44

114.64

116.85

119.05

121.25

123.46

125.66

127.87

130.07

132.28

134.48

136.69

138.89

141.10

143.30

145.51

147.71

149.91

152.12

154.32

156.53

158.73

160.94

163.14

165.35

167.55

169.76

171.96

174.17

176.37

178.57

180.78

182.98

185.19

187.39

189.60

191.80

194.01

196.21

198.42

200.62

202.83

205.03

207.24

209.44

211.64

213.85

216.05

218.26

00-14

FOREWORD

CONVERSIONTABLE

Liter to U.S. Gallon

II = 0.2642 U.S. Gal 1

0.264

0.528

0.793

1.057

1.321

1.585

1.849

2.113

2.378

2.642

2.906

3.170

3.434

3.698

3.963

4.227

4.491

4.755

5.019

5.283

5.548

5.812

6.076

6.340

6.604

6.869

7.133

7.397

7.661

7.925

8.189

8.454

8.718

8.982

9.246

9.510

9.774

10.039

10.303

10.567

10.831

11.095

11.359

11.624

11.888

12.152

12.416

12.680

12.944

13.209

13.473

13.737

14.001

14.265

14.529

14.795

15.058

15.322

15.586

15.850

16.115

16.379

16.643

16.907

17.171

17.435

17.700

17.964

18.228

18.492

18.756

19.020

19.285

19.549

19.813

20.077

20.341

20.605

20.870

21.134

21.398

21.662

21.926

22.190

22.455

22.719

22.983

23.247

23.511

23.775

24.040

24.304

24.568

24.832

25.096

25.361

25.625

25.889

26.153

Literto U.K. Gallon

1P = 0.21997 U.K. Gal 1

0.220

0.440

0.660

0.880

1.100

1.320

1.540

1.760

1.980

2.200

2.420

2.640

2.860

3.080

3.300

3.520

3.740

3.950

4.179

4.399

4.619

4.839

5.059

5.279

5.499

5.719

5.939

6.159

6.379

6.599

6.819

7.039

7.259

7.479

7.969

7.919

8.139

8.359

8.579

8.799

9.019

9.239

9.459

9.679

9.899

10.119

10.339

10.559

10.778

10.998

11.281

11.438

11.658

11.878

12.098

12.318

12.528

12.758

12.978

13.198

13.418

13.638

13.858

14.078

14.298

14.518

14.738

14.958

15.178

15.398

15.618

15.838

16.058

16.278

16.498

16.718

16.938

17.158

17.378

17.598

17.818

18.037

18.257

18.477

18.697

18.917

19.137

19.357

19.577

19.797

20.017

20.237

20.457

20.677

20.897

21.117

21.337

21.557

21.777

00-15

CONVERSIONTABLE

FOREWORD

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

7.2

14.5

21.7

28.9

36.2

43.4

50.6

57.9

65.1

72.3

79.6

86.8

94.0

101.3

108.5

115.7

123.0

130.2

137.4

144.7

151.9

159.1

166.4

173.6

180.8

188.1

195.3

202.5

209.8

217.0

224.2

231.5

238.7

245.9

253.2

260.4

267.6

274.9

282.1

289.3

296.6

303.8

311.0

318.3

325.5

332.7

340.0

347.2

354.4

361.7

368.9

376.1

383.4

390.6

397.8

405.1

412.3

419.5

426.8

434.0

441.2

448.5

455.7

462.9

470.2

477.4

484.6

491.8

499.1

506.3

513.5

520.8

528.0

535.2

542.5

549.7

556.9

564.2

571.4

578.6

585.9

593.1

600.3

607.6

614.8

622.0

629.3

636.5

643.7

651.0

658.2

665.4

672.7

679.9

687.1

694.4

701.6

708.8

716.1

100

723.3

730.5

737.8

745.0

752.2

759.5

766.7

773.9

781.2

788.4

110

795.6

802.9

810.1

817.3

824.6

831.8

839.0

846.3

853.5

860.7

120

868.0

875.2

882.4

889.7

896.9

904.1

911.4

918.6

925.8

933.1

130

940.3

947.5

954.8

962.0

969.2

976.5

983.7

990.9

998.2

1005.4

140

1012.6

1019.9

1027.1

1034.3

1041.5

048.8

1056.0

1063.2

1070.5

1077.7

150

1084.9

1092.2

1099.4

1106.6

1113.9

121.1

1128.3

1135.6

1142.8

1150.0

160

1157.3

1164.5

1171.7

1179.0

1186.2

193.4

1200.7

1207.9

1215.1

1222.4

170

1129.6

1236.8

1244.1

1251.3

1258.5

265.8

1273.0

1280.1

1287.5

1294.7

180

1301.9

1309.2

1316.4

1323.6

1330.9

338.1

1345.3

1352.6

1359.8

1367.0

190

1374.3

1381.5

1388.7

1396.0

1403.2

410.4

1417.7

1424.9

1432.1

1439.4

00-16

CONVERSIONTABLE

FOREWORD

kg/cm2

to lb/in2 1 kg/cm*

= 14.2233

lb/in*

14.2

28.4

42.7

56.9

71.1

85.3

99.6

113.8

128.0

142.2

156.5

170.7

184.9

199.1

213.4

227.6

241.8

256.0

270.2

284.5

298.7

312.9

327.1

341.4

355.6

369.8

384.0

398.3

412.5

426.7

440.9

455.1

469.4

483.6

497.8

512.0

526.3

540.5

554.7

568.9

583.2

597.4

611.6

625.8

640.1

654.3

668.5

682.7

696.9

711.2

725.4

739.6

753.8

768.1

782.3

796.5

810.7

825.0

839.2

853.4

867.6

881.8

896.1

910.3

924.5

938.7

953.0

967.2

981.4

995.6

1010

1024

1038

1053

1067

1081

1095

1109

1124

1138

1152

1166

1181

1195

1209

1223

1237

1252

1266

1280

1294

1309

1323

1337

1351

1365

1380

1394

1408

100

1422

1437

1451

1465

1479

1493

1508

1522

1536

1550

110

1565

1579

1593

1607

1621

1636

1650

1664

1678

1693

120

1707

1721

1735

1749

1764

1778

1792

1806

1821

1835

130

1849

1863

1877

1892

1906

1920

1934

1949

1963

1977

140

1991

2005

2020

2034

2048

2062

2077

2091

2105

2119

150

2134

2148

2162

2176

2190

2205

2219

2233

2247

2262

160

2276

2290

2304

2318

2333

2347

2361

2375

2389

2404

170

2418

2432

2446

2460

2475

2489

2503

2518

2532

2546

180

2560

2574

2589

2603

2617

2631

2646

2660

2674

2688

190

2702

2717

2731

2745

2759

2773

2788

2802

2816

2830

200

2845

2859

2873

2887

2901

2916

2930

2944

2958

2973

210

2987

3001

3015

3030

3044

3058

3072

3086

3101

3115

220

3129

3143

3158

3172

3186

3200

3214

3229

3243

3257

230

3271

3286

3300

3314

3328

3343

3357

3371

3385

3399

240

3414

3428

3442

3456

3470

3485

3499

3513

3527

3542

00-17

CONVERSION TABLE

FOREWORD

Temperature Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit ture reading or vice versa is to enter the accompanying

temperature

reading intoa Centigradetempera-

table in the centeror boldfacecolumn of figures.

These figuresrefertothetemperature in eitherFahrenheitor Centigrade degrees. Ifitis desired to convert from Fahrenheitto Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade

to Fahrenheit

and read the corresponding

temperature

Fahrenheit

degrees,

consider

the center column

as a table of Centigrade

values,

on the right. 1°C = 33.8”F

“C

“F

“C

“F

“C

“F

“C

“F

-40.4

-40

-40.0

-11.7

51.8

7.8

114.8

27.2

117.8

-37.2

-35

-31.0

-11.1

53.6

8.3

116.6

27.8

179.6

-34.4

-30

-22.0

-10.6

55.4

8.9

118.4

28.3

181.4

-31.7

-25

-13.0

-10.0

57.2

9.4

120.2

28.9

183.2

-28.9

-20

-4.0

-9.4

59.0

10.0

122.0

29.4

185.0

-28.3

-19

-2.2

-8.9

60.8

10.6

123.8

30.0

186.8

-27.8

-18

-0.4

-8.3

62.6

11.1

125.6

30.6

188.6

-27.2

-17

1.4

-7.8

64.4

11.7

127.4

31.1

190.4

-26.7

-16

3.2

-7.2

66.2

12.2

129.2

31.7

192.2

-26.1

-15

5.0

-6.7

68.0

12.8

131.0

32.2

194.0

-25.6

-14

6.8

-6.1

69.8

13.3

132.8

32.8

195.8

-25.0

-13

8.6

-5.6

71.6

13.9

134.6

33.3

197.6

-24.4

-12

10.4

-5.0

73.4

14.4

136.4

33.9

199.4

-23.9

-11

12.2

-4.4

75.2

15.0

138.2

34.4

201.2

-23.3

-10

14.0

-3.9

77.0

15.6

140.0

35.0

203.0

-22.8

-9

15.8

-3.3

78.8

16.1

141.8

35.6

204.8

-22.2

-6

17.6

-2.8

80.6

16.7

143.6

36.1

206.6

-21.7

-7

19.4

-2.2

82.4

17.2

145.4

36.7

208.4

-21.1

-6

21.2

-1.7

84.2

17.8

147.2

37.2

210.2

-20.6

-5

23.0

-1.1

86.0

18.3

149.0

37.8

100

212.0 221.0

-20.0

-4

24.8

4.6

87.8

18.9

150.8

40.6

105

-19.4

-3

26.6

89.6

19.4

152.6

43.3

110

230.0

-18.9

-2

28.4

0.6

91.4

20.0

154.4

46.1

115

239.0

-18.3

-1

30.2

1.1

93.2

20.6

156.2

48.9

120

248.0

-17.8

32.0

1.7

95.0

21.1

158.0

51.7

125

257.0

-17.2

33.8

2.2

96.8

21.7

159.8

54.4

130

266.0

-16.7

35.6

2.8

98.6

22.2

161.6

57.2

135

275.0

3.3

100.4

22.8

163.4

60.0

140

284.0

-16.1

37.4

-15.6

39.2

3.9

102.2

23.3

165.2

62.7

145

293.0

-15.0

41.0

4.4

104.0

23.9

167.0

65.6

150

302.0

-14.4

42.8

5.0

105.8

24.4

168.8

68.3

155

311.0

-13.9

44.6

5.6

107.6

25.0

170.6

71.1

160

320.0

-13.3

46.4

6.1

109.4

25.6

172.4

73.9

165

329.0

-12.8

48.2

6.7

111.2

26.1

174.2

76.7

170

338.0

-12.2

50.0

7.2

113.0

26.7

176.0

79.4

175

347.0

GENERAL

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

.Ol-2 01-3 01-6 01-8

01-l

GENERAL

GENERAL ASSEMBLY

01-2

GENERAL ASSEMBLY DRAWING

DRAWING

GENERAL

SPECIFICATIONS

SPECIFICATIONS Machine

model

WA900-1

Serial No. Operating

10001 and up

weight

94,700

Distribution

(front)

52,800

Distribution

(rear)

41,900

13.0

kN {kg)

229.5 {23,400)

Bucket capacity

(piled)

Rated load FORWARD

1st

km/h

7.0

FORWARD

2nd

km/h

12.3

FORWARD

3rd

km/h

28.0

REVERSE

1st

km/h

7.1

REVERSE 2nd

km/h

12.4

REVERSE 3rd

km/h

28.3

Max. rimpull

kN {kg1

588.4 (60,000)

Gradeability

deg

9,210

10,900

14,415 (with tooth)

4,585

4,760 (Cutting

Travel

speed

1 Overall

length

Overall

width

(chassis)

Bucket width

edge)

5,040 (Tire guard) (top of ROPS cab)

5,275

(Bucket raised)

9,520

Wheelbase

5,450

Tread

3,350

550

Height of bucket hinge pin

6,945

Dumping

clearance

5,020

Dumping

reach (tip of tooth)

2,100

deg

470

Overall

height

Min. ground

Bucket dump

clearance

(tip of tooth)

angle

Bucket tilt angle (SAE carrying Digging

depth (IO’ dump)

position)

(with tooth)

01-3

GENERAL

SPECIFICATIONS

Machine Serial

model

WA900-1

No.

10001 and up

Model

SA12V140

Type

4-cycle, water-cooled, V type, 12-cylinder direct injection, with 2-turbocharger, after-cooler

No. of cylinders

- bore x stroke

Piston displacement

12 - 140 x 165

e {cc1

30.48 {30,480}

Flywheel

horsepower

w/rpm {HP/rpml

618/2,000

{828/2,000}

Maximum

torque

Jmlrpm{kgmlrpm)

3,874/l ,400 {395/I ,400)

g/kw.h {g/HP.h]

202 (151)

$ E $

Fuel consumption

High idling speed

rpm

2,220

Low idling speed

rpm

650

)

ratio

Starting

motor

24 V 7.5 kW x 2

Alternator

24 V 75 A

Battery

12 V 200 Ah x 4

Torque converter

3-element,

Transmission

Reduction

l-stage, single-phase (TCA51-IA)

Planetary gear, multiple-disc, lraulically actuated, modulation

hytype

Spiral bevel gear

gear

Differential

Straight Planetary

Final drive

bevel gear

gear, single oil bath

Drive type

Front/rear-wheel

Front axle

Fixed-frame,

reduction,

drive

full-floating

i I

Rear axle i

Center pin support type, full-floating

Tire Wheel Inflation

45/65-45-58PR(L-5) rim

36.00 x 45WTB

pressure

kPa {kg/cm21

Main brake

667 (6.80) Front/rear front/rear

Parking A-

01-4

brake

wheel

braking,

separate

wheel, wet disc, airover-hydraulic

Mounted on front axle input shaft, dry disc, air release spring apply L

SPECIFICATIONS

GENERAL

Machine

WA900- 1

model

10001

Seria’l No.

Articulated

Fully hydraulically

Structure

Steering

Switch

pump Urnin

pump Delivery

Work equipment

(Variable

pump (Variable

Cylinder

Steering

power

steering

405 capacity piston pump: HPV90+90)

60 (Gear type: SAR(11032)

PPC pump

Control va Ive Set pressure

type

298 (Fixed capacity piston pump: HPF76+71)

pump

Transmission

421 (Gear type: SAR(4)112+SAR(3)100)

Torque converter, transmission pump

Hydraulic

and

2.5 (25) (Spool type, electric control)

valve

demand

405 capacity piston pump: HPV90+90)

31.4 (320) (Fully hydraulic type)

valve MPa {kg/cm21

PPC valve

3.7 {38} (2-lever type)

Main control valve

31.4 1320) (2-spool type)

Steering cylinder No. - bore x stroke

Reciprocating 2-160x503

Lift cylinder No. - bore x stroke

Reciprocating piston 2 - 260 x 1,368

Dump cylinder No. - bore x stroke

Reciprocating piston 1 - 300 x 906 Single Z bar link

Link type Bucket edge type

piston

Spade

nose bucket with teeth

01-5

WEIGHT TABLE

GENERAL

WEIGHT TABLE A

This weight

table is a guide for use when transporting

or handling

components. Unit: kg

Machine

WA900-1

model

Serial No.

10001 and up 3,200

Engine

710

Radiator Torque

610

converter

2,270

Transmission

Damper Upper

drive shaft

230

Center drive shaft

186

Front drive shaft

173

Rear drive shaft

186

Center support

~~~~

169

Front axle

8,190

Rear axle

7,700

Front differential

assembly

1,226

Rear differential

assembly

1,256

Planetary

carrier assembly

Planetary

hub assembly

238

(each)

600

Axle pivot (Rear axle)

286

Wheel

845

(each)

2,720

Tire (each) Steering

demand

valve

Steering

cylinder

(each)

206

Hydraulic

tank

894

Work equipment

pump (HPVSO + 90)

150

Torque

converter

charging

Switch

pump (HPVSO + 90)

Steering

pump

+ PPC pump

(HPF76 + 71)

150 145

PPC valve

Main control valve (each)

Lift cylinder

01-6

(each)

1 .ooo

z G d

WEIGHT TABLE

GENERAL

Unit: kg Machine

WA900-1

model

10001 and up

Serial No.

1,110

Dump cylinder Engine

88 (Top) 28 (Side)

hood

7,605

Front frame Rear frame

Bucket link (including

9,340 449

bushing)

(including

bushing)

1,790

Lift arm (including

bushing)

7,770

Bellcrank

Bucket (with teeth) Counterweight

11,520 2,500 + 1,087 + 1,600

+ weight

I Fuel tank Battery z &i d

(each)

305

Cab Air conditioner Ooerator’s

unit

seat

Floor plate

01-7

LIST OF LUBRICANT AND WATER

GENERAL

LIST OF LUBRICANT RESERVOIR

<IND 01 FLUID

AND WATER AMBIENT TEMPERATURE -22

-4

Hydraulic

CAPACITY 104

122Of

Specified

case

164 Q 43.3 US gal 36.1 UK gal

Engine oil

system

Brake Axle (Front and rear) (each)

See Note 1

Pins

Grease

Fuel tank

Diesel fuel

Cooling

Water

system

Add antifreeze 66.2 UK gal 1

% ASTM D975 Nil Note 1: For axle oil, use only recommended oil as follows. SHELL: DONAX TT or TD RPM TRACTOR HYDRAULIC FLUID CALTEX: TRACTOR HYDRAULIC FLUID CHEVRON: TDH OIL TEXACO: MOBIL: MOBILAND SUPER UNIVERSAL It is possible to substitute engine oil CLASS-CD SAEBO for axle oil. If noise comes from the brake, it is no problem of durability.

01-8

Refill

90 Q 98 Q 25.87 US gal 23.76 US gal 21.56 UK gal 19.80 UK gal

Engine oil pan

Transmission

140 Q 37.0 US gal 30.8 UK gal

LIST OF LUBRICANT AND WATER

GENERAL

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

Fuel sulphur

content

Change interval of oil in engine oil pan

0.5 to 1.0%

l/2 of regular

interval

Above

l/4 of regular

interval

1.0%

When starting the engine in an atmospheric temperature of lower than O”C, be sure to use engine oil of SAEIOW, SAEIOW-30 and SAE15W40, even though an atmospheric temperature goes up to 10°C more or less in the day time. Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to half. There is no problem if single grade oil is mixed with multigrade oil (SAEIOW-30, 15W-40), but be sure to add single grade oil that matches the temperature in the table. We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment applications. Specified capacity: Total amount of oil including oil for components and oil in piping. Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance. ASTM: SAE: API:

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

01-9

5 k d

STRUCTURE AND FUNCTION

Power train ................................................... IO- 4 Power train system ...................................... IO- 5 Engine control .............................................. IO- 6 Servo cylinder .............................................. IO- 7 Radiator and cooler ..................................... IO-I 1 Damper.. ........................................................ IO-12 Torque converter and transmission piping ............................... IO-13 Transmission hydraulic system diagram ..................................... IO-14 Transmission hydraulic circuit diagram ....................................... IO-15 Torque converter.. ........................................ IO-16 Torque converter oil filter ........................... IO-21 Transmission ................................................ IO-23 IO-31 Transfer ......................................................... Transmission control valve ......................... IO-32 Torque convertor oil cooler ........................ IO-50 Drive shaft.. ................................................... IO-51 Center support.. ............................................ IO-52 Axle ................................................................ 1o-53 Final drive ..................................................... IO-58 Floor support ................................................ 1o-59 Axle mount and center hinge pin .............. IO-60 Steering piping ............................................. IO-62 Steering column ........................................... 1O-63 Steering pump .............................................. 1O-64 Switch pump ................................................ IO-67 Steering demand valve ............................... IO-72 Tow-way restrictor valve ............................. IO-83 Steering unit (Orbit-roll) .............................. IO-84 Diverter valve ............................................... 1O-87 Brake and air piping .................................... IO-92

Brake and air circuit diagram ................... IO- 94 Air governor ............................................... IO- 96 Air tank ........................................................ IO- 98 Safety valve ................................................ IO- 98 Brake valve ................................................. IO- 99 Relay valve.. ................................................ IO-103 Two-way valve ........................................... 1O-l 04 Brake chamber ........................................... IO-105 Slack adjuster ............................................. IO-107 Brake.. .......................................................... IO-I 10 Parking brake .............................................. IO-I 11 Hydraulic piping ......................................... IO-I 14 Work equipment hydraulic circuit diagram ..................................... IO-I 17 Work equipment lever linkage.. ................ IO-I 19 Hydraulic tank.. ........................................... IO-120 Main piston pump.. .................................... IO-123 ES valve ...................................................... IO-131 Servo valve ................................................. IO-133 PPC valve .................................................... IO-136 PPC relief valve .......................................... IO-I 40 Accumulator.. .............................................. IO-141 Main control valve ..................................... IO-I 42 Lubrication of work equipment ................ IO-I 56 Work equipment linkage ........................... IO-158 Bucket positioner and boom kick-out ...... IO-160 Cab.. ............................................................. IO-166 Air conditioner.. .......................................... IO-167 Electric circuit diagram .............................. IO-172 Machine monitor system.. ......................... IO-175 Engine starting circuit.. .............................. IO-186 Engine stop circuit ..................................... IO-187 Preheating circuit ....................................... IO-188

10-l

Electrical transmission control .. . . . . . . . . . . .. . . .. IO-192 Kick-down switch . .. . .. . . . . . . . .. . .. . . . . . . . .. . .. . . . . . . . .. IO-197 Electrical parking brake control . .. . .. . . . . . . .. . . IO-203 Transmission clutch overrun controller . .. . .. . . . . . . . . .. .. . . . . . .. . . . . . . . IO-212

1o-2

POWER TRAIN

STRUCTURE AND FUNCTION

POWER TRAIN

SEW01312

OUTLINE l

The power from engine (16) is transmitted from the flywheel to damper (15) 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 (11) through upper drive shaft (I 4). 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 (IO). Then, the engine power is transmitted to steering pump (12), main pump (131, switch pump (171, and torque converter charging pump + PPC pump (18) through the pump driving gear in torque converter (1 I), thereby driving the pumps. In transmission (IO), the five hydraulicallyoperated 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 3 forward and 3 reverse gear speeds.

1o-4

The output shaft of transmission (IO) transmits the power to the output shaft of transfer (9) through the gear. The power from the output shaft of the transfer is transmitted to both the front axle (5) and the rear axle (21). In the front section of the chassis, the power is transmitted to front axle (5) through center drive shaft (7) and front drive shaft (6). In the rear section, the power is transmitted to rear axle (21) through rear drive shaft (24). The power transmitted to front axle (5) and rear axle (21) is reduced through pinion and ring gears in differential (22) and (I), and is transmitted to the axle shafts. The power from the axle shafts is reduced through final drive (19) and (3) and transmitted to wheel (20) and (4) through the planetary carrier.

STRUCTURE AND FUNCTION

POWER TRAIN SYSTEM

POWER TR .AIN SYSTEM

SEW01313

1. Differential (front) 2. Front brake 3. Final drive (front) 4. Front wheel 5. Front axle 6. Front drive shaft 7. Center drive shaft 8. Emergency steering 9. Transfer IO. Transmission

pump

11. Torque converter 12. Steering pump 13. Main pump 14. Upper drive shaft 15. Damper 16. Engine 17. Switch pump 18. Torque converter charging pump + PPC pump 19. Rear final drive

20. 21. 22. 23. 24. 25. 26.

Rear wheel Rear axle Rear differential Rear brake Rear drive shaft Center support Parking brake

1o-5

STRUCTURE

AND

FUNCTION

ENGINE

CONTROL

ENGINE CONTROL

SEW01314

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

Air cylinder Accelerator pedal Cable Servo cylinder Absorber injection pump Transmission oil filler

1O-6

OUTLINE 1. An engine low idling selection mechanism is used, and when the selection switch is operated, the engine low idling speed can be switched in two stages. 1) The engine low idling speed is set to approx. 650 rpm. Use for normal operations such as when waiting for a dump truck at low idling + OFF. 2) The engine low idling speed is set to approx. 850 rpm. Used on busy jobsites where it is needed to reduce the cycle time + ON. 2. A hydraulic assist engine control (servo cylinder (4)) is used to reduce the operating effort for the accelerator pedal.

SERVO CYLINDER

STRUCTURE AND FUNCTION

SERVO CYLINDER

1. 2. 3. 4. 5.

Rod Spring Body Piston Yoke

A. B.

Oil outlet port (Drain to transmission Oil inlet port (From oil filter)

SEW01315

OUTLINE . The servo cylinder is installed to the engine control linkage. This acts to reduce the operating force without changing the amount of movement of the accelerator pedal cable and injection pump rod. oil filler)

1o-7

STRUCTURE

SERVO CYLINDER

AND FUNCTION

OPERATION 1.

Accelerator

pedal not depressed

Accelerator pedal (6) is not being depressed, so the servo cylinder is not actuated. The pressurized oil from the transmission filter passes through the middle of rod (I) and flows to port A. 2.

Accelerator

pedal depressed To T&T/M

valve

SEW01648

When accelerator pedal (6) is depressed, cable (7) moves rod (1) to the left in the direction of the arrow. The oil from the transmission filter flows from port A through the hole in piston (4) and goes to chamber B.

10-8

SERVO CYLINDER

STRUCTURE AND FUNCTION

To T/C.T/M va Ive

SEW01649

When the oil flowing to chamber B reaches the specified pressure, it overcomes the force of spring (2) and moves piston (4) to the left in the direction of the arrow. Piston (4) continues to move until the hole in piston (4) is closed. 3.

As a result, the length of movement of rod (I) becomes equal to the length of movement of the piston, and the operating force is reduced by the hydraulic pressure.

Accelerator pedal released To T&T/M

valve B

From

I I SEW01650

When accelerator pedal (6) is released, cable (7) moves rod (I) to the right in the direction of the arrow. As a result, the oil at chamber B is drained. When this happens, piston (4) is moved to the right by spring (2) until the hole in piston (4) is closed.

1o-9

SERVO CYLINDER

STRUCTURE AND FUNCTION

ENGINE LOW IDLING SELECT SYSTEM OUTLINE . By using the engine

low idling selector device to set the engine low idling speed to two stages, it is possible to carry out operations more efficiently.

OPERATION Selector switch OFF When the selector switch is OFF, no electric current flows to solenoid valve (I), so the solenoid valve is not actuated and the air supply to air cylinder (2) is shut off. As a result, the air cylinder is not actuated and the engine speed is set to 650 rpm.

From drr air tank

s SEW01651

Ki x

Selector switch ON When the selector switch is turned ON, electric current flows to solenoid valve (1). and the solenoid valve is actuated. Air flows to air cylinder (21, and the air cylinder rod is pushed out by the air pressure. The air cylinder rod is connected by a link to accelerator pedal (31, so the accelerator pedal is depressed by an amount equal to the movement of the rod. When this happens, the engine speed is set to approximately 850 rpm.

SEW01652

10-10

STRUCTURE AND FUNCTION

RADIATOR

RADIATOR AND COOLER

AND COOLER

SEW01322

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

Radiator cap Water level sensor Fan guard Upper tank Radiator Lower tank (Hydraulic

Specification Core type: Model G7 Total heat dissipating area: 201.00 m* Cross-sectional area of water tubes: 288.52 cm2 oil cooler)

A. Oil inlet port B. Oil outlet port

10-11

DAMPER

STRUCTURE AND FUNCTION

DAMPER

1. Shaft Breather 3. Rubber cushion 4. Inner body 5. Outer body

SEW01323

FUNCTION l

The damper reduces the torsional vibration caused by changes in the engine torque, and acts to protect the units of the power train beyond the engine from the effects of torsional vibration.

OPERATION . The power of the engine is transmitted

from the flywheel to outer body (5). The torsional vibration of the engine is absorbed by rubber cushion (3), passes through inner body (4) and shaft (I), and is transmitted to the upper drive shaft between the torque converter.

10-12

STRUCTURE AND FUNCTION

TORQUE CONVERTER

TORQUE CONVERTER AND TRANSMISSION

AND TRANSMISSION

PIPING

SEW01324

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

Accelerator pedal Transmission control valve Torque converter Servo cylinder Torque converter oil cooler Torque converter charging pump Torque converter oil filter Transmission oil level gauge Transfer

10-13

STRUCTURE AND FUNCTION

TRANSMISSION

HYDRAULIC

TRANSMISSION

SYSTEM

(Engine running, F.R. lever in NEUTRAL, speed lever in 1st)

rrrmn29

A. B.

To PPC valve From hydraulic

10-14

tank

HYDRAULIC SYSTEM DIAGRAM

DIAGRAM

STRUCTURE AND FUNCTION

TRANSMISSION

HYDRAULIC

HYDRAULIC CIRCUIT DIAGRAM

CIRCUIT DIAGRAM

27 .03MPa 10.5k/cm21

12__ _ 1 -LL I

1. Transfer

case

2. Strainer 3. Torque converter charging pump (SAR4-112) 4. Torque converter charging pump (SAR3-100) 5. PPC pump (SARI-0321 6. Torque converter oil filter 7. Torque converter oil filter 8. Servo cylinder 9. Main relief valve 10. Torque converter relief valve

?.96MPa (20kdcm~l

11. Torque converter regulator valve 12. Oil cooler 13. Lubrication valve 14. Pilot filter 15. Pilot reducing valve 16. Priority valve 17. Modulating valve 18. Quick return valve 19. Reducing valve 20. Solenoid valve 21. Emergency manual spool

C% 0.29$'MPa 13':la/cm21

SDW01326

22. Reverse spool 23. Forward spool 24. 2nd spool 25. 1st spool 26. 3rd spool 27. Reverse clutch 28. Forward clutch 29. 2nd zlutch 30. 1st clutch 31. 3rd clutch 32. Torque converter 33. Transmission lubrication

10-M

STRUCTURE AND FUNCTION

TORQUE CONVERTER

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

Torque converter regulator valve Torque converter outlet oil pressure pick-up Torque converter inlet oil pressure pick-up Switch pump mounting Main pump mounting Coupling Steering pump mounting Torque converter charging pump + PPC pump mounting

A. B.

Torque converter Outlet port SEWOI 327 Torque converter oil temperature sensor mounting port Torque converter inlet port Drain pot-t (to transmission)

C. D.

lo-16

STRUCTURE

AND

FUNCTION

9. Turbine 10. Stator 11. PTO gear (Teeth 86) 12. Housing 13. Gear (Teeth 81) 14. Pump 15. Transmission input shaft 16. Gear (Teeth 81)

TORQUE

CONVERTER

1328

Specifications Model: TCA51-IA Type: 3-element, single stage, single phase Stall torque ratio: 2.84

10-17

STRUCTURE AND FUNCTION

TORQUE CONVERTER

Flow of motive force l

The torque converter is installed between the damper and transmission. The motive force from the damper passes through the drive shaft and enters coupling (6). Coupling (61, pump (14) and PTO gear (drive) (I I) are fixed with bolts. They are rotated directly by the rotation of the engine. The motive force of pump (14) uses oil to rotate turbine (9). This transmits motive force to transmission input shaft (15). The motive force of coupling (6) passes through PTO gear (drive) (11) and is also used as the motive force to drive the pump.

SEW01329

Ki s

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 (12) and flows to pump (14). In pump (14) centrifugal force is applied. The oil enters turbine (9) and the energy of the oil is transmitted to the turbine. Turbine (9) is fixed to transmission input shaft (151, so the motive force is transmitted to the transmission input shaft (15). The oil from turbine (9) is sent to stator (IO) and again enters the pump. However, part of the oil passes from the stator through outlet port B and is sent to regulator valve

I Y

(I). The oil sent to regulator valve (I) passes through the oil cooler to be cooled, and is then used to lubricate the transmission.

SEW01330

lo-18

STRUCTURE

AND

FUNCTION

TORQUE

CONVERTER

TORQUE

CONVERTER

RELIEF VALVE

OUTLINE The torque converter relief valve is inside the transmission valve, and acts to keep the oil entering the torque converter at a constant pressure. If the specified pressure is exceeded, it drains the oil. l

FUNCTION . The oil from the pump passes through transmission main relief valve (I), enters port A, and then flows to the torque converter. T/C regulator

+To (To

From

If the oil at port A exceeds the specified pressure, the oil from orifice a of torque converter relief valve (2) enters port B and moves torque converter relief valve (2) to the left in the direction of the arrow. As a result, the oil from port A flows from port C, lubricates the transmission, and is drained.

Pump

Priority Pilot

valve reducing

SDWOl653

To 1 Iubr

T/C WJlblr

tu valve reducino

From

Pump

SDWOl654

10-19

STRUCTURE AND FUNCTION

TORQUE

CONVERTER

TORQUE CONVERTER

REGULATOR

VALVE

0 0 i-i

The torque converter regulator valve is installed in the output circuit of the torque converter to regulate the hydraulic pressure inside the torque converter to the specified pressure.

1. 2. 3.

Valve body Spring Spool

Oil inlet port (From torque converter) B. Oil outlet port (to oil cooler)

To oil

cooler

OPERATION The oil from the torque converter flows from port A to port B. However, the hydraulic pressure at port B is lower than the tension of spring (21, so spool (3) does not move. l

From

torque

converter SDW01655

When the hydraulic pressure at port B becomes higher than the tension of spring (21, it pushes spool (3) in the direction of the arrow, and the oil at port A flows to port C.

From

torque

converter SDWOl656

1O-20

STRUCTURE AND FUNCTION

TORQUE CONVERTER

TORQUE CONVERTER OIL FILTER

OIL FILTER 1. 2. 3. 4. 5.

Relief valve Element Center bolt Drain plug Clogged sensor

A. B.

Inlet port Outlet port

Filtration area : 8,900 cm2 x 6 Relief pressure: 0.29 - 0.34 MPa (3 - 3.5 kg/cm2) (Bypass pressure)

A-A

SEW01336

OPERATION l

The oil from the torque converter charging pump (6) enters the filter inlet port A and passes from the outside of element (2) to the inside. It then flows to outlet port B.

To transmission control valve

SEW01657

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

To transmission control valve

SEW01658

10-21

STRUCTURE

AND

FUNCTION

TRANSMISSION

SEW01339

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

Transmission Transmission control valve Transfer Oil filler Transfer output coupling Drain plug Transfer output coupling

To torque

converter

charging

pump

1O-23

STRUCTURE AND FUNCTION

TRANSMISSION

1 O-24

STRUCTURE

z Ki d

AND

FUNCTION

TRANSMISSION

1. Input shaft 2. Reverse sun gear (Teeth 26) 3. Reverse ring gear (Teeth 90) 4. Gear (Teeth 90) 5. Reverse clutch 6. Planetary gear (Teeth 30) 7. Ring gear (Teeth 86) 8. Forward sun gear (Teeth 38) 9. Forward clutch 10. Planetary gear (Teeth 26) 11. Forward ring gear (Teeth 90) 12. Sun gear (Teeth 38) 13. Planetary gear (Teeth 26) 14. Ring gear (Teeth 140) 15. Ring gear (Teeth 90) 16. 2nd clutch 17. Planetary gear (Teeth 31) 18. 2nd ring gear (Teeth 140) 19. 2nd sun gear (Teeth 27) 20. Gear (Teeth 89) 21. 1st clutch 22. 1st sun gear (Teeth 27) 23. 1st ring gear (Teeth 89) 24. Planetary gear (Teeth 31) 25. 3rd clutch 26. Hub (Teeth 112) 27. Idle shaft 28. Output shaft 29. 1st carrier 30. 2nd carrier 31. Forward carrier 32. Reverse carrier

1o-25

STRUCTURE AND FUNCTION

TRANSMISSION

CLUTCH OUTLINE l

The transmission consists of a 3-FORWARD, 3-REVERSE 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 Forward or Reverse clutch with Ist, 2nd, 3rd clutch to give FORWARD 1 - 3 or REVERSE I- 3 speed, and is transmitted to the output shaft.

Speed

range

I Clutch combination

F, 1st

F, 2nd

F, 3rd

R, 1st

R, 2nd

R, 3rd

OPERATION OF CLUTCH

From transmission control valve

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 piston (2). When piston (2) moves, disc (4) and plate (5) are pressed together. Ring gear (6) is meshed with disc (4), so the rotation is stopped.

SDW01660

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 (31, and disc (4) and plate (5) are separated. Ring gear (6) then rotates freely, and no motive force is transmitted.

1 O-26

SDWOISS

STRUCTURE

AND FUNCTION

FORWARD

1st

TRANSMISSION

In the case of FORWARD Ist, FORWARD clutch (9) and 1st clutch (21) are engaged. The power from the torque converter transmitted to input shaft (I) is transmitted to output shaft (28). FORWARD clutch (9) is actuated by the hydraulic pressure applied to the clutch piston and holds ring gear (11) in position. 1st clutch (21) is actuated by the hydraulic pressure applied to the clutch piston and holds ring gear (23) in position. The power from the torque converter is transmitted to input shaft (I). The rotation of the input shaft is transmitted through sun gear (8) to planet gear (IO). Ring gear (11) is being held in position by FORWARD clutch (91, so the rotation of planet gear (IO) rotates carrier (31).

1o-27

TRANSMISSION

STRUCTURE AND FUNCTION

FORWARD 2nd

SEW01344

In the case of FORWARD 2nd, FORWARD clutch (9) and 2nd clutch (16) are engaged. The power from the torque converter transmitted to input shaft (I) is transmitted to output shaft (28). FORWARD clutch (9) is actuated by the hydraulic pressure applied to the clutch piston and holds ring gear (11) in position. 2nd clutch (16) is actuated by the hydraulic pressure applied to the clutch piston and holds ring gear (18) in position. The power from the torque converter is transmitted to input shaft (1). The rotation of the input shaft is transmitted through sun gear (8) to planet gear (IO). Ring gear (1 I) is being held in position by FORWARD clutch (91, so the rotation of planet gear (IO) rotates carrier (31).

lo-28

Ring gear (15) is being held in position, so the rotation of carrier (31) is transmitted through planet gear (13) to sun gear (12). It is also transmitted through intermediate shaft (27) to sun gears (19) and (22). Ring gear (18) is being held in position by 2nd clutch (16). For this reason, the rotation of sun gear (19) is transmitted through planet gear (17) to carrier (30). It is then transmitted to ring gear (23). The rotation of ring gear (23) and the rotation of sun gear (22) passes through planet gear (24) and is transmitted to carrier (29). It is then transmitted to output shaft (28).

STRUCTURE

AND

FORWARD

3rd

TRANSMISSION

FUNCTION

12 13

In the case of FORWARD 3rd, FORWARD clutch (9) and 3rd clutch (25) are engaged. The power from the torque converter transmitted to input shaft (I) is transmitted to output shaft (28). FORWARD clutch (9) is actuated by the hydraulic pressure applied to the clutch piston and holds ring gear (11) in position. 3rd clutch (25) is actuated by the hydraulic pressure applied to the clutch piston and engages output shaft (28) and hub (26). The power from the torque converter is transmitted to input shaft (1). The rotation of the input shaft is transmitted through sun gear (8) to planet gear (IO). Ring gear (II) is being held in position by FORWARD clutch (91, so the rotation of planet gear (IO) rotates carrier (31).

Ring gear (15) is being held in position, so the rotation of carrier (31) is transmitted through planet gear (13) and goes from sun gear (12) to intermediate shaft (27). Intermediate shaft (27) and output shaft (28) are formed into one unit by 3rd clutch (25). For this reason, the rotation of intermediate shaft (27) is transmitted to output shaft (28).

1 O-29

STRUCTURE AND FUNCTION

TRANSMISSION

REVERSE 1st

5 6

21 22

24 27

SEW01346

In the case of REVERSE Ist, REVERSE clutch (5) and 1st clutch (21) are engaged. The power from the torque converter transmitted to input shaft (I 1 is transmitted to output shaft (28). REVERSE clutch (5) is actuated by the hydraulic pressure applied to the clutch piston and holds carrier (32) in position. 1st clutch (21) is actuated by the hydraulic pressure applied to the clutch piston and holds ring gear (23) in position. The power from the torque converter is transmitted to input shaft (I). The rotation of the input shaft is transmitted through sun gear (2) to planet gear (6).

1O-30

Carrier (32) is being held in position by REVERSE clutch (5), so the rotation of planet gear (6) rotates ring gear (7). The direction of rotation of ring gear (7) is the opposite of the rotation of the engine. The rotation of ring gear (7) is transmitted to carrier (31). Ring gear (15) is being held in position, so the rotation of carrier (31) is transmitted through sun gear (12) to intermediate shaft (27). Ring gear (23) is being held in position by 1st clutch (21). For this reason, the rotation of sun gear (22) is transmitted from carrier (29) through planet gear (24) to output shaft (28).

TRANSFER

STRUCTURE AND FUNCTION

TRANSFER

‘7 SEW01347

OUTLINE l

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

TRANSMISSION PATH . Output shaft (1) of the transmission

is coupled to transfer input gear (2) by a spline. The motive force is transmitted to output shaft (5) through idler gears (31, (4) and output gear (9). 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.

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

Transmission output shaft Transfer input gear (Teeth 32) Transfer idler gear (Teeth 33) Idler gear (Teeth 34) Output shaft Front coupling Strainer Rear coupling Output gear (Teeth 44)

1o-31

STRUCTURE AND FUNCTION

TRANSMISSION

CONTROL VALVE

SEW01348

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

Pilot oil filter Main relief valve Torque converter relief valve Transmission solenoid valve Emergency manual spool Connector Lower valve Upper valve Breather

1 O-32

A. B. C. D. E. F.

Pilot reducing pressure pick-up Modulating valve piston load pressure pick-up Torque converter relief pressure pick-up Transmission lubricating pressure pick-up Modulating pressure pick-up Modulating pressure pick-up (After quick return valve)

STRUCTURE

AND

TRANSMISSION

FUNCTION

TRANSMISSION

CONTROL

VALVE

SOLENOID VALVE

2nd

is SEW01349

10. REVERSE solenoid valve 11. FORWARD solenoid valve 12. 2nd solenoid valve 13. 1st solenoid valve 14. 3rd solenoid valve

Actuation table for solenoid valve and clutch

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.

1o-33

STRUCTURE AND FUNCTION

TRANSMISSION

CONTROL VALVE

LOWER VALVE

.7 Y-Y

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

Transmission solenoid valve FORWARD spool REVERSE spool Pilot oil filter Torque converter relief valve Main relief valve 2nd spool 1st spool 3rd spool

1o-34

IO. Emergency manual spool 11. Priority valve 12. Pilot valve 13. Load piston 14. Quick return valve 15. Lubrication valve 16. Pilot reducing valve 17. Modulating valve

SEW01350

TRANSMISSION

STRUCTURE AND FUNCTION

CONTROL VALVE

UPPER VALVE

x-x

OUTLINE . The oil from the torque converter charging pump enters port A of main relief valve, and

passes through priority valve (1 I) via by main relief valve. It is then divided into three lines; there are; to the clutch pistons, to pilot reducing valve (16) and main relief valve. Priority valve (11) acts to control the three lines so that pilot reducing valve (16) is the priority circuit. The oil flowing to pilot reducing valve (16) controls the pilot pressure used to actuate the directional and speed spools. The oil regulated by pilot reducing valve (16) presses through the orifice in each spool and fills the spool.

SEW01351

The other oil line flows to modulating valve (17) and quick return valve (14). The action of modulating valve (17) and quick return valve (14) raises the clutch pressure smoothly. This reduces the shock when actuating the FORWARD, REVERSE and Ist, 2nd and 3rd speed clutches to change gear. Lubrication valve (15) controls the lubrication oil inside the transmission.

1o-35

STRUCTURE AND FUNCTION

TRANSMISSION

CONTROL VALVE

PILOT OIL FILTER OUT

A-A

SEW01352

1. 2. 3.

Oil filter head Element Case

1 O-36

Specification: Filtration area: 370 cm2 Mesh: 105 pm

STRUCTURE AND FUNCTION

MAIN

TRANSMISSION

CONTROL VALVE

RELIEF VALVE

FUNCTION l

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

OPERATION l

The oil from the pump passes through the oil filter and enters port A of main relief valve (I). Until the specified pressure is reached, the oil flows to the priority valve.

T/C RQUiatQr

z Ki d

To Priority (To Pilot va

valve reducing

Ive)

From

pump

SD1101662

When the pressure goes above the specified level, oil passes through the orifice in relief valve (I), pushes poppet (21, and moves relief valve (1) to the left. The oil is relieved to the torque converter, so the specified pressure is maintained. * Specified pressure: 2.8 MPa I28 kg/cm*}

’

From

$2 n”rnP

SDWO1663

1o-37

STRUCTURE AND FUNCTION

TRANSMISSION CONTROL VALVE

PILOT REDUCING VALVE FUNCTION l

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

OPERATION l

Clutch

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

From

oil

filter SDWOl664

When the pressure inside port C rises, pressurized oil flows from orifice “a” of pilot reducing valve (I) and goes to port D. As a result, pilot reducing valve (I) moves to the left, and port A and B are shut off, so the pressurized oil at port C is maintained at the same pressure. * Specified pressure: 2.0 MPa 120 kg/cm21

Clutch

1 AB

From

oil

filter SDW01665

1O-38

STRUCTURE AND FUNCTION

TRANSMISSION

CONTROL VALVE

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 I) Solenoid

Clutch

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

return valve

From

oil

filter SDWOl666

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 (2) enters port A and flows from port B to the drain circuit. Therefore, port C becomes the high pressure circuit and port A becomes the low pressure circuit, and directional and speed spool (2) is moved to the left, and the oil from the quick return valve flows to the clutch.

Clutch

From

oil

filter SOW01 667

1o-39

STRUCTURE AND FUNCTION

PRIORITY

TRANSMISSION

CONTROL VALVE

VALVE

FUNCTION . Priority valve (1) controls the minimum

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

OPERATION l

To Quick

The oil from the pump flows to port A of priority valve (I) and port B of pilot reducing valve (2).

return

valve

0 To speed

Pi lot *To

From

The oil entering port A flows from orifice “a” of priority valve (I) to port D. The hydraulic pressure and force of poppet spring (3) push back spring (4) and move priority valve (I) to the left. When this happens, port A and port C are connected, and the oil flows from port C to the modulating valve (5). * Specified pressure: 2.0 MPa (20 kg/cm*)

To quick

PUSP

return

valve

To speed

T/M main relief valve

spool

Pilot

oil

filter

+ From

1O-40

PUSP

SDW01669

STRUCTURE AND FUNCTION

MODULATING

VALVE

AND QUICK

TRANSMISSION

RETURN

CONTROL VALVE

VALVE

FUNCTION The modulating valve, and quick return valve act together to raise the transmission clutch pressure smoothly. This reduces shock when shifting speed range, and prevents the generation of peak torque in the power train. Therefore, operator fatigue is reduced to give better operating comfort, and at the same time, the durability of the power train is increased.

OiOl-

OPERATION 1. Immediately

(Second) Time SDW01670

after shifting gear (point A)

When the gear shift lever is operated to engage the clutch, the passage from the pump to the clutch cylinder is opened and oil flows to the clutch cylinder. Using the force of this flow, quick return valve (2) moves to the right in the direction of the arrow, and connects port E and port G. When the back pressure of piston (3) is removed, the tension of springs (4) and (5) move modulating valve (I) to the right in the direction of the arrow. At the same time, piston (3) is returned to the left in the direction of the arrow.

Clutch

To 9

ilve SOW01671

Hydraulic pressure starts to rise When the oil sent under pressure from pump fills the circuit from port A to the clutch cylinder, the hydraulic pressure starts to rise. The oil passing through orifice a of quick return valve (2) moves quick return valve (2) to the left in the direction of the arrow. As a result, the passage between port E and port G is closed.

Clutch

To sol

From Priority valve SDW01672

1o-41

STRUCTURE

AND

FUNCTION

In addition, the oil passes through orifice b of modulating valve (I) and flows to port C to push piston (6). In reaction to this, modulating valve (1) compresses springs (4) and (51, and moves to the left in the direction of the arrow. As a result, modulating valve (1) restricts the passage to port B. The oil passing through orifice a of quick return valve (2) passes through the center passage and then flows from orifice c to port E, and to back pressure port F of piston (3). For this reason, piston (3) moves to the right in the the direction of the arrow and compresses springs (4) and (5).

TRANSMISSION

CONTROL

VALVE

Clutch

s OI

FEm

priority

valve SDWOI

As the hydraulic pressure in the circuit rises, the back pressure of piston (3) rises and piston (3) moves to the right in the direction of the arrow. The tension of springs (4) and (5) opens the passage between port A and port B of modulating valve (I). In addition, as the hydraulic pressure pushing piston (6) rises, the reaction moves modulating valve (I) to the left in the direction of the arrow and compresses springs (4) and (5) to close port A and port B.

673

Clutch

sol

1 5

2, PI!%

From

priority

valve SDWOl674

1 O-42

STRUCTURE

AND

FUNCTION

Rise in hydraulic pressure completed The operation described above is repeated continuously to increase the load on springs (4) and (5). The hydraulic pressure rises gradually and finally piston (3) comes into contact with the valve stopper and does not move any further. When this happens, modulating valve (I) stops in a position where the passage to port B is kept closed, and this completes the rise in hydraulic pressure.

TRANSMISSION

CONTROL

VALVE

Clutch

To sol

m Priority

valve

1o-43

TRANSMISSION

STRUCTURE AND FUNCTION

REDUCING

CONTROL VALVE

VALVE

FUNCTION l

The reducing valve is in the circuit between the quick return valve and the 3rd speed spool. It acts to protect the 3rd clutch by reducing the hydraulic pressure acting on the 3rd clutch. The maximum pressure of the oil in the circuit is set by the transmission main relief pressure.

OPERATION (3rd speed spool actuated) l

The oil from quick return valve (1) enters port A, flows from port B to the 3rd speed spool, and the 3rd clutch is engaged.

tch

To solen0 valve

From modulatino valve

When oil fills the 3rd clutch, and the hydraulit pressure rises, the oil passes from port B through orifice a and enters port C. The pressure of the oil pushes poppet (31, and the reaction compresses spring (4) and moves reducing spool (2) to the right in the direction of the arrow. As a result, port A and port B are closed, and the oil stops flowing. The hydraulic pressure at this point is 2.0 MPa 120 kg/cm2).

utch

To solenoid valve

,,, B

‘I

From modulatins valve SDW01677

1o-44

STRUCTURE

AND

FUNCTION

TRANSMISSION

CONTROL

VALVE

EMERGENCY MANUAL SPOOL FUNCTION . 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.) * Particular attention must be paid for when using this spool.

Clutch

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 (I) enters port A, but it is shut off by solenoid valve (2).

return

valve

reducing

valve SDWO1678

When solenoid valve is abnormal: a. Clutch in disengaged position (Emergency manual spool is pushed to the right) Emergency manual spool (3) is pushed to the right, 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.

Clutch

IlVe

SDWOl679

Clutch

Clutch in engaged position (Emergency manual spool is pulled to the left) When emergency manual spool (3) is pulled to the left, 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. return

valve

reducing

valve S0W01680

1o-45

STRUCTURE AND FUNCTION

TRANSMISSION

LUBRICATION

TRANSMISSION

CONTROL VALVE

VALVE

FUNCTION l

The transmission lubrication valve protects the transmission lubrication circuit from abnormally high pressure.

OPERATlON l

The oil from the oil cooler and torque converter relief valve passes from port A and lubricates the transmission. The oil entering port A passes through orifice a and enters port B.

In this condition, if abnormally high pressure is generated by the restriction in the lubricating circuit, the oil entering port B compresses spring (2) and moves spool (I) to the left in the direction of the arrow. This opens port A and port C, as the oil in the lubricating circuit is relieved to port C. The hydraulic pressure at this point is 0.3 MPa (3

From torque converter relief valve A From oil cooler

”

From Quick return valve

From oil cooler From

From torque converter relief valve 4 e4

quick

kg/cm*)

SDW01662

1 O-46

STRUCTURE AND FUNCTION

TRANSMISSION

CONTROL VALVE

HYDRAULIC CIRCUIT SCHEMATICS FORWARD IST

‘13

A. B.

To PPC valve From hydraulic

1 O-48

SDW01374

tank

TRANSMISSION

STRUCTURE AND FUNCTION

OPERATION When the directional and speed control levers are moved to FORWARD Ist, solenoid valves (I) and (2) are opened. The oil from pumps (3) and (4) is divided into three 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 (5) through torque converter (6). It then lubricates the transmission and returns to the transfer case. One of the two oil lines flows from pilot reducing valve (IO) through the orifice of each speed spool to the solenoid valve. However, solenoid valves (I) and (2) of FORWARD spool (11) and 1st spool (12) 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. The port to the clutch is then connected.

CONTROL VALVE

The other oil line flows from priority valve (13) to quick return valve (14). It then flows through orifice “a”, and directional and speed spools (11) and (121, and flows to the FORWARD clutch and 1st clutch. When it starts to flow to the clutch, it passes through orifice “a” and creates a difference in pressure between port C and port D. Quick return valve (14) moves to the right, and the oil at the rear of modulating valve piston (17) 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 (17). Piston (17) 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.

1o-49

TORQUE CONVERTER OIL COOLER

STRUCTURE AND FUN;CTION

TORQUE CONVERTER

OIL COOLER

SEW01375

1. Torque converter oil cooler

OUTLINE The oil which comes out from the torque converter outlet port is at a high temperature because of the energy used in transmitting the motive force. This torque converter oil passes through oil cooler port A and enters the oil cooler. Here it is cooled by the engine cooling water. The oil then flows out from oil outlet port B, lubricates the transmission and returns to the transfer case. l

A. Oil inlet port (From torque converter regulator valve) B. Oil outlet port (To transmission lubricating) C. Water inlet port (From water pump) D. Water outlet port (To engine block)

1O-50

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 (31, center support (2) and front drive shaft (I) 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.

SEW01376

1. 2. 3. 4. 5.

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

10-51

CENTER SUPPORT

STRUCTURE AND FUNCTION

CENTER SUPPORT

SEW01377

1. 2. 3. 4.

Front coupling Case Grease nipple Rear coupling

1 O-52

FUNCTION . The center support

is installed to the front frame between the center drive 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 large stress on the drive shaft. Therefore, the center support is used to transmit the power smoothly, to reduce the stress on the drive shafts, and in this way improve the durability of the drive shafts.

STRUCTURE AND FUNCTION

AXLE

AXLE FRONT AXLE

SEW01378

1. Front differential 2. Drain plug 3. Front axle 4. Brake 5. Final drive 6. Spring cylinder 7. Parking brake

1o-53

STRUCTURE AND FUNCTION

FRONT

AXLE

DIFFERENTIAL

1. 2. 3. 4.

Bevel gear (Teeth 39) Housing Differential side gear (Teeth 28) Differential pinion gear (Teeth 22)

1o-54

5. 6. 7. 8.

Shaft Bevel pinion (Teeth IO) Spring cylinder Parking brake

STRUCTURE AND FUNCTION

AXLE

REAR AXLE

SEW01380

1. 2. 3. 4. 5.

Rear differential Rear axle Brake Final drive Drain plug

1o-55

STRUCTURE AND FUNCTION

AXLE

REAR DIFFERENTIAL

SEW01381

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

1O-56

Bevel pinion (Teeth 10) Bevel gear (Teeth 39) Shaft Differential pinion gear Differential side gear Differential housing Coupling

STRUCTURE

AND

AXLE

FUNCTION

OUTLINE The motive force from the drive shaft passes through bevel pinion (I) and is transmitted to 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 differential (4) to axle shaft (2). l

SEW00077

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

z Ei d

SEW00078

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

(2).

SEW00079

1o-57

FINAL DRIVE

STRUCTURE AND FUNCTION

FINAL DRIVE

SEW01382

Axle shaft

Brake Planetary gear (Teeth 39) Ring gear (Teeth 99) Drain plug Housing Sun gear (Teeth 18) Wheel

3. 4. 5.

6. 7. 8.

1O-58

OUTLINE l

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

OPERATION l

The motive force transmitted from the differential through axle shaft (1) to sun gear (7) is transmitted to planetary gear (3). The planetary gear rotates around the inside of fixed ring gear (4) and in this way transmits rotation at a reduced speed to planetary carrier. This motive force is then sent to wheels (8) which are installed to planetary carriers.

STRUCTURE AND FUNCTION

FLOOR SUPPORT

1. support 2. Viscous mount

_____---_/ A-A SEW01383

1o-59

STRUCTURE AND FUNCTION

AXLE MOUNT

AXLE MOUNT AND CENTER HINGE PIN

AND CENTER HINGE PIN

A-A SEW01384

OUTLINE l

The front frame and rear frame are joined by the center hinge pin through a bearing. The steering cylinders adjust the angle of curvature to the left and right of the front and rear frame (in other words, they adjust the turning radius).

1O-60

STRUCTURE AND FUNCTION

STEERING PIPING

z k d \ 5

SEW01386

1. Steering demand valve

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

Steering unit (Orbit-roll valve) Hydraulic tank Steering wheel Steering pump Stop valve Steering cylinder

1 O-62

STRUCTURE

AND

FUNCTION

STEERING

COLUMN

STEERING COLUMN

A-A

B-B SEW01387

1. 2. 3. 4. 5.

Steering demand valve Steering column Steering wheel Tilt lever Steering unit (Orbit-roll valve)

1 O-63

STEERING PUMP

STRUCTURE AND FUNCTION

STEERING PUMP

Pad2

Pa’d 1

PA1

PA2 SEW01388

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

Shaft (front) Cradle (front) Case (front) Swash plate Shoe Piston Cylinder block Valve plate

9. Impeller 10. Cradle (rear) 11. Shaft (rear) 12. Case (rear) 13. End cap (rear) 14. End cap (front) 15. Servo piston

Specification I Model Rated delivery pressure

2120 rpm

Theoretical delivery (front)

76.2 cc/rev

Max. delivery

This pump consists of two fixed displacement swash plate piston pumps and the impeller pump in the middle. For details of the operation, see HYDRAULIC PUMP. Note that the rocker cam moves variably.

1O-64

HPF 76 + 71 31.4 MPa I320 kg/cm*1

Rated rpm

Theoretical delivery (rear)

OUTLINE

Steering oumo

7 1.5 cc/rev 161.6 + 151.6 Umin

STRUCTURE AND FUNCTION

STEERING PUMP

A-A

D-D

B-B

Pad 1 PA1 -f-

PA2

Pad2

17. H.turn 3+

E-E

F-F SEW01683

1 O-65

STRUCTURE AND FUNCTION

SWITCH PUMP

Pad2

PA1 Pad1 Pad2 PA2

-_ a -_ -_

____I-=-i-u-_-

-i

PGS

Pad1

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

Front servo valve ES valve CO valve . NC valve Rear servo valve Relief valve Control pump Rear pump Front pump

SEW0 1684

Specification

Switch pump HPV 90 + 90

Model Rated delivery

pressure

31.4 MPa {320 kg/cm*} 2120 rpm

Rated rpm Theoretical

deliven/

(front)

97.4 cc/rev

Theoretical

delivery

(rear)

97.4 cc/rev

Max. delivery

206.5 + 206.5 Urnin

OUTLINE l

This pump consists of two variable displacement swash plate piston pumps, the impeller pump (built in between the front pump and rear pump), and the control pump. For details of the operation, see HYDRAULIC PUMP.

1O-67

STRUCTURE AND FUNCTION

SWITCH

PUMP

SWITCH PUMP

(HPV 90+90)

Pad2

PA1

PA2 SEW01391

1. Shaft (front) 2. Cradle (front) 3. Case (front) 4. Swash plate 5. Shoe 6. Piston 7. Cylinder block 8. Valve plate

1O-68

9. Impeller 10. Cradle (rear) 11. Shaft (rear) 12. Case (rear) 13. End cap (rear) 14. End cap (front) 15. Servo piston

STRUCTURE AND FUNCTION

SWITCH PUMP

c-c A-A

D-D

E-E

B-B

F-F SEW01392

1O-69

SWITCH PUMP

STRUCTURE AND FUNCTION

CO - NC VALVE

Charoino numn Pressure Psv OUT port

Jet sensor out let Pressure IN port

TVC valve outnut Pressure Pe F-R connectins port

CO.NC valve output Pressure Pecn OUT Port Charging Pressure IN port

TVC valve outvut Pressure Pe IN port

CO.NC valve “,;;;n Pdr OUT

TVC valve drain Pdr IN port

Main cwnn discharge Pressure PA2 IN port

Main nume discharge Pressure PAI IN port

Main pomp discharge Pressure PA1 IN port

1O-70

Main numn discharse Pressure PA2 IN port

Jet sensor outlet Pressure Pd IN port

D-D

numn Psv

E-E

F-F

G-G

H-H

SEW01 685

STRUCTURE

AND

FUNCTION

SWITCH

PUMP

CO Valve

I-

f E

A-A

w ‘IS

B-B

NC Valve

CO VALVE 1. Plug 2. 3. 4. 5. 6. 7. 8. 9.

Cover Seat Spring Seat Spool Piston Sleeve Plug

NC VALVE 10. Plug 11. Sleeve 12. Piston 13. Spool 14. Body 15. Seat 16. Spring 17. Plug 18. Cover

SEW01686

10-71

STEERING DEMAND VALVE

STRUCTURE AND FUNCTION

STEERING

DEMAND

VALVE

1. Overload relief valve

Main relief valve

Steering spool

Demand spool

Surge cut relief valve

A. To steering cylinder 6.

To steering cylinder

PI. From steering pump P2. From switch pump u

PB. To main control valve T.

To hydraulic tank (through hydraulic oil cooler)

1O-72

5 A-A

SEW01395

STEERING DEMAND VALVE

STRUCTURE AND FUNCTION

OVERLOAD

RELIEF VALVE

Poppet

Relief valve poppet

Check valve poppet

Pilot poppet

Spring

SDW01396

FUNCTION .

z r; z!

The overload relief valve is installed in the cylin‘der circuit of the steering demand valve. When the demand valve is at neutral and any impact is applied to the steering cylinder and abnormal pressure is generated, this valve functions as a safety valve to relieve the circuit to prevent breakage of the cylinder or hydraulic piping. It also functions to prevent any vacuum if any negative pressure is generated at the cylinder end.

OPERATION 1.

Operation of relief valve Port A is connected to the cylinder circuit and port B is connected to the drain circuit. The l

oil passes through the hole in poppet (I) and acts on the area of diameters dl and d2. Checkvalve poppet (3) and relief valve poppet (2) are securely seated.

SDW01397

When the pressure at port A reaches the set pressure of the relief valve, pilot poppet (4) opens and the oil goes around pilot poppet (4) and flows to port B.

SDW01396

1o-73

STRUCTURE AND FUNCTION

When pilot poppet (4) opens, the pressure at the rear of poppet (I 1drops, poppet (I 1moves to the right, and it is seated with pilot poppet

(4).

SDW01399

Compared with the pressure at port A, the pressure on the inside is low, so relief valve poppet (2) opens and the oil flows from port A to port B to prevent any abnormal pressure.

Operation of suction valve l

Negative pressure is generated at port A, the difference in the area of diameters d3 and d4 opens checkvalve poppet (31, and the oil flows from port B to port A to prevent a vacuum from forming in the circuit.

1o-74

STRUCTURE AND FUNCTION

STEERING DEMAND VALVE

MAIN RELIEF VALVE 1. Adjustment

Spring

Plug

Pilot poppet

Valve seat

screw

SDW01402

FUNCTION l

The main relief valve of the steering demand valve is inside the valve and sets the maximum pressure in the steering circuit when it is operated. In other words, when the valve is being operated and the steering circuit goes above the set pressure of this valve, it relieves the oil and actuates the flow control spool of the demand valve to drain the oil to the steering circuit.

1o-75

STEERING DEMAND VALVE

STRUCTURE AND FUNCTION

OPERATION OF STEERING RELIEF VALVE

To main

tch

From

control

valve

Pump

steerir SDW01631

When the pressure in the circuit rises and reaches the pressure set by spring (2) and adjustment screw (I), pilot poppet (3) opens and drains the oil. When this happens, the balance of the pressure in pressure receiving chamber (I) and pressure receiving chamber (II) is lost, and demand spool (4) moves to the left.

1 O-76

When demand spool (4) moves, the oil from the steering pump is drained and the oil from the switch pump is relieved to the main control valve, so the steering circuit pressure is prevented from going above the set value.

STRUCTURE

AND

STEERING

FUNCTION

DEMAND

VALVE

OPERATION OF DEMAND VALVE When steering

spool is at neutral

To main control valve

Pl Fromswitch PURP SDW01632

The oil from the steering pump enters port A and the oil from the switch pump enters port B. When steering spool (2) is at the neutral position, pressure receiving pressure chamber (II) is connected to the drain circuit through orifice b, and notch c is closed. Notch c is closed, so the pressure of the oil at port A and port B rises. This pressure passes through orifice a, goes to pressure receiving chamber (I) and moves demand spool (I) to the left.

When the pressure in pressure receiving chamber (I) reaches a certain value (set by spring (311, notch f opens and the oil from the steering pump goes to the drain circuit. Notch g is closed, so the oil from the switch pump all flows to the main control valve.

1o-77

STRUCTURE AND FUNCTION

STEERING DEMAND VALVE

WHEN STEERING SPOOL IS OPERATED Engine running at low speed

v .

When the steering is operated, oil flows from the Orbit-Roll to steering spool (2) and pushes steering spool (2) to the right. The circuit between pressure receiving chamber (II) and the drain circuit is shut off, and at the same time, notch c opens. As a result, the pressure in pressure receiving chamber (II) rises, and demand spool (1) moves to the right until notch h closes. The passage from port B to the main control valve is shut off, so the oil from the switch pump pushes up pump merge-divider check valve (4) and merges with the oil from the steering pump at port A.

lo-78

-4

main

control

valve

SDWOl633

The merged oil passes through notches c and d, pushes load check valve (51, and flows to the cylinder. The return oil from the cylinder passes through notch e and flows to the drain circuit. When this happens, the pressure before passing through notch c is sent to pressure receiving chamber (I) and the pressure after passing through notch c is sent to pressure receiving chamber (II). Demand spool (I) is actuated so that the difference in pressure on both sides of notch c is kept constant. Therefore, an oil flow corresponding to the opening of notch c is supplied to the cylinder port. These pressure differences (control pressure) are set by spring (3).

STEERING DEMAND VALVE

STRUCTURE AND FUNCTION

Engine running at high speed

-+a-zzh From switch PUMP % From steering Pump SDW01634

There is no need for supply of extra oil from the switch pump, so the steering pump pressure rises until notch g closes and shuts off the merge passage from port B. The pressure difference on both sides of notch c is controlled only by notch f, and the excess oil from the steering pump is drained from notch f to the drain circuit. (At this point, notch g is completely closed.)

The oil from the steering pump passes through notches c and d, pushes load check valve (51, and flows to the cylinder. The return oil from the cylinder passes through notch e and flows to the drain circuit. Notch g is closed, so the oil from the switch pump all flows from port B and is sent to the main control valve.

1o-79

STEERING DEMAND VALVE

STRUCTURE AND FUNCTION

OPERATION OF STEERING VALVE Neutral

To main con~trol itch Pump

From steerios o

The steering wheel is not being operated, so steering spool (2) does not move. The oil from the steering pump enters port A. The oil from the switch pump enters port B.

lo-80

valve

SDW01635

When the pressure at ports A and B rises, demand spool (1) moves to the left, so the oil from the steering pump passes through port C of the spool and is drained. The oil from the switch pump passes through port D and all flows to the main control valve.

STEERING DEMAND VALVE

STRUCTURE AND FUNCTION

Turning right

To main ram switch

control

valve

Pump

9 From

steering SDWO 1636

When the steering wheel is turned to the right, the Orbit-roll valve is operated and steering spool (2) moves to the left. The oil from the steering pump enters port A, then flows to steering spool (2) through demand spool (1). The oil pushes open load check valve (6) of the spool, and flows to the bottom end of the left cylinder and the rod end of the right cylinder to turn the machine to the right. The oil from the left and right cylin-

ders passes through load checkvalve (5) of the steering spool and is drained. The oil from the switch pump enters port B, goes through demand spool (I), pushes open checkvalve (41, and is merged with the oil from the steering pump.

lo-81

STRUCTURE AND FUNCTION

STEERING DEMAND VALVE

Turning left

-8 I

c:ontrol

main

From

steering

valve

PUMP

Pump SDW01637

When the steering wheel is turned to the left, the Orbit-roll valve is operated and steering spool (2) moves to the right. The oil from the steering pump enters port A, then flows to steering spool (2) through demand spool (I). The oil pushes open load check valve (5) of the spool, and flows to the rod end of the left cylinder and the bottom end of the right cylinder to turn the machine to the left. The oil from the left and right cylin-

1 O-82

ders passes through load checkvalve (6) of the steering spool and is drained. The oil from the switch pump enters port B, goes through demand spool (I), pushes open check valve (4), and is merged with the oil from the steering pump.

STRUCTURE

AND

TWO-WAY

FUNCTION

RESTRICTOR

VALVE

RESTRICTOR VALVE

1. 2. 3.

Poppet Spring Body

3 SEW01410

FUNCTION 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.

z Ki g

OPERATION When the oil is flowing to arrow *, it pushes spring (2) and flows through the orifice, and between poppet (I) and the poppet seat.

? a>

SEW01667

When the oil is flowing to arrow +-, the oil flows only from orifice a inside poppet (I), so the flow is controlled.

1 O-83

STEERING UNIT

STRUCTURE AND FUNCTION

STEERING UNIT (ORBIT-ROLL VALVE)

SEW01413

To hydraulic tank

Neutral position spring

Valve body

b. To steering cylinder (demand valve port Pb)

Check valve

To steering cylinder (demand valve port Pa)

Spool

From PPC pump

Sleeve

Gear rim

Gear

Cover

Drive shaft

10. Center pin

1O-84

STEERING UNIT

STRUCTURE AND FUNCTION

1 OUTLINE The steering unit is directly connected to the shaft of the steering wheel. The oil from the PPC pump passes through the steering demand valve, and is switched to the left and right steering cylinders to determine the direction of travel of the machine. The steering unit can be broadly divided into the following: spool (4) and sleeve (51, which have a rotor type direction selection function, and the gear set (combination of gear (7) and gear rim (611, which acts as a hydraulic motor when the steering is operated.

SEW01414

STRUCTURE l

5 &

Spool (4) is interconnected with the drive shaft of the steering wheel and is connected to sleeve (5) by neutral position spring (I) and center pin (IO) (when the steering wheel is at neutral, it does not contact the spool). The top of drive shaft (9) is meshed with center pin (IO) and forms one unit with sleeve (5). The bottom is meshed with the spline of gear (7) of the gear set. Valve body (2) has four ports. These are connected respectively to the pump circuit, tank circuit, and pilot circuit of the steering demand valve. In addition, the port at the pump end and the port at the tank end are connected by check valve (3) inside the housing. If there is any failure in the PPC pump, oil is sucked in directly from the tank end by the check valve.

Connecter to steering wheel shaft

4 :

8 i (Daal?l a D ::: ::::

SEW01638

SEW01416

1 O-85

STRUCTURE AND FUNCTION

STEERING UNIT

OPERATION When turning To steerino

demand

valve

From

PPC PULP

Ii I_

‘tj-__

To hydraulic tank

When the steering wheel is turned, spool (4) overcomes neutral position spring (I) and turns slightly in relation to sleeve (5). Because of this rotation, the ports of sleeve (5) and spool (4) overlap, so a passage is formed for the oil to flow, and the oil flows to gear (7).

SEW01 639

When the steering wheel is turned, the oil inside gear (7) flows, passes inside sleeve (5) and spool (41, operates the spool of the steering demand valve, and actuates the steering cylinders.

At neutral To steering

demand

To hydraulic tank

When the turning of the steering wheel is stopped (the rotation of the spool is stopped), the return force of neutral position spring (1) returns spool (4) and sleeve (5) to the neutral position, so the oil passage is shut off and the oil stops flowing.

1O-86

From

valve

PPC PurnD SEW01 640

When the non-reaction type steering valve is at the neutral position, the steering cylinder and spool (4) and sleeve (5) are blocked, so the reaction from the machine is not transmitted to the steering wheel.

DIVERTER VALVE

STRUCTURE AND FUNCTION

DIVERTER VALVE

/ 4

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

Check valve Check valve Check valve Check valve Spool Valve body

A. B. C. D. E. F.

To emergency pump Sensor mounting port To hydraulic oil tank To steering valve From hydraulic tank From steering circuit

x-x

SEW01419

FUNCTION The diverter valve is a selector valve which senses the pilot pressure from the steering pump and if there is no abnormality in the steering circuit, it drains the oil from the emergency pump to the tank. If no pilot pressure from the steering pump reaches the diverter valve, the oil from the emergency pump is switched to the steering circuit and flows to enable the machine to be steered.

1O-87

DIVERTER VALVE

STRUCTURE AND FUNCTION

EMERGENCY I

STEERING

RELIEF VALVE 4

5 1. 2. 3. 4. 5.

Main valve Valve seat Pilot poppet Spring Adjustment screw

SDW01420

FUNCTION Compared to the steering valve relief pressure of 31.4 MPa (320 kg/cm% the rated pressure of the emergency steering pump and diverter valve are both 20.6 MPa (210 kg/cm*}. Therefore, to protect the emergency steering pump and diverter valve, there is a relief valve in the piping from the diverter valve to the steering valve. When the emergency steering is being operated, and the hydraulic pressure generated by the steering exceeds 20.6 MPa 1210 kg/cm?, the relief valve is actuated.

OPERATION . Port A is connected to the pump circuit, and port C is connected to the drain circuit. The oil passes through the orifice in main valve (1) and fills port B. Pilot poppet (3) is in contact with valve seat (2).

SDW01422

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 (I) generates a difference in pressure between port A and port B. Main valve (I) is opened by the pressure at port A and the oil at port A is relieved.

1O-88

SOW01423

STRUCTURE AND FUNCTION

HYDRAULIC

CIRCUIT

SCHEMATICS

DIVERTER VALVE

FOR EMERGENCY

STEERING

Pump, engine working normally

Sensor Relief valve From steering cylinder To steering cylinder To main control valve Hydraulic tank Oil cooler Oil filter From orbit-roll valve

@ Emergency steering @ Main pump @ Steering pump I@ Switch pump

pump

When the steering pump and engine are working normally, the main pump, steering pump, and switch pump are rotated by the engine. Therefore, oil is sent to the steering valve, and the machine can be steered. In addition, the emergency steering pump is rotated by the transmission, so oil from port A of the diverter valve pushes open check valve (2) and enters port B. Pressure oil from the steering pump is flowing to port D, so it pushes spool (3) in the direction of the arrow. As a result, the oil from port B flows to port C and is drained to the hydraulic tank.

1 O-89

STRUCTURE AND FUNCTION

Failure in pump traveling

or engine

@Sensor @ Relief valve @ From steering cylinder @ To steering cylinder @ To main control valve @ Hydraulic tank @ Oil cooler @ Oil filter (jJ From Orbit-roll valve

DIVERTER VALVE

when

machine

@ @ @ @

Emergency steering Main pump Steering pump Switch pump

pump

If there is a failure in the pump or engine when the machine is traveling, the rotation of the wheels is transmitted through the transmission to rotate the emergency steering pump. The steering pump is not rotating, so no pressure oil is formed at port D. As a result, spool (3) is pushed in the direction of the arrow by spring (4). The oil from the emergency steering pump passes from port A through port B and flows to the steering valve to make steering possible.

/ Emergency

The emergency steering pump is designed so that it can rotate both directions.

1O-90

steerino

Pump

SEW01692

STRUCTURE AND FUNCTION

BRAKE AND AIR PIPING OUTLINE The air compressed by air compressor (II) enters two wet tanks and the moisture is removed. The air then enters two dry air tanks (171, (19) and also flows to parking brake solenoid valve (2). The air in dry air tanks (17), (19) flows to brake valves (61, (20). When the air compressed by air compressor (11) fills the circuit and the air pressure in two wet tanks reaches the maximum set pressure of air governor (12), the air governor is actuated. It opens the unloader valve of the compressor, so the compressor is put in a no-load condition and no air is compressed. When the air is used and the air pressure inside the tank drops below the minimum set pressure of air governor (121, the air governor is actuated. It closes the unloader valve of the compressor and the compressor is actuated. If the air governor does not work properly, and the pressure inside the tank reaches the set pressure, the safety valve opens and the air pressure is released to the atmosphere. This protects the air circuit. When brake valves (61, (20) are actuated, the air in dry air tanks (171, (19) flows to the brake chamber and applies pressure to the brake oil in the master cylinder. The pressurized oil passes through slack adjusters (I), (13) and pushes the wheel piston to apply brakes. The parking brake is applied mechanically by the spring in spring cylinder (21). 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, 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. This releases the parking brake.

1O-92

BRAKE AND AIR PIPING

STRUCTURE

AND FUNCTION

BRAKE AND AIR PIPING

SEW01428

1. Front slack adjuster 2. Parking brake solenoid 3. Horn 4. Horn valve 5. Air cylinder 6. R.H. brake valve 7. Solenoid valve 8. Air regulator valve 9. Rear brake 10. Air chuck 11. Air compressor

valve

12. Air governor 13. Rear slack adjuster 14. Brake oil tank 15. Rear brake chamber 16. Relay valve 17. Rear dry air tank 18. Front brake chamber 19. Front dry air tank 20. L.H. brake valve 21. Spring cylinder 22. Front brake

1o-93

STRUCTURE AND FUNCTION

BRAKE AND AIR CIRCUIT DIAGRAM

-- --~__

rI-

SDW01429

1o-94

STWCTURE AND FUNCTION

z 5 0

BRAKE AND AIR CIRCUITDIAGRAM

1. Front slack adjuster 2. Front brake 3. Horn 4. Horn valve 5. Air cylinder 6. R.H. brake valve 7. Solenoid valve 8. Check valve 9. Rear brake 10. Air compressor 11. Air governor 12. Rear slack adjuster 13. Brake oil tank 14. Front brake chamber 15. Rear brake chamber 16. Front air tank (wet) 17. Front air tank (dry) 18. L.H. brake valve 19. Spring cylinder 20. Relay valve 21. Two-way valve 22. Transmission cut-off switch 23. Brake oil level sensor 24. Stop lamp switch 25. Safety valve 26. Emergency brake switch 27. Air pressure sensor 28. Tire inflation 29. Check valve 30. Parking brake solenoid valve 31. Air regulator valve 32. Rear air tank (dry) 33. Rear air tank (wet) 34. Drain valve 35. Stop valve 36. Hydraulic tank

1o-95

STRUCTURE

AND

AIR GOVERNOR

FUNCTION

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

Exhaust port Spring Piston Unloader port Exhaust stem Inlet valve Tank port Filter

Specifications Cut-out pressure: 814 + 29 kPa (8.3 + 0.3 kg/cm*) Cut-in pressure : 686 + 29 kPa (7.0 f 0.3 kg/cm*}

6 7 8 SEL00276

FI JNCTION . The air governor maintains the pressu ire in the air circuit to the specified range.

Compressor working l The air pressure in wet tank (9) passes from tank port (7) through filter (8) and acts on the bottom of piston (3). When the air pressure in tank (9) is below the specified pressure (cut-out pressure), piston (3) is pushed down by spring (I). l When this happens, the air at unloader port (4) passes through exhaust stem (5) to the atmosphere and the compressor is actuated.

SEW01693

1O-96

AIR GOVERNOR

STRUCTURE AND FUNCTION

Compressor stopped compression When the pressure in wet tank (9) rises, and reaches the set pressure (cut-out pressure), piston (3) is pushed up against spring (I). When piston (3) is pushed up, exhaust stem (5) is closed and inlet valve (6) opens. The pressure from the tank passes through inlet valve (6) and unloader port (41, and acts on the unloader valve of the compressor. This puts the compressor in a no-load condition. When the air pressure inside the tank drops, piston (3) is pushed down by spring (I). When the pressure drops below the specified pressure (cut-in pressure), inlet valve (6) closes and exhaust stem (5) opens. The pressure at unloader port (4) passes through exhaust stem (5) and is released in the atmosphere, so the compressor starts to work again.

SEW01694

1o-97

STRUCTURE AND FUNCTION

AIR TANK.

SAFETY

VALVE

AIR TANK DRY. WET AIR TANK 1 A ------- l-l ------l-l

-------

------------

-----

._,

SEW01432

The air tank consists of two wet tanks and two dry tanks. The air from the compressor first enters the wet tanks and the moisture is removed. It is then divided and sent to the left and right dry tanks. A safety valve and air pressure sensor are installed in the wet tanks.

1. Air tank A. Drain

Specification

Name

1Capacity(e) ( Maximum

pressure

SAFETY VALVE 1. Cover 2. Adjustment

screw 3. Spring 4. Valve body 5. Valve seat 6. Lock plate 7. Lock terminal 8. Wire 9. Ball 10. Spring seat 11. Lock nut

Specificaiton

Setting pressure: 1.0 MPa 19.7 kg/cm21

FUNCTION The safety valve is installed in the wet tank, and acts as a safety device for the air circuit.

1 O-98

OPERATION . If the air governor does not work properly and the pressure inside the air tank rises above the set pressure, ball (9) is pushed up and the air escapes to the atmosphere.

STRUCTURE AND FUNCTION

BRAKE VALVE

SEW01434

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

Brake pedal Plunger Piston Inlet valve Piston Inlet valve Rubber spring

A. B. C. D.

From air tank From air tank To front brake chamber To rear brake chamber

OUTLINE There are two brake valves installed in parallel at the bottom of the operator’s compartment. These are operated by depressing the pedal. 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. l

1o-99

STRUCTURE

AND

BRAKE VALVE

FUNCTION

BRAKE ACTUATED Upper part When pedal (I) 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 air tank (I I) flows from port A to port C. This actuates relay valve (13). Air from air tank (11) flows to front brake chamber.

Lower part l When pedal (I) 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 relay valve (14). Air from air tank (II) flows to rear brake chamber. SDW01695

Operation of brake when lower valve fails . Even if there is leakage of air in the lower piping, the upper part will operate normally.

!t tank

10400

SDW01696

STRUCTURE

AND

FUNCTION

BRAKE VALVE

Operation of brake when upper valve fails Even if there is leakage of air in the upper piping, if pedal (I) is depressed, piston (5) will be pushed down mechanically and the upper part will operate normally. l

tank

To rear @

OPERATING

brake chamber

IN BALANCE

Upper part . When the pressure in the space below piston (3) and the air pressure from the brake chamber become high, the pressure pushes rubber spring (71, 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 . Upper piston (3) moves up, and inlet valve (4) closes. Piston (5) 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.

10-101

STRUCTURE AND FUNCTION

BRAKE VALVE

Upper part When pedal (I) 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 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 (11) pull the piston up. Exhaust port (IO) opens at the air pressure in brake chamber is released to the atmosphere.

SDW01699

10-102

STRUCTURE AND FUNCTION

RELAY VALVE

1. 2. 3. 4.

Valve body Relay piston Spring Inlet valve

A. B. C. D.

To brake chamber Exhaust port From brake valve From dry air tank

SEW01440

OPERATION When the brake valve is depressed and pressurized air flows to the top of relay piston (11, the relay piston is pushed down. Drain valve (5) closes and inlet valve (4) opens. Pressurized air is then supplied to the brake chamber from the tank. l

When the pressure on the brake valve is reduced, the pressure of the pressurized air at the top of relay piston (I) is reduced, so the pressure (spring force) at the bottom of relay piston (I) pushes the relay piston up. Drain valve (5) opens and the pressurized air in the brake chamber is drained.

SEW01700

I To brake valve

+ From br chamber

om tank +

SEW01701

10-103

STRUCTURE AND FUNCTION

TWO-WAY

TWO-WAY VALUE

VALVE 1. 2. 3. 4.

Body Seat Plug Cap

FUNCTION . The two-way I

4 SEW01443

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.

To brake chamber

From air tank

To brake chamber

From air tank

OPERATION l

The air circuit of the left and right brake valves is connected 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 two-way valve moves seat (2) and shuts off the circuit to port B. Therefore, the air pressure flows only to port C and actuates relay valve.

10-104

SDW01702

BRAKE CHAMBER

STRUCTURE AND FUNCTION

BRAKE CHAMBER

SEW01445

1. Air cylinder 2. Air piston 3. Spring 4. Rod 5. Breather 6. Piston 7. Master cylinder 8. Piston valve 9. Body 10. Sensor

Specification Air cylinder Cylinder

bore

Stroke Cylinder Master

capacity

(mm)

180

(mm)

133.5

(cc)

3,600

(mm)

132.5

(cc)

472

cylinder

Cylinder Stroke Delivery

bore

10-105

STRUCTURE AND FUNCTION

BRAKE CHAMBER

OPERATION Brake operated 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. From brakf va I ve

o slack djuster

Brake held in position When the brake pedal is kept depressed at a constant force, the hydraulic pressure is kept constant, so the brake is kept applied.

‘0 @ o slack djuster

Brake released 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.

To brake rom slack djuster

SDW01705

lo-106

SLACK ADJUSTER

STRUCTURE AND FUNCTION

SLACK ADJUSTER

B-

SEW01449

1. 2. 3. 4. 5.

Piston Cylinder Check valve Spring Bleeder

Specifications Maximum

available

pressure: 5.9 MPa 160 kg/cm*} (Safety valve set pressure: 0.97 MPa (9.9 kg/cm*)) 4.6 MPa (47 kg/cm*) Normal pressure: (Governor set pressure: 0.81 MPa (8.3 kg/cm*)) Check valve cracking pressure: 1.1 f 0.05 MPa (II.1 f 0.5 kg/cm*)

FUNCTION l

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.

10-107

STRUCTURE AND FUNCTION

SLACK ADJUSTER

OPERATION 1.

Brake pedal depressed The oil pumped out from brake chambers (9) flows in from port P of the slack adjuster. From port P the oil is divided and sent to left and right cylinders (2) and moves piston (4) a distance of stroke S to the right or left.

From relay

From relay SEW01706

Because of this, an amount of oil corresponding to stroke S flows from port C to brake cylinder (7). When this happens, the clearance between the brake piston and disc becomes 0, so no braking force is generated.

From relay valve SEW01707

10408

STRUCTURE

AND

FUNCTION

SLACK ADJUSTER

If the oil pressure in chambers (9) goes above a certain specified pressure, check valve (3) opens and the oil flows through pilot circuit D and applies pressure to port C. This gives the braking force. As a result, there is a constant time lag when the brake is applied.

From relay

From relay SEW01708

Brake pedal released When the brake is released, pressure is applied to the back of the brake piston because of the hydraulic pressure of the brake. Piston (4) is moved back stroke S and the disc clearance returns to normal.

To relay valve

Q3J

SEW01709

10-109

BRAKE

STRUCTURE AND FUNCTION

BRAKE

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

Guide pin Return spring Brake piston Plate Disc Floating seal

FUNCTION l

The brakes are wet-type multiple disc brakes, and are fitted to all four wheels.

10-110

Operation l

When the brake pedal is depressed, the brake oil in the brake chamber is pressurized, moves brake piston (3) to the right, and presses disc (5) and plate (4) together to hold them in position. Disc (5) is rotating together with the wheel, so when it is held in position, the rotation stops, the brake is actuated, and the machine is stopped. When the brake pedal is released, the pressure at the rear face of piston (3) is released, and the piston is moved to the left by the force of return spring (2) to release the brake.

STRUCTURE

AND FUNCTION

PARKING BRAKE

‘\

/.’ SEW01455

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

Spring cylinder Caliper Spring cylinder Disc Caliper Differential case

OUTLINE l The parking brake is a disc type and is installed on the front axle. . The force of the spring inside spring cylinder (I) is used to apply the brake mechanically; it is released by air pressure. l 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.

10-111

PARKING BRAKE

STRUCTURE AND FUNCTION

Brake operated l

When the parking brake switch lever is moved to ON, solenoid valve is actuated and the air from the air tank is shut off by valve. At the same time, the air from the spring cylinder is released to the atmosphere from between valve and body. Therefore, the piston of spring cylinder (I) is pushed by the tension of the spring, so when lever (2) is pushed, the parking brake is applied. Lever (2) rotates piston shaft (3) and moves piston (4) to the axial direction. Therefore, the pads are pushed against the disc, and the parking brake is applied.

,’/ 5 ‘._

SEW01710

Brake released l

When the parking brake switch is turned to OFF, the solenoid valve is actuated and valve closes the exhaust port. At the same time the air in the air tank enters the top part of the piston of spring cylinder (I 1. It overcomes the force of the spring and pushes the piston. This pulls rod (51, moves piston (4) and releases the brake. Therefore, air pressure is applied to the spring cylinder and the parking brake is kept released. However, if the air pressure inside the tank drops to a level where it cannot maintain the normal operation of the brake, the pressure sensor installed to the tank sends an electric signal to the solenoid valve. This releases the spring cylinder circuit, and the parking brake is automatically applied.

From solenoid

SEW01711

10-l12

STRUCTURE AND FUNCTION

HYDRAULIC *

PIPING

For details of this page, see 90-3 page.

10-l 14

HYDRAULIC PIPING

STRUCTURE AND FUNCTION

HYDRAULIC PIPING

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 from hydraulic tank is sent from main pump (41, steering pump, and switch pump (7) through the steering valve to two main control valves (IO). If the dump and lift spools of the main control valve are both in neutral, the oil passes through the drain circuit of the main control valve, is filtered by the filter inside the hydraulic tank, and returns to the tank. The dump or lift spool in 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 lift cylinder (9) or dump cylinder (I), 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 engine is at rest, the lift arm can be lowered to the ground because accumulator (3) is provided in the circuit. Hydraulic tank is a pressurized, sealed type 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 from cavitation. In the hydraulic tank there is pressurizing valve installed to pressurize the hydraulic tank with air pressure. It is used to carry out air bleeding of the pump when changing the oil inside the tank or when assembling after removing the piping of the piston pump and pump.

10-115

STRUCTURE AND FUNCTION

WORK EQUIPMENT +

WORK EQUIPMENT

HYDRAULIC

HYDRAULIC CIRCUIT DIAGRAM

CIRCUIT DIAGRAM

For details of this page, see 90-5 page.

i’

__,._..________________

10-117

STRUCTURE AND FUNCTION

MACHINE Ir

WORK EQUIPMENT

WITH JOYSTICK

STEERING

For details of this page, see 90-7

L____--_--..____.: r-7

lo-118

page.

HYDRAULIC CIRCUIT DIAGRAM

STRUCTURE AND FUNCTION

WORK EQUIPMENT

LEVER LINKAGE

A-A

SEW01461

1. Safety lever Lift control lever 3. Bucket control lever 4. Solenoid valve for boom kick-out 5. Solenoid valve for bucket positioner 6. PPC valve

10-119

STRUCTURE

AND

FUNCTION

HYDRAULIC

TANK

HYDRAULIC

TANK

SEW01462

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

Oil filler Breather Strainer Strainer Filter bypass valve Hydraulic filter Drain valve

A. B. C. D. E. F.

Oil cooler return port Main return port Gear pump suction Emergency pump return port Main piston pump suction port Emergency pump suction

10-120

OUTLINE 9 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 hydraulic filter (6) and returns to the tank. . Hydraulic filter (6) filters all the oil in the circuit. If hydraulic filter (6) becomes clogged, bypass valve (5) acts to allow the oil to return directly to the tank. This prevents damage to filter (6). Bypass valve (5) is also actuated when negative pressure is generated in the circuit.

STRUCTURE

AND

HYDRAULIC

FUNCTION

TANK

OIL FILTER BYPASS VALVE When the filter is clogged. Bypass valve (1) opens and the oil returns directly to the tank without passing through the filter. Bypass valve set pressure: 125 kPa (1.27 kg/cm*)

valve

tlic

tank

SEW01714

When negative pressure is formed in the return circuit. Valve (2) moves up and acts a check valve. Check valve set pressure: 26 kPa (0.26 kg/cm*) main

control

From

hvdraul

valve

lit

tank

SEW01715

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 between the tank and the outside atmospheric pressure opens poppet (31, and air from the outside is let into the tank to prevent negative pressure. Preventing rise in pressure inside the tank When the hydraulic cylinder 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

MAIN PISTON PUMP

STRUCTURE AND FUNCTION

MAIN

PISTON PUMP Pump

sub

ass'y

I_._

PA1

Pad1

Pad2

PA2

AL-----__.A

F P2

Servo valie

ass'y (R)

Ihe ass’Y(F)

Pa ill

Pad2

PA1

P‘GS

SEW01716

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

ES valve (Engine sensing) Front servo valve Rear servo valve Front main pump Rear main pump Control pump (BAR0251 Relief valve

OUTLINE . These pump assemblies

consist of two variable displacement swash-plate type pumps, two servo valve units, and impeller pump (built in between the front main pump and the rear main pump), a control pump and a relief valve.

lo-123

STRUCTURE AND FUNCTION

PISTON

PUMP

MAIN PISTON PUMP

(HPVSO + 90)

Ps Z

\ Pid

Pa’d2

SEW01391

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

Shaft (front) Cradle (front) Case (front) Swash plate Shoe Piston Cylinder block Valve plate

lo-124

9. Impeller 10. Cradle (rear) 11. Shaft (rear) 12. Case (rear) 13. End cap (rear) 14. End cap (front) 15. Servo piston

Specification Model Rated delivery pressure Rated rpm Theoretical delivery

: HPV 90 + 90 : 34.3 MPa (350 kg/cm2} : 2100 rpm : front 97.4 cc/rev

Max. delivery

: 204.5 + 204.5 Q/min

rear

97.4 cc/rev

MAIN PISTON PUMP

STRUCTURE AND FUNCTION

c-c

A-A

D-D

E-E

B-0

F-F SEW01392

10425

MAIN PISTON PUMP

STRUCTURE AND FUNCTION

FUNCTION l

The engine rotation and torque transmitted to the pump shaft is converted into hydraulic energy, and pressurized oil is discharged according to the load. It is possible to change the delivery amount by changing the swash plate angle.

STRUCTURE

SPI ine

Cylinder block (7) is supported to shaft (I) by a spline, and shaft (I) is supported by the front and rear bearings. The tip of piston (6) is spherical, and shoe (5) is caulked to it to form one unit. Piston (6) and shoe (5) form a spherical bearing. Rocker cam (4) has plane surface A, and shoe (5) is always pressed against this surface while sliding in a circular movement. Rocker cam (4) brings high pressure oil at cylindrical surface B with cradle (21, which is secured to the case, and forms a static pressure bearing when it slides.

10426

SEW01717

Piston (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7). Cylinder block (7) seals the pressure oil to valve plate (8) and carries out relative rotation. This surface is designed so that the oil pressure balance is maintained at a suitable level. The oil inside each cylinder chamber of cylinder block (7) is sucked in and discharged through valve plate (8). Impeller (9) is connected to shaft (I) through the spline boss (IO) and rotates together with the shaft. The oil sucked in through the suction port is sent to the cylinder chamber by centrifugal force to make suction easier.

MAIN PISTON PUMP

STRUCTURE AND FUNCTION

OPERATION 1. Operation of pump . Cylinder block (7) rotates together

with shaft (I), and shoe (5) slides on flat surface A. When this happens, rocker cam (4) moves along cylindrical surface B, so angle a between center line X of rocker cam (4) and the axial direction of cylinder block (7) changes. (Angle a is called the swash plate angle.)

Center line X of rocker cam (4) maintains swash plate angle a in relation to the axial direction of cylinder block (71, and flat surface A moves as a cam in relation to shoe (5). In this way, piston (6) slides on the inside of cylinder block (71, so a difference between volume E and F is created inside cylinder block (7). The suction and discharge is equal to this difference E - F. In other words, when cylinder block (7) rotates and the volume of chamber E becomes smaller, the oil is discharged during that stroke. On the other hand, the volume of chamber F becomes larger, and as the volume becomes bigger, the oil is sucked in.

X SEW01466

\ F SEW01467

If center line X of rocker cam (4) is in line with the axial direction of cylinder block (7) (swash plate angle = 01, the difference between volumes E’ and F’ inside cylinder block (7) becomes 0, so the pump does not carry out any suction or discharge of oil.

SEW01466

10-127

STRUCTURE AND FUNCTION

Control of discharge amount

MAIN PISTON PUMP

If swash plate angle a becomes larger, the difference in volumes E and F becomes larger and the discharge volume increases. Swash plate angle cx is changed by servo piston (15). Servo piston (15) moves in a reciprocal movement () in accordance with the command from the servo valve. This straight line movement is transmitted through the rod of rocker cam (4) to rocker cam (41, and rocker cam (41, which is supported by the cylindrical surface to cradle (IO), slides in an oscillating movement in direction ( 0 ) along the cylindrical surface.

SEW01469

1O-l 28

MAIN PISTON PUMP

STRUCTURE AND FUNCTION

CONTROL PUMP (BAR0251

-u n

mountins port

Discharae port

A-A SEW01718

1. Collar Body 3. Housing 4. Drive gear 5. Driven gear

Specification Model Theoretical delivery Max. delivery pressure

: BAR 25 : 25 cc/rev. : 2.9 MPa (30 kg/cm?

10429

STRUCTURE AND FUNCTION

MAIN PISTON PUMP

RELIEF VALVE

1. 2. 3. 4. 5. 6. SDWO1471

Adjustment screw Lock nut Pilot valve spring Pilot valve Main valve spring Main valve

Set pressure: 2.9 MPa (30 kg/cm*} (at 50 e/min)

FUNCTION The relief valve is built in the body of control pump. It relieves the oil delivered from the pump. Flow of the oil Chamber A forms a pump circuit and chamber C forms a tank drain circuit. The oil flows into chamber B through the main relief valve orifice to keep the chamber filled. Pilot valve is set in the valve seat.

SDWO1472

If the pressure in chamber B reaches the pilot valve spring force (set pressure), the pilot valve moves, allowing the oil in chamber B to flow into chamber C. In addition, the oil flows from chamber A to B through orifices.

SDWO1473

If the oil flows through the orifice of valve (61, a differential pressure occurs between the chambers A and B, moving valve (6) to the left. This allows the oil in chamber A to flow into chamber C.

10-130

ES VALVE

STRUCTURE AND FUNCTION

ES VALVE (Engine Sensing valve)

Pes / P2 +-___-_-~ I I I I

II I

(B) I Pd r

L____ .\Peo

Pas S

‘0

Peo

Pdr

SEW01475

1. Plug Valve body 3. Shaft 4. Plug 5. Plug 6. Spool 7. Spool 8. Plug 9. Plug

FUNCTION . This valve acts to control the delivery amount of the hydraulic pump to match the changes in the engine speed.

10-131

STRUCTURE

AND

FUNCTION

ES VALVE

FUNCTION l

A variable displacement piston pump is used for the hydraulic pump to save energy by reducing the consumption of hydraulic pressure when the engine is running at low speed. At the same time, it is also used to increase the engine acceleration from low speed. For this reason, a pressure difference valve is used to detect the engine speed by using a pressure difference system. The delivery (delivery per rotation) is then adjusted to match the engine speed.

OPERATION l

Oil from the PPC pump passes through pressure difference valve (I) and is sent to the PPC valve. Pilot pressure from the inlet and outlet ports (ports (A) and (B)) of the pressure differential valve is supplied to the ES valve (2). The difference in pilot pressure becomes larger as the flow from the PPC pump increases (in other words, as the engine speed increases). When the pilot pressure difference reaches point a (0.12 MPa {I .24 kg/cm%, the ES valve starts to operate, and actuates the servo valve and servo cylinder to change the swash plate angle of the pump. When the swash plate angle is changed, the piston stroke also changes to change the delivery of the pump (delivery per rotation). Until the difference in pilot pressure reaches 0.31 MPa (3.2 kg/cm21, the pump delivery (delivery per rotation) increases in proportion with the increase in the difference in pilot pressure (in other words, the increase in the engine speed). When the difference in pressure reaches 0.31 MPa (3.2 kg/cm% the pump delivery (delivery per rotation) reaches the maximum.

0.12*0.01

(1.24*0.1)

Apurox.800

(MPa(ke/cm'I)

0.31*0.02 Pilot pressure (3.2iO.2) difference

A~~rox.1100

Engine sPeed(rpm)

SDW01719

When the pilot pressure difference is below point a

SDW01720

When the pilot pressure difference is above point b

SDW01721

10432

SERVO VALVE

STRUCTURE AND FUNCTION

SERVO VALVE Servo

actuator

Servo

port

actuator

port

i Y-Y

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

Sleeve Body Spool Arm Plug Sleeve Spool Plug

SEW01722

Servo

actuator

port

Pd.r

Servo

actuator

port

sowo1723

10-133

STRUCTURE

AND

SERVO VALVE

FUNCTION

OPERATION 1.

Increasing of delivery amount angle changes to the right)

(swash

Control

plate

01~moW Main

Input signal pressure Pi acts on chamber E in the control piston from port D. Pressure PC in the charging pump is guided into port B. If input signal pressure Pi is raised a little, the oil pressure acting on chamber E will increase accordingly. Control piston (9) therefore moves to a position (rightward) where the force of spring (IO) is in balance with the oil pressure in chamber E, thus allowing arm (4) to swing rightward with servo piston (11) serving as the supporting point. As a result, guide spool (12) moves to the right.

10-134

putnp

SDW01724

With the movement of guide spool (121, port B and port A connect to each other, allowing oil pressure PC, in the control pump to act on chamber F in servo piston (I I). Servo piston (11) is then pushed rightward, increasing the swash plate angle of the main piston pump. Thus, the pump discharge is increased. Since arm (4) turns counterclockwise on pin (131, guide spool (12) moves leftward, causing port B, port C and drain port A to close. The pump discharge, therefore, increases with the change in input signal pressure Pi.

STRUCTURE

AND

FUNCTION

Decreasing of delivery amount angle changes to the left)

SERVO VALVE

(swash

plate

TO ser

. Chamber H

SDW01725

Next, let’s examine the case where servo piston (11) is moved leftward. Assume that the servo piston is in a balanced position at a certain location. If Pi is decreased, control piston (9) moves to a position where the oil pressure in chamber E balances with the force of spring (IO). Then, arm (4) swings leftward, using servo piston (11) as a support point, and cause, guide spool (12) to move leftward. With the movement of guide spool (121, port B and port A are shut off and port A becomes open to the drain.

On the other hand, port B and port C are connected to each other, allowing the oil to flow into chamber H in the servo cylinder. Servo piston (11) is then pushed leftward by the force of spring (141, decreasing the swash plate angle of the main piston pump. Thus, the pump discharge is decreased. Since arm (4) rotates clockwise on pin (131, guide spool (12) moves rightward, shutting off port B, port C and port A. The pump discharge, therefore, decreases with the change in input signal pressure Pi.

10-135

PPC VALVE

STRUCTURE AND FUNCTION

PPC VALVE (Proportional

Pressure Valve)

P : From pump T : To tank (drain) PI: To lift cylinder (Raise) P2: To dump cylinder (Dump) P3: To Iif? cylinder (Lower) P4: To dump cylinder (Tilt)

SEW01483

10-136

STRUCTURE AND FUNCTION

PPC VALVE

n A-A

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

Bolt Piston Plate Collar Retainer Center spring Metering spring Valve Body

c-c FUNCTION l

The PPC valve is installed to the bottom of the work equipment control lever and is connected to the control lever by a linkage. The oil from the PPC pump supplies the pilot pressure from the PPC valve to the end of each spool of the main control valve according to the amount that the control lever is moved, and actuates the spool.

SEW01484

1o-1 37

STRUCTURE

AND

PPC VALVE

FUNCTION

OPERATION 1.

Control lever at “neutral” (Fig. 1): Ports PA,, P2, PB, and P4 are connected to drain chamber D through fine control hole (f) in spool (IO).

Control lever operated slightly (fine control) (Fig. 2): When piston (4) starts to be pushed by plate (21, retainer (7) is pushed. Valve (IO) is also pushed by spring (9) and moves down. When this happens, fine control hole (f) 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 (f) to port P2 and PA,. When the pressure at port P2 rises, valve (IO) is pushed back. Fine control hole (f) 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 P2 escapes to drain chamber D. Valve (IO) moves up and down until the force of spring (9) is balanced with the pressure of port P2. The position of valve (IO) and body (11) (when fine control hole (f) is midway between drain chamber D and pump pressure chamber PP) does not change until the head of valve (IO) contacts the bottom of piston (4). Therefore, spring (9) is compressed in proportion to the travel of the control lever, so the pressure at port P2 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 P2) and the force of the return spring of the control valve are balanced.

‘BI -

1O-l 38

SDW01486

STRUCTURE

AND

FUNCTION

PPC VALVE

Control lever moved back from slightly operated position to neutral (Fine control) (Fig. 3): When plate (2) starts to be pushed back, piston (4) is pushed up by a force corresponding to the force of centering spring (8) and the pressure at port P2. At the same time, fine control hole (f) of valve (IO) is connected to drain chamber D, so the oil at port P2 escapes. If the pressure at port P2 drops too far, valve (IO) is pushed down by spring (9). Fine control hole (f) 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 P2 return 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 P4 to chamber Pe,.

Control lever operated to end of travel (Fig. 41: Plate (2) pushes piston (4) down, and piston (4) forcibly pushes in valve (IO). Fine control hole (f) is shut off from drain chamber D, and is connected to pump pressure chamber PP. Therefore, pressure oil from the charging pump passes through fine control hole (f), and flows from port P2 to chamber PA, to push the spool of the control valve. The oil returning from chamber A2 flows from port PB, through fine control hole (f’) to drain chamber D.

PA1

(Fig. 4)

PBl

SDWO 1400

PPC RELIEF VALVE

STRUCTURE AND FUNCTION

PPC RELIEF VALVE

1. 2. 3. 4. 5.

Main valve Valve seat Pilot poppet Spring Adjustment screw

Set pressure: 3.7 MPa (38 kg/cm*)

FUNCTION 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).

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 (I) and fills port B. Pilot poppet (3) is in close contact with valve seat (2). .

If the pressure at ports A and 6 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.

If the pressure at port B drops, a pressure difference is generated between ports A and B due to the orifice in main valve (I). Main valve (1) is pushed open by the pressure at port A, and the oil at port A is relieved.

10-140

: 2 0

SDW01490

St-JW01491

STRUCTURE

AND

FUNCTION

ACCUMULATOR

1. Cap 2. Nut 3. Body

4. 5. 6.

Bladder Oil port Nut

Specifications Type of gas: Nitrogen gas Gas amount: 3,000 cc Max. actuation pressure: 2.9 MPa I30 kg/cm*) Min. actuation pressure: 1.6 MPa (16 kg/cm*)

FUNCTION The accumulator is installed between the hydraulic pump and PPC valve. An inflatable bladder is filled with nitrogen gas, and the compressibility is used to store the pressure of the oil. As a result, the lift arm and bucket can be lowered under their own weight even after the engine has been stopped.

SEW01493

OPERATION . After the engine stops, when the PPC valve is a NEUTRAL, chamber A (volume of nitrogen gas: 3000 cc) inside the bladder is compressed by chamber B.

Before operation

After operation

When the PPC valve is operated, the pressure in chamber B drops below 2.9 MPa (30 kg/cm*) and the pressure of the nitrogen gas in chamber A makes the bladder expand. The actuating pressure is 1.6 to 2.9 MPa (16 to 30 kg/cm*).

From PPC pump SEW01494

To PPC valve SEW01495

10-141

STRUCTURE AND FUNCTION

MAIN CONTROL VALVE

MA2

SEW01496

1. Main relief valve 2. Dump spool return spring 3. Lift spool return spring 4. Lift spool 5. Dump spool 6. Body 7. Suction valve 8. Unloader valve 9. Float selector valve 10. Safety valve (with suction)

lo-142

MAI: From PA1 of PPC valve MA2: From PA2 of PPC valve MBI: From PB1 of PPC valve MB2: From PB2 of PPC valve Al : To dump cylinder bottom side A2 : To lift cylinder bottom side BI : To dump cylinder rod side B2 : To lift cylinder rod side P : Pump port Pl : From PA2 of PPC valve T : Drain port (to hydraulic tank)

MAIN CONTROL VALVE

STRUCTURE AND FUNCTION

5 4

D-D

E-E

c-c SEW01497

FUNCTION l

The two main control valves control 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 main relief valve (1). The oil passes through the bypass 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 lift 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.

There are two safety valves (with suction valves) (IO) 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 any lack of oil.

10-143

MAIN CONTROL VALVE

STRUCTURE AND FUNCTION

RELIEF VALVE

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

Main valve Valve seat Pilot poppet Pilot poppet spring Adjustment screw Lock nut

Set pressure: 31.4 MPa {320 kg/cm*) SDW01498

FUNCTION 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 . 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 (I) and flows to port B. Pilot poppet (3) is in close contact with valve seat (2). When the hydraulic pressure in the circuit inside port A and port B reaches the set pressure of pilot poppet spring (41, 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. When the pressure at port B drops, the orifice effect of main valve (I) 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.

’\

SDW01499

SDWOiSOO

SOW01501

10-144

MAIN CONTROL VALVE

STRUCTURE AND FUNCTION

SAFETY

VALVE

(with

suction 4

valve) 5

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

SEW00166

Suction valve Main valve Main valve spring Pilot piston Suction valve spring Valve body

Set pressure:

36.8 MPa (375 kg/cm2}

FUNCTION . 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 . 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 pilot piston (4). It also flows to port C through an orifice consisting of the main valve and pilot piston (4). 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 d2 > dr > d3 > da.

If abnormally high oil pressure occurs in port A, suction valve (I) is not actuated because of the relationship d2 > dr. However, because of the relationship d3 > d4 in port A and C, the hydraulic pressure on main valve (2) is equivalent to the area difference between d3 and da. If this pressure goes up to the main valve spring force (set pressure), main valve (2) is actuated, and the oil in port A flows into port B.

BC2

da d4

SEW00167

SEW00168

10-145

STRUCTURE

AND

MAIN CONTROL VALVE

FUNCTION

AS A SUCTION VALVE . If negative pressure is generated in port A, port D 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 dz and dr is applied to the safety valve because of the tank pressure in port E. Therefore, hydraulic pressure II e II acts to open the valve and hydraulic pressure “a” acts to close suction valve (1). . 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 l oil pressure lan + valve spring (5) force, 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

SEW01502

VALVE 1. 2. 3.

Main poppet Sleeve Spring

SEW00170

OPERATION . If negative pressure is generated in port A (lift cylinder rod end) (if the pressure is lower than in port B in the tank circuit), main poppet (I) opens because oil then flows from port B at the tank end to port A at the cylinder port end.

SEW01503

lo-146

STRUCTURE

AND FUNCTION

FLOAT SELECTOR

VALVE

MAIN

AND

UNLOADER

VALVE

CONTROL

VALVE

FUNCTION The float selector valve and the unloader valve are inside the main control valve. When the lift control lever is moved to the float position, the float selector valve detects this. When it is actuated, it actuates the unloader valve and sets the lift arm in the FLOAT position.

OPERATION 1. LOWER position This shows the condition with the lift control lever in the LOWER position.

From

steeyine

valve

From

steeyina

valve

FLOAT position When the lift control lever is pushed forward from the LOWER position, it enters the FLOAT position. Lift spool (I) of the main control valve is in the same condition as at the LOWER position. The hydraulic pressure at port A is higher than at the LOWER position, so float selector valve (2) moves in the direction of the rightward. The back pressure of unloader valve (3) is drained, so unloader valve (3) opens to give the FLOAT condition.

SDW01727

10-147

MAIN CONTROL VALVE

STRUCTURE AND FUNCTION

FLOAT position (pushed up) If the machine moves in reverse and the lift arm is pushed up, the pressure at the cylinder rod end becomes high. It passes through port B and is drained through unloader valve (3). A vacuum is formed at the cylinder end, so oil flows in from port C.

bottom

From steerins valve

SDW01728

From steering valve

SDW01729

FLOAT position (lowering under own weight) When the machine is moving in reverse and the lift arm comes down under its own weight, the pressure at the cylinder bottom end is high, and it is drained from port C. A vacuum is formed at the cylinder rod end, so oil flows in from port B.

lo-148

STRUCTURE

AND

OPERATION

FUNCTION

OF HYDRAULIC

MAIN

CONTROL

VALVE

CIRCUIT

LIFT AND DUMP SPOOLS IN “HOLD”

t-x/,,,r,/,/,,

OPERATION l The oil enters port A from the steering valve, and the maximum pressure is set by relief valve (11). . Dump spool (I) is at the HOLD position, so the bypass circuit is open and the oil at port A passes around the spool and flows to port B. Lift spool (2) is also at HOLD, so the bypass circuit is open and the oil at port B passes around the spool, enters port C of the drain circuit, passes through the filter in the hydraulic tank, and returns to the tank.

/,l,,,,,,I,,__.

..y

SDW01730

The oil from the PPC pump passes through check valve (131, and enters port L of the PPC valve. However, the lift and dump levers are at the HOLD position, so the oil returns to the hydraulic tank from PPC relief valve (12).

10-149

STRUCTURE AND FUNCTION

MAIN CONTROL VALVE

LIFT SPOOL IN “RAISE”

tJ.-,.,-,-,,,,,,,,,,,,,,,,,,,,,,,,,.,,,,.....

OPERATION . When lift lever (3) is pulled, the oil flows from port L of the PPC valve to port N and port S. In addition, the oil at port T passes through port M and flows to the drain cir-

cuit. The oil pressure at port S pushes lift spool (2) and moves it to the RAISE position. The oil from the steering valve passes through the bypass circuit of the dump spool

10450

SDW01731

and flows to the bypass circuit of lift spool (2). The bypass circuit is closed by the spool, so the oil pushes open check valve (IO). The oil flows from port H to port I, and flows to the cylinder bottom. At the same time, the oil at the cylinder rod end enters drain port C from port K and returns to the tank. Therefore, the lift arm rises.

MAIN CONTROL VALVE

STRUCTURE AND FUNCTION

LIFT SPOOL

IN “LOWER”

SDWOl732

OPERATION l

When lift lever (3) is pushed, the oil flows from port L of the PPC valve to port M and port T. In addition, the oil at port S flows to the drain circuit. The oil pressure at port T pushes lift spool (2) and moves it to the LOWER position. The oil from the steering valve passes through the bypass circuit of the dump spool and flows to the bypass circuit of lift spool

(2). The bypass circuit is closed by the spool, so the oil pushes open check valve (IO). The oil flows from port J to port K, and flows to the cylinder rod end. At the same time, the oil at the cylinder bottom enters drain port C from port I and returns to the tank. Therefore, the lift arm goes down.

10-151

MAIN CONTROL VALVE

STRUCTURE AND FUNCTION

LIFT SPOOL IN “FLOAT”

HYdrau

OF‘ERATION . When lift lever (3) is pushed to the FLOAT position, the PPC valve spool moves beyond the LOWER position to the FLOAT position. The pressure oil at port L flows to port M, and at the same time, it also flows to port T and port W. In addition, the pressurized oil at port S flows to port N. The pressurized oil at port T pushes lift spool (2) to the LOWER position. If a difference in pressure greater than the specified pressure is generated at port W and port X, valve (7) moves to the right,

lo-152

opens port Cl and port C, and connects to the drain circuit. When port Ct is connected to the drain circuit, unload valve (8) moves up and the oil from the pump flows to the drain circuit. Therefore, the oil at the cylinder rod end passes from port K through unload valve (8) and flows to the drain circuit. The oil at the cylinder bottom flows from port I to port C, and then flows to the drain circuit. Therefore, the lift arm is set to the FLOAT condition.

MAIN CONTROL VALVE

STRUCTURE AND FUNCTION

DUMP

SPOOL IN “DUMP”

Hydraulic It:“““““““““!<’ Hydraulic

oil

filter

SDWOl734

OPERATION l

When dump lever (4) is pushed, the pressure oil at port L of the PPC valve flows from port 0 to port V. In addition, the oil at port R flows to the drain circuit. The pressure oil at port V moves dump spool (I) to the DUMP position. The bypass circuit is closed by dump spool (I), so the oil from port A pushes open check

valve (IO). The oil from check valve (IO) flows from port F to port G, and then flows to the cylinder rod end. At the same time, the oil at the cylinder bottom flows from port D to drain port C, and returns to the tank, so the bucket is dumped.

10453

STRUCTURE AND FUNCTION

DUMP

SPOOL

MAIN CONTROL VALVE

IN “TILT BACK”

SDW01735

,“.“““‘,,,,,,l,/llll///,,,,,,,,/lr..,....

OPERATION l

When dump lever (4) is pulled, the pressure oil at port L of the PPC valve flows from port P to port R. In addition, the oil at port V flows to the drain circuit. The pressure oil at port R moves dump spool (I) to the TILT position. The bypass circuit is closed by dump spool

10-154

(I), so the oil from port A pushes open check valve (IO). The oil from checkvalve (IO) flows from port E to port D, and then flows to the cylinder bottom. At the same time, the oil at the cylinder rod end flows from port G to drain port C, and returns to the tank, so the bucket is tilted.

STRUCTURE AND FUNCTION

LUBRICATION OF WORK EQUIPMENT

SEW01514

1. 2. 3. 4.

Dump cylinder Front frame Steering cylinder Lift cylinder

10-156

5. 6. 7. 8.

Transmission Torque converter Damper Bellcrank

A. B. C. D. E. F.

Upper hinge pin Dump cylinder bottom pin Lift arm pin (left) Lift arm pin (right) Steering cylinder pin (left) Steering cylinder pin (right)

LUBRICATION OF WORK EQUIPMENT

STRUCTURE AND FUNCTION

SEW01515

G. H. 1. J.

Front axle support Transmission trunnion Rear axle support Rear axle support

10-157

STRUCTURE AND FUNCTION

WORK EQUIPMENT

LINKAGE

ii I

LINKAGE

‘II

SEW01516

1. Bucket Bucket hinge pin (grease filled type) Bucket link pin (grease filled type) Bucket link Bellcrank Dump cylinder

2. 3. 4. 5. 6.

lo-158

7. Lift arm 8. Lift cylinder 9. Cord ring 10. Tooth with tip 11. Sweeper wing

STRUCTURE AND FUNCTION

WORK EQUIPMENT LINKAGE

A-A

E-E

F-F

J-J G-G

H-H SEW01517

10-159

STRUCTURE AND FUNCTION

BUCKET POSITIONER AND BOOM KICK-OUT

SEW01518

1. 2. 3. 4.

Proximity switch (dump) Lever Proximity switch (boom) Plate

10-160

STRUCTURE AND FUNCTION

BUCKET POSITIONER AND BOOM KICK-OUT

BUCKET POSITIONER The bucket positioner is an electrically actuated system which is used to set the bucket to the desired angle when the bucket is moved from the DUMP position to the TILT position. When the bucket reaches the desired position, the bucket lever is returned from the TILT position to the HOLD position, and the bucket is automatically set to the suitable digging angle. Bar (2) is secured to dump cylinder rod (5) by bolts. In addition, proximity switch (1) is fixed to the cylinder by bolts. When the bucket is moved from the DUMP position to the TILT position, the bucket cylinder rod moves to the left, and at the same time, bar (2) also moves to the left. Bar (2) separates from proximity switch (I) at the desired position, and the bucket lever is returned to neutral.

BOOM KICK-OUT

k d

SEW01519

The boom kick-out is an electrically actuated system. It acts to move the lift arm lever to the HOLD position and stop the lift arm at the desired position before the lift arm reaches the maximum height. Plate (4) is fixed to the lift arm. In addition, proximity switch (3) is fixed to the frame. When the lift arm is moved from the LOWER position to the RAISE position, the lift arm rises, and when it reaches the desired position, the proximity switch and lever separate and the system is actuated to return the lift arm lever to the HOLD position.

SEW01520

10461

BUCKET POSITIONER AND BOOM KICK-OUT

STRUCTURE AND FUNCTION

OPERATION OF PROXIMITY SWITCH Proximity switch boom kick-out

Lift arm RAISE When the lift arm is lower than the set position for the kick-out, the sensor (steel plate) is above the detection surface of the proximity switch, so electricity flows in the proximity switch load circuit. The kick-out relay is turned ON and the current for the solenoid is shut off.

for To battery relay

Lift

Kick-out Kick-out

relay

solenoid

lever Cam

Lift

arm

Proximity

switch

\ Detector

u--

PPC

When the lift arm lever is moved to the RAISE position, the lift spool is held at the RAISE position by the cam follower and cam on the lever, and the lift arm rises.

Proximity

valve

Proximity switch boom kick-out

Solenoid

SEW01736

for To battery relay

switch

Detlctor SEW01737

lo-162

STRUCTURE AND FUNCTION

BUCKET POSITIONER AND BOOM KICK-OUT

When the lift arm rises and reaches the set position for the kick-out, in other words, the sensor (steel plate) separates from the detection surface of the proximity switch, an electric current is sent to the solenoid by the action of the proximity switch and relay circuit. As a result, the solenoid is actuated, and the cam is pulled away from the cam detent, so the lift spool is returned to the HOLD position by the return spring.

Proximity switch for boom kick-out To battery relay

Kick-out solenoid

SEW00166

Lift

arm

t I

Action of proximity switch

Position Proximity switch actuation display Kick-out relay Solenoid (for kick-out)

When sensor is in position at detection surface of proximity switch

When sensor is separated from detection surface of proximity switch

Lights up

Goes out

Current flows

Current is shut off

Current flows

lo-163

BUCKET POSITIONER AND BOOM KICK-OUT

STRUCTURE AND FUNCTION

Bucket TILT Proximity switch for bucketpositioner

When the bucket is dumped beyond the set position for the auto-leveler, the sensor (steel plate) is above the detection surface of the bucket proximity switch, so electric current flows in the proximity switch load circuit. The positioner relay is turned ON and the current for the solenoid is shut off.

. ;

Positioner Positioner

relay

solenoid

SEW00192

Cam Bucket

lever

\ Proximity

&itch

Detector WPPC

Solenoid

valve

When the bucket lever is moved to the TILT position, the dump spool is held at the TILT position by the cam follower and cam on the lever, and the bucket tilts.

SEW01739

Proximity

switch for bucketpositioner

SEW00192

Bucket

Proximil:

lo-164

switch

Det‘ector

*PPC

lever

valve

STRUCTURE AND FUNCTION

BUCKET POSITIONER AND BOOM KICK-OUT

When the bucket tilts and reaches the set position for the bucket leveler, in other words, the sensor (steel plate) separates from the detection surface of the proximity switch, electric current is sent to the solenoid by the action of the proximity switch and relay circuit. As a result, the solenoid is actuated, and the cam is pulled away from the cam detent, so the dump spool is returned to the HOLD position by the return spring.

Proximity switch for bucket positioner To battery relay

Positioner Positioner

relay

solenoid

SEW00196

Cam Bucket

lever

\ Proximity

switch

Solenoid

t)etector +PPC

valve

SEW01741

Action of proximity switch When sensor is in position at detection surface of proximity switch

When sensor is separated from detection surface of proximity switch

Proximity switch actuation display

Lights up

Goes out

Positioner relay

Current flows

Current is shut off

Current flows

Position

Solenoid (for bucket)

lo-165

STRUCTURE AND FUNCTION

CAB

1. 2. 3. 4.

Front glass Front wiper Rear wiper Door SEW01531

10-166

STRUCTURE AND FUNCTION AIR CONDITIONER

AIR CONDITIONER

SEW01742

1. Air vent 2. Air conditioner unit 3. Condenser 4. Dry reservoir 5. Compressor 6. Joint 7. Air vent

A. B. C. D. E.

Cooler outlet port Drain Cooler inlet port Hot water inlet port Hot water outlet port

lo-167

STRUCTURE AND FUNCTION

AIR CONDITIONER

UNIT

3 1. 2. 3. 4. 5.

AIR CONDITIONER

Hot water inlet port Hot water return port Refrigerant gas inlet port Refrigerant gas outlet port Defumidifier water drain

FUNCTION The air conditioner acts to provide a pleasant operating environment for the operator, thereby reducing operator fatigue.

SEW01533

Heating . The heating system uses the cooling water from the engine. Hot cooling water flows to the air conditioner unit from hot water pickup port (I), and hot air is blown out by the fan. When the temperature of the cooling water goes down, it is returned to hot water return port (2) and flows as cooling water for the engine. Cooling The refrigerant gas is compressed and pressurized by the air conditioner compressor and enters the air conditioner condenser. It is then cooled by heat dissipation, enters the air conditioner unit, and cold air is blown out by the fan. When the temperature of the refrigerant gas rises, it is returned to the compressor. l

10-168

STRUCTURE AND FUNCTION

AIR CONDITIONER

AIR CONDITIONER CONDENSER

1. 2. 3. 4.

Electric wiring Fan Refrigerant gas inlet port Refrigerant gas outlet port

AIR CONDITIONER COMPRESSOR

1. 2. 3. 4.

Refrigerant outlet port Refrigerant inlet port Relief valve Clutch

Specifications Type: Piston pump type Refrigerant used: R134a

10469

STRUCTURE AND FUNCTION

AIR CONDITIONER

DRY RESERVOIR

1. 2. 3.

10470

Body Drier Filter

STRUCTURE AND FUNCTION

AIR CONDITIONER

ELECTRIC

AIR CONDITIONER

CIRCUIT

Condenser _________________? Air-conditioner r--------------7

relay

r_--___,

;

r-- ----.

Condenser i___________, relay

4 /ml L-

__ _.

.-i

j L__-_____J

A/C

<OFF

L___~____________J

switch

Blower

switch

-_-_-_-_-_-_-_-_-_-_-_-______________________ Air

conditioner

unit

;-i,,,;,;

__-_-_-_-_--_-A

j L&&__J L______-_-_________ TPS

Blower

unit

I SDWDl743

10-171

ELECTRIC CIRCUIT DIAGRAM

STRUCTURE AND FUNCTION

ELECTRIC CIRCUIT DIAGRAM *

For details of this page, see 90-9 page. ._

10472

STRUCTURE AND FUNCTION

For details of this page, see 90-11 page.

ELECTRIC CIRCUIT DIAGRAM

STRUCTURE AND FUNCTION

MACHINE WITH JOYSTICK STEERING *

For details of this page, see go-13 page.

ELECTRIC CIRCUIT DIAGRAM

STRUCTURE AND FUNCTION

MACHINE

MONITOR

Warnina

lamp

MACHINE MONITOR SYSTEM

SYSTEM

Warnine

buzzer

OUTLINE l

The machine monitor system uses the sensors and other devices installed to various parts of the machine to observe the condition of the machine. It processes this information swiftly and displays it on the monitor panel to inform the operator of the condition of the machine. The machine monitor system consists of the monitor panel, sensors, alarm buzzer, warning lamp and power source. The displays can be broadly divided into the following: Cautions displayed on the monitors (abnormalities in the machine where an alarm is given) and normal conditions which are always displayed on the instrument panel (pilot lamps and readings for the gauges, speedometer, and service meter).

10-175

MACHINE MONITOR SYSTEM

STRUCTURE AND FUNCTION

MONITOR PANEL

SEW01541

1. Check IA. Brake oil level IB. Engine oil level IC. Coolant level 2. Caution (Warning) 2A. Battery charge 2B. Fuel level 2C. Transmission oil filter clogged 2D. Main steering failure 3. Caution (Emergency warning) 3A. Brake line failure 3B. Engine oil pressure 3C. Coolant level 3D. Air pressure 3E. Coolant temperature 3F. Torque converter oil temperature

10476

4. Pilot indicator 4A. Transmission cut-off 4B. Parking brake 4C. Work lamp 4D. Preheat monitor 5. Gauge 5A. Air pressure 5B. Coolant temperature 5C. Torque converter oil temperature 5D. Fuel level 6. Flasher Indicator 7. Speedometer 8. Head lamp (High beam) 9. Service meter 10. Service meter indicator 11. Cap

MACHINE MONITOR SYSTEM

STRUCTURE AND FUNCTION

The monitor consists of the following components. CHECK module, CAUTION module, gauge module, 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. The panel uses a liquid crystal display. CHECK, and CAUTION modules all use common parts. The microcomputer judges which module it is from the wiring harness to which it is connected.

INDICATION

5 G 0

Cate- gory

Symbol

i! OCJ Iii2 mi=

ON MONITOR PANEL Indication item

Indication range

Description

Brake

""""""""""""""""""""172160

Displayed when starting to ON with engine

Engine

y% ok

WV) 5

is running. Display flashes

Transmission oil --b o AE406940 filter clogged

‘u’ AE070330

V (0) 0

AL404450

Differential pressure above specified level (0.26 MPa 12.7kg/cm%

Main steering failure

When main steering circuit failure

Brake line failure

When stroke is over. Below specified pressure

is running. Display goes out when normal. Display flashes and lamps flash at same time.

Displays when engine is running. Display goes out when normal. Display flashes when abnormal. Displays when engine is running. Display goes out when normal. Display flashes when abnormal; buzzer and lamp actuated.

10-177

STRUCTURE AND FUNCTION

Category

Symbol

MACHINE MONITOR SYSTEM

Indication item

Indication range

Coolant level

Below low mark

Description

TD104320

Displays when engine is running.

Torque converter oil temperature

Above 130°C

Parking brake

When operated

A0061040

When operated

0 &

hlAu04480

5 ii:

Work

Transmission

Iamp

A0061070

cut-off

PREHEAT w

When operated

Display when starting switch is turned ON. Lights up when operated.

When preheating

0172160

El d

5 L

Travel speed SO10l642

= = -

High beam SO1ol645

H F

% --w 2; G’

,E,,

Flasher indicator (right I left)

0 - 100 km/h (0 - 100 HPH)

Digital display

When operated Displays when starting switch is turned ON; lights up when operated. When operated

1 Hazard

When operated

Service meter

0 99999th displayed

50101646

Lights up when operated. ,4;4$!d

when engine oil pressure is

Advances 1 for every hour of operation

meter 0 SOIO,MllService indicator

Flashes when service meter is operating.

Red

11. 0 8. 7

Air pressure

7. 5

Green

6. 7 6. 0

Red

2. 7

SD"01704

lo-178

One lamp lights up to indicate level.

MACHINE MONITOR SYSTEM

STRUCTURE AND FUNCTION

Category

Symbol

Indication

item

Indication

range

Description

106'C

Red

lDZf3'(

Coolant temperature

97-c 90-C

Green

One lamp lights up to indicate

level.

One lamp lights up to indicate

level.

BO'C 67-C

White

H130-c

Red

12O'C

Torque converter oil temperature

11O'C 90-c

Green

7D'C 50-c

C-

Green

FULL

All lamps light up below level.

Fuel lever AL404430 Red

EMPTY

WIRING HARNESS

CNPl (1 6P) cNP4 (12P)

CNP3 (1 6P)

, CNP3

@ CNP4

cNP5

indicated

STRUCTURE AND FUNCTION

3. 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 night lights will light up for several seconds. 2) CHECK MONITOR GROUP a) All 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 -IO%), the flashing interval will change slightly, but this is not an abnormality. 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).

lo-180

MACHINE MONITOR SYSTEM

STRUCTURE AND FUNCTION

SENSORS

Function The signals from the sensors are directly input to the monitor panel. With contact type sensors, one side is always grounded to the chassis. When the contacts are closed, the panel recognizes the signal as a normal signal. The sensor signal for the engine oil pressure is reversed by the relay.

Sensor actuation table Check item Engine oil level

Sensor type

When normal

When abnormal

Contact

OFF

Coolant level

Contact

OFF

Brake oil level

Contact

OFF

Fuel level

Resistor

Coolant temperature

Resistor

Torque converter oil temperature

Resistor

Engine oil pressure

Contact

Travel speed

Solenoid

Brake line failure Transmission

oil filter clogging

OFF

Contact

OFF

Contact

OFF

ENGINE OIL LEVEL SENSOR t

Circuit

1. Connector 2. Wire 3. Plug 2)

4. 5.

Float Switch

structure SEW01749

COOLANT LEVEL SENSOR

i-u=-

mrl[ 1. Connector

2. 3.

Wire Plug

4. 5.

Float Switch

Circuit

structure SEW01750

lo-181

MACHINE MONITOR SYSTEM

STRUCTURE AND FUNCTION

BRAKE OIL LEVEL SENSOR

Circuit

structure SEW01750

2. 3.

Connector Wire Plug

4. 5.

Float Switch

FUEL LEVEL SENSOR

Circuit

structure

SEW01751

1. 2. 3. 4.

10482

Float Contact Connector Variable resistor

MACHINE MONITOR SYSTEM

STRUCTURE AND FUNCTION

COOLANT TEMPERATURE, I

TORQUE CONVERTER OIL TEMPERATURE

SENSOR

00 Circuit

structure SEW01752

4. 5.

1. Connector 2. Wire 3. Tube Coolant temperature) (Yellow: (Black: Torque converter oil temperature)

ENGINE OIL PRESSURE SENSOR

@ @

Plug Thermistor

Structure

1. Plug 2. Contact ring 3. Contact 4. Diaphragm 5. Spring 6. Terminal

of circuit

PARKING BRAKE SENSOR

SEW01 753

I. Connector

2. 3.

Wire Switch

4. 5.

Diaphragm Plug

lo-183

STRUCTURE AND FUNCTION

MACHINE MONITOR SYSTEM

SPEEDOMETER SENSOR

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

B Circuit

Connector Core Coil Magnet Case Boot

structure SDWOl754

BRAKE LINE FAILURE SENSOR

@y-D Circuit

structure SEW01755

1. Ball

2. 3.

IO)

4. 5.

Shaft Switch

TRANSMISSION

Wire Connector

OIL FILTER CLOGGED SENSOR

a Circuit

1. Connector 2. Wire

lo-184

3. 4.

Boot Body

structure SEW01756

STRUCTURE

11)

AND

FUNCTION

MACHINE

MONITOR

SYSTEM

AIR PRESSURE SENSOR

1. 2. 3. 4. 5.

Connector Ventilation tube Wire Resistor Resistor selector

contact

Circuit structure SEW01757

12)

EMERGENCY STEERING OPERATION SENSOR

SEW01562

1. Shaft 2. Body 3. Terminal

4. 5.

Wire Connector

lo-185

STRUCTURE AND FUNCTION

ENGINE STARTING

Engine

stop

ENGINE STARTING CIRCUIT

CIRCUIT

motor

Alternator Engine motor

s too re lau

j=+@

Starting

motor

Startino switch C

ACC Battery

FUNCTION A neutral safety circuit is employed to ensure safety when starting the engine. With this circuit, it is impossible to start the engine if the directional lever is in any position other than N (Neutral).

OPERATlON When the directional lever is placed at N (neutral), the neutral contacts of the directional lever switch close. In this condition, if the starting switch is turned to the START position, electric current flows in the following circuit. 1) Battery (+) + starting switch terminal B -+ starting switch terminal C + starting motor terminal S + starting motor terminal E + directional lever switch terminal N + ground connection. In addition, current also flows from starting switch terminal BR + battery relay coil + ground connection, so the switch of the battery relay coil is closed. l

10-186

When the battery relay switch is closed, electric current flows from battery I+) + starting switch terminal B --, starting switch terminal ACC + engine stop motor relay coil -+ ground connection. When this happens, the circuit between engine stop motor relay contacts (3) and (5) becomes continuous. In this condition, electric current flows from battery (+) + engine stop motor terminal B + engine stop motor terminal P2 --, engine stop motor relay + engine stop motor terminal A -+ ground connection. As a result, the engine stop motor is actuated to cancel the fuel cut, so a circuit is formed battery (+I + battery relay + starting motor terminal B, and the engine starts. If the directional lever is in any position other than N (Neutral), the circuit in Item 1) is not formed, so the engine does not start.

STRUCTURE AND FUNCTION

ENGINE STOP CIRCUIT

Engine

stop

motor

Alternator Engine motor

stop relay

Directional

lever OF OR

Start in0 switch Battery

-SDW01760

OPERATION . When the starting switch is turned OFF, current stops flowing to the coil of the engine stop motor relay. No electric current flows, so the continuity between relay contact (3) and (5) is shut off, and the circuit between contacts (3) and (6) becomes continuous. When this happens, current flows from battery (+) + engine stop motor terminal B + engine stop motor terminal PI + engine stop motor relay (contact 3 and 6) -+ engine stop motor terminal A + ground connection. When current flows in the above circuit, the fuel supply is cut, and the engine stops.

10487

PREHEATING CIRCUIT

STRUCTURE AND FUNCTION

PREHEATING

CIRCUIT

PREHEATING AND POST-HEATING PREHEATING SWITCH

USING

Electrical air heater

intake

To machine (to display

monitor Pilot)

SOW01761

Function An electric fuel cut device is used, so the starting switch cannot be used to carry out post-heating operations in cold areas. (Postheating is carried out after starting the engine to heat the intake air by passing electricity through an electrical intake air heater in order to stop the discharge of white smoke from the exhaust quickly.) If you attempt to carry out post-heating with the starting switch, the switch passes through the OFF position before reaching the HEAT position, so the engine stops.) As a result, to carry out post-heating operation, a preheating switch is used.

10488

Operation c When the starting switch is ON, if this preheating switch is turned ON (moved up and held in position), current flows to the followinn circuit. 1) Starting switch terminal BR + preheating switch + electrical intake air heater relay terminal (I) + electrical intake air heater relay terminal (2) + ground connection. In addition, current flows from starting switch terminal BR + electrical intake air heater relay terminal (3) -+ electrical intake air heater relay terminal (5) + heater relay coil + ground connection, and the heater relay circuit is closed. 2) The starting switch is ON and the battery relay is closed, so current flows from battery (+I --, battery relay + heater relay + electrical intake air heater 4 ground connection, and the engine is preheated (or post-heated). . If the preheating switch is released, it automatically returns to AUTO.

PREHEATING CIRCUIT

STRUCTURE AND FUNCTION

PREHEATING WITH STARTING SWITCH

Electrical air heater

Heater relay

lnni

o Electrical

To machine (to display Electrical air heater

intake

monitor Pilot) intake

Start swi tc

i__-

L__i

Battery

SDW01762

Operation . If the starting switch is turned from the OFF position one stage to the left to the HEAT position, electric current will flow from starting switch terminal B to terminals BR and RI. 1) The current from terminal BR flows from starting switch terminal BR + battery relay coil + ground connection, and the battery relay is closed. In addition, the current from terminal (I) flows from starting switch terminal RI + electrical intake air heater relay terminal (I) + electrical intake air heater relay terminal (2) + ground connection. 2) When current flows in the above circuit from terminal RI to the ground connection, current also flows from starting switch terminal BR + electrical intake air heater relay terminal (3) -+ electrical intake air heater relay terminal (5) -+ heater relay coil -+ ground connection, and the heater relay is closed.

Because of the circuits in Items 1) and 2), electric current from the battery flows from battery (+) + battery relay + heater relay -+ electrical intake air heater + ground connection, and the engine is preheated.

lo-189

STRUCTURE AND FUNCTION

AUTOMATIC .

PREHEATING CIRCUIT

PREHEATING

During automatic preheating Electrical

To machine (to disPlav

heater

Battery

intake

monitor Pilot)

relay

When traveling (not being preheated)

Electrical air heater

Heater relay

To machine (to display Electrical air heater

tr--i-

monitor Pilot) intake

tr--i-

Battery

10490

intake

SDWOl764

STRUCTURE AND FUNCTION

PREHEATING CIRCUIT

OPERATION . In cold weather, if the starting switch is turned to ON, the temperature is low, so the bimetal timer contacts are closed and current flows in the following circuit. 1) Battery (+I + starting-switch terminal B -+ starting switch terminal BR + bimetal timer terminal (2) + circuits 2) and 3). 2) Current flows from bimetal timer terminal (3) + ground connection. 3) Current flows from bimetal timer terminal (I) + preheating switch AUTO terminal + preheating heater switch COM terminal + electrical intake air heater relay terminal (I) + electrical intake air heater relay terminal (2) + ground connection, and terminal (3) and terminal (5) of the electrical intake air heater are connected. When terminal (3) and terminal (5) of the electrical intake air heater are connected, current flows from starting switch terminal BR + electrical intake air heater terminal (3) -+ electrical intake air heater terminal (5) + heater relay coil + ground connection, and the heating relay is closed. 4) When the heater relay is closed, electric current flows battery (+I 4 battery relay -+ electrical intake air heater + ground connection, and the engine is preheated. * The starting switch is at ON, so the battery relay is closed. .

When the engine is preheated, current flows from circuit 2) to the resistor inside the bimetal timer. When this happens, the resistor generates heat, and the bimetal between terminal (I) and terminal (2) of the bimetal timer is heated. As a result, after some time (the time depends on the ambient temperature), the bimetal turns and closes. Circuit 3) is shut off, and electric current stops flowing to the heater relay coil, so the heater relay is opened and preheating finishes. Even after preheating has stopped, current flows between terminals (2) and (3) of the bimetal timer, so the bimetal is always heated. For this reason, the bimetal does not return to its original position until the starting switch is turned OFF, so no preheating is carried out after the engine starts.

10-191

ELECTRICAL TRANSMISSION

STRUCTURE AND FUNCTION

ELECTRICAL TRANSMISSION

CONTROL

CONTROL Kick-down switch ILift control lever) \

Combination

Relars(inside

rioht

console)

switch

wiring

harness Fure(inside rioht console)

SEW01766

FUNCTION

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. If the directional lever is placed in R or N, the transmission automatically returns to 2nd.

Transmission cut-off function

Transmission operated.

Transmission cut-off selection function

Selects if transmission cut-off function is used or not used. With this funciton, 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 FORWARD-REVERSE 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

10492

returned to neutral when

left brake pedal is

When the machine is driven in reverse, a back-up lamp lights up and a back-up horn sounds to warn people standing near the machine.

ELECTRICAL TRANSMISSION

STRUCTURE AND FUNCTION

COMBINATION

CONTROL

SWITCH

SEW01570

OUTLINE The FORWARD-REVERSE lever has three contacts; the speed control lever switch has three 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 l

FORWARD-REVERSE lever switch

3 1 Speed control lever switch

the desired position, the switch, which is connected by a shaft, moves and electric current flows in only that circuit to move the machine. The length of the FORWARD-REVERSE lever and the speed control lever can be adjusted by the adjusting screw.

Selecting FORWARD, REVERSE or NEUTRAL Selecting machine speed range Prevents speed control lever from going into 3rd speed during operations

Speed control lever stopper

4 /

Direction indicator lamp

Self cancel

Returns direction indicator lamp lever to neutral automatically after turnina left or riaht

Lamp switch

Selects clearance lamps, handlamps, parking lamps

Dimmer switch

Selects travel beam, low beam

8 1 Emergency flasher switch 9

Emergency flasher pilot lamp

1 Indicates direction when turning left or right

Makes left and right winkers flash at the same time Lights up when emergency flasher lamp is on.

10-193

STRUCTURE AND FUNCTION

TRANSMISSION l

ELECTRICAL TRANSMISSION

CONTROL

CUT-OFF SELECTOR SWITCH

When the left pedal is operated, the switch detects the air pressure in a brake circuit. It shuts off the power supply of the solenoid valve circuit for the FORWARD-REVERSE clutch, and returns the transmission to neutral. Brake

valve

(R.

From Relay

brake

oil

tank

valve

From air t

To front

brake

Two-wa valve T/M

Brake

valve

(L. H.)

cut-off

selector

switch

From Relay

brake

oil

tank

valve

To rear

L-1,

brake

SDW01767

11-----

Turnins point _ Low PreSSUre

::,

Starting point High Pressure SDW01768

10-194

STRUCTURE

AND

TRANSMISSION l

Transmission

FUNCTION

ELECTRICAL

TRANSMISSION

CONTROL

CUT-OFF ELECTRIC CIRCUIT cut-off selector

To machine

switch at OFF.

Neutralizer (battery

Transmission cut-off selector switch at ON and left brake is actuated.

To machine monitor +--q

relay power source)

Neutralizer (battery

relay ~o”er source)

Transmission cut-off select0 switchhnanual) iactuated

Reverse solenoid relau Battery

Starting (terminal

warI

To buck-up IalP relay

motor El

Machine monitor system neutral terminal

Battery swrce

I t 1

I I

br air

power Forward relar

~oleno

Startino (terminal

motor El

Mac?ine

monitor

SDW01769

OUTLINE l

toggle switch for two circuits installed in parallel with the transmission cut-off switch at the power source end of the transmission directional circuit.

This is a waterproof

OPERATION

Transmission cut-off selector switch at OFF 1) 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 cutoff switch. 2) 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.

Transmission cut-off selector switch at ON I) 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. 2) 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.

10-195

ELECTRICAL TRANSMISSION

STRUCTURE AND FUNCTION

NEUTRALIZER

terminal

RELAY ELECTRIC

CONTROL

CIRCUIT

B1 F

d lenoid Ias

Znd-1st selector relay

relay

Startino (terminal

motor E)

Machine neutral

monitor terminal

,stea

Seed

SDWOl770

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.

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.

10-196

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.

STRUCTURE AND FUNCTION

KICK-DOWN SWITCH

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

_-I

m l-l-l

* Circuit

Switch Washer Screw Cover Body Cable

structure

SEW01771

OPERATION l

The kick-down (shift down from 2nd to 1st) operates only when the transmission is in FORWARD 2. When traveling in FORWARD 2, 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 lift lever. After this, even if the kick-down switch is pressed, the transmission remains in FORWARD 1.

The kick-down is canceled (or will not operate) under the following conditions. l

. l

l l

When the directional lever is at N When the directional lever is at R When the speed control lever is at any position other than 2 When the parking brake is applied When the starting switch is at OFF

10-197

STRUCTURE AND FUNCTION

KICK-DOWN SWlTCH

KICK-DOWN ELECTRIC CIRCUIT Normally ON

Parkinn

Sta;linc

To machine monitol

sritchlnsnual)

terminal

brake

I I I

Transmission cut-off select sritchlmanuall OFF

n4r SDW01772

When directional lever is in FORWARD . If the directional lever is placed at F, current flows from battery (+I + neutralizer relay terminal (3) -terminal (5) --f 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 (I) and (21, and terminals (3) and (4) are closed. . Next, current flows from battery (+) + neutralizer relay terminal (3) - terminal (5) + transmission cut-off switch + FORWARD solenoid + FORWARD solenoid relay terminal (2) - terminal (I) + ground. The FORWARD solenoid is actuated, and the FORWARD clutches are joined.

10498

When lever is Dlaced in 2nd When the speed control lever is placed in 2nd, current flows from battery (+I -+ 2nd solenoid relay terminal (2) - terminal (I) + speed control lever switch 2nd terminal --f 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 (+) + 2nd solenoid + 2nd solenoid relay terminal (5) terminal (3) -+ Pnd-1st selector relay terminal (6) -terminal (3) -+ ground, and the 2nd solenoid is actuated to shift the transmission to 2nd. When the kick-down 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.

STRUCTURE AND FUNCTION

KICK-DOWN SWITCH

When kick-down switch is operated (When operating or traveling with speed control lever at FZI Back-up Parking ON-

brake

lam

6stop

Iamp

switch(manual1 -OFF

OFF

I !?F’Y!!

When kick-down switch is pushed ON When the kick-down switch is pressed, current flows from battery (+I --r neutralizer relay terminal (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 kick-down relay coil is actuated, and the circuits between terminals (I) and (21, and terminal (3) and (4) of the kickdown relay are closed. . A circuit is then formed from kick-down relay terminals (2) - (I) -+ 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 kick-down relay continues to be actuated. (Self-hold circuit of kick-down relay) When the kick-down relay is actuated, in the Pnd-1st 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) + l

ground. The coil of the Pnd-1st 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 Pnd-1st selector relay terminals (3) and (6) is opened, electric current stops flowing to the 2nd solenoid. When the circuit between the Znd-1st selector relay terminals (3) and (5) is closed, the electric current is switched to a circuit from battery (+) + 1st solenoid + Pnd-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 kick-down switch is pressed again, the circuit between kick-down relay terminals (I 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.

10-199

KICK-DOWN SWITCH

STRUCTURE AND FUNCTION

Cancellation of kick-down switch I (When directional lever is placed at N or RI

Back-uo

lam

hstop

lamp

smi tch c Altsrnator terminal

To machine

monitor

Transmission sritch(manuaI) cut-off air

Back-uo E z 4

IamD

switch pressure)

Starting

motor

Machine neutral

monitor terminal

system

SDeed

switch

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 (+I + neutralizer relay terminals (3) - (5) * FORWARD solenoid relay terminals (6) - (5) --, directional switch terminal F + 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 kick-down relay coil terminals (6) and (5). The kick-down relay is then reset, and the self-hold circuit is canceled. When the kick-down relay is reset, the circuit between terminals (3) and (4) of the kickdown relay is opened, so the current stops flowing in the circuit from neutralizer relay terminal (5) --f kick-down relay terminals (4)

1O-200

- (3) + 2nd-1st selector relay terminals (2) (I) -+ ground. The Pnd-1st selector relay is reset, so the circuit between terminals (3) and (5) is opened, and the circuit between terminals (3) and (6) is closed. The electric current stops flowing in the circuit from battery (+) + 1st solenoid + 2nd1st selector relay terminals (5) - (3) -+ ground, so the kick-down to 1st is canceled. Next, the circuit between terminals (3) and (6) of the Snd-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 REVERSE 2.

STRUCTURE AND FUNCTION

KICK-DOWN SWITCH

Cancellation of kick-down switch II (When speed control lever is at position other than 2nd)

Transmission cut-off select sritch(manuaI)

3rd

Back-up

lamp

5 3rd

Machine neutral

monitor terminal

system

Speed

switch

SDW01775

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 (+I -+ neutralizer relay terminals (3) - (5) --r kick-down relay terminals (2) - (I) -+ FORWARD solenoid relay terminals (4) - (3) + kick-down relay terminals (6) - (5) + speed control lever switch 2nd terminal -+ ground, and the kick-down relay is reset. When this happens, the circuit between kickdown relay terminals (I) and (2) is opened, and the self-hold 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 kick-down 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) + kick-down relay terminals (4) - (3) + and-1st selector relay terminals (2) - (I) + ground. 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 kick-down 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.

1O-201

STRUCTURE AND FUNCTION

KICK-DOWN SWITCH

Cancellation of kick-down switch Ill (When parking brake is applied)

Back-up Partine

To machine

brake

Iamp

6stoo

Iamp

switch(nanual1

nonito

Transmission cut-off setact sritchhuanual)

Startinu

motor

Machine neutral

monitor terminal

system

z4r

If the parking brake switch is turned ON (brake applied), electric current stops flowing 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 kick-down relay and 2nd1st selector relay are reset, and the actuation of the kick-down is canceled. When the Pnd-1st selector relay is reset, the circuit between terminals (3) and (5) of the 2nd-1st selector relay is opened, electric cur-

1O-202

SDW01776

rent stops flowing to the 1st solenoid, and the circuit between terminals (3) and (6) is closed, so a circuit is formed from battery (+I + 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 kick-down 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.

STRUCTURE

AND

ELECTRICAL

FUNCTION

PARKING

BRAKE CONTROL

ELECTRICAL PARKING BRAKE CONTROL

SEW01561

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

Spring cylinder Parking brake valve Parking brake switch Brake oil tank Wet air tank (Rear brake line) Dry air tank (Rear brake line) Dry air tank (Front brake line)

OUTLINE When electric current flows to the parking brake valve (solenoid valve), air pressure from the air tank (wet tank) is applied to the spring cylinder and the parking brake is released. . When the electric current is stopped, the air pressure from 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. l

1O-203

ELECTRICAL PARKING BRAKE CONTROL

STRUCTURE AND FUNCTION

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

It is dangerous if the parking brake can be canceled simply by turning the starting switch on after the automatic parking brake has been applied. Therefore, to ensure safety, the system is designed so that the brake cannot be canceled unless the parking brake switch is turned ON (brake applied) after the starting switch is turned to the ON position.

Neutralizer

If 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

Laroe size multi-Pin (3 pole bluejwith

lock

connector

‘nvl

Water Proof 0-rino for Panel face

1 O-204

Connection

table

chloride

OFF(released) SEW01778

z Ki ;:

STRUCTURE AND FUNCTION

ELECTRICAL PARKING BRAKE CONTROL

PARKING BRAKE VALVE Valve actuation table

Exhaust Pori

brake

chamber

From

air

OFF I

I o-j--o I

tank

No. I

Port

No.3

I SEW01779

PARKING SAFETY RELAY NEUTRALIZER RELAY Relay

connection 5

Relay actuation table

chart

2’

1 2

3 Terminal

No. 2

Terminal I

Terminal

No. I

Terminal

No. 6 SEW01780

EMERGENCY BRAKE SWITCH

Diaphragm

contact

SEW01781

1O-205

STRUCTURE AND FUNCTION

STARTING

SWITCH

Battery

ELECTRICAL PARKING BRAKE CONTROL

OFF

Batteryreiau ON-

OFF

To transmission directional circuit

V Starting

switch To transmission chanoino apeed

v circuit

SDW01782

When the starting switch is turned OFF, the battery relay is opened, so no electricity flows to the parking brake circuit. For this reason, 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)

1O-206

ELECTRICAL PARKING BRAKE CONTROL

STRUCTURE AND FUNCTION

STARTING

SWITCH

P-l.When parking brake switch is turned ON before starting switch is turned ON.

Battery

Batteryrelay

ON-

lam

stopIamP

OFF

EnerltnCY brake switch

Starting motor, (B terminal)

Parking brake safety relay

Battery relay

Battery

Back-up

valve

Start

ino

switch To transmission chanoinc speed

f circuit

SDW01763

’

Electric current flows as follows. 0 Battery (+I --f starting switch + battery so the relay coil -+ ground connection, battery relay is CLOSED. Electric current also flows as follows. @ Battery (+) + battery relay + parking brake switch terminal “3” + parking brake switch terminal “2” + parking safety relay terminal “2” + parking safety relay terminal “1” + ground connection. When this happens, the parking safety relay is actuated and circuit is closed. Therefore, the following circuit is formed.

Battery (+) -+ battery relay + parking safety relay terminal “3” + parking safety relay terminal “5” + parking safety relay terminal “2” --f parking safety relay terminal “1” + ground connection. The circuit of the parking safety relay remains closed because of circuit @I until the starting switch is turned OFF. In this condition, no electric current flows to the parking brake valve, so the parking brake is actuated. Also, in this condition, the circuit between terminal “3” and “5” of the neutralizer relay is open, so no electric current flows to the FORWARD-REVERSE circuit of the transmission, and the transmission is kept in neutral.

1 O-207

STRUCTURE

AND

FUNCTION

ELECTRICAL

PARKING

BRAKE CONTROL

2-2.Parking brake switch turned OFF (released) before starting switch is turned ON.

Battery

Back-UP

relay

ON-

Startino motor -I (B terminal)

lamp

stop

IBID

OFF

brake

switch

Battery

Startino

switch To transmission chanoina speed

t circuit

SDW01784

Electric current flows as follows. @ Battery (+I + 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. 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.

1O-208

STRUCTURE

ELECTRICAL

AND FUNCTION

Parking brake OFF (released), switch is turned ON.

PARKING

BRAKE CONTROL

after starting

Back-up

Ian~ 6

stopland

Parking brake valve

Startine

switch To transmission chanoino weed

i circuit

SDYOl765

When the parking brake switch is turned from the ON (applied) position to the OFF (released) position, the circuit between terminals 1 and 2 of the parking brake switch is connected and the operation of the parking brake safety relay is continued, so 0 electricity flows from battery (+I + battery relay + parking safety relay + parking brake switch to @ and @ below. @ a circuit is formed from emergency brake switch + parking brake valve -+ ground, so the parking brake is released. At the same time,

a circuit is formed from battery (+I -+ battery relay + neutralizer relay terminal 3 + neutralizer relay terminal 5 -+ transmission directional circuit, so the machine moves when the transmission switch is operated to FORWARD or REVERSE.

1 O-209

STRUCTURE AND FUNCTION

ELECTRICAL PARKING BRAKE CONTROL

Parking brake switch on (operated)

g$Lg_lll -__ P--,-__: Battery

Batteryrelay

Starting motor -I (B tsrminal)

Battery

BR Stsrtino

Alternator R terminal

?i%

t To transmission directional circuit

switch To transmission chanoino weed

1 circuit

SDWOl786

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.

10-210

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-REVERSE circuit 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.

STRUCTURE

AND

FUNCTION

When air pressure actuated)

Startino

drops (emergency

ELECTRICAL

PARKING

BRAKE CONTROL

brake

motor

brakeswitch

Startino

switch To transmission chanaina weed

When the air pressure goes down, the emergency brake switch installed to the wet tank is opened. As a result, the electric current does not flow to the parking brake valve, so the air pressure inside the spring cylinder is released and the parking brake is actuated. However, this case is different from the case when the parking brake switch is turned ON (applied), because electricity flows to the coil of the neutralizer relay.

’ circuit

As a result, electricity flows to the transmission directional circuit, and it becomes possible to engage the transmission clutch. Because of this, when the emergency brake is actuated, the engine brake can also be used, so it is possible to reduce the braking distance. At the same time, if the emergency brake is actuated and it is necessary to move the machine (for example, if the emergency brake is applied on a railroad crossing), it is possible if the transmission lever is operated.

10-211

STRUCTURE AND FUNCTION

TRANSMISSION

CLUTCH OVERRUN

CLUTCH OVERRUN CONTROLLER

CONTROLLER

Mounting

FUNCTION An overrun prevention controller is installed to prevent the 3rd clutch from overrunning when the speed switch is at 1st and the directional switch is at N (Neutral), and the machine is allowed to coast downhill by mistake. This protects the transmission clutch.

10-212

position

1. Cover

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

Base Clip Printed card Steering tower Controller Relay

TRANSMISSION

STRUCTURE AND FUNCTION

Soeedmeter

Battery

sensor

CLUTCH OVERRUN CONTROLLER

Power Neutral (batter

Battery source verrun

Dower

izer re lau ‘Y Power source)

Transmission cut-off selector switch (manual)

controller

OFEN

Transmission (air oressore

cut-off switch actuator)

-r Machine neutral

monitor terminal

Starting (terminal

motor El

system

switch

SOW01789

OPERATION The controller detects the position of the directional switch and the machine speed, and if the directional switch is at N (Neutral) and the travel speed is 12 km/h, current flows from controller terminal 3. The circuit between relay terminals 3 and 6 is then opened, so the current flowing to the transmission solenoid is cut and the 1st clutch is set at neutral. l

10-213

TESTING AND ADJUSTING

Standard Standard

value table for engine ....................... 20- 3 value table for chassis.. ..................... 204 Standard value table for electrical system ...... 20- 7 Tools for testing, adjusting, and troubleshooting .................................... 20-101 Adjusting valve clearance. ................................. 20-102 Measuring compression pressure.. ................... 20-103 Testing and adjusting fuel injection timing.. ... 20-104 Checking for abnormality in fuel level sensor.. .................................... 20-106 Measuring accelerator pedal operating force.. ........................................... 20-107

steering oil pressure ......................... emergency steering pressure.. ........ Adjusting joystick steering.. ............................... Measuring brake pedal ....................................... Measuring air pressure ...................................... Testing brake performance.. .............................. Checking brake piston leakage .......................... Measuring wear of brake disc ........................... Bleeding air from brake system.. ...................... Testing parking brake performance.. ................ Checking and adjusting parking brake ............. Measuring dump and lift control levers ..........

Measuring accelerator pedal operating angle.. ..........................................

Measuring 20-109

Measuring

20-I 11

shift lever.. ........................................

Measuring Measuring

engine stall speed ........................... 20-I 12 Measuring oil pressure of torque converter and transmissision ........ 20-l 14 Method for operation of emergency manual spool ........................... 20-I 17 Tire and wheel ..................................................... 20-I 18 Measuring steering wheel play .......................... 20-I 19 Measuring operating force and time of steering wheel .................................

20-124 20-127 20-128 20-130 20-131 20-132 20-133 20-134 20-135 20-137

pressure

of work equipment ...................................... Air bleeding from piston pump ........................ Measuring work equipment.. .............................

Measuring

z Ki

hydraulic

20-121 20-122

20-139 20-142 20-143

Measuring hydraulic drift of work equipment ......................................

20-120

20-144

Adjusting bucket positioner.. ............................. Adjusting boom kick-out.. .................................. Adjusting machine monitor (speedometer module). ...............................

20-145 20-146

TROUBLESHOOTING

20-201

. . . . . . .._.__..............................

When using the standard value table to make judgement following precautions are necessary.

The standard values in the table are the values for a new machine and are given as reference values for the time when the machine is shipped from the factory. These values should be used as a guide when estimating wear and tear after the machine is operated, and when carrying out repairs.

The permissible values given in the table are values estimated based on the results of various tests carried out on the machines shipped from the factory, so they should be used together with the information on the repair condition and other information such as the operating history of the machine when judging the condition of the machine.

These

standard

When safety

carrying out testing, adjusting, or troubleshooting, park the pins and blocks to prevent the machine from moving.

When carrying out work together near the machine.

When checking the water level, always wait for the water to cool down. the water is still hot, the water will spurt out and cause burns.

Be careful

values

do not form

not to get caught

a basis for judging

with

other workers,

for testing

20-147

and adjusting,

and troubleshooting,

the

claims.

always

in the fan, fan belt, or other

machine

on level ground

and use the

use signals and do not let unauthorized

rotating

If the radiator

cap is removed

people

when

parts.

20-l a

STANDARD VALUE TABLE FOR ENGINE

TESTING AND ADJUSTING

STANDARD

VALUE TABLE FOR ENGINE Engine

SAI

Measurement

Item

conditions

Unit

Standard

High idling Engine

2,250 f 50

Low idling

speed

650 +;

rpm

Rated speed At sudden Exhaust

acceleration

Max.

Bosch

Permissible

5.0

value

2,250 + 50 650

2,000

2,000 7.0

gas color At high idling

index

Intake valve Valve clearance (cold)

Compression (SAESO oil)

Exhaust

valve

1.5

2.0

0.43

0.80

1.47 11501

2.94 13001

0.25 - 0.39 12.5 - 4.01

0.18 II.81

Min. 0.12 {Min. 1.21

0.07 IO.71

Min. 0.10 {Min. 1.01

0.07 IO.71

80-

120

pressure

(Water Blowby (SAE30

value

2V140

pressure oil)

temperature: Operating range)

At high idling (Water

temperature: Operating range)

At high idling (SAESO) MPa

Oil pressure At low idling

(SAEBO) ‘kg’cm21 At low idling (SAEIOW) Whole speed range (inside oil pan)

Oil temperature

Fuel injection

timing

Before

top dead center

“C

(degreeI

I Belt tension

110

30 f 1

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

20-3 0

TESTING

AND

STANDARD Cats gcr

STANDARD

ADJUSTING

Measurement

force

Operating

angle

Stopper

conditions

Unit

Low idling

N{kgl

TLW01244

height l

Operating

TABLE

FOR

CHASSIS

VALUE TABLE FOR CHASSIS

Item

Operating

VALUE

Engine

stopped

I mm

N-FORWARC

force

&I N-REVERSE

N-FORWARD

Standard

value

58.8 161

Max. 88.3 {Max. 91

5.9 k2.9 IO.6 f 0.3)

Max. 13.7 {Max. 1.41

5.9 ?I 2.9 IO.6 k 0.3)

Max. 13.7 {Max. 1.41

37 k 5

37f

37 + 5

37f

Travel N-REVERSE

Operating

1st - 2nd

5.9 k 2.9 IO.6 + 0.31

Max. 13.7 {Max. 1.41

2nd - 3rd

5.9 k 2.9 IO.6 f 0.31

Max. 13.7 {Max. 1.4)

1st - 2nd

37 f 5

force

37f

Travel 2nd - 3rd Torque stall

converter

. Engine water temperature Green range l

Hydraulic

stall l

Full stall Transmission main relief valve pressure

oil temperature:

Hydraulic oil temperature: 45 - 55°C Torque converter 60 - 80°C

oil temperature:

2.75 +;.2g I28 +;}

2.75 +;.2g {28 +;I

0.69 k 0.10 {7f I}

0.59 + 0.20 16 + 2)

Torque converter outlet pressure

0.49 + 0.10 {5? I}

0.49 f 0.10 (55 I}

Lubrication pressure

0.14 ? 0.06 Il.4 f 0.61

0.14 k 0.06 Il.4 + 0.6)

1.96 f 0.10 (20 k I}

1.96 + 0.10 120 f I}

Pilot reducing pressure Modulating pressure (Except F3, R3) Torque converter inlet pressure

valve

Reducing valve pressure (For F3, R3)

20-4 0

Torque converter 60 - 80°C

gauge:

Engine

speed:

High idling

Torque converter 60 - 80°C

oil temperature: MPa kg/cm21

iu g

TESTING

CateWY

STANDARD

AND ADJUSTING

Measurement

Item l

Fitting of wheel lock ring

Unit

conditions

Tire inflation pressure: specified pressure

VALUE

Standard

value

Max. 2.5 Max.

TABLE FOR CHASSIS

Per~ais$ble

4.0

z Clearance lock ring

5 2 3

TEW00003

Play Operating

of wheel

force

: ‘=

* Engine stopped * Machine facing straight to front * Flat, horizontal, straight, dry paved road surface l

Performance

TEW00004

Hydraulic

oil

Low idling

I+

If 0

I*,

w ul

I+

P co

I+

speed

equipment

tu 1

Work

Work equipment

roximity switch -

3 -0

I042701

Travel

Work equipment

lever

Operating force

control

TESTING AND ADJUSTING

STANDARD System

STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM

VALUE TABLE FOR ELECTRICAL SYSTEM

Name of component

Connect0

No.

Judgement

nitho

Measurement conditions

table

If the condition is as shown in the table below, the sensor is defective.

Radiator water level sensor

Short connector connected

Monitor

OFF

CN136 disconnected

Monitor

Starting switch ON

CN136 If the condition is as shown in the table below, the sensor is normal. Oil level, water level normal

Continuity

Oil level, water level abnormal

No continuity

Starting switch OFF

If the condition is as shown in the table below, the sensor is defective.

Engine sensor

oil level

CN120

Short connector connected

Monitor

OFF

CN120 disconnected

Monitor

oil level

Engine oil level abnormal

Torque converter oil temperature sensor Engine water temperature sensor

I I

If the condition is as shown in the table below, the sensor is normal. Engine normal

Air pressure sensor

Starting switch ON

Starting switch OFF

Continuity No continuity

If the condition is as shown in the table below, the sensor is normal.

Starting switch OFF

If the condition is as shown in the table below, the sensor is normal.

Starting switch OFF

CNIIO

CN121 CN123

Normal temoerature

1oo”c

(25°C)

Approx.

37 - 50 kQ

Approx.

3.5

- 4.0 kR

If the condition is as shown in the table below, the sensor is normal. Fuel level sensor

ZN127

Full tank 1 Emotv

Approx.

12 R or less

1 Aoorox.

85 - 110 R

Starting switch OFF

When engine is running (l/2 throttle or above): 27.5 - 29.5 V

Start engine

Uternator % If the battery is old, or after starting in cold areas, the voltage may rise for some time.

20-7 a

STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM

TESTING AND ADJUSTING

Systen

Name of component

Zonnector ispetior nethoc No.

Judgement

Measurement conditions

table

Starting switch ON

If the condition is as shown in the table below, the sensor is defective.

Transmission filter sensor

Emergency steering actuation sense

Brake stroke limit switch

Engine oil pressure sensor

20-8 0

CN60 CN227

Short connector connected

Monitor

OFF

CN60, CN227 disconnected

Monitor

in the table

Starting switch OFF

If the condition is as shown in the table below, the sensor is defective.

Starting switch ON

If the condition is as shown below, the sensor is normal.

Short connector connected

Monitor

OFF

CN108 disconnected

Monitor

ZN108 in the table

Starting switch OFF

If the condition is as shown in the table below, the sensor is defective.

Starting switch ON

If the condition is as shown below, the sensor is normal.

Starting switch OFF

If the condition is as shown below, the sensor is normal.

:N61 :N62 IN64 :N87

in the table

Brake

normal

Continuity

Brake

abnormal

No continuity

If the condition is as shown in the table below, the sensor is defective.

Starting switch ON

If the condition is as shown below, the sensor is normal.

Engine started

in the table

Oil pressure above 0.07 MPa (0.7 kg/cm21

Continuity

Oil pressure below 0.03 MPa {0.3 kg/cm*}

No continuity

STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM

TESTING AND ADJUSTING

System

Name of component

Connector Inspection method No.

: g

: 8

Parking brake switch

Measurement conditions

table

Starting switch ON

If the condition is as shown in the table below, the sensor is defective.

Short connector connected

Monitor

OFF

I I

CN34

zn,

Brake oil level sensor

Judgement

If the condition is as shown in the table below, the sensor is defective.

Starting switch ON

CN59 If the condition

is as shown in the table

20-9 0

TESTING AND ADJUSTING

TOOLS FOR TESTING, ADJUSTING,

TOOLS FOR TESTING,

ADJUSTING,

Check or measurement iterr I 5;ym bo

Part No.

AND TROUBLESHOOTING

AND TROUBLESHOOTING Remarks

Part Name Digital

799-203-8001

Engine

speed

Multi-tachometer

6210-81-4111

Gear

6215-81-3500

drive

Ass’y

display L: 2,000 H: 60 20,000

rpm

07000-03050 01435-20630 Coolant,

1Bolt

799-101-1500

oil temperatures

Oil pressure

790-301-I 190

Nipple

Commercially available

Connector

795-502-I

Compression

590

795-502-1510

pressure

20PE gauge

I Adapter l

z 795-502-I

Ki Blowby

pressure

Valve

Exhaust

Accelerator pedal operation

Pushing

angle force

pedal operation

Brake

harnesses

Plate

799-201-1504

Blowby

795-125-1210

Feeler

gauge

799-201-9000

Handy

smoke

Smoke

meter

Commercially available Commercially available Commercially available Commercially available Zommercially evailable

Angle

793-520-I

Brake test kit

801

0 - 0.49 kPa 10 -500

checker

Push-pull

Discoloration 0 - 70% (with standard color) (E;zpration % x l/IO C Bosch

gauge

Push-pull

scale

Push gauge

parking

of and sensors

793-438- 1060

Nipple

Commercially available

Thickness

799-601-2500

T-adapter

799-603-2250

(Adapter

kit

799-603-2110

1Short

connector

mmH201

0.43, 0.80 mm checker

oil

Checking

520

0 - 6.86 MPa {O - 70 kg/cm2)

gauge

TESTING

AND ADJUSTING

ADJUSTING

VALVE

CLEARANCE

ADJUSTING VALVE CLEARANCE * *

Condition: Engine is cold, or hot. Adjust clearance between crosshead arm as follows.

and rocker unit: mm

Intake valve

Exhaust valve

0.43

0.80

Remove

the cylinder

head cover.

Rotate the crankshaft in the normal direction. While watching the movement of the intake valve of the R6 cylinder, bring the RI cylinder into the top dead center position of the compression stroke and align the “RI.6 TOP” line on vibration damper (2) with pointer (I). 1; When the RI cylinder comes near the top dead center of the compression stroke, the R6 intake valve will start to move (open).

Loosen locknut (6) of adjustment screw (5) of RI cylinder, insert the feeler gauge F corresponding to the specified clearance between crosshead (4) and rocker arm (3), and adjust the clearance with the adjustment screw until the thickness gauge can slide lightly.

Tighten locknut in this position, secure adjustment screw. m Locknut 58.8 +_ 5.9 Nm IS f 0.6 kgm1

Follow the same procedure to align the line with the pointer and adjust the valve clearance of each cylinder according to the firing order. -k Firing order: RI - Ll - R5 - L5 - R3 - L3 - R6 - L6 - R2 L2 - R4 - L4

*O-Ao2

TKWOlO61

TESTING AND ADJUSTING

MEASURING PRESSURE *

MEASURING

COMPRESSION

When carrying out a performance test or troubleshooting, if it is thought that the piston, piston ring, or cylinder liner are worn, measure the compression pressure.

measuring the compression pressure, be A When careful not to touch the exhaust manifold or other hot parts, or to get caught in rotating parts, such as the fan or fan belt. 1. Adjust the valve clearance. * For details, see TESTING AND ADJUSTING, Adjusting valve clearance.

z Ki g

Warm up the engine is 40 - 60°C.

Remove nozzle holder assembly der to be measured.

Install adapter D2 and plate D3 of tool A in the mount of the nozzle holder, then connect the compression gauge DI.

Set engine

Disconnect the wiring of the engine stop motor, crank the engine with the starting motor and measure the compression pressure. Ir

so that the oil temperature

multi-tachometer

from the cylin-

A in position.

Measure the compression pressure at the point where the pressure gauge indicator remains steady. When measuring the compression pressure, measure the engine speed to confirm that it is within the specified range.

COMPRESSION

PRESSURE

TESTING AND ADJUSTING

TESTING AND ADJUSTING FUEL INJECTION TIMING TESTING

FUEL INJECTION

1. Disconnect

fuel injection

TIMING pipe (I) of RI cylinder.

Remove delivery valve holder (2), then remove delivery valve (3) and spring (41, and install delivery valve holder (2) again.

Place accelerator

Operate priming pump and rotate crankshaft slowly in normal direction. Check point where fuel stops flowing from delivery valve holder (2).

Check that the fuel injection line of damper (5) is aligned with pointer (6) at the position where the fuel stops flowing: * BEYOND injection timing line: Timing RETARDED Ir BEFORE injection timing line: Timing ADVANCED If the test shows that the fuel injection timing is incorrect, adjust as follows.

20-104 0

pedal at FULL position.

FUEL INJECTION TIMING

TESTING AND ADJUSTING FUEL INJECTION TIMING

TESTING AND ADJUSTING

ADJUSTING FUEL INJECTION TIMING BY DELIVERY CHECK 1. Turn crankshaft center.

back 30 to 40” from

top dead

Rotate the crankshaft in the normal direction, and align the fuel injection line of damper (5) with pointer (6).

Loosen bolt (7) on the injection pump mounting flange bolt, and rotate the flange on the pump side little by little by operating the priming pump (8) until no fuel flows out of the delivery valve holder.

Tighten bolt (7) in oblong hole of mounting flange of fuel injection pump. * After tightening the nut, check again that the fuel stops flowing from the delivery valve holder at the point where the pointer is aligned with the line on the crankshaft pulley. Remove delivery valve holder (2), assembly delivery valve (3) and spring (41, then install delivery valve holder (2) again.

TEW01068

Delivery

Connect

fuel injection

holder: 32.4 f 2.0 Nm I3.3 f 0.2 kgm} pipe (I).

Sleeve nut: 23.5 f 1.0 Nm 12.4f 0.1 kgm)

TEW01069

TESTING

CHECKING

AND ADJUSTING

FOR ABNORMALITY

IN FUEL LEVEL SENSOR

CHECKING FOR ABNORMALITY IN FUEL LEVEL SENSOR If there is any marked difference between the level displayed and the amount of fuel remaining inside the fuel tank (for example, the fuel tank is full but the fuel gauge does not indicate FULL), measure the resistance at the three positions of the float shown in the diagram on the right with the fuel level sensor as an individual part. Method l

of measuring

Connect one pole to terminal (I), and touch the other pole against terminal (2) to measure the resistance. Resistance point

value

of fuel

level

sensor

at each Unit: Q

FULL (Top)

1 l/2 (horizontal)

Max. 12

(30)

1 EMPTY (Bottom) 85 - 110 EMPTY&lattom)

The standard

values

are only a guide. TLW01245

20- 106 0

TESTING AND ADJUSTING

MEASURING

ACCELERATOR PEDAL OPERATING FORCE

MEASURING ACCELERATOR PEDAL OPERATING FORCE OPERATING

FORCE

procedure

Measuring

gauge H in contact with the accelerator pedal at point 150 mm from pedal fulcrum “a”. The center of push-pull gauge H must be in contact with a point 150 mm from the pedal fulcrum. 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).

1) Put p%h-pull *

TLW01071

EW01072

Testing and adjusting

1) Stop the engine. 2) Disconnect cable (I) at the accelerator 3)

pedal, and check that the linkage move smoothly. Connect the cable at the bottom of the pedal, then disconnect at the connection for lever (2), and check that cable (I) moves smoothly. Leave cable (I) disconnect, and check that lever (2) moves smoothly.

TESTING AND ADJUSTING

MEASURING

ACCELERATOR PEDAL OPERATING FORCE

Disconnect cable (3) from servo cylinder (4) and lever (5), and check that cable (3) and lever (5) move smoothly. When carrying out this inspection, adjust or replace parts as necessary. Measure the operating force again and check that it is within the standard value. When operating force is heavy in spite of there is no abnormality in this inspection, check operation of servo cylinder (4).

z TEW01076

Fi is

20- 108 a

TESTING

AND ADJUSTING

MEASURING

ACCELERATOR

PEDAL OPERATING

ANGLE

MEASURING ACCELERATOR PEDAL OPERATING ANGLE 1.

Measuring I) Stop the engine. 2) Measure the operating angle a = CLI- ~12, put the angle gauge J in contact with the accelerator pedal it is operated from low idling and high idling.

Adjusting 1) Remove the cover at the bottom of the cab, then open the inspection cover at the rear of the cab and the engine inspection cover. 2) With the accelerator pedal at the low idling position, loosen nut (2) and adjust so that the installed length of cable (I) is XI. Standard value: X1 = 148 mm

TLW01246

Adjust joint (4) of the servo cylinder spool so that the installed length of servo return spring (3) is X2 at low idling. Standard value: X2 = 265 mm (at low idling)

XI (At

low

idling)

TLW01247

20-109 0

TESTING

AND ADJUSTING

MEASURING

ACCELERATOR

PEDAL OPERATING

ANGLE

Remove rod (5) at the engine end, and adjust the overall length to length x3. Standard value: X3 = 405 mm Temporarily assemble rod (51, install to governor lever (61, then adjust the length of rod (5) so that engine governor lever (6) contacts low idling stop bolt (7) lightly, and tighten locknut (8). + Install so that water drain hole a of the rod is at the bottom.

Start the engine, gradually depress accelerator pedal (IO), adjust length L2 of stopper (II) so that accelerator pedal (IO) and stopper (II) are in contact at the position where governor lever (6) contacts high idling stopper bolt (91, then secure with locknut (12). . Reference value: L2 = Approx. 45 mm

TLW01249

Adjusting air cylinder Loosen locknut (13) and adjust the secondary low idling by turning yoke (12) so that the clearance L3 is obtained between lever (11) at the engine end and air cylinder yoke (12) when the engine is stopped. . Standard value: L3 = 6.3 mm * After completing the adjustment, check that the engine speed is 850’i” rpm when the secondary low idling switch.

Detail

20-110 a

TKW01250

TLW01084

TESTING AND ADJUSTING

MEASURING Ir

MEASURING

SHIFT LEVER

Measurement conditions . Engine speed: Stopped Torque converter oil temperature: l

60 - 80°C

Put blocks under the wheels to stop the maALchine from moving.

MEASURING

OPERATING

FORCE

OF LEVER TLW01086

Stop the engine. Put marks a for dimension A and dimension B of the control levers. . Dimension A (directional lever, N position): 72.5 mm . Dimension B (speed lever, 2 position): 91 mm Install push-pull scale K or a spring balance to marked portion a of control lever (I), and measure the operating force when the lever is pulled in the direction of operation. * Carry out the measurement in each speed Ir

z & g

range.

MEASURING

TRAVEL

OF LEVER

Stop the engine.

Measure the travel when marked portion a of control lever (1) is moved in the direction of operation.

/IA

TEW01088

TESTING

MEASURING

AND ADJUSTING

MEASURING SPEED

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

Check that the low idling and high idling speeds are within the standard value. Before measuring the stall speeds remove cap (IA) from the rotation pick-up port, install tachodrive (IB) and gear drive (IQ, then install multitachometer A. (Prepare cable 799-203-8400 separately, and extend the cable so that the meter reaches the operator’s compartment.) 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.

Block the tires.

Ii Measuring 1. 2.

STALL SPEED

ENGINE STALL

ENGINE

torque

converter

TLW01090

stall

Start engine and run at low idling. Put the directional lever in FORWARD or REVERSE, and speed control lever (3) in the highest speed range. Using the brake, stop the machine and measure the engine speed with multi-tachometer A when the engine reaches accelerator pedal depress fully. * Turn transmission cut-off selector switch (2) to OFF, and use the left brake. (Check that the pilot lamp is OFF.) j, Do not run at stall speed for more than 20 seconds, and do not let the torque converter oil temperature rise above 120°C.

20-l 12 0

TLWOlO92

MEASURING

TESTING AND ADJUSTING

Measuring 1. 2.

hydraulic

ENGINE

STALL SPEED

stall

Start engine and run at high idling. Operate the dump or lift control lever (5) to move the cylinder to the end of its stroke and actuate the relief valve of the main control valve with multi-tachometer A. Measure the engine speed at this point. * Do not run the engine at stall speed for more than 20 seconds, and operate the control lever quickly.

Measuring full stall . Measure the engine speed with multi-tachometer A when 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, re-

move the abnormality speed again.

Speed

control

and measure the stall

20-113 0

TESTING

AND ADJUSTING

MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION

MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION Ir

Measurement conditions Coolant temperature: Inside operating range Torque converter oil temperature: 60 to 80°C

Apply the parking

Measuring *

brake and block the tires.

procedure

The following preparatory work is necessary before measuring any oil pressure. . Remove cover (I) on rear side of the cab. . Turn transmission cut-off selector switch (2) to OFF and use the left brake. (Check that the pilot lamp is OFF). . Remove the plug from the measuring port of the transmission valve. . Install hydraulic tester C to the measuring port, pull the gauge to the operator’s compartment, then start the engine and measure the pressure. Check that there is no leakage of oil from any joints.

TLW01092

TEWOIOSG

20-114 0

TESTING

AND ADJUSTING

MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION

Transmission main relief valve pressure 1) Measuring port (PO). 2) Start the engine and measure the pressure at 2000 rpm.

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.

Measuring modulating pressure 1) Measuring port (P2). 2) Put the directional lever in neutral, and measure the pressure when the speed control lever is operated. * Measure pressure except F3 and R3.

Torque converter inlet pressure I) Measuring port (PIo). 2) Start the engine and measure at high idling.

Ki is

Torque converter outlet pressure 1) Measuring port (PII) or (P12). 2) Start the engine and measure at high idling.

the pressure

Pii

the pressure

Measuring lubrication valve pressure 1) Measuring port (PSI. 2) Start the engine and measure the pressure at high idling.

Measuring reducing valve pressure 1) Measuring port (P3). 2) Start the engine and measure the pressure at high idling and low idling.

TLW01098

TESTING

AND ADJUSTING

Adjusting

procedure

Always stop pressure.

engine

before

MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION

adjusting

hydraulic

If it is impossible to measure relief pressure acculately, do not try to adjust pressure. Stop engine, then remove cover (I) on rear side of cab.

Adjusting of transmission main relief pressure 1) Loosen cap (2) to reduce spring tension. 2) Remove cover (3), and pull out plunger (41, then increase or decrease shims (5) to adjust oil pressure. * Standard shim thickness: 6.0 mm * Amount of adjustment for one shim (t = 0.5 mm): 11.8 kPa IO.12 kg/cm*} * To increase pressure, increase shims. To decrease pressure, decrease shims.

20-116 0

5’

TLW01099

TESTING

AND ADJUSTING

METHOD

FOR OPERATION

OF EMERGENCY

MANUAL

SPOOL

METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL OUTLINE l

The transmission valve is controlled electrically. Therefore, the emergency manual spool 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 A 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 safety. The emergency manual spool must never be used except when the transmission control has broken down. operating the emergency manual spool, A When follow the correct order of operation exactly, and pay full attention the machine.

E * d

to safety

when

moving

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.

2nd

1st

3rd

1. Open cover (I) on rear side of cab. 2.

Remove lock plate (3) of emergency manual spool (2) of the transmission valve. Ir Simply loosen the mounting bolts to remove the lock plate.

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 operating position.

REVERSE:

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

TLW01252

ADD~OX

‘w

Auurox.IOmm-

t ion

TKW01253

TESTING

AND ADJUSTING

TIRE AND WHEEL

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

Sit in the operator’s brake pedal fully.

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

seat, and depress

the left

the engine is started, the transmisA When sion is engaged and the machine will start. 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 and 3rd spool clockwise, and screw in approx. 10 mm to the OFF position. 7.

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.

TIRE AND WHEEL Measuring

procedure

Fitting of wheel lock ring Measure distances A and B at four places around the circumference.

Clearance of wheel Measure dimension

lock ring C.

I /I TEW00084

TLW01104

20-l 18 0

TESTING

AND ADJUSTING

MEASURING

STEERING

WHEEL

PLAY

MEASURING STEERING WHEEL PLAY * . .

Measurement condition Engine speed: Stopped Machine posture: Facing straight

Measuring

procedure

Turn the steering wheel lightly to the left and right 2 or 3 times and confirm the neutral position of the steering mechanism. Put mark (I) on the outside edge of the machine monitor.

Turn the steering wheel to the right, and when the steering wheel starts to become heavy (the steering valve lever starts to become heavy), make mark (2) on the steering wheel in line with mark (I).

Play

Turn the steering wheel to the left in the opposite direction to Step 2, and when the steering wheel starts to become heavy (the steering valve lever starts to become heavy), make mark (3) on the steering wheel, and measure the distance in a straight line between mark (2) and mark (3). TKW01254

TESTING AND ADJUSTING

MEASURING

OPERATING

MEASURING OPERATING FORCE AND TIME OF STEERING WHEEL Ir Measurement .

. . .

condition Road surface: Flat, horizontal, dry, paved surface. Coolant temperature: Inside operating range. Hydraulic oil temperature: 45 to 55°C Tire inflation pressure: Specified pressure. Engine speed: Low idling (bucket unload).

MEASURING ING WHEEL

OPERATING

FORCE

OF STEER-

Measuring procedure 1.

Hook push-pull scale K to the knob of the steering wheel. * Hook push-pull scale K to the center of knob.

Start the engine. * After starting the engine, raise the bucket about 400 mm and remove the safety bar.

Set push-pull scale K at a tangent, and read the value when the steering wheel is moving smoothly. Ir Do not read the value at the time the steering wheel starts to move.

MEASURING WHEEL

OPERATING

TIME FOR STEERING

Measuring procedure 1.

Start the engine. * After starting the engine, raise the bucket about 400 mm and remove the safety bar.

Turn the steering wheel so that the machine turned fully to the left or fully to the right.

Measure the time taken for the steering wheel to be turned to the right (left) 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.

20- 120 a

FORCE AND TIME OF STEERING

WHEEL

MEASURING

TESTING AND ADJUSTING

MEASURING PRESSURE * . .

STEERING OIL

Measurement condition Hydraulic oil temperature: Engine speed: High idling

MEASURING

MAIN

STEERING OIL PRESSURE

45 to 55°C

RELIEF PRESSURE

Loosen the oil filler cap slowly to release the A pressure inside the hydraulic tank. Then operate the steering wheel several times to release the remaining pressure in the hydraulic piping.

TEW01109

Fit safety bar (1) on the frame. Remove plug for measuring ing circuit. Install hydraulic

the left turn steer-

tester C to the measuring

port.

Start the engine and run at high idling. Turn the steering wheel to the left and measure the pressure when the relief valve is actuated. * When removing the plug for the right turn steering circuit, turn the steering wheel to the right and measure.

TESTING

TEWOIllO

AND ADJUSTING

AAlways stop the engine hydraulic pressure.

before

adjusting

the

Stop the engine.

Loosen lock nut (3), then turn adjustment screw (4) to adjust. Ir Amount of adjustment for 1 turn of adjustment screw. 1 turn: Approx. 17.8 MPa {I81 kg/cm*1 Ir Adjust the set pressure as follows. To INCREASE pressure, TIGHTEN screw. To DECREASE pressure, LOOSEN screw. * If it is impossible to measure relief pressure accurately, do not try to adjust the pressure.

37\

1 /

I II I II

( ’ I?------“‘_I ‘i--TEWOllll

TKWOI112

TESTING

MEASURING

AND ADJUSTING

EMERGENCY

STEERING

PRESSURE

MEASURING EMERGENCY STEERING PRESSURE * .

Measurement condition Hydraulic oil temperature:

MEASURING

45 to 55°C

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.

TEWOllO9

1. Fit safety bar (1) on the frame. 2.

Disconnect drive shaft (2) between transmission and center support at transmission side.

Disconnect drive shaft (3) between transmission and rear axle at transmission side.

Disconnect hose (4) to pilot port of diverter valve, replace elbow (5) by oil passage shut off elbow (for details, see next page), then connect hose (4). (As a result of this, oil pressure to pilot port of diverter valve is shut off, emergency steering is operating.)

Remove plug A for measuring between diverter valve and steering valve, install hydraulic tester.

Start engine, shift transmission gear shift lever to F3 or R3 raise speedometer until 24 km/h. Turn the steering wheel to the right and measure the pressure when the relief valve is actuated.

TEWOl113

TEW01114

TEWOl115

TEWO1116

20-122 0

TESTING

AND ADJUSTING

MEASURING

EMERGENCY

STEERING

PRESSURE

TESTING AND ADJUSTING stop the engine before adjusting the A Always hydraulic pressure. 1. Stop the engine. 2.

Remove

cap nut (6) of the relief valve.

Loosen lock nut (7), then turn adjustment screw (8) to adjust. Amount of adjustment for 1 turn of adjustment screw. 1 turn: Approx. 3.5 MPa 135.7 kg/cm*1 Adjust the set pressure as follows. To INCREASE pressure, TIGHTEN screw. To DECREASE pressure, LOOSEN screw. If it is impossible to measure relief pressure accurately, do not try to adjust the pressure. Preparatory of oil passage shut off elbow Prepare elbow (07236-10210), insert pin (dia.: 5 mm) in drilled hole, then weld pin and elbow to shut off passage.

TKWO1118

Pin (Dia. :5mm)

TKW01255

ADJUSTING

TESTING AND ADJUSTING

ADJUSTING STEERING ADJUSTING VALVE)

JOYSTICK STEERING

JOYSTICK

STOPPER

BOLT

(FOR

STOP

Preparatory work Operate the steering before adjusting the stopper bolt and check that there is contact of the

there is contact sides.

that on both the left and right

Adjusting 1. Set the stopper

bolt to the minimum

length. MInImum

TDW01034

Run the engine at low idling and operate the steering slowly to contact the frame end. In this condition, loosen the bolt to pull it out until the head of the stopper bolt contacts the tip of the stop valve spool. * Be careful not to loosen the bolt too far and push the spool.

_-_ I Lock

nut

_--

TOW01035

From this condition, turn the chassis back to make a clearance of approx. 20 mm between the tip of the stop valve and the head of the stopper bolt, then stop the engine.

From the condition in Step 3), loosen the bolt 8.5 - 9 turns (14.9 - 15.8 mm), and secure it in position with the lock nut.

Carry out Steps I) to 4) on the opposite

side.

14.9-15.6mm

Lock

nut

TDW01036

20-124 0

TESTING

AND ADJUSTING

ADJUSTING JOYSTICK POTENTIOMETER

LEVER

ADJUSTING

JOYSTICK

System

switch

cut-off

STEERING

Preparatory work Loosen the potentiometer mounting screws, remove potentiometer connector CN3, then connect a T-adapter (X type 3-pin). * Turn the starting switch OFF before doing this.

CNI Neutral detect switch

Adjusting neutral position I) Set the joystick selector switch to the OFF position (wheel mark side) and set the joystick lever to the N position. 2)

Turn the starting switch ON. * Turn only to the ON position. start the engine.

Do not

Neutr

posit

ion

Potentiometer

,al ion

Turning to left

Turni na to ri aht Jovst lever

ick

TEWO1037

Check the voltage between pins @ and @ of the T-adapter. . Voltage between pins: DC 5V + 0.05V Adjust the voltage by turning the potentiometer slowly so that the voltage between pins @ and @ of the T-adapter become the standard value. . Voltage between pins: DC 2.5V f O.lV (set value) After adjusting the voltage, tighten the potentiometer mounting screws.

Joust ick selector

switch

TEW01038

Tester

Potentiometer

‘T-adapter Mountinb

screws TEW01040

TEW01039

TESTING

ADJUSTING

AND ADJUSTING

Adjusting left and right turning position I) Operate the potentiometer to adjust the voltage at the left and right turn positions.

I 2)

Right turn

/ DC 4.17V f O.lV

After adjusting the voltage, bolt in position.

Neutral position

STEERING

-cl

lock the stopper

TEW01041

ADJUSTING JOYSTICK LEVER NEUTRAL DETECTION SWITCH Preparatory

JOYSTICK

Neutral Position

work

After adjusting the neutral position with the potentiometer, set the lever to the neutral position and loosen the nut of the cam plate. Adjusting I)

Set so that the tip of the roller of the neutral detection switch contacts the concave portion of the cam plate, then tighten the switch mounting bolts. It Never make the roller of the neutral detection switch push into the concave portion of the cam plate.

Tighten the nut so that the cam plate is not at an angle.

switch

20-126 0

TEWO1042

TESTING

AND ADJUSTING

MEASURING *

. .

. 1.

z Ki d

MEASURING

BRAKE PEDAL

Measurement condition Coolant temperature: Inside operating Engine speed: Low idling Air pressure: 0.7 MPa {7 kg/cm*)

range

Measuring operating force of pedal I) Fit push gauge L 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 L 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 422 N (43 kg) and measure the travel of the pedal with an angle gauge J.

Measuring play of pedal 1) Start the engine. 2) Push the brake pedal in lightly by hand, and use an angle gauge J to measure the travel of the pedal to the point where it starts to become heavy.

TEW01129

TESTING

AND ADJUSTING

MEASURING

AIR PRESSURE

* .

Measurement condition Coolant temperature: Inside operating

When measuring, connect nipple Cz, connector C3 to gauge CI, then insert in the tire inflation coupler on the machine.

Measuring set pressure of air governor 1) Open the drain valve and drain air from the tank.

range

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 cut-off (no-load rotation).

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).

Adjusting I) Stop the engine. 2) Loosen lock nut (I), 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.

0.14 MPa Il.4

kg/cm*}

After adjusting as above, measure again and check that all values are within standard.

20-128 a

TLW01133

TESTING

MEASURING

AIR PRESSURE

Measuring actuating stopping pressure of air pressure warning 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)

AND ADJUSTING

Using brake pedal, lower air pressure further, then start engine, and measure air pressure at which buzzer stops to sound. Ir If the pressure is not standard value, check the switch. If necessary, replace the switch. Ir After replacing the switch, measure the pressure again.

Measuring

safety valve

TKWOl134

TKWOll35

TESTING

TESTING Ir l

. . .

TESTING

AND ADJUSTING

BRAKE PERFORMANCE

Measurement condition Time lag when pressing the pedal: 0.1 sec. Air pressure: 0.6 MPa (6.0 kg/cm? Road surface: Flat, horizontal, straight, dry, paved surface. Machine speed: Speed when applying brakes: 20 km/h Tire inflation pressure: Specified pressure

Conditions for measurement 1) Start the engine and then start the machine. 2)

Place the speed control lever in the highest speed range and drive the machine.

When the machine is traveling at 20 km/h, depress the left brake pedal with 373 N {38 kg} * Decide the run-up road and point to apply the brakes, then apply the brakes when the braking point is reached.

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.

Stopping

Braking

Point

Braking

distance

Point

Brake pedal Position

operating

Run-UDroad TKWOl256

20- 130 0

TESTING

CHECKING LEAKAGE * . l

CHECKING

AND ADJUSTING

BRAKE PISTON

Measurement condition Coolant temperature: Inside operating range Test pressure: 4.2 - 5.2 MPa I43 to 53 kg/cm21 Air pressure: Upper limit of green range Block the tires securely.

Measuring procedure 1. Remove bleeder screw (I ), then install brake test kit Ml and nipple Mz in bleeder screw mount.

z k $

Start the engine and bleed the air. * Two worker are need for this operation: one depress the brake pedal and the other bleeds the air from bleeder screw (2). * Check that there is no leakage on air pipings and brake pipings.

Rise air pressure

Using block (length = 400 mm), pedal fully, then stop engine.

When gauge reading is 4.2 - 5.2 MPa 143 to 53 kg/cm2), leave for 5 minutes and check how much pressure drops.

After measuring, loosen bleeder screw to release pressure, then remove brake test kit Ml and nipple M2. * After completing operation, bleed air from brake circuit again.

to upper limit of green depress

range. brake

BRAKE PISTON

LEAKAGE

TESTING

MEASURING DISC * l

MEASURING

AND ADJUSTING

WEAR OF BRAKE

Measurement condition Coolant temperature: Inside operating Air pressure: Inside operating range Stop the machine tires.

WEAR OF BRAKE DISC

on level ground

range

and block the

Testing method 1. Remove plug (I). 2.

Depress stroke.

the brake pedal fully to the end of its

Measure depth a from the end face of the housing to the spring guide. (Measure with caliper C.) * Keep the brake pedal depressed uring.

Wear limit: a = 46.3 mm (Reference: When machine Ir

while meas-

is new, a = 40.7f1.4

mm) TEW01141

When the disc is near the wear limit, carry out inspection frequently, regardless of the maintenance interval.

20-132 0

TKW01142

TESTING

AND ADJUSTING

BLEEDING

AIR FROM BRAKE SYSTEM

BLEEDING AIR FROM BRAKE SYSTEM g

Put blocks under the tires.

Procedure 1. Remove cap (I) of bleeder A of the brake chamber, insert one end of vinyl hose (2) into the screw and put the other end in a container. 2.

Start the engine.

Depress the brake pedal, loosen the bleeder screw, and bleed the air. Tighten the screw, then release the brake pedal slowly. Carry out this operation with two workers: one worker depresses the brake pedal, and the other bleeds the air from the bleeder screw. Use the left pedal when depressing the brake pedal. Add brake oil when necessary to ensure that the brake system is always full.

4. s k B

Repeat this procedure until no more bubbles come out from the hose, then depress the brake pedal fully and tighten the bleeder screw while the oil is still flowing. Ir Repeat the same procedure to bleed the oil from each cylinder. After completing the operation, check the oil level in the oil tank and add oil if necessary.

In Steps 1-4, juster portion portion C.

After bleeding the air from each cylinder, remove cover (31, and check that over-stroke sensor rod (5) in brake chamber (4) has not come out. If it has come out, push it in to the end face of the brake chamber body.

TKW01143

I= ‘U

0 k_

I TKW01144

bleed the air first from slack adB and then from brake cylinder

TLW01145

f-m

TLWOll46

TESTING

AND ADJUSTING

TESTING

* l

. .

TESTING

PARKING

BRAKE PERFORMANCE

PARKING BRAKE

Measurement condition Tire inflation pressure: Specified pressure Road surface: Flat, dry, paved surface with (1 l”20’) gradient. Machine: In operating condition

l/5

Measuring procedure 1. Start the engine and drive the machine straight up a l/5 gradient with the bucket unloaded. 2.

Depress the brake, place the F-R lever in neutral, then stop the engine.

TKW01.258 L

Turn the parking brake switch ON, then slowly release the brake pedal and keep the machine must be kept stopped. Ir The measurement must be made with the machine facing either up or down the slope.

TKW01259

TESTING

CHECKING

AND ADJUSTING

PARKING

BRAKE

CHECKING AND ADJUSTING PARKING BRAKE * l

Measurement Air pressure:

condition Maximum

set pressure

Block the tires securely.

Measuring procedure 1. Turn the starting switch ON, and turn the parking brake switch (I) OFF to release the brake. * Operate the parking brake switch slowly. If it is not operated slowly, it may be impossible to release the brake. 2.

Measure the thickness of pad (2) with vernier calipers. * ‘When the starting switch is turned OFF, the parking brake is applied, so be careful not to turn it OFF. * For details of removing the pad, see DISASSEMBLY AND ASSEMBLY. * Measure 4 pads. * If the thickness is not within the standard value, replace the 2 pads as one set.

Measurement procedure 1. Turn the parking brake brake. 2.

switch

OFF to release

Insert thickness gauge N between disc (3) and pad (21, then measure the clearances (a) and lb). * The clearance value mentioned above indicates the total value of both sides. (a + b)

TLW01260

TESTING

AND ADJUSTING

CHECKING AND ADJUSTING

PARKING BRAKE

Adjustment Ir If the measured

value is not within the standard value, adjust as follows.

Turn the startinn switch ON, then turn the parking brake switch OFF to release the brake.. If the starting switch is turned OFF, the park* ing brake will be actuated, so be careful not to switch if off.

Turn adjustment bolt (1) at the caliper lever clockwise until pad (2) is lightly in contact with disc (3).

If the adjustment bolt is tightened too much and pad (2) and disc (3) are brought strongly into contact, it may cause the brake to squeak or the discs to overheat. Push outer lock, then turn bolt (I).

Turn adjustment bolt 180” f 30” (three or four notch) counterclockwise. This will adjust the total clearance on the left and right between pad (3) and disc (2) to 1.06 + 0.18 mm. + When replacing the pad, always replace 2 pads as one set. Sr Using same procedure, adjust opposite side parking brake.

After adjusting, measure the brake performance again and check that it is within the standard value.

20-136 0

TEW01152

TESTING

AND ADJUSTING

MEASURING

DUMP

AND

LIFT CONTROL

LEVERS

MEASURING DUMP AND LIFT CONTROL LEVERS . .

Measurement condition Coolant temperature: Inside operating Hydraulic temperature: 45 - 55°C Engine speed: Low idling

Install

the safety

range

bar on the frame.

Measuring procedure 1. Operating force of dump and lift control levers Fit push-pull scale K on dump and lift control levers and measure operating force. * Hook push-pull scale K on the center of the knob. Ir 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 Measure the travel of the dump and lift control levers at each position. Sr Mark “a” the knob of the lever and use a scale to measure.

TEW00134

TEWOll55

20-137 0

TESTING AND ADJUSTING

MEASURING

DUMP AND LIFT CONTROL LEVERS

Adjusting 1.

Remove

cover (I).

Place dump lever and lift lever in HOLD. Ir Apply lever lock to hold in position.

Loosen nut, then adjust length of rod (2) so that PPC valve is in HOLD. * If plate (31, roller (4) and spring (5) are damaged, replace them. * Operate the dump and lift levers, and check that the lever is held in position at TILT, DUMP, RAISE and FLOAT.

4 2

_______--

TKWOt

TESTING AND ADJUSTING

MEASURING

HYDRAULIC PRESSURE OF WORK EQUIPMENT

MEASURING HYDRAULIC PRESSURE OF WORK EQUIPMENT *

Measurement condition Coolant temperature: Inside operating Hydraulic oil temperature: 45 - 55°C Engine speed: High idling

Measuring

range

PPC relief pressure

Remove inspection cover (I) of front frame. A Loosen the oil filler cap slowly, then operate the control levers slowly to release the pressure in the accumulator completely. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Remove plug (2) for measuring pressure of oil in dump cylinder circuit of main control valve. Install hydraulic tester 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. 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. When removing the hydraulic pressure gauge, release the pressure in the same way as when installing the gauge.

TESTING

Adjusting PPC relief pressure Airways stop the engine before adjusting hydraulic pressure. 1) 2) 3)

MEASURING

AND ADJUSTING

HYDRAULIC

PRESSURE

OF WORK

EQUIPMENT

the

Stop engine and remove cover (I). Remove cap nut (2) of relief valve. Loosen locknut (3), then turn adjustment screw (4) to adjust. * One turn of the adjustment screw changes the pressure by about 0.96 MPa 19.8 kg/cm*} Ir Turn the adjustment screw to adjust as follows. To INCREASE pressure, TIGHTEN screw. To DECREASE pressure, LOOSEN screw. * If it is impossible to measure the relief pressure accurately, do not try to adjust the pressure.

Measuring

work

equipment

relief

valve

pres-

sure A

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 plug (5) for measuring pressure of oil in dump cylinder circuit. Install hydraulic tester 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. 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. When removing the hydraulic pressure gauge, release the pressure in the same way as when installing the gauge.

TKWOl 161

20-A40

TEW01162

MEASURING

TESTING AND ADJUSTING

Adjusting work equipment

A I)

2) 3)

Always stop the engine hydraulic pressure.

HYDRAULIC PRESSURE OF WORK EQUIPMENT

relief pressure before

adjusting

the

Raise lift arm, and put support under lift arm, then remove inspection cover (I) of front frame. Remove locknut (3) of relief valve (2). Turn adjustment screw (4) to adjust. One turn of the adjustment screw changes the pressure by about 12.6 MPa (128 kg/cm*}. Turn the adjustment screw to adjust as follows. To INCREASE pressure, TIGHTEN screw. To DECREASE pressure, LOOSEN screw. If it is impossible to measure the relief pressure accurately, do not try to adjust the pressure.

TEW01163

TLW01164

TESTING AND ADJUSTING

AIR BLEEDING FROM PISTON PUMP

AIR BLEEDING FROM PISTON PUMP When replacing oil inside hydraulic tank or removing piston pump or hydraulic pipings of piston pump, bleed air from piston pump to prevent pump inner parts seizing as follows. Loosen plugs (I), (2) and (3) on suction tube of piston pump.

Loosen adapter on block end of case drain hose (4) of piston pump.

Open valve (5) to pressurize oil inside hydraulic tank. (approx. 0.98 kPa (0.01 kg/cm*}) Pressurize hydraulic tank gradually, be careful not to spout oil from plug and hose adapter. * Tighten oil filler cap. * When air does not remain in air tank, charge air from others to air tank through tire inflation coupler.

‘\

TEW01165

When oil overflows from plugs (l), (2) and (3) and hose (4) in turn, and tighten plugs and hose adapter under air is bled completely.

TEW01168

TESTING

MEASURING

AND ADJUSTING

MEASURING MENT

WORK EQUIPLifting

* l

. . .

Measurement condition Coolant temperature: Inside operating Steering position: Neutral Hydraulic oil temperature: 45 - 55°C Engine speed: High idling

time

lift

TKW01261

Lowering

time

lift

arm

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.

L 3.

arm

range

Measuring procedure 1. Lifting time 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.

WORK EQUIPMENT

Dumping time of bucket Raise the lift 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.

TKW01.262

Dumping

time

bucket

/t==d

TKW01263

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.

Tilt

back

time

bucket

TKW01264

TESTING

AND ADJUSTING

MEASURING

HYDRAULIC DRIFT OF WORK EQUIPMENT

MEASURING HYDRAULIC DRIFT OF WORK EQUIPMENT Ir l

. l

. .

Measurement condition Coolant temperature: Inside operating range Hydraulic oil temperature: 45 - 55°C Stop engine, leave for 5 minutes, then measure for next 15 minutes. Lift arm horizontal Bucket horizontal Unloaded (Operating load) Fit the safety locks on the control

levers.

TKW01173

A Do not go under the work equipment. Measuring procedure 1. Set the lift arm and bucket horizontal, the engine.

then stop

Stop the engine, measuring.

then start

Measure the amount the lift B and dump A cylinder rods retract during 15 minutes.

wait for 5 minutes,

TDW00160

A: Retraction B: Retraction

20- 144 a

of dump cylinder

of lift cylinder

rod

TESTING AND ADJUSTING

ADJUSTING

BUCKET POSITIONER

ADJUSTING BUCKET POSITIONER 1.

Inspection procedure 1) With the engine stopped, check that the clear-

ance between switch (I) and angle (2) is within the standard value. Start the engine, run at high idling and check the actuating position. (Measure three times and take the average.)

Adjusting

1) Lower the bucket to the ground and operate

3) 4)

the bucket to the desired digging angle. Return the lever to the hold position and stop the engine. Fix support (3) to the bucket cylinder bracket so that the tip of angle (2) align the center of the switch. Remove cover (4) of switch. Adjust the switch so that the clearance between the switch response surface and the angle is 3 - 5 mm (must not interfere), then lock in position. w Mounting nut of switch: 17.2 f 2.5 Nm Il.75 f 0.25 kgm} * After adjusting, operate the dump lever and check that the bucket is actuated at the desired position. li Install cover (4) of switch.

TEW01174

/’

TKW01265

TEW01176

TESTING AND ADJUSTING

ADJUSTING 1.

BOOM KICK-OUT

Inspection procedure I) With the engine stopped, check that the clear-

ADJUSTING

ance between switch (I) and plate (2) is within the standard value. 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

3) 4)

position, stop the engine, then lock the lift control lever. Loosen mounting bolt (3), fix plate so that center of switch (I) align with lower end of plate (2). Remove switch cover (4). Adjust the switch so that the clearance between the switch response surface and plate (2) is 3 - 5 mm (must not interfere), then lock in position. w Mounting nut of switch: 17.2 f 2.5 Nm II.75 f 0.25 kgm} * After adjusting, operate the lift lever and check that the lift arm stops at the desired position.

TEW01177

(Must not interfere)

TKW01266

TEW01179

20-146 0

ADJUSTING

TESTING AND ADJUSTING

ADJUSTING MACHINE MONITOR (SPEEDOMETER MODULE)

MACHINE MONITOR (SPEEDOMETER MODULE)

1 cNP2

CNPl

cNP4

cNP6

Procedure for adjustment NP3

Remove the machine monitor, and adjust at the adjustment portion at the rear of the speedometer. 1) 2)

Remove rubber caps 1 and 2 at the rear of the speedometer. Inside the rubber caps there are rotary switches. Using a flat-headed screwdriver, turn the switch to adjust as shown in the diagram on the right. Switch 3 has connection with adjustment the speedometer, so do not touch it.

1 Switch

Tire size 45/65-45-58PR 3)

(L5) (STD) 1

1 1 Switch

CNP6

TEW01180

Rotary switch /

1 7 (or 8)

After completing adjustment, fit the rubber caps securely, and install the machine monitor.

Reference

Compensation

Switch position

Suitable setting (%I

+I4 +I2 +I0

Switch position

1 8 1 9 1A I B 1 C I D I E I F

Suitable setting (%)

values for switch 2

-2

234567

-4

-6

-8

-10 -12

-14

zo- 147 a

TROUBLESHOOTING Points to remember

when troubleshooting

Sequence

in troubleshooting

of events

Points to remember

when

carrying

Checks before troubleshooting Method

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

20-202

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

20-203

out maintenance

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

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

of using troubleshooting

charts ............................................................................................

20-204 20-212 20-214

Judgment

of power train .....................................................................................................................

20-222

Connector

types and mounting

20-224

Connector

arrangement

Connection

table for connector

locations

diagram

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

........................................................................................................ pin numbers

Troubleshooting

of engine

system

(S mode)

Troubleshooting

of engine,

transmission,

Troubleshooting

of machine

monitor

Troubleshooting

of hydraulic

and mechanical

Troubleshooting

of joystick steering

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

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

parking

system

controller

i.. ........................................................

brake electric

system

(E mode)

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

20-225 20-226 20-251 20-301

(M mode). .................................................................

20-401

system

20-501

(T mode) ....................................................

system.. ..................................................................

20-551

z & d

20-201 0

POINTS TO REMEMBER WHEN TROUBLESHOOTING

TROUBLESHOOTING

POINTS TO REMEMBER A

WHEN TROUBLESHOOTING

Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.

carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not A When allow any unauthorized person to come near. If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for A the engine to cool down before starting troubleshooting.

A Be extremely careful not to touch any hot parts or to get caught in any rotating parts. A

When disconnecting

wiring,

always disconnect

the negative

(-1 terminal

of the battery first.

A When removing the plug or cap from a location which is under pressure from oil, water, or air, always release the internal

pressure first. When installing

measuring

equipment,

be sure to connect it properly.

The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1.

When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately any failure occurs: . Parts that have no connection with the failure or other unnecessary parts will be disassembled. . It will become impossible to find the cause of the failure. It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. Points to ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before? Check before troubleshooting 1) Check the oil level 2) Check for any external leakage of oil from the piping or hydraulic equipment. 3) Check the travel of the control levers.

20-202 0

4) 5)

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

SEQUENCE OF EVENTS IN TROUBLESHOOTING

TROUBLESHOOTING

SEQUENCE

OF EVENTS IN TROUBLESHOOTING

TEW00180

TEWOOl81

Jobsite

Ring

I Ring

;tep 1 IExamination,

1) When

confirmation a request

of symptoms

for

repairs

is received,

first

ask the following points. . Name of customer . 21

Type,

serial

Details

number

of jobsite,

Ask questions

of machine etc.

to gain

an outline

of the prob-

lem. * .

Condition Work

of failure

being

TEW00182

carried

out at the time

of the

failure *

Operating

Past history,

environment details

of maintenance,

etc.

TEW00183

causes.

itep 3 IPreparation 1)

of troubleshooting

tools

TEW00185

Look at the table

of troubleshooting

the shop

and

prepare

the necessary

pressure

gauge

kit, etc.

manual

tools

tools. . T-adapter . 2)

Hydraulic

Look essary

troubleshooting)

in the parts replacement

book

and

prepare

Decide

action

Before

starting

to take

repair

simple

the nec-

parts. TEW00183

troubleshooting,

Check

before

starting

Other

check

items

See the Troubleshooting manual,

Drive the

select

and

locate

and

failures.

Section

of the shop

a troubleshooting

operate

the

and

judge

condition

items

machine if there

flowchan

to confirm is really

TEW00188

Was there chine

anything

before

Did the failure . TEWOO189

Had any repairs failure?

strange

the failure occur

about

the

ma-

out before

the

occurred?

suddenly?

been carried

TEwoo190

20-203 0

TROUBLESHOOTING

POINTS

TO REMEMBER

WHEN

CARRYING

OUT MAINTENANCE

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil). 1.

POINTS TO REMEMBER WHEN HANDLING ELECTRIC EQUIPMENT

Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and’ repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses. TEW00191

Main failures occurring in wiring harness Defective contact bf connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces.

Improper insertion

1 Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper correction or breakage.

Crimped portion

20-204 a

TEW00192

TEW00193

TROUBLESHOOTING

POINTS

TO REMEMBER

WHEN

CARRYING

OUT MAINTENANCE

Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.

I High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. As already said, the connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be shortcircuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it. Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. + When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. If there is oil or water in the compressed * air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.

TEW00194

TEW00195

TEW00196

20-205 0

TROUBLESHOOTING

POINTS

TO REMEMBER

Removing, installing, wiring harnesses

and drying connectors

Disconnecting connectors Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors and not the wires. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. Ir Never pull with one hand.

WHEN

CARRYING

OUT MAINTENANCE

and

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

TEW00212

I 0

TEW00213

Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. + If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.

TEW00199

20-206

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

Connecting connectors

Check ihe connector visuallv. 1) Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). 2) Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. 3) Check that there is no damage or breakage to the outside of the connector. If there is any oil, water, or dirt stuck to * the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. * If there is any damage or breakage, replace the connector.

Cliks into position

TEwoo199

Fix the connector securely. Align the position of the connector correctly, then insert it securely. For connectors with lock stopper, push in the connector until the stopper clicks into position. Correct any protrusion of the boot and any misalignment of the wiring harness For connectors fitted with boots, correct any protrusion or the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. If the connector cannot be corrected eas* ily, remove the clamp and adjust the position.

If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.

TEW00215

20-207 0

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

Drying wiring harness If there is any oil or dirt on the wiring

harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. @ Disconnect the connector and wipe off the water with a dry cloth. + If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove ‘all oil and water from the compressed air before blowing with air.

TEW00196

Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. * Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector.

TEWOOZOZ

Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. Ir After completely drying the connector, blow it with contact restorer and reassemble.

T-adapter

TEW00203

20-208 0

TROUBLESHOOTING

POINTS

TO REMEMBER

WHEN

CARRYING

OUT MAINTENANCE

Handling control box The control box contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the control box. Do not open the cover of the control box unless necessary.

TEW00204

Do not place objects on top of the control box. Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. During rainy weather, do not leave the control box in a place where it is exposed to rain.

Do not place the control box on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand) Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the control box. Fit an arc welding ground close to the welding point.

Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connect connectors. check that all the related connectors are properly inserted. 2) Before carrying out troubleshooting, -k Disconnect and connect the related connectors several times to check. connectors before going on to the next step. 3) Always connect any disconnected * If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated. of circuits (measuring the voltage, resistance, continuity, or 4) When carrying out troubleshooting current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. * If there is any change, there is probably defective contact in that circuit.

20-209 0

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

3. POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling it is necessary or assembling hydraulic equipment, to be particularly careful. 11 Be careful of the operating environment. Avoid adding hydraulic oil, replacing filters, repairing the machine in rain or high winds, places where there is a lot of dust. 21

or or

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

Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out on to the ground, collect it and ask the customer to dispose of it, or take it back with you for disposal.

TEW00208

Do not let any dirt or dust get in during refilling operations. Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil Filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.

20-210 a

TEW00209

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

51 Change hydraulic oil when the temperature

high. When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Do not drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil.

Flushing operations After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil. TEW00210

Cleaning operations After repairing the hydraulic equipment (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultrafine (about 31.~) particles that the filter built into the hydraulic equipment cannot remove, so it is an extremely effective device.

TEWOO21 1

20-211 0

TROUBLESHOOTING

CHECKS BEFORE TROUBLESHOOTING

T I

Judgement standard

Item 1. Check fuel level, type of fuel

Add fuel

2. Check for dirt or water in fuel

Clean, drain

3. Check hydraulic

Add oil

Replace

5. Check brake oil level

Add oil

6. Check engine oil

Add oil

7. Check coolant

level

Add water

of dust indicator

Clean or check

IReferto troubleshooting

Tighten or replace

IRepair or replace

IRepair

oil level

, ,

4. Check filter (hydraulic, /

Remedy

8. Check clogging

torque

converter)

9. Check air pressure

1IO. Check for loose or corroded 1Il. Check for loose or corroded 112. Check for loose or corroded 113. Check for abnormal

battery terminals alternator starting

or wiring

terminals

or wiring

motor terminals

or wiring

noise or smell

$1 14. Check for oil leakage

IRepair

i, 15. Bleed air from system 5

IBleed air

116. Check battery

voltage

17. Check battery

electrolyte

(engine stopped)

23 - 26V -

level

Iqepair or replace I4dd electrolyte

I‘eplace 18. Check for discolored, 19. Check for missing

burned, or bare wiring

wiring

clamps, hanging

wires

210. Check for water on wiring (check carefully

for water at connectors

2‘1. Check for broken or corroded 2‘2. Check alternator

voltage

20-212 a

IIry place affected by \fvater

at over half throttle) 25 V

8.5 - 29.5V

iqeplace f3eplace F3epair or check

after starting)

2 3. Noise when battery (turn starting

I3epair

(If the battery charge is low, it may reach approx. immediately

I3eplace

and terminals)

fuses

(engine running

relay is operated

switch ON-OFF)

FXeplace

E; Ki TS

METHOD

TROUBLESHOOTING

METHOD 1.

Category

OF USING TROUBLESHOOTING of troubleshooting

Troubleshooting code No. E-x x J-x x M-x x s-x x T-x x

OF USING

TROUBLESHOOTING

CHARTS

code number

Troubleshooting Troubleshooting Troubleshooting Troubleshooting Troubleshooting

Component of engine, transmission, parking brake electric of joystick steering controller of machine monitor of engine of hydraulic and mechanical system

system

Method of using troubleshooting table for each troubleshooting mode code numb& and problem 1) Troubleshooting The title of the troubleshooting chart gives the troubleshooting code, service code, and failure mode (problem with the machine). (See Example (1)) 2) Distinguishing conditions Even with the same failure mode (problem), the method of troubleshooting may differ according to the model, component, or problem. In such cases, the failure mode (problem) is further divided into sections marked with small letters (for example, (a)), so go to the appropriate section to carry out troubleshooting. If the troubleshooting table is not divided into sections, start troubleshooting from the first check item in the failure mode. (See Example (2)) chart 3) Method of following troubleshooting l Check or measure the item inside, and according to the answer follow either the YES line or the NO line to go to the next 0 . (Note: The number written at the top right is an index number; it does not indicate the order to follow.) corner of the I . Following the YES or NO lines according to the results of the check or measurement will lead finally to the Cause column. Check the cause and take the action given in the Remedy column on the right. (See Example (3)) . Below the [ ] there are the methods for inspection or measurement, and the judgement values. If the judgement values below the I are correct or the answer to the question inside the I is YES, follow the YES line; if the judgement value is not correct, or the answer to the question is NO, follow the NO line. . Below the I is given the preparatory work needed for inspection and measurement, and the judgement values. If this preparatory work is neglected, or the method of operation or handling is mistaken, there is danger that it may cause mistaken judgement, or the equipment may be damaged. Therefore, before starting inspection or measurement, always read the instructions carefully, and start the work in order from Item I). 4) General precautions When carrying out troubleshooting for the failure mode (problem), precautions that apply to all items are given at the top of the page and marked with *. (See Example (4)) The precautions marked Ir are not given in the I , but must always be followed when carrying out the check inside the I . tools 5) Troubleshooting When carrying out the troubleshooting, prepare the necessan/ troubleshooting tools. For details, see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING. 6) Installation position, pin number A diagram or chart is given for the connector type, installation position, and connector pin number connection. When carrying out troubleshooting, see this chart for details of the connector pin number and location for inspection and measurement of the wiring connector number appearing in the troubleshooting flow chart for each failure mode (problem).

20-214 0

Z & 2

METHOD

TROUBLESHOOTING

< Example (1)

E-4

OF USING

TROUBLESHOOTING

CHARTS

PARKING

BRAKE DOES NOT WORK

(2) a) If parking

brake does not work

when

parking

brake switch

b) If parking

brake does not work

then air pressure

is ON (applied).

has dropped.

(3) Cause

YES 1 Is problem removed when CNI 1 is disconnected? I) Disconnect CNll. 2) Start engine. (Charge air pressure) 3) Turn parking brake switch ON.

2 Is there continuity _ between CNll NO (female) (1) and W? 1) Disconnect CNll. 2) Turn starting switch OFF. 3) Disconnect CN53. 4) Disconnect CN70.

3 YES

~rfih?ifiz’”h I\ 1) Connect T-adapter (socket adapter) to CN35. 2) Start engine. (Charge air pressure) 3) Turn parking brake switch ON.

Defective parking brake rwitch

teplace

Contact of wiring harness it CNll (female) (1) and 2)

hfter inspection, epair or replace

Defective parking brake ;olenoid

ieplace

Iontact of wiring harness It CNll (female) (1) and 3)

&her inspection, epair or replace

(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 ( 1) * When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go the next check.

20-215 0

METHOD

TROUBLESHOOTING

Using troubleshooting

chart for engine-related

This troubleshooting chart is divided into three sections: questions, check items, and troubleshooting. The questions and check items are used to pinpoint high probability causes that can be located from the failure symptoms or simple inspeciton without using troubleshooting tools. Next, troubleshooting tools or direct inspection are used to check the high probability causes to make final confirmation. [Questions] Sections @ + @ in the chart on the right corresponds to the items where answers can be obtained from the user. The items in @ are items that can be obtained from the user, depending on the user’s level. [Check items1 The serviceman carries out simple inspection to narrow down the causes. The items under @ in the chart on the right correspond to this. The serviceman narrows down the causes from information @ that he has obtained from the user and the results of @ that he has obtained from his own inspection. [Troubleshooting] Troubleshooting is carried out in the order of probability, starting with the causes that have been marked as having the highest probability from information gained from [Questions] and [Check items].

20-216 0

failure

OF USING

TROUBLESHOOTING

CHARTS

TROUBLESHOOTING

z L g

METHOD

OF USING

TROUBLESHOOTING

CHARTS

The basic method of using the troubleshooting chart is as follows. Items listed for [Questions] and [Check items1 that have a relationship with the Cause items are marked with 0, and of these, causes that have a high probability are marked with 0. Check each of the [Questions] and [Check items] in turn, and marked the 0 or Q in the chart for items where the problem appeared. The vertical column (Causes) that has the highest number of points is the most probable cause, so start troubleshooting for that item to make final confirmation of the cause. ‘%I. For [Confirm recent repair history] in the [Questions] Section, ask the user, and mark the Cause column with A to use as reference for locating the cause of the failure. How+ ever, do not use this when making calculations to narrow down the causes. ,%2. Use the n in the Cause column as reference for [Degree of use (Operated for long period)] in the [Questions] section as reference. As a rule, do not use it when calculating the points for locating the cause, but it can be included if necessary to determine the order for troubleshooting.

20-217 0

METHOD

TROUBLESHOOTING

OF USING

TROUBLESHOOTING

CHARTS

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

s-7 Exhaust gas is black (incomplete combustion) General causes why exhaust gas is black . Insufficient intake of air . Improper condition of fuel iniection . Excessive injection of fuel

1 Operated

Noise of interference

1k&age

of atr between

15 heard from

turbocharger

around

for long period

turbocharaer

and head. loose clamp

I I Remedy

;

20-Z 8 0

METHOD OF USING TROUBLESHOOTING

TROUBLESHOOTING

CHARTS

Clarify the relationship between the three symptoms in the [Questions] and [Check items1 section and the five Cause items in the vertical column.

Three symptoms

t”’

Add up the total of Oand Omarks where the horizontal lines for the three symptoms and the vertical columns for the causes intersect. (I 1 Clogged air cleaner element: 000 (2) Air leakage between turbocharger and head: 00 (3) Clogged, seized injection nozzle: 0 (4) Defective contact of valve, valve seat: 0 (5) Worn piston ring, cylinder: 0 Step 3 The calculation in Step 2 show that the closest relationship is with [Clogged air cleaner element]. Follow this column down to the troubleshooting area and carry out the troubleshooting item marked 0. The Remedy is given as [Clean], so carry out cleaning, and the exhaust gas color should return to normal.

20-219 a

TROUBLESHOOTING

METHOD

OF USING

TROUBLESHOOTING

CHARTS

Method of using matrix troubleshooting tables The troubleshooting tables use the same method as for other troubleshooting table (YES/NO type) to locate the causes of failures in the machine. The troubleshooting tables are divided broadly into categories for the main components, such as the steering system and work equipment hydraulic system. Follow the procedure given below and carry out troubleshooting to locate the problems accurately and swiftly.

Step 1. Questioning the operator The questions to ask the operator are given below the failure symptom. If the answers to the questions match the information given, follow the arrow to reach the probable cause of the failure. Consider the contents of the questions and consult the table while proceeding to Steps 2 and 3 to grasp the true cause.

Step 2. Checks before troubleshooting Before starting the main troubleshooting and measuring the hydraulic pressure, first check the Checks before Starting items, and check for oil leakage and loose bolts. These checks may avoid time wasted on unnecessary troubleshooting. The items given under Checks before Starting are items which must be considered particularly for that symptom before starting troubleshooting.

Checks before

Step 3. Using cross-reference table 1) Operate the machine to carry out the checks in the troubleshooting item column. Mark the items where the results match the symptom. * It is not necessary to follow the troubleshooting checks in order; follow an order which is easiest to carry out troubleshooting. 2) Find the appropriate cause from the cause column. If the symptom appears, the 0 marks on that line indicate the possible causes. (For item No. 2 in the table on the right, the possible causes are c or

e.) If there is only one 0: Carry out the other troubleshooting items (where the same cause is marked with 01, check if the symptom appears, then repair. If there are two OS: Go on to Step 3) to narrow down the possible causes.

20-220 0

Steering

does not work t

Symptom

[Exam-

ple] Ask the operator about the following points. . Did the steering suddenly stop working? + Breakage in steering equipment . Had the steering gradually been becoming heavy? + Internal wear of steering equipment, defective seal

. .

[Example]

Is the oil level and type of oil in the hydraulic tank correct? Is there any leakage of oil from the steering control valve?

[Example

No.

starting

Problems

Steering does not work to the left or right

Same as Item 1, but abnormality in actuation of work equipment

Steering can only be operated to one side.

Steering wheel is heavy and cannot be turned.

[Example

TROUBLESHOOTING

METHOD OF USING TROUBLESHOOTING

CHARTS

Operate the machine and check the troubleshooting items other than those in 1). Operate the machine and check the items in the same way as in I), and if the symptom appears, mark that item. (In the chart on the right, the symptom appears again for item 5). Find the appropriate cause from the cause column. In the same way as in Step 21, if the symptom appears, the 0 marks on that line indicate the possible causes. (For item No.5 in the table on the right, the possible causes are b or e.) Narrow down the possible causes. There is one common cause among the causes located in Steps 2) and 4). (One cause marked 0 appears on the line for both items.) This cause is common to both the symptoms in troubleshooting Steps I) and 3). * The causes which are not common to both troubleshooting items (items which are not marked 0 for both symptoms) are unlikely causes, so ignore them. (In the example given on the right, the causes for Troubleshooting Item 2 are c or e, and the causes for Troubleshooting Item 5 are b or e, so cause e is common to both.) Repeat the operations in Steps 3), 4) and 5) until one cause (one common cause) remains. * If the causes cannot be narrowed down to one cause, narrow the causes down as far as possible. Remedy If the causes are narrowed down to one common cause, take the aciton given in the remedy column. The symbols given in the remedy column indicate the following: X: Replace, n: Repair, A; Adjust, C: Clean

rL-

Applicable troubleshooting item located in Step 3). Applicable troubleshooting item located in Step 1). hese causes

ommon causes

Action to take

20-221 0

JUDGMENT

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 in the electrical system, go to troubleshooting items E-8 - E-13; if the abnormality is not in the electrical system, go to troubleshooting items Tl - T4. Judgment

flow

2 YES When emergency YES ScreWOf SpOOlOf - problem speed 1 range is loosened, does machinemove?

)

Defective transmission

solenoid valve

Go to troubleshooting Tl-T4

for transmission,

Go to troubleshooting for transmission, electrical system, Item E-8

Testing

of transmission

solenoid

Stop the machine on level ground blocks under the tires.

and put

Air tank at specified

Install a T-adapter (or socket adapter) to connector CN89, and check the voltage between the connector pin and the chassis ground. Turn the starting switch ON. * 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.

2. 3. 4.

and inspection

Checking

directional

Standard

condition

pressure.

solenoid

circuit Result of inspection

Normal

source)

0 [continuous] at two places Go to troubleshooting E-8 (d)

FORWARD

REVERSE

0: 0 - 0.5V [continuous] 0: 20 - 30V [battery voltage]

20-222 a

Go to Tl -T4

8-pin

No 0 [continuous] Go to troubleshooting

E-8 lb), (c)

No 0 [battery voltage] Go to troubleshooting

E-8 (a)

TROUBLESHOOTING

Checking

speed solenoid

Standard

condition

l-pin

JUDGMENT

ON POWER TRAIN

circuit

2-pin

3-pin

7-pin (Power source)

0: 0 - 0.5V [continuous] 0: 20 - 30V [battery voltage]

Result of inspection Normal

Go to Tl -T4

0 [continuous] at two places or more Go to troubleshooting E-8 (f) No 0 [continuous] Go to troubleshooting

E-8 (e)

No 0 [battery voltage] Go to troubleshooting

E-8 (e)

20-223 0

CONNECTOR TYPES AND MOUNTING

TROUBLESHOOTING

CONNECTOR TYPES AND MOUNTING * The Address column in the table below shows the address (3-dimensional

CN 1 1 CN 13

Automobile 3

CN 14

Econoseal

Main

CN 15

Econoseal 12

Headlamp,turn signalindicatorswitch A-7

CN 16

Econoseal 12

Transmission combination switch

A-7

CN 18

Transmissioncut-offselectorswitch

C-6

CN 19

Automobile 4 Automobile 2

Low idling 2-stage selector switch

D-6

CN21

Econoseal

Transmission

CN28

Econoseal

R.H. combination

switch

F-6

CN29 CN31

switch 1Econoseall 8 1L.H. combination connector 1Econoseall 12 1intermediate

1 H-l 1 J-8

CN32

Econoseal

intermediate

CN34

Econoseal

Parking

brake switch

Econoseal

Parkina

brake solenoid

Lift proximity

CN35

location

Address

Parking

brake switch

A-8

Heater

switch

A-8

Mounting

switch

cut-off switch

connector

Econoseal

CN39

Econoseal

Bucket

proximity

CN40

For relav

Caution

IamD relav

arrangement

drawing

No. of pins

1 DLI I DLI

1 18 I Monitor I 5 I Monitor

location

Address

F-2

switch

Intermediate

G-l

switch

F-6 H-9

Econoseal 12

CN58

I Automobile1 4 I Rear wiDer

CN59 ~~60

I Econoseal 1 2 Brake oil level switch I Econoseall 2 I Transmission oil filter

CN61

Econoseal

Brake chamber

limit switch

K-4

CN62

Econoseal

Brake chamber

limit switch

K-4

CN64

Econoseal

Brake chamber

limit switch

K-3

CN65 CN68

Econoseal 12 5 For relay

CN69

For relay

Kick-out

relay

CN70

For relay

Parking

safety

CN72

For relay

Neutral

relay

CN74

Automobile 4

connector

Intermediate

1 D-9 1B-5,G-6 I l-7 I 1 K-5 I K-2

connector

J-8

relay

G-9 G-9 relay

G-9 G-9

indicator

unit

F-8 D-9

CN77

Econoseal 12

CN78

Econoseal 12

Fuse box

D-9

CN79

Econoseal 12

Fuse box

1 E-9 I E-9

Fuse box

CN80

I EconosealI 12 1Fuse box

CN83

For relay

2nd solenoid

relay

CN84

Econoseal 12

Intermediate

connector

l-9

CN85

Econoseal

Intermediate

connector

J-9

CN86

Econoseal

Intermediate

connector

CN87

Econoseal

Brake chamber

CN88

Econoseal

Intermediate

connector

l-9

CNP5

CN89

1Econoseal 12

Intermediate

connector

1 J-9

CNPG

Mounting

F-2

1Automobile1 6 1Front wiper

Turn signal

Connectar Tvpe

J-8

CN55

Positioner

Connectar No.

l-l

CN52

20-224 0

in the connector

A-6

CN37

LOCATIONS

drawing).

ConNo. nectar of pins Tvpe Automobile 3

Connectar No.

LOCATIONS

limit switch

F-8

l-9 K-3 panel panel

1 D-4 1 c-3

TROUBLESHOOTING

CONNECTOR ARRANGEMENT

CONNECTOR ARRANGEMENT * For details of this page, see page 90-201. g :: ; 4 :olc: ; 2 2 : -gE”ZZ . I

DIAGRAM I i .E

DIAGRAM

TROUBLESHOOTING

CONNECTION No. of pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

TABLE FOR CONNECTOR

PIN NUMBERS

ECONOSEAL CONNECTOR Female terminal (Socket)

Male terminal (Pin)

TEZW220

TEZ00221

3 @I! 1

-1

TEW01184

TEW01185 z I

2. TEW01186

TEW01187

a’ 20-226 0

‘3 TEW01188

‘1

TEWO1190

TEW01189

TEWOII91

TROUBLESHOOTING

No. of pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

MIC type CONNECTOR Female

terminal

(Socket)

Male terminal

(Pin)

UOLI

BLPOW46

BLFUOO45

BLPOOO5Q

BLPOMl49

BLPO3052

BLPOOO51

TEW00260

rI7

TEW00259

20-227 0

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

TROUBLESHOOTING

No. of pins

DLI type CONNECTOR Female

terminal

(For monitor

panel) Male terminal

(Socket)

(Pin)

TEW01192

TEW01193

TEW01194

TEW01195

TEW01196

TEW01197

20-228 0

TROUBLESHOOTING

No. of pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

BENDIX Female

terminal

(MS) type CONNECTOR

(Socket)

Male terminal

(Pin)

TEW01198

TEW01199

No. of pins

RELAY CONNECTOR

BLPOcQ74

BLWO076

20-229

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

No. of pins

N-SLC type CONNECTOR Female

terminal

(Socket)

Male terminal

BLPOoo64

(Pin)

BLWOOB3

3 2

4 TEZ00219

TEZOOZ 16

TEZOO218

TEZ00217

BLWOOBS

BLPOoO72

20-230 0

TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)

s- 1

Starting

s- 2

Engine does not start ...............................................................................................................

20-253

(1) Engine

20-253

performance

is poor (Starting

.20-252

does not turn ..........................................................................................................

(2) Engine turns but no exhaust (3) Exhaust

;; Ki g

always takes time). ................................................

gas comes

out but engine

does not pick up smoothly

out (Fuel is not being injected)

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

20-254

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

20-255

does not start (Fuel is being injected).

s- 3

Engine

s- 4

Engine stops during

s- 5

Engine

does not rotate smoothly

S- 6

Engine

lacks output

s- 7

Exhaust

gas is black (incomplete

S- 8

Oil consumption

s- 9

Oil becomes

S-IO

Fuel consumption

S-l 1

Oil is in cooling

s-12

Oil pressure

s-13

Oil level rises .............................................................................................................................

20-266

S-l 4

Water

.20-267

S-l 5

Abnormal

noise is made ..........................................................................................................

20-268

S-16

Vibration

is excessive

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

20-269

operations

(Follow-up

is poor). ......................................................

.............................................................................................. (hunting)

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

(no power). ..............................................................................................

is excessive

contaminated

(or exhaust

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

gas is blue). .......................................................

quickly .........................................................................................

is excessive water,

combustion).

or water

................................................................................................ spurts back, or water

lamp lights up (drop in oil pressure)

temperature

becomes

too high (overheating)

level goes down.. ........................

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

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

.20-256 20-257 .20-258 20-259 .20-260 .20-261 20-262 20-263 20-264 .20-265

20-251 0

S-l

TROUBLESHOOTING

S-‘1 Starting

performance

is poor (Starting

General causes why starting performance . Defective electrical system . Insufficient supply of fuel . Insufficient intake of air . Improper selection of fuel

always takes time)

is poor

(At ambient temperature of -10°C [-14”Fl or below, use ASTM D975 No. 1, and -10°C [-14OFl or above, use ASTM D975 No. 2 diesel fuel.) Ir Battery charging rate.

20°C [68’Fl

100%

90%

80%

75%

70%

1.28

1.26

1.24

1.23

1.22

1.30

1.28

1.26

1.25

1.24

0°C 132’Fl -10°C I-14’Fl

The specific gravity should exceed the value for the charging rate of 70% in the above table. In cold weather the specific gravity must exceed the value fo the charging rate of 75% in the above table. Legend 0 : Possible causes (judging from Questions and check items) 0 : Most probable causes (judgingfrom Questionsand Check items) A : Possible causes due to length of use (used for a long period) l : Items to confirm the cause Confirm recent repair history Degree of use Ease of starting

I Operated

for long period Gradually becan C.^.+^

I I I I I I I 1 1 IA[A~ 1 I

1) LIttIe fuel comes out even when Injection I... .-. pump sleeve I I I I I I I I I I loi I I I 1 2) Little fuel comes out even when fuel filter air bleed olua_ is loosened Leakage from fuel piping There is hunting from engine (rotation is irregular)

p .5 j : = 2 I=

When compression pressure is measured, it is found to be low When air element is inspected directly, it is found to be clogged When fuel filter, strainer are inspected directly, they are found to be clogged When feed pump strainer is inspected directly, it is found to be clogged Heater mount does not become warm Voltage is 26 - 30V betweem alternator terminal B and Yes terminal E with engine at low idling No Either specific gravity of electrolyte or voltage of battery is low Stop fuel injection to one cylinder at a time. If there is no change in engine speed, that cylinder is not working When check is made using delivery method, injection timing is found to be incorrect When control rack is pushed, it does not return When fuel cap is inspected directly, it is found to be clogged When overflow valve is inspected, it is found to be stiff, or always stays open

Remedy

20-252 0

s-2

TROUBLESHOOTING

S-2 Engine does not start 0 Engine does not turn

Causes

General causes why engine does not turn . Internal parts of engine seized * If internal parts of the engine are seized, carry out troubleshooting for “Engine stops during operations”. . Failure in power train . Defective electrical system Legend 0 : Possible causes (judging from Questions and check items) Q : Most probable causes (judgingfrom Questionsand Check items) a : Possible causes due to length of use (used for a long period) ) : Items to confirm the cause: Confirm recent repair history Operated for long period

Condition of horn when starting switch is turned ON

Horn does not sound

Horn sound level is low Rotating speed is slow

1 lo,1

Makes grating noise

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

I I I I I I I

III

Degree of use

1 1 1 I

Soon disengages again

When starting switch is turned to START, pinion does not move out When startina switch is turned to ON, there is no clickina sound Battery terminal is loose

When starting switch is turned to ON, linkage does not move

When battery is checked, battery electrolyte is found to be low

specific gravity of electrolyte, voltage of battery is low

5 z

:or the following conditions 1) - 5). turn the starting switch 3FF. connect the cord, and carry out troubleshooting at ON

t .c .= % $ ._

1) When terminal B and terminal C of starting switch are connected, engine starts

P z

2) Even when terminal B and terminal C of starting motor are connected, engine does not start

5 g ‘g 2 ; 4 e

3) When terminal B and terminal C of safety relay are connected, engine starts 4) When terminal of safety switch and terminal B of starting motor are connected, engine starts

2 2

5) There is no 24V voltage between battey relay terminal B and terminal E

Yhen ring gear is inspected directly, tooth surface is found o be chipped )oes not move even when engine stop motor linkage is lisconnected

20-253 0

s-2

TROUBLESHOOTING

Engine turns but no exhaust gas comes out (Fuel is not being injected) (including cases with V-type engine where there is no fuel injection for the bank on one side)

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

out

Standards for use of fuel Ambient temprature Tvpe

offuel -22 -30

-4 -20

-l;b

32 0

50 10

68 20

86 30

104°F 40°C

I< 2 e >

I< 2 2

Legend 0 : Possible causes (judging from Questions and check items) 0 : Most probable causes (judgingfrom Questionsand Check items) n : Possible causes due to length of use (used for a long period)

7 1

0: Confirm recent repair history Degree of use

Operated for long period

000

Exhaust gas suddenly (when starting again) stops coming out

Replacement of filters has not been carried out according to operation manual

-0 1) Injection pump coupling dose not turn

2) No fuel comes out even when fuel filter air bleed plug is loosened

C -

3) No fuel comes out even when injection pump air bleed plug is loosened

4) No fuel spurts out even when injection pipe sleeve nut is loosened

080

Rust and water are found when fuel is drained Inspect injection pump directly

Control rack does not move

Inspect feed pump directly When fuel filter, strainer are inspected directly. they are found to be clogged When priming pump strainer is inspected directly, it is found to be clogged When fuel cap is inspected directly, it is found to be clogged Inspect fuel cut solenoid directly

20-254 0

TROUBLESHOOTING

s-2

@I Exhaust gas comes out but engine not start (Fuel is being injected)

does

General causes why exhaust gas comes out but engine does not start . Lack of rotating force due to defective electrical system . Insufficient supply of fuel . Insufficient intake of air . Improper selection of fuel Legend 0 : Possible causes (judging from Questions and check items) ost probable causes (judgingfrom Questions and Check items) e to length of use (used for a long period)

Degree of use

Operated for long period

Suddenly failed to start

I I I I4

I I I I I I I 1 I

lol0l

is cranked, abnormal noise is heard from

Indicator lamp does not light up Starting motor cranks engine slowly Mud is stuck to fuel tank cap When engine is cranked with starting motor, I) Little fuel comes out even when injection pump sleeve nut is loosened 2) Little fuel comes out even when fuel filter air bleed plug and injection pump air bleed plug are loosened $

There is leakage from fuel piping

When exhaust manifold is touched immediately after starting engine, temperature of some cylinder is low

I I I

I I

I 0 0

When fuel filter is drained, no fuel comes out

I I I I I I I I I I I PI

Remove head cover and check directlv

I.1

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

I 1.1

When compression pressure is measured, it is found to be low When fuel filter, strainer are inspected directly, they are found to be clogged When feed pump strainer is inspected directly, it is found to be clogged When air element is inspecteddirectly, it is found to be clogged Heater mount does not become warm

I I

I I I

I I

I I I I I I I I I I 0 0

0 0 0 0

Either specific gravity of electrolyte or voltage of battery is low Tt~z;ed

pump is operated, there is no response, or pump

Stop fuel injection to one cylinder at a time. If there is no change in engine speed, that cylinder is not working

0 0

I I I I I I 1 I I 1.1

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

Remedy

I I 0

$ $ z c c c .= $ .= $ z $ $ 4 2 x $ g ~~~Uc_lU~~~“G~

c g

c 8 $ z

20-255 0

s-3

TROUBLESHOOTING

S-3 Engine does not pick up smoothly

(Follow-up

is poor)

General causes why engine does not pick up smoothly . Insufficient intake of air . Insufficient supply of fuel . Improper condition of fuel injection . Improper fuel used

Legend 0 : Possible causes (judging f : Most probable causes (judgi

Questions and check items) om Questions and Check kerns.)

Item has not been carried out according to

Engine pick-up suddenly became poor

Cola.m‘c.“h~l,e+ “3.2 I

“I

c.IIII.aYIL

IlOlIO

J”’

I Black

101

Enailne oick-uo is different between left and riaht banks

I I I I I I

When air element is inspecteddirectly,it is found to be clogged

10 1 1 / 1 1 I

When fuel filter, strainer are inspected directry, they are found to be clogged When feed pump strainer is inspected directly, it is found to be clogged Stop fuel injection to one cylinder at a time. If there is no change in engine speed, that cylinder is not working When control rack is pushed, it is found to be heavy, or does not return When compression pressure is measured, it is found to be low When turbocharger is rotated bv hand, it is found to be heavv When valve clearance is checked directly, it is found to be outside standard value When fuel cap is inspected directly, it is found to be clogged

1 10

Blue under light load

I I I I I I I I I I I I I@/ I I I I I I I I 0

0 0

I I I 1 I I I IeI

I I I I

S-4

TROUBLESHOOTING

S-4 Engine stops during operations (For V type engine, including cases where one bank stops) General causes why engine stops during operations Seized parts inside engine . Insufficient supply of fuel Overheating Ir If there is overheating and insufficient output, carry out troubleshooting for overheating. . Failure in power train Ir If the engine stops because of a failure in the power train, carry out troubleshooting for the chassis. l

Legend 0 : Possible causes (judging from Questions and check items) 8 : Most probable causes (judgingfrom Questionsand Check items) A : Possible causes due to length of use (used for a long period1 l : Items to confirm the cause.

Abnormal noise was heard and engine stopped suddenly Condition when engine

Try to turn by hand using

TROUBLESHOOTING

s-5

S-5 Engine does not rotate smoothly

(hunting)

General causes why engine does not rotate smoothly Air in fuel system . Defective governor mechanism l

Causes

Legend 0 : Possible causes (judging from Questions and check items) 0 : Most probable causes (judgingfrom Questionsand Check items) A : Possible causes due to length of use fused for a long period) l : Items to confirm the cause. Confirm recent repair history Degree of use

Condition of hunting

Operated for long period

Occurs at certain speed range

Occurs at low idling

Ocuurs even when raised

000

speed is

0000

When feed pump is operated, 1) No response, light, return is quick 2) No response, light, return is normal Engine speed sometimes rises too high Engine is sometimes difficult to stop

1°101

I I I I I I I 101 I lslol I I I I I I I I01010I I I I I I I

Governor lever (solenoid plunger) is stiff SDOOIvalve is stiff When control rack is pushed, it is found to be heavy, or does not return

I I.1 I

I I I I I I I I*1

When fuel cap is inspected directly, it is found to be clogged When feed pump strainer is inspected directly, it is found to be clogged When fuel filter, strainer are inspected directly, they are found to be clogged

20-258 0

TROUBLESHOOTING

S-6

S-6 Engine lacks output (no power) (With V-type engine, for cases where there is injection for only one bank, go to troubleshooting S-2-0 or S-4.) General causes why engine lacks output . insufficient intake of air . Insufficient supply of fuel . Improper condition of fuel injection . Improper fuel used

(if non-specified fuel is used, output drops) Lack of output due to overheating If there is overheating and insufficient + output, carry out troubleshooting for overheating. Legend 0 : Possible causes (judging from Questions and check items) @ : Most probable causes (judgingfrom Questions and Check items)

Deoree of use Power was lost

1Ooeratedforlono

oeriod IAl

IAIZIAI

Suddenly Gradually

r-1

! 1 iOi-/-i‘-/

Engine oil must be added more frequently

/ i-1

/ / J

Replacement of filters has not been carried out according to

High idling speed under no load is normal, but speed suddenly drops when load is applied When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low

I I I I I I

I I

I I I

When air element is inspecteddirectly, it is found to be clogged When trubocharoer is rotated bv hand. it is found to be heaw When compression pressure is measured, it is found to be low When fuel filter, strainer are inspected directly, they are found to be clogged When feed pump strainer are inspected directly, it is found to be clogged Stop fuel injection to one cylinder at a time. If there is no change in engine speed, that cylinder is not working When control rack is pushed, it is found to be heavy, or dose not return When valve clearance is checked directly, it is found to be outside standard value When faed pump is operated, operation is too light or too heavy When fuel cap is inspected directly, it is found to be clogged When injection pump boost compensator is inspected, it does not work

Remedy

20-259 0

s-7

TROUBLESHOOTING

S-7 Exhaust gas is black (incomplete

combustion)

General causes why exhaust gas is black . Insufficient intake of air . Improper condition of fuel injection l

Excessive

injection

of fuel

Causes

Legend 0 : Possible causes (judging from Questions and check items) 0 : Most probable causes (judgingfrom Questions and Check items) A : Possible causes due to length of use (used for a long period) 0 : Items to confirm the cause.

Color of exhaust gas

Power was lost

) Leakage of air between turbocharger and head, loose clamp

1 1 1 ( 1 1 1 101 I

When turbocharger is rotated by hand, it is found to be heavy

When air cleaner is inspected directly, it is found to be clogged When compression pressure is measured, it is found to be low change in engine speed, that cylinder is not working

20-260 0

l 0

TROUBLESHOOTING

Oil consumption

S-8

is excessive (or exhaust gas is blue)

Do not run the engine at idling for more than 20 minutes continuously. (Both low and high idling) General causes why oil consumption is excessive . Abnormal combustion of oil . External leakage of oil l Wear of lubrication system * Judge the oil consumption by comparing it with the fuel consumption during the same period. More than 0.5%: Check the engine More than 1.0%: There is some abnormality

Causes

Legend 0 : Possible causea (judging from Questions and check items) 0 : Most probable causes (judgingfrom Questionsand Check items) A : Possible causes due to length of use (used for a long period)

When exhaust pipe is removed, inside is found to be dirty with oil Inside of turbocharger intake pipe is dirty with oil

00 0

Oil level in clutch or TORQFLOW transmission damper chamber rises

Clamps for intake system are loose

I 101 I 1

When compression pressure is measured, it isfoundto be low 10101

1 I 1 I I 1 I I I I I

nt is inspected, it is found to be

When intake manifold is removed, dust is found inside When intake manifold is removed, inside is found to be dirty with oil

20-26 1 0

s-9

TROUBLESHOOTING

S-9 Oil becomes contaminated

quickly

General causes why oil becomes contaminated quickly . Intake of exhaust gas due to internal wear Clogging of lubrication passage . Improper combustion . Improper oil used Operation under excessive load l

Causes

Legend 0: Possible causes (judging from Questions and check items) 8 : Most probable causes (judgingfrom Questionsand Check items) A : Possible causes due to length of use (used for a long period) l : Items to confirm the cause.

Engine oil temperature rises quickly When compression pressure is measured, it is found to be low

.!?

When breather element is inspected directly, it is found to be clogged with dirty oil, or hose is broken When oil filter is inspected directly, it is found to be clogged When oil cooler is inspected directly, it is found to be clogged

a b i

Turbocharger drain tube is clogged Excessive play of turbocharger shaft When safety valve is directly inspected, spring is found to be catching or broken Oil is above H level on oil level gauge

20-262 0

S-IO

TROUBLESHOOTING

S-IO

Fuel consumption

is excessive

General causes why fuel consumption is excessive . Leakage of fuel . Improper condition of fuel injection . Excessive injection of fuel

Causes

Legend 0 : Possible causes (judging from Questions and check items) Q : Most probable causes (judgingfrom Questions and Check items) A : Possible causes due to length of use (used for a long period) : Items to confirm the cause.

More than for other machines of Condition of fuel consumption

Exhaust gas color There is irregular combustion

When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low

Match mark on injection pump is misaligned

There is external leakage of fuel from engine

Engine oil level rises and smells of diesel fuel

Engine low idling speed is high

Injection pump test shows that injection amount is excessive Stop fuel injection to one cylinder at a time. If there is no change in engine speed, that cylinder is not working When control rack is pushed, it is found to be heavy, or does not return When check is made using delivery method, injection timing is found to be incorrect Remove head cover and check directly

0 0 0 0

20-263 0

TROUBLESHOOTING

S-II

Oil is in cooling water, down

S-l 1

or water spurts back, or water level goes

General causes why oil is in cooling water . Internal leakage in lubrication system . Internal leakage in cooling system

Legend 0 : Possible causes (judging from Questions and check items) 0 : Most probable causes (judgingfrom Questionsand Check items) A : Possible causes due to length of use (used for a long period)

5 Q) 6

20-264 0

Hydraulic oil, torque converter transmission oil is cloudy white When hydraulic oil, torque converter, transmission oil is drained, water is found

Causes

TROUBLESHOOTING

S-12

s-12

Oil pressure lamp lights up (drop in oil pressure)

General

causes why oil pressure

lamp lights

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

Standards

for use of oil Selection of oil SAE number according to ambient temperature

Type of oil

-22 -30

-4 -20

14 -10

32 0

50 10

68 20

86 30

Causes

104°F 40°C

Engine oil

Legend 0 : Possible causes (judging from Questions and check items) 0 : Most probable causes (judgingfrom Questionsand Check items) n : Possible causes due to length of use (used for a long period) l : Items to confirm the cause.

Condition when oil pressure

1 When oil filter is inspected directly, it is found to be cloooed

I t

Remove oil pan and check directly Oil pump rotation is heavy, there is play

1 ~0~0~0~ I ! ! ! !~-! p[

There is catching of relief valve or regulator valve, spring, or valve guide is broken When oil level sensor is replaced, oil pressure sensor lamp goes out When oil pressure is measured, it is found to be within standard value When oil cooler is inspected, it is found to be clogged

20-265 a

TROUBLESHOOTING

S-13

s-13

Oil level rises

If there is oil in the cooling water, carry out troubleshooting for “Oil is in cooling water”. General causes why oil level rises . Water in oil (cloudy white) . Fuel in oil (diluted, and smells of diesel fuel) . Entry of oil from other component

Legend 0 : Possible causes (judging from Questions and check items) 0 : Most probable causes (judgingfrom Questionsand Check items) A : Possible causes due to length of use (used for a long period) 0 : Items to confirm the cause. Confirm recent repair history 2 .g

Degree of use

There is oil in radiator cooling water

Operated for long period

Leave radiator cap open. When engine is run at idling, an abnormal number of bubbles appear, or water spurts back

000

Exhaust gas is white When engine is first started, drops of water come from muffler

nnn

00 0

I 101 I I I I I I I I I I

loI

Water pump breather hole is clogged with mud

When water pump breather hole is clean, water comes out

Oil level goes down in clutch, TORQFLOW transmission, or damper chamber

loI

Oil level goes down in hydraulic tank Engine oil smells of diesel fuel

I I I I I lololol

I I

Fuel is added more frequently Pressure-tightness test of oil cooler shows there is leakage

I.1

I Pressure-tightnesstest of cylinder head showsthere is leakage I I When compression pressure is measured, it is found to be IOW I Remove water pump and check directly I Check rear seal directly When pump auxiliary equipment is removed, seal is found to be broken

IRemove head cover and check directly Remove injection pump and check directly

20-266 0

I I I I I I I I I I Il I

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

I I

/@I I I I.1

I I

s-14

TROUBLESHOOTING

Caitses

Water temperature (overheating)

becomes too high

General causes why water temperature becomes . Lack of cooling water (deformation, damage . Drop in heat dissipation efficiency . Defective cooling circulation system . Rise in oil temperature of power train *

Carry out troubleshooting

too high of fan)

for chassis.

Legend 0 : Possible causes (judging from Questions and check items1 Q : Most probable causes (judgingfrom Questions and Check items) A : Possible causes due to length of use (used for a long period) : Items to confirm the cause. Confirm recent repair history Degree of use

Suddenly overheated

Condition of overheating

.P z 2 u

Rises quickly Water temperature gauge

000

Always tends to overheat

Operated for long period

0 0

Does not go down from red range

0 0

I I I I I lol I I I I I I I lol I

IRadrator water level sensor liahts up AFan belt whines under sudden load

white oil is floating on cooling water

r ..

Coohnq water flows out from overflow hose

I Excessive air bubbles inside radiator, water spurts back

I Engme 011level has risen, oil is cloudy white

I I I I I I I I Iol I I I I I I I I I I I I 101 I I I I I I I I I lot I Iol I

I There is play when fan pulley is rotated

Power train oil temperature enters red range before engine water temperature

Temperature difference between top and bottom radiator tank is excessive Temperature difference between top and bottom radiator tank is slight When water filler port is inspected,the core is found to be clogged When a function test is carried out on the thermostat, it does not open even at the cracking temperature When water temperature is measured, it is found to be normal

When measurement is made with radiator cap tester, set pressure is found to be low When compression pressure is measured, it is found to be low Remove oil pan and check directly

Remedy

20-267 0

s-15

TROUBLESHOOTING

S-15

Abnormal

noise is made Causes

Judge if the noise is an internal noise or an external noise. General causes why abnormal noise is made . Abnormality due to defective parts . Abnormal combustion noise . Air sucked in from intake system

Legend 0 : Possible causes (judging from Questions and check items) 0 : Most probable causes (judgingfrom Questionsand Check items) n : Possible causes due to length of use fused for a long period) 0 : Items to confirm the cause. 1Confirm recent repair history Degree of use g .-6 I z u

Condition of abnormal noise

III

III1

Operated for long period Gradually occurred Suddenly occurred

Non-specified fuel has been used Engine oil must be added more frequently

nColor or exhaust gas

I Blue under lioht load Black

Metal particles are found in oil filter Blow-by gas is excessive Noise of interference is heard from around turbocharger Engine pickup is poor and combustion is irregular When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low z c

Abnormal noise is loud when accelerating engine

% o

Clanging sound is heard from around cylinder head

Leakage of air between turbocharger and head, loose clamp 1Vibrating noise is heard from around muffler IWh en comoression oressure is measured. it is found to be low When turbocharqer is rotated bv hand, it is found to be heaw Remove gear cover and check dire&

Stop fuel injection to one cylinder at a time. If there is no cn change in engine speed, that cylinder is not working .5 When controlrackis pushed,it is found to be heavy or does not return z Injection pump test shows that injection amount is incorrect Fan is deformed, or belt is loose When valve clearance is checked directly, it is found to be outside standard value Remove cylinder head cover and check directly When muffer is removed, abnormal noise disappers Metal particles are found in oil pan, oil filter

20-268

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

TROUBLESHOOTING

S-16

Vibration

S-16

is excessive

If there is abnormal noise together with the vibration, carry out troubleshooting for “Abnormal noise is made”. General causes why vibration is excessive . Defective parts (abnormal wear, break-

. l

age) Improper Abnormal

alignment combustion Causes

Legend 0 : Possible causes (judging from Questions and check items) Q : Most probable causes (judgingfrom Questions and Check items) A : Possible causes due to length of use (used for a long period)

Condition of vibration

Remove oil pan and check directly

Injection pump test shows that injection amount is incorrect

I I I I I I I I

I.1

Dent in vibration damper

20-269 0

TROUBLESHOOTING OF ENGINE, TRANSMISSION, PARKING BRAKE ELECTRIC SYSTEM (E MODE)

Electrical E- 1

circuit system . . .. . .. . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . .. . .. . . . . . . .. . . .. . . .. . . .. . . . . . . .. . .. . . . . . . .. . .. . . . .. . . 20-302

Engine does not start circuit . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . .. .. .. . . . . . . . . .. . . . . . . . .. . . . . . . . . . . . .. .. . . . . . . .. . . . . . . .. . . . . . . 20-306

Inspection

of starting

inspection

of battery - battery

Inspection

of starting

switch - engine

Engine

E- 3

Engine stops when traveling Parking

. .. . . . . . . . . . . .. . .. . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . .. . . . . . . .. . . .. . . . . . . .. . .. . . . . . . .. . .. . . . . . . .. . . . . . .. 20-310

brake does not work

If parking

brake does not work when

If parking

brake does not work then air pressure

(does not wotk as emergency E- 5

Parking

brake is not released

E- 6

Parking

brake is released

E- 7

When

parking

(Parking z &

E- 8

E- 9

brake is applied,

brake is working

is ON (applied)..............

20-311

has dropoed

brake) ,........................................................................

switch

starting

transmission

20-311

is turned

ON . .. . .. . . . . . .. .. . . . . . . . . .. . . . . . . .. . .. . . .. . .. . . 20-314

deos not enter neutral.

. . . . . . . .. . . .. . . . . . . . .. .. . . . . . .. .. . . . . . . . . .. . . . . . . . .. . . .. . . . . . .. . .. . . . . . .. . . . . . .. 20-314

normally.)

does not work normally

Problem

in parking

brake, transmission

Defective

continuity

in FORWARD

Defective

continuity

in REVERSE solenoid

Contact

cut-off switch,

neutral

relay circuit ..............

20-316

circuit.. ......................................................

.20-318

circuit.. .........................................................

20-320

solenoid

in F-R circuit ..........................................................................................................

20-322

e) Problem

in speed solenoid

20-326

in speed circuit .....................................................................................................

Contact

Kick-down

Fl - F3 switches

switch

E-II

Kick-down

operation

E-12

Kick-down

works

E-13

Machine

kick-down

switch

is ON

relay does not carry out self-hold is not canceled

by mistake

when

does not travel when is not carried

operation)

. .. . . . . . .. . .. . . . . . . .. . . .. . . . . . . .. . . . . . .. 20-339

. . .. . . .. . . . . . . .. . .. . . . . . . .. . .. . . . . . . . .. . .. . . . . . .. . . . . . . . .. . . .. . . . . . . .. .. . . . . . . .. . . .. . . 20-340 traveling

kick-down

in F2 . . . . . . . . .. . . .. . . . . .. . . . .. . . . . . .. . . .. . . . . . .. . . . . . . . .. . .. . . . . . .. . 20-342

switch

is pressed . . .. .. . . . . . .. . . . . . . . . . . . .. . . . . . . .. .. . . . . . . .. . . . 20-342

out

Preheating

is not carried

out automatically

Preheating

is not carried

out normally

Preheating

20-330

correctly) .. . . . . . . . . . . .. . . . . . . .. . .. . . . . . . . . . . .. . . . . . . .. . .. . . . . . . .. . . .. . . .. . . .. . . . . . . .. . .. . . . . . . .. . 20-336

only works when

Preheating

cuicuit.. ..................................................................................

switch does not work.

Kick-down

E-15

brake switch

. . . . . . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . .. . . .. . . .. . .. . . . .. . . .. .. . . . . . . . .. . .. . . .. . .. . 20-312

when

(Kick-down

E-14

parking

Transmission

(Normal E-10

stop motor . . .. . .. . . . . . . .. . . .. . . . . . . .. . .. . . . . . .. . . . . . . . . . .. . . . . . .. . . 20-308

does not stop .. . . . . . . . . . . .. . . .. . . . . . .. . .. . .. . . . . . . . .. . . . . . . . . . .. . .. . . . . . . . .. . . . . . . . . . .. . . . . . . .. . .. . . . . . . .. . . .. . . . . . .. . . . . . .. . 20-310

E- 2

E- 4

switch . . . . . . . .. . . . . . . . .. . . . . . . . . .. . .. . . . . . . .. . . . . . .. .. . . . 20-306

relay - starting

. . . . . . . . .. . . .. . . . . . .. . . .. . . . . . .. . . . . . . .. . .. . . . . . . . .. . .. . . . . . .. . . . . . . . 20-345

or automatically

. . .. . . . . . . . .. . . . . . . . . . .. .. . . . . . . .. .. . . . . . .. . . . . . 20-346

stays on

Automatic

preheating

is not canceled

Preheating

continues

even when

.. . . .. . . . . . .. . . . .. . . .. . .. . . . . . . .. . . .. . . . . . . .. . . . . . . . . . .. . . . . . .. . . .. . .. . .. . . . . . 20-348

heater switch

is turned

OFF . . . . . . . .. . .. . . .. . .. . . . . . . .. . . . . . . . .. . 20-350

20-301 0

TROUBLESHOOTING

ELECTRICAL CIRCUIT SYSTEM

ELECTRICAL CIRCUIT SYSTEM ENGINE STARTING CIRCUIT SYSTEM

T/M control

switch

Gear shift switch n

F-R switch n To transmission control valve To meter

Panel

-_-_-_-_-_-_-_CN129

CNl30

CN131

CNl32

N222

Starting

switch

CN14 #tart

ins

motor r

CN77 I$

CN85

86G”

CNI 14

TDW01269

20-302 0

ELECTRICAL CIRCUIT SYSTEM

TROUBLESHOOTING

ENGINE STOP CIRCUIT SYSTEM

atterv clay Starting

switc

u341

To startins

IPOB

CN222 Main

breaker

CNl 14

__._

To start motor

ino

Alternator

TDW01270

20-303 0

TROUBLESHOOTING

TRANSMISSION

ELECTRICAL CIRCUIT SYSTEM

CONTROL, PARKING BRAKE CIRCUIT SYSTEM

CN31 Parking brake valve

Parking safety

Emergency

brake relay

Neutralizer

brake

relay

Transmission cut-off switch

Transmission cw ;;;,;t;, ,wiyhe 1

1 Main

breaker

_-_-_-_____

m7h(;RtKl switch Gear ‘switch

shift

To battery relay

CN89

F-R switch

Transmission CNQQ~.-_-_-_-.

8_1

CNlOl 2nd-1st

selector

2nd

solenoi

Kick-down

20-304 0

motor(E)

relay

CN83 d relay

swi tc h relay

switch

harnes

_______

REVERSE solenoid

relay

FORWARD solenoid

relay

Back-up

I amp relay

To stop lamp 6r back-up To back-up lamp

lamw fuse

CN228

TDW01271

TROUBLESHOOTING

ELECTRICAL CIRCUIT SYSTEM

PREHEATING CIRCUIT SYSTEM

CN85

timer

Heat

Main

breaker

CN300

heater

relay

To startins

motor--

air

heater

air

heate TDWO 1272

20-305 0

E-l

TROUBLESHOOTING

E-l

Engine does not start 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. (CNOA( When disconnecting connectors 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 b) Inspection of battery Cause Remedy - starting switch.

Inspection

of starting

circuit Defective starting motor ass’y

‘ES

Is voltage between

1) Disconnect CN125, 126 (starting motor ass’y) 2) Turn starting switch to START.

between CN125, 126 (3) (female) and chassis ?

Is there continuity between CN16 (9) ’ (male) and (l)?

I) Disconnect CN125.126 N (starting motor inlet) 2) Place F-R lever at N. 3) Turn starting switch OFF.

YES

l-l

1) Disconnect NO T-adapter (socket adapter) to CN16 (F-R lever inlet). 2) Place F-R lever at N. 3) Turn starting switch OFF.

YES

between CN14 (3) (female) and

of battery

- battery

relay - starting

2 YES

switch ON. 2) Measure voltage of each connecting terminal of thick cable. 1) Turn starting switch ON c) OFF.

1) Turn starting switch ON. h

20-306 a

‘ES

Replace

After inspection, repair (clean) or repair

Defective F-R switch

After inspection, repair Wean) or repair

Defective contact, or disconnection in wiring harness between CN125, 126(l)(female)-CN114 (4) - CN85 (5) - CN14 (3)

After inspection, repair (clean) or repair

Defective starting switch

1) Connect T-adapter (socket adapter) to CN14 (female) 2) Turn starting switch to START.

b1 Inspection

Defective contact, or disconnectionin wiring harness between CN125, 126 (31 (female) - CN114 (7) CN85 (8) - CN16 (9) (female), or defective contact. or disconnectionin wiring harness between F-R switch chassis ground

switch

Defective contact, or disconnection in thick cable between starting motor - battery relay

After inspection, repair (clean) or repair

Both terminals are NO: Defective contact, or disconnectionin wiring harness between battery battery relay One terminal is ON: Defective battery relay

After inspection, repair (clean) or repair

Defective battery relay

Replace

Defective contact, or disconnection in wiring harness between battery 5 YES relay signal terminal (t) Is voltage between CN116 (2) or CN226 (2) YES starting switch (diode) - CN85 12)- CN14 (2) terminal BR and 4 -starting switch terminal BR chassis 20 - 3OV? Is voltage between Defective starting switch starting switch _ 1)Turn starting NC Defective contact, or terminal B and switch ON. disconnection in wiring chassis 20 - 3OV? harness between banery 1 j Connect relay - CN116 (1) - CN85 (7) T-adapter NO - CN77 (1) - fuse - CN77 (21 (socket adapter) to CN14 ( female) - CN14 (1) -starting switch termenal B 2) Turn starting switch OFF.

Replace

After inspection, repair (clean) or repair

TROUBLESHOOTING

Inspection

of starting

E-l

switch

- engine

stop motor

YES

4 YES Is there continuity ES between CN275 (female) (8) and

I‘1

1) Disconnect CN275.

I) Turn starting switch ON cf OFF and check visually.

between CN275 (female) (3) - (7). (5) - (7) as shown I) Disconnect CN275.

6 YES

$Z&-?.I Is voltage between CN253 h10 (1) and chassis 120-3OV?

Is voltage between CN275 NO (female) (4) and chassis 20 - 3OV?

1) Disconnect CN253. 1) Turn starting switch ON.

I) Disconnect CN275.

Table

-II

z & x

1 Operation

Continuity

Starting

switch

(3) - (7): No continuity

(5) - (7): Continuity

Starting

switch

OFF

(5) - (7): No continuity

(3) - (7): Continuity

20-308 0

E-l

TROUBLESHOOTING

Cause

Remedy

Defective adjustment of - linkage between engine stop motor and govermor

Prdjust

Defective engine stop motor

Replace

Defective contact, or disconnection in wiring harness between CN275 (female) (8) and chassis ground

after

inspection,

*epair

or replace

4fter

inspection,

.epair

or replace

Vter

inspection,

,epair

or replace

Defective engine stop relay. or defective contact, or disconnection in wiring harness between CN275 (female) (5) - CN253 (51, or bwtween CN275 (female) (7) CN253 (3) Defective contact, or disconnection in wiring harness between CN253 and chassis ground

(2)

Defective kill switch, or defective contact, or disconnection in wiring harness between CN253 tllCN13 11). (2) - CN14 (4) starting switch terminal ACC Defective contact, or disconnection in wiring harness between CN275 (female) (4) - CN272 (2) CN77 (2). (1) -main breaker

Wter inspection, ,epair

or replace

4fter

inspection,

.epair

or replace

20-309 0

E-2, E-3

TROUBLESHOOTING

E-2 Engine does not stop * * *

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. 1) When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNOA( When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check.

Cause

Defective adjustment of linkage between engine stop motor and govermor

Remedy

idjust

Defective engine stop motor 3

or relay, or defective contact, or disconnection in wiring

YES

harness between CN253 (3) (female) - CN275 (7). (8) chassis ground Defective contact, or disconnectionin wiring harness between CN253 (61 lfemalet - CN275 (31, (4) CN77 (2)

Is voltage

; between CN253 (6) (female) and chassis 20 - 3OV?

1) Turn starting switch ON tf OFF and check

between CN253

Connect (socket adapter) to CN253 (female). 4 YES

1) Connect T-adapter (socket adapter) N to CN253 (female). 2) Turn starting switch OFF.

1) Turn starting switch OFF.

ieplace

Wter inspection, epair or replace

Contact between +24V and wiring harness between CN14 (5) (male) - kill switch CN253 (11,or misconnectingwiring

\*er inspection, epair or replace

Defective starting switch

ieplace

Defective adjustment of linkage between engine stop motor and govermor

idjust

Defective engine stop relay

ieplace

Defective contact, or disconnection in wiring harness between CN253 (2) (female) chassis groud

dter inspection, epair or replace

Defective engine stop motor, or contact between +24V and wiring harness between CN253 (3) (female) - CN275 (7). (8) -chassis

dter inspection, epair or replace

E-3 Engine stops when traveling -I

4YE!

1) Turn starting switch ON ++ OFF and check visually. between CN253

1) Connect T-adapter (socket adapter) to CN253 F (female). 2) Turn starting switch ON.

Is voltage : between CN253 (3) (female) and chassis?

Is there continuity YES_ between CN253 (2) _ (female) and 3 chassis? _

1) Turn starting switch OFF.

1) Connect T-adapter NO (socket adapter) to CN115 (female). 2) Turn starting switch ON. 5 YES

Defective contact, or disconnection in wiring harness between CN253 (1) Ifemale) kill switch - CN14 15) (female) Defective starting switch

dter inspection, epair or replace

leplace

E-4

TROUBLESHOOTING

E-4 Parking brake does not work *

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. (CNOA( When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check.

Ir * *

Cause

If parking brake does not work switch is ON (applied).

when

parking

YES 1 Is problem removed when CNII is disconnected? I) Disconnect CNII. 2) Start engine. (Charge air pressure). 3) Turn parking brake switch ON.

YES 2 Is there continuity between CNll NO (female) (1) and (2)? _ 1) Disconnect CNII. 2) Turn starting switch OFF. 3) Disconnect CN53. 4) Disconnect CN70.

z Ki g

1 YES II

removed when CNl09 is disconnected? 1) Turn starting switch ON. 2) Turn parking brake switch ON c) OFF.

defective parking brake witch

place

Contact of wiring harness t CNll (female) (I) and 2)

ter inspection, lair or replace

jefective parking brake olenoid

iplace

:ontact of wiring harness ,t CNII (female) (1) and 3)

ter inspection, lair or replace

lefective emergency brake switch

!place

Defective parking brake olenoid

:place

_ 3 YES Is voltage between CN35 (female) (1) NO and chassis approx. OV? 1) Connect T-adapter (socket adapter) to CN35. 2) Stan engine. (Charge air pressure) 3) Turn parking brake switch ON.

If parking brake does not work then air pressure dropped. (does not work as emergency brake)

1Is oroblem

Remedy

brake

has

20-311 0

TROUBLESHOOTING

E-5

E-5 Parking brake is not released * Ir * * *

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. (CNOA( 1) When disconnecting connecotrs or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check. The air tank pressure shoud be 0.69 - 0.81 MPa 17 - 8.3 kg/cm*). If it is below the standard pressure, carry out troubleshtooting of chassis.

2 Is there continuity between CN35 (2) (male) and chassis?

YES _

I) Disconnect

CN35. 1Turn starting switch OFF.

YES

YES between

CN35

YI removed when relay is replaced?

chassis 20 - 3OV?

1)Connect

1) Interchange parking brake safety relay (CN70) with backup lamp

T-adapter (socket adapter) to CN35 (male). 2) Start engine. (Travel) (Charge air pressure)

s continuity of CNll (1). (2), (3)

1 t

I) Disconnect CNII. 2) Turn starting switch OFF. 3) Turn parking brake switch ON cf OFF.

20-312 0

relay (CN23O). 2) Start engine. (Charge air pressure)

Is problem removed when NO short connector is connected? 4 1) Connect short connector to CN 109 (female). 2) Start engine. (Charge air pressure)

‘ES -

i N

between CN70 (3) (female) and chassis 20 - 3OV? I) Disconnect CN70. 2) Turn starting switch ON.

r 1) Disconnect CNll. 2) Turn starting switch ON. 3) Turn parking brake switch ON + OFF.

E-5

TROUBLESHOOTING

Table 1 Operation

Between terminals

(1) and (2) Between terminals (3) and (2)

ON (PARKING)

No continuity

Continuity

OFF (TRAVEL)

Continuity

No continuity

YES

Is voltage YES between CN109 (1) (female) and 9 chassis 20 - 3OV? Is there continuity / I YES between CN70 (1) I) Disconnect NO CN109. (female) and 8 2) Turn starting switch ON. ._ chassis? P 3) Turn parking brake switch ON + OFF. Is voltage 1) Disconnect _ _ between CN70 CN70. NO (2) (female) and 2) Turn starting chassis 20 - 3OV? switch OFF. 1) Disconnect CN70. 2) Turn starting NO switch ON. 3) Turn parking brake switch ON.

Cause

Defective parking brake solenoid

Replace

Defective contact, or disconnection in wiring harness between CN109 (2) (female) - CN35 (1) (male)

After inspection, repair or replace

Defective contact, or disconnection in wiring harness between CN109 (1) (female) - CN31 (11) (female)

After inspection, repair or replace

Defective contact, or disconnection in wiring harness between CN70 (1) (female) - chassis

After inspection, repair or replace

Defective contact, or disconnection in wiring harness between CN70 (2) (female) - CNll (2) (female)

After inspection, repair or replace

1Defective contact, or disconnection in wiring harness between CN 11 (2) (female) - CN70 (5) (female) Defective contact, or disconnection in wiring harness between CN70 (3) (female) - CN78 (10) -fuse

_-rive

Remedy

parking brake

After inspection, repair or replace

Replace

TROUBLESHOOTING

E-6, E-7

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. (CNOA( 1) When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check. Cause

YES

V ES 1 relay is replaced? I) Interchange

1) Discon _.... CNll.

2) Start engine. (Charge air pressure) 3) Turn starting switch ON.

YES

Is there continuity NO between CN70 (3) (female) and (5)? 1) Disconnect CN70. 2) Turn starting switch OFF.

E-7 When parking brake is applied, transmission does not enter neutral (Parking brake is working normally) 1 YES Is there continuity between neutralizer relay CN72 (male) (3) and (5)? 1) Disconnect neutralizer relay CN72. 2) Turn starting switch OFF.

20-314 0

Defective parking brake safety relay

qeplace

defective parking brake switch

qeplace

Iisconnection in wiring Tarness between CN70 (3) and (5). (2) (female)

jfter inspection, .epair or replace

Iisconnection in wiring ?arness between CNll (1) and (3) (female)

Jfter inspection, .epair or replace

Abnormal contact ,etween +24V and wiring Tarness between CN72 (5) - CN18 (1). (2) - CN89 (8) :N99 (A)

Wer inspection, ,epair or replace

~zM-..-_\,~,when 3

(CN70) with backup lamp relay (CN230). 2) Start engine. (Charge air pressure). 3) Turn starting switch ON.

Remedy

3efective neutralizer relay

TROUBLESHOOTING

E-8

E-8 Transmission * Jr * *

does not work normally

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. (CNOn( 1) When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check.

Carry out a check of the transmission solenoid control circuit with the tester as follows.

Stop the machine on level ground blocks under the tires.

Turn the starting

A 3.

z Ki d

switch

1 Transmission

Normal

Pin No.

and put

1. Install a T-adapter (for Econoseal) to CN89, and check the voltage between the pin in Table 1 and the chassis ground. 2.

Table

g u 2

Actuation

Table

CN89 (1)

(2)

(3)

235678

(F)

FORWARD (F)

O”

REVERSE (RI

(RI

;‘,o,F;

Remedy

‘Goto 0

Tab’e *

ON.

Do not start the engine.

Turn the parking lease)

brake switch ON+OFF

(re-

When depressing the foot brake, depress the R.H. brake. + If the L.H. brake is depressed, the transmission is cut-off, so it is impossible to check. Check the voltage and continuity 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.

0: 0 - 0.5V [continurousl 0:

20 - 30V [battery

Table

voltage1

Result of inspection

when

operating

F-R lever Trouble-

Result of Cause

shooting

Problem in transmission cut-off switch, parking brake, neutral relay circuit

Go to E-8-a)

Problem

in F circuit

Go to E-8-b)

(R) Problem

in R circuit

E-8-c)

in R circuit

Go to E-8-d)

inspection

0 No [battery voltage]

at all

0 No [continuous1

(F)

0 No

Go to

[continuous]

0 [continuous] at two places

Table

Problem

Result of inspection

vottage]

in power

speed lever Troubleshooting

Cause

at att Problem

0 [continuous] at two places or more

when operating

circuit

E-z Contact

in speed

circuit

Go to E-8-f)

20-315 0

E-8

TROUBLESHOOTING

Problem

in parking

brake, transmission

cut-off

switch,

neutral

relay circuit

2 YES YE

transmission cutoff switch is turned OFF? ) Start engine.

Is problemremoved whenshortconnector is connectedinsteadof transmission cut-off

1) Connect short connector to CN21 (female). 2) Turn transmission cut-off selector switch ON. 3) Start engine.

YES

removed when relay is replaced?

J YES

1) Interchange neutralizer relay (CN72) with backup lamp relay (CN230). hlo 2) Start engine. -

Is problem removed when relay is replaced?

I) Interchange parking brake safety relay (CN70) with backup lamp relay (CN230). 2) Start engine.

Is voltage between CN72 (2) (female) and chassis 20 - 3OV? I 1) Disconnect CN72. 2) Turn starting switch ON.

1) Disconnect CN72. 2) Turn starting switch OFF.

NO d

YES I-

CN70 (female) (2). F

CNll (male) (1). (2), (3) as shown 1) Disconnect CNll. 2) Turn starting switch OFF. 3) Turn parking brake switch ON -OFF.

2) Turn starting switch ON. 3) Turn parking brake switch ON (applied).

20-316

E-8

TROUBLESHOOTING

Table 1 EOoeration

IBetween

terminals

(1) and (2) IBetween

terminals

(3) and (211

ON (PARKING)

No continuity

Continuity

OFF (TRAVEL)

Continuity

No continuity

Cause

YES

Is there continuity between CN70 (1) (female) and chassis? 1) Disconnect CN70. 2) Turn starting switch OFF.

Remedy

Defective transmission cut-off switch

Replace

Defective contact, or disconnection in wiring harness between CN21 (female) (1). (2) - CN18 (female) (1). (2)

4fter inspection, repair or replace

Defective neutralizer relay

Redace

Defective parking brake safety relay

Replace

Defective contact, or disconnection in wiring harness between CN72 (5) (female) - CN21 (1) (female) CN21 (2) (female) - CN99 (A (female)

After inspection, repair or replace

Defective contact, or disconnection in wiring harness between CN72 (1) (female) and chassis

After inspection, repair or replace

Defective contact, or disconnection in wiring harness between CNll (1) (female) - CN72 (2) (female)

After inspection, repair or replace

Defective contact, or disconnection in wiring harness between CN70 (1) (female) -chassis

After inspection, repair or replace

- If incorrectvoltage for (3): Defective contact, or disconnectionin wiring harness between CN70 (3) (female) - CN78 - fuse * If incorrectvoltage for @I, (5 Defective contact, or disconnectionin wiring harness between CN70 (2). (51 (female) - CNll (2). CNll (3) (female) - CN78 - fuse

After inspection, repair or replace

Defective parking brake switch

20-3 17 a

E-8

TROUBLESHOOTING

Defective continuity in FORWAED solenoid circuit

YES

ES Is there continuity YIES between CN99 (D) (female) and chassis?

1) Disconnect CN99. 2) Turn starting switch OFF. 3) Place F-R lever in FORWARD.

YES

h 1) Interchange FORWARD solenoid relay (CN228) with REVERSE solenoid relay (CN94). 2) Start engine. 3) Turn parking brake switch ON c) OFF. 4) Place F-R lever in FORWARD.

between CN99 (A) (female) and chassis 20 - 3OV? ) Disconnect CN99. 2) Turn starting switch ON. 3) Turn parking brake switch ON cf OFF.

20-318

between CN228 (5)

5 I

(6) (female) and

, between CN16 I

1) Disconnect CN16. 2) Turn starting switch OFF. 3) Place F-R lever in FORWARD.

I) Disconnect CN228. 2) Turn starting switch ON.

CN228. 2) Turn starting switch OFF. 3) Place F-R lever in FORWARD.

TROUBLESHOOTING

E-8

7 YES Is there continuity between CN228 (1) (female) and chassis? 1) Disconnect CN228. 2) Turn starting switch OFF.

II NO

8 YES

Is there continuity between CN16 (1) (female) and chassis? 1) Disconnect CN16. 2) Turn starting switch OFF.

Cause

Remedy

Defective FORWARD solenoid relay

Replace

Defective contact, or disconnection in wiring harness between CN228 (1) (female) -chassis

After inspection, repair or replace

Defective contact, or disconnection in wiring harness between CN16 (2) (female) - CN228

After 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 CN228 (6) (female) - CN72 (5)

After inspection, repair or replace

Defective F-R lever switvh

Reolace

Defective contact, or disconnection in wiring harness between CN99 (A) $arh!T$zc: (female) -transmission cut-off switch - CN53 (5)

20-319 a

E-8

TROUBLESHOOTING

Defective

continuity

in REVERCE solenoid

circuit

YES

2 between CN99 (C)

I) Disconnect CN99. 2) Turn starting switch OFF. 3) Place F-R lever in REVERSE.

removed

YES when

1) Disconnect CN99. 2) Turn starting switch ON. 3) Turn parking brake switch Oh tf OFF.

3) Turn parking brake switch ON c) OFF. 4) Place F-R lever in REVERSE.

Is there continuity between CN94 (5) (female) and chassis?

5 d I) Disconnect I) interchange REVERSE solenoid relay (CN94) with FORWARD solenoid relay (CN228). 2) Start engine.

Ichassis20-30V?

20-320 0

YES 6

(6) (female) and chassis 20 - 3OV?

CN94. 2) Turn starting switch OFF. 3) Place F-R lever in REVERSE.

lNO

llEfhereCDntinYity

between CN16 NO (male) (1) and (3)~ 4 1) Disconnect CN16. 2) Turn starting switch OFF. 3) Place F-R lever in REVERSE.

CN94. 2) Turn starting switch ON. 3) Turn parking brake switch ON + OFF.

‘No

z 5-

E-8

TROUBLESHOOTING

Cause

Remedy

Replace

7 YES Is there continuity between CN94 (1) (female) and chassis? I) Disconnect CN94. 2) Turn starting switch OFF.

9 YES

Is there continuity between CN16 (I) (female) and chassis? 1) Disconnect CN16. 2) Turn-starting switch OFF.

Defective REVERSE solenoid relay

Replace

Defective contact, or disconnection in wiring harness between CN94 (2) (female) - CN99 (C)

After inspection, repair or replace

Defective contact, or disconnection in wiring harness between CN94 (I) (female) -chassis

After inspection, repair or replace

Defective contact, or disconnection in wiring harness between CN94 (5) (female) - CN16 (3)

After 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 CN94 (6) (female) - CN78 (fuse)

After inspection, repair or replace

Defective

F-R lever switch

Defective contact, or disconnection in wiring

.._...___ I_...__..

_.._I

(female) -transmission cut-off switch - CN72 (5)

I After inspection, repair or replace

20-321 0

E-8

TROUBLESHOOTING

Contact

in F-R circuit (l/2)

Is there continuity between CN99 (D) (male) and chassis7 Is there continuity between chassis and (0. (FL(G), and

Continuous locations when there is problem in FORWARD.

(HI?

Is there continuity between CN99 CD)

I) Disconnect CN99. !) Turn starting switch OFF.

YES

NO ,!f~~~~~~~y?

1) Disconnect CN99. 2) Disconnect CN89. 3) Turn starting switch OFF.

Is there

continuity

between

CN89

1) Disconnect CN99. 2) Disconnect CN89. 3) Turn starting switch OFF.

Check for lever positionsother than specified where there is continuity,

(5)

YES

(male) and (1). (2), (3). (6)?

1) Connect T-adapter to CNSS. 2) Turn starting switch ON. 3) Turn parking brake switch ON + OFF.

Continuous locations when there is problem in REVERSE.

YES

, Is there continuity between CN99 IC) (male) and chassis? - Is there continuity between chassis

yr$fDL (FL (G). and 1) Disconnect CN99. 2) Turn starting switch OFF.

20-322 0

10 YES

Is there continuity between CN99 (0 NO (female) and connect body? = I) Disconnect CN99. 2) Disconnect CN89. 3) Turn starting switch OFF.

To A (2/2)

Is there continuity between CN89 (5) (female) and chassis? 1) Disconnect CN89. 2) Disconnect CN16. 3) Disconnect FORWARD solenoid relay (CN228). 4) Turn starting switch OFF.

YES 6

Is there continuity between CN16 (2) (male) and (1). f3), (4). (5). (6). (8)?

1) Disconnect CN16. 2) F-R lever at N or R position. 3) Turn starting switch OFF.

E-8

TROUBLESHOOTING

Remedy

Cause

- Defective insulation

between

CN92 (D) (male) and connector body, or abnormal contact between chassis ground and wiring harness of After inspection, CN99 CD)inside control valve repairor replace * Defective wiring between pins of CN99

Abnormal contact with wiring harness between CN89 (5) (male) - CN99 ID) (female) and After inspection, wiring harness between CN89 repair or replace (1). (21, (31. (6) (male) -CN99 0. (F), (GL (H) (female) Abnormal contact with wiring harness between CN89 (5) (female) - CN288 (2) (female) and chassis or ground connection wiring

Defective transmission control switch

YES

. II

1. -1. ._

Is there continuity between CN16 (2) l-l ., I \mare, ano IIcnassrsr

1) Disconnect CN16. 2) Turn starting switch OFF.

After inspection, repair or replace

8 YES

between CN16 (2) NO (female) and chassis? 1) Disconnect NO CN16. 2) Disconnect CN228. 3) Turn starting switch OFF.

Replace I

Abnormal contact with wiring harness between CN16 (2) (female) - CN228 (5) (female) and chassis or ground connection wiring Short circuit between terminals (1) and (2) of a FORWARD solnoid relay CN228 (male)

After inspection, repair or replace

Replace

* Defective insulation between CN99 (Cl (male) and connector body, or abnormal contact between chassis ground and wiring harness of After inspectio”’ cN99 (D) inside c0mr0l valve replace . Defective wiring between pins of CN99

repair or

Defective insulation between CN99 0 (female) and connector body

After inspection, repair or replace

20-323 0

TROUBLESHOOTING

Contact

E-8

in F-R circuit (2/2)

YES

A (From l/2) I

1) Disconnect CN99. 2) Disconnect CN89. 3) Turn starting switch OFF.

20-324 0

Is there continuity between CN89 (6) (male) and (l), (2). (3). (5)?

Y ES

between CN89 (6)

Y 1:3

“,.“WCt 1) Disuvllllr CN89. 2) Disconnect CN16. 3) Disconnect REVERSE solenoid relay (CN94). 4) Turn starting switch OFF.

between CN16 (3) (male) and (1). (2). (4). (5). (6). (8)? 1) Disconnect CN16. 2) F-R lever at N or R position. 3) Turn starting switch OFF.

YES

14 i

Is there continuity between CN16 (3) NO (male) and chassis?

1) Disconnect CN16. 2) Turn starting switch OFF.

15 YES

1) Disconnect CN16. 2) Disconnect CN94. 3) Turn starting switch OFF.

E-8

TROUBLESHOOTING

Cause

Remedy

1ll;l;iy;ztgmission

Rep,ace

Defective transmission control switch

Replace

20-325 0

E-8

TROUBLESHOOTING

Problem

in speed solenoid

circuit (l/2)

YES 3

4 YES I) Disconnect CN99. 2) Place speed lever in 1st. 3) Turn starting switch OFF.

Y ES

2nr

20 to problem speed range

IES

between CN99 (B) (female) and 1) Disconnect CN99. 2) Turn starting switch ON. 3) Turn parking brake switch Oh I + + OFF.

20-326

Is there continuity between CN16 (8) (female) and chassis?

I) Connect T-adapter (socket adapter) to CN16 (female). 2) Turn starting switch OFF.

I 3r(

Is there continuity between CN99 (G) (female) and chassis?

N 1) Disconnect CN16. NO 2) Place speed lever in 1st. 3) Turn starting switch OFF.

YES 6

Is problem - removed when 1) Disconnect 7 YES _ _ NO relay is replaced? CN99. ~ Is problem 2) Place speed 1) Interchange 2nd - removed when lever in 2nd. solenoid relay NO relay is replaced? 3) Turn starting KN83) with switch OFF. backup lamp I) Interchange NO 4) Turn parking relay (CN230). Znd-1st selector brake switch ON 2) Start engine. relay (CNlOl) -+ OFF. with backuo 3) Turn oarkina lamp relay’ brake’switch ON (CN230). + OFF. 2) Start engine. 3) Turn parking brake switch ON + OFF.

E-8

TROUBLESHOOTING

To A (To 2/2)

ToB(To2/2)

Cause

Remedy

Defective 1st solenoid

Zeplace

Defective contact, or disconnection in wiring harness between CN99 (H (female) - CN89 - CN16 (4

Uter inspection, epair or replace

Defective speed lever switch

teplace

Defective 2nd solenoid

Ieplace

Defective 2nd solenoid relay

leplace

Defective Znd-1st selector relay

leplace

Wter inspection, *epair or replace 1Defective contact, or disconnection in wiring harness between CN99 (8) (female) - CN89 (7) - CN78 (8) -fuse - CN78 (7) - main breaker

4fter inspection, .epair or replace

20-327 0

E-8

TROUBLESHOOTING

Problem

in speed solenoid

circuit

(2/2)

10 YE

chassis 20 - 3OV?

A (From l/2) -

CN83. 2) Turn starting switch ON. 3) Turn parking brake switch ON + OFF.

between CN83 (3)

Is there continuity between CN83 (1) (female) and chassis?

1) Disconnect CN83. 2) Turn starting switch OFF.

1) Disconnect CN83. 2) Place speed lever in 2nd. 3) Turn starting switch OFF.

11 YE between CNlOl (3) N

1) Disconnect CNlOl. 2) Turn starting switch OFF. YES

BH_

1) Disconnect CN16. 2) Place speed lever in 2nd. 3) Turn starting switch OFF.

YES

Cause

Remedy

Iefective contact, or fisconnection in wiring iarness between CN83 (5) female) - CN99 (G)

lher inspection, .epair or replace

Iefective contact, or fisconnection in wiring larness between CN83 (2) female) - power source

ifter inspection, epair or replace

Iefective contact, or fisconnection in wiring larness between CN84 (3) female) - CNIOI (6)

Wter inspection, ,epair or replace

Iefective contact, or fisconnection in wiring iarness between CNIOI 3) (female) -chassis

Wer inspection, epair or replace

Iefective contact, or jisconnection in wiring larness between CN83 (1) female) - CN16 (5)

Wter inspection, ,epair or replace

Defective speed lever iwitch

teplace

Defective 3rd solenoid

teplace

Iefective contact, or fisconnection in wiring larness between CN99 (F) female) - CN16 (6)

Ifter inspection, ,epair or replace

Defective speed lever ;witch

teplace

131

3) Turn starting switch OFF.

20-328 a

I NO

E-8

TROUBLESHOOTING

Contact

in speed circuit (l/31

2) Turn starting 4

1) Disconnect ;;;;: 2) Disconnect

YES

I 5

3) Turn starting switch OFF.

1) Connect T-adapter to CN99. 2) Turn starting switch ON. 3) Turn parking brake switch ON + OFF.

2nd and 3rd

ToA

20-330 0

2/3)

1) Disconnect CN99. 2) Disconnect CN89. 3) Turn starting switch OFF.

Is there continuity

. between CN89 (I) N

YES

(female) and chassis? 1) Disconnect CN89. 2) Disconnect CN18. 3) Turn starting switch OFF.

Is there continuity between CN89 (1) (female) and (2). (3), (5), (6P

5 Ki z

1) Disconnect CN89. 2) Disconnect CN16. 3) Disconnect CNlOl. 4) Turn starting switch OFF.

E-8

TROUBLESHOOTING

Cause

Remedy

* Defective insulation between CN99 (H) and connector body, or abnormal contact between chassis ground and wiring harness of CN99 IH) inside control valve * Defective wiring between pins of CN99 Defective insulation between CN99 IH) (female) and connect& body

After inspection, repair or replace

Aher inspection, repair or replace

Abnormal contact with wiring harness between CN89 (1) (male) - CN99 (HI (female) anc wiring harness between CN89 After inspection, (2) - (6) (male) - CN99 (C) - fG1 repair or replace (female) Abnormal contact with wiring harness between CN89 (1) (female) - CN16 (4) (female) - After inspection, CNlOl (5) (female) and chassir repair or replace wiring harness Abnormal

contact with wiring

After inspection, repair or replace

Abnormal contact with wiring harness of CN16 (4) (female) After inspection, and wiring harness of CN16 (5 repair or replace (female)

YES

7 Is there continuity

1) Disconnect CN99. 2) Disconnect CN89. 3) Disconnect CN16. 4) Turn starting switch OFF.

Is there continuity between CN16 (4) _ (male) and (1). (2L (3). (5). (6). (8)? 1) Disconnect CN16. 2) Place speed lever in 2nd 3) Turn starting switch OFF.

YES 9

Is there continuity between CN16 (4) f,,O (male) and 10 YES chassis? ~ Is there continuity between (3) and (5) 1) Disconnect NO of Znd-1st SeleCtOr CN16. CNlOl (male)? 2) Turn starting switch OFF. NO 1) Disconnect Znd-1st selector relay (CNlOl).

Defective transmission control switch

Replace

Defective transmission control switch

Replace

Defective relay

Replace

Pnd-1st selector

Abnormal contact with wiring harness of CNlOl (5) (female) and wiring harness of CNlOl (3) (female)

After inspection, repair or replace

20-331 0

TROUBLESHOOTING

E-8

Contact in speed circuit (2/31

A (From l/3)

YES 2nd

Is there continus between CN99 (G) (male1and chassis? ISthere continuity between (0. (DL IF), (G), LH)and chassis?

‘FS 12

1) Disconnect CN99. 2) Turn starting switch OFF.

3rd To B (To 3/3)

20-332 0

Is there continuity between CN99 (Gl N ) (female) and i-l connector body? I) Disconnect CN99. 3) Disconnect CN89. 3) Turn starting switch OFF.

YES 13 Is there continuity between CN89 (2) N , (male) and (1). (3), I(5). (6)?

YES

I) Disconnect CN99. 2) Disconnect CN89. 3) Turn starting switch OFF.

Is there continuity between CN89 (2) NO (female) and chassis? 1) Disconnect CN99. 2) Disconnect CN16. 3) Turn starting switch OFF.

YES 15 Is there continuity between CN89 (2) NO (female) and (l), (3). (5), (6)? 1) Disconnect CN89. 2) Disconnect CNlfi _..._. 3) Disconnect CN83. 4) Turn starting switch OFF.-

YES 16 Is there continuity _ between (3) - (5) of NO 2nd solenoid relay CN83 (male)?

1) Disconnect CN83 NO

E-8

TROUBLESHOOTING

Cause

. Defective insulation between CN99 (Gland connector body, or abnormal contact between chassis ground and wiring harness of CN99 (G) inside control valve * Defective wiring between pins of CN99 (male) Defective insulation between

~~~~~~~

Remedy

After inspection, ,epair or replace

After inspection, .epair or replace

\fter inspection, .epair or replace

harness between CN89 (2) (female) - CN83 (5) (female) and chassis or ground connection wiring

\fter inspection, ,epair or replace

Abnormal contact with wiring harness of line for CN89 (2) (female) and wiring harness 01 ?eplace line for CN89 (1). (3). (5L (6) (female)

YES 17 Is there continuity between (3) - (5) of 2nd solenoid relay CN83 (male)? I) DisconnectCN83. 2) Disconnect CN89. 3) Turn starting switch OFF.

1) Disconnect CN16. 2) Place speed lever in 1st or 2nd 3) Turn starting switch OFF.

19 YES Is there continuity . betweenCN16f5) h : (male) and chassis? 1) Disconnect CN16. 2) Turn starting switch OFF.

Replace

Abnormal contact with wiring harness of CN83 (3) (male) and wiring harness o CN83 (5) (male) -

After inspection, ,epair or replace

Defective transmission control switch

Iqeplace

Defective transmission control switch

Iqeplace

‘ES Is there continuity between CN16 (5) NO (male) and (1). (2). (3). 14). 16). (8)7

Defective 2nd solenoid relay

Abnormal contact with wiring harness between . CN83 (1) (male) - CN172 (5) (male) - CN16 (5) (male) ant I chassis or ground connection wiring

I Vter

inspection,

I.epair or replace

20-333 a

TROUBLESHOOTING

Contact

E-8

in speed circuit (3/3)

B (From 2/3)

YES 20

3rd L

Is there continuity between CN99 (F) hnale) and chassis? Is there continuity between chassis

1) Disconnect CN99. 2) Turn starting switch OFF.

YES

between CN99 (Fj (female) and connector body? 1) Disconnect CN99. 2) Disconnect CN89. 3) Turn startina switch OFF.-

L‘ES 22-

Is there continuity between CN89 (3) (male) and (1). (2). (5), (8)? 7, “;‘“^““sct ” t[&“” 2) Disconnect CN89. 3) Turn starting switch OFF.

20-334 0

YES 23

Is there continuity between CN16 (6) (male) and (I), (2), (3). (4), (51, (8)? ~ 1) Disconnect CN16. NO 2) Place speed lever in 2nd. 3) Turn starting switch OFF.

24 YES 7 Is there continuity between CN16 (6) (male) and chassis?

I) Disconnect CN16. 2) Turn starting switch OFF.

z NO

Ki z!

E-8

TROUBLESHOOTING

Remedy

Cause * Defective

insulation

between

After inspection, repair or replace

_~~,

connector

body

Abnormal

contact

After inspection, repair or replace with

wiring

harness between CN89 (2) (male) - CN99 IF) (female) and wiring harness between CN89 After inspection, repair or replace (1). (2L (5). (6) (male) - CN99 (0, (D). (F). IGL (HI (female) Defective transmission control switch

Replace

Defective transmission control switch

Replace

Abnormal contact with wiring harness between After inspection, CN16 (6) (female) - CN8g (3) repair or replace (female) and chassis or ground connection wiring

20-335

E-9

TROUBLESHOOTING

E-9 Kick-down switch does not work (l/2) (normal Fl - F3 switches correctly) * Ir Ir

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. 1) When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNOA( When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check.

YIES

YES

I ‘ES

removed when relay is replaced? I) Interchange kick-down relay (CNl72) with REVERSE _, solenoid relay n (CN94). 2) start engine.

1I Is there continuity between CN102 (I) (male) and (2) (male)? I) Disconnect CN102. 2) Press kick-down I switch. 3) Turn starting switch OFF.

I I) Interchange FORWARD solenoid relay (CN228) with REVERSE solenoid relay (CN94). 2) Start engine.

YES

removed when

YES

I) Interchange Znd-1st selector relay (CNlOl) with backup lamp relay (CN230). 2) Start engine.

YES

Is there continuity between CNlOl (I)

1) Disconnect CNlOl. 2) Turn starting switch OFF.

20-336 a

Is there continuity between CNIOI (5)

1) Disconnect CNIOI. 2) Place speed lever in 1st. 3) Turn starting switch OFF. ‘NO

IL NO

TROUBLESHOOTING

E-9

Cause

Defective kick-down relay

Remedy

?eplace

qeplace

Defective Znd-1st selector relay

9 YES YES

Is there continuity YES between CN172 _ f2Lf4) (female) and 7 CN72 (5) (female)?

Is there continuity between CNlOl (2) (female) and CN172 (3) (female)? 1) Disconnect CNIOI and CN172. 2) Turn starting switch OFF.

I) Disconnect CN172 and CN72. 2) Turn starting switch OFF. NO

Is there continuity between CN172 (5) (female) and chassis? 1) Disconnect NO CN172. 2) Place speed lever in 2nd. 3) Turn starting switch OFF.

-To

A (2/2)

Defective contact, or disconnectionin wiring harness between CN172 (5) (female) and CN16 (5) (female)

Wer inspection, ,epair or replace

Defective contact, or disconnectionin wiring harness between CN172 f2), (4) (female) - CN72 (5) (female

Vter inspection, spair or replace

Defective contact, or disconnectionin wiring harness between CNlOl (2) (female) - CN172 (3) (female)

Vter inspection, ,epair or replace

Defective contact, or disconnectionin wiring harness between CNlOl (5) (female) - CN16 (4) (female)

Vter inspection, epair or replace

Defective contact, or disconnectionin wiring harness between CNlOl (1) (female) -chassis

Wter inspection, repair or replace

rive

kick-down

Replace

20-337 0

E-9

TROUBLESHOOTING

E-9 Kick-down switch does not work (2/2) (normal Fl - F3 switches correctly)

I 12 YES Is there continuity YES_ between CN172 (1) _ 11 (female) - CN102 (1) (female)?

* (From ‘/*I

P Is there continuity 1) Disconnect YES between CN228 (4) CN172and (female) -CN172 10 CN228. _ (1) (female)? Is there continuity ~ 2, T”rn switchstarting OFF. 1) Disconnect between CN172 (6) CN172and NO (female) - CN228 CN228. (3) (female)? 2) Turn starting 1) Disconnect switch OFF. CN172 and NO CN228. 2) Turn starting switch OFF.

20-338

Cause

Remedy

Defective contact, or disconnection in wiring harness between CN102 (2) (female) - CN72 (5) (female)

After inspection, repair or replace

Defective contact, or disconnection in winng harness between CN172 (1) (female) - CN102 (1) (female)

After inspection, repair or replace

Defective contact, or disconnection in wiring harness between CN228 (4) (female) - CN172 (1) (female)

After inspection, repair or replace

Defective contact, or disconnection in wiring harness between CN172 (6) (female) - CN228 (3) (female)

After inspection, repair or replace

E-10

TROUBLESHOOTING

E-10 Kick-down only works when kick-down switch is ON. (Kick-down switch relay does not carry out self-hold operation) Ir Ir *

When disconnecting or connecting the T-adapter (or socket adapter) or shot-t 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. (CNOA( 1) When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check.

* YES 1

YES

with REVERSE solenoid relay (CN94). 2) Start engine.

Defective kick-down relay

Replace

Defective contact, or disconnection in wiring harness between CN172 (2) (female) - CN72 (5)

After inspection, repair or replace

Defective contact, or disconnection in wiring harness between CN172 (1) (female) - CN102 (1) (female)

After inspection, repair or replace

I) Disconnect CN172 and CN72. 2) Turn starting switch OFF.

20-339 0

E-II

TROUBLESHOOTING

E-II Ir *

Kick-down

operation

is not canceled

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. (CNOA( When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check.

YES

‘ES

I) Kick-down is not canceled even when F-R lever is

removed when relay is replaced? I) Interchange Znd-1st selector relay (CNlOl) with backup lamp relay (CN230). 2) Start engine.

YES

, I

I) Disconnect CNIOI. 2) Turn starting switch OFF. 20 to problem ocation

!) Kick-down is not canceled even when oarkina brake is applied.

1) Interchange FORWARD solenoid relay (CN228) with REVERSE solenoid relay (CN94). 2) startengine. ~

5 YES

Is problem

4 -

removed when relay is replaced?

Dose parking brake work?

YES

1) Interchange kickdown relay (CN172) with REVERSE solenoid relay (CN94). 2) Start engine.

NO I) Kick-down is not canceled even when speed lever is moved from 2nd to other speed range.

YES 6 Is problem removed when relay is replaced? Is there continuity 1) Interchange neutralizer relay - between CNl72 NO (female) (3) and (CN72) with (4)? backup lamp relay (CN230). 1) Disconnect 2) Start engine. CN172. 2) Place F-R lever in NEUTRAL. 3) Turn starting switch OFF.

20-340 a

YES 7

E-II

TROUBLESHOOTING

Cause

Remedy

Defective 2nd-1st selector relay Contact with wiring harness between CNlOl (female) (3) and (5), or contact with wiring harness between CNlOl (5) (female) and chassis

After inspection, repair or replace

Defective FORWARD solenoid relay

Replace

Contact with wiring harness between CN228 (female) (3) and (4)

After inspection, repair or replace

Defective neutralizer relay

Contact with wiring harness between CN72 (female) (3) and (5)

After inspection, repair or replace

For details, see Troubleshooting chart E-4 , “Parking brake does not i work”

8 YES

h Is there

continuity

between CN172 (female) (1) and (2)? 1) Disconnect CN172. 2) Turn starting switch OFF.

Defective kick-down switch relay

Replace

Contact with wiring harness between CN172 (female) (3) and (4)

After inspection, repair or replace

Contact with wiring harness between CN172 ,(female) (1) and (2)

After inspection, repair or replace

Contact with wiring harness between CN172 (female) (1) and (4)

After inspection, repair or replace

20-341 0

E-12, E-13

TROUBLESHOOTING

E-12 Kick-down * * *

works mistake when traveling

in F2

Is there continuity between (1) and (2) of kick-down relay CN172 (male), and between (3) and (4)?

YES 2

1) Disconnect kick Is problem -down relay - removed when CN172. NO relay is replaced? 2) Turn starting switch OFF. 1) Interchange 2nd-1st selector relay KNqol) with backup lamp relay (CN230). 2) Start engine.

E-13 Machine 1 YES Is problem removed when relay is replaced? 1) Interchange Znd-1st selector relay (CN107) with backup lamp relay (CN230). 2) Start engine. 3) Place speed lever in 2nd 4) Place F-R lever in FORWARD

20-342 0

YES 3

Is there continuity _ between CN102 NO (male) (1) and (2)? 1) Disconnect CN102. 2) Turn starting switch OFF. 3) Do not press kick-down switch.

YES 4 Is there continuity between CN102 (female) (1) and (2)? I) Disconnect CN102. 2) Turn starting switch OFF.

does not travel when kick-down

YES

Is there continuity between CN172 (female) (1) and (2)? 1) Disconnect NO CN172. 2) Turn starting switch OFF. 3) Place F-R lever in NEUTRAL

switch is pressed

TROUBLESHOOTING

E-12, E-13

Cause

Defective

kick-down

relay

Replace

Defective relay

Pnd-1st selector

Rep,ace

Defective switch

kick-down

Remedy

Replace

Contact with wiring - harness between CN102 (female) (1) and (2)

After inspection, repair or replace

Contact with wiring harness between CN172 (female) (I) and (2)

After inspection, repair or replace

Contact with wiring harness between CN172 (female) (3) and (4)

After inspection, repair or replace

D$eyctive 2nd-1st selector

Rep,ace

20-343 0

E-14

TROUBLESHOOTING

E-14 Preheating *

is not carried out

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. 1) When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNOA( When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check.

* *

Preliminary

troubleshooting

Cause

1 YES

_[ Defective preheating <iisplay circuit

Is intake manifold warm? 1) Turn starting switch ON. 2) Turn heater switch ON.

Place starting switch in HEAT position

1lisconnection

YES

Is there continuity between heater switch CN13 (male) (1) - (21. and between (2) - (3)? 1) Disconnect NO CN13. 2) Turn heater switch to ON or AUTO.

20-344 0

For details, see Troubleshooting of machine monitor M-15-b Carry out troubleshooting

YES

Remedy

in wiring heater rwitch CN13 (2) (female) (IN307 (1) (female) tlarness between

- IDefective heater switch

After inspection, repair or replace

Replace

Carry out troubleshooting

TROUBLESHOOTING

Preheating

is not carried

E-14

out automatically.

Cause

1Is voltage between YES 2 Is voltage between YES auto-preheating _ timer CNs1 (2) end _ 13)(ground 1 connection) 20 -3OV? Is there continuity between heater _ switch CN13 (male) (3) and (2)? 1) Disconnect CN13. 2) Turn heater switch to AUTO. 3) Turn starting switch ON.

1) Turn starting switch ON.

I NO

auto-preheating trmer CN81 (1) and 13)(ground connection) 20 -3OV? 1) Must be below NO actuating temperature of preheating timer (near - 2O’C). 2) Turn starting switch ON.

Remedy

Defective contact, or I disconnection in wiring After inspection, harness between CN81 (1) repairor replace (female) - CN13 (3) (female) Defective timer

auto-preheating

Replace

Defective contact, or disconnection in wiring harness between CN81 (2) (female) - CN14 (2) (female)

Replace

Defective

Replace

heater switch

20-345

E-14

TROUBLESHOOTING

Preheating

is not carried

out normally

or automatically.

YES

terminal CN182, CN183 and chassis 20 - 3OV?

I$l;8O;,nd

I) Turn starting switch ON. 2) Turn heater switch ON.

chassis

1) Turn starting switch ON. 2) Turn heater switch ON.

Is voltage between CNI 14 NO (9) and chassis 26 - 3OV? 1) Connect T-adapter :~~~~,adjapter)N~ 2) Turn starting switch ON. 3) Turn heater switch ON.

1) Turn starting switch ON.

20-346 0

YES

5 Is voltage between CN86 (6) ;&chassis 20 - -

YES

6 I) Connect T-adapter Is problem (socket adapter) L removed when to CN86. No relay is replaced? 2) Turn starting switch ON. 1) Interchange 3) Turn heater electrical intake switch ON. air heater relay (CN307) with backup lamp relay (CN247). 2) Turn starting switch ON. 3) Turn heater switch ON.

E-14

TROUBLESHOOTING

Cause

Remedy

Defective electrical intake air heater, or disconnection in wiring harness of electrical intake air heater

After inspection, repair or replace

Defective heater switch

Replace

Defective contact, or disconnection in wiring harness between CN114 (9) (female) - CN182, CN183

After inspection, repair or replace

Defective contact, or disconnection in wiring harness between CN86 (8) (male) - CN114 (9) (male)

After inspection, repair or replace

Defective electrical intake air heater relay

0 Is voltage between electrical intake air heater relay CN307 (3) Ifemale) and chassis 20 - 3OV?

YES

1Is there continuity N

Defective contact, or disconnection in wiring harness between CN307 (5) (female) - CN86 (6) (female)

After inspection, repair or replace

Defective contact, or disconnection in wiring harness between CN14 (2) (male) - CN307 (3) (female)

After inspection, repair or replace

Disconnection in wiring harness between heater switch CN13 (2) (female) CN307 (1) (female)

After inspection, repair or replace

Defective heater switch

Replace

Disconnection in wiring harness between starting motor terminal B - CN179, CN181, or defective contact terminal

After inspection, repair or replace

1) Disconnect CN307. NO 2) Turn starting switch ON. 3) Turn heater switch to ON.

1) Disconnect CN307. 2) Turn starting switch ON. 3) Turn heater switch ON.

Replace

[~fz%/, 1

1) Disconnect NO CN13. 2) Turn heater switch to ON or AUTO.

20-347 0

E-15

TROUBLESHOOTING

E-15 Preheating * * *

stays 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. (CNOA( When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check. Preliminary

troubleshooting

Cause

1 YES

:arry out roubleshooting

Is intake manifold warm? 1) Turn startina switch ON. * 2) Turn heater switch to ON.

a1 Automatic

preheating

1 YES Is voltage between auto-preheating timer CN81 (1) and (3) (ground connection)20 -3OV? I) Turn starting switch ON. 2) Turn heater switch ON. 3) Turn starting switch ON, wait for approx. 2 min, then measure.

20-348

Remedy

Defective preheating lisplay circuit

:or details, see -roubleshootinf rf machine nonitor M-15-b

Defective auto-preheating imer

leolace

kconnection in wiring rarness between CN81 male) (3) and chassis, lefective continuity

&her inspection, epair or replace

is not canceled.

E-15

TROUBLESHOOTING

Preheating

continues

even when

heater

switch

is turned

OFF.

YES 1 Is there continuitv between heater switch CN13 (male) (1) and (2)? I) Disconnect CN13. 2) Turn heater switch OFF. 3) Turn starting switch OFF.

20-350 0

YES 2

Is problem removed when relay is replaced?

YES 3

Is voltage between electrical intake air heater relay CN307 YES air heater relay NO (male) (11 and 4 (CN307) with chassis 20 - 3OV? ~ Is voltage between backup lamp 1) Pull out rely. electrical intake air relay (CN247). - heater relay CN307 2) Turn heater 5 YES 2) Turn starting NO (female) (5) and switch ON. Is there continuity chassis 20 - 3OV? switch OFF. 3) Turn starting between heater relay p 3) Turn heater I) Pull out rely. switch OFF. - contactCN179 switch OFF. 2) Turn heater NO CN178, and between CN181-CNlSO? switch ON. 3) Turn starting NO 1) Turn starting switch OFF. switch OFF. 1) Interchange electrical intake

E-15

TROUBLESHOOTING

Cause

Defective heater switch

Remedy

Replace

After inspection,

Defective heater relay

Contact between +24V and After inspection, electrical intake air heater repair or replace

20-351 0

TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)

z & d

Electrical circuit svstem .......... ............ .............................. .................. ............ ............ ........................... 20-403 M- 1 BRAKE OIL LEVEL flashes when engine is stopped.. ........................................................... .20-405 M- 2 ENGINE OIL LEVEL flashes when engine is stopped ........................................................... .20-405 M- 3 RADIATOR WATER LEVEL flashes when engine is stopped ............................................... .20-407 M- 4 BATTERY CHARGE flashes when engine is running.. .......................................................... .20-407 M- 5 TRANSMISSION OIL FILTER CLOGGING flashes when engine is running ....................... 20-409 20-410 M- 6 FUEL LEVEL flashes when engine is running ........................................................................ BRAKE LINE FAILURE flashes when engine is running.. ..................................................... .20-410 M- 7 M- 8 ENGINE OIL PRESSURE flashes when engine is running ................................................... .20-412 M- 9 RADIATOR WATER LEVEL flashes when engine is running ............................................... .20-412 DROP IN AIR PRESSURE flashes when engine is running.. ................................................ .20-414 M-10 M-l 1 ENGINE WATER TEMPERATURE flashes when engine is running .................................... .20-414 TORQUE CONVERTER OIL TEMPERATURE flashes when engine is running ................... 20-414 M-12 PARKING BRAKE lights up abnormally, or does not light up M-13 a) If PARKING BRAKE stays lighted up ............................................................................... .20-416 b) If PARKING BRAKE does not light up ............................................................................. .20-416 WORKING LAMP lights up abnormally, or does not light up M-14 a) If WORKING LAMP stays lighted up.. ............................................................................... 20-418 b) If WORKING LAMP does not light up.. ............................................................................ .20-418 PREHEATING lights up, or does not light up M-15 a) PREHEATING lights up.. ..................................................................................................... 20-420 b) PREHEATING does not light up ........................................................................................ 20-420 MAIN STEERING FAILURE lights up, or does not light up M-16 a) MAIN STEERING FAILURE lights up.. .............................................................................. .20-422 b) MAIN STEERING FAILURE does not light up ................................................................. .20-422 TRANSMISSION CUT-OFF lights up, or does not light up M-17 a) TRANSMISSION CUT-OFF lights up ................................................................................. 20-424 b) TRANSMISSION CUT-OFF does not light up.. ................................................................ .20-424 Turn signal Hi beam light up, or do not light up M-18 a) Turn signal (right) pilot display lights up ....................................................................... .20-426 b) Turn signal (left) pilot display lights up .......................................................................... .20-427 c) Turn signal (right) pilot display does not light up ......................................................... .20-428 d) Turn signal (left) pilot display does not light up.. .......................................................... .20-428 e) Hi beam pilot does not light up.. ...................................................................................... 20-429 f) Hi beam pilot stays lighted up ......................................................................................... .20-429 Turn signal does not flash even when hazard switch is turned ON .................................. .20-431 M-19 Speedometer display does not work normally.. ................................................................... .20-433 M-20 Hourmeter does not work normally.. ...................................................................................... 20-434 M-21 When starting switch is turned ON, monitor panel M-22 does not work, or only part works a) None of monitor panel lights up ..................................................................................... .20-435 b) Except for speedometer module, none of monitor panel lights up.. ........................... 20-435 c) None of CAUTION items light up .................................................................................... .20-436 d) Some other parts do not light up.. ................................................................................... 20-436 When starting switch is turned ON, all monitor panel lights up, but does not go out.. . 20-436 M-23

20-401 0

M-24

M-25

M-26

M-27 M-28

M-29 M-30

M-31

M-32

M-33

20-402 0

ENGINE OIL PRESSURE flashes or BATTERY CHARGE flashes when engine is stopped a) ENGINE OIL PRESSURE flashes, and alarm buzzer and warning lamp are actuated ... 20-437 b) BATTERY CHARGE flashes, and warning lamp lights up ............................................. .20-437 None of machine monitor panel lighting lights up, or part does not light up a) Even when combination lamp is placed at SMALL, 20-439 none of panel lighting lights up ................................................................................. b) Even when working lamp switched ON, none of monitor panel lights up.. ............... 20-440 c) Even when starting switch is turned ON, none of monitor panel lights up.. ............. 20-442 d) Part of panel does not light up ......................................................................................... 20-442 When starting switch is turned to ON position (engine stopped), buzzer does not sound for 1 sec. CAUTION item is flashing but buzzer does not sound.. ................................................ .20-444 No abnormality is shown on monitor display, but alarm buzzer sounds ......................... 20-444 When starting switch is turned to ON position (engine stopped), warning lamp does not light up for 2 sec. CAUTION item is flashing but warning lamp does not flash ....................................... .20-446 No abnormality is shown on monitor display, but warning lamp lights up ..................... 20-447 Abnormality in Fuel gauge a) If nothing is displayed in display area ............................................................................ .20-448 b) If indicator remains at FULL .............................................................................................. 20-448 Abnormality in air pressure gauge a) If nothing is displayed in display area ............................................................................ .20-449 b) If indicator remains at maximum level ........................................................................... .20-449 Abnormality in engine water temperature gauge a) If nothing is displayed in display area ............................................................................ .20-450 b) If indicator remains at minimum level ............................................................................ .20-450 Abnormality in Torque converter oil temperature gauge a) If nothing is displayed in display area ............................................................................. 20-452 b) If indicator remains at minimum level ............................................................................. 20-452

TROUBLESHOOTING

ELECTRICAL CIRCUIT SYSTEM

ELECTRICAL CIRCUIT SYSTEM MACHINE MONITOR SYSTEM *

For details

of this page, see page 90-203.

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c-= w--

r;f _._ ;z:: I z 5-Z _-..-_ :.

-a,... *so..-. _z__

my.-

:_ :: -SC _-.

<S”

i..: _.._

i _-_-_-._.__-_-.-._.-

20-403 0

TROUBLESHOOTING

ELECTRICAL CIRCUIT SYSTEM *

For details of this page, see page 90-205.

. . : ;

ELECTRICAL CIRCUIT SYSTEM

TROUBLESHOOTING

M-l

M-l,

M-2

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. Sr When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNOA( )) + When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check.

Cause

3 YES 2 YE 1

I) Connect T-adapter NO (socket adapter) to CN59 (female). 2) Turn starting switch OFF.

Is there continuity between CN59

Is there continuity between CN59 (female) (2) and chassis ground?

YES

Is there continuity between CNP3 (female) (1) and chassis ground?

I) Connect T-adapter (socket adapter) N0 to CN59 (male) (brake oil level sensor I). 21 Turn starting switch OFF.

Remedy

Defective monitor panel

seplace

Defective contact, or disconnection in wiring harness between CNP3 (female) (I) - CN65 (3) CN59 (female) (I)

Vter inspection, epair (clean) or eplace

Defective contact, or disconnection in wiring harness between CN59 (female) (2) - CN65 (4) chassis ground

Wer inspection, epair (clean) or eplace

Defective brake oil level sensor

leplace

Defective engine oil level sensor

ieplace

Defective monitor panel

Ieplace

Defective contact, or disconnection in wiring harness between CN120 [female) (I) - CN86 (2) CNP3 (female) (2)

u?er inspection, epair (clean) or eplace

Defective contact, or disconnection in wiring harness between CN120 [female) (2) -chassis ground

hfter inspection, epair (clean) or eplace

Ri g

M-2

ENGINE OIL LEVEL flashes when engine is stopped YES

1 3 YES Doesmgo

out? -

I) Connect short connector to CN120 (female) (engine oil level sensor). 2) Turn starting switch ON.

Is there continuity between CN120 NO (female) (2) and chassis ground?

Is there continuity YES between CNP3 (female) (2) and 2 chassis ground?

I) Connect T-adapter (socket adapter) to CN120 (female). 2) Turn starting switch OFF.

1) Connect short NO connector to CN120 (female). 2) Connect T-adapter to CNP3 (female). 3) Turn starting switch OFF. NO

20-405 0

M-l,

TROUBLESHOOTING

M-l

electrical

circuit drawing

CNP3 Monitor

Brake level

CN65

oi I sensor

Dane1

a TDW01275

M-2

electrical

circuit drawing

CNP3

CN120

Engine level

oil sensor

3 3 TDW01276

20-406 0

M-2

M-3, M-4

TROUBLESHOOTING

M-3

RADIATOR

WATER LEVEL flashes when engine is stopped

YES

Remedy

Defective radiator water level sensor

Replace

Defective monitor panel

Replace

1) Connect short connector to CN136 (female)

11Connect short

NO connector to CN136 (female). 2) Connect T-adapter to CNP3 (fernaM 3) Turn starting switch OFF.

1) Connect T-adapter (socket adapter) to CN136 (female). 2) Turn starting switch OFF.

2) Turn starting switch ON.

M-4

Defective contact, or disconnection in wiring After inspection, harness between CN136 repair (clean) or [female) (1) - CN128 (2) replace CN84 (2) - CNP3 (female) (31 Defective contact, or disconnection in wiring harness between CN136 [female) (2) and chassis ground

After inspection, repair (clean) or replace

Defective monitor panel

Replace

Defective contact, or disconnection in wiring harness between alternator terminal R CN114 (1) - CN86 (1) CNP4 (5)

After inspection, repair (clean) or replace

Defective alternator

Replace

BATTERY CHARGE flashes when engine is running

(If BAlTERY CHARGE flahes when the engine to M-8. Engine oil pressure abnormal.) 2

Is voltage of alternator terminal R normal?

YES

Is voltage between YES CNP4 (female) (5) and chassis 1 ground normal?

1) Turn starting switch ON. 2) Measure voltage between alternator terminal Rand chassis ground. 3) Is reading 20 3OV?

11Connect T-adapter NO to CNP4 (female). 2) Turn starting switch ON. (Start engine) 31 Is reading 20 - 3OV?

is stopped,

20-407 0

M-3, M-4

TROUBLESHOOTING

M-3

Related electrical circuit drawing

CN84

CNP3

CN128

CN136

Radiator water level sensor

3 3 TDW01277

M-4

Related electrical circuit drawing

CNP4

CN86 3

CN114 t

Alternator

terminal

TDW01278

20-408 0

TROUBLESHOOTING

M-5

TRANSMISSION running

OIL FILTER CLOGGING

flashes when engine is

Jr When Ir Ir

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. (CNOA( 1) When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check. Cause

4YES

~ YES

p Is there continuity YES between CN~O (female) (2) and 2 chassis ground?

Is there continuity - between CN60 (male) (1) and (2)? 1 I) Connect

Is there continuity between CN227 (male) (1) and (2)? I) Connect T-adapter (socket adapter) to CN227 (male). 2) Turn starting switch OFF.

M-5

Defective contact, or disconnectionin wiring harness between CN227 (femalel (1) - CN65 12) - CNP3 1) Connect T-adapter NO (female) (lo), or between to CNP3 (female). CN227 (female) (2) - CN60 2) Turn starting switch (female) (11 OFF. Disconnection in wiring harness between CN60 NO (female) (2) - CN65 (4) chassis ground

1) Connect T-adapter (socket adapter) to CN60 (female). 2) Turn starting switch OFF.

T-adapter (socket adapter) No to CN60 (male). 2) Turn starting switch OFF. NO

electrical

Replace

After inspection, repair (clean) or replace

Defective transmission oil filter clogging sensor 1

Replace

Defective transmission oil filter clogging sensor 2

Replace

circuit drawing

CN65 Monitor

Defective monitor panel

Is there continuity YES between CNP3 (female) (10) and 3 chassis ground?

Remedy

CN227

Panel

TOW01279

20-409 0

M-6, M-7

TROUBLESHOOTING

M-6 * *

FUEL LEVEL flashes when engine is running

Cause

1 YES

Remedy

See M-30 (Abnormality ‘uel level gauge)

Does fuel gauge display EMPTY? 1) Turn starting switch ON.

M-7

Iefective

monitor panel

Iefective

monitor panel

qeplace

BRAKE LINE FAILURE flashes when engine is running

Check that there is no abnormality

with the chassis I YES

YIES between CNP3 (female) (4) and 2 Is there continuity (female) (2) and chassis ground?

continuity of each

1) Connect T-adapter (socket adapter) to each sensor (male). 2) Turn starting switch OFF. 3) Connector numbers are CN61, 62, 64, and 87.

20-4 10 0

1) Connect T-adapter (socket adapter) ‘I to CN62 N (female). 2) Turn starting switch OFF.

I) Connect T-adapter to CNP3 (female). 2) Turn starting switch OFF.

Iefective contact, or fisconnection in wiring iarness between CN62 female) (1) - CN65 (9) ZNP3 (female) (4) lefective contact, or lisconnectionin wiring rarness between CN62 female) (21- CN61 (female) I), CN61 (female) (2) - CN64 female) (1). CN64 (female) (2) CN87 (female) (1). CN87 female) (2) - CN65 (female) 41,or CN65 Ifemale) (4) hassis ground rlon- continuous sensor is fefective

\fter inspection, epair (clean) or eplace

dter inspection, epair (clean) or eplace

teplace

TROUBLESHOOTING

M-6

electrical

M-6, M-7

circuit drawing

CNP4 Monitor

Pane I

CNSS

CN127

Fuel level sensor

TOW01280

M-7

electrical

circuit drawing

Ki d

CNP3

CN65

Monitor Panel

CN62 r 3

3 CN61

Brake sensor

stroke

CN87

TDWO1281

20-411 a

M-8. M-9

TROUBLESHOOTING

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. )) When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNOA( 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 engine oil pressure sensor

qeplace

Defective monitor panel

Ieplace

Defective contact, or disconnectionin wiring harness between CN213 (ring terminal) - CN303 (3). (6) CNP3 (female) (9). or defectiw engine oil pressure sensor relay

Vter inspection, ,epair (clean) or splace

Contact between chassis ground and wiring harness between CN122 -CN114 (5) - CN86 (7) - CN303 (2)

Vter inspection, ,epair (clean) or ,eolace

(Doesmgoo”t?t YES I) Remove ring terminal of CN122 from N engine oil pressure sensor. 2) Turn starting switch ON. 3) Start engine.

Note) If

M-9

YES

EHP

switch ON NO (start engine). 2) Is reading 20 - 3OV?

flashes when engine is stopped,

Go to M-24 (Engine oil pressure or battery charge flashes when engine is stopped.)

is defective.

RADIATOR WATER LEVEL flashes when engine is running YES

Defective radiator water level sensor

Zeplace

Defective monitor panel

teplace

Defective contact, or disconnection in wiring harness between CN136 (female) (1) - CN128 (2) CN84 (2) - CNP7 (female) (6

\fter inspection, epair (clean) or eplace

Defective contact, or disconnection in wiring harness between CN136 (female) (2) and chassis ground

rfter inspection, epair (clean) or eplace

1 3

YES

YI 2 1) Connect short connetor to radiator water level sensor N CN136 (female). 2) Turn starting switch ON. 3) Start engine.

20-412 0

Is there continuity between CN136

1)Connect T-adapter (socket adapter) to CN136 (female). 2) Turn starting switch OFF.

lEHP I

1) Connect short connector to

CN136 (female). 2) Connect T-adapter to CNP3 (female). 3) Turn starting switch OFF. 10

M-8, M-9

TROUBLESHOOTING

M-8

electrical

circuit drawing

1303

Enoine oil pressure relay

CN79

P LA

CNP3

Service meter

M-9

CN86

CN114

-3

electrical

Engine Pressure sensor

CN213 11,

CN232

oil

TOW01282

circuit drawing

CN84

CNP3 3

CN128

CN136

Radiator level

water sensor

20-413 0

M-10. M-II.

TROUBLESHOOTING

M-10 * * *

M-12

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. 1) When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN0A.l 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 YES

See M-31 (Abnormality pir pressure gauge)

Is air pressure gauge within red level? 1) Turn starting switch ON.

Iefective

qeplace

monitor panel

M-l 1 ENGINE WATER TEMPERATURE flashes when engine is running 1 YES Is engine water temperature gauge within red level?

Iefective

1) Turn starting switch ON.

M-12

monitor panel

Ieplace

TORQUE CONVERTER OIL TEMPERATURE flashes when engine is running 1 YES

Is torque converter oil temperature gauge within red level? 1) Turn starting switch ON.

20-4 14 0

see M-32 (Abnormality in mgine water temperature gauge)

see M-33 (Abnormality orque converter oil emperature gauge)

IIefective

monitor panel

teplace

TROUBLESHOOTING

M-10

M-10,

electrical

M-II,

circuit drawing

CNP4

CN65

CNllO

Air Pressure sensor

CN85

M-l 1 Related

electrical

M-12

TDW01283

circuit drawing

CNP4

CN84

CNl23

cN114

Engine water temperature

sensor

(lj -

CN85 TDW01284

M-12

electrical

circuit drawing

CNP4 Monitor

Panel

CN89

cN121

-3

Torque converter oi I temperature sensor

CN85 TDW01285

20-415 0

M-13

TROUBLESHOOTING

M-13 PARKING BRAKE lights up abnormally, *

or does not light up

* +

If (PARKING BRAKE) stays lighted up Cause

YES

Remedy

defective parking brake sensor

Ieplace

Iefective

Xeplace

hYE! YE‘S (female) (5) and chassis ground?

1 brake work when switch is turned

1) Connect short connector to CN34 (female) (parking brake sensor). 2) Turn starting switch ON.

connectorto CN34 (female) between

CN34

Iefective contact, or disconnection in wiring larness between CN34 female) (1) - CN32 (4) :NP3 (female) (5)

Wer inspection, epair (clean) or eplace

Iefective contact, or disconnection in wiring larness between CN34 female) (2) and chassis ground

Wter inspection, epair (clean) or eplace

(parking brake SWWX).

T-adapter to CNP3 (female). 3) Turn starting switch OFF. 2)

1) connect T-adapter (socket adapter) to CN34 (female) (parking brake sensor). 2) Turn starting switch OFF.

1) Turn starting switch ON.

Connect

see Troubleshooting :hassis

0 b)

monitor panel

for

if (PARKING BRAKE) does not light up

brake work when switch is turned

1) Disconnect connector CN34. 2) Turn starting switch ON.

1) Turn starting switch ON.

20-416 0

YES

Defective parking brake sensor

seplace

Contact between chassis ground and wiring 7arness between CN34 female) (1) - CN32 (4) :NP3 (female) (5)

After inspection, ,epair (clean) or eplace

Iefective

qeplace

NO 1) Connect T-adapter NO to CNP3 (female). 2) DisconnectCN134. 3) Turn starting switch OFF.

monitor panel

see Troubleshooting :hassis

for

TROUBLESHOOTING

M-13

electrical

M-13

circuit drawing

CNP3

CN32

CN34

Parking display

brake switch

3 3

20-417 0

M-14

TROUBLESHOOTING

M-14

WORKING

LAMP lights up abnormally,

* *

When disconnecting connectors or connecting Tadapters, return them to the original condition immediately after checking, then go to the next check.

or does not light up

Note)

Even is all the working lamp bulbs are broken, or there is defective contact or a disconnection in the wiring harness fo the working lamp,-l,j)l will stay lighted up.

Cause

Remedy

a) If (WORKING LAMP) stays lighted up YES 1

Doesago

out? -

~ 1) Remove CN257. _ NO 2) Turn starting switch ON.

{eplace

Iefective

Ieplace

YES

Is voltage between CNP3 (female) (14) _ and chassis ground normal? 1) Connect T-adapter to CNP3 (female). 2) Turn starting switch ON. 3) Remove CN257. 4) Is reading 0 - lV?

Defective working lamp switch

monitor panel

:ontati between +24V and Niring harness between ZN257 (female) (2) - CN254 female) (5) or CN254 female) (4) - CNP3 (female) 14). or defective front Norking lamp relay

\fter inspection, ,epair (clean) or ,eplace

Iefective

Ieplace

If (WORKING LAMP) does not light up 3

YES

YfcH-

(male) (1) and (2) as shown in table?

to CNP3 (femelel. 2) Turn starting switch ON. 3) Turn working lamp switch ON. 4) Is reading 20 - 3OV7

Is voltage between CN79 (male) (9)

1) Connect T-adapter (socket adapter) to CN79 (male). 2) Turn starting switch ON. 3) Is reading 20 3OV?

Is there continuity

NO _-

1) Disonnect CN257 (male). NO 2) Turn starting switch OFF. 3) Turn working lamp switch ON-OFF.

Table Working lamp switch

CN257 (male) (I) - (2)

20-418 0

OFF

Continuity

No continuity

monitor panel

Iefective contact, or fisconnection in wiring ?arness between CN257 female) (2) - CN254 (female) (5), (6) -chassis ground, or between CNP3 (female) (14) - CN254 (female) (4). (3) - +24V

Mer inspection, repair (clean) or replace

Defective working lamp switch

Replace

Defective contact, or disconnection in wiring harness between main breaker - CN79 (male) (9)

After inspection, repair (clean) or replace

TROUBLESHOOTING

M-14

electrical

circuit drawing

Fuse

box

Head lamp switch

Monitor Pane I

Lamp

Front lamp

CN254 r

wokina relay

t24v

Lamp

(T)(i)

CNP6

_CN221

Service meter I=

3 7

r kina tch

lamp

TOW01287

20-419 0

M-15

TROUBLESHOOTING

M-15

PREHEATING

lights up, or does not light 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. 1) When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNOU When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check.

Cause

Remedy

(PREHEATING) lights up 1 YES

see E-14, E-15

Is voltage between CNP3 (female) (15) and chassis ground normal? Iefective monitor panel

teplace

Iefective monitor panel

leplace

NO 1) Connect T-adapter to CNP3 (female). 2) Turn starting switch ON. 3) Is reading 20 - 3OV?

(PREHEATING) does not light up 1 YES

Is voltage between CNP3 (female) (15) and chassis ground normal?

Gee E-14, E-15 1) Connect T-adapter to CNP3 (female). 2) Turn starting switch ON. 3) Is reading 20 3OV?

20-420 0

M-15

TROUBLESHOOTING

M-15 Related electrical circuit drawing

t24V Bimetal

Electrical air heater

Monitor

(ba tterv

relay)

Heater

CN81

timer

switch

intake relay

Panel

CNl80

CN181 TDW01288

M-16

TROUBLESHOOTING

M-16

MAIN STEERING FAILURE lights up, or does not light

* *

(MAIN STEERING FAILURE) lights up

;eplace

3 YES Doesmgo

out? YES

Is voltage between CNP3 (female) (6) and chassis ground normal?

2 I) Connect short _ ,s there continuity p connector to 1) Connect T-adapter NO CN108 (female) _ to CNP3 (female). _ between CNtg6 2) Connect short connector (main steering ~0 (female) (1) and to CN108 (female). chassis ground? failure sensor). ’ 3) Turn starting switch ON. 2) Turn starting 1) Connect T-adapter 4) Is reading 0 - l.W? switch ON. (socket adapter) to CN108 (female). ~0 !) Turn starting switch OFF.

Defective monitor panel

leplace

Defective contact, or disconnection in wiring harness between CNl08 (female) (2) -CN68 (2) CN44 (female) (1) - CN44 (female) (2) - CNP3 (female) (6), or defective diode at CN44 (male)

Jter inspection, spair or replace

Defective contact, or disconnection in wiring harness between CN108 (female) (1) -CN88 (1) chassis ground

rfter inspection, spair (clean) or aplace

(MAIN STEERING FAILURE) does not light up YES 1

~ . 2) Turn starting switch ON.

20-422 0

1) Connect T-adapter to CNP3 (female). 2) Turn starting switch ON. 3) Disconnect CN108 (female). 4) Is reading 0 1.5V?

Defective main steering failure sensor

leplace

Short circuit between chassis ground and wiring harness between CN108 (female) (2) - CN88 (1) CN44 (I), (2) - CNP3 (female) (6)

after inspection, epair (clean) or eplace

Defective monitor panel

leplace

M-16

TROUBLESHOOTING

M-16 Related electrical circuit drawing

CN44

CN88 Monitor

Panel

CN108

ne Main steeri failure sen sor

TDW01289

20-423 a

TROUBLESHOOTING

M-17

M-17 TRANSMISSION Ir * *

CUT-OFF lights up, or does not light 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. (CNOA( When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check.

Cause

(TRANSMISSION

YES

1) Short circui’ between CP (fern I”, 2)

Turn starting switch OFF.

b1 (TRANSMISSION

Defective transmission cut-off switch

Replace

Defective monitor panel

Replace

Defective contact, or disconnection in wiring harness between CN18 (female) (3) and CNP3 (female) (11)

After inspection, repair (clean) or replace

Defective contact, or disconnection in wiring harness between CN18 (female) (4) and chassis ground

After inspection, repair (clean) or replace

CUT-OFF) does not light up Defective transmission cut-off switch

YES 1 DoesBlight up?

YES

Is there continuity _ between CNP3 11 Remove CN18. 2) Turn starting NO (female) (11) and chassis ground? switch ON.

1)Connect T-adapter to CNP3 (female). 2) Turn starting switch OFF.

20-424 0

Remedy

CUT-OFF) lights up

Contact between chassis ground and wiring harness between CN18 (female) (3) and CNP3 (female) (I 1)

After inspection, repair (clean) or replace

Defective monitor panel

Replace

TROUBLESHOOTING

M-17

Related electrical circuit drawing

CNP3

CN18

20-425 0

TROUBLESHOOTING

M-18 Ir Ir *

M-18

Turn signal Hi beam light up, or do not light 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. (CNOU 1) 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

2 YES

Does turn signal go out? I 1) Remove CN15. 2) Turn starting switch ON.

Is voltage between CN15 (male) (5) and chassis ground normal?

1)Connect

T-adapter to CN15 (male). 2) Turn starting switch ON. 3) Does voltage switch repeatedly between 0 tf 20 - 3OV? 3 YES

Is voltage between CNPl (female) (7) _ and chassis ground normal? 1) Connect T-adapter to CNPl (female). 2) Turn starting switch ON. 3) Turn right turn signal switch ON. 4) Does voltage switch repeatedly between 0 c) 20 - 3OV?

20-426

Cause

Remedy

Contact between +24V and wiring harness between CN15 (female) (3) -right turn signal switch, or between CN15 (female) (5) and turn signal switch

After inspection, repair or replace

Contact between +24V line and wiring harness between CN15 (male) (5) and CN74 (female) (4)

After inspection, repair or replace

Defective monitor panel

Replace

Contact between +24V and wiring harness between CNPI (female) (7) and CN15 (male) (3)

After inspection, repair or replace

M-18

TROUBLESHOOTING

Turn signal (left) pilot display lights up

2 YES

I) Remove CN15. 2) Turn starting switch ON.

Is voltage between ; CN15 (male) (5) and chassis ground normal? NO 1) Connect T-adapter to CN15 (male). 2) Turn starting switch ON. 3) Does voltage switch repeatedly between 0 t) 20 - 3OV? 3 YES

Cause

Remedy

Contact between +24V and Niring harness between 3N15 (female) (6) - left turn signal switch, or between EN15 (female) (5) and turn signal switch

After inspection, repair or replace

Contact between +24V line and wiring harness between ZN15 (male) (5) and CN74 (female) (4)

After inspection, repair or replace

Defective monitor panel

Is voltage between CNPl (female) (6)

1) Connect T-adapter to CNPl (female). 2) Turn starting switch ON. 3) Turn left turn signal switch ON. 4) Does voltage switch repeatedly between 0 tf 20 - 3OV?

Contact between +24V and wiring harness between CNPI (female) (6) and CN15 (male) (6)

After inspection, repair or replace

M-18

TROUBLESHOOTING

Turn signal (right) pilot display does not light up

Cause

Remedy

Defective monitor panel

qeplace

Defective contact, or disconnection in wiring harness between CNPl [female) (7) and CN15 Imale) (3)

4fter inspection, .epair (clean) or .eplace

1)Connect

NO T-adapter to CNPl (female). 2) Turn starting switch ON. 3) Turn turn signal switch ON. 4) Does voltage switch repeatedly between 0 tf 20 - 3OV7

Does front and

I) Operate right turn signal. 2) Turn starting switch ON.

Carry out troubleshooting of turn signal

d1 Turn signal (left) pilot display does not light up 2

YES

Is voltage between YEiS CNPl (female) (6) and chassis ground normal?

1) Operate left turn signal. 2) Turn starting switch ON.

20-428 0

1) Connect NO T-adapter to CNPl (female). 2) Turn starting switch ON. 3) Turn turn signal switch ON. 4) Does voltage switch repeatedly between 0 tt 20 - 3OV? [ NO

Iefective

monitor panel

Iefective contact, or jisconnection in wiring iarness between CNPl female) (6) and CN15 male) (6)

Zarry out troubleshooting ,f turn signal

Ieplace

Wter inspection, epair Wean) or eplace

M-18

TROUBLESHOOTING

Hi beam pilot does not light up If the head lamp does not switch to Hi beam, the head lamp system 2

check

YES

I) Turn starting switch ON. 2) Place conbination switch at HEAD. 3) Place dimmer switch at Lo beam.

Remedy

Defective monitor panel

Is voltage between CNPI (female) (5 ) and chassis ground normal?

right front lamps

Cause

1) Connect NO T-adapter to CNPl (female). 2) Turn starting switch ON. 3) Place combination switch at HEAD. 4) Place dimmer switch at Hi beam. 5) Is reading 20 - 3OV?

Defective contact, or disconnection in wiring harness between CNPl (female) (5) and CN31 (male) (1)

After inspection, repair (clean) or replace

Both head lamp bulbs (Lo beam lamps) broken? (If theLo beam bulb is broken, the Hi beam pilot will not light up even if the lamp is switched to Hi beam)

Replace

Defective monitor panel

Replace

Defective contact, or disconnection in wiring harness between CN15 (female) (9) and combination switch

After inspection, repair (clean) or replace

Hi beam pilot stays lighted up YES

YES

L I 1) Turn starting switch ON. N 2) Place combination switch at HEAD. 3) Place dimmer switch at Lo beam.

switch at HEAD. 3) Place dimmer switch at l-ii beam.

1) Connect T-adapter (socket adapter) to CN15 (male). 2) Turn startina switch OFF.-

Defective contact, or disconnection in wiring harness between CN15 (female) (12) and combination switch Defective contact, or disconnection in wiring harness between CN15 (male) (12) and chassis ground

After inspection, repair (clean) or replace

20-429 0

TROUBLESHOOTING

M-18

M-18 a), b), cl, d1 related electrical circuit drawing

Monitor

signal

switch

Turn

TOW01291

M-18 e1, f) related electrical circuit drawing

w Fuse box

+24v Hea d lamp

switch

CN29 Monitor

Panel

)(Ej-

CN27

CN26

Rioht lamp

20-430 0

head (Lo)

Left lamp

head (Lo)

TOW01292

TROUBLESHOOTING

M-19 * *

M-19

Turn signal does not flash even when hazard switch is turned ON

I 2 YES

YES

1 Is voltage between CNPl (female) (3) and chassis ground normal?

1)Connect

Is voltage between CNPl (female) (6). (7) and chassis ground normal? I) Connect NO T-adapter to CNPl (female). 2) Turn starting switch ON. 3) Does voltage switch repeatedly between 0 cf 20 - 3OV?

YES T-adapter to 3 . CNPl (female). Is voltage between 2) Turn hazard CN15 (female) 12) switch ON. 3) Is reading 20 - NO and chassis 4 YES ground normal? 3OV? _ Is voltage between I) Connect CN15 (male) (1) T-adapter to NO and chassis ground normal? CN15 (female). 2) Turn hazard I) Connect NO switch ON. T-adapter to 3) Is reading 20 CN15 (male). 3OV? 2) Turn hazard switch ON. 3) Is reading 20 3OV?

Cause

Defective monitor panel

See M-18 c), d) Troubleshooting signal

Remedy

Replace

of turn

Defective contact, or disconnectionin wiring harness between CNPl (female) (3) - CN15 (male)

(2)

Defective contact, or disconnection in wiring harness between CN15 (female) (11 and hazard switch or between CN15 (female) (2) and hazard switch, of defective hazard switch Defective contact, or disconnection in wiring harness between CN15 (male) (1) and +24V line

After inspection, repair (clean) or replace After inspection,

, repair (clean) or replace

After inspection, repair (clean) or replace

20-43 1 0

TROUBLESHOOTING

M-19

Related electrical circuit drawing

t24v A

CN15

Monitor

CN74 I\

Turn

(I) Turn

sign

+24v

(2)

1cN75

signal

switch

iria I

JcN76

ICN46

lCN471

TDWOlZSl

TROUBLESHOOTING

M-20 Jr Ir *

M-20

Speedometer

display does not work normally

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. 1) When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNOA( 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 monitor panel

Replace

Defective speed sensor mount

Replace

Defective contact, or disconnection in wiring harness between CNPl (9). (10) (female) - CN65 (12). (11

After inspection, repair (clean) or replace

Defective contact, or disconnection in wiring harness between CN65 (male (121, (11) - CN98 (1). (2)

After inspection, repair or replace

Defective speed sonsor

Replace

3 between CNPl (female) (3) and (10) 300R- lkR?

2 IES

between CN98 (male) (1) and (2) 1) Connect T-adapter (socket adapter: to CN98 (speed sensor) (male). 2) Turn starting switch OFF.

M-20

1) Connect T-adapter to CNPl (female). 2) Turn starting switch OFF.

between CN65 (male) (11) and I) Connect T-adapter (socket adapter) to CN65 (male). 2) Turn starting switch OFF.

electrical

circuit drawing

CNPl Monitor

NC I Loosen speed sensor locknut and turn speed sensor clockwise. If it contacts the gear within one turn, the distance is within 1.5mm.

Cbi98

Ct'I65 3

-3

Speed

sensor

Panel

TDW01293

20-433 0

M-21

TROUBLESHOOTING

M-21 Ir Ir Ir

Hourmeter

does not work normally

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. 1) When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNOA( When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check.

Remedy

YES

Defective engine oil pressure sensor

Replace

1Defective monitor panel

Replace

Defective contact, or disconnection in wiring ~harness between CN213 ~(ring terminal) - CN303 (3). (6) - CNP3 (female) (9), or defective engine oil pressure sensor relay

After inspection, repair (clean) or replace

Contact between chassis ground and wiring harness between CN122 - CN114 (5) - CN86 f71- CN303 (21

After inspection, repair (clean) or replace

1 Does hourmeter work, or does display lamp liaht uo? 1) Remove CN122 (engine oil pressure sensor). 2) Turn starting switch ON.

M-21

3 YES 2 Is voltage between CN122 ) and chassis ground nom-‘? 1) Turn starting switch ON. (Start engine) 2) Is reading 20 3OV?

YES

Is there continuity between CNPG (female) (4) and chassis ground? 1) Connect NO T-adapter to CNP3 (female). 2) Turn starting switch OFF.

Related electrical circuit drawing

CN303 I

Engine

oil

Pressure relay

CN79

Monitor Pane I

CN86

CNll4

Service meter

Engine oil Pressure sensor

CN213 CN232

20-434

M-22

TROUBLESHOOTING

M-22 When starting switch is turned ON, monitor work, or only part works * * *

panel does not

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. (CNOA( )I When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check. Cause

None of monitor

panel

YES

T-adapter to NO CN79 (male). 2) Turn starting switch ON.

Except for speedometer panel lights up

Is voltage between CNP5 (female) I11 and (7) 10 -ZOV? Is voltage between (2) and (7) approx. 5v7 1) Connect T-adapter to CNP5 (female). 2) Turn starting switch ON.

YES k

module,

lefective monitor panel

3eplace

kfective contact, or lisconnection in wiring larness between CN79 (6) :NPl (1). or between CNPI 2)-CN85(1)-chassis Iround

Zlean (defective :ontact) or .eplace

ibnormality in wiring larness between battery erminal (+) - battery relay nain breaker-CN149 :N79 (male) (51

no switch ON.

Remedy

lights up

Vter inspection, .epair or replace

none of monitor

Iefective monitor panel Iefective contact, or lisconnection in wiring rarness between CNP2 (1) CNP5 (1). CNP2 (2) :NP5 (2). CNP2 (7) - CNP5 7). or defective nomitor ranel

Zlean (defective :ontact) or ,eplace

20-435 0

I ,,rm

TC3

alsconnection

F 11,.VU,,VJ harness betweenCNPZ (female)and CNP5 (female)?

I) Connect NO T-adapter to CNP2 andCNP5 (female). 2) Turn starting switch OFF.

Some

Defective monitor panel

Replace

Defective monitor panel

Replace

Defective monitor panel

Replace

When starting switch is turned ON, all monitor panel lights up, but does not go out tii

M-22, 23

Clean (defective contact) or replace

other parts do not light up

M-23

Defective contact, or Id’ Isconnection in wirina harness between CNP; (female) and CNP5 (female)

electrical

ctq79

CNPl Monitor Pane I

circuit drawing

Fuse

box

Main breaker n

(i)(i) CN85

CN149 I

Battery relay

( Battery terminal

(+I

3 TDW01.294

20-436 a

M-24

TROUBLESHOOTING

M-24 ENGINE OIL PRESSURE flashes or BATTERY CHARGE 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. )I When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNOU When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check.

* *

Cause

warning

lamp are actuated YES

1 Does

•!I

go out?

Defective alternator

Replace

Defective monitor panel

Replace

YES

Is voltage of CNP4 (female) (5) normal?

I) Remove wiring of alternator Ni0 terminal R. 2) Turn starting 1) Connect T-adapter NO switch ON. to CNP4 (female). 2) Turn starting switch ON. (Do not start (With wiring at R terminal engine). removed) 3) Is reading 0 - IV?

Remedy

(ENGINE OIL PRESSURE) flashes, and alarm buzzer and

(BATTERY CHARGE) flashes,

and warning

Contact between +24V and wiring harness between alternator terminal R - CNI 14 (I) CN86 (1) - CNP4 (female) (5)

After inspection, repair (clean) or replace

lamp lights up

YES

Defective engine oil pressure sensor

Replace

Defective monitor panel

Replace

Contact between chassis ground and wiring harness between CN303 (3). (6) CNP3 (female) (9). or defective engine oil pressure sensor relay

After inspection, repair (clean) or replace

Defective contact, or disconnection in wiring harness between CN122 CN114 (51- CN86 (7) CN303 (2). (I) - CN79 (male (6)

After inspection, repair (clean) or replace

1 3 YES -

I) Connect CN122 Is voltage (engine oil between CN122 pressure N 1 and chassis sensor) to normal? chassis ground. I) Turn starting 2) Turn starting switch ON. switch ON. (Start engine) 2) Remove CN122. 3) Is reading 20 3OV?

YES

Is voltage between CNP3 (female) (9) and chassis ground normal? 1) ConnectT-adapter NO to CNP3 (female). 2) Turn starting switch ON. 3) Connect CN122 to chassis ground. 4) Is reading 20 - 3OV?

20-437 0

M-24

TROUBLESHOOTING

M-24 a)

Related electrical circuit drawing

CNP4

CN86

CN114

Alternator

terminal

TDWOl278

M-24 b)

Related electrical circuit drawing

CN303

Ensine oil pressure relay

Service meter I&

Engine oil Pressure sensor

CN232 TDWOl282

20-438 0

TROUBLESHOOTING

M-25

None of machine not light up

monitor

panel lighting

lights up, or part does

sr When

* *

Even when

combination

lamp is placed at SMALL,

none of panel lighting

CNPI (female) 115) and CNPG(female)

CNPl (female) N( and CNPG(female). 2) Turn starting switch ON. 31 Place combination switch at SMALL. 4) Is reading 20 3OV? t0

between CN23 (1) ground normal?

2 YE

between CN 15 (8)

1) Connect T-adapter to CN15. 2) Turn starting switch ON. 3) Place combination switch at SMALL. 4) Is reading 20 3OV?

1 CN15 (male) (4)

I) Connect T-adapter (socket adapter) to CN15 (male). 2) Turn starting switch ON. 3) Is reading 20 3OV?

1) Place combination switch at SMALL. 2) Measure voltage between CN23 (female) (1) and chassis ground with CN23 still connected. 3) Turn starting switch ON. 4) Is reading 20 - 3OV? 4 YES Is continuity between CN15 (female) (4) and (8) as shown in Table l? 1) Disconnect CNl5. 2) Turn starting switch OFF.

Table

lights up

Cause

Remedy

Abnormality in monitor panel, or all lamp bulbs broken, or defective contact or disconnection in wiring harness between CNPI (female) (16) - lamp connetor, or between lamp connector, CNPG (female) (3) -chassis ground

After inspection, repair (clean) or replace

Defective contact, or disconnection in wiring harness between CN23 (female) (I) - CNPI (female) (15) - CNP6 (female) (2)

After inspection, repair (clean) or replace

Defective contact, or disconnection in wiring harness between CN15 (male) (8) - CN77 (I I), (121 - CN23 (female) (2). or defective diode ass’y

After inspection, ,epair (clean) or .eplace

Defective contact, or disconnection in wiring harness between CN15 Ifemale) (4) -head lamp ant parking lamp switch - CN15 [female) (8)

Wter inspection, ,epair (clean) or .eplace

Defective contact of head !amp and parking lamp switch

qeplace

Defective contact, or disconnection in wiring larness between battery -clay output - CN78 (1). (2) CNl5 (male) (4)

After inspection, .epair (clean) or gplace

Combination switch

Continuity

SMALL

Yes

OFF

20-439 0

M-25

TROUBLESHOOTING

Even when

working

lamp switched

ON, none of monitor

panel lights up

yE> a I

Is voltage between CN22 (1) and chassis ground normal? I

T-adapter to CNPI .(female) and CNP6 (female). 2) Turn starting switch ON. 3) Place combination switch at SMALL. 4) Is reading 20 - 3OV?

Is voltage between

‘No

(female) (1) and chassis ground with CN22 still connector. 3) Is reading 20 - 3OV?

1) Turn working lamp switch ON. 2) Measure voltage between CN254 (female) (5) and chassis ground. 3) Is reading 20 - 3OV?

I) Keep CN257 connected. 2) Turn starting switch ON. 3) Is reading 20 3OV?

lamp

switch ON. 2) Measure voltage between CN22

Is voltage between CN257 (female) (1)

1) Turn working

I) Keep CN257 connected. 2) Turn starting IO switch ON. 3) Turn working lamp switch ON. 4) Is reading 20 - 3OV?

Table 2

I Working lamp switch

Continuity

Yes

OFF

TROUBLESHOOTING

M-25

disconnectionin wiring harness between CNPl (female) (16) -lamp corm&or, or between lame connector (2). cNP6 (fen&) 13)chassis ground Defective contact, or disconnectionin wiring harness between CN22 (female1(1) -CNPl (female) 115).CNP6 (female) (2)

After inspection, repair (clean) or replace

After inspection, repair Wean) or replace

Defective contact, or disconnectionin wiring After inspection, harness between CN79 (11). (12) - CN254 (female) (3). (4) - repair (clean) or CN22 (female) (2). or defective replace diode ass’y, relay ass’y Defective contact, or After inspection, disconnection in wiring repair (clean) or harness between CN257 (female) (2) - CNP254 replace (female) (5) Defective contact, or After inspection, disconnection in wiring repair (clean) or harness between CN257 replace (male) (1) -working lamp switch - CN12 (male) (2). or defective working lamp switch

20-441 a

M-25

TROUBLESHOOTING

Even when starting panel lights up

switch

is turned

1 YES Is voltage between CNPI (female) (16) and chassis ground normal? I

1) Connect T-adapter NO to CNPl (female). 2) Turn starting switch ON. 3) Is reading 20 - 3OV?

ON, none of monitor

Cause

Remedy

All lamps broken, or defective contact, or disconnection in wiring harness between CNPl (female) (161 -lamp connetor (l), lamp connector (2) -chassis ground

After inspection, repair (clean) or replace

Defective monitor panel

Replace

Disconnection wiring

Replace

Part of panel does not light up 1 YES

Is lamp bulb broken? 1) Remove lamp and check visually.

20-442 0

H NO

in lamp

Defective contact, or disconnection in wiring harness between CNPl (female) (16) - lamp connector (l), (2) -chassis ground

After inspection, repair (clean) or replace

TROUBLESHOOTING

M-25

electrical

circuit drawing

Fuse

box

+24v CN23 CNPl

Head switch

Monitor Pane I

lamp

CN79

Lamp

CN254

IamP

relay

Lamp

Service meter

TDWOl287

20-443 0

TROUBLESHOOTING

When starting switch is turned to ON position (engine stopped), buzzer does not sound for 1 sec. -

M-26

CAUTION *

M-26, M-27

item is flashing but 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. (CNOfV )) When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check. The buzzer does not sound for charge level and fuel level of CAUTION items.

* * *

Cause

YES

monitor

Remedy

?eplace

1 Connect

CNP4

(female) (8) and chassis ground. Does alarm buzzer

YES 21

Iefective contact, lisconnection in wiring jarness between CN148 male) - CNP4 (female) (8

Clean (defectiv :ontact) or replace

Defective alarm buzzer

qeplace

Iefective contact, or lisconnection in wiring rarness between CN147 female) - +24V line

Mter inspection pepair Wean) or .eplace

Defective alarm buzzer

qeplace

Contact between chassis tround and wiring rarness between CNP4 female) (8) - CN148

Wter inspection ,epair (clean) or splace

Iefective monitor panel

3eplace

1) Connect T-adapter

1) Turn starting NO switch ON. 2) Is reading 20 - 3OV?

M-27 *

No abnormality is shown on monitor display, but alarm buzzer sounds

The alam buzzer sounds when the parking brake is applied and the transmission is in any position except NEUTRAL.

2 YES

(female). Dose alarm buzzer sound?

1) Disconnect CNP4 (female). 2) Turn starting switch ON.

20-444 0

1) Disconnect CN148. 21 Turn starting switch ON. -

M-26,

TROUBLESHOOTING

M-26, 27

electrical

M-27

circuit drawing

buzzer Mon itor

Panel TDW01295

20-445

M-28

TROUBLESHOOTING

M-28

When starting switch is turned to ON position (engine stopped), warning lamp does not light up for 2 sec. CAUTION item is flashing but 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 connecting the T-adapter (or socket adapter), connect to the connector specified. (CNOA( When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check.

+ *

Cause

YES

Defective monitor panel

1 3

Does warning lamp light up?

YE 9

1)Connect

CNP4 (female). (female) (7) to chassis ground. 3) Turn starting switch ON.

M-28

YES

CN17 (female) (1)

I) Connect T-adapter to CN17 (female). 2) Connect CNP4 (female) (7) to chassis ground. 3) Turn starting switch ON.

electrical

Monitor

Pane

FH_

1) Connect T-adapter to CN17 (female). 2) Turn starting switch ON. 0

Warning lamp bulb broken, or defective contact, or disconnection in wiring harness between CN17 (male) (1) - lamp, or CN17 (male) (2) - lamp Defective contact, or disconnection in wiring harness between CN17 (female) (2) -chassis ground Defective contact, or disconnection in wiring harness between CNP4 (female) (7) - CN40 (female) (3). (5) - +24V line, or between CN17 (female) (1) CN40 (female) (3), (5) - +24\ line, or defective lamp relay

Remedy

Replace

After inspection, repair (clean) or replace

circuit drawing

DWO 296

20-446 0

TROUBLESHOOTING

M-29 * * *

M-29

No abnormality lights up

is shown on monitor

display, but warning _ lamp

I YES

Defective monitor panel

1 Does warning lamp go out?

Contact between chassis ground and wiring harness between CNP4 (female) (7) CN40 (female) (21

YES

Is there continuity between CNP4

1) Disconnect CNP4 (female). NO (female) (7) and chassis ground? 2) Turn starting switch ON. 1) Connect T-adapter to CNP4 (female). 2) Turn starting switch OFF.

M-29

electrical

Cause

Contact between +24V line and wiring harness between CN17 (female) (1) -CN40 (female) (3). or defective lamp relay

Remedy

Replace

After inspection, m~~i~‘ean’

After inspection, repair (clean) or replace

circuit drawing

Monitor

TOW01296

20-447 0

TROUBLESHOOTING

M-30 * * *

M-30

Abnormality

in fuel gauge

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. (CNOA( 1). When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check. Cause

lf nothing

is displayed

in display

area

YES

1 1

1) Connect NO T-adapter to CNP4 (female). 2) Connect short connector to CN127 (female). 3) Turn starting switch OFF.

lf indicator

remains YES

M-30

2 Is there continuity _ between CNP4 NO (female) (4) and chassis ground? 1) Connect T-adapter to CNP4 (female). 2) Remove CN127. 3) Turn starting switch OFF.

electrical

Pane

Defective monitor panel

Replace

YES _

Defective fuel sensor

Replace

Ccontact between chassis ground and wiring harness between CNP4 (female) (4) CN86 (3) - CN127 (female) (1)

After inspection, repair (clean) or replace

Defective monitor panel

Replace

circuit drawing

CNP4 Monitor

Replace

at FULL

1 Does whole display area of fuel gauge go out? _ 1) Disconnect CN127 (fuel sensor). 2) Turn starting switch ON.

Defective fuel sensor

Defective contact, or disconnection in wiring After inspection, harness between CN127 repair (clean) or (female) (2) -chassis replace ground, or between CN127 (female) (1) - CN86 (3) CNP4 (female) (4)

~ 2) Turn starting switch ON.

Remedy

CN86

CN127

3 3

Fuel level sensor

TDWOlPBO

TROUBLESHOOTING

M-31 * * *

M-31

Abnormality

in air pressure gauge

If nothing

is displayed

in display

area

YES

1 I

pressure sensor). 2) Turn starting switch ON.

remains

at maximum

YES z g

Does whole display area of air pressure gauge 2 YES go out? ~ Is there continuity _ between CNP4 _ I) Disconnect ND (female) (1) and CNllO (air chassis ground? pressure sensor). NO 1) Connect 2) Turn starting T-adapter to switch ON. CNP4 (female). 2) Disconnect CNllO. 3) Turn starting switch OFF.

M-31

electrical

teplace

Defective monitor panel

ieplace

ifter inspection, epair (clean) or eplace

level

1 k

Defective air pressure sensor

Defective contact, or disconnection in wiring harness between CNllO (female) (1) - CN65 (1) CNP4 (female) (l),or between CNllO (female) (2) - CN65 (10) - CN85 (1) chassis ground

I) Connect NO T-adapter to CNP4 (female). 2) Connect short connector to CNllO (female). 3) Turn starting switch OFF.

If indicator

Remedy

Defective air pressure sensor

leplace

Ccontact between chassis around and wiring harness between CNP4 (female) (1) EN85 (1) - CNllO (female) II)

after inspection, epair (clean) or eplace

Defective monitor panel

leplace

circuit drawing

CNP4 Monitor

CN65

CNllO

Air Pressure sensor

(IJ CN85

TDW01283

20-449 0

M-32

TROUBLESHOOTING

M-32 Ir * *

Abnormality

in engine water temperature

gauge

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. 1) When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNOA( When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check. Cause

If nothing

is displayed

in display

area

YES

2 YES

level?

Is there continuity between CNP4

1) Disconnect CN123 (engine water temperature). 2) Turn starting switch ON.

Replace

Ccontact between chassis ground and wiring harness between CN123 (female) (1) -CN114(3)-CN84(9)CNP4 (female) (2)

After inspection, repair (clean) or replace

Defective monitor panel

Replace

Defective engine water temperature sensor

Replace

Defective monitor panel

Replace

(female) (2) and chassis ground?

remains

at minimum

YES 1 Does whole display area of engine water temperature gauge go out?

20-450 0

Defective engine water temperature sensor

1) Connect NO T-adapter to CNPL (female). 2) Disconnect CN123. 3) Turn starting switch OFF.

If indicator

1) Connect short connector to CN123 (male). 2) Turn starting switch ON.

Remedy

YES

Is there continuity _ between CNP4 NO (female) (2) and chassis ground? 1) connect T-adapter to CNP4 (female). 2) Connect short connector to CN123 (female). 3) Turn starting switch OFF.

level

Defective contact, or disconnection in wiring harness between CNP4 (female) (2) - CN84 (9) CN114 (3) - CN123 (female) cl), or between CN123 (female) (2) - CN114 (2) CN84 (lO),CN85 (1) - chassi: ground

After inspection, repair (clean) or replace

TROUBLESHOOTING

M-32

electrical

M-32

circuit drawing

CNP4 Monitor Dane1

CN84

CN114

CN123

-$J

Engine water temperature

sensor

CN85 TDW01284

20-451 0

M-33

TROUBLESHOOTING

M-33

Abnormality

in torque converter

oil temperature

gauge

is displayed

in display

YES 1 Does torque converter oil temperature gauge show minimum ieVe

YES

Is’there continuity between CNP4

1) Disconnect cN121 (torque converter oil temperature). 2) Turn starting switch ON.

Zeplace

Ccontact between chassis ground and wiring harness between CN121 (female) (1) - CN89 (10) - CNP4 (female) (3)

Mer inspection, epair (clean) or eplace

Defective monitor panel

teplace

Defective torque converter oil temperature sensor

leplace

Defective monitor panel

leplace

1) Connect NO T-adapter to CNP4 (female). 2) Remove CN121. 3) Turn starting switch OFF.

remains

at minimum

level

YES

1 Does whole display area of torque converter oil temperature gauge 90 out?

YES

Is there continuity 1) Connect short _ between CNP4 NO (mate) (3) and connector to chassis ground? CN121 (female). 2) Turn starting switch ON.

1) Connect T-adapter to CNP4 (female). 2) Connect short connector to CN121 (female). 3) Turn starting switch OFF.

Defective torque converte oil temperature sensor

NO (female) (3) and chassis ground?

lf indicator

M-33

Remedy

area

electrical

Defective contact, or disconnection in wiring harness between CNP4 [female) (3) - CN89 (10) CN121 (female) (1). or between CN121 (female) (2) - CN89 (9) - CN85 (1) chassis ground

circuit drawing

CN121

CNP4 Monitor

ifter inspection, eoair (clean) or

Torque converter oi I temperature sensor

Panel

CN85 TDWOl285

20-452

TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (T MODE)

POWER TRAIN T- 1

Machine

does not move . . .. . .. . . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . .. . .. . . . . . . .. . . .. . . . . .. . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . .. . .. . . . . . .. . . . . 20-502

T- 2

Machine

lacks power

T- 3

Excessive

time

T- 4

Torque

or speed . .. . .. . . . . . . . .. . .. . . . . . . .. . . .. . . . . . . .. . . . . . .. . .. . . . . . . . .. . .. . . . . . . .. . . .. . . . . . . .. . . . . . .. . .. . . . . . . 20-503

lag when

converter

starting

machine

oil temperature

or shifting

gear . . . . . .. . . . . . . . . . . . .. . . . . . . .. . .. . . . . . .. . . . . . .. . .. 20-504

too high . .. . .. . . . . . . .. . . .. . . . . . .. . . . . . . . .. .. . . . . . . . .. . . .. . . . . . .. . . . . . . . . . .. . . . . . .. . . 20-505

STEERING SYSTEM T- 5

Steering

wheel

does not turn . . . . . .. . . . . . . . .. . . .. . . . . . . . . . . .. . . . . . . .. . .. . . . . . .. . . . . . . . . . . . .. . . . . . . . . . .. .. . . . . .. . .. . . . . . .. . . . . . . 20-506

T- 6

Steering

wheel

is sluggish . .. . . .. . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . .. . . .. . . .. . . . . . . . . . . .. . . . . . . .. . . .. . . . . .. . . . .. . . . . .. 20-507

T- 7

Steering

wheel

moves

T- 8

Machine

tends to turn naturally

unsteadily

or is subjected

to large shock . . . . . .. . . . . . . . . . . .. . . . . . . .. . .. . . .. . .. . . 20-508

in one particular

direction

when traveling

. . . . . . .. . . . . .. .. . . . . . 20-508

BRAKE SYSTEM

z Fi d

T- 9

Air pressure

does not rise at all . . .. . .. . . . . . . . .. . .. . . . . . . .. . . . . . . . . . . .. . .. . . . . . . . .. . . . . . . . . . .. . . .. . . .. . .. . . . . . . . . . . .. . . . . . .. . . 20-509 does not rise to the specified

T-10

Air pressure

T-II

Brake is ineffective

T-12

Brake does not release,

T-13

Parking

or not very effective

range . . .. . . . . . . . . .. .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . .. .. .. . . . . . .. . . . . . . . . 20-510

. . .. . .. . . . . . . .. . .. . . .. . . .. . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . .. .. . . . . . . .. 20-511

or drags . . .. .. . . . . . . . . .. . .. . . . . . . .. . .. . . .. . . . . .. . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . .. . . . .. . . . . .. . . . . . . .. 20-512

brake does not release,

or drags . .. . . . . . .. . .. . . . . . . .. . . .. . . . . . . .. . .. . . . . . . .. . . .. . . . . . . . . .. .. . . . . . . .. .. . . . . . . . .. 20-513

WORK EQUIPMENT T-14

Lift arm does not rise ...............................................................................................................

20-514

T-15

Lift arm moves slowly or does not have sufficient

lifting power.. .....................................

.20-515

T-16

Lift arm movement

a certain

T-17

Bucket cannot

T-18

Lift arm has large hydraulic

T-19

Lift arm movement

T-20

Lift arm lowers

T-21

Bucket does not tilt back ..........................................................................................................

becomes

be held down with lift arm cylinder is unsteady

Bucket moves slowly

T-23

Bucket movement

T-24

Bucket cannot

T-25

Bucket has large hydraulic

T-26

Bucket moves

T-27

Bucket dumps

T-28

Control

control

lever is shifted from

tilt back power

“Hold”

to “Raise”

20-516 .20-517 ...... 20-517 20-518

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

.20-519 .20-520

by the bucket cylinder..

.20-520

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

drift.. ............................................................................................. when

machine

travels

when

control

levers of lift arm and dump

20-520

under load.

valve in “Hold”) ..........................................................................................

momentarily

.20-516 .20-516

slow during tilt back.. ..............................................................

or has insufficient

be held down

control

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

during work.. ......................................................................

when

becomes

unsteadily

height.. ................................

drift.. ...........................................................................................

momentarily

T-22

(Main

slow after it reaches

lever is shifted from

move stiffly and sluggishly..

“Hold”

20-521

to “Tilt back”. .. 20-521

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

.20-522

20-501 0

TROUBLESHOOTING

T-l

POWER TRAIN T-l

Machine

does not move

Ask the operator the following points . Did the machine suddenly stop moving? l

Yes = Component seized or damaged Was there any abnormal noise when the machine stopped moving? Yes = Component broken.

Checks before troubleshooting . Is oil level in transmission case correct? . Is monitor display normal? . Is drive shaft broken?

Remedv /A/&/A/A/A/

I I I I I

: moves normally in certain speed ranges.

Note

1: If the solenoid valve and hydraulic pressure are normal, the “m” in the Causes column indicates that the valve spool does not work. Note 2: 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.

20-502 a

The following symbols are used to indicate the action to be taken when a cause of failure is located.

T-2

TROUBLESHOOTING

T-2

Machine

lacks power or speed

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

No.

Problems

Abnormal

Torque converter stall speed too high.

noise from between pump and filter.

Torque converter stall speed too low

1 Transmission

Iron or alumimum case.

( Modulating

I I I lol

main relief valve pressure too low

I I I I I I

particles stuck to strainer of transmission

pressure drops when oil temperature

rises.

I loI I I I I I I I I The following

symbols

to be taken when

are used to indicate

a cause of failure

the action

is located

20-503

TROUBLESHOOTING

T-3

Excessive time lag when starting

machine or shifting gear

Checks before troubleshooting . Is oil level in transmission

case correct? Is there any leakage of oil from joints of piping or valves?

Transmission range

modulating pressure too low in every speed

0000

As in Items 4; indicator fluctuates violently

Torpue converter oil temperature

is above operating tange.

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

TROUBLESHOOTING

T-4

T-4 Torque converter

oil ,temperature

too high

Ask the operator the following points . Does torque converter oil temperature go up during torque converter stall, and down when the torque converter is not installed? Yes = Normal (incorrect selection of gear speed) Checks before troubleshooting . Is oil level in transmission . Is filter clogged?

case correct?

Checking for abnormalities * If the oil temperature is normal but the oil temperature gauge is outside the operating range, the oil temperature gauge is defective.

S Ri d

No.

Problems

Pump makes abnormal noise when oil temperature

High idling and low idling speeds are too low.

Hydraulic pressure at inlet port of torque converter too low

Transmission

modulating

pressure too low

is low.

0 0

0 00

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

A: Adjust

C: Clean

Repair

20-505 0

TROUBLESHOOTING

T-5

STEERING SYSTEM T-5 Steering

wheel does not turn

Ask the operator the following questions . Did the steering wheel suddenly cease

to turn? +Damage to equipment in steering circuit. Did steering wheel show signs of being sluggish for some time? + Worn parts in steering circuit or faulty seal.

Checks before troubleshooting . Is oil level in hydraulic tank and type of oil satisfactory? . Has the safety bar been removed from the frame?

Steering wheel is sluggish and does not turn properly.

Oil pressure in steering circuit does not rise at all

Steering wheel

1 0 I 0

101 lol

lolo] I I

turns but steering does not work

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: Adjust

20-506 0

Repair

C: Clean

T-6

TROUBLESHOOTING

T-6 Steering

wheel is sluggish

Ask the operator the following questions . Did the steering wheel suddenly become

sluggish? +Damage to equipment in steering circuit. Did the steering wheel show signs of being sluggish for some time? + Worn parts in steering circuit or faulty seal.

Checks before troubleshooting . Is oil level in hydraulic tank and type of oil satisfactory? . Is the adjustment of the steering valve control lever correct? . Is there any oil leakage from the oil pressure hose, valves, cylinders, etc.? . Is there any seizure between the pin, pin bearing and bushing of the center hinge and the steering cylinder pin and bushing? . Check tire inflation pressure. Fault check . 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 standard value table to see whether or not there is any abnormality.

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

20-507 0

TROUBLESHOOTING

T-7 Steering

T-7, T-8

wheel moves unsteadily

or is subjected to large shock

Checks before troubleshooting . Is oil level in hydraulic tank and also oil

type satisfactory? Is there any play in the center pin hinge bearing or steering cylinder pin bushing? Does tire inflation pressure fluctuate? Is play of steering wheel within standard valve?

. .

Fault check

Operate the wheel loader in a safe place and check the conditions under which the steering wheel becomes unsteady. * If, in addition to the steering wheel being unsteady, there are other faults such as sluggishness, etc., refer to item T-6 “Steering wheel is sluggish”.

No.

Problems

Machine body is unsteady when traveling on bumpy road surface.

Steering wheel becomes unsteady if suddenly turned when working or traveling.

Machine body becomes unsteady when traveling at high speed.

I Machine bodv becomes unsteadv

durina enaine startina.

T-8 Machine tends to turn naturally traveling Causes:

000 0

101

in one particular

direction when

Faulty steering valve Oil leakage in steering cylinder. . Does tire inflation pressure fluctuate? l

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

20-508 0

TROUBLESHOOTING

T-9

BRAKE SYSTEM T-9 Air pressure does not rise at all Ask the operator the following questions . Did the air puressure suddenly cease to

rise? +Damage in air circuit or equipment. Was the air pressure difficult to raise for some time? +Air leakage, performance drop in air equipment.

Checks before troubleshooting

Damage air hose or tube, external damage to equipment associated with air system. Is the drain cock completely closed?

Fault check . Check the air pressure by air gauge.

If the pointer of the air gauge on the instrument panel remains at “0” despite opening the air drain valve and confirming that the air is pressurized, the gauge is fauty.

No.

argepipe of compressor when engine is running but puressure does not build up.

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

20-509 0

T-10

TROUBLESHOOTING

T-10

Air pressure does not rise to the specified range

Checks before troubleshooting l

. l

Check for possible air leakage from hose, tube and air equipment. Is the drain cock completely closed? Check for deformation of compressor air intake hose.

air

Fault check . Install a pressure gauge in the air circuit and measure the air pressure, then compare the measured value with the standard value table to see whether or not it deviates from the specified value.

Air discharged from compressor discharge pipe is weak when engine is running.

Compressor starts to build up pressure when cuicuit between air governor and unloader is disconnected.

Air comes out of discharge pipe of compressor when engine is running but pressure does not bulid up.

/////ill/

000

0 00000

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

20-510 0

C: Clean

T-11

TROUBLESHOOTING

T-II

Brake is ineffective

or not very effective

Ask the operator the following questions . Did the brake suddenly ceases to be effective? + Damage in air or brake equipment. . Did break gradually deteriorate? + Deterioration of seal or parking, wear of lining. Checks before troubleshooting . Is kind of brake oil correct? (SAEIOW-

CD)

Is air pressure and brake oil quantity satisfactory? . Is there any leakage of air or brake oil 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 inflation pressure and tire thread. . Measure the pressure in the air circuit. If there is an abnormality, refer to item T-9 “Air pressure does not rise at all” and item T-10 “Air pressure does not rise to the specified value”. If the measured value is normal, move on to the following problems. Fault check . Check it against the value in the standard value table to see whether or not braking performance is bad. . Check braking of the left and right wheels or both front and rear. l

Remedy

No.

Problems

Air leaks from brake valve when a certain brake pedal is depressed. Braking action is effect when other brake pedal is depressed.

When depress brake pedal, there is no resistance.

When depress the brake pedal, air leaks from the brake chamber relay valve.

When brake is applied, abnormal noise is heard from axle brake area.

Q p

b n

I Excessive metal particles in axle oil.

1 Leakage of brake oil inside axle more than specified.

When the machine is raised using jack, the wheel axles placed on a stand and the brake operated with the engine in the forward 1st speed position, however a certain wheel turns fast.

l.p 4

d’-” LI

0 0

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. lHol Air leaks from the breather of the brake chamber when the brake pedal is depressed.

xXxXxX>

-1 6

,c $

/ll”l/Il/ I I

III

I I

000

lol

I I I I lol

I I I 0

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

a: Repair C: Clean

T-12

TBOUBLESHOOTING

T-12 l

does not Does brake pedal Does parking brake gage?

completely

disen-

Fault check l Abnormal heat generation in brake. . Inertial travel on flat ground.

nd brake disen

ed if brake chamber air

A certain wheel rotates sluggishly when the machine is raised and place forward 1st position.

The following

symbols

to be taken when

are used to indicate

the action

a cause of failure is located. ,!I: Repair X: Replace C: Clean A: Adjust

20-512 0

T-13

TROUBLESHOOTING

T-13

Parking brake does not release, or drags

Checks before troubleshooting . Is the pressure in the air circuit within the specified range? (if the air circuit pressure is 0.39 MPa I4.0 kg/cm*} or less, the parking brake solenoid valve will automatically operate to engage the parking brake.)

No.

Problems

When parking brake switch turned to OFF, air leaks from spring cylinder, and cylinder rod does not return fully.

Parking brake not release even when parking brake switch is turned OFF.

The spring cylinder operates normally and the rod and lever return, however the brake drags.

0 0

The following symbols are used to indicate the action to be taken when a cause of failure is located.

T-14

TROUBLESHOOTING

WORK EQUIPMENT T-14

Lift arm does not rise

Ask the operator the following questions . Did the problem suddenly fail to rise? + Seizure or damage to various units. Was unusual noise produced? ( Where did it emanate from?) . Were there previous signs of the boom slowing down? + Wear of parts of flattening of spring. Checks before troubleshooting . Is oil level in hydraulic tank correct? . Is travel of lift control lever and spool correct?

gine is at high idling, steering action is light and

The following

symbols

to be taken when

20-514 0

are used to indicate

a cause of failure

the action

is located.

T-15

TROUBLESHOOTING

T-15

Lift arm moves slowly or does not have sufficient

lifting power

Checks before troubleshooting . Is the travel 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 from 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.

Bucket tilt back force and speed are abnormal and lift arm lifting speed is low.

Bucket tilt back force and speed are normal but lift arm lifting speed is slow.

Some as Item 1 except that lift arm lifting speed becomes particularly low when oil temperature rises.

Hydraulic pump emits unusual noise.

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 has a large amount of hydraulic drift.

The relief pressure of relief valve of main control valve.

I lol 0

0 00

0 0 0 0

000

The following

symbols

are used to indicate

the action

to be taken when a cause of failure is located. X: Replace LI: Repair C: Clean A: Adjust

20-515 0

TROUBLESHOOTING

T-16

T-16, T-17, T-18

Lift arm movement height

becomes slow after it reaches a certain

Checks before troubleshooting . External deformation of lift cylinder. Cause l

Swollen or internally damage lift cylinder tube. Regarding other faults occurring during lift arm rise, refer to item T-15 “Lift arm moves slowly or does not have sufficient lifting power”.

T-17

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, “Lift arm moves slowly or does not have sufficient lifting power”.

refer to item T-15

Checks before troubleshooting . Is level of oil in the hydraulic .

tank correct? Is travel of main control valve and lift arm spool correct?

Cause . Is level of oil in the hydraulic .

Is travel of main control

T-18

tank correct? valve and lift arm spool correct?

Lift arm has large hydraulic drift

Ask the operator the following questions . Did the hydraulic drift suddenly become l

large? + Dirt lodged in valve or damaged parts. Did the hydraulic drift gradually become large? + Worn parts.

Checks before troubleshooting . Is the type and temperature .

of the oil in the hydraulic Is the lift arm spool in the neutral position? -_j Seized link bushing, faulty spool detent.

tank correct?

Problem and cause l

When measuring hydraulic drift, internal of lift cylinder produces oil leak noise. + Damaged piston packing. When measuring hydraulic drift, lift cylinder does not produce oil leak noise. + Faulty oil sealing of lift spool. + Faulty check valve between pipings.

20-516 0

T-19, T-20

TROUBLESHOOTING

T-19

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. Problem and cause Check the amount of hydraulic drift and whether or not the machine body can be lifted up by the lift cylinder. 1. If the amount of hydraulic drift is greater than the standard value, refer to item T-18 “Lift arm has large hydraulic drift”. 2. If the machine body can not be lifted up by the lift cylinder, refer to item T-17 “Bucket can not 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. Ir If a vacuum is generated frequently + fault suction valve on lift cylinder rod side.

T-20

Lift arm lowers momentarily “Hold” to “Raise”

when control lever is shifted from

The lift arm lowers 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. Cause . Faulty seating of main control valve or lift arm check valve.

20-5 17 0

T-21

TROUBLESHOOTING

T-21

Bucket does not tilt back

Ask the operator the following questions . Did the bucket suddenly ceases to move?

+ Seized or damaged equipment. Was any unusual noise emitted (where did it emanate from)? Where there previous signs of the bucket slowing down? + Worn parts of flattened spring.

Checks before troubleshooting . Is amount of oil in hydraulic tank satisfactory? . Is the travel of the dump control lever and spool correct?

Steegring action is light and excessively fast when the engine

action is heavy and slow when the engine is at high lol

I 1 I

I 1 I I I

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

20-518 0

TROUBLESHOOTING

T-22

Bucket moves slowly or has insufficient

tilt back power

Checks before troubleshooting . Is the oil quantity in the hydraulic tank and the type of oil satisfactory? . Is the travel of the dump control lever and the main control valve spool correct? . Seizure of bushing in bucket linkage? (Does emits unusual noise?) Fault checks Check the amount of deficient tilt back force by performing actual work. . Measure the operating speed of the bucket and check it against the standard value table to determine whether or not it is normal. l

eed are abnormal and also

The following

symbols

to be taken when

are used to indicate

a cause of failure

the action

is located.

T-23, T-24, T-25

TROUBLESHOOTING

Bucket movement

T-23

becomes slow during tilt back

Checks before troubleshooting External deformation of dump

cylinder.

Cause . Swollen or internally damaged dump cylinder tube. . Reading other faults which occur when the bucket operates, slowly or has insufficient tilt back power”.

refer to item T-22 “Bucket moves

Bucket cannot be held down by the bucket cylinder

T-24

Refer to item T-22 “Bucket moves

slowly

or has insufficient

tilt back power”.

Checks before troubleshooting . Is oil level in hydraulic tank satisfactory? . Is the travel of the main control valve dump spool correct? Cause . Faulty seat of safety with suction valve of control valve for the bottom Oil leakage from seal of dump cylinder piston.

side of dump cylinder.

T-25

Bucket has large hydraulic drift

Ask the operator the following questions . Did the hydraulic drift suddenly become large? + Dirt lodged in valve or damaged parts. . Did the hydraulic drift gradually become large? -_j Worn parts.

Checks before troubleshooting . .

Is the type and temperature of the oil in the hydraulic Is the dump spool in the neutral position? + Seized link bushing, faulty spool detent.

Fault check . Use the standard actually large.

value

table

to check whether

Cause Oil leakage in dump cylinder . Faulty seating of safety valve (with suction valve) Faulty oil sealing of dump spool. . Faulty check valve between pipings.

tank correct?

or not the hydraulic

20-520 0

at bottom

side.

drift of the bucket

TROUBLESHOOTING

T-26

T-26. T-27

Bucket moves unsteadily when qachine (Main control valve in “Hold”)

Checks before troubleshooting . Is oil level in hydraulic tank any type of oil correct? . Excessive play in pin and bushing of work equipment duced?)

travels under load.

linkage.

(Was an unusual

Cause . Faulty piston seal of dump cylinder. . Faulty safety valve with suction valve for the head side of dump cylinder. ,lf the above symptoms occur together with other symptoms, refer to the corresponding to each fault.

T-27

Bucket dumps momentarily “Hold” to “Tilt back”

noise pro-

problems

items

when control lever is shifted from

The bucket dumps momentarily under its own weight 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 . Faulty seating

of main control valve dump

spool check valve.

20-521 0

T-28

TROUBLESHOOTING

T-28

Control levers of lift arm and dump move stiffly and sluggishly

Fault check Using the standard value table, check whether or not the operating force of the lever is large.

Movement of lift and dump levers becomes sluggish along with change in oil temperature.

Movement of lift and dump levers becomes partially sluggish Irrespective of oil puressure and temperature.

Movement of lift and dump levers becomes generally sluggish irrespective of oil puressure and temperature.

Movement of lift and dump levers does not become light even when the link of the control lever is disconnected at the valve connection part and the lever operated.

I O loI

I lwm

The following

symbols

are used to

to be taken when a cause of failure is located. X: Replace A: Repair A: Adjust

20-522 0

C: Clean

TROUBLESHOOTING OF JOYSTICK STEERING CONTROLLER SYSTEM (J MODE)

Function .........................................................................................................................................

Troubleshooting

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

20-553

Table of failure codes ....................................................................................................................

20-553

Table of failure modes and causes .............................................................................................

20-554

J-l

Failure code 1121 Abnormality

J-2

z G g

in transmission

in caution

20-559

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

20-560

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

20-561

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

20-562

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

20-563

solenoid

cut relay system.. .................................................................

20-564

in joystick steering

neutral signal system ............................................................

20-565

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

20-566

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

20-567

in steering

L.H. steering

solenoid

L.H. steering

solenoid

in steering

Failure code 1371 in joystick steering

lever potentiometer

Failure code [381 in model selection

wiring

harness

Failure code 1391 Abnormality

J-15

solenoid

Failure code 1361

Abnormality J-14

R.H. steering

Failure code 1341

Abnormality J-13

R.H. steering solenoid

Failure code 1331

Abnormality J-12

20-558

Failure code [321

Abnormality J-l 1

lamp system .........................................................................................

F,N,R signal system ...............................................................

Short circuit in steering J-IO

20-557

Failure code [311

Disconnection J-9

N relay system ............................................................................

in joystick steering

Short circuit in steering J-8

20-556

Failure code [301 Disconnection

J-7

R relay system .............................................................................

Failure code 1251 Abnormality

J-6

in transmission

Failure code 1191 Abnormality

J-5

20-555

Failure code [I81 Abnormality

J-4

F relay system .............................................................................

Failure code [I31 Abnormality

J-3

in transmission

20-553

Abnormality

in power source voltage ........................................................................................ in joystick steering

ON-OFF

signal system ..........................................................

20-568 20-569

20-551 0

J-16

Abnormality

in transmission

F solenoid

system .......................................................................

20-570

J-17

Abnormality

in transmission

R solenoid

system

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

20-571

J-18

Abnormality

in transmission

N solenoid

system ......................................................................

20-572

J-19

Disconnection

in joystick steering

F switch system ..................................................................

20-573

J-20

Disconnection

in joystick steering

R switch system.. ................................................................

20-574

J-21

Disconnection

in joystick steering

N switch system ................................................................

20-575

20-552 a

TROUBLESHOOTING

1. FUNCTION

The control mechanism of the joystick steering controller consists of the controller, neutral detection switch, potentiometer input, solenoid valve output, and F,N,R display lamp output. This control mechanism carries out control of the steering. The controller receives the data from the potentiometer and neutral detection switch, carries out processing according to the input signals from each switch, and controls the solenoid valves. 2.

TROUBLESHOOTING The joystickcontroller has a troubleshooting function, and when failure codes J-l to J-14 are detected, the failure mode is displayed on the digital display of the controller which is installed inside the right console box. There is no detection function for failure codes J-l 5 to J-21. They are used when there is a disconnection or other problem in the transmission F, N, or R solenoid relays or switches.

TABLE OF FAILURE CODES

Ki x

L.H. steering solenoid

JOYSTICK STEERING CONTROLLER SYSTEM

TROUBLESHOOTING

JOYSTICK STEERING CONTROLLER SYSTEM

TABLE OF FAILURE MODES AND CAUSES

Failure Code

T/M does not enter R T/M does not enter N Caution lamp stays lighted up

0 0

5/T does not turn to left %T does not turn to right

0 0

3-r turns fully to left j/T turns fully to right Ueither S/l nor T/M work

JST: Joystick steering S/T : Steering T/M: Transmission

20-554 a

0 0

0 000

TROUBLESHOOTING

J-l

* * + Ir

J-l

FAILURE CODE [I21 ABNORMALITY SYSTEM

IN TRANSMISSION

F RELAY

Before carrying out troubleshooting, check that all the related connectors are properly inserted. Except when using the joystick steering lever, place it at the N position and turn the joystick steering selector switch ON. Always connect any disconnected connectors before going on to the next step. Turn the starting switch to the OFF position before disconnecting any connector.

Cause

YES

Remedy

Defective controller

Replace

Defective contact or disconnection in wiring harness between CNJS4 (I) and CNJSJ (21)

Repair or replace wiring harness

Defective contact or disconnection in wiring harness between CNJS4 (2) and chassis

Repair or replace wiring harness

1 Is resistance between CNJSJ (female) (21) and chassis normal?

3 YES 2

1) Disconnect CNJS3. 2) 250 - 330R ~0

Is resistance between CNJS4 (male) (1) and (2) normal? 1) Disconnect CNJS4. 2) 250 - 330R

YES

Is resistance between CNJS4 (female) (2) and chassis normal? 1) Disconnect CNJSL. 2) Max. 10 NO

Defective CNJS4 F output reverse relay

CNJS12

F relay

F selector

relay

coil

TOW01043

20-555 0

TROUBLESHOOTING

J-2

Ir Ir * *

J-2

FAILURE CODE [I31 ABNORMALITY SYSTEM

IN TRANSMISSION

R RELAY

Cause

YES

between CNJSB (female) (20) and chassis normal? 1) Disconnect CNJS3. 2) 250 - 33022

Is resistance between CNJSB (female) (2) and chassis normal?

Is resistance between CNJS5 (male) (1) and (2) normal?

1) Disconnect CNJSI. 2) 250 - 330R

YES

1) Disconnect CNJS5. 2) Max. 1R

Remedy

Defective controller

Replace

Defective contact or disconnection in wiring harness between CNJS5 (I) and CNJS3 (20)

Repair or replace wiring harness

Defective contact or disconnection in wiring harness between CNJS5 (2) and chassis

Repair or replace wiring harness

Defective CNJSB R output reverse relay

Replace

CNJS13

R selector

relay

Controller

ChJS3 CNJ.35

R output reverse relay

CND7 TDW01044

20-556 0

TROUBLESHOOTING

J-3

* * * +

J-3

FAILURE CODE [I81 ABNORMALITY SYSTEM

IN TRANSMISSION

N RELAY

Remedy

Cause

YES

between CNJSJ (female) (11) and chassis normal?

YES

Is resistance YES between CNJSG (female) (2) and chassis normal?

1) Disconnect CNJS3. 2) 250 - 33OQ N

Is resistance between CNJSG (male) (1) and (2) normal? 1) Disconnect CNJSG. 2) 250 - 330R

1) Disconnect CNJSG. 2) Max. 1R

Defective controller

Replace

Defective contact or disconnection in wiring harness between CNJSG (1) and CNJS3 (11)

Repair or replace wiring harness

Defective contact or disconnection in wiring harness between CNJSG (2) and chassis

Repair or replace wiring harness

Defective CNJSG N output ‘everse relay

Replace

CNJS14

N selector

relay

Controller

CNJS3 ChJ.36

N output reverse relay

TDW01045

20-557 a

J-4

TROUBLESHOOTING

J-4

+ * * *

FAILURE CODE [I91 ABNORMALITY

IN CAUTION

LAMP SYSTEM

Remedy

Cause

Replace

Repair or replace wiring harness

between CNJSl (female) (16) and

YES 1) Disconnect 2) 250 - 330R

Repair or replace wiring harness

between CNJSll 2) Max. 1R

1) Disconnect CNJSll. 2) 250 - 330R

Defective CNJSll lamp relay

caution

Replace

Controller

CNJS3

CNJSl caution relay

lamp

L-l” CNJSj _

taut ion IamP relay

@ T @(1>

%R 1’ 2

CNDl

TDW01046

20-558 0

TROUBLESHOOTING

J-5

* j, * *

J-5

FAILUF :ECODE [25] ABNORMALITY IN JOYSTICK STEERING F,N,R SIGNA _ SYSTEM

I YES

3 Is resistance between CNJS2 (female) (11) and CNJSJ (female) (8) normal?

YES

Is resistance between CNJS2 (female) (121and CNJSJ (female) (8) normal?

YES

between CNJSZ (female) (131and CNJSB (female) (8) 1) Disconnect CNJS2 and CNJS3. 2) Min. 1MR

Cause

Remedy

1 Defective controller

1) Disconnect CNJSS and

I NO

Short circuit in JST lever N switch or short circuit between CNl (3) and CNl (6)

swltcn or snon CI~CUII between CNl (5) and CNI (6)

Replace Replace, repair JST lever N switch, or repair, replace wiring harness Replace , repair JST lever R switch, or repair, replace wiring harness Replace, repair JST lever F switch, or repair, replace wiring harness

Controller

CkJS3 I-,

Joust ick steering I

lever

CNJS2

CNl 3 .a

TDW01047

20-559 0

TROUBLESHOOTING

J-6

* * * J,

J-6

FAIL1 ‘RE CODE [301 DISCONNECTION IN STEERING R.H. STEERING SOLE NOID

Before carrying out troubleshooting, check that all the related connectors are properly inserted. Except when using the joystick steering lever, place it at the N position and turn the joystick steering selector switch ON. Always connect any disconnected connectors before going on to the next step. Insert the T-adapter to CNJSB and turn the starting switch ON.

Remedy

Cause

YES

4 YE!

between CNJSB (7) and CNJSI (16) normal?

Defective controller or defective CNJS7 cut relay (see Troubleshooting No. 10)

Replace

Defective contact or disconnection in wiring harness between CNJS7 (3) and CNJSI (16)

Repair or replace wiring harness

Defective contact or disconnection in wiring harness between CNJS17 (1) and CNJS7 (5)

Repair or replace wiring harness

Defective R.H. steering solenoid valve

Replace

Defective contact or disconnection in wiring harness between CNJSI (7) and CNJS17 (2)

Repair or peplace wiring larness

TdW[

1) Insert T-adapter. 2) Turn starting switch ON. 3) Max. 30R

Y 1) Disconnect CNJS17. 2) Max. 30R

1) Turn starting switch OFF. 2) Disconnect CNJS.17. 3) Max. IQ

1) Disconnect CNJS7 and

1 2,KS::

Controller

CkJS3

Steer ina solenoid

20-560 0

valve

JS7

Steer ina solenoid cut relay

TDW01048

TROUBLESHOOTING

J-7

* * Ir +

J-7

FAILURE CODE 1311 SHORT CIRCUIT IN STEERING R.H. STEERING SOLENOID

Before carrying out troubleshooting, check that all the related connectors are properly inserted. Except when using the joystick steering lever, place it at the N position and turn the joystick steering selector switch ON. Always connect any disconnected connectors before going on to the next step. Insert the T-adapter to CNJS3 and turn the starting switch ON.

YES Is resistance

YES 1

z & z!

Is resistance between CNJSB (female) (7) and chassis normal?

1) Disconnect CNJSB. 2) Min. lOI

!iZgi-J-

between CNJS17 (male) (1) and CNJS17 (male) (2) nOrmal? 1) Disconnect CNJS17. 2) 10 - 30R

YES

1) Disconnect CNJS7 and CNJS17. 2) Max. 1R

Disconnection in wiring harness between CNJS7 (3) and CNJS17 (l), orshort circuit with ground

harness

Short circuit in R.H. steering Rep,ace solenoid I

Short circuit in power source between CNJSB (7) and CNJS17 (2)

~ea$reo~iring

Repair or replace wiring harness

Controller

C’NJSJ

, R. H. S/T S/T

solenoid

cut

Steer ina solenoid

valve

(+I relay

(iii

ChJS7

Steering solenoid cut relay

TROUBLESHOOTING

J-8

* * * *

FAILURE CODE [32] DISCONNECTION SOLENOID

IN STEERING L.H. STEERING

Before carrying out troubleshooting, check that all the related connectors are properly inserted. Except when using the joystick steering lever, place it at the N position and turn the joystick steering selector switch ON. Always connect any disconnected connectors before going on to the next step. Insert the T-adapter to CNJSB and turn the starting switch ON.

Cause

Remedy

Defective controller or defective CNJS7 cut relay (see Troubleshooting No.

‘ES

I10) 1 Is resistance I between CNJSB (6) and CNJSB (16) I normal?

Is resitiance YES between CNJS16 (male) (I) and CNJSlG (male) 12) normal?

1) Insert T-adapter. 2) Turn starting switch ON. 3) Max. 3OQ ween CNJSI (61 and CNJS16 (female) (2) normal?

1) Disconnect CNJS16. 2) Max. 30R

YES 3_

Defective contact or 4 YES disconnection in wiring Is resistance harness between CNJS7 (3) between CNJ616 and CNJS3 (16) (female) (1) and CNJS7 (female) (5) Defective contact or normal? disconnection in wiring NO harness between CNJS16 1) Disconnect (1) and CNJS7 (5) CNJS7 and CNJS16. 2) Max. 1R Defective L.H. steering

solenoid valve

Repair or replace wiring harness

Replace

;; contact or . . I Defective ..

1) Turn starting switch OFF. 2) Disconnect CNJSl6. 3) Max. 1Q

Repair or replace wiring harness

Controller

CNJS3

Steer ina solenoid

CNJS7

Steer ina solenoid cut relay

valve

TOW01049

20-562 0

Ki g

J-9

TROUBLESHOOTING

J-9

* * * *

FAILURE CODE [33] SHORT CIRCUIT IN STEERING L.H. STEERING SOLENOID Before carrying out troubleshooting, check that all the related connectors are properly inserted. Except when using the joystick steering lever, place it at the N position and turn the joystick steering selector switch ON. Always connect any disconnected connectors before going on to the next step. Turn the starting switch to the OFF position before disconnecting any connector, or before connecting the T-adapter (or socket).

Remedy

YES 2 ~ Is resistance between CNJS16 _ (male) 11) and CNJSl6 (male) 12) normal?

YES

between CNJSJ (6) and chassis

5 Ki

I) Disconnect CNJS16. 2) lo-30R

1) Disconnect CNJS3. 2) Min. 10R

3 YES Is resistance between CNJSB (female) (161and CNJS7 Ifemale) (31 normal? 1) Disconnect CNJS7 and CNJS16. 2) Max. 10

Defective controller

Replace

Disconnection in wiring harness between CNJS7 (3) and CNJSlG(1). or short circuit with ground

Repair or replace wiring harness

Short circuit in LH. steering solenoid

Replace

Short circuit in power Isource between CNJS3 (6)

and CNJS16 (2)

Repair or replace wiring harness

Controller 1

CNJS3

B Left

turn

CNJS7

Steer ine solenoid cut relay

’

Steer ina solenoid

valve

TOW01049

20-563 a

J-IO

TROUBLESHOOTING

J-IO FAILURE CODE [34] ABNORMALITY IN STEERING SOLENOID CUT RELAY SYSTEM * * Ir *

I Y (1 1

Defective controller

Replace

Defective contact or disconnection in wiring harness between CNJS7 (2) and chassis

Repair or replace wiring harness

Defective steering relay

Replace

i 3

between CNJSl (female) (7) and chassis normal? 1) Disconnect CNJSI. 2)50-1lOR

Remedy

Cause

YES 2 r _ NO

Is resistance between CNJSl (female)

(7) and

‘) DisconneCt

CNJS7. 2)Max.50-110Q

CNJS7 (female) (1) normal? 1) Disconnect CNJS7. 2) Max. IQ

Is resistance between CNJS7 (female) (11 and CNJS7 (female) (2) normal?

YES

SOL cut

Defective contact or disconnection in wiring harness between CNJSl (7) and CNJS7 (1)

Repair or replace wiring harness

Controller

CNJS3 L. H. S/T

solenoid

(+I

R. H. S/T

solenoid

(+I

cut

relay

Steer in9 solenoid

valve

S/T

solenoid

IS7

Steer in9 solenoid cut relay

TDW01050

20-564 0

J-l 1

TROUBLESHOOTING

J-l 1 FAILURE CODE 1361ABNORMALITY IN JOYSTICK STEERING NEUTRAL SIGNAL SYSTEM * Ir *

Cause

YES

1 Defective controller

YE: Is resistance between CNl (female) (12) and chassis normal?

YES

between CNJSZ [female) (15) and CNJS3 (female) (9) 1) Disconnect CNJS2 and CNJS3. 2) Min. 1MR

I) Disconnect CNJS2 and CNJSS. 2) Operate JST lever fully to leh or right. 3) Max. 1R

3 Is resistance between CNl . (female) (12) and N( 3 CNl (female) (13) normal?

YES

1) Disconnect CNl. 2) Operate JST lever fully to left or right. 3)Max. 1R

‘) Discon”ect CNl. 2) Max. ln

Defective contact or disconnection in wiring 4 YES harness between CNl (13) and CNJS2 (15). or short circuit with +24V

Defective contact or disconnection in wiring harness between CNl (12) and chassis, or short circuit with +24V

Repair or replace wiring harness

Defective JST lever neutral switch

Is resistance between CNl (male) 112)and CNl (male) 113) normal? 1) Disconnect CNl. 2) Min. 1MQ

Remedy

Defective JST lever neutral switch

Replace

Wiring harness between CNl (13) and CNJS2 (15) short circuiting with chassis ground

Repair or replace wiring harness

Controller

CNl

CiIJS3 @

GND

-3

CNJS2 J/T

steering

neutral

CN4

Neutral switch

detection

3 I

CND18

TDWOIOSI

20-565 0

J-12

TROUBLESHOOTING

J-12 FAILU RE CODE [371 ABNORMALITY LEVEF : POTENTIOMETER Ir * * *

IN JOYSTICK STEERING

Before carrying out troubleshooting, check that all the related connectors are properly inserted. Except when using the joystick steering lever, place it at the N position and turn the joystick steering selector switch ON. Always connect any disconnected connectors before going on to the next step. Connect the T-adapter and turn the starting switch ON.

Cause

YES

Ikfective

qeplace

controller

defective JST ,otentiometer, center point Jut of alignment

between CNJSZ (20) and CNJS? (9) normal?

Iefective contact or lisconnection in wiring larness between CNJSZ 10) and CNl (10). short :ircuit with +24V, short :ircuit with ground or jefective contact or jisconnection in wiring larness between CNJSZ (9) and CNl (11). or short :ircuit with +24V

1) 2.4 - 2.6V

Remedy

between CNJS2 (20) and CNJS2 (9) YES 3

1) Operate JST lever to left or right. (0.8 - 4.2V)

Does resistance

NC 1) Operate JST lever to left or right. (0 - 2k.Q)

defective JST lotentiometer

I NO

teplace, adjust :enter point Igain

tepair or eplace wiring larness

leplace

Controller CN3 Potentiometer

Potentiometer

GND

3 -3

20-566 0

TOW01052

J-13

TROUBLESHOOTING

J-13

* * * *

FAILURE CODE [381 ABNORMALITY HARNESS

IN MODEL SELECTION WIRING

Is voltage between CNJS2 (18) and chassis ween CNJSZ (18) and CNJS28 (female) (4) normal?

between CNJSZ (17) and chassis I) Max.

switch OFF. 2) Max. 10

1V 5 ween CNJSP (17) and CNJS28 (female) (3) normal?

between CNJSP (16) and chassis

YES

Defective controller

Replace

Disconnection in wiring harness between CNJS28 (1) and chassis, or short circuit with +24V ground

Repair or replace wiring harness

Disconnection in wiring harness between CNJS28 (4) and CNJS2 (18). or short I circuit with +24V ground

Repair or replace wiring harness

Disconnection in wiring harness between CNJS28 (1) and chassis, or short circuit with +24V ground

Repair or replace wiring harness

1) Turn starting switch OFF. 2) Max. 1R

2) Turn starting switch ON. 3) Max. 1V

Repair or replace wiring harness

IE between CNJSZ (16)and CNJS28

1) Turn starting switch OFF. 2) Max. 1R

Repair or replace wiring harness

Controller

CNJS3 @ I ,CNJSs

CNJS28

20-567

J-14

TROUBLESHOOTING

J-14 FAILURE CODE 1391 ABNORMALITY

* * * *

IN POWER SOURCE VOLTAGE

Before carrying out troubleshooting, check that all the related connectors are properly inserted. Except when using the joystick steering lever, place it at the N position and turn the joystick steering selector switch ON. Always connect any disconnected connectors before going on to the next step. Connect the T-adapter and turn the starting switch ON.

2 YES 1 Is voltage between CNJSJ (8) and chassis normal?

1) Turn starting switch OFF. 2) Max. 1 R

1) 20-30V

Is continuity between CNJS19 and CNJSB (8) normal?

YES

Is continuity between CNJSB (8) and CNJS3 (19) normal?

1) Turn starting switch OFF. 2) Disconnect CNJS19. 3) Max. 1 R

YES

Defective controller

Defective contact or disconnection in wiring harness between CNJS3 (8) and CNJS.3 (39)

Repair or replace wiring harness

Blown chassis spare power source fuse

Replace

Defective contact or disconnection in wiring harness between CNJSJ (8) and CNJS19

Repair or replace wiring

Controller

CNJS19

Spare power source

I OA. TDW01054

20-568 0

J-15

TROUBLESHOOTING

J-15 ABNORMALITY

* * * *

IN JOYSTICK STEERING ON-OFF SIGNAL SYSTEM

Before carrying out troubleshooting, check that all the related connectors are properly inserted. Except when using the joystick steering lever, place it at the N position and turn the joystick steering selector switch ON. Always connect any disconnected connectors before going on to the next step. Insert the T-adapter to CNJSP and turn the starting switch ON.

I YES 1 Is voltage between CNJSZ (14) and chassis normal? ~ 1) 20-30V

I 2

Is resistance bet_ ween CNJSZ (14) NO and CNl (female) (1) normal? 1) Turn starting switch OFF. 2) Disconnect CNl. 3) Max. 1R

YES

Cause

Remedy

Defective controller

Replace

Defective JST console limit ON-OFF switch

Repair or replace wiring harness

Defective contact of wiring harness between CNJSP (14) and CNl (female) (1). or defective JST ON-OFF switch

Replace switch

Joust ick ON-OFF switch

Al CNJS15-

Controller

CNJSliI

Spare Power source

I 10A

m(T)

CNJS2

CNl

CNl 1

Joust ick steer ine console I imit ON-OFF SW itch

3 -3

CN12

TDW01055

J-16

TROUBLESHOOTING

J-16 ABNORMALITY IN TRANSMISSION

* * * *

F SOLENOID SYSTEM

Cause

YES

Is resistance betwean CNJS4 hale) (5) and CNJSl2

YES lr

CNJS4 and CNJSlP.

1) Disconnect

CNJSIP. 2) 250 - 33OR

From joystick ON-OFF switch

Defective controller, or abnormality in JST FNR signal system (see Troubleshooting No. 5)

Replace

Defective contact or disconnection in wiring harness between CNJS4 (5) and CNJSlP (5)

Repair or replace wiring harness

Defective CNJS12 F output selector relay

Replace

steering

CNJS12 3 To GNDK To transmission< solenoid

Remedy

F selector

relay

3 3 3

Controller

F relay

To transmission

lever

CNJS4

F output reverse

relay

coil

I:jEi

CND8 TDW01056

20-570 a

TROUBLESHOOTING

J-17 ABNORMALITY

Ir * * *

J-17

IN TRANSMISSION

R SOLENOID

SYSTEM

Remedy

1 YES Is resistance

YES

, -

Is continuity between CNJS13 (male) (1) and CNJSl3 (male) 12) normal? 1) Disconnect CNJS13. 2) 250 - 33OQ

between CNJSB (male) (5) and CNJSl3 (male) (5) normal? 1) Disconnect CNJSB and CNJS13. 2) Max. 1R

From joystick ON-OFF switch

To transm solenoid

Defective controller, or abnormality in JST FNR signal system (see Troubleshooting No. 5)

Replace

Defective contact or disconnection in wiring harness between CNJS5 (5) and CNJSl3 (5)

Repair or replace wiring harness

Defective CNJSIB R output selector relay

Replace

steering

ission< Db

Controller To transmission CNJS5

lever

R output reverse

relay

WD7 TDW01057

20-571 a

TROUBLESHOOTING

J-18

J-18 ABNORMALITY

* *

IN TRANSMISSION

N SOLENOID

SYSTEM

* *

Remedy

Cause

Defective controller, or abnormality in JST FNR signal system (see Troubleshooting No. 5)

2 YES YES

Is continuity between CNJS14 (male) (1) and CNJS14 (male) (2) normal? 1) Disconnect CNJS14. 2) 250 - 33os2

Is resistance between CNJSG (male) (5) and CNJS14 (male) (5) normal? 1) Disconnect CNJSG and CNJS14. 2) Max. 10

’ Replace

~ NO

From

joystick

Defective contact or disconnection in wiring harness between CNJSG (5) and CNJS14 (5)

Repair or replace wiring harness

Defective CNJSl4 N output selector relay

Replace

steering

GND-=

bl-

To transmission< solenoid

Controller

iNJS3

transmission

lever

CNJSb

N output’ reverse

relay

TOW01056

20-572 0

TROUBLESHOOTING

J-19

* * * *

DISCONNECTION

J-19

IN JOYSTICK STEERING F SWITCH SYSTEM

YES 1 1

YES

CNJSL and CNJSI. F switch. 3) Max. 1R

between CNJSZ (female) (13) and

1) Disconnect CNJSZ and CNl. 2) Max. IQ

Defective controller

Replace

Disconnection in wiring harness between CNl 6) and chassis power source

Repair or replace wiring harness

Disconnection in wiring harness between CNJSP (13) and CNl (5)

Repair or replace wiring harness

Controller

Joust ick steering

lever

TDW01047

20-573 0

J-20

TROUBLESHOOTING

J-20 DISCONNECTION

IN JOYSTICK STEERING R SWITCH SYSTEM

* *

Before carrying out troubleshooting, check that all the related connectors are properly inserted. Except when using the joystick steering lever, place it at the N position and turn the joystick steering selector switch ON. * Always connect any disconnected connectors before going on to the next step. Sr Turn the starting switch to the OFF position before disconnecting any connector, or before connecting the T-adapter (or socket).

YES 1 Is resistance between CNJS2 (female1(12) and CNJSB (female) (8) Is resistance normal? p between CNJSS 1) Disconnect - (female) (12) and CNJSP and NO CNl (female) (4) CNJSJ. normal? 2) Press JST lever 1) Disconnect R switch. CNJSP and 3) Max. 1C CNl.

jYES

Defective controller

Replace

Disconnection in wiring harness between CNI (6) and chassis power source

Repair or replace wiring harness

Disconnection in wiring harness between CNJSZ (12) and CNl (4)

Repair or replace wiring harness

2) Max. IQ

Controller

IPower sou

Joust ick

TOW01047

20-574 a

TROUBLESHOOTING

J-21

J-21 DISCONNECTION IN JOYSTICK STEERING N SWITCH SYSTEM

* * * *

Cause

YES 1

Remedy

Defective controller

leplace

Disconnection in wiring harness between CNI (6) and chassis power source

iepair or eplace wiring larness

Disconnection in wiring harness between CNJSZ Ill) and CNl (3)

lepair or eplace wiring iarness

Is resistance

between CNJSZ (female) (1 I) and CNJSJ (female) (8) -

~OUll~l? 1) Disconnect CNJS2 and NO CNJSB. 2) Press JST lever N switch. 3) Max. 10

2 .~ YES

Is resistance

between CNJSZ (female) (11) and CNl (female) (3) IVJrlllal?

1) Disconnect CNJSZ and CNl. 2) Max. 1R

Controller

CilJS3 I I

lrLltl

CNJS2

Joust ick steering

lever

CNl 3 3 a 3 TDW01047

20-575 0

& ci 2

DISASSEMBLY

METHOD OF USING MANUAL .................. .30- 3 PRECAUTIONS WHEN CARRYING OUT OPERATION ................................... 30- 5 FUEL INJECTION PUMP FOR RIGHT BANK Removal and Installation ...................... 30- 8 FUEL INJECTION PUMP FOR LEFT BANK Removal and Installation ...................... 30- 9 ENGINE OIL COOLER Removal and Installation ..................... .30-10 WATER PUMP Removal and Installation .................... ..30-11 NOZZLE HOLDER Removal and Installation ..................... .30-12 CYLINDER HEAD Removal .................................................. 30-13 Installation .............................................. 30-I 5 RADIATOR Removal .................................................. 30-18 Installation .............................................. 30-21 ENGINE Removal .................................................. 30-24 Installation .............................................. 30-30 DAMPER Removal ................................................. .30-37 Installation ............................................. .30-40 Disassembly .......................................... .30-43 Assembly ............................................... .30-45 TORQUE CONVERTER, TRANSMISSION Removal .................................................. 30-49 Installation .............................................. 30-55 TORQUE CONVERTER Disassembly .......................................... .30-62 Assembly ............................................... .30-66 TORQUE CONVERTER VALVE Disassembly and Assembly.. ............... .30-71 PTO Disassembly .......................................... .30-72 Assembly ............................................... .30-74

AND ASSEMBLY

TRANSMISSION Disassembly ......................................... 30- 77 Assembly .............................................. 30- 92 TRANSFER Disassembly ........................................ .30-l 08 Assembly .............................................. 30-I 16 TRANSMISSION VALVE Disassembly and Assembly.. ............. .30-128 CENTER SUPPORT Removal ................................................ 30-132 Installation ........................................... .30-133 Disassembly ........................................ .30-l 35 Assembly .............................................. 30-137 DRIVE SHAFT Disassembly ........................................ .30-l 40 Assembly .............................................. 30-I 42 FRONT AXLE 30-I 44 Removal ................................................ Installation ............................................ 30-146 REAR AXLE Removal ................................................ 30-I 48 Installation ........................................... .30-154 DIFFERENTIAL Removal ................................................ 30-I 61 Installation ........................................... .30-163 Disassembly ........................................ .30-l 66 Assembly ............................................. .30-169 FINAL DRIVE Disassembly ........................................ .30-175 Assembly ............................................. .30-178 STEERING UNIT Removal ................................................ 30-181 Installation ........................................... .30-l 82 STEERING DEMAND VALVE Removal ................................................ 30-183 Installation ........................................... .30-185 DIVERTER VALVE Disassembly and Assembly.. ............. .30-187

30-l 0

BRAKE VALVE Disassembly ........................................ .30-189 Assembly ............................................. .30-191 BRAKE CHAMBER Disassembly ........................................ .30-l 93 Assembly .............................................. 30-196 SLACK ADJUSTER Disassembly ........................................ .30-l 99 Assembly .............................................. 30-200 BRAKE Removal ................................................ 30-201 Installation ........................................... .30-202 Disassembly ........................................ .30-203 Assembly .............................................. 30-205 SPRING CYLINDER Removal ................................................ 30-208 Installation ........................................... .30-209 Disassembly ........................................ .30-210 Assembly .............................................. 30-211 PARKING BRAKE CALIPER Removal ................................................ 30-212 Installation ............................................ 30-213 Disassembly ........................................ .30-214 Assembly .............................................. 30-215 PARKING BRAKE PAD Removal and Installation ................... -30-216 HYDRAULIC TANK AND FILTER CASE Removal ................................................ 30-217 Installation ............................................ 30-219

HYDRAULIC PUMP Removal ................................................ 30-221 Installation ............................................ 30-222 SWITCH PUMP Removal ............................................... .30-223 Installation ........................................... .30-224 PISTON PUMP Disassembly ........................................ .30-225 Assembly .............................................. 30-230 PPC VALVE Removal ............................................... .30-245 Installation ........................................... .30-247 Disassembly and Assembly.. ............. .30-248 MAIN CONTROL VALVE Removal ................................................ 30-249 Installation ............................................ 30-251 Disassembly ........................................ .30-254 Assembly ............................................. .30-256 HYDRAULIC CYLINDER Disassembly ........................................ .30-258 Assembly .............................................. 30-260 CENTER HINGE PIN Removal ............................................... .30-262 Installation ........................................... .30-270 WORK EQUIPMENT Removal ............................................... .30-279 Installation ........................................... .30-284 FUEL TANK Removal ............................................... .30-288 Installation ........................................... .30-290

;5 & g

DISASSEMBLY

AND ASSEMBLY

METHOD

OF USING MANUAL

When

removing

METHOD

or installing

OF USING

MANUAL

unit assemblies

(I) When removing

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

Precautions related to safety when carrying out A ................................................................. the operation OF 0

ASSEMBLY

. .. . . .. . . . . . Title of operation

xxxx (I) . . . . . . . . . . . . .. . . . . . . .. . .. . . . . . . . . . . . .. . . . . . . . * . . . . . . . . .. . . .. . . . . . . .. . . . .. . . . . . . . . .. . . . . . . . .. . . .. . . .. . . . .

n n A (2):

0 0 0 0 assembly

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

Step in operation Technique or important point to remember when removing XXXX (1). m Indicates that a technique is listed for use dxg installation

(3)

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

See Lubricant

and Coolant

Table

INSTALLATION OF 0 0 0 ASSEMBLY . . .. Title of operation l Carry out installation in the reverse order to removal. m ...................... .......................... Technique used during installation * .......... ............ ............ ............ .. Technique or important point to remember when installing an A (2). l Adding water, oil . . . . . . .. . . .. . . . . . . .. . . . .. . . . . Step in operation * . .. . .. . . . . . . . .. . . .. . . . . . . .. . .. .. . . . . . .. . . . .. . . . . Point to remember when adding water.or oil %8

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

Quantity

of filling

General precautions when carrying out installation or removal are given together as PRECAUTION WHEN CARRYING OUT these precautions when carrying out the operation.

Listing (I)

oil and water

(disassembly OPERATION,

or assembly) of units so be sure to follow

of special tools

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

30-3 0

DISASSEMBLY

4. Ir

METHOD OF USING MANUAL

AND ASSEMBLY

General tightening

torque table (when using torque wrench)

In the case of metric nuts and bolts for which there is no special instruction, given in the table below.

Thread

Width

diameter

tighten

to the torque

across flats 0

SAD00481

T SAD00482

6 8 IO 12 14

IO 13 17 19 22

13.2 2 1.4 31.4 + 2.9 65.7 + 6.8 112 + 9.8 177 f 19

kgm 1.35 -c 0.15 3.2 + 0.3 6.7 f 0.7 11.5 f 1.0 18.0 f 2.0

16 18 20 22 24

24 27 30 32 36

279 383 549 745 927

f 29 + 39 -c 58 +. 78 + 98

28.5 f 3 39 + 4 56 +. 6 76 + 8 94.5 f IO

27 30 33 36 39

41 46 50 55 60

1320 1720 2210 2750 3280

+. 140 + 190 f 240 -c 290 f 340

135 + 15 175 f 20 225 f 25 280 c 30 335 f 35 Seal surface

SAD00483

Table of tightening

In the case of flared nuts for which there is no special instruction, table below. Thread

6. +

torques for flared nuts

Width

diameter mm

across flats mm

14 18 22 24 30 33 36 42

19 24 27 32 36 41 46 55

Table of tightening

torques for split flange bolts

tighten to the torque given in the

Tightening

kgm

24.5 f 4.9 49 f 9.8 78.5 f 9.8 137.3 f 29.4 176.5 * 29.4 196.1 + 49 245.2 + 49 294.2 f 49

2.5 f 0.5 5&l 8&l 1423 18 2 3 20 + 5 25 2 5 30 f 5

In the case of split flange in the table below.

bolts for which there is no special instruction,

Thread

Width

diameter mm IO 12 16

across flats mm 14 17 22

torque

tighten

Tightening

to the torque

torque

kgm

65.7 2 6.8 112 + 9.8 279 f 29

6.7 + 0.7 11.5 +‘I 28.5 + 3

given

DISASSEMBLY

AND ASSEMBLY

PRECAUTIONS

WHEN CARRYING

WHEN

when

carrying

out removal

OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) general precautions given below when carrying out the operation.1 Precautions

CARRYING

of units, be sure to follow

the

work

If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering. When draining oil, prepare a container of adequate size to catch the oil. Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. Check the number and thickness of the shims, and keep in a safe place. When raising components, be sure to use lifting equipment of ample strength. When using forcing screws to remove any components, tighten the forcing screws alternately. Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. Precautions when handling piping during disassembling Fit the following blind plugs into the piping after disconnecting I) Hoses and tubes using sleeve nuts Plug (nut end)

07376-50210

07221-20210

(Nut),

07376-50315

07221-20315

(Nut),07222-00312 (I%_@

07376-50422

07221-20422 (Nut),07222-00414 (Plug)

07376-50522

07221-20522 (Nut),07222-00515 (plug)

07376-50628

07221-20628 (Nut),07222-00616 (plug)

07376-51034

07221-21034 (Nut),07222-01018 (plug)

07376-51234

07221-21234 (Nut),07222-01219 (plug)

Flange

operations.

(Plug)

,“,“,“’

07222-00210

Split flange

disassembly

Sleeve nut (elbow end) Use the two items below as a set

ttE:ef’

it during

type hoses and tubes (hose end)

Sleeve head (tube end)

Splitflange

07379-00400

07378-10400

07371-30400

07379-00500

07378-10500

07371-30500

If the part is not under hydraulic

pressure,

the following

corks can be used.

DEW00401

30-5 0

DISASSEMBLY

Precautions

PRECAUTIONS

AND ASSEMBLY

for installation

WHEN

CARRYING

OUT OPERATION

operations

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

when

completing

the operations

If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine to circulate the water through the system. Then check the water level again. If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been removed for repair, always bleed the air from the system after reassembling the parts. For details, see TESTING AND ADJUSTING, Bleeding air. * Add the specified amount of grease (molybdenum disulphide grease) to the work equipment related parts. Other

precautions

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

s k g

DISASSEMBLY

AND ASSEMBLY

PRECAUTIONS WHEN CARRYING OUT OPERATION

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. 1.

2. 3. 4.

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 until no more air comes out from the plugs. After completing bleeding the air, tighten the plugs. w Plug: 11.3 + 1.5 Nm (1.15 - 0.15 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. * After repair or long storage, follow the same procedure.

30-7 0

DISASSEMBLY

AND ASSEMBLY

FUEL INJECTION

PUMP

REMOVAL OF FUEL INJECTION PUMP ASSEMBLY FOR RIGHT BANK (WITHOUT GOVERNOR) a Close the oil filler valve of the fuel tank. 1.

Open left side cover.

Remove

Disconnect

injection

Disconnect

fuel hose (3).

Disconnect

fuel injection

Remove mounting bolts at injection to remove rack control rod (5).

Remove

Remove mounting bolts, then remove fuel injection pump assembly. + When removing the fuel injection pump assembly, be careful not to drop the key.

coupling

bottom

cover (I).

pump

lubrication

tube (2).

tube (4). pump

end

lock bolt (6).

DEW03901

INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY FOR RIGHT BANK (WITHOUT GOVERNOR) 1.

Fit key and install fuel injection

Tighten

coupling

Connect

rack control

rod (5).

Connect

fuel injection

tube (4).

Sleeve

pump’assembly.

lock bolt (6).

nut: 23.5 t 1.0 Nm 12.4 + 0.1 kgm}

Fit gasket and connect

fuel hose (3).

Fit gasket and connect injection pump lubrication tube (2). * Check the fuel injection timing. For details, see TESTING AND ADJUSTING, Testing and adjusting of fuel injection timing.

Install cover (1).

Close side cover.

I'- DEW03902

DISASSEMBLY

FUEL INJECTION

AND ASSEMBLY

PUMP

REMOVAL OF FUEL INJECTION PUMP ASSEMBLY FOR LEFT BANK (WITH GOVERNOR)

A Close the oil filler of the fuel tank. 1. Open left side cover. 2. Remove

cover (I).

3. Remove

control

rod (2).

4. Disconnect

injection

pump

5. Disconnect

fuel hose (4).

6. Disconnect

air tube (5).

7. Disconnect

fuel injection

lubrication

DEW03904

tube (6).

a. Remove mounting bolts at injection to remove rack control rod (7). 9. Remove

coupling

tube (3).

pump

end

lock bolt (9).

bolts, then remove fuel in10. Remove mounting jection pump assembly. * When removing the fuel injection pump assembly, be careful not to drop the key.

INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY FOR LEFT BANK (WITH GOVERNOR) 1. Fit key and install fuel injection 2. Tighten

coupling

lock bolt (9).

3. Connect

control

rod (7).

4. Connect w

fuel injection Sleeve

DEW03905

pump assembly.

tube (6).

nut: 23.5 t 1.0 Nm I2.4 + 0.1 kgm}

5. Fit gasket and connect

air tube (5).

6. Fit gasket and connect

fuel hose (4).

7. Fit gasket and connect tion tube (3).

injection

pump

lubrica-

8. Connect rack control rod (7). * Do not move adjust portion (8). * Check the fuel injection timing. For details, see TESTING AND ADJUSTING, Testing and adjusting of fuel injection timing. 9. Install cover (I). 10. Close side cover.

30-9 0

DISASSEMBLY

AND ASSEMBLY

ENGINE OIL COOLER

REMOVAL OF ENGINE OIL COOLER ASSEMBLY 1.

Open the left cover.

Loosen

DEW03907

OIL COOLER ASSEMBLY 1. Fit gasket

and install

rear oil cooler

assembly

and install front oil cooler

assembly

(3). 2.

Fit gasket (2).

Install fuel injection pump assembly for right bank (I). * For details, see INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY FOR RIGHT BANK (WITHOUT GOVERNOR).

Tighten radiator drain valve and add water to the specified level. * Run the engine to circulate the water through the system. Then check the water level again.

Close the left cover.

30610

DISASSEMBLY

AND ASSEMBLY

WATER

PUMP

REMOVAL OF WATER PUMP ASSEMBLY 1.

Open left cover.

Loosen drain valve and drain cooling water. * If the coolant contains antifreeze, dispose of it correctly.

Remove

cover (I).

Remove

corrosion

Disconnect

Remove

bypass pipe (4).

Remove

water

resistor (2).

pipe (3).

pump

(5).

INSTALLATION OF WATER PUMP ASSEMBLY

Install water

Install bypass pipe (4).

Connect

Install corrosion

Install cover (I).

Tighten drain valve and add water through water filler to the specified level. Ir Run the engine to circulate the water through the system. Then check the water level again.

Close left cover.

pump

(5).

pipe (3). resistor (2).

30-11 0

DISASSEMBLY

AND ASSEMBLY

NOZZLE HOLDER

REMOVAL OF NOZZLE HOLDER ASSEMBLY 1. Remove

side cover.

Remove head cover mounting move head cover.

Disconnect

Remove

fuel injection

bolt (I),

and re-

tube (3).

lock nut (4) and disconnect

connection

(5).

Disconnect

Screw in forcing bolt @ (Thread dia. 10 mm, Pitch = 1.5 mm) to nozzle holder and remove nozzle holder assembly (8). * When removing the nozzle holder, clean around the nozzle holder and prevent dust or dirt from entering. * Checking gasket on the tip of nozzle holder fitting.

bolt (6) and remove

nozzle holder.

INSTALLATION OF NOZZLE HOLDER ASSEMBLY *

Check that dirt and foreign sleeve of nozzle holder.

Check that there is a gasket on the tip of nozzle holder fitting.

Check that there is no damage

matter are not in the

to O-ring.

1. Fit O-ring and install nozzle holder assembly (81, and fit holder (71, then tighten bolt (6). m Bolt: 66.2 t 7.4 Nm 16.75 + 0.75 kgm1 2.

Insert connection (5) and tighten lock nut (4). w Connection: 37.3 t 2.9 Nm I3.8 f; 0.3 kgm1 m Lock nut: 39.2 + 4.9 Nm t4.0 f 0.5 kgm}

Connect fuel injection

Fit O-ring, (I). w

tube (3).

install head cover (2) and tighten

Bolt: 3.9 t 1.0 Nm IO.4 + 0.1 kgm1

Install side cover.

bolt

DISASSEMBLY

REMOVAL

CYLINDER HEAD

AND ASSEMBLY

OF CYLINDER HEAD ASSEMBLY

Special tool No.

Part No.

Part Name

790-471-1000

Lifting tool

Loosen radiator drain valve and drain cooling water. * If the coolant contains antifreeze, dispose of it correctly.

Remove hood (I). + When removing the right side No. 1, 2, 3, 4, 5, 6 cylinder head assembly. 1) Remove clamp (3) of Komaclone tubes (21, then disconnect. 2) Disconnect drain tube (71, then remove mounting band (5) and flange bolt (6) of muffler assembly (41, and remove muffler assembly.

DISASSEMBLY

AND ASSEMBLY

3. Remove

rocker arm housing

cover (8).

4. Remove,

rocker arm assembly

(9).

5. Remove

holder

6. Loosen

lock nut, then

CYLINDER

HEAD

(IO). remove

inlet connector

(II).

DEW03921

7. Using bolt @ (Dia. = 10 mm, Pitch = 1.5 mm), remove nozzle holder assembly (12). 8. Remove

push rod (13).

9. Remove

rocker housing

10. Remove

closshead

11. Remove

cylinder

12. Remove

gasket (17).

(14).

(15). head assembly

(16).

DEW03924

DISASSEMBLY

INSTALLATION Special

CYLINDER

AND ASSEMBLY

OF CYLINDER HEAD ASSEMBLY

tools

No.

Part No.

Part Name

-/A

790-471-1000

Lifting tool

795-125-1210

Feeler gauge

1 1

1. Set gasket (17) on cylinder head mounting surface, then install cylinder head assembly (16). * Remove all carbon and dirt from the contact surfaces of the cylinder head and cylinder. * Check that the grommets have not come out. * Fit the gasket with the TOP mark facing up. & Mounting bolt: Antifriction compound (LM-PI

Ir w

HEAD

DEW03924

First tighten the mounting bolts two or three revolutions by hand, then tighten the bolts as follows. Tighten the bolts in the order shown. Cylinder head mounting bolts:

Unit: Nm {kgm)

210.8 - 220.7 121.5- 22.51

I 6

Mark the bolts and the cylinder head with a felt-tip pen, and turn the bolts with following degrees.

DEW03925

Install crosshead (15). Ir Adjust crosshead (15) according to following steps: i) Loosen lock nut and tighten adjusting screw. ii) Hold upper face of crosshead lightly and screw in adjusting screw. iii) After adjusting screw comes into contact with valve stem, screw in an additional 20”. iv) Tighten lock nut at this position. m Lock nut: 58.8 f 5.9 Nm 16 f 0.6 kgml

30-l 5 0

DISASSEMBLY

AND ASSEMBLY

CYLINDER

HEAD

3. Fit gasket and install rocker arm housing (14), then tighten mounting bolts. m Mounting bolt: 98.1 f 4.9 Nm II0 f 0.5 kgm} 4. Install push rods (13). * Check that the push rod is properly the cam follower.

fitted in

DEW03927

DEW03928

5. Align mounting hole of nozzle holder connection and insert nozzle holder (12). * Check that there is no dirt or foreign matter inside nozzle holder sleeve. * Check that there is a gasket fitted to the tip of the nozzle holder. 6. Tighten connection (I I) then lock with lock nut. m Connection: 37.3 + 2.9 Nm 13.8 z 0.3 kgm1 w Lock nut: 39.2 = 4.9 Nm I4.0 + 0.5 kgm} 7. Install holder (IO). * Set one side of holder on head of mounting bolt of rocker arm housing and tighten. 8. Install rocker arm assembly (9). * Check that round part of the adjusting screw is completely inserted into the push rod socket. 9. Using tool A, adjust valve clearance. For details, see ADJUSTING VALVE ANCE.

CLEAR-

10. Fit O-ring and install head cover (8) then tighten with mounting bolts. w Mounting bolt: 3.9 = 1.0 Nm IO.4 + 0.1 kgm}

DEW03931

DISASSEMBLY

AND ASSEMBLY

When installing the right side No. 1, 2, 3, 4, 5, 6 cylinder head assembly. 1) Install flange bolt (6) and mounting band (5) of muffler assembly (4). After installing muffler assembly (41, connect drain tube (7). 2) Connect 2 Komaclone tubes (2) to muffler, and install clamp (3).

11. Install hood (I). 12. Tighten radiator drain valve and add water to the specified level. Ir Run the engine to circulate the water through the system. Then check the water level again.

CYLINDER

HEAD

DISASSEMBLY

REMOVAL a

OF RADIATOR

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. 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. Disconnect the cable from the negative (-1 terminal of the battery.

DEW03932

Draining water Loosen drain valve (I) and drain cooling water. * If the coolant contains antifreeze, dispose of it correctly. -

RADIATOR

AND ASSEMBLY

Cooling

water:

301 e

Cover Remove exhaust assembly, open side hood (2) and engine inspection cover (31, then remove engine hood (4). * Remove mounting bolts of bar (5). * Remove bracket of engine hood. kg IF?l

Exhaust

assembly:

fblkg

Engine

hood: 88 kg

Radiator guard 1) Remove radiator r+lkg 2)

22 kg (1 piece)

grille.

Grille: Approx.

30 kg

Disconnect electric wiring (7) and (8) from connector. * After disconnecting the radiator water level sensor wiring, move the connector towards the radiator. Ir Remove connector (9) from the clamp. * Remove backup buzzer (IO).

DEW03934

DISASSEMBLY

AND ASSEMBLY

Sling radiator guard (II), bolts, then lift off. &I kg

Radiator

RADIATOR

remove

guard: Approx.

mounting

225 kg

DEW03936

Radiator hoses 1) Disconnect cooling water drain hose from radiator. 2) Loosen clamp of lower hose (13). 3) Disconnect hose (14).

(12)

Loosen hose clamps of tubes (15) and (16). * Disconnect hose (17) from the radiator.

Cooler piping Disconnect hydraulic

cooler hoses (18) and (19).

DEW03939

30-19 0

DISASSEMBLY

RADIATOR

Fan guard, support 1) 2)

AND ASSEMBLY

Remove Remove

fan guard (20) from radiator. left and right radiator supports

(21).

Radiator Sling radiator (221, remove mounting bolts, then remove radiator. * Raise the radiator slightly and check that the lower and upper hoses have come out, then lift off the radiator. * Be careful not to let the fan hit the radiator core. I3 kg

Radiator:

710 kg

z & g

30&20

DISASSEMBLY

AND ASSEMBLY

INSTALLATION 1.

RADIATOR

OF RADIATOR

Radiator Raise radiator (22) and set in mounting position, then tighten mounting bolts. Check that the upper and lower hoses are set to the correct mounting positions. Tighten the mounting bolts partially, and tighten them fully after installing the support. Be careful not to let the fan hit the radiator core.

Fan guard, support 1) Install fan guard (20) to radiator. * Install so that the clearance from the fan is uniform all around the circumference. 2) Install left and right radiator supports (21). * Tighten the radiator mounting bolts fully. w Mounting bolt: 549 2 59 Nm I56 I 6.0 kgml (width across flats: 30 mm)

Cooler piping Install hydraulic

cooler

hoses (19) and (18).

Radiator hoses 1) Tighten hose clamps of tubes (15) and (16). * Connect hose (17) to radiator.

30-2 1 0

DISASSEMBLY

RADIATOR

AND ASSEMBLY

2) Connect hose (14). 3) Tighten clamp of lower hose (13). 4) Tighten clamp of cooling water drain hose (12).

Radiator guard 1)

Raise radiator guard (11) and set in mounting position, then tighten mounting bolts temporarily. Ir Tighten fully after installing the engine hood.

Connect electric wiring (71, (8) and connector. * Install backup buzzer (IO). Install radiator guard.

(9) to

DEW03934

DISASSEMBLY

AND ASSEMBLY

RADIATOR

Cover I) Install engine hood (4) and exhaust assembly, then close side hood (2) and engine inspection cover (3). * Tighten the mounting bolts of the side hood. 2) Install radiator tube bracket at the bottom of engine hood.

Refilling with water, oil 1) Tighten drain valve (I) and add cooling water through fied level. %8 2)

radiator

Cooling

water filler to the speci-

water:

301 J?

Tighten drain plug and add hydraulic oil through oil filler to the specified level. * Run the engine to circulate the water and the oil through the system. Then check the water and the oil levels again.

30-23 0

DISASSEMBLY

AND ASSEMBLY

REMOVAL a

ENGINE

OF ENGINE

Draining water Loosen drain valve (I) and drain cooling water. Ir If the coolant contains antifreeze, dispose of it correctly. -

Cooling

Oil drain valve Disconnect tank.

water: 301 e

engine

oil drain valve

(2) from fuel

Cover Remove left and right side panels (31, engine inspection cover (41, side hood (5), exhaust,assembly, and engine hood (6). t Remove bracket of the engine hood.

22 kg (1 piece)

kg rF?l

Exhaust

assembly:

&I kg

Engine

hood: 88 kg

f?lkg

Side hood: 35 kg

& kg

Engine

inspection

cover: 25 kg

Air cleaner, bulkhead

1) Disconnect * * * 2)

hoses (9) and (IO) of air conditioner. Loosen the air conditioner hose slightly to release the gas. Disconnect wiring (11) at the connector and remove the clamp. Remove the clamp of the air conditioner hose. Remove dashboard (12).

DISASSEMBLY

3) 4) 5)

AND ASSEMBLY

ENGINE

Loosen clamp of tube hose (13). Disconnect engine stop cable (14) and electric wiring connector (15). Disconnect engine fuel control cable (16) at servo cylinder end.

Loosen hose clamp between air cleaner and turbocharger, and remove left and right hoses (17). Sling air cleaner and bulkhead assembly (18A), then remove mounting bolts, and lower. kg rE?l *

Air cleaner,

Remove

bulkhead:

193 kg

bar (18B) first. DEW03947

DEW04665

Air piping Disconnect

air piping

(19) and (20).

Drive shaft Disconnect upper drive shaft (21). Drive shaft: 58.0 kg

DEW03946

DISASSEMBLY

AND ASSEMBLY

ENGINE

Bar 1)

Disconnect heater hose (23) from engine, remove clamp from bar (24), move hose towards front, then disconnect bar. Remove air conditioner hose (25) from compressor, and remove clamp from bars (24) and (26), remove hose, then disconnect bar. * Disconnect the both ends of fuel hoses (27) and (28).

DEW03953

Radiator guard 1)

Remove &I kg

radiator Radiator

grille. grille: 30 kg

Disconnect electric wiring (29), (30), and (31) from connector. + .After disconnecting the radiator water level sensor wiring, move the connector towards the radiator. Sling radiator guard (32), then remove mounting bolts, and lift off. C?Ikg

Radiator

guard: 225 kg

DEW03956

DISASSEMBLY

AND ASSEMBLY

ENGINE

9. Radiator hose 1) Remove tubes (33) and (341, and disconnect hose (35).

Disconnect tube (36) (between radiator and water pump), tube (37) (between water pump and torque converter cooler), and tube (38) (between torque converter and engine).

10. Air hose Disconnect hose (41) between air governor air compressor unloader valve. 11. Fuel hose Disconnect

and

fuel hose (40).

12. Blow-by hoses Disconnect left and right blow-by

hoses (39).

DEW03963

DISASSEMBLY

AND ASSEMBLY

13. Electric wiring I) Disconnect ground connection cable (43). 2) Disconnect cable (44) from starting motor.

3) 4) 5)

Disconnect engine wiring at connector (45). Disconnect alternator cable at connectors (46) and (47). Disconnect ground connection wiring (48).

14. Fan guard, fan

1) Remove fan guard (49). 2) Sling fan and remove mounting bolts, then secure fan to bar at top of radiator with wire. * Be careful not to damage the radiator core with the fan.

15. Engine 1) Sling engine, and remove left and right front

mounting bolts (50).

ENGINE

DISASSEMBLY

Remove

AND ASSEMBLY

ENGINE

left and right rear mounting

bolts

(51).

Lift off engine assembly (52). * Be careful not to hit any parts when lifting off. * Check that all hoses and wires are disconnected. r&lkg

Engine

assembly:

Approx. 3200 kg

Lift off fan (53) from radiator. * Be careful not to damage core with the fan. +I kg

the

DEW03969

radiator

Fan: 63 kg

30-29 0

DISASSEMBLY

INSTALLATION 1.

ENGINE

AND ASSEMBLY

OF ENGINE

Engine I) install mounting brackets (54) to left and right front side. * Install pin (55) securely. w Mounting bolt (56): 549 z 59 Nm I56 + 6.0 kgm} (width across flats: 30 mm)

Install mounting bracket (57) to rear. w Mounting bolt (58): 549 t. 59 Nm I56 + 6.0 kgm} (width across flats: 30 mm)

Install rubber (59) and plate (60) to each mount. * When installing the rubber, use water or coat with rubber grease. Do not use any coating agent which is not specified. & Mounting rubber: Water or rubber grease

Raise fan (53) and set inside radiator, then secure to top bar with wire. * Be careful not to damage the radiator core with the fan.

DEW0

-53

DFWO3970

DISASSEMBLY

AND ASSEMBLY

ENGINE

Raise engine (52) and set in mounting position. j, Be careful not to hit any parts when installing. * Set the torque converter cooler hose in the mounting position.

lEW03969

Tighten left and right mounting bolts (51) of rear bracket. w Mounting bolts: 927 + 103 Nm 194.5 + 10.5 kgm) (width across flats: 36 mm)

Tighten mounting bolts (50) of left and right front brackets. w Mounting bolts: 927 t 103 Nm 194.5 z 10.5 kgm} (width across flats: 36 mm)

Fan, fan guard 1)

Raise fan, and install to fan pulley. * Be careful not to damage the core with the fan. Install fan guard (49).

radiator

DISASSEMBLY

ENGINE

AND ASSEMBLY

Electric wiring 1) Connect ground connection wiring (48). 2) Connect engine wiring at connector (45). 3) Connect alternator cable at connectors (46) and (47).

4) 5)

Connect Connect

cable (44) to starting motor. ground connection cable (43).

Fuel hose Connect fuel hose (40).

Air hose Connect hose (41) between air governor compressor unloader valve.

and air

DEW03962

Blow-by Connect

hose left and right blowby

hoses (39).

DEW03963

DISASSEMBLY

ENGINE

AND ASSEMBLY

Radiator hose 1) Connect tube (37) (between water pump and torque converter cooler), tube (38) (between torque converter cooler and engine), and tube (36) (between radiator and water pump) with hoses.

install tubes (34) and (33), and connect

hose

(35).

Radiator guard 1) Raise radiator guard (32) and set in mounting position, then tighten mounting bolts. Tighten mounting bolts fully after install* ing each hood.

DEW03959

2) 3)

Connect electric wiring connector. Install radiator grille.

(29), (30) and (31) to

DISASSEMBLY

AND ASSEMBLY

ENGINE

Bar I) Install bar (26), then install air conditioner hose (25) to compressor, and secure hose to

bar with clamp. * Connect both ends of fuel hoses (27) and (28). Install bar (241, and connect heater hose (23) to engine, then secure hose to bar with clamp.

10. Drive shaft Raise upper drive shaft (21) and install. Ir Wipe the mating face of the coupling clean, and check that there is no dirt or dust caught in it. m Mounting bolt: 176.5 + 19.6 Nm I18 t 2 kgm1

11. Air piping Connect air piping (19) and (20). 12. Air cleaner, bulkhead 1) Raise air cleaner and bulkhead assembly (18A), and set in mounting position, then tighten mounting bolts.

DEW03953

DEW03950

30634

’

\’

' DEW03951

DISASSEMBLY

ENGINE

AND ASSEMBLY

2) Install left and right hoses (17) between cleaner clamp.

and turbocharger,

and tighten

Connect engine fuel control cable servo cylinder and engine bracket.

air with

(16) to

4) 5)

Connect engine stop cable (14) and electric wiring connector (15). Install tube hose (131, and tighten clamp.

I 6) 7)

DEW04685

DEW03947

DEW03948

Install dividing plate (12). Connect air conditioner hoses (9) and (IO). * After starting the engine, charge the gas. For details, see Shop Manual for Air conditioner. * Install the hose clamp. Connect wiring (11) with connector, and install clamp.

30-35 0

DISASSEMBLY

AND ASSEMBLY

13. Cover

Install engine hood (61, exhaust assembly, left and right side panels (3), engine inspection cover (4), and side hood (5). + Install bracket of engine hood.

14. Oil drain valve

Connect engine oil drain valve (2) to fuel tank. 15. Refilling

with

water

Tighten drain valve (I) and add water through radiator water filler to the specified level. Ir Run the engine to circulate the water through the system. Then check the water level again.

ENGINE

DISASSEMBLY

DAMPER

AND ASSEMBLY

REMOVAL

OF DAMPER

A 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.

Cover Remove left and right side panels (I) side hood (3) and exhaust assembly, gine hood (4). Engine

and (21, and en-

hood: 88 kg

Side hood: 35 kg Exhaust

assembly:

22 kg (I piece)

Air cleaner, bulkhead

1) Remove bar (5). Ir

Remove clamp of hose (6) for fuel control servo cylinder.

2) Disconnect

air conditioner hoses (7) and (8). Remove hose clamp, and move hose towards machine body. * Disconnect wiring (9) at connector and remove clamp. Remove dashboard (IO). *

4) 5)

Loosen clamp of tube hose (II). Disconnect engine fuel control cable (12) at servo cylinder.

DISASSEMBLY

DAMPER

AND ASSEMBLY

6) Disconnect tric wiring

engine stop cable (13) and elecconnector (14).

DEW03981

Loosen hose clamp between turbocharger, and remove hoses (15).

Sling air cleaner and bulkhead assembly remove mounting bolts, then lower. * Remove bar (17) first. kg

193 kg

Air cleaner,

bulkhead:

air piping

(18) and (19).

Air piping Disconnect

air cleaner and left and right

Drive shaft Disconnect l+l kg

upper drive shaft (20).

Drive shaft: 58.0 kg

(161,

DEW03982

DISASSEMBLY

DAMPER

AND ASSEMBLY

Damper 1)

Using eyebolts, sling cover assembly (23), then remove mounting bolts (22), and lift Off.

el kg

Cover assembly:

113 kg

After removing cover assembly, loosen 2 bolts at top of damper (241, sling with hanger, bolts (251, and lift then remove mounting Off.

Damper:

122 kg

30-39 0

DISASSEMBLY

INSTALLATION 1.

DAMPER

AND ASSEMBLY

OF DAMPER ASSEMBLY

Damper 1)

Raise damper (241, set to flywheel mount, then tighten mounting bolts (25). m Mounting bolt: 277.5 t 31.4 Nm (28.3 t 3.2 kgml

Using eyebolts, raise cover assembly (23), then set to mounting position, and tighten mounting bolts (22). m Mounting bolt: 110.8 + 11.8 Nm (II.3 t 1.2 kgm} Flywheel

* &

Before installing the cover assembly, with grease. Lip of oil seal (Portion a):

DEW04687

coat

ENS Grease &

Spline

of shaft (Portion b): Molybdenum disulphide dry lubricant (LM-PI (Leave for 2 - 3 minutes to dry naturally after coating, then install)

Remove all other grease completely before using ENS grease. Do not mix it with other grease. Use a different grease gun for ENS grease. ENS grease Part No.: 427-12-11871 (2 kg can)

DISASSEMBLY

AND ASSEMBLY

Drive shaft Install upper drive shaft (20). w Drive shaft: 176.5 = 19.6 Nm (18 + 2 kgm1

Air piping Install air piping

(18) and (19).

Air cleaner, bulkhead 1) Raise air cleaner and bulkhead assembly (161, set to mounting position, tighten mounting bolts, then install bar (17).

3) 4) 5)

DAMPER

I-J

IIll

Connect left and right hoses (15) between air cleaner and turbocharger, and tighten clamp. Connect engine stop cable (13) and electric wiring connector (14). Connect engine fuel control cable (12) at servo cylinder end. Connect tube hose (II), and tighten clamp.

DEW03981

1 I

DEW03982

DISASSEMBLY

AND ASSEMBLY

6) 7)

Install dividing plate (IO). Install air conditioner hoses (7) and (8). * Install the hose clamp. * Connect wiring (9) with the connector, and install the clamp.

Install bar (5). * Install the clamp of hose (6) for the fuel control servo cylinder.

DAMPER

Cover

Install engine hood (41, exhaust assembly, left and right side hoods (31, and side panels (1) and (2).

3976

DISASSEMBLY

DISASSEMBLY 1.

DAMPER

AND ASSEMBLY

OF DAMPER

Cover 1) Remove oil seal (2) from cover (I). 2) Remove stopper snap rings (4) and (5) of shaft (3). 3) Pull out shaft (3) from cover (1). Sr After pulling out shaft (31, remove oil seal (8).

Face cover (1) in the opposite direction, and remove bearing (6) and spacer (7). Ir Bearing (6) cannot be used again after it has been removed. Always replace it in the same way as oil seals (2) and (8).

r I

DEW03992

DEW03993

DISASSEMBLY

DAMPER

AND ASSEMBLY

Damper 1) Remove

mounting bolts (91, and using forcing screws, remove flange (IO). Ir Tighten the 3 forcing screws evenly.

Do not remove sary.

spacer (1 I) unless neces-

DEW03998

Remove

rubber

(12).

Remove inner body (14) and flange (15) from outer body (13). Ir Screw in the mounting bolts, tap with a hammer and remove.

DEW03997

DISASSEMBLY

ASSEMBLY 1.

DAMPER

AND ASSEMBLY

OF DAMPER

Damner 1) Install flange 115) under outer body (13), then install inner body (14). Align the bolt mounting holes of the bot* tom flange and outer body. Contact surface of flange and outer body: Gasket sealant (LG-4)

2) Assemble

rubber (12) between inner body (14) and outer body (13). & Whole surface of rubber: Grease (G2-LI) & Outside circumference of inner body: Grease (G2-LI) & Inside circumference of outer body: Grease (G2-LI) a Between inner body and rubber: Grease (G2-LI)

Fill clearance 70 cc grease.

“a” evenly

at 4 places with

Install flange (IO), and tighten mounting bolts (9). 6 Contact surface of flange and outer body: Gasket sealant ILG-4) m Mounting bolt: 277.5 f 31.4 Nm (28.3 2 3.2 kgm}

DISASSEMBLY

AND ASSEMBLY

Cover I) Using tools A and B, press fit bearing (6) and spacer (7) in cover (I). Ir When press fitting the bearing, check that the inside diameter of the spacer and the inside diameter of the bearing are aligned. & Outside circumference of bearing outer race: Coat with adhesive (LT-2) & Bearing: ENS grease Tool A; A: 0130, B: 32 Tool B; C: 0169, D: 095, E: 130, F: 150

Using tools B and C, press fit oil seal (8) in cover (I). * Press fit the oil seal so that the lip surface is on the bearing side. Tool C; G: 0145:::, H: 0114&, I: 18.0, J: 3.5::::, K: 15.0 Ir Fill clearance a between oil seal (8) and the bearing with grease. & Clearance a between oil seal and bearing: ENS grease Amount of grease: 80 g 6 Lip of oil seal: ENS grease

DAMPER

DEW0

DEW04002

DISASSEMBLY

3) 4)

DAMPER

AND ASSEMBLY

install stopper snap ring (5) of bearing (6) to cover (I ). Using tool D, press fit oil seal (2) in cover (I). * Press fit the oil seal so that the lip surface is on the bearing side. Tool D;L: 095, M: 0139-k , N: 0190, 0: 18, P:15, 0: 128, R: 143

DEW04003

Using tool D, press fit shaft (3) in cover (1). a Inside of inner race of bearing (6):

Adhesive (LT-21

DEW04004

Assemble

snap ring (4) to shaft (3).

30-47 0

DISASSEMBLY

* &

& 7)

DAMPER

Fill clearance b between oil seal (2) and the bearing with grease. Clearance b between oil seal and bearing: ENS grease Amount of grease: 160 g Lip of oil seal: ENS grease

Remove plug (161, then fill through plug hole. & Grease area d between

w 6

AND ASSEMBLY

with

grease

bearings: ENS grease Amount of grease: 700 t 30 g Plug: 7.4 t 2.5 Nm (0.75 2 0.25 kgml Shaft spline portion (portion e): Molybdenum disulphide dry lubricant (LM-P) (Leave to dry naturally for 2 - 3 minutes after coating, then install.)

Fill portion f with grease. & Portion f: ENS grease Amount of grease: 30 g Ir Always keep to the specified amount for grease in the grease areas (a, b, d, f). Ir Always remove all other grease completely before using ENS grease. Do not mix it with any other grease. Use a different grease gun for each type of grease. * ENS grease Part No.: 427-12-11871 (2 kg can)

DISASSEMBLY

REMOVAL

TORQUE

AND ASSEMBLY

OF TORQUE CONVERTER

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. Drain the oil from the hydraulic tank and transmission.

Hydraulic

CONVERTER

AND TRANSMISSION

tank: 550 JJ

Transmission:

140 f?

Cover

1) Remove

transmission inspection and cover (2) at rear of cab.

cover

(I)

DEW04007

2) Open air cleaner cover, and remove bars (3) *

and (4). Remove the clamps of hoses (5) and (6) for the fuel control servo cylinder.

Hydraulic hose Disconnect the following hydraulic hoses. . Hose (5) between torque converter charging pump and servo cylinder . Hose (6) between servo cylinder and transmission oil supply tube . Hose (7) between PPC pump and ES valve . Hoses (8) and (9) between hydraulic pump servo valve and ES valve

DISASSEMBLY

TORQUE CONVERTER AND TRANSMISSION

AND ASSEMBLY

Switch pump I)

Disconnect the following hydraulic piping from pump. Tube (IO) between hydraulic tank and switch pump . Hoses (11) and (12) between switch pump and manifold . Drain hose (13) between switch pump and hydraulic tank Sling switch pump (14), remove mounting bolts, then lift off. * Be careful not to damage the O-ring on the mounting surface when lifting off. l

A kg

Switch

pump:

145 kg

Torque converter charging and PPC pump

1) Disconnect

the following hydraulic piping from pump. Tubes’(15) and (16) between torque converter charging pump and torque converter filter Tube (17) between PPC pump and ES valve Tube (18) between transmission case and torque converter charging pump Tube (19) between hydraulic tank and PPC pump Loosen the clamp of the tube.

2) Sling pump

(201, remove mounting bolts, then lift off. + Be careful not to damage the O-ring on the mounting surface when lifting off.

&I kg

Torque converter pump: 41 kg

charging

and PPC

DISASSEMBLY

TORQUE CONVERTER AND TRANSMISSION

AND ASSEMBLY

Upper drive shaft Sling upper drive shaft (21), remove mounting bolts, then lift off. * Make match marks on the coupling before removing. * Push the coupling on the damper side into the damper, then disconnect the coupling. kg LE?l

Upper

drive shaft: 58 kg

DEW04014

Hydraulic pump 1) Disconnect the following hydraulic piping from pump. . Tube (22) between hydraulic tank and hydraulic pump . Hoses (23) and (24) between hydraulic pump and manifold l Tube (25) between hydraulic tank and servo pump . Drain hose (26) between hydraulic pump and hydraulic tank 2) Sling hydraulic pump (271, remove mounting bolts, then lift off. * Be careful not to damage the O-ring on the mounting surface when lifting off.

G Ki d

+I kg

Hydraulic

pump:

150 kg

Steering pump 1)

Disconnect the following hydraulic piping from pump. l Tubes (28) and (29) between steering pump and steering valve . Drain hose (30) between steering pump and hydraulic tank * Remove the clamps of the tubes.

DEW04016

DISASSEMBLY

AND ASSEMBLY

TORQUE

CONVERTER

AND TRANSMISSION

Hose (31) between hydraulic tank and steering pump Sling steering pump, remove mounting bolts, then lift off. Ir Be careful not to damage the O-ring on the mounting surface when lifting off. kg r5?l

pump:

145 kg

Emergency steering pump (If equipped) I) Remove hydraulic hoses (321, (33) and (34). 2) Sling pump (351, remove mounting bolts, then lift off. * Be careful not to damage the O-ring on the mounting surface when lifting off. &l kg

Steering

Emergency

steering

pump: 50 kg

Hydraulic hoses Remove hoses (36) and (37) leading to sight gauge. * Remove the drain hose from the engine control servo cylinder from the oil supply tube.

10. Torque converter piping 1)

Remove hose (38) from torque converter cooler. * Disconnect wiring (39) for the speedometer sensor from the connector.

’

\‘

DEW04021

DISASSEMBLY

AND ASSEMBLY

TORQUE CONVERTER AND TRANSMISSION

2) Remove transmission lubrication tube (40). 3)

Remove hose (41) between torque converter filter and transmission.

Remove tube (42) between torque converter and torque converter cooler. Ir Disconnect wiring (43) for the torque converter oil temperature sensor from the connector.

11. Electric wiring Remove wiring (44) for transmission solenoid valve from connector. * When removing the connector, be careful not to deform the thread case.

12. Drive shaft 1) Sling rear drive shaft (45), remove mounting bolts, then lift off. * When raising the drive shaft, use a lifting tool of ample length and raise from both ends of the transmission. & kg

Rear drive shaft: 186 kg

DEW04022

DISASSEMBLY

TORQUE

AND ASSEMBLY

CONVERTER

AND TRANSMISSION

2) Sling center drive shaft (461, remove mounting bolts, then lift off. r+ kg

Center drive shaft: 186 kg

'@?---.

DEW04026

13. Transmission, torque converter assembly and torque converter asI) Sling transmission sembly (47). * Make the lifting tool as short as possible.

DEW04027

2) Remove mounting

bolts of trunnion (48). Secure the trunnion to the torque converter with wire. If there are shims between the frame and trunnion, check the number and thickness of the shims, and keep in a safe place. Disconnect trunnion grease hose (49) from the trunnion. Remove mounting bolts (51) of front mounting bracket (50). * Remove front mounting bracket (50). * Be careful not to lose pin between the transmission and bracket. Move transmission and torque converter assembly (47) towards engine, and lift off carefully. Ir The assembly passes near to the glass of the cab windows, so be careful not to break it.

el kg

Transmission, torque sembly: 2880 kg

converter

DEW04028

as-

DEW04025

DISASSEMBLY

INSTALLATION TRANSMISSION Special No.

TORQUE

AND ASSEMBLY

OF TORQUE CONVERTER

CONVERTER

AND TRANSMISSION

AND

tools Part No.

Transmission,

Part Name

torque

converter

assemblv

1) Raise transmission and torque converter as-

sembly (471, move carefully from engine end and set about 200 mm from mounting position. Ir Be careful not to break the glass of the cab windows. 2) Set mounting bracket (50) in mounting position, and tighten mounting bolts. * Check that the pin is inserted securely between the transmission and bracket. w Mounting bolt: 927 t 103 Nm I94.5 + 10.5 kgm} (width across flats: 36 mm) 3) Lower transmission and torque converter assembly carefully and set in mounting position. 4) Partially tighten mounting bolts (51) of front mount bracket and mounting bolts of trunnion (48). * After tightening the mounting bolts of the trunnion and front bracket, connect grease hose (49). 5) Install tools Al and AZ to the top and bottom center hinge pins with tool A3, put dial gauge @ in contact with coupling at transmission end, then measure parallelism of coupling and shaft AI.

Transmission

Shim DEW04669

DEW04690

DEW04666

DISASSEMBLY

AND ASSEMBLY

TORQUE CONVERTER AND TRANSMISSION

Insert shims between the trunnion and frame, and adjust. After adjusting with shims, tighten the mounting bolts fully. Parallelism: Within 0.1 mm After positioning, remove the lifting tool. Trunnion mounting bolt: 549 I 59 Nm I56 + 6 kgm} (width across flats: 30 mm) Front bracket mounting bolt: 927 + 103 Nm I94.5 = 10.5 kgm} (width across flats: 36 mm)

r DEW04034

Drive shaft I) Raise center

drive shaft (46) and set in mounting position, then tighten mounting bolts. w Mounting bolt: 385.4 + 41.2 Nm 139.3 f 4.2 kgm1

'@?---I

Raise rear drive shaft (45) and set in mounting position, then tighten mounting bolts. * Tighten from the rear differential end. w Mounting bolt: 385.4 + 41.2 Nm (39.3 + 4.2 kgm}

Electric wiring Connect wiring (44) for transmission solenoid valve to connector. + When installing the connector, be careful not to deform the thread case.

DEW04024

DEW04026

DISASSEMBLY

AND ASSEMBLY

TORQUE CONVERTER AND TRANSMISSION

Torque converter piping

1) install tube (4i)- between

torque converter and torque converter cooler. * Connect wiring (43) for the torque converter oil temperature sensor to the connector.

2) Install hose (41) between 3)

torque converter filter and transmission. Install transmission lubrication tube (40) to transmission.

DEW04022

Install hose (38) from torque converter cooler. * Connect wiring (39) for the speedometer sensor to the connector.

Hydraulic hose Install hoses (36) and (37) between sight gauge and oil supply tube. Ir Install the drain hose from the engine control servo cylinder to the oil supply tube.

30-57 0

DISASSEMBLY

AND ASSEMBLY

TORQUE

Emergency steering pump (if equipped) I) Raise pump (35) and set in mounting position, then tighten mounting bolts. * Fit the O-ring on the mounting surface securely in the groove. 2) Install hydraulic hoses (321, (33) and (34).

Steering pump I) Raise steering pump and set in mounting position, then tighten mounting bolts. * Fit the O-ring on the mounting surface securely in the groove. 2) Install the following hydraulic piping to pump. . Hose (31) between steering pump

. .

hydraulic

tank

CONVERTER

AND TRANSMISSION

and

Tubes (28) and (29) between steering pump and steering valve Drain hose (30) between steering pump and hydraulic tank * Install the clamps of the tubes.

Hydraulic pump I) Raise hydraulic pump (27) and set in mounting position, then tighten mounting bolts. * Fit the O-ring on the mounting surface securely in the groove.

DEW04016

DISASSEMBLY

Connect

TORQUE CONVERTER AND TRANSMISSION

AND ASSEMBLY

the following

hydraulic

piping

pump. . Tube (22) between hydraulic tank and hydraulic pump . Hoses (23) and (24) between hydraulic pump and manifold Tube (25) between hydraulic tank and servo pump . Drain hose (26) between hydraulic pump and hydraulic tank l

Upper drive shaft Raise upper drive shaft (21) and set in mounting position, then tighten mounting bolts. * Align the match marks of the coupling. m Mounting bolt: 385.4 t 41.2 Nm I39.3 + 4.2 kgm}

DEW04014

10. Torque converter charging and PPC pump

1) Raise torque

converter charging and PPC pump (20) and set in mounting position, then tighten mounting bolts. * Fit the O-ring on the mounting surface securely in the groove.

Install

the

following

hydraulic

piping

pump. . Tubes (15) and (16) between torque converter charging pump and torque converter filter . Tube (17) between PPC pump and ES valve . Tube (18) between transmission case and torque converter charging pump Tube (19) between hydraulic tank and PPC pump * Install the clamp of the tubes. l

DEW040

DISASSEMBLY

AND ASSEMBLY

TORQUE CONVERTER AND TRANSMISSION

11. Switch pump I) Raise switch pump (14) and set in mounting position, then tighten mounting bolts. * Fit the O-ring on the mounting surface securely in the groove.

Connect

the following

hydraulic

piping

pump. hydraulic tank and Tube (IO) between switch pump . Hoses (11) and (12) between switch pump and manifold . Drain hose (13) between switch pump and hydraulic tank l

12. Hydraulic hoses Install the following hydraulic hoses . Hose (5) between torque converter charging pump and servo cylinder . Hose (6) between servo cylinder and transmission oil supply tube . Hose (7) between PPC pump and ES valve . Hoses (8) and (9) between hydraulic pump servo valve and ES valve

13. Cover I) Install bars (3) and (4). +

Install the clamps of hoses (5) and (6) for the fuel control servo cylinder.

DISASSEMBLY

TORQUE CONVERTER AND TRANSMISSION

AND ASSEMBLY

Install transmission inspection cover (2) at rear of cab.

cover (I) and

14. Refilling with oil 1) Add hydraulic oil through hydraulic filler to the specified level. 98

Hydraulic

oil through oil filler to the specified level.

I&)

& z!

tank oil

tank: Approx. 550 e

2) Add transmission

DEW04007

Transmission:

transmission

Approx. 140 J?

Bleed air from steering pump, switch pump, and hydraulic pump before starting engine. Jr For details, see TESTING AND ADJUSTING. * Run the engine to circulate the oil through the system. Then check the oil levels again.

30-61 0

DISASSEMBLY

AND ASSEMBLY

DISASSEMBLY Special

TORQUE

OF TORQUE CONVERTER

CONVERTER

ASSEMBLY

tools Part Name

No.

Part No.

Q’ty

790-501-5000

Unit repair

790-901-5110

Bracket

790-901-5120

Plate

792-535-2610

Wrench

stand

Preparatory work . Remove torque converter and PTO assembly. For details, see DISASSEMBLY OF TRANSMISSION ASSEMBLY. Set torque converter and PTO assembly (1) on tool A.

f?l kg

Torque

converter,

PTO assembly: 610 kg

Valve assembly 1) Remove tubes (2) and (31, and block 2) Remove valve assembly (5). 3) Remove tube (6) and block (7).

(4).

I 52.

PTO assembly I) Remove holder

(8) and coupling

DEW04035

DEW04036

7’

DEW04037

(9).

,..

DEW04038

DISASSEMBLY

AND ASSEMBLY

TORQUE

CONVERTER

2) Using eyebolts @ (Dia. = 16 mm, Pitch = 2.0 3)

mm), sling PTO assembly. Screw in forcing screws 0, assembly (IO).

and lift off PTO

Turbine - case assembly 1) Remove plug (II), and drain oil inside turbine case. 2) Leave 2 bolts on opposite sides, and remove all remaining pump mounting bolts (12). 3) Set case side at top, and remove 2 remaining mounting bolts. 4) Using eyebolts @ (Dia = 16 mm, Pitch = 2.0 mm), lift off turbine . case assembly (13).

DEW04041

Disassemble turbine . case assembly as follows. i) Remove mounting bolts, then remove pilot (14) and gear (15). ii) Remove snap ring (16) and plate (17).

DEW04042

DEW04043

iii) Using 2 forcing screws @ (Dia. = IO mm, Pitch = 1.25 mm) remove turbine (18). Ir Use the forcing screws to push the inner race of the bearing.

DEW04044

DISASSEMBLY

AND ASSEMBLY

iv) Remove v) Remove

bearing bearing

TORQUE CONVERTER

(20) from case (19). (21) from pilot.

2i 20

DEW04045

DEW04046

Stator 1) 2)

Remove Remove

snap ring (22). stator (23).

DEW04048

Pump assembly I) Using tool B, loosen nut (24). Ir

Leave the nut in position to prevent bearing and pump from flying off.

the

2) Remove 2 plugs (25) at stator shaft end. 3)

Remove inner race of bearing from hole where plug was removed, then remove pump assembly (26).

DEW04050

DEW04051

DISASSEMBLY

4) 5)

TORQUE CONVERTER

AND ASSEMBLY

Remove bolts, then remove collar (271, pump (28) and cage. Remove bearing (29) from cage (30).

DEW04052

DEW04053

DEW04056

DEW04057

Stator shaft 1)

Remove

8 mounting

bolts (31).

Remove

stator shaft (32) from case (33).

3) 4)

Remove Remove

seal ring (34). sleeve (35).

30-65 0

DISASSEMBLY

AND ASSEMBLY

ASSEMBLY Special

TORQUE

OF TORQUE CONVERTER

CONVERTER

ASSEMBLY

tools

No.

Part No.

Part Name

790-501-5000

Unit repair stand

790-901-5110

Bracket

790-901-5120

Plate

792-535-2610

Wrench

Preparatory work Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. Set torque converter case (33) on tool A.

Stator shaft 1) Expand fit sleeve (35) to stator shaft. 2) Install seal ring (34) to stator shaft. + Make the protrusion of the seal ring from the shaft uniform.

DEW04057

DEW04056

DEW04059

DEW04060

Operate repair stand, rotate torque converter case 90”, install stator shaft (321, then tighten 8 mounting bolts (31) from opposite side. & Mounting bolt: Adhesive (LT-2) @EI Mounting bolt: 274.6 + 29.4 Nm {28 = 3.0 kgm1

30&66

DISASSEMBLY

AND ASSEMBLY

TORQUE CONVERTER

Pump assembly 1)

Using push tool @ (outside diameter: mm), press fit bearing (29) in cage.

195

DEW04061

DEW04062

DEW04063

DEW04052

Install cage (30) and collar (27) to pump (28). & Mounting bolt: Adhesive (LT-2) w Mounting bolt: 68.6 z 4.9 Nm I7 = 0.5 kgml

Using push tool @ (inside diameter: 115 mm), press fit inner race (36) to stator shaft. * Be careful to install the inner race facing in the correct direction. Set pump assembly (26) in position. j, Be careful not to damage the seal ring. * Coat the seal ring with grease (G2-LI), make the amount of protrusion from the shaft uniform, and fix in position. Using push tool @ (inside diameter: 115 mm), press fit inner race (36) to stator shaft. * Be careful to install the inner race facing in the correct direction.

Stator shaft

DEW04064

Adjustment marks

30-67 0

DISASSEMBLY

AND ASSEMBLY

TORQUE CONVERTER

Using tool B, install nut (24) to stator shaft & Nut: Adhesive (LT-2)

Nut: 613 + 25 Nm 162.5 2 2.5 kgm}

DEW04069

Stator 2)

Align spline, install stator Install ring (22).

DEW04048

Turbine case

1) Using push tool @ (outside mm), press fit bearing

diameter: 155 (20) in case (19).

DEW04070

DEW04071

2) Set turbine (18) in push tool @ (outside di3)

ameter: 105 mm, height: 165 mm). Using push tool @I (inside diameter: mm), press fit case (19) to turbine (18).

110

DEW04073

DISASSEMBLY

4) 5)

AND ASSEMBLY

TORQUE CONVERTER

Fit plate (17) and install snap ring (16). Using push tool 0 (inside diameter: 90 mm), press fit bearing (21) in pilot.

6) 7)

DEW04043

DEW04074

DEW04075

DEW04076

Install gear (15). Install pilot (14). & Mounting bolt: Adhesive (LT-2) w Mounting bolt: 274.6 f 29.4 Nm I28 f 3.0 kgm}

Using eyebolts @ (Dia. = 16 mm, Pitch = 2.0 mm), raise turbine case assembly (131, align oil groove of case with drain hole of pump, then install. Tighten pump mounting bolts temporarily. 6 Mounting bolt: Adhesive (LT-2)

EW04077

IO) Rotate repair stand 90” and tighten mounting bolts (12). w Mounting bolt: 53.9 2 4.9 Nm 15.5 z 0.5 kgm} 11) Tighten drain plug (I I). 12) Tighten 2 plugs (25). m Plug: 7.4 + 2.5 Nm (0.75 2 0.25 kgm}

30-69 0

DISASSEMBLY

TORQUE CONVERTER

AND ASSEMBLY

PTO assemblv

1) Fit O-ring; then using eyebolts @ (Dia. = 16 mm, Pitch = 2.0 mm),

install PTO assembly

(IO). + Be careful not to damage when installing.

2) 3)

the

oil seal

Install coupling (9). Fit O-ring and install holder (8). w Mounting bolt: 274.6 +. 29.4 Nm {28 + 3.0 kgml

Valve assembly 1) 2) 3) m

Fit O-ring and install block (7) and tube (6). Fit O-ring and install valve assembly (5). Fit block (4) and install tubes (3) and (2). Valve assembly mounting bolt: 49.0 + 4.9 Nm I5 + 0.5 kgml Tube mounting bolt: 24.5 2 4.9 Nm 12.5 2 0.5 kgml

DEW04037

DEW04036

DISASSEMBLY

AND ASSEMBLY

DISASSEMBLY,

TORQUE CONVERTER VALVE

ASSEMBLY

OF TORQUE CONVERTER

VALVE

DEW04080

DISASSEMBLY OF VALVE ASSEMBLY 1. 2.

TORQUE

CONVERTER

Remove cover (I), then remove valve (21, spring (3) and valve (4). Remove cover (51, then remove spring (6) and valve (7).

DEW04081

ASSEMBLY ASSEMBLY

OF TORQUE

CONVERTER

VALVE

Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.

Assemble valve (7) and spring (61, then fit Oring and install cover (5). Assemble valve (41, spring (31, and valve (2), then install cover (1).

30-71 0

DISASSEMBLY

AND ASSEMBLY

DISASSEMBLY

PTO

OF PTO ASSEMBLY

Preparatory work .Remove PTO assembly. For details, see DISASSEMBLY OF TORQUE CONVERTER ASSEMBLY.

The procedure for disassembly and assembly of the gear and shaft assemblies is the same, but for gear and shaft assemblies I, II, III and IV, the shaft and bearing are different.

DEW04082

Retainer 1) Using forcing screws @ (Dia. = 10 mm, Pitch = 1.25 mm), remove retainer (I). 2) Remove oil seal (2).

I I

DEW04084

I I

Snap ring Remove snap ring (3).

I 3.

DEW04083 1 1

Bearing 1) Turn over PTO case assembly 2) Remove bearing (5).

DEW04085

(4).

DEW04086

DISASSEMBLY

AND ASSEMBLY

PTO

Shaft assembly

1) Remove snap ring (6). 2)

Using push tool @ (outside diameter: mm), tap shaft assembly and remove.

DEW04087

DEW04088

Remove snap ring (7). Set shaft assembly in position, then using push tool 0, pull out bearing (8) from shaft (9). * Push tool @ Unit: mm

Gear, shaft assembly No.

Push tool outside diameter

inner race (IO).

Spacer, gear I) 2)

Lift up gear (I I) and remove. Remove spacer (12). * Gear (I I) must be installed facing in the correct direction, so remember the direction.

-e

---Q&y DEW04091

DEW04090

Inner race Remove

Snap ring, bearing 1) 2) 3)

Turn over case. Remove snap ring (13). Turn over case again, and remove (14).

bearing

DEW04092

DISASSEMBLY

AND ASSEMBLY

ASSEMBLY

PTO

OF PTO ASSEMBLY

Preparatory work Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.

The procedure for disassembly and assembly of the gear and shaft assemblies is the same, but for gear and shaft assemblies I, II, III and IV, the shaft and bearing are different.

DEW04082

Bearing, snap ring I) Using push tool @ (outside diameter = 115 mm), press fit bearing (14).

DEW04096

2). Install snap ring (13). 2.

Spacer, gear I) Install spacer (12). 2) Set gear (I I) in position. * Be careful to install gear (11) facing in the correct direction.

\,-,

Install with this surface facine UP

DEW04692

A- -

DEW04097

DISASSEMBLY

AND

ASSEMBLY

Shaft assembly 1) Using push tool 0, shaft. Ir Push tool @

PTO

press fit bearing

(8) in

Unit: mm Gear, shaft assembly No. I, II, III

Push tool inside diameter

75 DEW04100

2) 3)

Install snap ring (7) Using push tool 0, press fit shaft assembly (9). * Push tool @ Unit: mm Gear, shaft assembly No. I, II, III

Push tool outside diameter

155 120

k ;5

DEW04101

Snap ring Install snap ring (3).

Bearing Using push tool @ (outside diameter: press fit bearing (5) in case.

145 mm),

DEW04103

DEW04104

Retainer 1) Press fit oil seal (2) to retainer. & Oil seal press-fitting surface: Gasket sealant (LG-4) 2) Fit O-ring, then using guide bolts 0 (Dia. = 10 mm, Pitch = 1.25 mm), install retainer (1). 6 Lip of oil seal: Grease (G2-LI)

DEW04105

DEW04106

30-75 0

DISASSEMBLY

AND ASSEMBLY

PTO

Inner race 1) Turn over PTO case assembly (4). 2) Set bottom of shaft on stand 8. + Set the PTO case assembly so that there is no play.

DEW04107

Using push tool @ (inside diameter: 70 mm), press fit inner race (15).

DEW04108

DEW04109

Install snap ring (6). Ir Check that the gear rotates smoothly.

I’

30&76

DEW04110

DISASSEMBLY

AND ASSEMBLY

DISASSEMBLY Special

Part No.

799-301-I

ASSEMBLY

600

Part Name

QYy

Oil leak tester

Torque converter assembly Using eyebolts, remove torque converter assembly (I) from transmission assembly (2). &I kg

OF TRANSMISSION

tools

No.

TRANSMISSION

Torque

converter

assembly:

650 kg

DEW04111

Control valve assembly I) Remove 11 mounting bolts. + The length of the bolts is different, so check before removing. * Remove only the bolts marked @ in the diagram.

Mountina - Mountina

bolts position

Iiftino

bolts

DEW04693

Using eyebolts @ (Dia. = 10 mm, Pitch = 1.5 mm), lift off control valve assembly (3). IL”Ikg

Control

valve assembly:

110 kg

4 DEW04113

Sleeve Remove

sleeve (4).

DISASSEMBLY

Transmission case 1) Raise transfer and transmission and put transfer (14) at bottom. kg CF?l

Transfer,

transmission

assembly: 2200 kg

Transmission

case: 180 kg

Tie bolts I) Using tool A, check the operation ton before disassembling.

R assembly,

Using eyebolts @ (Dia. = 12 mm, Pitch = 1.75 mm), lift off transmission case (15). kg IE?l

TRANSMISSION

AND ASSEMBLY

Remove

tie bolts (16).

of the pis-

DISASSEMBLY

AND ASSEMBLY

TRANSMISSION

Plate Using eyebolts @ (Dia. = 10 mm, Pitch = 1.5 mm), lift off plate (17). Plate: 30 kg

DEW04119

Spring Remove spring (18). Jr This spring is different from the other springs, so keep it separately in a safe place.

Spring, disc, plate Remove spring (191, disc (2OL and plate (21). * There are springs between each plate.

No. 1 ring gear Remove ring gear (22).

DEW04122

DISASSEMBLY

TRANSMISSION

AND ASSEMBLY

10. Shaft, No. 1 carrier assemblv I) Using eyebolts @ (Dia. -= 12 mm, Pitch = 1.75 mm), lift off shaft and No. 1 carrier assembly (23)

Disassemble shaft and No. 1 carrier as follows. bly Remove snap ring (24). i) ii) Remove gear (25).

assem-

L 23

DEW04123

24 DEW04124

iii) Remove collar (27) from rier assembly (26).

shaft and car-

DEW04126

I snap iv) Remove shaft assembly bly (30).

DEW04125

ring (281, then remove (29) from carrier assem-

29 DEW04127

DEW04128

DISASSEMBLY

AND ASSEMBLY

Remove

bearing

TRANSMISSION

(31).

DEW04129

vi) Remove vii) Remove

sun gear (32). bearing (33).

I viii)Remove ix) Remove

DEW04130

DEW04131

DEW04132

DEW04133

bearing (34). snap ring (35).

Remove pin, then remove thrust washer (361, planetary gear (37), needle bearing (381, and spacer (39). * When removing the pin, be careful not to lose the ball.

38 DEW04134

i7 DEW04135

30-81 0

DISASSEMBLY

AND ASSEMBLY

TRANSMISSION

11. No. 2 ring gear I) Remove mounting bolts (401, then remove plate (41). 2) Remove ring gear (42).

12. No. 1 piston, housing 1) Using eyebolts 0 (Dia. = 10 mm, Pitch = 1.5 mm), lift off piston and housing (43). l&lkg 2)

Piston, housing: 65 kg

Remove piston (45) from housing (44).

DEW04137

DEW04138

13. Spring Remove spring (46). * This spring is different from the other springs, so keep it separately in a safe place.

DEW04139

14. Spring, disc, plate Remove spring (471, disc (481, and plate (49). * There are springs between each plate.

DISASSEMBLY

TRANSMISSION

AND ASSEMBLY

15. Guide Pin Remove

guide

pin (50).

16. Ring gear Remove

ring gear (51).

DEW04141

DEW04142

17. No.2 piston, housing 1)

Using eyebolts @ (Dia. = 10 mm, Pitch = 1.5 mm), lift off piston and housing (52). kg LFkl

Remove

Piston, housing:

65 kg

piston (54) from housing

(53).

18. No. 2, 3 carrier assembly 1) Remove snap ring (55). 2) Using puller, pull out bearing press-fit portion of No. 2 and 3 carrier assembly (56).

DEW04144

DEW04143

I ler

DEW04694 DEW04146

Using eyebolts @ (Dia. = IO mm, Pitch = 1.5 mm), lift off carrier assembly (56). &I kg

Carrier assembly:

90 kg

Disassemble No. 2 and 3 carrier assembly as follows. i) Remove sun gear (57). ii) Remove mounting bolts (58), then remove retainer (59). DEW04147

DEW04148

30-83 0

DISASSEMBLY

AND ASSEMBLY

TRANSMISSION

iii) Remove pin, then remove thrust washer (601, planetary gear (611, and needle bearing (62). * When removing the pin, be careful not to lose the ball.

sd si DEW04150

iv) Remove

bearing

62 DEW04151

(63).

DEW04152

19. Ring gear, plate I) Remove ring gear (64). 2) Using eyebolts (Dia. = 10 mm, mm), lift off plate (65).

Pitch = 1.5

DEW04153

DEW04154

20. No. 3 piston, housing I) Remove collar (66).

DEW04155

DISASSEMBLY

TRANSMISSION

AND ASSEMBLY

2) Using eyebolts 0 (Dia. = IO mm, Pitch = 1.5 mm), lift off piston and housing (67). &I kg 3)

Piston, housing: 65 kg

Remove piston (69) from housing (68).

DEW04156

DEW04157

21. Spring Remove spring (70). + This spring is different from the other springs, so keep it separately in a safe place.

DEW04158

22. Spring, disc, plate Remove spring (711, disc (721, and plate (73). + There are springs between each plate.

DEW04159

23. No. 3 ring gear Remove ring gear (74).

‘\

“I

DEW04 160

30-85 0

DISASSEMBLY

AND ASSEMBLY

TRANSMISSION

24. No. 4 piston, housing 1) Using eyebolts 0 (Dia. = 10 mm, Pitch = 1.5 mm),

lift off piston and housing Piston, housing:

&?Ikg 2)

Remove

(75).

65 kg

piston (77) from housing

(76).

DEW04161

DEW04162

25. Spring

Remove spring (78). * This spring is different from the other springs, so keep it separately in a safe place.

\1 26. Spring, disc, plate Remove spring (791, disc (80), and plate (81). * There are springs between each plate.

DEW04163

a0 ,a2

27. Guide pin Remove

guide pin (82).

\ 79 DEW04164

28. Plate Remove

DEW04165

plate (83).

DEW04166

DISASSEMBLY

AND ASSEMBLY

29. Shaft assembly I) Remove shaft assembly

TRANSMISSION

(84).

2) Remove snap ring (85). 3)

Set in press, then using push tool @ (inside diameter: 80 mm, Length: 400 mm), remove bearing (86).

DEW04168

DEW04169

30. No. 4 ring gear, carrier assembly 1) Using eyebolts @ (Dia. = IO mm, Pitch = 1.5 mm), lift off ring gear and carrier assembly (87). &I kg

Ring gear, carrier assembly:

80 kg

‘I

DEW04170

2) Disassemble

No. 4 ring gear and carrier assembly as follows. Remove bearing assembly (88) from ring i) gear and carrier assembly (87).

88 87

DEW04171

30-87 0

DISASSEMBLY

ii)

AND ASSEMBLY

Remove

collar (91) from bearing

TRANSMISSION

(90).

DEW04172

iii) Remove mounting bolts (92), then remove retainer (93). iv) Remove snap ring (941, then remove ring gear (95).

DEW04173

VI Remove pin, then remove thrust washer (961, planetary gear (971, and needle bearing (98). Ir When removing the pin, be careful not to lose the ball.

DEW04175

31. Sun gear Remove sun gear (99).

DEW04176

DISASSEMBLY

TRANSMISSION

AND ASSEMBLY

32. Cover assembly 1)

Turn over transfer kg rE?l

Transfer

assembly.

assembly:

1100 kg

Remove mounting bolts (51, then using forcing screws @ (Dia. = 12 mm, Pitch = 1.75 mm), remove cover assembly (6).

DEW04178

Remove snap ring (8) from remove bushing (9).

cover

DEW04179 I I

(71, then

DEW04180

DEW04181

33. Collar assembly 1) Remove snap ring (IO). 2) Using puller 0, remove collar assembly (I I). j, When using the puller, remove the outside seal ring.

DEW0418:

DEW04183

34. Inner race Using puller @, pull out rotating clutch assembly (1201, then remove inner race (121). Ir When pulling out the rotating clutch assembly, fit a block under the rotating clutch to prevent it from falling.

DEW04185

30-89 0

DISASSEMBLY

AND ASSEMBLY

TRANSMISSION

35. Rotating clutch assembly I)

Raise transfer assembly (I 221, and disassemble rotating clutch assembly. &I kg

Remove

Transfer flange

assembly:

1100 kg

(100) of bearing.

DEW04186

FINE DISASSEMBLY OF ROTATING CLUTCH ASSEMBLY 36. No. 5 carrier assemblv I) Remove

mounting

bolts (101).

2) Using eyebolts 0 (Dia. = 10 mm, Pitch = 1.5 mm), sling carrier assembly (1021, then using forcing screws (Dia. = 12 mm, Pitch = 1.75 mm), lift off carrier assembly. kg rE?l

Carrier assembly:

Disassemble Remove ii) Remove iii) Remove

65 kg

carrier assembly snap ring (103). collar (104). bearing (105).

DEW04187

DEW04188

DEW04189

DEW04190

as follows.

iv) Remove pin (1061, then remove thrust washer (1071, planetary carrier (1081, and needle bearing (109). Ir When removing the pin, be careful not to lose the ball.

108

109

107 DEW04192

DISASSEMBLY

AND ASSEMBLY

TRANSMISSION

37. Sun gear, No. 5 ring gear 1) 2)

Remove Remove

sun gear (110). ring gear (I 11).

DEW04193

DEW04194

38. Spring, disc, plate Remove spring (I 12), disc (I 13), and plate (I 14). + There are springs between each plate.

DEW04195

39. Retainer, 1) 2)

pressure plate Remove mounting bolts (115), then remove retainer (116). Remove pressure plate (117).

40. Bearing Using puller 0,

remove

bearing

DEW04196

DEW04197

DEW04198

DEW04199

(118).

41. Inner race Remove inner race (119).

30-91 0

DISASSEMBLY

AND ASSEMBLY

ASSEMBLY Special

TRANSMISSION

OF TRANSMISSION

ASSEMBLY

tool

No.

Part No.

Part Name

799-301-1600

Oil leak tester

Precautions when assembling Coat the rotating and sliding surfaces of all parts with engine oil (SAEIOW) before installing. Coat the seal rings and roller bearings with grease (G2-LI), then install them, making sure that they are not off center. . Align the notches on the discs when installing. . Check that the snap rings are fitted securely. Clean all parts, and repair any damage. l

FINE ASSEMBLY OF ROTATING CLUTCH ASSEMBLY 1. Inner race Using push tool @I (Dia. = 123 mm, 270 mm), press fit inner race (119). 2.

Bearing 1) Install 2 seal rings to drum. 2) Using push tool @ (Dia. = 73 mm), bearing (118).

Length

press fit

11’9

DEW04200

DEW04201

Pressure plate, retainer 1) Fit seal ring to pressure plate (1171, then install to drum. 2) Fit retainer (116) and tighten mounting bolts (I 15). m Mounting bolt: 66.2 = 7.4 Nm (6.75 = 0.75 kgm}

DEW04197

DEW04202

DISASSEMBLY

Spring,

AND ASSEMBLY

TRANSMISSION

disc, plate

Install spring (1121, disc (1131, and plate (114). + There are springs between each plate. * Number of discs: 6 Number of plates: 5

-L DEW04195

No. 5 ring gear, sun gear 1) Install ring gear (III). 2) Install sun gear (110).

DEW04194

DEW04193

DEW04203

DEW04204

DEW04190

DEW04189

No. 5 carrier assembly 1) Assemble carrier assembly as follows. i) Install needle bearing (1091, planetary gear (1081, and thrust washer (1071, then knock in pin (106). * Be careful not to forget the ball when installing.

ii)

Using push tool (Dia. = 133 mm), press fit bearing (105). iii) Fit 2 seal rings to collar (104) and install. iv) Install snap ring (103).

30-93 0

DISASSEMBLY

AND ASSEMBLY

TRANSMISSION

2) Using eyebolts 0 (Dia = IO mm, Pitch = 1.5

mm), raise carrier assembly (102) and install. Tighten mounting bolts (101). w Mounting bolt: 110.3 t. 12.3 Nm ill.25 z 1.25 kgm}

DEW04188

I 7.

DEW04187

Rotating clutch assembly I) Install flange (100) of bearing. 2) Raise transfer assembly (1221, and connect rotating clutch assembly.

DEW04186

Using push tool @ (inside diameter: 103 mm, length: 70 mm), press fit inner race (121) to rotating clutch (120). Sr Press fit the inner race at approx. 2O”C, and be extremely careful that the bearing roller does not fall over.

8A. Collar assembly I) 2)

Install 2 seal rings to collar. Using push tool @I (inside diameter: 83 mm), press fit collar assembly (II). Ir Align the collar assembly exactly with the position of the dowel pin and press fit gradually.

DEW04695

Collar /

Case

DEW04696 I1

Install snap ring (IO).

DEW04206

DEW04207

DISASSEMBLY

TRANSMISSION

AND ASSEMBLY

Cover assembly 1) Set in press, then using push tool @ (outside diameter: 135 mm), press fit bushing (9) in cover (7). 2) Install snap ring (8).

DEW04209

DEW04210

Fit O-ring and install cover assembly (6), then tighten mounting bolts (5).

10. Sun gear 1) Turn over transfer assembly. & kg 2)

Transfer assembly: 1100 kg

Install sun gear (99).

DEW04212

1 96

DEW04213

11. No. 4 ring gear, carrier assembly 1) Assemble No. 4 ring gear and carrier assembly as follows. i) Assemble needle bearing (98) in planetary gear (97), fit thrust washers (96) to both ends and set to carrier.

DEW04214

DISASSEMBLY

ii)

AND ASSEMBLY

TRANSMISSION

Fit ball (120) and push in pin (121). * Be careful not to forget the ball when installing to the shaft.

DEW04215

I iii) Fit snap ring (94) to ring gear (951, and . install ring gear. iv) Fit retainer (93) and tighten with mounting bolts (92). * Check that the snap ring installed to the ring gear is set securely between the retainer and the carrier. w Mounting bolt: 66.2 t 7.4 Nm i6.75 + 0.75 kgm}

DEW04216

Set in press, then using push tool @ (inside diameter: 103 mm), press fit collar (91) in bearing (90). * Install a seal ring on the collar.

DEW04217

vi)

DEW04216

Install bearing assembly (88) to ring gear and carrier assembly (87). * Install seal rings to the ring gear and carrier assembly.

DEW04171

DISASSEMBLY

TRANSMISSION

AND ASSEMBLY

2) Using eyebolts @ (Dia. = 10 mm, Pitch = 1.5 mm), raise ring gear and carrier (87) and install.

assembly

12. Plate Align with dowel

pin, and install plate (83).

13. Shaft assembly 1) Install snap ring (85). 2) Set in press, then using push tool @ (inside diameter: 103 mm, length: 165 mm), press fit bearing (86) in shaft.

DEW04220 1 1 I

Tap shaft assembly ing.

DEW04221

(841, and press fit bear-

DEW04222

TRANSMISSION

DISASSEMBLY AND ASSEMBLY

14. Guide pin Install guide pin (82). 15. Disc, spring plate Install disc (801, spring (791, and plate (81). * There are springs between each plate. + Number of discs: 5 Number of plates: 4

DEW04223

DEW04224

16. Spring Install spring (78). * This spring is different from the other springs, so be careful to distinguish it when installing. * Free height of spring: 91 mm

DEW04225

17. No. 4 piston, housing 1) Fit seal ring, then install piston (77) in housing (76). * Install the seal ring with the groove facing the housing as shown in the diagram. 2) Using eyebolts CiJ(Dia. = 10 mm, Pitch = 1.5 mm), align with dowel pin, raise piston and housing (751, and install. * When installing, check through the clearance between the piston and the transfer that spring (78) has not fallen over.

DEW04697

DEW04227

DEW04228

18. No. 3 sun gear Install ring gear (74).

DISASSEMBLY

AND ASSEMBLY

19. Disc, spring,

plate

TRANSMISSION

install disc (721, spring (711, and plate (73). * There are springs between each plate. * Number of discs: 4 Number of plates: 3

DEW04229

20. Spring Install spring (70). * This spring is different from the other springs, so be careful to distinguish it when installing. * Free height of spring: 91 mm

21. No. 3 piston,

housing

Fit seal ring, then install piston (69) in housing (68). * Install the seal ring with the groove facing the housing as shown in the diagram. Using eyebolts (Dia. = 10 mm, Pitch = 1.5 mm), align with dowel pin, raise piston and housing (67), and install. * When installing, check through the clearance between the piston and the housing that spring (70) has not fallen over.

Seal rina

69 DEW04698

Install collar (66).

’

DEW04232

DISASSEMBLY

AND ASSEMBLY

TRANSMISSION

22. Plate, ring gear I) Using eyebolts (Dia. = 10 mm, Pitch = 1.5 mm), align with dowel pin, then raise plate (65) and install. 2) Install ring gear (64).

DEW04233

DEW04234

23. No. 2, 3 carrier assembly 1) Assemble No. 2 and 3 carrier assembly as follows. i) Using push tool (outside diameter: 175 mm), press fit bearing (63).

DEW04152

ii)

Assemble needle bearing (62) in planetary gear (611, and fit thrust washers (60) to both ends, then set in carrier. iii) Fit ball (122) and push in pin (123). * Be careful not to forget the ball when installing the shaft.

tEWO4,5,

'22DEW04235

iv) Fit retainer (59) and tighten mounting with bolts (58). @El Mounting bolt: 66.2 + 7.4 Nm I6.75 f 0.75 kgm} VI Using eyebolts @ (Dia. = 10 mm, Pitch = 1.5 mm), raise carrier assembly (56) and install.

DEW04236

30-&oo

DEW04237

DISASSEMBLY

TRANSMISSION

AND ASSEMBLY

vi) Insert seal ring in collar, then assemble to shaft. * When the seal ring is assembled to the collar, install so that the narrow width “a” of the seal ring and collar is at the bottom.

Sea! ring

DEW04238

DEW04699

DEW04240 1

DEW04241

vii) Install sun gear (57). viii)lnstall snap ring (55).

No. 2 piston, housing 1) Fit seal ring, then install piston (54) in housing (53). Jr Install the seal ring with the groove facing the housing as shown in the diagram. 2) Using eyebolts @ (Dia. = 10 mm, Pitch = 1.5 mm), align with dowel pin, raise piston and housing (521, and install. Ring gear Install ring gear (51).

Seal rins

Guide pin Install guide pin (50). Disc, spring, plate Install disc (481, spring (471, and plate (49). Ir There are springs between each plate. * Number of discs: 6 Number of plates: 5

J!A!!&!

DEW04700

DEW04142

DEW04243

DEW04141

DISASSEMBLY

AND ASSEMBLY

TRANSMISSION

28. Spring Install spring (46). * This spring is different from the other springs, so be careful to distinguish it when installing. * Free height of spring: 108.5 mm

DEW04139

29. No. 1 piston, housing 1) Fit seal ring, then install piston (45) in hous-

ing (44). * Install the seal ring with the groove facing the housing as shown in the diagram. Using eyebolts @ (Dia. = IO mm, Pitch = 1.5 mm), align with dowel pin, raise piston and housing (431, and install. + When installing, check through the clearance between the housing and the piston that spring (46) has not fallen over.

30. No. 2 ring gear 1) Fit snap ring (42A) to ring gear (421, and install ring gear. 2) Fit plate (411, and tighten with mounting bolts (40). * Check that the snap ring installed to the ring gear is set securely between the plate and the carrier. w Mounting bolt: 66.2 z 7.4 Nm I6.75 f 0.75 kgm}

Seal rino

DEW04701 1 1

DEW04137

42A

DEW04245

30-Ao2

DISASSEMBLY

AND ASSEMBLY

TRANSMISSION

31. Shaft, No. 1 carrier assembly I) Assemble shaft and No. 1 carrier assembly as follows. i) Assemble needle bearing (38) and spacer (39) in planetary gear (371, fit thrust washers (36) to both ends and set to carrier. ii) Fit ball (124) and push in pin (125). * Be careful not to forget the ball when installing to the shaft.

iii) iv)

VI vi)

Install snap ring (35). Using push tool (outside diameter: mm), install bearing (34).

Using push tool @ (outside diameter: mm), install bearing (33). Install sun gear (32).

DEW04246

DEW04247

DEW04133

DEW04248

DEW04249

DEW04130

DEW04250

DEW04251

155

135

vii) Set in press, then using push too @ (inside diameter: 85 mm, length: 280 mm), press fit bearing (31).

30-103 0

DISASSEMBLY

AND ASSEMBLY

TRANSMISSION

viii)Press fit shaft assembly (29) in carrier assembly (301, and install snap ring (28).

DEW04252

ix) Fit seal ring and install collar (27) to shaft and carrier assembly (26).

I x) xi)

DEW04126

Install gear (25). Install snap ring (24).

DEW04125

DEW04124

2) Using eyebolts

@I (Dia. = 12 mm, Pitch = 1.75 mm), raise shaft and No. 1 carrier assembly (23) and install. 23

DEW04123

30-Ao4

DISASSEMBLY

AND ASSEMBLY

TRANSMISSION

32. No. 1 ring gear Install ring gear (22).

DEW04122

33. Disc, spring, plate Install disc (201, spring (19L and plate (21). * There are springs between each plate. j, Number of discs: 6 Number of plates: 5

EW04121

34. Spring Install spring (18). * This spring is different from the other springs, so be careful to distinguish it when installing. * Free height of spring: 108.5 mm

W04120

35. Plate Using eyebolts @ (Dia. = 10 mm, Pitch = 1.5 mm), raise plate (17) and install. Ir When installing, check through the clearance between the plate and the piston that spring (18) has not fallen over.

DEW04119

DISASSEMBLY

AND ASSEMBLY

TRANSMISSION

36. Tie bolts Install 17 tie bolts (16). w Tie bolt: 372.7 + 19.6 Nm (38 = 2 kgm1

37. Piston operation check Using tool A, check stroke of each piston. Sr Air pressure: 0.3 - 0.5 MPa (3 - 5 kg/cm*} Unit: mm Piston

Standard

No. 1

7.6

No. 2

8.6

No. 3

7.0

No. 4

7.2

stroke

Transmission case I) Fit O-ring, then using eyebolts @ (Dia. = 12 mm, Pitch = 1.75 mm), raise transmission case (15) and install.

'04116

39. Sleeve 1) Raise transfer and transmission and set in upright position.

assembly: 2200 kg Fit O-ring and install sleeve (4).

kg C!?l 2)

Transfer,

assembly

transmission

f-l-!

30-Ao6

DISASSEMBLY

TRANSMISSION

AND ASSEMBLY

40. Control valve assembly 1) Fit gasket, then using eyebolts @I (Dia. = 10 mm, Pitch = 1.5 mm), install control valve assembly (3). * Align the hole position of the gasket at the mating surface.

DEW04113

Tighten 11 mounting bolts. * Tighten the mounting bolts uniformly in turn so that there is no deformation of the valve. m Mounting bolt: 49.0 t 4.9 Nm (5 2 0.5 kgml * Check the length of the bolts when installing.

41. Torque converter assembly Using eyebolts, install torque bly (I) to transmission (2).

converter

Mounting

Long

bolts

position

lifting

bolts

DEW04693

assem-

DEW04111

30-l 07 0

DISASSEMBLY

AND ASSEMBLY

DISASSEMBLY

TRANSFER

OF TRANSFER ASSEMBLY

Clean all parts and repair any burrs.

Transmission assembly Disassemble transmisison assembly. For details, see DISASSEMBLY OF TRANSMISSION ASSEMBLY.

Cage assembly 1) Remove snap ring (I), then remove mounting bolts (2). 2) Using forcing screws @ (Dia. = 12 mm, Pitch = 1.75 mm), remove cage assembly (3).

DEW04254

Set in press, then using push tool @ (outside diameter: 185 mm), remove bearing (5) from cage (4).

DEW04256

DEW04255

DEW04257

No. 1 gear Using eyebolts @ (Dia. = 12 mm, mm), lift off gear (6).

Pitch = 1.75

Gear: 40 kg

3o-Ao8

DEW04258

DISASSEMBLY

Snap ring, bearing 1) 2)

TRANSFER

AND ASSEMBLY

Remove Remove

snap ring (7). spacer (8).

Using push tool @ (outside mm); remove bear-%-q (9).

diameter:

175

DEW04259

DEW04260

DEW04261

DEW04262

Cage assembly I) Remove mounting bolts (IO), then screw in forcing screws @ (Dia. = 12 mm, Pitch = 1.75 mm) and remove fitting portion of cage.

DEW04263

DEW04264

DEW04265

DEW04266

2) Using eyebolt @ (Dia. = 12 mm, Pitch = 1.75 mm), lift off cage assembly (I 1). * The cage is thick, so raise it vertically.

el kg

Remove

Cage assembly: bearing

40 kg

(13) from cage (12).

30-109 0

DISASSEMBLY

TRANSFER

AND ASSEMBLY

No. 3 gear 1) Using eyebolts 1.75 mm), kg rL?l

@ (Dia. = 12 mm, Pitch = lift off gear assembly (14).

Gear assembly:

50 kg

I 2) 3)

DEW04267

Remove bolt (60) from gear (15), then remove holder (61). Remove snap ring (62) from gear (15), then remove holder (63).

62 60

I 4)

Remove

bearing

inner

race (16) from

gear

(15). Remove

bearing

inner

race (17) from

gear

DEW04266

(15).

DEW04269

DEW04270

Coupling, cage assembly 1)

Remove mounting bolt (181, then holder (19). Ir Width across flats of mounting

remove bolt: 55

Rem?: coupling cage mounting bolts (64). * Make match marks on the spline of the shaft and the coupling.

DEW04271

DISASSEMBLY

AND ASSEMBLY

TRANSFER

Screw in forcing screws @ (Dia. = 12 mm, Pitch = 1.75 mm) and remove fitting portion of cage. Check the number and thickness of shims * (201, and keep in a safe place. Using eyebolts @ (Dia. = 12 mm, Pitch = 1.75 mm), lift off coupling and cage assembly (21). A kg

Coupling,

cage assembly:

55 kg DEW04272

-E273

Disassemble coupling and cage assembly as follows. i) Set in press, then using push tool @ (outside diameter: 135 mm), remove coupling (23) from cage (22).

DEW04274

ii) Remove iii) Remove

d=a-

DEW04275

oil seal (24) from cage (22). bearing (25) from cage (22).

DEW04276

Remove

collar (26).

' DEW04277

DISASSEMBLY

AND ASSEMBLY

TRANSFER

Strainer assembly 1) Remove cover (27). 2) Remove spring (28).

/>_e

--I

I/ DEW04278

Remove

strainer

assembly

(29).

DEW04279

DEW04280

Cage assembly 1) Turn over transfer. &I kg

Transfer:

770 kg

2) Remove mounting 3)

bolts (30). Screw in forcing screws @ (Dia. = 12 mm, Pitch = 1.5 mm) and remove fitting portion of cage. II ‘7 DEW04281

Using eyebolts @ (Dia. = 12 mm, Pitch = 1.75 mm), lift off cage assembly (31). Cage assembly:

30 kg

DEW04282

DISASSEMBLY

Remove

AND ASSEMBLY

bearing

TRANSFER

(33) from cage (32).

-u--

DEW04284

10. No. 2 gear assembly

1) Using eyebolts mm),

iDia. = 12 mm, Pitch = 1.75 lift off gear assembly (34). Gear assembly:

&I kg

50 kg

DEW04285

2) Remove 3)

bolt (65) from gear (351, then remove holders (66) and (67). Remove bearing inner races (36) and (37) from gear (35).

35 37 36 65

DEW04286

11. Bearing Remove

bearing

(38).

DEW04287

30-113 0

DISASSEMBLY

AND ASSEMBLY

TRANSFER

12. Cage assembly I) Remove mounting bolts (39). 2) Using forcing screws @ (Dia. = 12 mm, Pitch = 1.5 mm),

3) 4)

Remove

remove

bearing

cage assembly

(40).

DEW04288

DEW04289

DEW04290

DEW04291

DEW04292

DEW04293

(42) from cage (41).

Remove cover (43) from cage (41).

13. Coupling assembly I) Remove mounting

bolts (441, then remove holder (45). * Width across flats of mounting bolt: 55

Lift rrcoupling assembly (46). * Support the block under the shaft.

Remove inner race (48) from coupling (47).

DEW04294

DISASSEMBLY

TRANSFER

AND ASSEMBLY

14. Cage assembly

1) Remove

mounting bolts (49), then screw in forcing screws (Dia. = 12 mm, Pitch = 1.5 mm) and remove fitting portion of cage. Using eyebolts @ (Dia. = 12 mm, Pitch = 1.5 mm), lift off cage assembly (50). &l kg

Cage assembly:

45 kg

3) 4)

DEW04295

Remove oil seal (52) from cage (51). Remove snap ring (53) from cage (511, then remove bearing (54).

DEW04297

DEW04298

15. No. 4 gear, shaft assembly 1)

Using holder (45) and mounting bolts (441, lift off No. 4 gear and shaft assembly (55). &I kg

No. 4 gear, shaft assembly:

90 kg

I 2)

Lift off gear (57) from shaft (56). A kg

DEW04299

Remove

Gear: 60 kg spacer (58) from shaft (56).

DEW04300

DEW04301

30-115 0

DISASSEMBLY

AND ASSEMBLY

ASSEMBLY 1.

OF TRANSFER

TRANSFER

ASSEMBLY

No. 4 gear, shaft assembly I) Install spacer (58) to shaft (56). 2) Raise gear (57) and install to shaft (56).

DEW04301

Using holder (45) and mounting bolts (441, raise No. 4 shaft assembly (55) and install. Ir Support the block under the shaft.

I 2.

DEW04300

DEW04299

DEW04302

DEW04303

Cage assembly I) Set in press, then using push tool @ (outside diameter: 245 mm), press fit bearing (54) in cage (511, and install snap ring (53).

Using push tool (outside diameter: press fit oil seal (52) in cage (51). & Oil seal: Grease (G2-LI)

195 mm),

DEW04304

DISASSEMBLY

AND ASSEMBLY

TRANSFER

Fit O-ring, then using eyebolts @ (Dia. = 12 mm, Pitch = 1.75 mm), raise cage assembly (50) and install. 4) Tighten with mounting bolts (49).

DEW04296

Coupling assembly I) Set in press, then using push tool @ (inside diameter: 135 mm), press fit inner race (48) in coupling (47).

DEW04305

2) 3)

Raise coupling assembly (46) and install. Fit O-ring and holder (45), and tighten with mounting bolts (44). w Mounting bolt: 2207 t 147 Nm I225 + 15 kgm1

Cage assembly I) Fit O-ring and install cover (43) to cage (41).

DEW04306

30-117 0

DISASSEMBLY

TRANSFER

AND ASSEMBLY

Using push tool @ (outside diameter: 165 mm), press fit bearing (42) in cage (41).

Fit cage mounting

assembly (40) bolts (39).

and

tighten

DEW04307

DEW04308

with

DEW04309

Bearing Using push tool @I (outside press fit bearing (38).

diameter:

165 mm),

DEW04310 / /

DEW04311

DEW04312

DEW04313

No. 2 gear assembly 1) Set in press, then using push tool @ (inside diameter: 85 mm), press fit inner race (37) in gear (35). 2) Set in press, then using push tool @ (inside diameter: 85 mm), press fit inner race (36) in gear (35). & Inside of inner race: Adhesive (LT-2)

DISASSEMBLY

3) 4)

AND ASSEMBLY

TRANSFER

Align holders (66) and (67) with dowel pin of gear (351, then install. Tighten bolt (65). Ir Check that the clearances (4 places) between the gear and the inner race is max. 0.04 mm.

Using eyebolts (Dia. = 12 mm, Pitch = 1.75 mm), raise gear assembly (34) and install.

DEW04285

I 7.

Cage assembly 1) Set in press, then using push tool @ (outside diameter: 165 mm), press fit bearing (33) in cage (32).

DEW04314

DEW04315

2) Fit O-ring, then using eyebolts @ (Dia. = 12 mm, Pitch = 1.75 mm), (31) and install.

raise cage assembly

DEW04283

30-119 0

DISASSEMBLY

Tighten

AND ASSEMBLY

with mounting

TRANSFER

bolts (30).

DEW04316

Snap ring, bearing I) Install snap ring (7).

Using push tool @ (outside mm), press fit bearing (9).

diameter:

DEW04317

DEW04316

DEW04319

DEW04320

175

Strainer assembly I) Turn over transfer. Transfer: 2)

Install strainer

700 kg

assembly

(29).

DEW04260

30-&20

DISASSEMBLY

AND ASSEMBLY

TRANSFER

Install spring (28). Insert the spring securely in the groove at the top of the strainer. Fit O-ring and install cover (27).

DEW04321

DEW04322

10. Coupling, cage assembly I) Install collar (26).

DEW04277

Assemble coupling and cage assembly follows. i) Set in press, then using push tool (outside diameter: 220 mm), press bearing (25) in cage (22).

as Push with press

@ fit

DEW04703

I ii)

Using push tool @ (outside diameter: 195 mm), install oil seal (24) in cage (22). & Oil seal: Grease (G2-LI) Push with

DEW04704

30-121 0

DISASSEMBLY

AND ASSEMBLY

iii) Set in press, then using push tool (outside diameter: 160 mm), press coupling (23) in cage (22).

TRANSFER

@ fit

11. Adjusting coupling, cage assembly

1) Fit O-ring, then using eyebolts @ (Dia. = 12

mm, pitch = 1.75 mm), raise coupling and cage assembly (21) and install. Fit holder (191, and tighten with mounting bolt (181, then measure clearance between cage and case with feeler gauge @I. m Mounting bolt: 2207 2 147 Nm {225 + 15 kgm1

DEW04326

DEW04327

Remove mounting bolt (18) and holder (191, then using forcing screw @ (Dia. = 12 mm, Pitch = 1.5 mm), insert shim (20) with thickness of measured clearance + (0 + 0.05) mm.

4) Tighten coupling cage mounting bolt (64). 5) Fit holder (19) and tighten with mounting bolt (18). w Mounting bolt: 2207 f 147 Nm I225 + 15 kgm}

DEW04271

3o-A22

DISASSEMBLY

TRANSFER

AND ASSEMBLY

12. No. 3 gear

1) Set in press, then using push tool @ (inside diameter: 85 mm), in gear (15).

3) 4)

press fit outer

race (17)

DEW04329

DEW04270

DEW04330

DEW04269

Set in press, then using push tool @I (inside diameter: 85 mm), press fit outer race (16) to gear (15).

Align with dowel and secure with Align with dowel and tighten bolt

pin, then install holder (631, snap ring (62). pin, then install holder (611, (60).

Using eyebolts @ (Dia. = 12 mm, Pitch = 1.75 mm), raise gear assembly (14) and install.

DEW04267

30- 123 0

DISASSEMBLY

AND ASSEMBLY

TRANSFER

13. Cage assembly

1) Set in press, then using push tool @ (outside diameter: 165 mm), (13) in cage (12).

press fit bearing

DEW04331

DEW04266

2) Fit O-ring, then using eyebolts @ (Dia. = 12

mm, Pitch = 1.75 mm), (11) and install. Tighten with mounting

raise cage assembly bolts (IO).

DEW04332

DEW04333

14. No. 1 gear I) Install spacer (8). 2) Using eyebolts @ (Dia. = 12 mm, 1.75 mm), raise gear (6) and install.

Pitch =

DEW04334

DEW04335

15. Cage assembly 1)

Set in press, then using push tool @ (outside diameter: 210 mm), press fit bearing (5) in cage (4).

DEW04336

30-A24

DEW04337

DISASSEMBLY

2) 3)

AND ASSEMBLY

Fit cage assembly mounting bolts (2). install snap ring (1).

(3)

TRANSFER

and

tighten

with

DEW04338

16. Transmission assembly Assemble transmission assembly. For details, see ASSEMBLY OF TRANSMISSION ASSEMBLY. 17. Adjusting speedometer sensor I) Screw in sensor (68) until it contacts outside surface of gear (69). * Before installing the sensor, check that the gear is at the outside surface compared with the mounting surface. 2) After sensor (68) contacts gear (691, turn it back 3/4 - 1 turn and secure with locknut

TransmTssion case DEW04705

(70). Ir Be careful that the outlet direction of the sensor harness is not the opposite direction to the sensor connector clamp. & Sensor thread: Adhesive (LT-2) w Sensor locknut: 39.2 + 9.8 Nm I4 t 1 kgm}

30-125 0

DISASSEMBLY

REMOVAL VALVE a

TRANSMISSION

AND ASSEMBLY

OF TRANSMISSION

Cover Open platform

cover (I).

Electric wiring Disconnect transmission from transmission.

solenoid

valve wire (2)

Transmission valve Using eyebolts, lift off transmission &I kg

Transmission

valve (3).

valve: 96.1 kg

INSTALLATION TRANSMISSION 1.

VALVE

OF VALVE

Transmission valve Set transmission valve (3) in mounting position, and tighten mounting bolts. + Align the position of the holes of the gasket at the mating surface exactly. Ir Tighten the mounting bolts on opposite side in turn to prevent the valve from being distorted. w Mounting bolt: 49.0 = 4.9 Nm 15 2 0.5 kgm}

Electric wiring Connect transmission solenoid valve wire (2) to transmission. * When connecting the connector, be careful not to deform the thread case.

Cover Close platform

cover (I).

30-&26

DEW04340

i lP DEW04341

DISASSEMBLY

AND ASSEMBLY

DISASSEMBLY, ASSEMBLY DISASSEMBLY,

ASSEMBLY

TRANSMISSION

OF TRANSMISSION

OF UPPER VALVE

VALVE

ASSEMBLY

DEW04342

DISASSEMBLY

OF UPPER VALVE ASSEMBLY

1. Remove cover (I), then remove valve (21, spring (3), valves (4) and (51, shim (6), and springs (7) and (8). j, Check the number and thickness of the shims, and keep in a safe place.

Remove plug (91, then remove spring (IO), valves (11) and (121, spring (13), and valve

Remove cover (241, then remove piston (25), shim (261, and springs (27) and (28). * Check the number and thickness of the shims, and keep in a safe place.

Using bolts (Dia. = 10 mm, Pitch = 1.5 mm), remove stopper (29), then remove valve (30).

Remove

Remove plug (331, then remove spring (341, valves (35) and (36), spring (37), and valve

cover (31), then remove

boss (32).

(14).

Remove plug, pull out pin (15), then remove stopper (16). Remove cover (171, then remove valve (181, spring (191, valves (20) and (211, and shims (22) and (23). * Check the number and thickness of the shims, and keep in a safe place.

30-A28

(38). 9.

Remove cover (39), then remove and spring (41).

valve

(40)

10. Remove plug, pull out pin (421, then remove stopper (43).

DISASSEMBLY

AND ASSEMBLY

TRANSMISSION

VALVE

ASSEMBLY OF UPPER VALVE ASSEMBLY *

Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.

1. Set stopper (43) in valve body (44), knock in pin (42), and install plug.

Assemble spring (41) and valve (40) in valve body (44), then fit O-ring and install cover (39).

Set valve (36), spring (37), and valve (38) in valve (35), assemble valve (35) and spring (34) in valve body (44), then fit O-ring and install plug (33). w Plug: 127.5 2 19.6 Nm I13 + 2 kgml

Fit O-ring and assemble boss (32) in valve body (44), then align with dowel pin and install cover (31).

z & ls

Assemble valve (30) in valve body (44), then fit O-ring and install stopper (29).

Set shim (26) in piston (25), assemble in valve body, then fit O-ring and install cover (24). * Standard shim thickness: 0.5 mm x 4

Set shims (22) and (23), and springs (28) and (27) in valve (21), assemble valves (21) and (20), spring (19) and valve (18) in valve body (44), then fit O-ring and install cover (17). * Standard shim thickness: 0.5 mm x 4 (both large and small shims)

Set stopper (16) in valve body (44), and knock in pin (15), then install plug.

Set valve (12), spring (13), and valve (14) in valve (II), assemble valve (11) and spring (10) in valve body (44), then fit O-ring and install plug (9). w Plug: 127.5 t 19.6 Nm I13 f 2 kgm)

10. Set shim (6). and springs (7) and (8) in valve (5), assemble valves (5) and (4), spring (3), and valve (2) in valve body (44), then fit O-ring and install cover (1). * Standard shim thickness: 0.5 mm x 6

30- 129 0

DISASSEMBLY

AND ASSEMBLY

DISASSEMBLY, ASSEMBLY OF LOWER VALVE ASSEMBLY

DISASSEMBLY

OF LOWER VALVE ASSEMBLY

Remove solenoid valve assembly, then remove spring (1).

Remove cover (21, then using bolts (Dia. = 10 mm, Pitch = 1.5 mm), remove stopper (3).

Remove valve (4).

ASSEMBLY OF LOWER VALVE ASSEMBLY *

Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.

Assemble valve (4) in valve body (5).

Fit O-ring and assemble stopper (3) in valve body (51, then install cover (2).

Assemble spring (I) in valve body (51, and install solenoid valve assembly.

30-A30

TRANSMISSION

VALVE

DISASSEMBLY

AND ASSEMBLY

TRANSMISSION

VALVE

DISASSEMBLY, ASSEMBLY OF RELIEF VALVE ASSEMBLY 7 Main /

Torsue relief

relief

va’ve

converter valve

DEW04706

DISASSEMBLY

OF RELIEF VALVE ASSEMBLY

Remove cover (I), then remove valve (2). spring (31, valves (4) and (51, and shim (6). * Check the number and thickness of the shims, and keep in a safe place.

Remove

plug (71, then

remove

springs

(8) and

(9).

ASSEMBLY OF RELIEF VALVE ASSEMBLY Ir

Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.

Set springs (8) and (9) in plug (71, and install to valve body (IO).

Set shim in valve (51, and assemble valves (5) and (41, spring (31, and valve (2) in valve body (IO), then install cover (1). * Standard shim thickness: 0.5 mm x 12 (Main relief valve) 0.5 mm x 2 (Torque converter relief valve)

30-131 0

DISASSEMBLY

AND ASSEMBLY

REMOVAL

SUPPORT

OF CENTER SUPPORT

Stop the machine on level ground and turn the steering wheel fully to the left lock. Lower the work equipment to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels.

Drive shaft 1) Lift off center drive shaft (1). &I kg

CENTER

Center drive shaft: 186 kg DEW04345

Lift off front drive shaft (2). Ir Move the drive shaft towards the front differential, move the center support end to the side and remove the pilot portion at the differential end. & kg

Front drive shaft: 173 kg

Center support Sling center support (31, remove mounting bolts, then lift off. * If there are shims inserted between the center support and frame, check the number of shims and use as a guide when assembling. * When lifting off, be careful not to damage the steering cylinder rod. & kg

Center support:

169 kg DEW04347

30-A32

DISASSEMBLY

AND ASSEMBLY

INSTALLATION

CENTER SUPPORT

OF CENTER SUPPORT

Special tools No.

Part No.

790-101-7230

Shaft

795-101-7240

Guide

01010-31230

Screw

Part Name

QW 1 I

1 1 DEW04347

Center support I) Set center support (3) in mounting 2)

position, and tighten mounting bolts temporarily. Install tools AI and AZ with A3 to the top and bottom of hinge pins. Then install dial gauge @ to coupling at cneter support end and measure parallelism of coupling and shaft

Al.

DEW04669

Insert shims in the center support mount to adjust. * After adjusting with shims, tighten the mounting bolts fully. Ir Parallelism: Max. 0.1 mm QEI Mounting bolt: 927 z 103 Nm 194.5 t 10.5 kgm} (width across flats: 36 mm)

Drive shaft 1) Set front

drive shaft (2) in mounting position, then tighten mounting bolts. * Install the differential end of the drive shaft first. w Mounting bolt: 385.4 t 41.2 Nm f39.3 = 4.2 kgm1

DEW04707

DISASSEMBLY

AND ASSEMBLY

Set center drive shaft (1) in mounting position, and tighten mounting bolts. Ir Wipe the coupling mount surface clean with a cloth w Mounting bolt: 385.4 z 41.2 Nm j39.3 L 4.2 kgml

Greasing Supply grease until grease comes out from breather (4). 6 Center support: Grease (G2-LII

30-A34

CENTER SUPPORT

DISASSEMBLY

AND ASSEMBLY

DISASSEMBLY 1.

CENTER SUPPORT

OF CENTER SUPPORT

Retainer Remove mounting bolts (2) of retainer (I). Ir Rotate the coupling and remove all mounting bolts. * Turn over the center support.

I 2.

‘

DEW04351

Coupling Remove center bolt (31, then remove holder (41, O-ring and coupling (5). * Check the number and thickness of the shims between the holder and shaft.

z k

DEW04352

d 3.

Retainer Remove

bolts, then

remove

retainer

(6). * Remove the O-ring at the retainer (6) and case (7).

mounting

mating

face

I 4.

DEW04353

Shaft 1) Set shaft and case assembly 2)

(8) on press stand. Remove shaft (9) with press. * Be extremely careful as the shaft will drop out suddenly.

DEW04354

30- 135 0

DISASSEMBLY

3) *

AND ASSEMBLY

CENTER SUPPORT

Remove bearing cone (IO) and retainer from shaft. Remove O-ring (11) from retainer.

Oil seal Remove

oil seal (12) from retainers

(1)

(I) and (6).

I. 6

12 DEW04356

Case Remove

bearing

cup (13) from case.

30-&36

DEW04357

DISASSEMBLY

AND

ASSEMBLY Special

ASSEMBLY

CENTER SUPPORT

OF CENTER SUPPORT

tools

790-101-5421

Grip

01010-51240

Bolt

1 1 DEW04357

Bearing cup Assemble bearing

cup (13) in case.

Oil seal Using tools C and Cl, assemble oil seal (12) in retainers (I) and (6). & Outer circumference of oil seal: Grease (G2-LI)

12 DEW04358 3.

Bearing cone 1 Assemble retainer (I) to shaft, then using tools B, C, and Cl, press fit bearing cone

2) 4.

(IO). * After assembling the bearing, check that there is no clearance from the end of the shaft. & Lip of oil seal: Grease (G2-LI) & Inside circumference of bearing: Grease (G2-LI) Assemble O-ring (11) in retainer.

Case 1) Install case (7) to shaft. 2) Using tools B, C, and Cl, press fit bearing cone (141, then fit O-ring (15). Jr Fill the inside of the case with grease. Ir When press fitting bearing (141, be careful not to apply excessive force.

DEW04359

30- 137 0

DISASSEMBLY

AND ASSEMBLY

CENTER SUPPORT

Retainer 1) Secure retainer (6) to case (7). Jr Be careful not to get the O-ring caught. m Mounting bolt: 110.8 z 11.8 Nm ill.3 + 1.2 kgm)

7 DEW04353

Tighten retainer (I) with mounting bolts (2). Sr Be careful not to get the O-ring caught. w.Mounting bolt: 110.8 + 11.8 Nm ill.3 + 1.2 kgm}

DEW04351

Coupling II Select shim as follows. l Rotate case (7) and tighten bolt (3) until starting torque is (7.8 - 11.8 Nm (0.8 1.2 kgm)). . Measure clearance “a” between holder (4) and shaft (9) at holes in holder at 3 places, take the average clearance, and select shims of a thickness equal to the average clearance + 0.1 to 0.15. * To measure the clearance, first measure the thickness of the holder.

DEW04360

Assemble coupling (51, install O-ring (16), shim (17) selected above, and holder (9), then tighten bolt (3). * Rotate the case and tighten the bolts to the specified torque. w Bolt (3): 2746 t 294 Nm 1280 + 30 kgm} (width across flats: 55 mm)

DEW04361

30-A38

DISASSEMBLY

CENTER SUPPORT

AND ASSEMBLY

Align the spline of the shaft and coupling so that the match marks are aligned.

Couulino /

Match marks

Shaft

DEW04709

End play Check that end play is within specified range. * End play: 0.05 - 0.15 mm Ir Carry out greasing after installing the center support to the chassis.

DEW04363

30-139 0

DISASSEMBLY

AND ASSEMBLY

DISASSEMBLY 1.

Splined Loosen

yoke retainer

(I)

DRIVE SHAFT

OF DRIVE SHAFT and

remove

splined

yoke

(2).

DEW04364

Bearing assembly Remove mounting bolts (31, then remove bearing assembly (4). Jr Make match marks on the yoke and bearing.

DEW04365

Bearing cap I) Remove bearing cap (5) from sem bly. * Remove strap (6) of cap.

bearing

as-

DEW04366

Remove bearing (71, seal (8) and washer (9) from bearing cap.

Delrin

7 0 cx, DEW0436:

30-A40

9 OEW04366

DISASSEMBLY

AND ASSEMBLY

DRIVE SHAFT

Sleeve yoke 1) Remove mounting bolts (11) from sleeve yoke (IO), then remove bearing assembly (4). Make match marks on the yoke and bear* ing.

DEW04369

Remove sembly.

bearing

cap (5) from

bearing

as-

DEW04370

Remove bearing (7), seal (8), washer (9) from bearing cap.

and

Delrin

DEW04367

DEW04371

30-M 0

DISASSEMBLY

AND ASSEMBLY

ASSEMBLY 1.

DRIVE SHAFT

OF DRIVE SHAFT

Bearing cap I) Install bearing (71, and seal (8) to bearing cap (5). 6 Bearing, seal: Grease (G2-LI)

DEW04372

2) Assemble

Delrin washer (9) and bearing (5) to bearing assembly (4). & Bearing cap: Grease (G2-LI)

cap

DEW04373

Bearing assembly Assemble bearing assembly (4) to sleeve yoke (IO). + Align the match marks correctly. * Wipe the mounting face of the bearing cap with a clean cloth. w Mounting bolt: 385.4 f 41.2 Nm (39.3 + 4.2 kgm}

DEW04374

Splined yoke II Assemble

bearing

cap (5). & Bearing

(7) and seal (8) in bearing

seal: Grease

(G2-LI)

DEW04367

30-&42

DEW04366

DISASSEMBLY

AND ASSEMBLY

DRIVE SHAFT

Assemble Delrin washer (9) and bearing cap (5) to bearing assembly (4). * Do not weld the strap. The heat when welding will damage the bearing.

DEW04375

Assemble bearing assembly (4) to splined yoke (2). * Align the match marks carefully. * Wipe the mounting face of the bearing cap with a clean cloth. m Mounting bolt: 385.4 + 41.2 Nm (39.3 + 4.2 kgm}

DEW04376

Align match marks, insert splined sleeve yoke (IO), and secure with

yoke in retainer

(I). * Check that the yokes are facing in the same direction. * If the spline is worn, replace the whole drive shaft assembly.

DEW04377

:. x m

Upper drive shaft Bearing cap mounting bolt (11): 213.8 2 6.9 Nm 121.8 z 0.7 kgm}

DEW04378

30-143 0

DISASSEMBLY

REMOVAL

AND ASSEMBLY

FRONT AXLE

OF FRONT AXLE

A Stop the machine

. .

Block the rear tires and apply the parking brake securely. Insert blocks @ between the top face (I) of the rear axle housing and frame (2). (both left and right)

Jack up the machine and set blocks @ under the front frame on the left and right.

I 1.

Tires, wheels Sling left and right tires and wheels mounting nuts, then lift off. Tire, wheel:

DEW04380

(31, remove

3475 kg

Drive shaft Lift off front drive shaft (4). * Make match marks on the drive shaft coupling to act as a guide when assembling. Ir Move the drive shaft towards the front differential, then move the center support end to the side and remove the pilot portion at the differential end. r&lkg

Front drive shaft: 173 kg 382

DISASSEMBLY

AND ASSEMBLY

FRONT AXLE

Brake hoses Disconnect brake hoses (5) and (6) from connection of tube. * Fit covers after disconnecting the piping.

Air hose Disconnect air hose (7) from parking brake chamber. * Check that the parking brake is actuated. -k Disconnect the air hoses from the left and right parking brake chambers.

Front axle

1) Sling axle (81, remove mounting use hoist and jack to maintain lower on top of roller. A kg

bolts, then balance, and

Front axle: 8190 kg

Fix chains around the figure.

the axle as shown

DEW04385

2) Pull out front axle (8) from chassis. *

Roller for moving the axle to the side. Reference drawing.

DEW04710

30-145 0

DISASSEMBLY

AND ASSEMBLY

INSTALLATION 1.

FRONT AXLE

OF FRONT AXLE

Front axle I) Pull front axle under machine body. 2) Fit lifting tool to front axle (81, set jack under differential case, and maintain balance while setting in mounting position. * Fit chains around the axle and keep the axle pad surface horizontal. 3) Tighten mounting bolts of front axle. w Mounting bolt: 3521 + 353 Nm I359 1 36 kgm} (width across flats: 60 mm) DEW04385

Air hoses Connect air hoses (7) to parking brake chamber. * Install air hoses to left and right parking brake chamber.

I 3.

DEW04384

Brake hoses Connect brake hoses (5) and (6) to tube. * Wipe the connection clean with a cloth.

Drive shaft Raise front drive shaft (41, and set in mounting position, then tighten mounting bolts. + Install the differential end of the drive shaft first. QEI Mounting bolt: 385.4 = 41.2 Nm (39.3 + 4.2 kgm}

382

30-A46

DISASSEMBLY

FRONT AXLE

AND ASSEMBLY

Tires, wheels 1) Set left and right tires and wheels (3) in mounting position, then install mounting nuts. w Mounting nut: 823.8 i: 88.3 Nm (84.0 + 9.0 kgm} (width across flats: 36 mm)

Jack up machine, and remove block @ from under front frame.

DEW04380

Remove block @ between top face (I) rear axle housing and frame (2).

Bleeding air from brake system Bleed air from brake system, then check operation of brakes. Ir For details of bleeding the air, see TESTING AND ADJUSTING.

DEW04379

30-147 0

AND ASSEMBLY

DISASSEMBLY

REMOVAL

REAR AXLE

OF REAR AXLE

Disconnect the cable from the negative (-1 terminal of the battery. Put blocks under the front wheels to prevent the machine from moving, and apply the parking brake securely.

DEW04387

Counterweight I)

Remove left and right steps (I), (2) and (3).

Electric wiring, battery cables . Remove battery cable (4) from left and right battery relays. . Disconnect wiring (5) for left and right lights at connector. . Disconnect wiring (6) for left and right relays at connector. . Disconnect cable (7). . Disconnect cable (8) for left and right ground connections.

Sling counterweight (9-l), (9-2) remove left and right mounting and (II), then lift off. A kg

Counterweight Counterweight Counterweight

and covers

DEW04388

and (g-3), bolts (IO)

(9-I): 2500 kg (9-2): 1087 kg (9-3): 1600 kg

30-A48

9-2

DEW04390

DISASSEMBLY

Pull out the disconnected battery cables and wirings (12) ad (13) to the left and right from holes.

REAR AXLE

AND ASSEMBLY

Fuel tank

1) Loosen drain valve and drain fuel. -

Fuel : 1200 e

Remove engine oil drain valve (141, cooling water drain valve (15) of torque converter cooler, and cooling water drain valve (16) from fuel tank.

Disconnect fuel hoses (17) and (18). * Remove the clamps of the fuel hoses, left and right engine blowby hoses and engine block water drain hoses.

;5 Ri s

DEW04392

4) 5)

Disconnect wiring (19) for fuel unit from connectar. Sling fuel tank (20 0, remove mounting bolts, then lift off. Fix the lifting tool to the lifting hooks, be * careful to maintain the balance, and lift off slowly. Jr Check that all the fuel has been drained. Lay a pallet under the tank, set blocks in * position in line with the fuel tank, then pull out the fuel tank from the chassis. &I kg

Fuel tank : 684 kg

DEW04394

30-l 49 0

DISASSEMBLY

REAR AXLE

AND ASSEMBLY

Frame support Jack up rear frame and set stand under frame. * Insert blocks @ between the top face of the rear axle housing and frame (both left and right). * For safety, put steel sheets under the stand. (When making the stand, see the drawing given later.)

and

Steel DEW04396

Tire, wheel Sling left and right rear tire and wheel move mounting nuts, then lift off. &I kg

Tire, wheel

iheet DEW04711

(211, re-

: 3475 kg

Drive shaft Sling rear drive shaft (221, remove mounting bolts, then lift off. Ir Use a lifting tool of ample length for the drive shaft, and lift up from both ends of the transmission. I+ kg

Rear drive shaft : 186 kg

DEW04399

Brake piping Disconnect hose (23) between brake chamber and slack adjuster from slack adjuster.

DEW04400

30-go

DISASSEMBLY

AND ASSEMBLY

REAR AXLE

Rear axle, support I)

Remove mounting cover (24). &I kg

cover

118.4 kg

Remove

Thrust cover (24) is heavy, so handle it as follows and use fixed signals when removing. . Leave one bolt in position at the bottom, and use this bolt as a pivot to rotate the cover carefully. . Hold the cover with a pallet, remove the remaining bolt, then remove the cover carefully.

grease tube.

Remove thrust washer (251, thrust plate (26) and thrust washer (27). &I kg

Thrust

bolts, then remove thrust

Thrust

DEW04712

plate : 76 kg

Sling rear axle. + Fit a chain around the axle and be careful to maintain the balance.

DEW04403

.25

DEW04405

DEW04404

DISASSEMBLY

AND ASSEMBLY

REAR AXLE

Secure front support (28) to rear axle with wire, and remove front support mounting bolts. * Remove grease tube (29).

Move rear axle approx. 250 mm to front, remove from rear support, then using hoist and jack to maintain balance, lower rear axle. &I kg

Rear axle, support

: 7986 kg

Lay steel sheets under the part being lowered, and lower one end of the axle on to the roller. Pull out rear axle and support (30) from the body. * Be careful not to damage the slack adjuster and brake tube.

DEW04407

DEW04409

Front support 1) Remove front support (31) from rear axle. * Be careful not to damage the O-ring (or seal). lI+lkg

Front support

: 285.5 kg

Remove retainer (32), O-ring (or seal) (331, and bushing (34) from front support (31). * For machines where the bushing and support are stuck together, remove bushing (34) in the procedure for Step 10.

DISASSEMBLY

REAR AXLE

AND ASSEMBLY

Rear support Remove O-ring (or seal) (35) and bushing (36) from rear support. * For machines where the bushing and support are stuck together, remove bushing (36) in the procedure for Step 10.

DEW04410

Reference stand.

drawing

for

rear frame

support 6350xlZt

(STKR41)

Like Plate

above steel

welded Darts 12t is Possible.

4-C20

4-22 Perforation No processing is Possible.

DEW04713

10. Procedure for removing bushing 1) Insert tip of a knife between bushing and support, separate bushing and support around whole circumference, then remove bushing. If the adhesive is hard, and it is difficult * to separate the bushing and support, heat the bushing to 100°C with boiling water or with a small torch, then try again to separate the bushing and support.

2) Coat adhesion

portion (where it is held to the support) with adhesive removing liquid, wait for 2 - 3 minutes, then remove adhesive. & Portion with hardened adhesive : Adhesive removing liquid

30-153 0

DISASSEMBLY

AND ASSEMBLY

INSTALLATION 1.

OF REAR AXLE

Rear support 1) Remove dirt and oil from adhesive surface of axle support. 2) Soak a cloth in primer, and wipe adhesion surface of bushing. & Adhesion surface of bushing: Primer 3) After coating with primer, coat bushing with adhesive within 5 minutes. & Bushing: Adhesive * Coat each bushing (36) with approx. 18 g of adhesive.

Install bushing (36) and O-ring (or seal) (35) to rear support. + Install the seal to the support within 30 60 seconds of starting to coat it with adhesive. * Do not mix the primer and adhesive when using. * Assemble the bushing so that the chamfered side is on the thrust plate side. * Assemble the seal so that the lip is on the outside. * Fit the O-ring securely in the groove, and be careful that it is not caught when it is installed. &

REAR AXLE

Bushing,

Front support 1) Remove dirt

O-ring: Grease

(G2-LI)

Coat circumference at area marked X with adhesive DEW04714

DISASSEMBLY

AND ASSEMBLY

install bushing (341, retainer (321, and O-ring (or seal) (33) to front support. Install the seal to the support within 30 60 seconds of starting to coat it with adhesive. Do not mix the primer and adhesive when using. Assemble the bushing so that the chamfered side is on the inside of the support. Assemble the seal so that the lip is on the outside. P$& Bushing, O-ring: Grease (G2-LI) w Retainer mounting bolt: 176.5 2 19.6 Nm {I8 +. 2 kgm}

REAR AXLE

DEW04409

O-ring type

type 1

Raise front support (311, and insert in rear axle mount. * Be careful not to damage the O-ring with the coupling. * Secure the rear axle and front support with a chain. & Rear axle mount: Grease (G2-LI)

DEW04408

DISASSEMBLY

AND ASSEMBLY

REAR AXLE

Rear axle, support I) Insert rear axle and support (30) under chassis. 2) Using hoist and jack to maintain balance, insert rear axle into rear support mount, then tighten mounting bolts of front support (28). * Tighten the mounting bolts of the front support on opposite sides in turn. w Mounting bolt: 3521 + 353 Nm I359 = 36 kgm} (width across flats: 60 mm) 3) Connect grease tube (29) to front support. 4) Install thrust washer (271, thrust plate (261, thrust washer (25). 6 Thrust washer: Grease (G2-LI) m Mounting bolt: 927 t 103 Nm (94.5 t 10.5 kgm} (width across flats: 36 mm)

DEW04407

DEW04416

\ 5)

Set thrust cover (24) in mounting position, and tighten mounting bolts. * Install the grease tube. @EI Mounting bolt: 927 + 103 Nm i94.5 2 10.5 kgm} (width across flats: 36 mm) * Thrust cover (24) is heavy, so handle it as follows and use fixed signals when installing. . Raise the cover with a pallet, and assemble one bolt. . Using the bolt as a pivot, rotate the cover and set it in position, then install the other bolts.

DEW04403

DEW04712

DISASSEMBLY

REAR AXLE

AND ASSEMBLY

Brake piping Connect hose (23) between brake chamber slack adjuster to slack adjuster.

and

DEW04400

Drive shaft Raise rear drive shaft (22) and connect to rear axle. * When connecting the drive shaft, wipe the mating faces clean before installing. m Mounting bolt: 385.4 + 41.2 Nm I39.3 + 4.2 kgm}

DEW04399

Tires, wheels 1) Set left and right tires and wheels (21) in mounting position, and tighten mounting nuts. m Mounting nut: 927 + 103 Nm 194.5 + 10.5 kgm} (width across flats: 36 mm)

Lowering machine I) Jack up machine, and remove stand from under frame. 2) Remove block @ from rear axle housing. and

Steel

DEW04396

30-157 0

DISASSEMBLY

REAR AXLE

AND ASSEMBLY

Fuel tank I)

Raise fuel tank (20) and set in mounting position, then tighten mounting bolts. * When raising, keep horizontal and set in the mounting position. * Tighten the mounting bolts on opposite sides in turn. w Mounting bolt: 927 z 103 Nm 194.5 t 10.5 kgm} (width across flats: 46 mm)

Connect tor.

wiring

(19) for fuel unit to connec-

Connect fuel hoses (17) and (18). * Install the hoses without twisting or interference. Jr Install the clamps of the fuel hoses, left and right engine blowby hoses, and engine block water drain hoses.

Install engine oil drain valve (141, cooling water drain valve (15) of torque converter, and cooling water drain valve (16) to fuel tank.

DEW04394

DEW04392

DISASSEMBLY

AND ASSEMBLY

REAR AXLE

Counterweight I)

Raise counterweight (g-2), (9-I) and (9-3) and set in mounting position,then tighten mounting bolts (IO), (II). w Mounting bolt (11): 1716 + 196 Nm (175 t 20 kgm) (width across flats: 46 mm) w Mounting bolt (IO): 927 t 103 Nm (94.5 + 10.5 kgm} (width across flats: 36 mm)

-3

9-2

-k

Insert the left and right battery cables and wirings (12) and (13) into the battery relay side through holes in the counterweight. Insert the wiring first.

\ 2)

DEW04390

Electric wiring, battery cables Install bakery cable (4) to left and right battery relays. . Connect cable (8) for left and right ground connection. . Connect wiring (5) for left and right lights at connector. . Connect wiring (6) for left and right relays at connector. . Connect cable (7). * Connect the cables to the negative (-1 terminal of the battery after the completion of the operation and before starting the engine.

DEW04391

DEW04388

30-159 0

DISASSEMBLY

AND ASSEMBLY

Install left and right steps (I), and covers (2) and (3).

IO. Refilling with oil and fuel I) Tighten drain valve and add fuel through filler to the specified level. Q 2)

REAR AXLE

oil

Fuel: 1200 1

Grease rear axle support (front and rear). 6 Axle support: Grease (G2-LI) DEW04387

11. Bleeding air from brakes Bleed air from brake system, then check operation of brakes. + For details of bleeding the air, see TESTING AND ADJUSTING.

30-A60

DISASSEMBLY

REMOVAL 1.

DIFFERENTIAL

OF DIFFERENTIAL

ASSEMBLY

Remove axle assembly and set on block 0. For details, see REMOVAL OF AXLE ASSEMBLY. &I kg

Front axle assembly:

8190 kg

l&lkg

Rear axle assembly:

7700 kg

Remove drain plug of final case and drain plug at bottom of differential case, and drain oil from final drive case. * There is a large amount of oil drained, and the oil spurts out suddenly, so be careful when draining. -

AND ASSEMBLY

Remove

DEW04418

Final drive case: Approx. 360 !2 final drive case cover (2).

DEW04419

Remove snap ring, then remove sun gear (3). -)r When removing the sun gear, pull out the torque shaft slightly to remove.

Raise torque shaft (4), and pull out from spline of differential assembly. * Remove the torque shaft on the opposite side in the same way.

4421

30-161 0

DISASSEMBLY

AND ASSEMBLY

DIFFERENTIAL

When removing front differential assembly, remove parking brake assembly as follows. 1) Loosen the adjustment bolt, and remove the plate. 2) Pull out pin, and remove spring cylinder assembly (7). 3) Remove brake pad assembly (8). 4) Remove disc (91, then remove bracket.

DEW04422

Remove holder, then remove coupling (IO). Ir Check the number and thickness of the shims assembled inside the holder, and keep in a safe place. kg rE5

Coupling: 40 kg

Remove mounting bolts, pull out differential assembly (II) slightly, then using lifting hooks @ adjust balance with bar and remove differential assembly. &I kg

Differential assembly: 1250 kg

A When pulling out the differential assembly, support the bottom of the differential sembly with a garage jack.

as-

I II

DEW04424

DISASSEMBLY

DIFFERENTIAL

AND ASSEMBLY

INSTALLATION

OF DIFFERENTIAL

Fit O-ring, then using lifting hooks 0, sling differential assembly (I I), adjust balance with bar, and set in mounting position.

Remove lifting hook, push into differential case, then tighten mounting bolts. A When removing the lifting hooks, support the bottom of the differential assembly with a garage jack. & Mounting bolt: Adhesive (LT-2) w Mounting bolt: 932 + 98 Nm {95 + 10 kgm}

Adjusting shaft shim * Adjust the shaft shim when the differential assembly placed.

or axle

housing

have

been

ASSEMBLY

DEW04424

Front a;Ie housing

re-

DEW04718

1) Tighten the mounting

bolts of shaft (12) uniformly, and measure clearance a between axle housing and shaft. * Do not assemble any shim. m Mounting bolt: 3.9 t 1.0 Nm (0.4 t 0.1 kgm} (When measuring clearance)

‘19

2) Select a shim of 0.1 + 0.05 mm larger than the measured value of clearance a, then assemble the shim. Ir Shim thickness = Clearance a + (0.1 + 0.05 mm) w Mounting bolt: 279.5 + 29.4 Nm 128.5 2 3.0 kgm}

30-163 0

DISASSEMBLY

AND ASSEMBLY

install coupling

Fit O-ring and assemble removed shim, then tighten holder. 6 Holder mounting bolt: Adhesive (LT-2) m Holder mounting bolt: 2746 + 294 Nm {280 2 30 kgm}

When installing front differential assembly, install parking brake assembly as follows. bracket and install disc (9). 1) & Mounting bolt: Adhesive (LT-2) m Mounting bolt: 549 + 59 Nm (56 I 6 kgm}

DIFFERENTIAL

(IO).

21 Install brake pad assembly 31

(8). Install spring cylinder assembly (7) and secure with pin. + Bend the cotter pin securely. Fit the plate and tighten the adjustment bolt. * Adjust the parking brake. For details, see TESTING AND ADJUSTING, ADJUSTING PARKING BRAKE.

DEW04422

Raise torque shaft (41, set temporarily in mounting position, align spline portion, then push torque shaft into differential assembly mounting position.

4’ 4421

Install sun gear (3) and secure with snap ring. Ir Raise the torque shaft slightly to align the tooth faces of the sun gear and carrier gear.

30-A64

DISASSEMBLY

9. Fit O-ring

AND ASSEMBLY

DIFFERENTIAL

and install final case cover (2).

10. Tighten the final drive case drain plug and drain plug at bottom of differential case, then add oil through level plug until oil flows out.

Final drive case: Approx.

11. Install axle assembly. For details, see INSTALLATION SEMBLY.

360 e

OF AXLE

ASDEW04419

30-165 0

DISASSEMBLY

AND ASSEMBLY

DISASSEMBLY

DIFFERENTIAL

OF DIFFERENTIAL

ASSEMBLY

Special tools No.

Part No.

Part Name

790-501-3000

Engine repair stand

790-901-5110

Bracket

790-101-2102

Puller (30 ton)

790-101-1102

Pump

1 28

Preparatory work Set differential

d kg

Differential

Remove

case (2).

l+l kg 2.

assembly

(I) to tools A and AI.

assembly:

1250 kg

Case: 45 kg

Remove

oil seal (3) from case.

DEW04429

Fit the coupling (4) temporarily, ion and cage assembly (5). L&lkg Ir

Coupling,

Check shims,

and remove

DEW04430

pin-

pinion, cage assembly:

180 kg

the number and thickness and keep in a safe place.

of the

DEW04431

Disassemble pinion and cage assembly as follows. I) Remove coupling, and sling cage (61, then using tools B, C and 0, pull out bearing (71, and remove cage. * If tools B, C and @ are not used, support the flange surface of the cage, push the pinion shaft with a press to disassemble.

DEW04432

3o-P

DEW04433

DISASSEMBLY

2) 3)

DIFFERENTIAL

AND ASSEMBLY

Remove outer race (8). Remove bearing (11) from pinion shaft (10).

Remove left and right locks, then loosen the nut (12) with a bar to a point where it can be turned by hand.

Remove mounting (14).

Remove differential gear case assembly (15).

bolts (13), then remove cap

DEW04434

A kg 8.

Disassemble differential gear case assembly as follows. I) Remove mounting bolts (16), then remove case (17). kg rE?l 2)

5 Ki d

DEW04435

Differential gear case assembly: 1250 kg

3) 4)

Case: 85 kg

Remove bearing (18) and thrust washer from case. Remove bevel gear (19). Remove pinion gear assembly (20) together with cross shaft (21). &I kg

DEW04436

Pinion gear, cross shaft: 110 kg

DEW04437

DEW04440

DEW04441

DEW04438

DEW04439

DISASSEMBLY

AND ASSEMBLY

DIFFERENTIAL

Disassemble pinion gear assembly as follows. I) Raise lock plate, hold pinion gear assembly (20) with press, then using wrench 0, loosen lock nut (22) and remove. 2) Push shaft (23) with press, and remove pinion gear (24) and bearing (25).

3) 4)

Remove Remove

Remove

DEW04442 1 /

DEW04443

DEW04444

DEW04445

collar (26). bearing (27) from shaft.

outer races (28) and (29).

9. Remove

bevel gear (30).

10. Remove

thrust washer

(31).

11. Remove mounting bolts, and using eyebolts (Dia. = 24 mm, Pitch = 3.0 mm), remove bevel gear. &I kg

Bevel gear: 320 kg DEW04446

30-A68

0 DEW04449

DEW04447

DEW04448

DISASSEMBLY

AND ASSEMBLY

ASSEMBLY

DIFFERENTIAL

OF DIFFERENTIAL

ASSEMBLY

Special tools No.

Part No.

Part Name

O’ty

790-501-3000

Engine repair stand

790-901-5110

Bracket

792-525-3000

Depth micrometer

Coat the rotating surfaces of the bearing roller, inner race and outer race rollers with engine oil before installing.

Using the eyebolts (Dia. = 24 mm, Pitch = 3.0 mm), install the bevel gear. 6 Mounting bolt: Adhesive (LT-2) w Mounting bolt: 932 rf 98 Nm 195 = 10 kgm}

z z S

Install thrust washer (31). * Align the thrust washer when installing.

with the dowel

Install bevel gear (30). Ir Assemble pinion gear as follows. I) Install outer races (29) and (28). 2) Press fit bearing (27) in shaft. 3) Assemble collar (26).

DEW04446

DEW04445

DEW04450

I 0

0 DEW04449

30-l 69 0

DISASSEMBLY

DIFFERENTIAL

AND ASSEMBLY

4) Assemble 5)

pinion gear (24) and bearing (25) in shaft. Fit lock plate and tighten lock nut (22) with wrench 0. Ir Bend the lock plate securely. m Lock nut:

981 f 98 Nm {IO0 t 10 kgm}

DEW04451

Assemble differential gear case assembly as follows. 1) Assemble pinion gear assembly (20) in cross shaft (211, and install to case. * Align the notch in the pinion gear with the cross shaft dowel pin when installing. 2) Install bevel gear (19). + Move the bevel gear and check that the pinion gear assembly rotates smoothly. 3) Install thrust and washer bearing to case. * Align the thrust washer with the dowel pin when installing. 4) Install case, and tighten mounting bolts. 6 Mounting bolt: Adhesive (LT-2) w Mounting bolt: 932 f 98 Nm (95 t 10 kgm}

DEW04442

DEW04452

DEW04441

DEW04440

DEW04437 1 1

DEW04453

Tighten nut (12) temporarily, and put differential gear and case assembly (15) in differential case. * Align the nut with the groove in the differential case, then check that it rotates smoothly by hand.

30-A70

DISASSEMBLY

AND ASSEMBLY

DIFFERENTIAL

Install cap (14) and tighten mounting bolts (13). & Mounting bolt: Adhesive (LT-2) m Mounting bolt: 932 2 98 Nm 195 2 10 kgm1 * Check the match mark on the bearing cap when installing. Ir When tightening the bolts, rotate the bevel gear 20 - 30 times to settle the bearing before tightening.

DEW04436

Adjust the preload of the bevel gear as follows. I) Using tool B, measure distance D.

DEW04454

Adjust with the nut so that the increase in distance D is 0.39 r 0.15 mm. * The increase becomes the amount of deflection of the case from before giving preload to after giving preload. * If the increase deflection is greater than the standard distance, return to the position before adjusting with the adjustment nut. When returning the adjustment nut, rotate the bevel gear, and tap the bearing cap and bevel gear with a plastic hammer to check that there is no clearance at “b”. Then adjust again.

OEW04455

30- 171 0

DISASSEMBLY

AND ASSEMBLY

DIFFERENTIAL

Assemble pinion and cage assembly as follows. 1) Install bearing (II) to pinion shaft (IO). * Check that there is no clearance between the bearing inner race and the pinion. 2) Install outer race (8) to cage. 3) Install pinion shaft to cage (6). 4) Install bearing (7). 5) Install coupling (41, and tighten holder with mounting bolt to 323.6 + 19.6 Nm {33 f 2.0 kgm) temporarily, then measure clearance between holder and pinion. + Add 0.11 mm to the measured value for the clearance to decide the shim thickness.

DEW04435

DEW04434

DEW04456

Insert shim and rotate cage while tightening holder mounting bolts to specified tightening torque. & Mounting bolt: Adhesive (LT-2) w Mounting bolt: 2746 t 294 Nm (280 + 30 kgm} Rotate the cage 20 - 30 times, then using push-pull scale 0, check the starting torque. * Starting torque: 22.6 +. 6.9 Nm (2.3 + 0.7

kgm) Check that the bearing roller big end and inner race lip are in contact.

DEW04457

There must no clearance

DEW047 21

DEW04458

30-A72

DISASSEMBLY

z &i g

AND ASSEMBLY

Fit O-ring and assemble shim, then install pinion and cage assembly (5) to differential case. * If the shim was disassembled, assemble the same number and thickness of shims that was removed. & Mounting bolt: Adhesive (LT-2) w Mounting bolt: 549 f 59 Nm {56 + 6 kgm}

Adjusting tooth contact, backlash Ir Adjust backlash as follows. I) Move bevel gear with adjustment nut. When adjusting the bevel gear, do not change the preload of the bearing. Always turn the adjustment nuts at both ends the same amount in the same direction. 2) Put dial gauge @ at right angles in contact with the face of the tooth at the outside of the bevel gear. Turn the adjustment nut and adjust until the movement of the gauge indicator is 0.43 - 0.61 mm. * Adjust at 3 or 4 places. Keep the pinion gear locked when measuring. * Adjust tooth contact as follows. I) Adjust the position of the bevel pinion by changing the shims between the differential case and bearing cage. 2) Adjust tooth contact between pinion gear and bevel gear. For details, see Adjusting tooth contact.

DIFFERENTIAL

DEW04461

30- 173 0

DISASSEMBLY

Tooth

DIFFERENTIAL

AND ASSEMBLY

Adjust tooth contact Coat face of 7 or 8 teeth of bevel pinion lightly with red lead (minimum). Hold the bevel gear by hand to brake it, and rotate the bevel pinion forward and backward and inspect the pattern left on the teeth. Adjust the tooth contact as follows.

contact

DEW00910

Cause

Procedure

for adjustment

Correct contact 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 bevel pinion by adjusting the shims at the bevel pinion cage. Adjust the bevel gear in the same way as when adjusting backlash.

Bevel pinion is too far from bevel gear.

1. Reduce shims at bevel pinion to bring closer to bevel gear. 2. Move bevel gear further away from bevel pinion and adjust backlash correctly.

Bevel pinion is too close to bevel gear.

1. Increase shims at bevel pinion to move away from bevel gear. 2. Move bevel gear closer to bevel pinion and adjust backlash correctly.

DEW00934

? ’

Bevel gear is too close to bevel pinion.

1. Reduce shims at bevel pinion to bring closer to bevel gear. 2. Move bevel gear further away from bevel pinion and adjust backlash correctly.

Bevel gear is too far from bevel pinion.

1. Increase shims at bevel pinion to move away from bevel gear. 2. Move bevel gear closer to bevel pinion and adjust backlash correctly.

After adjusting tooth contact and backlash, stall left and right locks. 6 Mounting bolt: Adhesive (LT-2)

30-&74

in-

DEW00909

DISASSEMBLY

DISASSEMBLY Special

FINAL DRIVE

AND ASSEMBLY

OF FINAL DRIVE

tool O’ty

Part Name

No.

Part No.

792-l 04-3600

Fixture

Loosen wheel nut, jack up machine with work equipment, insert stand under axle, then sling wheel assembly, remove wheel nut, and lift off wheel assembly (I 1. &I kg

z Ei B

Wheel

assembly:

3475 kg

Remove drain plug of final case, and drain oil from final case. Sr There is a large amount of oil drained, and the oil spurts out suddenly, so be careful when draining. &

Final drive case: Approx.

360 j?

Remove

final drive case cover (2).

--_--z!iL 1

Remove snap ring, then remove sun gear (3). * Pull out the torque shaft approx. 150 mm, then push in the sun gear approx. IO mm, and remove the snap ring.

Snap

ring

DEW04722

Remove A kg *

torque Torque

Remove

shaft (4). shaft: 105 kg

retainer

(5).

DISASSEMBLY

AND ASSEMBLY

FINAL DRIVE

Remove 3 hexagonal bolts, then using eyebolts @ (Dia. = 12 mm, Pitch = 1.75 mm), lift off carrier case assembly (6). * When pulling out the carrier case assembly, insert a bar in the casting hole at the bottom of the case, and adjust the balance when pulling out. l&lkg

Carrier case assembly:

390 kg

Disassemble carrier case assembly as follows. 1) Remove mounting bolts (71, then remove retainer (8). 2) Using a copper hammer, knock out shaft, then remove pinion gear (9) and bearing form carrier case.

DEW04467

Remove the bearing from pinion gear, then remove cup (II), spacer (12), and snap ring (13). Keep the bearing and cup as set.

DEW04468

Using tool A, secure wheel hub (14) and floating seal case (15). * Secure tool A at 4 places on opposite sides to prevent uneven contact of the floating seal.

DISASSEMBLY

FINAL DRIVE

AND ASSEMBLY

Remove retainer (161, then remove shim (17). It Check the number and thickness of the shims, and keep in a safe place.

Lift off ring gear assembly (18). * When pulling out the ring gear assembly, insert a bar in the casting hole at the bottom of the case, and adjust the balance when pulling out.

lel kg

Ring gear assembly:

240 kg

DEW04472

10. Remove lock plate, then remove from ring gear hub (19).

Ring gear hub: 95 kg

el kg

Ring gear: 150 kg

ring gear (20)

30- 177 0

DISASSEMBLY

AND ASSEMBLY

ASSEMBLY Special

FINAL DRIVE

OF FINAL DRIVE

tools

No.

Part No.

792-l 04-3600

Part Name Fixture

O’ty 4

Install ring gear (20) to ring gear hub (191, and secure with lock plate. & Mounting bolt: Adhesive (LT-21 w Mounting bolt: 112.8 + 9.8 Nm Ill.5 + 1.0 kgm} j, Clean all the grease and oil from the bolt thread and mounting hole.

DEWD4473

Adjust wheel bearing as follows. 1) Align ring gear assembly (18) with spline of axle shaft, and tighten retainer (16) with 4 bolts temporarily. * Measure thickness “b” of the retainer before installing.

-00104476

Remove tool A, rotate the hub 5 - 6 times, then tighten the mounting bolts uniformly to the specified torque. w Mounting bolt: 78.5 t 4.9 Nm I8.0 t. 0.5 kgml

2) Using

calipers @ or depth micrometer through measuring hole of retainer, measure distance “a” from retainer to end face of axle shaft. Measure at 2 places and take the average. Use the measured values to calculate the thickness of the shim. Difference C between measured values = a - b + 0.3 mm (Round the measurement up to the nearest 0.1 mm). Select the combination of shims to give the required thickness with the minimum number of shims.

DEW04475

DISASSEMBLY

FINAL DRIVE

AND ASSEMBLY

Using tool A, secure wheel hub (14) and floating seal case (15). * Secure tool A at 4 places on opposite sides to prevent uneven contact of the floating seal.

Remove retainer, and fit selected shim (17) and retainer, then tighten mounting bolts. f Remove tool A, rotate the hub 5 - 6 times, then tighten the mounting bolts uniformly to the specified torque. & Mounting bolt: Adhesive (LT-2) m Mounting bolt: 932 + 98 Nm (95 t 10 kgm} * After tightening the bolts, rotate the hub and check for any abnormality in the rotation of the bearing rollers.

0 \

Assemble planetary carrier as follows. 1) Install snap ring (13) and spacer (12) to pinion gear. 2) Press fit cup (1 I), and assemble the bearing.

DEW04468

Set pinion gear (9) and bearing in carrier case, assemble shaft, then press fit shaft with copper hammer. Tighten retainer (8) with mounting bolts. 6 Mounting bolt: Adhesive (LT-21 m Mounting bolt: 274.6 + 29.4 Nm I28 + 3.0 kgm}

DEW04467

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE

4. Fit O-ring, then using eyebolts @ (Dia. = 12 mm, Pitch = 1.75 mm), raise carrier case assembly (6), align tooth faces of planetary gear and ring gear, then set in mounting position and tighten 3 hexagonal bolts. * When installing the carrier case assembly, insert a bar in the casting hole at the bottom of the case to adjust the balance when installing.

5. Raise torque shaft (5) and set in mounting

posi-

tion temporarily.

----_ sk -_

6. Align spline and push torque shaft in mounting position of differential assembly. * Leave the torque shaft protruding approx. 150 mm, install the snap ring to the sun gear, then push in completely.

7. Install retainer

(4) and sun gear (3), and secure with snap ring. Ir When aligning the tooth faces of the sun gear and carrier gear, raise the torque shaft slightly to align.

Snap rina

DEW04722

6. Fit O-ring and install final case cover (2). 9. Tighten drain plug of final case, until it flows out from level plug. Q

Final drive case: Approx.

and add

oil

360 fi

DEW04419

10. Raise wheel assembly (I), install to wheel hub, then temporarily tighten nuts. Jack up machine with work equipment, remove stand from under axle, then lower machine. 11. Tighten wheel nuts fully. w Wheel nut: 824 t 88 Nm I84 f 9 kgm}

30-A80

DISASSEMBLY

REMOVAL

STEERING

AND ASSEMBLY

OF STEERING

UNIT

g Stop the machine

Turn the steering wheel left and right 2 to 3 times after the engine stop to set the steering demand valve neutral.

1. Cover Remove 2.

cover under cab.

Column joint Remove lock bolt (I), then remove column joint (2) from steering column shaft. * Fix the joint with wire and others to prevent it from dropping off when pull off the joint.

I 3.

Hydraulic piping Disconnect 4 hydraulic

hoses

of steering

DEW04479

unit

(3).

DEW04723

4. Steering unit Remove 4 mounting bolts (5) of bracket (41, then remove steering unit (3). Ir Mounting bolts include cushion, spacer, etc. Do not miss them.

DEW04481

DISASSEMBLY

STEERING

AND ASSEMBLY

INSTALLATION

OF STEERING

UNIT

1. Steering unit . Install steering unit (3) to bracket (41, hold plates (6) and (7) and tighten with mounting bolt (8).

Install bracket (4) on the floor with mounting bolt (5). Ir Tighten it after setting cushion and spacer to mounting bolt (5) and bracket (4). DEW04482

Hydraulic piping Connect hoses to each port of steering unit (3). Steering unit (L port): Connect red color coded hose. Steering unit (R port): Connect blue color coded hose. Steering unit (P port): Connect no color coded hose. Steering unit (T port): Connect clamp tightening hose.

DEW04723

DEW04483

Column joint Install column joint (2) to steering unit, mount the column shaft and tighten lock bolt (1). m Lock bolt (1): 55.9 t 6.9 Nm (5.7 + 0.7 kgm}

Cover Install cover under cab.

DEW04479

DISASSEMBLY

AND ASSEMBLY

REMOVAL

OF STEERING

STEERING

DEMAND

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.

Step Remove

DEMAND

VALVE

step (I) on cab front.

Hydraulic piping Disconnect the following tubes from steering demand valve. . Remove tube (2) between steering demand valve (Pz port) and switch pump. . Remove tube (3) between steering demand valve (PI port) and steering pump. . Remove tube (4) between steering demand valve (P, B port) and main control valve. * Remove the bolts of bracket (5) for fixing tube (4) in advance. . Remove tube (6) between steering demand valve (A port) and steering cylinder. . Remove tube (7) between steering demand valve (B port) and steering cylinder. Remove tube (8) between steering demand valve (T port) and return port of hydraulic oil tank. . Remove tubes (9) and (IO) between steering unit and steering demand valve pilot circuit. * Remove the tube clamp in advance. l

30- 183 0

DISASSEMBLY

STEERING DEMAND VALVE

AND ASSEMBLY

Steering demand valve Sling steering demand valve, remove mounting bolts (II). then remove steering demand valve (12). &I kg

Steering

demand

valve: 66 kg

Bracket Remove bracket (13) from steering demand

valve

(12). DGWO4487

30-&84

DISASSEMBLY

INSTALLATION 1.

STEERING

AND ASSEMBLY

OF STEERING

Bracket Install bracket (13) to steering demand

DEMAND

VALVE

valve (12).

Steering demand valve Hang steering demand valve (12), put it over attaching portion and tighten mounting bolt (1 I).

DCW04487

Hydraulic piping Connect the following tubes to steering demand valve. l Connect tubes (9) and (IO) between steering unit and steering demand valve pilot circuit. l Connect tube (8) between steering demand valve (T port) and return port of hydraulic oil tank. l Connect tube (7) between steering demand valve (B port) and steering cylinder. l Connect tube (6) between steering demand valve (A port) and steering cylinder. l Connect tube (4) between steering demand valve (P, B port) and main control valve. * Attach bracket (5) for fixing tube (4). l Connect tube (3) between steering demand valve (PI port) and main control valve. l Connect tube (2) between steering demand valve (Pz port) and steering pump. * Use new O-rings. * Attach tube clamps.

30- 185 0

DISASSEMBLY

AND ASSEMBLY

SteD

STEERING DEMAND VALVE

Ins;all step (I) on cab front.

Greasing . Feed hydraulic oil to the specified . * *

level from the oil filler port of the hydraulic tank. Bleed air in steering pump, switch pump and hydraulic pump before engine start. Refer to the section TESTING AND ADJUSTING. Reconfirm the hydraulic oil level after engine started and the oil was circulated.

30-A86

DGW04484

DISASSEMBLY

AND ASSEMBLY

DISASSEMBLY,

ASSEMBLY

DIVERTER

OF DIVERTER VALVE

DISASSEMBLY

OF CHECK VALVE

Remove

Remove springs (5) and (6).

Disconnect

Remove

VALVE

covers (1) and (2).

DEW04488

ASSEMBLY 1.

(3) and (4), and check valves

OF CHECK VALVE

Assemble check valve (IO) and spring (9) in body (8), then fit O-ring and install to valve body (7). m Mounting bolt (I 1): 98.1 Nm IlO kgm)

valve body (7) and body (8). 2.

spring (9) and check valve (10).

Assemble backup rings (12) and (13), and Orings (14) and (15) in covers (I) and (2), then install together with check valves (5) and (6), and springs (3) and (4) in body (8).

30- 187 0

DISASSEMBLY

DIVERTER VALVE

AND ASSEMBLY

DISASSEMBLY

OF SELECTOR VALVE

Remove cover (I), spring (2) and retainer (3). g Be careful when removing cover (I) because it is under force from a spring.

Remove cover (4), and pull out spool (6) from valve body (5).

30-A88

DEW04489

ASSEMBLY OF SELECTOR VALVE 1.

Assemble spool (6) in valve body (51, then fit O-ring (7) and install cover (4). m Mounting bolt: 112.8 = 9.8 Nm ill.5 2 1.0 kgm}

Assemble retainer (3) and spring (2) to spool of valve body (51, then fit O-ring (8) and install cover (I). w Mounting bolt: 66.7 t 6.9 Nm I6.8 2 0.7 kgm

DISASSEMBLY

AND ASSEMBLY

DISASSEMBLY

BRAKE VALVE

OF BRAKE VALVE

1. Body assembly 1)

Make match lower body.

marks

“a” on upper

body and

DEW04490

Remove mounting bolts (I), remove upper body (2) and lower body (3), then disconnect.

)

'--+

DEW04491

Upper valve assembly I) Fix flat-headed screwdriver @ in vice 0, then put in contact with screwdriver slot in stem inside relay piston exhaust passage.

Remove nut (4), and remove washer (51, plain washer (6), spring seat (71, rubber spring (8), upper piston (91, return spring (IO), relay piston spring (II), relay piston (12L and stem assembly (13). a When loosening the nut, the piston will fly out due to the force of the return spring, so hold the piston down by hand when loosening the nut.

0 M

DEW04493

30-189 0

DISASSEMBLY

AND ASSEMBLY

Remove snap ring (14), then remove valve (15) from upper body.

BRAKE VALVE

primary

I 4)

Remove

snap ring (16), and disassemble retainer (18), (19) and (20), upper valve spring (21), valve retainer

DEW04495

Lower valve

1) Remove 2)

exhaust cover (24), then secondary valve assembly (25). Remove O-ring from lower body.

remove

1 3)

Remove snap ring (27), and disassemble secondary valve assembly into washer (28), Oring retainer (29), O-rings (30) and (31), lower valve spring (32), valve retainer (33), and lower valve (34).

DEW04496

DEW04497

DISASSEMBLY

AND ASSEMBLY

ASSEMBLY 1.

BRAKE VALVE

OF BRAKE VALVE

Lower valve assembly 1) Set valve set of lower valve (34) at bottom, then assemble valve retainer (33), lower valve spring (32), O-ring retainer (291, and washer (28), and secure with snap ring (27). * Assemble O-rings (30) and (31) to the Oring retainer before installing the retainer.

DEW04497

Assemble secondary valve assembly (25) in lower body, and install exhaust cover (24).

DEW04496

Upper valve assembly 1) Set valve seat of upper valve (23) at bottom, then assemble valve retainer (221, upper valve spring (211, O-ring retainer (181, and washer (17), and secure with snap ring (16). * Assemble O-rings (19) and (20) to the Oring retainer before installing the retainer.

DEW04495

Assemble primary valve assembly (15) in upper body, and secure with snap ring (14).

DEW04494

30-l 91 0

DISASSEMBLY

BRAKE VALVE

AND ASSEMBLY

Fix flat-headed screwdriver @ in vice CiJ, assemble relay piston spring (I I), relay piston (12) and stem assembly (13) at bottom of upper body, then set on screwdriver. * Do not forget to fit an O-ring to the relay piston when assembling.

4) Assemble

return spring (IO),, upper piston (9), rubber spring (8), spring seat (7), and washers (5) and (6) from top of upper body, and tighten with nut (4). Ir Do not forget to fit an O-ring to the upper piston when assembling. AThe piston will fly-out due to the force of the return spring, so hold the piston down by hand when assembling. m Nut: 5.4 + 1.5 Nm IO.55 + 0.15 kgm}

DEW04493

Body assembly 1) Install O-ring

(35) to lower

body (3).

0 0

0 00 fi$tzlJ

@ 0

DEW04498

I 2)

Align match marks of upper lower body (3), assemble, mounting bolts (I).

body (2) and then tighten

Match marks 2

‘+I if?!? 30-&92

DEW04814

DISASSEMBLY

AND ASSEMBLY

DISASSEMBLY 1.

Accessory Remove breather

BRAKE CHAMBER

OF BRAKE CHAMBER (I ), bleeder

(2) and sensor (3).

DEW04500

Cylinder Loosen locknut (4), then remove cylinder (5). * There is an O-ring fitted to the threaded apart of the cylinder, so remove it.

Piston assembly I) Move retainer (6) to right, remove pin (7), then remove piston assembly (8). * Use a guide pin (outside diameter: 2.5 mm, length: 50 mm) to remove the pin. DEW04501

'WO4505

Remove

rod (91, then remove

O-ring.

Disassembly of piston assembly 1) Remove snap ring (IO), then remove seat (II), spring (12) and valve (13). * Spring (12) is small, so be careful not to lose it. 2) Remove packing (15) from piston (14).

9’

DEW04502

BRAKE CHAMBER

DISASSEMBLY AND ASSEMBLY

Body Hold body (16) with hand, remove mounting bolts, then remove body. g The tension of the spring on the body is 245 N (25 kg), so be careful when removing it. Ir Remove the O-ring from the contact surfaces of the body and air cylinder.

DEW04506

I 6.

Disassembly of body 1)

Remove snap ring (171, then remove ring (18), packing (191, seat (20) and packing (21).

I8 19 20 21

DEW04507

Remove snap ring (221, then (23) and seal (24).

remove

DEW04508

ring

DEW04509

Air piston 1) Remove spring (26) and piston assembly (27) from air cylinder

(25).

DEW04510

30&94

DISASSEMBLY

2) 3)

BRAKE CHAMBER

AND ASSEMBLY

Remove nut, then remove piston (28) and rod (29). Remove packing (30) and ring (31) from piston.

29 c 3 sff

:\ DEW04511

Remove rod.

O-ring

(32) and washer

(33) from 33

DEW04512

30- 195 0

DISASSEMBLY

ASSEMBLY 1.

BRAKE CHAMBER

AND ASSEMBLY

OF BRAKE CHAMBER

Assembly of piston assembly 1) Install washer (33) and O-ring

(32) on rod

(29). Ir When fitting the O-ring, wind tape around the threaded part of the rod to prevent damage to the O-ring. & O-ring: Brake oil

DEW04513

DEW04514

2) Assemble

packing (30) and ring (31) on piston (28). & Packing: Grease (G2-LII Insert rod (29) in mount of piston (281, then secure with nut. Ir After tightening the nut, check that there is no clearance between the stepped part of the rod and the piston. & Piston mounting hole: Grease (G2-LII m Nut: 137.3 = 19.6 Nm I14 + 2 kgm}

Assembly of body I) Install seal (24) and ring (23) in body (161, then secure with snap ring (22). * Install the seal with the lip facing the outside. Sr Check that the snap ring is fitted securely in the groove. & Seal: Brake oil

DEW04515

DEW04517

DEW04516

DISASSEMBLY

AND ASSEMBLY

BRAKE CHAMBER

Turn over body, assemble packing (211, seat (20) and packing (191, insert ring (18), then secure with snap ring (17). Ir install the seal with the lip facing the outside. Check that the snap ring is fitted securely * in the groove. AJ& Packing: Brake oil

17 18 I! 20 21 DEW04522

Piston assembly Insert piston assembly (27) in air cylinder (25). * Coat the inside circumference of the air cylinder with grease. When inserting the piston assembly, tilt at an angle of 30”, insert about l/3, then lay the air cylinder on its side and insert the piston fully. * Check that the piston assembly moves smoothly.

Body assembly Insert spring (26) in air cylinder mount, fit Oring (34) to body assembly (161, 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). w Mounting bolt: 43.1 f 5.9 Nm (4.4 z 0.6 kgm}

Assembly of piston 1) Insert valve (13L spring (12) and seat (II) in piston (141, then secure with snap ring (IO). * Be careful to insert the spring facing in the correct direction. Check that the snap ring is fitted securely * in the groove.

DEW04519

DEW04521

30-197 0

DISASSEMBLY

BRAKE CHAMBER

AND ASSEMBLY

Assemble packing (15) to piston. * Install the packing with the lip facing the outside. & Packing: Grease (G2-LI)

DEW04523

Piston assembly Blow air into air cylinder and blow out 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. J, After inserting the pin, check that the retainer has moved back to its original place and that the pin is hidden.

DEW04524

DEW04525

Cylinder Install nut (4) and O-ring (36) on cylinder (5L screw into mount, then secure with nut. * Screw the cylinder in fully, then turn it back until the breather and bleeder are in a straight line. & Inside surface of cylinder: Brake oil D Nut: 137.3 t 29.4 Nm (14 + 3 kgm1

Sensor Fit O-ring on rod (9) and sensor (31, then install to mount. * Insert the rod until it is level with the body. w Sensor: 54.9 2 5.9 Nm 15.6 + 0.6 kgm}

Accessories Install breather (I) and bleeder (2). w Bleeder: 9.3 L 2.5 Nm IO.95 f 0.25 kgm)

30-&98

DEW04526

DISASSEMBLY

AND ASSEMBLY

DISASSEMBLY 1.

OF SLACK ADJUSTER

Bleeder Remove

SLACK ADJUSTER

2 bleeders

(2) from body (I).

Cylinder Remove mounting bolts, then disconnect (I) from cylinders (3) and (4). a

body

Cylinder has spring tension inside. Carefully remove them holding two parts together.

DEW04527

Piston 1) Remove spring (5) and O-ring (6). 2) Push out piston (7) and remove O-ring. Gently push out the piston with a rod (diameter 10 mm) when remove it. Pay attention not to give damage to screw portion with the rod.

DEW04528

‘5

DEW04529

Poppet 1)

Remove cover (8) from cylinder (4), then remove plug (9), spring (IO) and poppet (II). * Remove the poppet by air blowing through the oil hole of the cylinder. -k Hold the oil port of the cylinder by hand and pay attention not to blow air hard. Remove O-ring (12) from the poppet.

DEW04530

30- 199 0

DISASSEMBLY

SLACK ADJUSTER

AND ASSEMBLY

ASSEMBLY

OF SLACK ADJUSTER

1. Poppet 1) - i’it O-ring (12) to poppet (11). * Use new O-rings. 2) Install poppet (II), spring (IO), plug (8) and cover (8), then assemble into the cylinder.

DEW04531

Piston 1) Fit O-ring (13) to piston (7). * Use new O-rings. 2) Insert piston (7) into cylinder (4). * Confirm that the piston moves smoothly.

DEW04532

7 i

II hh

DEW04533

DEW04534

Cylinder I) Install O-ring (6) and spring (5) to cylinders (3) and (4). * Spring installation load: 117.7 N {I2 kg} * Use new O-rings.

Install cylinders (3) and (4) to body (1). m Mounting bolt: 176.5 t 19.6 Nm {I8 + 2 kgm1

Bleeder Install 2 bleeders

(2).

I 30-p

DEW04535

DEW04527

DISASSEMBLY

REMOVAL Special

OF BRAKE ASSEMBLY

tools

No. 1-r A

BRAKE

AND ASSEMBLY

Part Name

Part No. 1 792-104-3600

1 Fixture

O’ty I

Disconnect

brake tube (I).

Sling wheel wheel hub.

hub (21, remove

DEW04536

OF FINAL DRIVE

nut, then

remove

5 Ri z

DEW04537

Bearing (3) will fall out, so remove the bearing while removing the wheel hub.

&I kg

Bearing:

fblkg

Wheel

45 kg

hub: 90 kg

I 4.

DEW04538

Sling brake assembly (41, and remove mounting bolts, then remove brake assembly. * Bearing (5) will fall out, so remove the bearing while removing the brake assembly. f?lkg

Bearing:

43 kg

&I kg

Brake assembly:

380 kg

’

DEW04539

30-20 1 0

DISASSEMBLY

AND ASSEMBLY

INSTALLATION

BRAKE

OF BRAKE ASSEMBLY

Fit O-ring and raise brake assembly (41, set in mounting position, then tighten mounting bolts. & Mounting bolt: Adhesive (LT-2) w Mounting bolt: 932 + 98 Nm (95 + 10 kgm1

Install bearing

(5).

DEW04539

Fit O-ring, raise wheel hub (21, set in mounting position, then tighten mounting bolts. & Mounting bolt: Adhesive (LT-2) w Mounting bolt: 549 + 59 Nm {56 + 6 kgm}

DEW04537

Install bearing

(3).

DEW04536

Connect

brake tube (I).

Install ring gear assembly. For details, see ASSEMBLY ASSEMBLY.

OF FINAL

DRIVE

DEW04536

30-;02

DISASSEMBLY

DISASSEMBLY Special

BRAKE

AND ASSEMBLY

OF BRAKE ASSEMBLY

tools

No.

Part No.

Part Name

792-l 04-3600

Fixture

O’ty 4

Remove mounting bolts, and screw in eyebolts @ (Dia. = 16 mm, Pitch = 2.0 mm), then remove cylinder assembly (I). L&lkg

Cylinder

assembly:

140 kg

DEW04540

Disassemble cylinder as follows. 1) Screw in eyebolts @ (Dia. = 16 mm, Pitch = 2.0 mm), push in spring with bar 0, then pull out pin (2). 2) Remove spring (31, shaft (41, and washer.

DEW04541

3) 2.

Remove

Remove stopper disc (7).

DEW04542

piston (5). bolt, then remove

plate (6) and

DEW04543

DISASSEMBLY

Remove

AND ASSEMBLY

BRAKE

tool A.

DEW04546

Screw in eyebolts @ (Dia. = 16 mm, Pitch = 2.0 mm), then remove outer drum (8). kg CE?l

Outer drum: 240 kg

Knock out retainer (IO) through removal hole in inner gear (91, then remove together with floating seal (11).

Remove mounting from outer drum.

Remove

oil seal (13).

Remove

floating

bolts, then remove

hub (12)

seal (14).

DEW04549

30-io4

DISASSEMBLY

AND ASSEMBLY

ASSEMBLY Special

BRAKE

OF BRAKE ASSEMBLY

tools

No.

Part No.

792-l 04-3600

Fixture

791-585-1510

Installer

792-530-I

Push-tool

700

Part .Name

O’ty 4 I

1 1

Using tools B and BI, install floating seal (14) to hub. * When assembling the floating seal, clean the surface of the O-ring with alcohol and assemble without twisting. * Use a new part for the O-ring.

DEW04549

Install oil seal (13). * Tap the outside circumference of the oil seal with a plastic hammer to install uniformly. & Lip of oil seal: Grease (GZ-LB

DEW04550

Fit O-ring and install hub (12) to outer drum. Sr Use a new part for the O-ring. & Mounting bolt: Adhesive (LT-21 m Mounting bolt: 549 2 59 Nm I56 2 6 kgm1

Using tools B and Bl, install floating seal (11) to retainer (IO). * When assembling the floating seal, clean the surface of the O-ring with alcohol and assemble without twisting. Ir Use a new part for the O-ring.

0EW04551

30-205 0

DISASSEMBLY

AND ASSEMBLY

Fit O-ring to inner gear (91, align with dowel pin and install retainer (IO) together with floating seal (11). * When installing the retainer to the inner gear, tap the end of face of the retainer with a copper hammer to install. * Use a new part for the O-ring.

Using eyebolts @ (Dia. = 16 mm, Pitch = 2.0 mm), install outer drum (8) to inner gear. Ir Coat the sliding surface of the floating seal thinly with engine oil, and be careful not to damage the floating seal when installing the outer drum.

Using tool A, fix inner gear and outer gear. * Center the inner gear and outer gear, and tighten with tool A.

Assemble disc (7) and plate (6). Ir Align the notched teeth at 6 places around the circumference of the disc and plate when assembling.

Fit O-ring and tighten stopper bolts of disc and plate. * Use a new part for the O-ring.

30-io6

BRAKE

DEW04546

DISASSEMBLY

AND ASSEMBLY

BRAKE

Assemble cylinder as follows. I) Assemble seal rings to cylinder and piston, and set piston (5) at bottom. * Coat to each seal ring with engine oil.

Cross-sectional

DEW04724

DEW04543

2) 3)

Assemble washer, shaft (41, and spring (3) to piston from cylinder end. Screw in eyebolts @ (Dia. = 16 mm, Pitch = 2.0 mm), compress spring with bar 0, then install pin (2) in shaft.

DEW04542

DEW04541

10. Fit O-ring, then screw in eyebolts mm, Pitch = 2.0 mm),

0 (Dia. = 16 install cylinder assembly

(I). * Use a new part for the O-ring. & Mounting bolt: Adhesive (LT-2) w Mounting bolt: 549 t 59 Nm I56 + 6 kgm}

30-207 0

DISASSEMBLY

REMOVAL

SPRING

AND ASSEMBLY

OF SPRING CYLINDER ASSEMBLY

Linkage 1) Release parking brake and turn adjusting bolt (I) in counterclockwise direction, then check that there is play in linkage (2). 2) Remove pin (3) and disconnect linkage (2) from adjuster (4).

Air piping Apply parking brake and disconnect air hose (5) of spring cylinder. Check that there is no air in the spring cylin* der. After removing, fit covers to prevent dust or * dirt from entering.

Spring cylinder Remove mounting nut of spring then remove spring cylinder.

cylinder

(6),

CYLINDER

DISASSEMBLY

AND ASSEMBLY

INSTALLATION

SPRING CYLINDER

OF SPRING CYLINDER ASSEMBLY

Spring cylinder Set spring cylinder (6) in mounting position, and install. w Mounting nut: 196.1 2 19.6 Nm 120.0 2 2.0 kgm}

Air piping Connect air hose (5) to spring cylinder.

Linkage 1) Release parking brake, send air to spring cylinder, then connect linkage (2) to adjuster (4) with pin (3). 2) Turn adjusting bolt (I) to clockwise until it cannot be tightened further, turn back 180” (or 3 - 4 notches). * Adjust the linkage. For details of adjusting the linkage, see TESTING AND ADJUSTING. + Check the operation of the parking brake.

30-209 0

DISASSEMBLY

DISASSEMBLY 1.

SPRING CYLINDER

AND ASSEMBLY

OF SPRING CYLINDER ASSEMBLY

Remove ter (2).

screw, then remove

Remove

retainer

holder

(I) and fil-

(3) and nut, then remove

boot

(4). 3.

Remove

nuts (5) and (61, then remove

shaft (7).

Remove

nuts (8) and (9) from shaft (7).

Using a press, hold down piston (IO) and support (II), remove bolt (121, then release press slowly to remove support (11) and spring (13). AThere is a force of 5001 N (510 kg1 on the piston and support, so operate the press carefully.

Remove piston (IO), then remove (15) from piston

Remove

rings (14) and

rings (17) and (18) from case (16).

8 DEW04555

Push tool DEW04725

30-g 0

DISASSEMBLY

ASSEMBLY

CYLINDER

OF SPRING CYLINDER ASSEMBLY

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 rings or seals when assembling.

Install rings (18) and (17) to case (16). & Ring (17): Engine oil (EO-30CD)

Install rings (15) and (14) on piston (IO), then install in case (16). & Ring (15): Engine oil (EO-30CD)

Set spring (13) and support (I I) in position, then using a press, gradually apply pressure until bolt hole of support (11) is aligned with bolt hole of case, then install bolt. a

5 Ki d

SPRING

AND ASSEMBLY

More than 5001 N (510 kg1 of force is needed to compress the spring, so operate the press extremely carefully. Outer circumference of support: Gasket sealant

Install bolt (12). w Bolt: 137.3 t 39.2 Nm I14 2 4 kgm1

Install nuts (9) and (8) to shaft (7).

Install shaft (7) to cylinder, then install nuts (5) and (6). * Installed length L of shaft: 65 mm m Nuts (8), (6): 71.1 1 17.1 Nm I7.25 2 1.75 kgm}

Set boot (4) in position, tainer (3).

and install

Set filter (2) in position,

and install holder

nut and re-

(1).

DOW04557

30-211 0

DISASSEMBLY

PARKING BRAKE CALIPER

AND ASSEMBLY

REMOVAL

OF PARKING BRAKE CALIPER

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 put blocks under the wheels to prevent the machine from moving.

Spring cylinder 1) 2) 3)

Release parking brake and remove pin (I), then disconnect linkage. Apply parking brake, release air from spring cylinder, then disconnect air hose (2). Remove nut, then remove spring cylinder (3). * Remove the spring cylinder side in the same way.

on the right

Caliper 1) Remove

plate (4). Remove the mounting bolts, then remove cover (5). After removing the plate, remove pad

(6). Sling to prevent the caliper from falling.

Remove caliper (7). Ir Use two workers to remove the caliper. PI kg

Caliper: 40 kg

DISASSEMBLY

AND ASSEMBLY

INSTALLATION

s Ki d

PARKING BRAKE CALIPER

OF PARKING BRAKE CALIPER

Caliper I) Set caliper (7) and pad (6) in mounting position, and install plate. Insert the plate in the groove securely to * prevent the caliper from falling. * Use two workers to install the caliper and pad. Install cover (5), and tighten the mount* ing bolts. & Mounting bolt: Adhesive (LT-2) w Mounting bolt: 927 2 103 Nm (94.5 + 10.5 kgm} (width across flats: 36 mm)

Spring cvlinder ’ Set spring cylinder (3) in mounting position, and tighten nut. Install the spring cylinder so that the air * hose mount is at the top. w Nut: 196.1 = 19.6 Nm I20.0 z 2.0 kgm} 2) Connect air hose (2) to spring cylinder. 3) Release parking brake, and send air to spring cylinder, then assemble pin (I) and connect linkage. * Adjust the linkage. For details, see TESTING AND ADJUSTING.

30-2 13 0

DISASSEMBLY

AND ASSEMBLY

DISASSEMBLY 1.

Remove

PARKING BRAKE CALIPER

OF PARKING BRAKE CALIPER

snap ring (I), then pull out adjuster

(2).

DEW04560

Remove

washers

(3) and (41, and seal (5).

DEW04561

Remove

bolt, then

remove

cap (6) and gasket

(7). 4.

Remove piston from piston.

shaft (8) and thrust

Remove piston caliper (IO).

(11) and piston

bearing

(9)

seal (12) from

DEW04562

IO DEW04564

DEW04563

DISASSEMBLY

ASSEMBLY 1.

PARKING BRAKE CALIPER

AND ASSEMBLY

OF PARKING BRAKE CALIPER

Assemble piston seal (12) in caliper (IO), insert piston (I I). 6 Piston, piston seal: Grease (G2-LI)

and

IO DEW04564

Screw piston shaft (8) into piston, and install thrust bearing (9). * Be careful to install the thrust bearing facing in the correct direction. 6 Thrust bearing: Grease (G2-LI)

9 DEW04563

Fit gasket (7) and install cap (6). w Mounting bolt: 176.5 + 19.6 Nm I18 + 2 kgm1

Install seal (5) and washers (3) and (4). Ir Fit the seal securely in the groove. & Seal: Grease (G2-LII

Assemble

adjuster

(2) and secure with snap ring

(1).

DEW04562

/---i-

DEW04560

DEW04 561

30-2 15 0

DISASSEMBLY

REMOVAL PAD

AND ASSEMBLY

OF PARKING BRAKE

A 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 put blocks under the wheels to prevent the machine from moving. j, Turn the main switch ON, and release the parking brake.

Turn adjustment bolt (I) in counterclockwise direction to increase clearance between pad and disc.

Remove

Loosen mounting bolts of plate (3). * Sling to prevent caliper (4) from falling.

Move plate to side carefully so that pad does not fall, then remove pad (5). Ir When removing the front pad, first remove the rear pad and move the caliper to the front, then remove the front pad. f Remove the pad of the parking brake caliper on the right side in the same way.

cover (2).

INSTALLATION BRAKE PAD

OF PARKING

Insert pad (5) between caliper and disc. * The pad is new, so turn the adjustment bolt further in the counterclockwise direction to increase the clearance. Ir Raise caliper (4) slightly and the pad can be inserted smoothly. Sr Sling the pad with wire to prevent it from falling.

Install plate (3). * Align the caliper and groove of the pad correctly with both plates. & Plate mounting bolt: Adhesive (LT-21 w Plate mounting bolt: 927 f: 103 Nm 194.5 + 10.5 kgm1 (width across flats: 36 mm)

Turn adjustment bolt (I) in clockwise direction to adjust clearance between pad and disc. Ir For details of adjustment procedure, see TESTING AND ADJUSTING.

PARKING

BRAKE PAD

DISASSEMBLY

AND ASSEMBLY

REMOVAL

HYDRAULIC TANK AND FILTER CASE

OF HYDRAULIC

TANK AND FILTER CASE

To keep the hydraulic circuits clean and to protect the hydraulic equipment, be careful of the following points when disassembling or assembling. Before disassembling, wash the machine. Be particularly careful to completely clean the area that is to be disassembled. Do not let dirt or dust get into the hydraulic circuits when disassembling or assembling. Carry out thorough flushing of the parts, and be particularly careful to do this thoroughly for the circuits or parts that have failed. When disassembling or after flushing, always mask the openings of the piping or hydraulic equipment completely.

Draining oil

z & g

Remove drain plug (I) and loosen plug (21, then drain hydraulic oil. 2.

Hydraulic

550 e

ROPS canopy Sling ROPS canopy, and remove mounting then lift off. &I kg

oil: Approx.

ROPS canopy:

bolts,

1260 kg

Floor frame, ladder (3), and remove I) Sling right floor frame mounting bolts, then lift off. Sr Be careful to maintain the balance of the lifting tool. * Remove the mounting bolts at the bottom of the floor frame cover. & kg

Right floor frame:

149.6 kg

2) Sling ladder (41, and remove mounting

bolts,

then lift off. & kg

Ladder: 44.6 kg

30-2 17 0

DISASSEMBLY

HYDRAULIC TANK AND FILTER CASE

AND ASSEMBLY

Hydraulic piping I) Disconnect tube (5) between hydraulic tank and hydraulic pump from hydraulic tank. 2) Disconnect tube (6) between hydraulic tank and PPC pump from hydraulic tank.

Disconnect tubes (7) and (8) between hydraulic tank and diverter valve from hydraulic tank. -)r Loosen the clamps of the tubes. Disconnect return tube (9) between main control valve and hydraulic tank from hydraulic tank. Disconnect return tube (IO) between oil cooler and hydraulic tank from filter case. * Disconnect air hose (II) from the hydraulic tank. DEW04570

Hydraulic tank, filter case Sling hydraulic tank and filter case (121, and remove mounting bolts (13) and (141, then lift Off. *

Be careful not to catch the tubes on the tank. Raise the hydraulic tank slightly, then lift off to the outside of the machine.

r+ kg

Hydraulic

tank, filter case: 892 kg

14 DEW04573

DISASSEMBLY

AND ASSEMBLY

INSTALLATION 1.

OF HYDRAULIC

HYDRAULIC TANK AND FILTER CASE

TANK AND FILTER CASE

Hydraulic tank, filter case Set hydraulic tank and filter case (12) in mounting position, and tighten mounting bolts (13) and (14). Ir Be careful of the hydraulic piping when installing. m Mounting bolts (13) and (14): 927 = 103 Nm (94.5 = 10.5 kgm1 (width across flats: 36 mm)

DEW04575

Hydraulic piping 1) 2)

3) 4)

Install return tube (IO) between oil cooler and hydraulic tank to filter case. Install return tube (9) between main control valve and hydraulic tank to filter case. Install air hose (11) to the hydraulic tank. *

Install tube (6) between hydraulic tank and PPC pump to hydraulic tank. Connect tube (5) between hydraulic tank and hydraulic pump to hydraulic tank.

Connect tubes (7) and (8) between hydraulic tank and diverter valve to hydraulic tank. Sr Tighten the clamps of the tubes. Ir Check that the O-rings at the connection are fitted in the grooves.

DEW04570

DISASSEMBLY

HYDRAULIC

AND ASSEMBLY

Floor frame, ladder 1) Raise right floor frame (3) and set in mounting position, then tighten mounting bolts. 2) Raise ladder (4) and set in mounting position, then tighten mounting bolts.

ROPS canopy Raise ROPS canopy and set in mounting position, then tighten mounting bolts. w Mounting bolts: 2794 t 294 Nm I280 t 30 kgm1 (width across flats: 35 mm)

Refilling with oil I) Tighten plugs (I) and (2) and add hydraulic oil through oil filler to the specified level. 2) Before starting engine, bleed air from steering pump, switch pump and hydraulic pump. Sr For details, see TESTING AND ADJUSTING. * Run the engine to circulate the oil through the system. Then check the oil level again. I&

Hydraulic

30-$20

oil: Approx.

550 a

TANK AND

FILTER CASE

DEW04567

DISASSEMBLY

AND ASSEMBLY

REMOVAL

HYDRAULIC PUMP

OF HYDRAULIC

PUMP

Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Operate the steering wheel and the control levers several times to release the remaining pressure in the hydraulic piping. Then drain the oil from the hydraulic tank.

Cover Remove

transmission

inspection

DEW04577

cover (1).

Hydraulic pump the following hydraulic piping I) Disconnect from pump. . Tube (2) between hydraulic tank and hydraulic pump . Hoses (3) and (4) between hydraulic pump and manifold . Tube (5) between hydraulic tank and pump for servo . Drain hose (6) between hydraulic pump and hydraulic tank . Hoses (7) and (8) between hydraulic pump servo valve and ES valve. * Remove the clamps of the tubes. 2) Sling hydraulic pump (91, and remove mounting bolts, then lift off. * Be careful not to damage the O-ring on the mounting surface when lifting off. & kg

Hydraulic

pump:

150 kg

30-22 1 0

DISASSEMBLY

AND ASSEMBLY

INSTALLATION 1.

HYDRAULIC

OF HYDRAULIC

PUMP

Hydraulic pump I) Raise hydraulic pump (9) and set in mounting position, then tighten mounting bolts. * Fit the O-ring on the mounting surface securely in the groove.

Connect

the following

hydraulic

piping

pump. . Tube (2) between hydraulic tank and hydraulic pump . Hoses (3) and (4) between hydraulic pump and manifold . Tube (5) between hydraulic tank and pump for servo . Drain hose (6) between hydraulic pump and hydraulic tank . Hoses (7) and (8) between hydraulic pump servo valve and ES valve. * Install the clamps of the tubes. 2.

Cover Install transmission

inspection

cover (I).

DEW04577

Refilling with oil I) Add hydraulic oil through hydraulic filler to the specified level. Q 2)

Hydraulic

tank: Approx.

tank oil

550 $

Before starting engine, bleed air from steering pump, switch pump, and hydraulic pump. * For details, see TESTING AND ADJUSTING. * Run the engine to circulate the oil through the system. Then check the oil level again.

3o-i22

DISASSEMBLY

REMOVAL

AND ASSEMBLY

SWITCH

OF SWITCH PUMP

G 0 1.

Cover Remove

PUMP

transmission

inspection

DEW04577

cover (1).

Switch pump I) Disconnect the following hydraulic piping from pump. Tube (2) between hydraulic tank and switch pump . Hoses (3) and (4) between switch pump and manifold . Drain hose (5) between switch pump and hydraulic tank * Remove the clamps of the tubes. l

DEW04580

Sling switch pump (61, remove mounting bolts, then lift off. * Be careful not to damage the O-ring on the mounting surface when lifting off. r&lkg

Switch

pump:

145 kg

30-223 0

DISASSEMBLY

AND ASSEMBLY

INSTALLATION

SWITCH

PUMP

OF SWITCH PUMP

1. Switch pump I) Raise switch pump (6) and set in mounting position, then tighten mounting bolts. * Fit the O-ring on the mounting surface securely in the groove.

Connect

the following

hydraulic

piping

pump. . Tube (2) between hydraulic tank and switch pump . Hoses (3) and (4) between switch pump and manifold . Drain hose (5) between switch pump and hydraulic tank. * Install the clamp of the tube.

Cover Install transmission

inspection

cover (I).

DEW04577

Refilling with oil I) Add hydraulic oil through hydraulic filler to the specified level. %& 2)

Hydraulic

tank: Approx.

tank oil

550 Q

Before stating engine, bleed air from steering pump, switch pump, and hydraulic pump. * For details, see TESTING AND ADJUSTING. * Run the engine to circulate the oil through the system. Then check the oil level again.

30-i24

DISASSEMBLY

PISTON

AND ASSEMBLY

PUMP

DISASSEMBLY OF PISTON PUMP ASSEMBLY (HPVOSO + 090, HPF076 + 071) Special

No.

tools

Part No.

Part Name

Q’ty

790-501-5000

Unit repair stand

790-901-2110

Bracket

790-901-1331

Plate

790-345-I

Plate

020

Preparatory work l Set pump assembly

1 1

in tool A.

(HPF076+071)

DEW04726

ES valve assembly, hose (HPV 90 + 90 only) I) Remove ES valve assembly (2). 2) Remove hoses (3) and (4).

(HPV090+090)

DEW04727

Rear pump assembly 1) Sling rear pump assembly (7). 2) Remove 4 nuts at front pump assembly end, then remove rear pump assembly (7). Ir Disconnect at the middle of the end caps. With gear pump (HPV 90 + 90 only) *

DEW047 28

30-225

DISASSEMBLY

AND ASSEMBLY

PISTON PUMP

DISASSEMBLY OF PUMP * The font pump can be further disassembled this point, but for rear pump assembly fore disassembling install to plate A3.

from (7), be-

DEW04729

DEW04730

Impeller I) Remove bolt (151, then remove shim (17). 2) Remove impeller (8).

plate (9) and

DEW04731

Servo valve assembly (HPVOSO + 090 only) Remove servo valve assembly. * Remove the cover of the HPF pump.

End cap I) 2) 3) 4)

Remove

snap ring (131, then remove washer

(14). Remove inner race (20) and bearing (21). Remove end cap (23). Remove valve plate. * This is stuck to the cylinder block, so be careful not to damage it when levering it

DEW04732

Off.

Note: When reusing the cylinder block and valve plate, keep them in a set. 5) Remove outer race and bearing from end cap.

DEW04733

30-i26

DISASSEMBLY

PISTON PUMP

AND ASSEMBLY

Valve plate Remove valve plate (45). Ir Be careful not to drop the valve plate.

Pump sub-assembly Support cylinder block and shaft, then pump sub-assembly (49).

remove

DEW04735

Servo piston

1) Using forcing screw @ (Dia. = 10 mm, Pitch

1.5 mm) and nut 0, remove cap (27) and ihim (28). Remove spring (31). * The forcing screw and spring are for (HPV 90 + 90) only.

DEW04737

3) 4)

Repeat Step 1) and remove cap (29) and shim (30). Remove servo piston (32). * The servo pistons used for the front and rear are not the same part, so mark them to distinguish them. * On the HPF pump, there is a spacer on the right side as seen from the rear of the pump.

DEW04738

30-227 0

PISTON PUMP

DISASSEMBLY

AND ASSEMBLY

DISASSEMBLY

OF SUB PUMP ASSEMBLY

Cylinder, shaft

1) Set pump sub-assembly

(49) in a vice. Be careful not to damage the flange surface of the cradle. Remove slider (38) and cylinder block (35). Ir

Screw in forcing screws, and remove housing (40) and shim. * Check the number and thickness of the shims, and keep in a safe place. The charging pump is installed to the rear pump, so collar (IO) assembled in the pilot pump must be removed. (HPVOSO + 090 only) Remove the cover of the HPF pump.

DEW04741

Knock out drive shaft piston end to remove.

assembly

DEW04742

(41) from

L-l

10. Piston Remove 4 screws (56), then remove retainer bearing (571, shoe retainer (58L spacer (59), and piston (60).

DEW04743

DEW04745

3o-;28

DEW04744

DISASSEMBLY

WHEN

REUSING

AND ASSEMBLY

PUMP

PISTON

PUMP

DRIVE SHAFT AND CYLIN-

DER BLOCK l

Removal of bearing from pump drive shaft. 1) Remove snap ring (55), then remove washer (54), inner race A (53) and bearing (68).

Using bearing race B (52).

race puller 0,

remove

inner

DEW04746

L 52

DEW04747

Disassemble 1) Remove

cylinder block snap ring (34).

DEW04746

Remove cylinder

washer (36) and spring block (35).

(37) from

3.5

DEW04749

30-229 0

DISASSEMBLY

PISTON

AND ASSEMBLY

PUMP

ASSEMBLY OF PISTON PUMP ASSEMBLY (HPVOSO + 090, HPF076 + 071) Special

790-501-5000

Unit repair stand

1 790-901-1331

1 Plate

I 790-345-1020

I Plate

Precautions when assembling 1) Clean all parts and remove any burrs. 2) Coat all rotating parts and sliding parts with engine oil (EOIO-CD) before installing. * Always use the following parts in sets. i) Cradle and rocker arm. ii) Cylinder block and valve plate

tools

7gO-445-3400

Gauge (for min. swash plate angle)

1 1

HPV

pump. However, explanation is given for the rear pump in all places where there is any difference.

Note: The assembly procedure is basically the same for both the front and rear, so explanation is given below for the front

1 796-720-2220 1Socket

I 796-730-2120

I Screwdriver

1 795-630-1803

1Torque wrench set 1

I 796-720-3800

1Wrench

Cradle and piston assembly 1) Fit dowel pin, and install rocker cam stopper (64) to cradle (65). & Stopper bolt: Adhesive (LT-2) m Stopper bolt: 13.2 f 1.5 Nm Il.35 2 0.15 kgm}

Fit dowel pin to cradle, set rocker cam (62) in position, then install plate (63). * The side of the rocker cam with the groove faces the oil hole side of the cradle. & Plate bolt: Adhesive (LT-2) m Plate bolt: 30.9 t 3.4 Nm I3.15 + 0.35 kgm} * After tightening the bolts, check that the rocker cam moves smoothly.

DEW04750

,63

DEW04751

30-;30

DISASSEMBLY

AND ASSEMBLY

PISTON PUMP

Select the spacer thickness as follows. i) Assemble shoe retainer (58) to piston (601, put on the leve’l block, then measure distance @ to top surface of shoe retainer. ii) Select spacer thickness as follows. Spacer thickness = distance @ + (0.03 to 0.07 mm) * There are three types of spacers.

DEW04752

Install spacer (59) selected in Step 31-i) and ii), then install piston (601, shoe retainer (58) and retainer bearing (57). & Bearing retainer bolt:

Adhesive (LT-2) w

Bearing retainer bolt: 13.2 t 1.5 Nm II.35

= 0.15 kgm}

Hold rocker cam in position, pull piston (60) with a force of 19.6 to 29.4 N (2 to 3 kg}, and measure clearance @ between piston shoe and rocker cam. Measure the clearance with the rocker * cam at position a or b, and measure for all nine pistons. * Clearance: 0.03 - 0.07 mm + If clearance @ is not within the standard range, adjust the spacer again.

DEW04753

DEW04754

Pull

Rocker cam

Retainer bearing

DEW04756

30-231 0

DISASSEMBLY

AND ASSEMBLY

PISTON

Shaft assembly 1) Press fit inner race B (52) (inside 45 mm) to shaft (41).

Fit bearing

(681, then

install

PUMP

diameter:

inner

race A

(53).

I 3)

Select washer as follows. i) Install snap ring (55). * Check that the snap ring is not deformed or damaged, and correct any burrs before installing. Install with the cut inside part facing the opposite direction from the inner race. ii) Using a feeler gauge, measure clearance @ between snap ring (55) and inner race. Ir Push the snap ring securely into the groove on the opposite side from the inner race. iii) Install selected washer. Washer thickness = clearance @ + (0 to 0.1 mm) * Check that there is no play between the *

DEW04756

DEW04759

mm, mm

DEW04746

DISASSEMBLY

AND ASSEMBLY

PISTON

PUMP

Press fit drive shaft (41) to cradle (65).

DEW04760

Install oil seal (50) to housing (40). & Lip of oil seal: Grease (G2-LI)

DEW04761

Fit O-ring and shim (391, and install housing (40) to cradle. m Mounting bolt: 30.9 r 3.4 Nm j3.15 = 0.35 kgm1 Ir Wind the shaft with tape to prevent damage to the oil seal lip surface. * Install cover to rear pump. m Cover mounting bolt: 110.3 z 12.3 Nm (Il.25 = 1.25 kgm1

DEW04762

For the rear pump, do not install the charging pump at this point. If the charging pump is installed, it is impossible to stop the shaft from turning when adjusting the end play of the bearing.

30-233 0

DISASSEMBLY

PISTON PUMP

AND ASSEMBLY

Select shim for housing as follows. i) Push drive shaft (41) in completely, and measure dimension a of end face of bearing outer race and cradle. ii) Measure dimension b of housing (40).

DEW04763

DEW04764

iii) Select shim to give following thickness. * Shim thickness: b - a = c + 0.05 to 0.15 mm. + Therefore, there is a clearance of 0.05 to 0.15 mm at portion d.

For the rear pump, install collar (66) to charging pump (671, and measure distance @ of the collar. (HPVOSO + 090 only) For the HPF pump, measure the dimensions of the collar of the cover.

DEW04766

DEW04767

Cylinder block Align with drive shaft and piston, and install cylinder block (35). * Always keep the cylinder block and valve plate in a set, or make match marks to prevent mistakes when assembling. Ir Install the spring and washer inside the cylinder block after adjusting the preload.

30-z34

DEW04768

DISASSEMBLY

AND ASSEMBLY

PISTON

Servo piston (HPVOSO + 090 only) I) Install pump case (33) in tool A. 2) Install servo piston (32). The servo pistons used for the front and * rear are not the same part, so be careful not to make any mistake when assembling them.

PUMP

(Lx<LJ from 0 The length the center is different on the side with the spring and on the side with no .sDrina

DEW04775

Adjust stroke of servo piston as follows. i) Align tool B with dowel pin and groove g for servo valve arm of servo piston, and set tool B in position. * As seen from the rear of the pump, the right side (the top when mounted on the machine; the side with the spring) is the maximum swash plate angle side. (maximum flow side) Note: For the rear pump, use the same tool turned over. ii) Measure distance @ between servo piston and case. iii) Measure distance @ of cap (29). iv) Select shim thickness as follows. @ - @ = @ + 0.05 mm -f After adjusting the shim, put it in a set with the cap.

Dowel

DEW04773

Dowel Pin

servo valve mountino

DEW04770

Gauge

Servo valve mauntino

Clearance

Servo

piston

DEW04776

Servo Piston

DEW04774

30-235 0

DISASSEMBLY

AND ASSEMBLY

PISTON PUMP

To adjust the minimum swash plate angle, replace tool B with the tool for the minimum angle, and repeat the same procedure as in Steps i) to iv). Note that the case faces in the opposite direction from the maximum swash plate angle side.

DEW04777

Servo piston (HPF pump only) I)

Install servo piston (32). * Install the servo piston so that the shallow notch on the inside (the side to fit the spring of the HPV pump) is on the left as seen from the rear of the pump. Position the servo piston as follows. i) Align with the dowel pin and groove g of the servo piston, then set tool B in position. * The center moves to the left as seen from the rear of the pump.

Measure distance @ between servo piston and case. iii) Measure distance @ of cap (29). iv) Select shim thickness as follows. @ - @ = @ f 0.05 mm Ir After adjusting the shim, put it in a set with the cap. Ir Assemble a spacer on the right side as seen from the rear of the pump, then measure. When measuring, press the spacer securely to the piston.

DEW04770

DEW04771

ii)

Dowel Pin

Gauge

Servo

Servo valve

:--\

DEW04773

DEW04j72

Dowel Pin

Gauoe

Servo valve mountine surface

piston DEW04776

DEW04774

DISASSEMBLY

AND ASSEMBLY

PISTON

Pump sub-assembly 1) Install slider (38) and O-ring. Fit the O-ring in the pilot portion and the * joint portion. 2) Install 2 joints on case. Install with the small hole facing the cra* dle side. 3) Align the slider with the servo piston, and install pump sub-assembly (49). Be careful that the O-ring is not caught. * Also, be careful not to drop the cylinder. m Mounting bolt: 112.8 + 9.8 Nm Ill.5 + 1.0 kgm} Ir Set the rear pump on a separate plate and assemble. Adjusting axial play of bearing I) Install the following parts in the end cap. Install bearing (48) (outside diameter: 42 i) mm). & Bearing mounting surface: Grease (G2-LI) ii) Install outer race (46) to end cap (42). * Be careful not to damage the rolling surface of the roller.

PUMP

DEW04778

a DEW04780

DEW04781

iii) Coat with engine oil, align with pin and bearing, and install valve plate (45). iv) Install joint (44). * lnstal with the small hole facing the case side. Install the part with only one joint to the suction port side.

DEW04782

Install end cap (42) to case (33). w Mounting bolt: 68.7 f 4.9 Nm (7.0 z 0.5 kgm} m Mounting nut: 235.4 z 19.6 Nm I24 + 2 kgm} w Stud bolt: 132.4 + 14.7 Nm 113.5 + 1.5 kgm} (Tighten the nut of the stud bolt.)

DISASSEMBLY

PISTON

AND ASSEMBLY

Install bearing

(21) and inner race (20).

I 4) 5)

PUMP

DEW04184

Assemble one of 5 types of washer (14), then install snap ring (13). Select washer so that clearance @ between snap ring and washer is 0 - 0.1 mm.

DEW04785

Set dial gauge @ on case, move shaft backwards and forwards, and measure axial play. * Axial play: 0.1 - 0.3 mm Sr If the axial play is not within the standard range, select the shim again. After completing measurements, remove end cap. * When removing the end cap, be careful not to drop the valve plate.

DEW04786

For the rear pump, after tightening the bolts, install the charging pump to hold the cradle bearing in position. Then set dial gauge @ on the end cap side, and measure. HPVOSO + 090 only

DEW04787

30-238

DEW04788

DISASSEMBLY

AND ASSEMBLY

PISTON PUMP

End cap

1) Assemble

spring (37) and washer (36) in cylinder block (35), then install snap ring (34). * Be careful not to damage the valve plate contact surface. Install end cap. (for details, see Step 6-I) iii), iv), 6-2))

DEW04789

DEW04790

Install bearing (211, inner race (201, spacer (18), boss (16), shim (151, and plate (14), then tighten bolts (13). & Bolt: Adhesive (LT-21 m Bolt: 68.7 = 4.9 Nm I7.0 + 0.5 kgml

DEW04791

For the rear pump, fit the O-ring, then install charging pump assembly (40). (HPVOSO + 090 only) w Mounting bolt: 112.8 + 9.8 Nm Ill.5 + 1.0 kgml

DEW04793

Servo piston cap 1) Install spring (31). (HPVOSO + 090 only) * Install the pump on the right as seen from the rear (the top when mounted on the machine). (The rear pump is also the same.)

DEW04794

30-239 0

DISASSEMBLY AND ASSEMBLY

2) 3)

Fit shim

(30)

and

O-ring,

PISTON PUMP

then

install

cap

(29). Fit shim (28) and O-ring, then using forcing screws @ (Dia. = 10 mm, Pitch = 1.5 mm) and nut 0, install cap (27). + Use the forcing screw for the HPV 090 + 090 only. * Do not change the combination of cap and shim when installing. m Mounting bolt: 68.7 L 4.9 Nm I7.0 2 0.5 kgml

=-FF?--ig

DEW04795

9. Servo valve assembly (HP090 + 090 only) Fit O-ring, align arm with servo piston, then install servo valve assembly (12). * Be careful not to let the O-ring drop out. Tighten the bolts gradually on opposite sides in turn. w Mounting bolt: 30.9 2 3.4 Nm 13.15 z 0.35 kgml

DEW04797

10. Impeller I)

Install impeller (8) to coupling (26). & Mounting bolt: Adhesive (LT-2) m Mounting bolt: 4.9 + 0.5 Nm IO.5 2 0.05 kgml

30-240

DISASSEMBLY

AND ASSEMBLY

Adjust clearance between impeller and end cap portion a as follows. Measure thickness b of plate (9). i) ii) Assemble plate (9) to coupling (261, and install impeller. * Check that impeller and end cap portion a are in contact. iii) Measure dimension c from end face of coupling to plate (9). iv) Measure dimension d from end face of coupling to shaft (41). VI Use measured values d, c, and b as follows to select shim. . d - (c + b) + (0.5 f 0.1 mm = shim thickness vi) Assemble shim selected in Steps i) - v), then install impeller (8). & Mounting bolt: Thread tightener (LT-2) m Mounting bolt: 66.2 + 7.4 Nm (6.75 = 0.75 kgm} vii) Note clearance @ between impeller and end cap. * Clearance 0: 0.5 + 0.1 mm * If the clearance is not within the standard value, adjust the shim again.

Check interference of impeller (8) and rear end cap as follows. i) Measure dimension of end face of rear end cap to end face of front end cap portion e. protrusion dimension f of ii) Measure impeller vane from front end cap. iii) Check that measured dimension is e > f. * If the above dimension is f c e, there is no clearance at portion g, so the impeller vane will contact the rear end cap at the time of assembly. To prevent this, repeat the procedure at step IO-21 and adjust the shim (17) again.

PISTON

end

PUMP

CBP

Front

DEW04800

30-241 0

DISASSEMBLY

4) 5)

AND ASSEMBLY

PISTON

PUMP

Install selected spacer (IO) to rear pump. Fit selected spacer (9) to front pump, then install impeller (8).

DEW04801

DEW04802

11. Rear pump assembly 1) Install-O-rings to-front and rear end caps. 2) Raise rear pump assembly (71, align spline, and install. w Mounting nut: 235.4 + 19.6 Nm I24 = 2 kgml w Stud bolt: 132.4 + 14.7 Nm 113.5 + 1.5 kgm} Ir With gear pump (HPVOSO + 090 only)

DEW04728

12. ES valve assembly, hose (HPVOSO + 090 only) 1) Fit O-ring and install ES valve assembly (2). 2) Install hoses (3) and (4)

(HPV090+090) 2.

DEW04727

After completion of assembly, check the quality of the parts. After completing the assembly of the pump assembly, use a test stand (A type or C type) to check the quality. For details of the procedure for checking quality, see TESTING METHODS.

(HPF076+071)

30-;42

DEW04726

DISASSEMBLY

AND ASSEMBLY

PISTON PUMP

CHECKING CONTACT BETWEEN CYLINDER BLOCK AND VALVE PLATE, AND ROCKER CAM AND CRADLE 1.

Checking contact between valve plate

Cylinder block

Centering tool

cylinder block and

1) Make a centering

tool for the cylinder block and valve plate. + The tool can be made of a soft material such as plastic or bakelite. Remove grease from the parts to be checked. -)r Do not wipe with a cloth. Set the tool in position, and coat the cylinder block side with inspection paint. Ir Apply the paint thinly. Put the valve plate on top, push with a force of 39.2 to 49.0 N (4 to 5 kg), and rotate 2 to 3 times. Remove the valve plate, transfer the contact surface to tape, and check the contact surface. The standards follows.

for the contact surface are as

DEW04803

Valve Plate

Cylinder block DEW04804

30-243 0

DISASSEMBLY

AND ASSEMBLY

PISTON PUMP

Checking contact between rocker cam and cradle 11 Remove grease from the parts to be checked. * Do not wipe with a cloth. 2) Set the tool in position, and coat the cradle side with inspection paint. * Apply the paint thinly. 3) Put the rocker cam on top, push with a force of 39.2 to 49.0 N (4 to 5 kg), and move 2 to 3 times from the stopper contact position to the maximum angle. 4) Remove the rocker cam, transfer the contact surface to tape, and check the contact surface. Ir

The standards follows.

HPVOSO *

for the contact surface are as

Min. 80%

Min. 50%

If there is no contact at the center but only at the outside, the contact is no good.

DEW04805

Reference: If the contact is not within the contact standard value, when carrying, always lap both parts together. * Parts with scratches cannot be reused.

DISASSEMBLY

REMOVAL

AND ASSEMBLY

PPC VALVE

OF PPC VALVE

To keep the hydraulic circuits clean and to protect the hydraulic equipment, be careful of the following points when disassembling or assembling. . Before disassembling, wash the machine. Be particularly careful to completely clean the area that is to be disassembled. . Do not let dirt or dust get into the hydraulic circuits when disassembling or assembling. . Carry out thorough flushing of the parts, and be particularly careful to do this thoroughly for the circuits or parts that have failed. When disassembling or after flushing, always mask the openings of the piping or hydraulic equipment completely.

Loosen the filler cap to remove the pressure in the hydraulic oil tank, and repeat shifting the operation lever for the work equipment between tilt and neutral 40 times or more to remove the remaining pressure in the accumulator and the pipings. -

Cover Remove cover at rear of cab and cover (1) of console box on right side of operator’s seat.

Hydraulic piping Disconnect the following hydraulic pipings from PPC valve (2). . Hose between PPC valve (P4) and main control valve (PBI) (Colored “red”) . Hose between PPC valve (P2) and main control valve (PAI) (Colored “blue”) . Hose between PPC valve (P3) and main control valve (PA2) (Colored “yellow”) . Hose between PPC valve (PI) and main control valve (PB2) (Colored “green”) . Hose between PPC valve (P) and accumulator (Colored “white”) . Hose between PPC valve (T) and drain * Cover hoses with blind plugs to prevent dust in hoses.

i; Ki z

DGW04583

DISASSEMBLY

PPC VALVE

Linkage Remove separate

AND ASSEMBLY

cotter pin and linkage (4).

PPC valve 1) Remove 2) Sr

loos&

lock nut (3) to

bolt (7), then remove plate (5), seat (6) and PPC valve (2). Remove mounting bolt (8) of PPC valve (21, then remove PPC valve from the plate. Work space is narrow. Pay attention for the above works.

30-i46

DISASSEMBLY

AND ASSEMBLY

INSTALLATION

PPC VALVE

OF PPC VALVE

PPC valve 1) Install PPC valve (2) to plate (5). 2) Install sheet (6) to PPC valve (2), set it on the right console box and tighten with bolt (7). Ir On the mounting, pay attentions to the direction of the PPC valve. + When install bolt (7) to plate (51, secure cushion and washer being set before tightening the bolt.

Linkage Set linkage (4) on the portion to be mounted and tighten lock nut (3) to fix it with cotter pin. * Refer to TESTING AND ADJUSTING for linkage adjustment.

Hydraulic piping Connect hose to PPC valve (2). Connect hose between PPC valve (PI) and main control valve (PB2) (Colored “blue”) Connect hose between PPC valve (P2) and main control valve (PAI) (Colored “blue”) Connect hose between PPC valve (P3) and main control valve (PA21 (Colored “yellow”) Connect hose between PPC valve (P4) and main control valve (PBI) (Colored “red”) . Connect hose between PPC valve (PI and accumulator (Colored “white”) [%I Connect hose between PPC valve (T) and drain m Hose tightening torque: 90.7 + 12.2 Nm 19.25 + 1.25 kgm} QEEI Hose tightening torque: [marked with %I 152.0 t. 39.2 Nm (15.5 t 4.0 kgm} l

& & ;:

Cover Install cover at rear of cab and cover (I) of console box on right side of operator’s seat.

Refilling with oil Add hydraulic oil through fied level.

oil filler to the speci-

DISASSEMBLY

PPC VALUE

AND ASSEMBLY

DISASSEMBLY ASSEMBLY

OF PPC VALVE

1. Remove

bolt (I), then remove

plate (2).

Remove

seal (3), then remove

collar (4).

Remove

piston (5).

Remove

piston assembly

Disassembly of piston assembly Remove the following parts from piston assembly (6). 1) Push down 2)

retainers

(6) from

body (17).

(8), and remove

collar

(7). Remove retainers (8), main spring (9), spring (IO), shim (II), and piston (12).

Remove

snap ring (13).

Remove retainer from body (17).

ASSEMBLY ASSEMBLY

(14), spring (15), and valve (16)

OF PPC VALVE

Assembly of piston assembly Assemble the following parts to piston (12). 1) Assemble shim (II), spring (IO), and main spring (9). 2) Push down retainer (8), and install collar (7).

Assemble valve (16), spring (14) to body (17).

Install snap ring (13).

Assemble

piston assembly

(15),

and retainer

(6) to body (17).

Install piston (5), then install collar (4) and seal (3).

Align with dowel pin, and install plate (2), then install bolt (I). w Bolt: 44.1 + 4.9 Nm 14.5 + 0.5 kgm1

30-i48

DISASSEMBLY

REMOVAL

AND ASSEMBLY

To keep the hydraulic circuits clean and to protect the hydraulic equipment, be careful of the following points when disassembling or assembling. . Before disassembling, wash the machine. Be particularly careful to completely clean the area that is to be disassembled. . Do not let dirt or dust get into the hydraulic circuits when disassembling or assembling. l Carry out thorough flushing of the parts, and be particularly careful to do this thoroughly for the circuits or parts that have failed. . When disassembling or after flushing, always mask the openings of the piping or hydraulic equipment completely.

Cover Remove

CONTROL

VALVE

OF MAIN CONTROL VALVE

Fi ;:

MAIN

cover (1) from the front frame.

Hydraulic piping Disconnect the following hydraulic piping from main control valve. . Hoses (IA) and (2) between steering demand valve and main control valve. Disconnect them on the side of the main control valve. . Hoses (3) and (4) between main control valve and bucket cylinder. Disconnect them on the side of the main control valve. . Tubes (7) between main control valve and the hydraulic oil tank. Disconnect them on the side of the main control valve. * Remove the clamp before removing the tube. l Tubes (5) and (6) between main control valve and the lift cylinder. Disconnect them on the side of the main control valve. * Remove the clamp before removing the tube. Ir Cover pipings disconnected with blind plugs to prevent dust in them.

30-249 0

DISASSEMBLY

MAIN CONTROL VALVE

AND ASSEMBLY

PPC piping Disconnect the following PPC pipings from the main control valve. l Tubes (8) and (9) between PPC valve and the dump spool piston l Tubes (IO) and (11) between PPC valve and the lift spool piston . Hose (12) between main control valve and the hydraulic oil tank * Cover pipings disconnected with blind plugs to prevent dust in them. * Attach tag plate and others to tubes disconnected to distinguish attaching positions.

I 4.

-”

DEW04593

Main control valves Screw eyebolts into main control valves, remove mounting bolts, then raise main control valves (13) and (14) and remove to outside of frame. Main control valve: *

181 kg

When raising the valve, be careful not to hit the valve against the frame. Also be careful not to get your fingers caught. DEW04594

I II

DEW04595

DISASSEMBLY

INSTALLATION 1.

MAIN CONTROL VALVE

AND ASSEMBLY

OF MAIN CONTROL VALVE

Main control valves Using eyebolts, raise main control valves (13) and (14) on mounting plate inside frame, then tighten mounting bolts. * Tighten the mounting bolts temporarily. Tighten them fully after installing the PPC piping.

DEW04595

‘\PJU

DEW04593

PPC piping Connect the following PPC pipings to main control valve. . Hose (12) between main control valve and hydraulic oil tank Tubes (IO) and (II) between PPC valve and lift spool piston . Tubes (8) and (9) between PPC valve and dump spool piston l

DEW04592

30-25 1 0

DISASSEMBLY

AND ASSEMBLY

Hydraulic piping Connect the following hydraulic pipings to main control valve. l Tube (7) between main control valve and hydraulic oil tank. Tubes (5) and (6) between main control valve l and lift cylinder. Tubes (3) and (4) between main control valve l and dump cylinder. Ir Set clamps for fixing tubes. . Hoses (IA) and (2) between steering demand valve and main control valve. Ir Use new O-rings for connecting tubes and hoses.

Cover Install cover (I) to front frame.

Refilling with oil Add hydraulic oil through hydraulic tank oil filler to the specified level. Ir Before starting engine, bleed air from hydraulic pump. * Run the engine to circulate the oil through the system. Then check the oil level again.

Air bleeding Conduct air bleeding in the brake system. * For details, see TESTING AND ADJUSTING.

MAIN

CONTROL

VALVE

DISASSEMBLY

AND ASSEMBLY

DISASSEMBLY

MAIN CONTROL VALVE

OF MAIN CONTROL VALVE ASSEMBLY

-.L

40 /

DEW04

596

DISASSEMBLY

Removal

AND ASSEMBLY

of selector

MAIN

CONTROL

VALVE

valve assembly

Ii 2)

1) Remove main relief valve assembly (19). 2) Loosen nut (20), then remove holder (21). 3)

4) 5)

z Ki d

Remove nut (21) from holder (21), then remove screw (23), retainer (24), spring (25), and poppet (26). Remove seat (27) and backup ring (28) from sleeve (29). Remove snap ring (30), then remove valve (31), spring (32) and backup ring (33). * If there is any defect in sleeve (29) or valve (31), replace the whole assembly.

Safety valve assembly (34) with suction valve Remove safety valve assembly (34). * The safety valve cannot be adjusted after installing on the machine, so do not disassemble it.

Suction valve assembly (351 Remove suction valve assembly

Check valve assembly (36) Remove plate (37), then remove valve (39).

(35).

spring (38) and

Unload valve assembly (40) Remove flange (41), then remove seal (43) and valve (44).

spring

(42),

Remove

valve

body

plugs

(45) and

(46) from

(47).

30-255

DISASSEMBLY

AND ASSEMBLY

ASSEMBLY

MAIN CONTROL VALVE

OF MAIN CONTROL VALVE ASSEMBLY 40 /

DEW04596

DISASSEMBLY

z k ;:

AND ASSEMBLY

Install plugs (46) and (45) to valve body (47). m Plug (46): 68.6 + 9.8 Nm I7.0 f 1.0 kgm} m Plug (45): 152.0 = 24.5 Nm I155 2 2.5 kgml

Assembly of unload valve assembly (40) Assemble valve (44), seal (43) and spring (42) in valve body (47), then fit O-ring and install flange (41).

Assembly of check valve assembly (36) Assemble valve (39), and spring (38) in valve body (47), then fit O-ring and install plate (37).

Suction valve assembly (35) Install suction valve assembly (35) to valve body (47). m Suction valve: 186.3 2 9.8 Nm (19.0 f 1.0 kgm)

Safety valve assembly (34) with suction valve Install safety valve assembly (34). m Safety valve assembly: 186.3 = 9.8 Nm (19.0 t 1.0 kgm)

Assembly of main relief valve assembly (19) 1) Assemble spring (32) and valve (31) in sleeve (29), and install backup ring (33) and snap ring (30), then assemble O-ring in sleeve (29). 2) Fit O-ring and backup ring (28) and assemble seat (27) in sleeve (29). 3) Assemble poppet (26), spring (25), retainer (24) and screw (23) in holder (21), then fit O-ring and tighten nut (20). 4) Fit O-ring and installed nut (22).

Install m

Assembly of spool assembly (9) 1) Assemble spool (14) in valve body (47). 2) Install retainer (13), springs (12) and (II), then O-ring and install case (IO). 3) Install retainer (18), springs (17) and (16), then fit O-ring and install case (15). 4) Install elbows (8) and (7) to cases (IO) and

MAIN

CONTROL

VALVE

Install of selector valve assembly I) Install joint (6), tee (5), hose (4) to valve body, and connect elbow (8). 2) Install valve (3), tee (2), hose (I) to valve body, hand connect elbow (7). w Valve: 68.7 z 9.8 Nm I7.0 z 1.0 kgm} w Tee: 34.3 2 4.9 Nm I3.5 + 0.5 kgm} w Hose: 49.0 + 19.6 Nm IS.0 + 2.0 kgm} w Joint: 34.3 f 4.9 Nm 13.5 t 0.5 kgm}

main relief valve assembly (19). Main relief valve assembly: 323.6 f 44.1 Nm I33.0 = 4.5 kgm)

(15). w

Elbow: 90.7 + 12.3 Nm (9.25 = 1.25 kgm)

30-257 0

DISASSEMBLY

AND ASSEMBLY

DISASSEMBLY Special

HYDRAULIC CYLINDER

OF HYDRAULIC

CYLINDER

tool

No.

Part No.

Part Name

o’ty

792-502-1001

Cylinder repair stand

Cylinder assembly 1) Set cylinder assembly

(I) on Tool A.

A DEW04597

Remove

mounting

bolts (2) of head cover.

DEW0

Pull out piston rod (3) from cylinder. When pulling out the rod, the oil remaining inside the cylinder will come out, so catch it in a container. If the piston rod cannot be pulled smoothly out of the cylinder, rotate the piston rod slightly when pulling out.

Steering cylinder piston rod assembly: 8% kg

Dump cylinder

Lift cylinder

* 2.

rel

Remove

piston rod assembly: 520 kg

DEW04599

piston rod assembly: 450 kg

the cylinder

from tool A.

Piston rod 1) Remove spacer mounting bolts (4), then remove spacer (5). 2) Pull out piston (6) and head cover (19). 3) Remove O-ring (8) and backup rings (7) and (9) from piston rod (3). 3

30-258

DISASSEMBLY

HYDRAULIC CYLINDER

AND ASSEMBLY

Piston 1) 2)

Remove Remove

wear ring (IO) from piston (6). piston ring (I I).

-li’ IO

DEW04601

Head cover 1) 2)

Remove O-ring (12) and backup ring (13). Remove snap ring (14), then pull out dust seal (15), rod packing (16), buffer ring (171, and bushing (18) from head cover (19).

18 I2 13

DEW04602

30-259 0

DISASSEMBLY

ASSEMBLY Special

HYDRAULIC

AND ASSEMBLY

OF HYDRAULIC

CYLINDER

tools

No.

Part No.

Part Name

O’ty

790-502-1001

Cylinderrepair stand

790-720-1000

Expander

790-720-1680

Ring

796-720-1710

Ring

796-720-1730

Ring

Coat the sliding surfaces of all parts with hydraulic oil before installing. Be careful not to damage U-packings, dust seals or O-rings when installing.

Head cover 1) Press fit bushing (18) in head cover (19), and install buffer ring (17), rod packing (16), dust seal (151, and snap ring (14). * Be careful not to deform the bushing when press fitting. 2) Install backup ring (13) and O-ring (12) to head cover (19). * Do not try to force the backup ring into position. Warm it in warm water (50 to 60°C) before fitting it.

CYLINDER

Piston I) Set piston ring (II) on tool B and expand it. * Set the piston ring on the expander and turn the handle 8-10 times to expand the ring. 2) Remove piston ring (11) from tool, and install on piston (6). 3) Set ring @ of tool C, then using clamp 0, tighten piston ring (I I). Ir Ring Part No. 796-720-1680 (Steering cylinder) 796-720-1710 (Lift cylinder) 796-720-1730 (Dump cylinder) * Clamp Part No. 07281-01919 (Steering cylinder) 07281-02909 (Lift cylinder) 07281-03209 (Dump cylinder) 4) Install wear rings (IO) to piston (6).

15 16

17 DEW04602

DEW04603

r3 Ii

DEW04601

DISASSEMBLY

HYDRAULIC

AND ASSEMBLY

Piston rod I) Install head cover (19) to piston rod (3). 2) Install O-ring (8) and backup rings (7) and (9) to rod. * Coat the backup ring with grease to prevent it from protruding, and assemble it carefully. & Backup ring, O-ring: Grease (G2-LI) 3) Install piston (6). 4) Set spacer (5) in position, and tighten spacer mounting bolts (4). * Remove all oil and grease from the mounting bolts and mounting holes. & Mounting bolt: Adhesive (Locktite 262) w Mounting bolt: 110.3 f 12.3 Nm (II.25 + 12.3 kgm} (Steering cylinder) w Mounting bolt: 277.0 2 31.9 Nm 128.25 + 3.25 kgm) (Lift, dump cylinder)

CYLINDER

DEW04600

3 DEW04599

Cylinder assembly ii Set cylinder in tool A. 2) Assemble piston rod (3) in cylinder. 3) Tighten head cover mounting bolts (2). Ir Coat the O-ring and backup ring on the cover side with grease. w Steering cylinder mounting bolt: 460.9 + 14.2 Nm I47.0 + 14.5 kgm} (width across flats: 30 mm) w Dump cylinder mounting bolt: 2452 +. 245 Nm I250 z 25 kgm} (width across flats: 55 mm) w Lift cylinder mounting bolt: 1545 2 172 Nm (157.5 = 17.5 kgm} (width across flats: 46 mm) 4) Remove cylinder assembly (I) from tool A.

‘

DEW04598

d DEW04597

30-261

DISASSEMBLY

REMOVAL

AND ASSEMBLY

CENTER HINGE PIN

OF CENTER HINGE PIN

Remove the work equipment operation.

Stop the machine on level ground and install the safety bar on the frame. Then stop the engine, apply the parking brake and put blocks under the wheels to prevent the machine from moving.

Disconnect the cable from the negative (-1 terminal of battery. Open the drain valve, and then drain air inside the air tank.

before staring the

1. ROPS canopy Sling ROPS canopy, remove mounting bolts and lift off. * Disconnect wiring for lights at connector. DEW04604

& kg

ROPS canopy:

1260 kg

Covers 1) Remove cover under cab. 2) Remove cover (I) at rear of cab and inspection cover (2).

Electric wiring I) Disconnect ground connection. 2) Disconnect the following electric wiring from connector. . Wiring (4) for emergency steering operation sensor . Wiring (5) for rear frame . Wiring (6) for transmission . Wiring (7) for air equipment . Wiring (8) for front frame . Wiring (8A) for window washer * Remove the wiring clamps. * After removing the clamp, move the wiring for the front frame towards the front frame.

DISASSEMBLY

AND ASSEMBLY

Air piping . Disconnect hoses (9) and (IO) between brake valve and air tank from tube at brake valve end. . Disconnect hoses (II) and (12) between brake valve and relay valve from tube at brake valve end.

Pipings for air conditioner, heater . Disconnect hoses (13) and (14) for air conditioner at coupler. . Disconnect heater hoses (15) and (16) at air conditioner unit end. . Disconnect drain hose (17) at air conditioner unit end. g

Remove the radiator water is cool, then hoses.

CENTER

HINGE

cap, check that cooling disconnect the heater I6 DEW04608

Brake, air, PPC piping . Disconnect hoses (18) and (19) between steering unit and steering demand valve at center hinge pin end. . Disconnect air hose (20) for parking brake at center hinge pin end. . Disconnect hoses (21) and (22) between brake chamber and slack adjuster at center hinge pin end. . Disconnect hoses (23), (241, (25) and (26) between PPC valve and main control valve at center hinge pin end. * After disconnecting the hoses, mark them with tags to distinguish when installing. * Remove each clamp.

Fuel control cable Disconnect fuel control cable (27) from lever (28) at servo cylinder end.

30-263 0

DISASSEMBLY

CENTER HINGE PIN

Cab, floor frame Temporarily sling the cab, floor frame, remove 4 nuts (30) for the viscous mount to remove it. Ir If there is limitation regarding the height of hoist crane, remove either ladder rail of right or left. &I kg

AND ASSEMBLY

Cab, floor frame:

950 kg

support Remove

mounting Support:

bolts (31C) for support

(31).

129 kg

I 10. Steering

cylinder pin Remove lock plate (31 B) of steering cylinder pins on the right and left and remove pin (31A).

11. Hydraulic piping Disconnect the follwing hoses from connection ports on front frame side. . Hose (32) between steering pump and steering demand valve. . Hose (33) between switch pump and steering demand valve. . Hose (34) between pump of work equipment and steering demand valve. . Hose (35) between pump of work equipment and hydraulic oil tank. . Hose (36) between steering demand valve and hydraulic oil cooler. . Hose (37) between diverter valve and steering demand valve.

DGW04612

Sling center drive shaft (38), remove bolts and lift off. A kg

mounting

Center drive shaft: 186 kg

I) Using hydraulic jack under rear frame, adjust height and insert block 0. * Insert hydraulic jacks and blocks on the left and right sides of the frame. 2) Using jack, insert block @ under front frame.

DEW04616

3) 4)

Insert block @ under counterweight. Using lever block, move hydraulic hoses to right side of machine body.

Remove mounting bolts, then remove retainer (39). * There are shims between the retainer and the frame, so check the number and thickness of the shims, and keep in a safe place.

Id 2

DEW04617

30-265 0

DISASSEMBLY

AND ASSEMBLY

Install eyebolts lift off pin. I5 kg

CENTER HINGE PIN

to lower hinge pin (401, then

Lower hinge pin: 68 kg

.42

DEW04621

DEW04622

DEW046

30-266

DISASSEMBLY

CENTER

AND ASSEMBLY

HINGE

16. Disconnecting frame Remove safety bar, pull out front frame to front and disconnect frames. Ir Be careful not to let the spacer at the bottom of the upper hinge bite into the rear frame. * Be careful to maintain the balance when carrying out the operation. * Move the frame about 100 mm at a time. * Remove spacer (47) from the rear frame.

17. Lower hinge 1) Remove mounting

bolt, then remove retainer

(48). Ir There are shims between the retainer and the frame, so check the number and thickness of the shims, and keep in a safe place.

Remove

dust seal (49) from

DEW04625

retainer.

DEW04626

Remove

spacer (50) from front frame.

DEW04627

30-267 0

DISASSEMBLY

AND ASSEMBLY

Remove plate (51) from remove dust seal (52).

Remove

bearing

CENTER HINGE PIN

front

frame,

then

(53).

DEW04629

18. Upper hinge 1) Remove retainer (54). * There are shims between the retainer and the frame, so check the number and thickness of the shims, and keep in a safe place.

DEW04630

Remove

dust seal (55) from

retainer.

DEW04631

30-268

DISASSEMBLY

AND ASSEMBLY

Remove plate (56) from remove dust seal (57).

CENTER

front

frame,

HINGE

then

DEW04632

Remove

bearing

(58).

DEW04633

30-269 0

DISASSEMBLY

AND ASSEMBLY

INSTALLATION

CENTER HINGE PIN

OF CENTER HINGE PIN

Special tools

/“/

DEW04634

Upper hinge I) Assemble

tools A, B, D, E, G, and I at top of front frame upper hinge, and set bearing (58) in tools G and I. Set on press-fitting part from top and press fit. When press fitting, use tool I as a guide. 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 (59). The clearance of the bearing and spacer (59) is adjusted, so do not change the combination. When replacing the bearing or spacer, replace as set.

DEW04807

Press fit dust seal (55) on retainer. * When press fitting the dust seal, fit with the lip on the outside. & Seal lip: Grease (G2-LI)

DEW04636

DISASSEMBLY

AND ASSEMBLY

CENTER HINGE PIN

Tighten retainer (54) with then measure clearance “a”

Mounting bolt (when adjusting shim): 78.5 2 7.9 Nm I8 = 0.8 kgm} Mounting bolt: 549 + 59 Nm I56 2 6 kgml

DEW04637

60 a

DEW04640

DEW04636

Assemble dust seal (57) in hinge, and install plate (56). + When press fitting the dust seal, fit with the lip on the outside. & Seal lip: Grease (GZ-LI)

DEW04632

Lower hinge I)

Using tools A, B, C, E, F, H, and J, press fit bearing (53) and spacer (61) on front frame. * When press fitting, use tool H as a guide. * Be careful not to fit the bearing at an angle. * Fill the inside of the bearing with grease.

DISASSEMBLY

AND ASSEMBLY

CENTER

HINGE

When assembling the bearing, do not forget to assemble spacer (61). * The clearance of the bearing and spacer (61) is adjusted, so do not change the combination. When replacing the bearing or spacer, replace as a set. Press fit dust seal (49) on retainer (48). * When press fitting the dust seal, fit with the lip on the outside. & Seal lip: Grease (G2-LI)

I 40

DEW04644

DEW04641

Tighten retainer (48) with 10 mounting bolts, then measure clearance “b” between retainer and hinge at four places around the circumference. Select shim (62) of 0.08 - 0.18 mm less than measured value. * Do not select a shim which is thicker than the clearance at the four measured places. * After selecting the shim, tighten the retainer to the specified tightening torque. m Mounting bolt (when adjusting shim): 245.2 + 24.5 Nm I25 f 2.5 kgm} m Mounting bolt: 927 2 103 Nm 194.5 + 10.5 kgm}

DEW04645 DEW04643

DISASSEMBLY

AND ASSEMBLY

CENTER

HINGE

Assemble dust seal (52) to hinge, and install plate (51). * When press fitting the dust seal, fit with the lip on the outside. & Seal lip:

DEW04628

DEW04627

* *

* &

hammer to settle in position. Always tap lightly with the copper hammer. Never hit hard. Do not coat the mounting surfaces of spacer (47) and frame and spacer (47) and pin (46) with grease. Remove eyebolt @ from the pin. Outside circumference of hinge pin: Grease

(G2-LI)

DEW04623

DISASSEMBLY AND ASSEMBLY

CENTER HINGE PIN

install retainer (45). * To tighten mounting bolts (43) and (44) to the specified tightening torque, tap the head of the upper hinge pin with a copper hammer, then tighten to the specified torque. * If the mounting bolts do not reach the specified tightening torque, there may be grease on spacer (471, so remove this and tighten again. 6 Mounting bolts (431, (44):

Adhesive (LT-2) w

Mounting

DEW04646

bolts (43) and (44): 549 + 59 Nm I56 z 6 kgm}

Lower hinge pin

1) Insert lower hinge pin (401, then install spacer (42). &

Outside

circumference

of hinge pin:

Grease (G2-LI) 2)

Install retainer (39) to lower hinge pin without shims, then tighten mounting bolts until they reach specified tightening torque. * Use a jack to raise the front frame until spacer (63) contacts the rear frame. * To tighten the mounting bolts to the specified tightening torque, tap the head of the lower hinge pin with a copper hammer, then tighten to the specified torque. * Before installing the retainer, measure the thickness of the retainer to select the shims. w Mounting bolts (64) and (65): 927 + 103 Nm I94.5 = 10.5 kgm} (width across flats: 36 mm)

DEW04647

DEW04649

Remove all mounting bolts (641, then measure clearance “C” between retainer and frame at three 6 mm diameter holes to calculate average clearance. Select shim so that average clearance is 0.08 to 0.18 mm. * Do not select a shim which is thicker than the clearance at the three measured places.

30-274

DISASSEMBLY

AND ASSEMBLY

CENTER

HINGE

Install selected shim (66) and retainer (39). Ir remove all grease and oil from the mounting bolts and mounting bolt holes. & Mounting bolts (64) and (65): Adhesive (LT-2) w Mounting bolts (64) and (65): 927 f 103 Nm (94.5 + 10.5 kgm} (width across flats: 36 mm)

L’

L.-L,-7

’

t -

Frame support 1) Remove block @ from counterweight.

2) 3)

Remove block @ from front frame. Jack up rear frame, and remove block 0.

DEW04616

DEW04650

DEW04617

Drive shaft Raise drive shaft (38) and set in mounting position, then tighten mounting bolts. w Mounting bolt: 385.4 r 41.2 Nm (39.3 f 4.2 kgm]

30-275 0

DISASSEMBLY

AND ASSEMBLY

CENTER

Hydraulic piping 1) Connect the following hoses to connection port on the front frame. Hose (35) between pump of work equipment and hydraulic oil tank. Hose (34) between pump of work equipment and steering demand valve. Hose (33) between switch pump and steering demand valve. Hose (32) between steering pump and steering demand valve. Hose (36) between steering demand valve and hydraulic oil cooler. Hose (37) between diverter valve and steering demand valve. Securely set O-rings into the groove. Use new O-rings. Steering cylinder pin After attaching right and left steering cylinder pins (31A1, mount lock plate (31B). A Adjust pin holes using a rod. Never use your fingers. + Adjust the shim so that clearance d gets the specified value. Clearance d = 3.0 mm or less

IO. support Sling support (31), set it over the attaching and tighten it with lock bolts (31C).

HINGE

DCW04614

*b! -

DEW04651

DEW04652

point

DCW04612

11. Cab, floor frame Sling the cab, floor frame, set it over the attaching point and tighten 4 lock nuts (30).

DISASSEMBLY

AND ASSEMBLY

CENTER

HINGE

12. Fuel control cable Attach fuel control cable (27) to lever (28) on the servo cylinder side and lock nuts. * Refer to TESTING AND ADJUSTING after the engine start, check the engine revolution speed and adjust it.

DEW04808

13. PPC piping and brake air piping Connect hoses (23), (241, (25) and (26) between the PPC valve and main control valve. Connect hoses (21) and (22) between brake chamber and slack adjuster. Connect the parking brake air hose (20). Connect hoses (18) and (19) between steering unit and steering demand valve. Confirm tag plates for hoses and pay attention for the correct connection points. Attach clamps for hoses.

14. Air conditioner and heater piping . Connect air conditioner hoses (13) and (14) with couplers. . Connect heater hoses (15) and (16). . Connect drain hose (17). Gas charge * Charge air conditioner gas. (R134a) * Charge standard: 1.5 to 1.6 kg * Be sure to give sufficient evacuation through repeated evacuation method before refrigerant charge. * Prevent liquid freon from coming into the cooling system caused by incorrect operation such as placing the refrigerant can upside down. * Do not activate the compressor before refrigerant charge. * Check that the refrigerant charge level is correct. * Check the oil level in the compressor. (Specified oil level: 150”04 cc ND-OIL81

I6 DEW04608

DISASSEMBLY

CENTER

AND ASSEMBLY

15. Air piping Connect hoses (II) and (12) between valve and the relay valve. Connect hoses (9) and (IO) between valve and the air tank. l

brake

HINGE

16. Electrical wiring 1) Connect the following electrical wirings to connectors. . Wiring (8) for front frame Wiring (8A) for window washer Wiring (7) for air equipment . Wiring (6) for transmission . Wiring (5) for rear frame . Wiring (4) for emergency steering operation sensor * Install wiring clamps. 2) Install ground connection. l

17. Cover 1) Install cover (1) at rear of cab and inspection cover (2). 2) Install cover under cab. 18. ROPS canopy Raise ROPS canopy and set in mounting position, then tighten mounting bolts. * Connect wiring for lights. m Mounting bolt: 2746 + 294 Nm I280 t 30 kgml (width across flats: 55 mm) 19. Refilling with oil Add hydraulic oil through fied level. W j, * *

Hydraulic

oil:

oil filler to the speci-

Approx.

550 L?

Before starting the engine, bleed the air from the piston pump circuit. For details, see TESTING AND ADJUSTING. After bleeding the air, run the engine to circulate the oil through the system. Then check the oil level again.

DEW04605

20. Bleeding air Bleed air from brake system. Ir For details of bleeding the air, see TESTING AND ADJUSTING.

DEW04604

DISASSEMBLY

REMOVAL

AND ASSEMBLY

/’

I \

DGW04654

Bucket link I) Remove retainer (I). Ir Shim (2) between the retainer and the bucket is used for the standard in assembling. Confirm the number. 2) Remove pin lock bolt (3) and cam (4). 3) Temporarily sling bucket link (51, slowly pull pin (6) from bucket link until it is pulled off. & kg Ir

EQUIPMENT

OF WORK EQUIPMENT

WORK

Lock pin: 87 kg

Shim (7) between the bucket link and the bucket is used for the standard in assembling. Confirm the number.

I I

DGW04655

Bucket I) Remove retainer (8). * Shim (9) between the retainer and the bucket is used for the standard in assembling. Confirm the number. 2) Remove pin lock bolt (IO) and cam (11). 3) Slowly pull right and left lock pins (12) and remove them. & kg

Lock pin:

71.2 kg DEW04656

Shim (13) between the bucket and the boom is used for the standard in assembling. Confirm the number. Move the machine backward and separate the bucket.

30-279 0

DISASSEMBLY

AND ASSEMBLY

WORK EQUIPMENT

Bucket link Sling bucket link (51, and pull out mounting pin slowly to remove from bellcrank. * There is a cord ring installed in the connection, so remove it. Ir Insert mounting pin (14) in bellcrank pin hole, and tighten lock bolt temporarily. &I kg

Bucket link: 495 kg

DEW04658

Dump cylinder I) Insert block @ between

bellcrank and lift arm, and secure bellcrank. Ir This must be done to prevent the bellcrank from falling towards the machine when the dump cylinder pin is removed.

Sling dump cylinder (15), and pull out mounting pin (16) slowly to disconnect cylinder rod and bellcrank. * Disconnect grease hose (17) from the pin. * Do not pull the pin out completely. After disconnecting the dump cylinder, insert the pin in the bellcrank mount and install the lock bolt.

Raise dump cylinder, and secure with lever block. * For safety reasons, fix the cylinder securely.

DEW04661

30-i80

DISASSEMBLY

AND ASSEMBLY

WORK

EQUIPMENT

Lift cylinder pin 1) Raise lift arm until pin (18) is higher than fender, then sling lift arm and bellcrank. 2) Disconnect grease tube (19) from mounting pin. E?lkg

Lift arm, bellcrank:

Approx.

9950 kg

DEW04662

Support rear of lift cylinder (20) with a lever block, remove lock bolt, then pull out slowly until pin comes out of cylinder. * After removing the lift cylinder, insert left and right mounting pins (21) in the lift arm pin holes, and tighten the lock bolt temporarily.

Lift arm, bellcrank 1) Remove boom kick-out switch (22). Ir Remove cover first, then remove

/--switch.

2) Remove stay for left and right lights. Sr

Disconnect connectors (23) of left and right electric wiring. Disconnect left and right grease tubes (24) from mounting pin, and remove nipple (25).

30-28 1 0

DISASSEMBLY

WORK EQUIPMENT

Pull out left and right mounting pins (26) slowly, and lift off lift arm and bellcrank (27). * If there are shims between the front fame and lift arm, check the number and thickness of the shims to act as a guide when assembling. * Lift off the left and right mounting pins. r+ kg

AND ASSEMBLY

Mounting

pin: 159 kg

Bellcrank Pull out mounting pin slowly, and lift off bellcrank (28) from lift arm. * Do not pull out mounting pin (29) completely. Lift off after removing the bellcrank.

r+ kg

Bellcrank:

1792 kg

f?lkg

Mounting

pin: 179 kg

Dust seal, bushing I) Pull out dust seal (31) and bushing (32) from lift arm (30). * Remove dust seal (33) and bushing (34) from the connection of the lift arm and frame.

DDW04669

Pull out dust seal (35) and bushing bellcrank (28).

DEW04670

(36) from

DEW04671

3o-i82

DISASSEMBLY

AND ASSEMBLY

WORK EQUIPMENT

Pull out dust seal (37) and bushings (38) from bucket link (5). * Remove dust seal (39) and bushing (40) from connection of the bellcrank and link.

After using for a long time, if wear of the pin makes it difficult to remove the pin, make a jig such as the one shown below, and use it to remove the pin.

Nut

DEW04809

30-283 0

DISASSEMBLY

AND ASSEMBLY

INSTALLATION

WORK

OF WORK EQUIPMENT

Use a bar to align the pin holes. Never use your fingers.

Dust seal, bushing Using a press, press fit bushings and dust seals to bucket link, bellcrank and lift arm. * Assemble the dust seals to that the seal lip faces the outside. Assemble to the dimensions shown below. & Bushing: Grease (G2-LI) Bushins

EQUIPMENT

Bellcrank Raise bellcrank (28), set in position in lift arm mount, then assemble mounting pin (291, and lock with bolt. * Raise the mounting pin and set in lift arm mount, then push it in until it is level with the surface of the boss.

DEW04610

Dust seal

DEW048 81I

Lift arm, bellcrank I) Raise lift arm and bellcrank (271, set in mounting position, then assemble mounting pin (261, and lock with bolts. * Align the holes of the front frame and lift arm mounts, then insert shims so that clearance “a” is equal on the left and right. Ir Clearance “a”: Max. 1.5 mm * After installing the pin, set a support under the tip of the lift arm.

DEW04677

30-i84

DISASSEMBLY

2) 3)

Lii

AND ASSEMBLY

WORK

EQUIPMENT

Install left and right nipples (25), and connect grease tube (24). Install stays for left and right lights. * Connect connector (23) of electric wiring.

Install boom kick-out switch (22). * For details of adjusting procedure, TESTING AND ADJUSTING.

cylinder

see

1) Start engine,

and raise rod of lift cylinder (20) slowly, align lift arm holes, then install mounting pin (21) and lock with bolt. a Use a bar to align the pin holes. Never use your fingers.

Connect

grease

tube

119) to mounting

(18).

DEW04662

30-285 0

DISASSEMBLY

Dump cylinder 1) Raise dump cylinder (15) and remove lever block, then set in mounting position. 2) Insert rod mounting pin (16), and tighten lock bolt. a Use a bar to align the pin holes. Never use your fingers.

WORK EQUIPMENT

AND ASSEMBLY

Connect grease hose (17) to pin. j, Remove block @ between bellcrank lift arm.

and

Bucket link 1) Raise bucket link (5) and set in position in bellcrank mount, then tighten mounting pin (14). Ir Raise the mounting pin and set it in position on the bellcrank, then push it in until it is level with the surface of the bellcrank.

' DEW04658

Insert cord ring (41) in groove. * Pull the cord ring slightly when inserting it in the groove. Insert bolts (42) in cord ring to secure it. -Cr Tighten the bolts, but stop when the cord ring starts to deform.

30-i86

DISASSEMBLY

WORK

AND ASSEMBLY

EQUIPMENT

Bucket 1) Move the lift arm closely to the bucket, operate levers, adjust buck& lock pin holes and insert pin (12). * When mounting the lift arm on the bucket, insert shims (13) evenly on both sides and insert the pin. * Clearance: 1.5 mm or less

2) Temporarily

tighten bolt (IO) so that cam (11) touches lock pin (12). Ir Securely tighten it after mounting retainer (8).

Install retainer (81, measure the clearance and insert the shim so that the clearance becomes narrower than the specified value. * Clearance: 0.2 mm or less * Set the shim “Clearance A + 0.2 mm” and insert it. DGW04655

Bucket link Sling bucket link (51, adjust the hole of lock pin (6) and insert pin (6). Ir For the procedure from the above, follow that for the bucket pin.

I \

DGW04654

Greasing 1) Grease bucket pin from grease fitting in center of pin, and bucket link from grease fitting in link. Add grease until grease comes out from dust seal. 6 Bucket pivot portion: Grease (G2-LII 6 Bucket link portion: Grease (G2-LI) 2)

Grease each pin.

DEW04680

30-287 0

DISASSEMBLY

REMOVAL

AND ASSEMBLY

FUEL TANK

OF FUEL TANK

g Stop the machine

Draining fuel Loosen fuel drain valve and drain fuel. -

Steps Remove and (3).

Fuel: 1200 fi

left and right steps (I),

and covers

(2)

Drain valve Remove engine oil drain valve (41, torque converter cooling water drain valve (51, and cooling water drain valve (6) from fuel tank.

Cover Remove filler port cover on the fuel tank (7) and fuel cut valve cover (8).

Fuel hose Disconnect the following hoses. . Hoses (9) and (IO) between injection pump and fuel tank. . Disconnect both edges of hose (I I) between left priming pump and fuel filter. . Hose (12) between fuel tank and fuel filter. * Disconnect them on filter side.

DGW04662

To fuel injection Pump

Fuel tank DEW04612

30-288

DISASSEMBLY

FUEL TANK

AND ASSEMBLY

Electric wiring Disconnect nector.

wiring

(13) for fuel

unit from

con-

DEW04664

Fuel tank Sling fuel tank, and remove mounting bolts, then lift off. * Fix the lifting tool to the lifting hooks, be careful to maintain the balance, and lift off slowly. * Check that all the fuel has been drained. * Lay a pallet under the tank, set blocks in position in line with the fuel tank, then pull out the fuel tank from the chassis. A kg

Fuel tank: 664 kg

30-289 0

DISASSEMBLY

AND ASSEMBLY

INSTALLATION 1.

FUEL TANK

OF FUEL TANK

Fuel tank Raise fuel tank and set in mounting position, then tighten mounting bolts. * When raising, keep horizontal and set in the mounting position. * Tighten the mounting bolts on opposite sides in turn. m Mounting bolt: 927 + 103 Nm 84.5 = 10.5 kgm) (width across flats: 46 mm) DEW04684

Electric wiring Connect wiring

(13) for fuel unit to connector.

To fuel injection Pump

Fuel hose Connect the following hoses. . Hoses (9) and (IO) between injection pump and fuel tank. Connect both edges of hose (11) between left priming pump and fuel filter. . Hose (12) between fuel tank and fuel filter. * Set clamps for hoses. l

Fuel tank DEW04612

Cover Mount filler port cover on the fuel tank (7) and fuel cut valve cover (8).

30-z90

OGW04662

DISASSEMBLY

AND ASSEMBLY

Drain valve Install engine oil drain valve (4), torque converter cooling water drain valve (5) and cooling water drain valve (6) to fuel tank.

Step Install left and right covers (2) and (3), and steps (I). * Perform

air bleeding

FUEL TANK

for the fuel piping.

30-291 0

MAINTENANCE

STANDARD

Engine mount ............................................... 40- 2 Transmission mount.. ................................. 40- 3 Damper.. ....................................................... 40- 4 Torque converter charging pump and PPC pump ...................................... 40- 5 Torque converter.. ....................................... 40- 6 Torque converter regulator valve.. ........... 40- 7 Transmission ............................................... 40- 8 Transfer ........................................................ 40-I 1 Transmission control valve ................ ....... 40-12 Drive shaft.. .................................................. 40-17 Center support.. .......................................... 40-18 Differential.. .................................................. 40-19 Final drive .................................................... 40-22 Axle mount .................................................. 40-24 Center hinge pin.. ....................................... 40-26 Steering column ......................................... 40-28 Diverter valve ............................................. 40-29 Steering cylinder mount.. .......................... 40-30 Emergency steering pump.. ...................... 40-31 Steering cylinder ........................................ 40-32 Brake chamber ........................................... 40-33 Brake valve .................................................. 40-34 Slack adjuster ............................................. 40-36 Parking brake ............................................... 40-37 Brake.. ........................................................... 40-38 Spring cylinder ........................................... 40-40 Control pump ............................................. 40-41 PPC valve ..................................................... 40-42 Main control valve ...................................... .40-44 Dump cylinder .............................................. 40-46 Lift cylinder ................................................... 40-47 Bucket linkage .............................................. 40-48 Bucket positioner and boom kick-out ....... .40-50

40-l

MAINTENANCE STANDARD

ENGINE MOUNT

SEW01594

40-2

MAINTENANCE

TRANSMISSION

STANDARD

TRANSMISSION

MOUNT

A-A

u B-B

SEW01595

Unit: mm

Clearance between trunnion and torque converter case

Clearance between O.D. of rubber

MAINTENANCE

STANDARD

DAMPER

DAMPER 5*31.4Nm ._*3.2kPml

SEW01596

Unit: mm

No.

Check item

Criteria Tolerance

Standard size

Clearance between bearing and shaft

Remedy

Standard clearance

Clearance limit

Shaft

Hole

+0.015 +0.003

0 -0.020

-0.035 -0.003

0.025

Clearance between bearing and housing

170

0 -0.025

-0.008 -0.033

-0.033 0.017

0.030

Clearance between inner body and shaft

94.3

+0.035 +0.013

+0.071 +0.036

0.001 0.058

0.1

I 4

5 6

Standard size

Tolerance

Repair limit

115

0 -0.087

-0.140

Wear of surface in shaft and oil seal

Wear of surface in sleeve and oil

I seal

I Backlash of spline

40-4

140

I 0.068 - 0.263

MAINTENANCE

TORQUE CONVERTER CHARGING PUMP AND PPC PUMP

STANDARD

TORQUE CONVERTER

T/C charoino

CHARGING

PUMP

PUMP AND PPC PUMP

T/C charging

SAR(4) -I 12

PUITD

PPC PUnlP

SAR(3) -100

SAR(1) -32

SEW01790 Unit: mm

No.

Criteria

Check item

Standard

Model

Clearance between side plate, gear

SAR3 - 100

SARI

- 032

SAR4 - 112

Clearance between inside diameter of plain bearing and outside diameter of gear shaft

SAR3 - 100

SARI

Insertion

Rotating

depth of pin

torque

Discharge Oil: EOlO-CD Temperature:

0.13 - 0.18

0.22

0.10 - 0.15

0.06 - 0.140

0.06 - 0.149

0.20

0 -0.5

SAR3 - 100

14 0 -0.5

SARl

-0.5

- 3.2 kgm}

Model

Revolution (rpm)

Discharge pressure

Standard discharge (Elmin)

Repair limit discharge (elmin)

SAR4 - 112

2200

2.9 MPa {30 kg/cm21

242

222

SAR3 - 100

2200

2.9 MPa {30 kg/cm*)

212

194

SARl

2200

2.9 MPa 130 kg/cm21

- 032

Replace

0.20

SAR4 - 112

18.6 - 31.4 Nm il.9

0.19

0.06 - 0.119

- 032

limit

0.19

- 032

of spline shaft

45 - 55°C

Clearance

clearance

0.11 - 0.16

SAR4 - 112

gear case and

Remedy

40-5

MAINTENANCE

STANDARD

TORQUE CONVERTER

53.9*4.9Nm

SEW01598

Unit: mm No.

Check item

Criteria

Standard 1

Inside diameter of retainer

Inside diameter of sleeve

Width and thickness of seal ring

Backlash

40-6

Tolerance

Repair

limit

of seal ring surface

size

Remedy

170

+0.040 0

‘IJO.5

+0.035 0

85.1

Width

4.45

0 -0.1

4.05

Thickness

6.0

fO.l

5.5

of seal ring surface

of PTO gear (Drive gear)

0.20 - 0.52

Repair chrome plating or replace

Replace

MAINTENANCE

TORQUE CONVERTER REGULATOR VALVE

STANDARD

TORQUE CONVERTER

REGULATOR

VALVE

. n

SEW01599

Unit: mm No.

Check item

Clearance between poppet and spool

Clearance between spool and body

Criteria

Remedy

Replace

Poppet spring

Spool spring

Free length

installation length

Installation load

Free length

Installation load

43.9

22.4 N j2.28 kg}

20.6 N 12.1 kg}

172

107.9 N 111 kg}

167

98.1 N {IO.0 kg}

40-7

MAINTENANCE STANDARD

TRANSMISSION

TRANSMISSION (l/2)

‘*&

66.7t6.9Nz {6.&0.7kgm}

1‘1 1

6.7&6.9Nm

{6&0.7kgm~

\i 66.7S9Nm I6.@.7kgm)

B \

66.7*.9Nm {6.&0.7kgmI

MAINTENANCE STANDARD

TRANSMISSION

TRANSMISSION (2/2)

Unit: mm

0.15 - 0.40

MAINTENANCE

TRANSFER

STANDARD

TRANSFER

SEW01602

Unit: mm

No.

Check item

Oil seal sliding surface shaft coupling (RI

Standard

Oil seal sliding surface shaft coupling (F)

size

Clearance and case

between

Tolerance

limit

of output

170

0 -0.10

169.8

170

0 -0.10

169.8

output

Clearance

clearance

limit

Replace

cover -0.05 - 0.05 After installed shim

Backlash between idler gear

input gear and

Backlash between idler gear

output

Repair

of output

Standard 3

Remedy

Criteria

gear and

Backlash between 2nd shaft gear and 3rd shaft gear

0.23 - 0.59

40-l 1

MAINTENANCE

STANDARD

TRANSMISSION 1)

TRANSMISSION

CONTROL VALVE

UPPER VALVE

14 9 12

6 II

16 15 4

5 6

__-__

SEW01603

40-12

MAINTENANCE

TRANSMISSION

STANDARD

CONTROL VALVE

Unit: mm

No.

Check item

Criteria

Clearance between pilot reducing valve spool and body

Clearance and body

Clearance between quick return valve spool and body

Clearance between modulating valve spool and body

Clearance between spool and body

reducing

Clearance between spool and body

lubrication

between

Remedy

Tolerance

Standard size

Standard clearance

Clearance limit

Shaft

Hole

-0.035 -0.045

+0.016 0

0.035 0.061

0.08

-0.035 -0.045

+0.013 0

0.035 0.058

0.08

-0.035 -0.045

+0.013 0

0.035 0.058

0.08

priority valve

valve

Standard

Priority valve spring

(Large)

Priority valve spring

(Small)

Pilot reducing

Reducing

Modulating

valve spring

(Small)

Modulating

valve spring

(Large)

Lubrication

valve spring

Shim adjustment valve

Thickness of shim for modulating valve

limit

Installation length

Installation load

Free length

Installation load

54.0

195.2 N I19.9 kg}

71.8

185.4 N Il8.9 kg}

80.0

73.0

234.4 N (23.9 kg}

87.3

222.6 N t22.7 kg}

100

75.0

716.9 N (73.1 kg}

97.0

680.6 N (69.4 kg}

74.5

48.0

116.7 N III.9 kg}

72.3

110.8 N (Il.3 kg}

Free length

Repair

size

Replace

5 Ki B

valve spring

for pilot reducing

One shim will charge the pressure

by 31.4 kPa fO.32 kg/cm’1

Large

1 (One shim will charge

the pressure

by 37.3 kPa IO.38 kg/cm?

Small

1 (One shim will charge

the pressure

by 41.2 kPa IO.42 kg/cm*) Adjust

Thickness

of shim for priority

valve

&&stment

of shim for reducing

;‘,“,“ment

of shim for lubrication

3 (One shim will charge

the pressure

by 136.3 kPa Il.39

kg/cm?

One shim will charge the pressure

by 28.4 kPa fO.29 kg/cm*)

One shim will charge the pressure

by 3.9 kPa fO.04 kg/cm21

40-13

MAINTENANCE

STANDARD

TRANSMISSION

CONTROL VALVE

2) LOWER VALVE

SEW01604

40-14

MAINTENANCE

TRANSMISSION

STANDARD

CONTROL VALVE

Unit: mm Check item

No.

Clearance and body

between

forward

Clearance and body

between

first

Clearance

between

second

between

spool

speed spool

I spool and body

Clearance between 4 I spool and body

speed

-0.035 -0.045

+0.013 0

0.035 0.058

0.08

-0.035 -0.045

+0.013 0

0.035 0.058

0.08

-0.035 -0.045

+0.013 0

0.035 0.058

0.08

-0.035 -0.045

+0.013 0

0.035 0.058

0.08

-0.035 -0.045

+0.013 0

0.035 0.058

0.08

-0.035 -0.045

+0.016 0

0.035 0.061

0.08

-0.035 -0.045

+0.016 0

0.035 0.061

0.08

third speed

Clearance and body

Clearance between spool and body

Clearance between converter torque relief valve spool and body

reverse

spool

main relief valve

Standard

Springs for FORWARD, REVERSE, first, second, and third speeds

relief valve spring

Torque

Main

relief valve spring

(inner)

I Main

relief valve spring

(outer)

converter

Thickness

Remedy

Criteria

Repair

size

limit

Free length

Installation length

Installation load

Free length

Installation load

113.8 N Ill.6 kg}

107.9 N 111 kg}

206.5

143

517.8 N l52.8 kg)

200

492.3 N i50.2 kg}

185

138

681.6 N i69.5 kg}

179

647.2 N I66.0 kg}

926.7 N 194.5 kg}

155

880.6 N i89.8 kg}

160

of main relief valve shim

Standard shim thickness: 6.0 (One shim will charge the pressure 11.8 kPa lo.12 kg/cm2})

of T/C relief shim

Standard shim thickness: 1.0 (One shim will charge the pressure 6.9 kPa CO.07 kg/cm*})

I Adjust

Thickness

40-15

MAINTENANCE

STANDARD

TRANSMISSION

CONTROL VALVE

SOLENOID VALVE

SEW01605

40-16

MAINTENANCE STANDARD

DRIVE SHAFT

SEW01606

40-17

MAINTENANCE

STANDARD

CENTER SUPPORT

2 A-A

Unit: mm T

No.

Check item

Criteria

Remedy

Clearance between case and bearing 230

0 -0.030

-0.022 -0.051

-0.051 -0.008

0.011 Replace

Clearance between case and bearing

215

0 -0.030

-0.022 -0.051

-0.051 -0.008

0.011

Clearance between and bearing

130

+0.052 +0.027

0 -0.025

-0.007 -0.027

-0.024

Clearance between coupling shaft and bearing

120

+0.045 +0.023

0 -0.025

-0.007 -0.023

-0.020

Wear of oil seal surface

coupling shaft

Wear of oil seal surface

End play of coupling shaft

40-l 8

Standard size

Tolerance

Repair limit

160

0 -0.100

-0.20

160

0 -0.100 End play 0.05 - 0.15

Repair chrome plating or replace

-0.20 Replace

MAINTENANCE

STANDARD

DIFFERENTIAL

(l/2)

1st

2746*294Nm (280*30kml

step :3.9*l.ONm (When measuring

(0.4iO.lkPml clearancetno

2nd step :279.5*29.4Nm (shim installed)

shim))

(28.5*3.0kPm) SEW01 791

Unit: No.

Check

item

of side

gear

Criteria Standard

Thickness

size

Tolerance

Remedy

Repair

limit

washer 9.0

8.5

10.75

10.25

Replace 2

Thickness

Wear

of pinion

of oil seal

gear

surface

washer

150

0 -0.100

40-l 9

DIFFERENTIAL

MAINTENANCE STANDARD

DIFFERENTIAL (Z/2)

20 SEW01609

40-20

MAINTENANCE

DIFFERENTIAL

STANDARD

Unit: mm No.

Check item

Clearance of bearing outer race in differential gear assembly

280

-0.035 0

-0.016 +0.036

0.071 -0.016

180

+0.074 +0.049

0 -0.025

-0.049 -0.099

2 3

Clearance of outer race of pinion shaft bearing

Clearance of inner race of pinion shaft bearing

Clearance of outer race of pinion shaft bearing

Clearance of inner race of pinion shaft bearing

160

+0.040 +0.015

0 -0.025

-0.015 -0.065

Clearance of differential pinion gear outer race bearing

160

0 -0.025

-0.028 -0.068

-0.003 -0.068

Clearance of differential pinion gear inner race bearing

+0.013 -0.009

0 -0.015

-0.028 0.009

Clearance of differential pinion gear outer race bearing

140

0 4.018

-0.028 -0.068

-0.010 -0.068

Clearance of differential pinion gear inner race bearing

+0.013 -0.009

0 -0.015

-0.028 0.009

Clearance between differential carrier and cage

330

0 -0.057

+0.057 0

o-o.114

Clearance between spider and differential pinion bushing

0 -0.030

+0.030 0

0 - 0.060

Clearance of bevel gear pin

+0.029 +0.008

+0.033 0

-0.029 0.025

Backlash of bevel gear

0.43 - 0.61

Backlash of differential gear

0.31- 0.40

Remedy

Clearance of bearing inner race in differential gear assembly

Criteria

I I

Free rotating torque of pinion gear

22.6 Nm {2.3 kgm}

16 Preload of pinion bearing

21 kN 12,140 kg}

Free rotating torque of bevel gear

25.5 Nm 12.6 kgm)

1 Preload of side bearing

28 kN (2,860 kg)

Rear face runout of bevel gear

0.13

Standard thickness of shims for I stow shaft

Clearance “a” + (0.1 + 0.05)

Standard thickness of shims for differential cage

2.0

40-21

MAINTENANCE

STANDARD

FINAL DRIVE

926.7* 103.ONm (94.5*10.5koml (Final value) SEW01792

40-22

MAINTENANCE

FINAL DRIVE

STANDARD

Unitz mm

is -No. 1

Clearance between planetary shaft and bearing

Clearance between planetary gear and bearing

Clearance between axle housing and bearing

Clearance between wheel hub and bearing

Clearance between and bearing

Clearance between wheel hub and bearina

Thickness of retainer at ring gear hub mount

axle housing

Backlash between planet gear and sun gear

Backlash between planet gear and ring gear

Thickness of standard shim for wheel hub

I Remedy

Criteria

Check item

0 -0.045

460

-0.045 -0.108

-0.108-o

~1 30

Replac I

fO.1

29.6

Standard clearance

Clearance limit

0.26 - 0.58

1.0

0.30 - 0.78

1.2

2.0

40-23

MAINTENANCE

STANDARD

AXLE MOUNT

A-A B-0

// 7

40-24

SEW01611

MAINTENANCE STANDARD

AXLE MOUNT

Unit: mm

E d

No.

Criteria

Check item

Remedy

Clearance of shaft and hole (Front support side) (Before press-fit bushing)

(Front support side)

Tolerance

Standard size 5

Thickness of thrust washer f0.2

Thickness of thrust plate

-0.21 -0.35

Thickness of rear bushing

fO.1

Thickness of front bushing

fO.l

40-25

MAINTENANCE

STANDARD

CENTER HINGE PIN

1, 13

4! 19 1 , 17

40-26

MAINTENANCE

STANDARD

CENTER HINGE PIN

Unit: mm No.

Check item

Clearance between lower hinge pin and bushing

Criteria

146.05

Remedy

-0.043 -0.068

+0.070 0

0.043 0.138

-0.043 -0.068

+0.063 0

0.043 0.131

Clearance between lower hinge pin (small) and spacer

Clearance between lower hinge pin and bearing

146.05

-0.043 -0.068

+0.025 0

0.043 0.093

Clearance between lower hinge pin and spacer (large)

146.05

-0.043 -0.068

+0.063 0

0.043 0.131

Clearance between lower hinge spacer (large) and bushing

206.0

-0.050 -0.122

+0.077 0

0.050 0.199

Clearance between front frame and upper hinge bearing

234.95

+0.025 0

-0.067 -0.113

-0.138 -0.067

Clearance between upper hinge pin and rear frame

127

-0.043 -0.068

+0.063 0

0.043 0.131

Thickness for lower hinge and retainer 18

146.05

1.0

+0.8

Shim thickness for lower hinge and retainer

1.93

Shim thickness for lower hinge and retainer

2.20

Shim thickness for upper hinge and retainer

2.31

Adjust

40-27

MAINTENANCE

STANDARD

STEERING COLUMN

A-A

SEW01613

unrt: mm No

Check item

Clearance between steering shaft and column bushing

Criteria

1 St;;;rd

shafiTo’er”““,,,.

/ ::I;;;

Ciyyz;ce Replace bushing

40-28

Remedy

4090

+0.150 +0.050

0.050 0.230

MAINTENANCE

STANDARD

DIVERTER VALVE

Unit: mm

No.

Check item

Criteria

Tolerance

Standard size 1

Clearance

between

Shaft

body and spool

Remedy

Standard clearance Hole +0.015 +0.007

40 Standard

Clearance limit

size

0.020 0.030

Repair

limit

I Replace

Free length

Installation length

Installation load

Free length

Installation load

122.6

216.7 N (22.1 kg}

120.7

205.9 N 121.0 kg}

Check valve spring

79.2

54.5

5.6 N IO.57 kg}

77.9

5.3 N IO.54 kg)

Check valve spring

79.2

57.5

4.9 N IO.50 kg}

77.9

4.6 N (0.47 kg}

Spool spring

40-29

MAINTENANCE

STEERING CYLINDER MOUNT

STANDARD

STEERING CYLINDER MOUNT

1’

A-A

B-8

SEW01615

Unit: mm

Remedy

Criteria

Check item

Tolerance Clearance between mounting pin and bushing connection of steering cylinder rod and frame

Standard size

110

Clearance between mounting pin and bushing at connection of steering cylinder bottom and frame

Connection of steering cylinder and front frame

Connection of steering cylinder and rear frame

Width of spacer

40-30

Hole

-0.036 -0.090

+0.350 +0.250

Clearance limit

0.286 0.440

1.0

Width of boss

Width of hinge

Standard clearance (Clearance a + b)

s3 0 -0.2

116 f 1.5

0.5 - 3.7

110+0.* 0

116 f 1.5

After adjusting with shim: Less than 1.0

Standard size

Tolerance

Repair limit

10.5 -

Shaft

Standard clearance

+0.5

Replace

MAINTENANCE

EMERGENCY STEERING PUMP

STANDARD

EMERGENCY STEERING PUMP Model SAM(3)lOO + 100

A-A

Unit: mm No.

Check item

Clearance between gear case and side plate gear

Criteria

Pump model

’I

SAM(31100

Standard

SAM(3)lOO

Insertion

clearance

0.10 - 0.15

0.020 - 0.043

Standard 3

Remedy

size

Clearance limit 0.19

0.075

1 Rotatin g torque of spline shaft Discharge Oil: EOlO-CD Temperature: 45 to 55°C

Replace

Tolerance Replace

depth of pin +0.5 0

14 4

13.7 - 23.5 Nm (1.4 - 2.4 kgm)

I Pump model

Re;rpdit;on

Pressure

Standard discharge (elmin)

SAM(31100 + 100

2000

20.6 MPa 210 kg/cm?

352

I Repairlimit discharge Wmin) 312

40-31

MAINTENANCE

STANDARD

STEERING CYLINDER

SEW01617

Unit: mm No

Tolerance

Standard size 1

Remedy

Criteria

Check item

Standard clearance

Shaft

Hole

100

-0.036 -0.090

+0.265 +0.049

0.085 0.355

Clearance between rod and bushing

Clearance between piston rod mounting pin and bushing

110

-0.036 -0.090

+0.307 +0.220

0.256 0.397

Clearance between cylinder bottom mounting pin and bushing

110

-0.036 -0.090

+0.020 0

0.036 0.110

160

Cylinder bore

40-32

Replace bushing

I Standard size

Clearance limit

Tolerance +0.3 0

I I

Repair limit

MAINTENANCE

BRAKE CHAMBER

STANDARD

BRAKE CHAMBER

&-lxlrIi

-7

43.2*5.9Nm (4.4*0.6bml

SEW01618

Unit: mm Remedy

Criteria

Check item

No.

I Tolerance

Clearance piston

Outside

between

diameter

I Air piston stroke

cylinder

Standard size

and

of oil seal

I Standard clearance

Clearance limit

Shaft

Hole

-0.030 -0.076

+0.046 0

0.030 0.122

0.15

69.6

+0.500 -0.300

+0.046 0

0.346 0.500

1.0

Min. 133.5 (Normal

pressure:

Max. 0.93 MPa 19.5 kg/cm%

Replace

40-33

MAINTENANCE

STANDARD

BRAKE VALVE

5 SEW01619

40-34

MAINTENANCE

BRAKE VALVE

STANDARD

Unit: mm No. -

Check item

Clearance between pedal mounting pin and mount plate

Criteria

Remedy

10.0

-0.015 -0.050

+0.036 0

0.086 0.015

10.0

-0.015 -0.050

+0.058 0

0.015 0.108

Clearance between roller and pin

Clearance between mount plate and plunger

26.5

-0.020 -0.160

+0.033 0

0.020 0.193

Clearance between primary piston and upper body

60.0

+o. 150 +0.050

+0.401 +0.325

0.175 0.351

Clearance between relay piston and lower body

66.5

0 -0100

+0.760 +0.100

0.100 0.860

Outside diameter of roller

Standard size 26.2

Repair limit

Tolerance

+0.1

26.0

Replace 7

Free height of rubber spring

14.4

12.0

f0.2

Repair limit

Standard size

Piston return spring

Primary valve spring

Inner stem spring

Free length

Installation length

Installation load

Free length

65.3

14.6

103.0 N {IO.5 kg}

41.3

14.3

44.1 N 14.5 kg}

35.6

16.0

27.5 N c2.8 ka)

30 34

Outer stem spring

41.0

16.0

39.2 N 14.0 kg}

Relay piston spring

39.5

12.1

46.1 N 14.7 kg}

Secondan/ valve spring

16.5

10.2

19.6 N I2.0 kg}

Installation load

40-35

MAINTENANCE

STANDARD

SLACK ADJUSTER

SEW01 620

Unit: mm No.

Check item

Clearance between body and piston

Criteria

80 -

-0.030 -0.076

Slack adjuster spring

Check valve spring

40-36

0.030 0.150

+0.074 0

Standard size

Remedy

0.250

Repair limit

Free length

Installation length

Installation load

Free length

230

117.7 N I12 kg}

45.4

66.7 N {6.8 kg}

Installation load

Replace

MAINTENANCE

STANDARD

PARKING BRAKE

SEW01621 Unit: mm No

Criteria

Check item

Tolerance

Standard size 1

Wear of pad

Remedy Repair limit

Remaining thickness of friction material I

22.7

Including backing plate

31.7

12.7 1.2

Face runout of disc

0.6

Wear of rod connecting pin

12.7

Wear of disc (Thickness of disc)

3.7

-6.10 -6.17

Rebuild Thickness of plate must be under 23 mm

f0.7 Less than 23 mm

Clearance between pad and disc (Total of both sides)

Clearance between brake body and elate

Replace

0.94 Adjust 1.25

40-37

MAINTENANCE

STANDARD

BRAKE

SEW01622

40-38

MAINTENANCE

BRAKE

STANDARD

Unit: mm No.

Remedy

Criteria

Check item

Repair limit

Standard size

d 1

Return spring

Free length

Installation length

Installation load

Free length

Installation load

114.0

98.8

999.3 N 1101.9 kg}

112.3

887.5 N l90.5 kg}

Repair limit

Standard size Thickness of plate

2.15

2.4 3 I Thickness of disc Total thickness of plate and disc

5.1

4.6

107.4

100.4

Standard size

Tolerance

580

0 -0.175

Wear of contact surface of oil seal

Wear of surface in contact with piston seal

585

+O.llO 0

Wear of surface in contact with piston seal

630

+O.llO 0

7 I

Deformation of friction surface of plate and disc

Standard

I I

Replace

Repair limit

0.70

Max. 0.45 I

Backlash between outer gear and plate

0.21 - 0.64

Backlash between inner gear and disc

0.21 - 0.64

40-39

MAINTENANCE

STANDARD

SPRING CYLINDER

SDW0167.3

Unit: mm No.

Criteria

Check item

Remedy

Clearance between cylinder and piston

Clearance between piston insert center boss

Replace

Standard size Piston spring

Free

length 260

Installation length

Repair limit

I Installation load

Free length

7355&490 N {750?50 kg}

Play of rod in axial direction

2.1

Installed dimension of rod

128

Installation load

Adjust -

40-40

MAINTENANCE STANDARD

CONTROL PUMP

CONTROL PUMP (BAR025)

SEW01624

Unit: mm No.

Check item

Criteria

Remedy

Standard size

Repair limit

0.090 - 0.130

0.145

Top clearance of gear Replace

Side clearance of gear

0.055 - 0.075

0.105

Clearance between gear shaft and bushing

0.045 - 0.076

0.13

Discharge Oil: EOIO-CD Temperature: 45 to 55OC Tightening torque for housing case mounting bolt

Pump model

BAR25

Re;rpdition

3,200

Pressure

2.9 MPa (30 kg/cm21

110.3 f 12.3 Nm Ill.25

discharge (Urnin)

Standard

Repair limit discharge (Urnin)

f1.25 kgm}

Tighten

40-4 1

MAINTENANCE

PPC VALVE

STANDARD

PPC VALVE

‘3

11.7 f 1.a*o

.9*3.4Nm 5*0.35koml

SEW01625

40-42

MAINTENANCE

PPC VALVE

STANDARD

Unit: mm

No. -

Standard

Centering spring (Dump, lift arm lower)

Centering spring (Tilt, lift arm raise)

Metering

Return spring

Main valve spring

I Remedy

Criteria

Check item

spring

size

Repair

limit

29.4

33.3 N {3.4 kg}

17.5

14.7 N {I.5 kg}

19.6 N {2.0 kg}

15.7 N Il.6 kg}

30.5

58.4 N 15.95 kg1

47.1 N 14.8 kg}

Replace 6

Poppet

spring

33.6

40-43

MAINTENANCE STANDARD

MAIN

MAIN CONTROL VALVE

CONTROL VALVE

A-A

‘3

B-B

E-E

c-c

40-44

SEW01626

MAINTENANCE

MAIN CONTROL VALVE

STANDARD

Unit: mm No.

Remedy

Criteria

Check item

Repair limit

Standard size

Replace

5.9 N IO.6 kg}

Suction valve spring of safety valve

27.9

18.0

6.9 N to.70 kg1

Suction valve spring

27.9

18.0

6.9 N IO.70 kg}

5.9 N IO.6 kg}

Float sector valve spring

53.0

42.1

137.3 N l14.0 kg1

109.8 N {I 1.2 kg)

Unloader valve spring

82.7

47.0

49.0 N l5.0 kg}

39.2 N 14.0 kg}

Relief valve poppet spring

30.7

26.9

319.7 N 132.6 kg}

256.0 N l26.1 kg}

40-45

MAINTENANCE

STANDARD

DUMP CYLINDER

yrl--_F~;y

kom 2452*245Nm

1250*25kPml

2770*319Nm (28.25*3.25kPml SEW01627

Unit: mm

Clearance between

rod and bushing

MAINTENANCE

LIFT CYLINDER

STANDARD

LIFT CYLINDER

SEW01628

Unit: mm No.

I Check item

Criteria

Remedy

Clearance between rod and bushing 160

-0.043 -0.106

+0.228 +0.048

0.091 0.334

0.634

Clearance between piston rod mounting pin and bushing

180

-0.043 -0.106

+0.395 +0.295

0.338 0.501

1.0

Clearance between cylinder bottom mounting pin and bushing

180

-0.043 -0.106

+0.395 +0.295

0.338 0.501

1.0

Cylinder bore

Standard size 260

I I

Tolerance +0.2 0

Replace bushing

Repair limit Replace

40-47

MAINTENANCE

STANDARD

BUCKET LINKAGE

b SEW01629

40-48

MAINTENANCE STANDARD

BUCKET LINKAGE

Unit: mm No.

Check item

Clearance between pin and bushing at boss ends of bucket link

Remedy

160 2

Clearance between pin and bushing at joint of lift arm and bucket

-0.043 -0.106 -0.043 -0.106

160 I

+0.395 +0.295

0.338 0.501 I

1.0 1.0 I

Clearance between pin and bushing at joint of lift arm and frame

200

-0.050 -0.122

+0.435 +0.320

0.370 0.557

1.0

Clearance between pin and bushing at joint of dump cylinder rod and bellcrank

180

-0.043 -0.106

+0.395 +0.295

0.338 0.501

1.0

Clearance between pin and bushing at joint of dump cylinder bottom and frame

180

-0.043 -0.106

+0.395 +0.295

0.338 0.501

1.0

Clearance between pin and bushing at joint of bellcrank and lift arm

200

-0.050 -0.122

+0.435 +0.320

0.370 0.557

1.0

Clearance between pin and bushing at joint of lift cylinder bottom and frame

Clearance between pin and bushing at joint of lift cylinder rod and bellcrank

180

-0.043 -0.106

+0.395 +0.295

0.338 0.501

1.0

5; Ei

0.338 0.501

+0.395 +0.295

Width between bosses 9

Standard clearance (Clearance a + b)

Width of hinge

Joint of dump cylinder and bellcrank 213 f 0.8

210

+ 0.8 0

1.4 - 3.8

210 f 2.9

0.3 - 7.7

Joint of lift arm and frame

214 + 0.8

Joint of lift arm and bucket

259

+ 1.5 o

254 f 4.9

0.1 - 11.4

Joint of bucket link and bucket

259

+ 1.5 o

254 f 3

2.0 - 9.5

Joint of bellcrank

Joint of lift cylinder

Joint of bellcrank

Joint of lift arm and dump cylinder

213

210

+ 0.8 0

2.2 - 4.0

Joint of lift cylinder

213 * 1.5

210

+ 0.8 0

0.7 - 4.5

Wear of bucket tooth

Replace also if other parts are biting into pin

Insert shims on both sides to make clearance on both left and right sides less than 1.5 mm.

and bucket link and frame

and lift arm

Standard

size

Insert shims on both sides to make clearance on both left and right sides less than 1.5 mm

Repair limit Replace

40-49

MAINTENANCE

BUCKET POSITIONER AND BOOM KICK-OUT

STANDARD

BUCKET POSITIONER

AND BOOM KICK-OUT

&3.3*34.3Nm 19.0*3.5kPml

SEW01630

Unit: mm

No.

Criteria

Check item

Remedy

I 1

Clearance

of bucket position

switch

3 - 5 (no interference)

Clearance

of boom kick-out

switch

3 - 5 (no interference)

Clearance positioner

between bucket protector and switch

40-50

0.5 - 1

Adjust

OTHERS

Hydraulic piping ........................................................................................................................................ Work equipment hydraulic circuit diagram ........................................................................................... Work equipment hydraulic circuit diagram (Machine with joystick steering) ................................... Electric circuit diagram ............................................................................................................................. Electric circuit diagram ............................................................................................................................. Electric circuit diagram (Machine with joystick steering) .................................................................... Connector arrangement diagram ......................................................................................................... Electrical circuit system .......................................................................................................................... Electrical circuit system ..........................................................................................................................

go- 3 go- 5 90- 7 go- 9 90-I 1 90-13 go-201 go-203 go-205

90-l 0

Komatsu America international Company 440 North Fairwav Drive I Vernon Hills, IL 66061-8112 U.S.A. Attn: Technical Publications Fax No. (847) 970-4186

PROPOSAL

FOR MANUAL

REVlslON

FOR INTERNAL USE ONLY -- No. PMR 2

NAME OF COMPANY:

PHONE NO:

: S

DEPARTMENT:

E R

NAME:

MANUAL NAME: MANUAL NO: MACHINE MODEL: S/N IF APPLICABLE: PAGE NO:

PROBLEM:

Attach photo or sketch. If more space is needed, use another sheet.

1 FOR INTERNAL USE ONLY CORRECTIVE ACTION:

PFMRl 081696

LOCATION:

DATE:

STRUCTURE AND FUNCTION

HYDRAULIC PIPING

HYDRA

1. Dump cylinder 2. PPC valve 3. Accumulator 4. Main piston pump 5. Hydraulic oil cooler 6. Triple gear pump (Torque converter charging + PPC) 7. Switch piston pump 8. Transmission 9. Lift cylinder 10. Main control valve

SEW01458

90-3

WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM

STRUCTURE AND FUNCTION

WORK EQUIPMENT

HYDRAULIC

CIRCUIT DIAGRAM

F+_.! TIM

-T

i__

PPC' drain

PPC drain

@):D”IW @:Float @:Loxer @:Raise @:Tilt SW01712

1. Hydraulic tank

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

PPC pump (SAR032) Differential pressure regulating valve Main pump (HPV90+90) E.S. valve Servo valve Servo valve Control pump (BAR0251

9. Relief valve (Set pressure: 2.9 MPa 130 kg/cm% 10. Switch pump (HPV90+90) 11. Steering pump (HPF76+71) 12. Emergency steering pump (SAM(3)100+100) 13. Diverter valve

14. Emergency relief valve (Set pressure: 20.6 MPa I210 kg/cm% 15. Hydraulic oil cooler 16. PPC valve 17. Accumulator 18. PPC relief valve (Set pressure: 3.7 MPa I38 kg/cm211

19. Oil filter 20. Main control valve main relief valve (Set pressure: 31.4 MPa 1320 kg/cm% 21. Dump spool 22. Lift spool 23. Float selector valve (Set pressure: 3.3f0.05 MPa 63.5kO.5 kg/cm% 24. Unloader valve

25. Safety valve (with suction valve) (Set pressure: 36.8 MPa 1375 kg/cm?) 26. Main control valve main relief valve (Set pressure: 31.4 MPa (320 kg/cm% 27. Dump spool 28. Lift spool 29. Float selector valve (Set pressure: 3.3kO.05 MPa (33.5kO.5 kg/cm?) 30. Unloader valve 31. Safety valve (with suction valve) (Set pressure: 36.8 MPa 1375 kg/cmz)) 32. Dump cylinder 33. Lift cylinder 34. Steering demand valve 35. Demand spool 36. Steering spool 37. Steering relief valve 38. Two-way restrictor valve 39. Steering cylinder 40. Steering unit (Orbit-roll valve) 41. Stop valve 42. CO valve 43. NC valve

90-5

WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM

STRUCTURE AND FUNCTION

MACHINE

WITH JOYSTICK STEERING

(( (( I

~---_-------. :______________. -----~----~~~---.

I___._.

iI)

I @):D”W @:Float (g:Lo*er @:lWe @:Ti

It SDW01713

1. Hydraulic tank

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

PPC pump (SAR032) Differential pressure regulating valve Main pump (HPV90+90) E.S. valve Servo valve Servo valve Control pump (BAR0251

9. Relief valve (Set pressure: 2.9 MPa 130 kg/cm211 10. Switch pump (HPV90+90) 11. Steering pump (HPF76+71) 12. Emergency steering pump (SAM(3)100+100) 13. Diverter valve

Emergency relief valve (Set pressure: 20.6 MPa {210 kg/cm?) 15. Hydraulic oil cooler 16. PPC valve 16A. Dump spool 16B. Lift spool 17. Accumulator

18. PPC relief valve (Set pressure: 3.7 MPa I38 kg/cm% 19. Oil filter 20. Main control valve main relief valve (Set pressure: 31.4 MPa 1320 kg/cm% 21. Dump spool 22. Lift spool

23. Float selector valve (Set pressure: 3.3kO.05 MPa (33.5f0.5 kg/cm*}) 24. Unloader valve 25. Safety valve (with suction valve) (Set pressure: 36.8 MPa I375 kg/cm% 26. Main control valve main relief valve (Set pressure: 31.4 MPa 1320 kg/cm% 27. Dump spool 28. Lift spool 29. Float selector valve (Set pressure: 3.3kO.05 MPa (33.5f0.5 kg/cm?) 30. Unloader valve 31. Safety valve (with suction valve) (Set pressure: 36.8 MPa (375 kg/cm% 32. Dump cylinder 33. Lift cylinder 34. Steering demand valve 35. Demand spool 36. Steering spool 37. Steering relief valve 38. Two-way restrictor valve 39. Steering cylinder 40. Steering unit (Orbit-roll valve) 41. Stop valve 42. CO valve 43. NC valve 44. Solenoid valve

90-7