Wheel Loader Shop Manual PDF

CONTENTS
01 10 20 30 40
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 TESTING AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 30-1 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
00-2
The affected pages are indicated by using the following marks. It is requested that necessary actions be taken to these pages according to the table below.
Mark " ! ( )
Indication New page to be added Page to be replaced Page to be deleted
Action Add Replace Discard
Pages without marks were previous additions or revised pages. LIST OF ORIGINAL, NEW AND REVISED PAGES MARK ! " " " " ! PAGE 00-1 00-2 00-2-1 00-2-2 00-2-3 00-2-4 00-3 00-4 00-5 00-6 00-7 00-8 00-9 00-10 00-11 00-12 00-13 00-14 00-15 00-16 00-17 00-18 00-19 00-20 REV MARK PAGE 01-14 REV MARK PAGE 10-37 10-38 10-39 10-40 10-41 10-42 10-43 10-44 10-45 10-46 10-47 10-48 10-49 10-50 10-51 10-52 10-53 10-54 10-55 10-56 10-57 10-58 10-59 10-60 10-61 10-62 10-63 10-64 10-65 10-66 10-67 10-68 10-69 10-70 10-71 10-72 10-73 10-74 10-75 REV MARK PAGE 10-76 10-77 10-78 10-79 10-80 10-81 10-82 10-83 10-84 10-85 10-86 10-87 10-88 10-89 10-90 10-91 10-92 10-93 10-94 10-95 10-96 10-97 10-98 10-99 10-100 10-101 10-102 10-103 10-104 10-105 10-106 10-107 10-108 10-109 10-110 10-111 10-112 10-113 10-114 REV
! !
! !
01-1 01-2 01-3 01-4 01-5 01-6 01-7 01-8 01-9 01-10 01-11 01-12 01-13
10-1 10-2 10-3 10-4 10-4 10-6 10-7 10-8 10-9 10-10 10-11 10-12 10-13 10-14 10-15 10-16 10-17 10-18 10-19 10-20 10-21 10-22 10-23 10-24 10-25 10-26 10-27 10-28 10-29 10-30 10-31 10-32 10-33 10-34 10-35 10-36
! !
00-2-1
MARK
PAGE 10-115 10-116 10-117 10-118 10-119 10-120 10-121 10-122 10-123 10-124 10-125 10-126 10-127 10-128 10-129 10-130 10-131 10-132 10-133 10-134 10-135 10-136 10-137 10-138 10-139 10-140
REV
MARK
PAGE 20-21 20-22 20-23 20-24 20-25 20-26 20-27 20-28 20-29 20-30 20-31 20-32 20-33 20-34 20-35 20-36 20-37 20-38 20-39 20-40 20-41 20-42 20-43 20-44 20-45 20-46 20-47 20-48 20-49 20-50 20-51 20-52 20-53 20-54 20-55 20-56 20-57 20-58 20-59 20-60 20-61 20-62 20-63 20-64 20-65 20-66 20-67 20-68 20-69
REV
MARK
PAGE 20-70 20-71 20-72 20-73 20-74 20-75 20-76 20-77 20-78 20-79 20-80 20-81 20-82 20-83 20-84 20-85 20-86 20-87 20-88 20-89 20-90 20-91 20-92 20-93 20-94 20-95 20-96 20-97 20-98 20-99 20-100 20-101 20-102 20-103 20-104 20-105 20-106 20-107 20-108 20-109 20-110 20-111 20-112 20-113 20-114 20-115 20-116 20-117 20-118
REV
MARK
PAGE 20-119 20-120 20-121 20-122 20-123 20-124 20-125 20-126 20-127 20-128
REV
! !
20-1 20-2 20-3 20-4 20-5 20-6 20-7 20-8 20-9 20-10 20-11 20-12 20-13 20-13 20-14 20-15 20-16 20-17 20-18 20-19 20-20
20-201 20-202 20-203 20-204 20-205 20-206 20-207 20-208 20-209 20-210 20-211 20-212 20-213 20-214 20-215 20-216 20-217 20-218 20-219 20-220
20-401 20-402 20-403 20-404 20-405 20-406 20-407 20-408 20-409 20-410 20-411 20-412 20-413 20-414 20-415
00-2-2
MARK
PAGE 20-416 20-417 20-418 20-419 20-420 20-421 20-422 20-423 20-424
REV
MARK " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " "
PAGE 30-13 30-13 30-14 30-15 30-16 30-17 30-18 30-19 30-20 30-21 30-22 30-23 30-24 30-25 30-26 30-27 30-28 30-29 30-30 30-31 30-32 30-33 30-34 30-35 30-36 30-37 30-38 30-39 30-40 30-41 30-42 30-43 30-44 30-45 30-46 30-47 30-48 30-49 30-50 30-51 30-52 30-53 30-54 30-55 30-56 30-57 30-58 30-59
REV
MARK " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " "
PAGE 30-61 30-62 30-63 30-64 30-65 30-66 30-67 30-68 30-69 30-70 30-71 30-72 30-73 30-74 30-75 30-76 30-77 30-78 30-79 30-80 30-81 30-82 30-83 30-84 30-85 30-86 30-87 30-88 30-89 30-90 30-91 30-92 30-93 30-94 30-95 30-96 30-97 30-98 30-99 30-100 30-101 30-102 30-103 30-104 30-105 30-106 30-107 30-108
REV
MARK " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " "
PAGE 30-110 30-111 30-112 30-113 30-114 30-115 30-116 30-117 30-118 30-119 30-120 30-121 30-122 30-123 30-124 30-125 30-126 30-127 30-128 30-129 30-130 30-131 30-132 30-133 30-134 30-135 30-136 30-137 30-138 30-139 30-140 30-141 30-142 30-143 30-144 30-145 30-146 30-147 30-148 30-149 30-150 30-151 30-152 30-153 30-154 30-155 30-156 30-157
REV
20-501 20-502 20-503 20-504 20-505 20-506 20-507 20-508 20-509 20-510 20-511 20-512 20-513 20-514 20-515 20-516
20-701 20-702 20-703 20-704 20-705 20-706
" " " " " " " " " "
30-1 30-2 30-3 30-4 30-5 30-6 30-7 30-8 30-9 30-10 30-11
00-2-3
MARK " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " "
PAGE 30-12 30-159 30-160 30-161 30-162 30-163 30-164 30-165 30-166 30-167 30-168 30-169 30-170 30-171 30-172 30-173 30-174 30-175 30-176 30-177 30-178 30-179 30-180 30-181 30-182 30-183 30-184 30-185 30-186 30-187 30-188 30-189 30-190 30-191 30-192 30-193 30-194 30-195 30-196 30-197 30-198 30-199 30-200 30-201 30-202 30-203 30-204 30-205
REV
MARK " " " " " " " " " " " " " " " " " " " "
PAGE 30-60 30-206 30-207 30-208 30-209 30-210 30-211 30-212 30-213 30-214 30-215 30-216 30-217 30-218 30-219 30-220 30-221 30-222 30-223 30-224
REV
MARK "
PAGE 30-109 40-27 40-28 40-29 40-30 40-31 40-32 40-33 40-34 40-35 40-36 40-37 40-38 40-39 40-40 40-41 40-42 40-43 40-44 40-45 40-46 40-46 40-47 40-48 40-49 40-50 40-51 40-52
REV
MARK "
PAGE
REV
30-158 FOLD-OUTS 10-120 10-121
40-1 40-2 40-3 40-4 40-5 40-6 40-7 40-8 40-9 40-10 40-11 40-12 40-13 40-14 40-15 40-16 40-17 40-18 40-19 40-20 40-21 40-22 40-23 40-24 40-25 40-26
00-2-4
PRODUCT PUBLICATIONS INFORMATION
VARIOUS PRODUCT PARTS & SERVICE PUBLICATIONS ARE AVAILABLE TO ALL KOMATSU CONSTRUCTION EQUIPMENT OWNERS, INCLUDING OPERATION & MAINTENANCE MANUALS, PARTS BOOKS AND SHOP MANUALS.
SPECIAL PUBLICATIONS SUCH AS SERVICE TOOL, AIR CONDITIONING, AND TURBOCHARGER SHOP MANUALS ARE ALSO AVAILABLE AS WELL AS SELECTED OPERATION & MAINTENANCE AND SHOP MANUALS IN FOREIGN LANGUAGES.
THE PUBLICATIONS LISTED BELOW ARE AVAILABLE FOR THIS PARTICULAR MACHINE(S).
DESCRIPTION PARTS BOOK - PAPER: Engine and Chassis
FORM NUMBER
BEPB002100
PARTS BOOK - MICROFICHE: Engine and Chassis BEPM002100
OPERATION & MAINTENANCE MANUAL: Engine and Chassis CEAM001300
SHOP MANUAL: Chassis Engine: CEBM001101 SEBM010002
SAFETY MANUAL
WLT70-1
PARTS AND SERVICE PUBLICATIONS CAN ONLY BE ACQUIRED BY AUTHORIZED KOMATSU DISTRIBUTORS, USING THE KOMATSU AMERICA INTERNATIONAL COMPANY PARTS INFORMATION PROCESSING SYSTEM (PIPS). IF THE PIPS SYSTEM IS NOT AVAILABLE AT THE DISTRIBUTOR LOCATION, THEN THE FOLLOWING REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS CAN BE USED. FORM KDC91D IS SHOWN ON THE REVERSE SIDE OF THIS PAGE.
00-3
REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS
COMPLETE FORM AND RETURN TO < Komatsu 440 North Fairway Drive Vernon Hills, IL 60061-8112 U.S.A. Attn: Technical Publications Fax No. (847) 970-4186 Tel No. (847) 970-5887
America International Company
COMPANY NAME
SHIP TO
<
ATTN. STREET ADDRESS
PURCHASE ORDER NO.
ORDER DATE
TYPE or PRINT ONLY
<
CITY, STATE, ZIP CODE COUNTRY
PHONE NO.
FAX NO.
SHIPPING METHOD
DISTR/BRANCH CODE
IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND MACHINE SERIAL NUMBER MUST BE SHOWN.
PARTS BOOK QTY. PUBLICATION FORM NO.
P-Paper M-Microfiche
PUBLICATION DESCRIPTION
MODEL NUMBER
SERIAL NUMBER
KDC91D 081696
CURRENT PRICES WILL BE CHARGED
00-4
SAFETY
SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended and described in this manual are both effective and safe methods of operation. Some of these operations require the use of tools specially designed for the purpose. To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. ! Always wear safety glasses when hitting parts with a hammer. ! Always wear safety glasses when grinding parts with a grinder, etc.
clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. PREPARATIONS FOR WORK 7. Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
8.
9. 3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them. 6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area
10.
PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil,
00-5
SAFETY water or air circuits, first remove the pressure completely from the circuit. 12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 13. Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first. 14. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16. When removing components, be careful not to break or damage the wiring, Damaged wiring may cause electrical fires. 17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18.
SAFETY NOTICE As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts. Be sure to assemble all parts again in their original places. Replace any damaged part with new parts. ! When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 20. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.
19.
21.
22.
23.
24.
00-6
FOREWARD
GENERAL
FOREWARD
GENERAL This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components. GENERAL This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts. STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating "Problems" to "Causes" are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. MAINTENANCE STANDARD This section gives the judgement standards when inspecting disassembled parts.
NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your distributor for the latest information.
00-7
FOREWARD
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL

VOLUMES Shop manuals are issued as a guide to carrying out repairs. They are divided as follows: Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Electrical volume: Each issued as one to cover all models Attachment volume: Each issued as one to cover all models These various volumes are designed to avoid duplication of information. Therefore to deal with all repairs for any model, it is necessary that chassis, engine electrical and attachment be available. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to your distributors. Get the most up-to-date information before you start any work. FILING METHOD Caution 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number: Example 1 (Chassis volume): 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item Example 2 (Engine volume): Refer to the pertinent engine manual. Drain 3. Additional pages: Additional pages are indicated by a hyphen (-) and numbered after the page number. File as in the example. Example: 10-4 10-4-1 Added pages 10-4-2 A 10-5 REVISED EDITION MARK When a manual is revised, an edition mark ( ....) is recorded on the bottom outside corner of the pages. REVISIONS Revised pages are shown at the LIST OF REVISED PAGES between the title page and SAFETY page. SYMBOLS So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following symbols.
Symbol
Item Safety
Remarks
Special safety precautions are necessary when performing the work. Special technical precautions or other precautions for preserving standards are necessary when performing the work. Weight of parts or systems. Caution necessary when selecting hoisting wire or when working posture is important, etc. Places that require special attention for tightening torque during assembly. Places to be coated with adhesives and lubricants etc. Places where oil, water or fuel must be added, and the capacity. Places where oil or water must be drained, and quantity to be drained.
Weight
Tightening torque
Coat Oil, water
00-8
FOREWARD
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
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 parts. 2) Check for existence of another part causing interface with the part to be removed. WIRE ROPES 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard "Z" or "S" twist ropes without galvanizing Rope diameter (mm) 10.0 11.2 12.5 14.0 16.0 18.0 20.0 22.4 30.0 40.0 50.0 60.0 Allowable load (tons) 1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0
3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load.
Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 4) Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight becomes 1000 kg when two ropes make a 120E hanging angle. On the other hand, two ropes are subject to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150E.
The allowable load value is estimated to be 1/6 or 1/7 of the breaking strength of the rope used. 2) Sling wire ropes from the middle portion of the hook. 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.
00-9
FOREWARD
COATING MATERIALS
COATING MATERIALS
The recommended coating materials prescribed in the shop manuals are listed below.
Category Code LT-1A Part No. 790-129-9030 Qty 150 g Container Tube Plastic container Plastic container Can Plastic container --Tube Main applications,features ! Used to prevent rubber gaskets, rubber cushions and cork plugs from coming out ! Used in places requiring an immediately effective, strong adhesive. Used for plastics (except polyethylene, polypropylene, tetrafluoroethylene, and vinyl chloride), rubber, metal and non-metal. ! Features: Resistance to heat, chemicals ! Used for anti-loosening and sealant purposes for bolts and plugs. ! Used as adhesive or sealant for metal, glass or plastic.
LT-1B
790-129-9050
20 g (x2)
LT-2 Adhesive LT-3
09940-00030 790-129-9060 Set of adhesive and hardening agent 790-129-9040 79A-129-9110 790-129-9010
50 g Adh 1 kg Hard agt 500 kg 250 g 50 cc 200 g
LT-4 Loctite 648-50 LG-1
! Used as sealant for machined holes. ! Features: Resistance to heat, chemicals ! Used at joint portions subject to high temperature. ! Used as adhesive or sealant for gaskets and packing of power train case, etc. ! 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 resistant gasket for at high temperature locations such as engine pre-combustion chamber, exhaust pipe. ! ! ! ! Features: Resistance towater, 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.
LG-3
790-129-9070
1 kg
Can
Gasket sealant
LG-4
790-129-9020
200 g
Tube
LG-5
790-129-9080
1 kg
Plastic container Tube
! Used as sealant for various threads, pipe joints, flanges. ! Used as sealant for tapered plugs, elbows, nipples of hydraulic piping. ! Features: Silicon based, resistant to heat, cold. ! Used as sealant for flange surface, thread. ! Used as sealant for oil pan, final drive case, etc. ! Features: Silicon based, quick hardening type. ! Used as sealant for flywheel housing, intake manifold, oil pan, thermostat housing, etc. ! Used as lubricant for sliding parts (to prevent squeaking). ! Used to prevent seizure or scuffing of the thread when press fitting or shrink fitting. ! Used as lubricant for linkage, bearings, etc.
LG-6
09940-00011
250 g
LG-7 Rust preven-tion lubricant Molybdenum disulfide lubricant
09920-00150
150 g
Tube
---
09940-00051
60 g
Can
---
09940-00040 SYG-350Ll SYG-400Ll SYG-400Ll-A SYG-160Ll SYGA-160CNLl SSG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-16CNCA SYG2-400M
200 g
Tube
Lithium grease
G2-L1
Various
Various
! General purpose type
Calcium grease
G2-CA
Various
Various
! Used for normal temperature, light load bearing at places in contact with water or steam.
Molybdenum disulfide grease
---
400 g (10/case)
Bellows type
! Used for places with heavy load.
00-10
FOREWARD
STANDARD TORQUE REQUIREMENTS

STANDARD TORQUE REQUIREMENTS OF BOLTS AND NUTS The following charts give the standard torques values of bolts and nuts. Exceptions are given in sections of DISASSEMBLY AND ASSEMBLY. 1 kgm = 9.806 Nm Thread diameter of bolt Width across flat
mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39
mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60
kgm 1.35 0.15 3.20 0.3 6.70 0.7 11.5 1.0 18 2.0 28.5 3 39 4 56 6 76 8 94.5 10 135 15 175 20 225 25 280 30 335 35
Nm 13.2 1.4 31.4 2.9 65.7 6.8 112 9.8 177 19 279 29 383 39 549 58 745 78 927 98 1320 140 1720 190 2210 240 2750 290 3280 340
This torque table does not apply to the bolts with which nylon packing or other non-ferrous metal washers are to be used, or which require torquing to otherwise specified values.
00-11
FOREWARD TORQUE REQUIREMENTS OF SPLIT FLANGE BOLTS Use these torques values for split flange bolts. Thread diameter of bolt mm 10 12 16 Width across flat mm 14 17 22
torque requirement values kgm 6.70 0.7 11.5 1.0 28.5 3 Nm 65.7 6.8 112 9.8 279 29
TORQUE REQUIREMENTS FOR FLAIRED NUTS Use these torque values for flaired part of nut. Thread diameter of bolt mm 14 18 22 24 30 33 36 42 Width across flat mm 19 24 27 32 36 41 46 55 torque requirement values kgm 2.5 0.5 5 2 8 2 14 3 18 3 20 5 25 5 30 5 Nm 24.5 4.9 49 19.6 78.5 19.6 137.3 29.4 176.5 29.4 196.1 49 245.2 49 294.2 49
00-12
FOREWARD
ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe. CLASSIFICATION BY THICKNESS
Copper wire Nominal number 0.85 2 5 15 40 60 100 Number of strands 11 26 65 84 85 127 217 Dia. Of strand (mm) 0.32 0.32 0.32 0.45 0.80 0.80 0.80 Cross section (mm) 0.88 2.09 5.23 13.36 42.73 63.84 109.1 Cable O.D. (mm) 2.4 3.1 4.6 7.0 11.4 13.6 17.6 Current rating (A) 12 20 37 59 135 178 230 Applicable circuit
Starting, lighting, signal etc. Lighting, signal etc. Charging and signal Starting (Glow plug) Starting Starting Starting
CLASSIFICATION BY COLOR AND CODE

Priority 1
Classification
Circuits Code
Charging W White WR White/Red WB

White/Black
Ground B Black ---------------------
Starting B Black BW
Black/White
Lighting R Red RW
Red/White
Instruments
Signal G Green GW
Green/White
Other L Blue LW
Blue/White
Y Yellow YR
Yellow/Red
Primary Color Code
2 Color Code BY
Black/Yellow
RB
Red/Black
YB
Yellow/Black
GR
Green/Red
LR Blue/Red LY
Blue/Yellow
Color Code Auxiliary Color Code
WL
White/Blue
BR Black/Red ---------
RY
Red/Yellow
YG
Yellow/Green
GY
Green/Yellow
WG
White/Green
RG
Red/Green
YL Yellow/Blue YW
Yellow/White
GB
Green/Black
LB Blue/Black -----
5 Color Code 6 Color --Red/Blue

Green/Blue
---
RL
GL
00-13
FOREWARD
CONVERSION TABLES
CONVERSION TABLES
METHOD OF USING THE CONVERSION TABLE The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. EXAMPLE ! Method of using the Conversion Table to convert from millimeters to inches. 1. Convert 55 mm into inches. (1) Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line from . (2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down from . (3) Take the point where the two lines cross as . This point gives the value when converting from millimeters to inches. Therefore, 55 millimeters = 2.165 inches. 2. Convert 550 mm into inches. (1) The number 550 does not appear in the table, so divide by 10 (move the decimal 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 one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to Inches mm 0 10 20 30 40 50 60 70 80 90 0 0.394 0.787 1.181 1.575 1.969 2.362 2.756 3.150 3.543 0 1 0.039 0.433 0.827 1.220 1.614 2.008 2.402 2.795 3.189 3.583 2 0.079 0.472 0.866 1.260 1.654 2.047 2.441 2.835 3.228 3.622 3 0.118 0.512 0.906 1.299 1.693 2.087 2.480 2.874 3.268 3.661 4 0.157 0.551 0.945 1.339 1.732 2.126 2.520 2.913 3.307 3.701 5 0.197 0.591 0.984 1.378 1.772 2.165 2.559 2.953 3.346 3.740 6 0.236 0.630 1.024 1.417 1.811 7 0.276 0.669 1.063 1.457 1.850 2.244 2.638 3.032 3.425 3.819
1 mm = 0.03937 in 8 0.315 0.709 1.102 1.496 1.890 2.283 2.677 3.071 3.465 3.858 9 0.354 0.748 1.142 1.536 1.929 2.323 2.717 3.110 3.504 3.898
2.205 2.598 2.992 3.386 3.780
00-14
FOREWARD Millimeters to Inches
CONVERSION TABLES
1 mm = 0.03937 in mm 0 10 20 30 40 0 0.394 0.787 1.181 1.575 0 1 0.039 0.433 0.827 1.220 1.614 2 0.079 0.472 0.866 1.260 1.654 3 0.118 0.512 0.906 1.299 1.693 4 0.157 0.551 0.945 1.339 1.732 5 0.197 0.591 0.984 1.378 1.772 6 0.236 0.630 1.024 1.417 1.811 7 0.276 0.669 1.063 1.457 1.850 8 0.315 0.709 1.102 1.496 1.890 9 0.354 0.748 1.142 1.536 1.929
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
2.008 2.402 2.795 3.189 3.583
2.047 2.441 2.835 3.228 3.622
2.087 2.480 2.874 3.268 3.661
2.126 2.520 2.913 3.307 3.701
2.165 2.559 2.953 3.346 3.740
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.032 3.425 3.819
2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
Kilogram to Pound 1 kg = 2.2046 lb kg 0 10 20 30 40 0 0 22.05 44.09 66.14 88.18 1 2.20 24.25 46.30 68.34 90.39 2 4.41 26.46 48.50 70.55 92.59 3 6.61 28.66 50.71 72.75 94.80 4 8.82 30.86 51.91 74.96 97.00 5 11.02 33.07 55.12 77.16 99.21 6 13.23 35.27 57.32 79.37 101.41 7 15.43 37.48 59.53 81.57 103.62 8 17.64 39.68 61.73 83.78 105.82 9 19.84 41.89 63.93 85.98 108.03
50 60 70 80 90
110.23 132.28 154.32 176.37 198.42
112.44 134.48 156.53 178.57 200.62
114.64 136.69 158.73 180.78 202.83
116.85 138.89 160.94 182.98 205.03
119.05 141.10 163.14 185.19 207.24
121.25 143.30 165.35 187.39 209.44
123.46 145.51 167.55 189.60 211.64
125.66 147.71 169.76 191.80 213.85
127.87 149.91 171.96 194.01 216.05
130.07 152.12 174.17 196.21 218.26
00-15
FOREWARD Liter to U.S. Gallon
CONVERSION TABLES
1R = 0.2642 U.S. Gal
R
0 10 20 30 40 0
1 0.264 2.906 5.548 8.189 10.831
2 0.528 3.170 5.812 8.454 11.095
3 0.793 3.434 6.076 8.718 11.359
4 1.057 3.698 6.340 8.982 11.624
5 1.321 3.963 6.604 9.246 11.888
6 1.585 4.227 6.869 9.510 12.152
7 1.849 4.491 7.133 9.774 12.416
8 2.113 4.755 7.397 10.039 12.680
9 2.378 5.019 7.661 10.303 12.944
2.642 5.283 7.925 10.567
50 60 70 80 90
13.209 15.850 18.492 21.134 23.775
13.473 16.115 18.756 21.398 24.040
13.737 16.379 19.020 21.662 24.304
14.001 16.643 19.285 21.926 24.568
14.265 16.907 19.549 22.190 24.832
14.529 17.171 19.813 22.455 25.096
14.795 17.435 20.077 22.719 25.361
15.058 17.700 20.341 22.983 25.625
15.322 17.964 20.605 23.247 25.889
15.586 18.228 20.870 23.511 26.153
Liter to U.K. Gallon 1R = 0.21997 U.K. Gal
R
0 10 20 30 40 0
1 0.220 2.420 4.619 6.819 9.019
2 0.440 2.640 4.839 7.039 9.239
3 0.660 2.860 5.059 7.259 9.459
4 0.880 3.080 5.279 7.479 9.679
5 1.100 3.300 5.499 7.699 9.899
6 1.320 3.520 5.719 7.919 10.119
7 1.540 3.740 5.939 8.139 10.339
8 1.760 3.950 6.159 8.359 10.559
9 1.980 4.179 6.379 8.579 10.778
2.200 4.399 6.599 8.799
50 60 70 80 90
10.998 13.198 15.398 17.598 19.797
11.281 13.418 15.618 17.818 20.017
11.438 13.638 15.838 18.037 20.237
11.658 13.858 16.058 18.257 20.457
11.878 14.078 16.278 18.477 20.677
12.098 14.298 16.498 18.697 20.897
12.318 14.518 16.718 18.917 21.117
12.528 14.738 16.938 19.137 21.337
12.758 14.958 17.158 19.357 21.557
12.978 15.178 17.378 19.577 21.777
00-16
FOREWARD kgm to ft. lb
CONVERSION TABLES
1 kgm = 7.233 ft. lb kgm 0 10 20 30 40 0 0 72.3 144.7 217.0 289.3 1 7.2 79.6 151.9 224.2 296.6 2 14.5 86.8 159.1 231.5 303.8 3 21.7 94.0 166.4 238.7 311.0 4 28.9 101.3 173.6 245.9 318.3 5 36.2 108.5 180.8 253.2 325.5 6 43.4 115.7 188.1 260.4 332.7 7 50.6 123.0 195.3 267.6 340.0 8 57.9 130.2 202.5 274.9 347.2 9 65.1 137.4 209.8 282.1 354.4
50 60 70 80 90
361.7 434.0 506.3 578.6 651.0
368.9 441.2 513.5 585.9 658.2
376.1 448.5 520.8 593.1 665.4
383.4 455.7 528.0 600.3 672.7
390.6 462.9 535.2 607.6 679.9
397.8 470.2 542.5 614.8 687.1
405.1 477.4 549.7 622.0 694.4
412.3 484.6 556.9 629.3 701.6
419.5 491.8 564.2 636.5 708.8
426.8 499.1 571.4 643.7 716.1
100 110 120 130 140
723.3 795.6 868.0 940.3 1012.6
730.5 802.9 875.2 947.5 1019.9
737.8 810.1 882.4 954.8 1027.1
745.0 817.3 889.7 962.0 1034.3
752.2 824.6 896.9 969.2 1041.5
759.5 831.8 904.1 976.5 1048.8
766.7 839.0 911.4 983.7 1056.0
773.9 846.3 918.6 990.9 1063.2
781.2 853.5 925.8 998.2 1070.5
788.4 860.7 933.1 1005.4 1077.7
150 160 170 180 190
1084.9 1157.3 1129.6 1301.9 1374.3
1092.2 1164.5 1236.8 1309.2 1381.5
1099.4 1171.7 1244.1 1316.4 1388.7
1106.6 1179.0 1251.3 1323.6 1396.0
1113.9 1186.2 1258.5 1330.9 1403.2
1121.1 1193.4 1265.8 1338.1 1410.4
1128.3 1200.7 1273.0 1345.3 1417.7
1135.6 1207.9 1280.1 1352.6 1424.9
1142.8 1215.1 1287.5 1359.8 1432.1
1150.0 1222.4 1294.7 1367.0 1439.4
00-17
FOREWARD kg/cm to lb/in
CONVERSION TABLES
1kg/cm = 14.2233 lb/in kg/cm 0 10 20 30 40 0 0 142.2 284.5 426.7 568.9 1 14.2 156.5 298.7 440.9 583.2 2 28.4 170.7 312.9 455.1 597.4 3 42.7 184.9 327.1 469.4 611.6 4 56.9 199.1 341.4 483.6 625.8 5 71.1 213.4 355.6 497.8 640.1 6 85.3 227.6 369.8 512.0 654.3 7 99.6 241.8 384.0 526.3 668.5 8 113.8 256.0 398.3 540.5 682.7 9 128.0 270.2 412.5 554.7 696.9
50 60 70 80 90
711.2 853.4 995.6 1138 1280
725.4 867.6 1010 1152 1294
739.6 881.8 1024 1166 1309
753.8 896.1 1038 1181 1323
768.1 910.3 1053 1195 1337
782.3 924.5 1067 1209 1351
796.5 938.7 1081 1223 1365
810.7 953.0 1095 1237 1380
825.0 967.2 1109 1252 1394
839.2 981.4 1124 1266 1408
100 110 120 130 140
1422 1565 1707 1849 1991
1437 1579 1721 1863 2005
1451 1593 1735 1877 2020
1465 1607 1749 1892 2034
1479 1621 1764 1906 2048
1493 1636 1778 1920 2062
1508 1650 1792 1934 2077
1522 1664 1806 1949 2091
1536 1678 1821 1963 2105
1550 1693 1835 1977 2119
150 160 170 180 190
2134 2276 2418 2560 2702
2148 2290 2432 2574 2717
2162 2304 2446 2589 2731
2176 2318 2460 2603 2745
2190 2333 2475 2617 2759
2205 2347 2489 2631 2773
2219 2361 2503 2646 2788
2233 2375 2518 2660 2802
2247 2389 2532 2674 2816
2262 2404 2546 2688 2830
200 210 220 230 240
2845 2987 3129 3271 3414
2859 3001 3143 3286 3428
2873 3015 3158 3300 3442
2887 3030 3172 3314 3456
2901 3044 3186 3328 3470
2916 3058 3200 3343 3485
2930 3072 3214 3357 3499
2944 3086 3229 3371 3513
2958 3101 3243 3385 3527
2973 3115 3257 3399 3542
00-18
FOREWARD Temperature
CONVERSION TABLES
Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vise versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1EC = 33.8EF EC -40.4 -37.2 -34.4 -31.7 -28.9 -28.3 -27.8 -27.2 -26.7 26.1 -25.6 -25.0 -24.4 -23.9 -23.3 -22.8 -22.2 -21.7 -21.1 -20.6 -20.0 -19.4 -18.9 -18.3 -17.8 -17.2 -16.7 -16.1 -15.6 -15.0 -14.4 -13.9 -13.3 -12.8 -12.2 -40 -35 -30 -25 -20 -19 -18 -17 -16 -15 -14 -13 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10 EF -40.0 -31.0 -22.0 -13.0 -4.0 -2.2 -0.4 1.4 3.2 5.0 6.8 8.6 10.4 12.2 14.0 15.8 17.6 19.4 21.2 23.0 24.8 26.6 28.4 30.2 32.0 33.8 35.6 37.4 39.2 41.0 42.8 44.6 46.4 48.2 50.0 EC -11.7 -11.1 -10.6 -10.0 -9.4 -8.9 -8.3 -7.8 -7.2 -6.7 -6.1 -5.6 -5.0 -4.4 -3.9 -3.3 -2.8 -2.2 -1.7 -1.1 -0.6 0 0.6 1.1 1.7 2.2 2.8 3.3 3.9 4.4 5.0 5.6 6.1 6.7 7.2 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 EF 51.8 53.6 55.4 57.2 59.0 60.8 62.6 64.4 66.2 68.0 69.8 71.6 73.4 75.2 77.0 78.8 80.6 82.4 84.2 86.0 87.8 89.6 91.4 93.2 95.0 96.8 98.6 100.4 102.2 104.0 105.8 107.6 109.4 111.2 113.0 EC 7.8 8.3 8.9 9.4 10.0 10.6 11.1 11.7 12.2 12.8 13.3 13.9 14.4 15.0 15.6 16.1 16.7 17.2 17.8 18.3 18.9 19.4 20.0 20.6 21.1 21.7 22.2 22.8 23.3 23.9 24.4 25.0 25.6 26.1 26.7 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 EF 114.8 116.6 118.4 120.2 122.0 123.8 125.6 127.4 129.2 131.0 132.8 134.6 136.4 138.2 140.0 141.8 143.6 145.4 147.2 149.0 150.8 152.6 154.4 156.2 158.0 159.8 161.6 163.4 165.2 167.0 168.8 170.6 172.4 174.2 176.0 EC 27.2 27.8 28.3 28.9 29.4 30.0 30.6 31.1 31.7 32.2 32.8 33.3 33.9 34.4 35.0 35.6 36.1 36.7 37.2 37.8 40.6 43.3 46.1 48.9 51.7 54.4 57.2 60.0 62.7 65.6 68.3 71.1 73.9 76.7 79.4 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 EF 117.8 179.6 181.4 183.2 185.0 186.8 188.6 190.4 192.2 194.0 195.8 197.6 199.4 201.2 203.0 204.8 206.6 208.4 210.2 212.0 221.0 230.0 239.0 248.0 257.0 266.0 275.0 284.0 293.0 302.0 311.0 320.0 329.0 338.0 347.0
00-19
FOREWARD
MEMORANDA
00-20
01 GENERAL
SPECIFICATION DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . 01- 2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01- 3 WEIGHT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01- 6 FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . 01- 7 ENGINE OIL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 01- 8 DIESEL FUEL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 01- 9 COOLANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 01-10
01-1
GENERAL
SPECIFICATION DRAWINGS
SPECIFICATION DRAWINGS
WA180-3
01-2
GENERAL
SPECIFICATIONS Model: WA180-3 Serial Number: A80001 and up WEIGHT (Includes full fuel tank,and optional counterweigh) Operating weight Distribution front axle Distribution rear axle PERFORMANCE Bucket capacity (piled) Rated load 1st 2nd FORWARD 3rd 4th 1st REVERSE 2nd 3rd 4th Grade ability Minimum turning radius DIMENSIONS Overall length Overall width (chassis) Bucket width (with bolt on cutting edge)) Overall height (top of cab) Overall height (bucket raised) Wheelbase Tread Minimum ground clearance Height of bucket hinge pin Dumping clearance (tip of cutting edge) 6415 mm 2260 mm 2440 mm 3095 mm 4695 mm 2700 mm 1820 mm 425 mm 3540 mm 2715 (2775) mm Outside of chassis Center of outside wheel 1.7 m 2720 kg 7.2 km/h 12.0 km/h 22.0 km/h 34.5 km/h 7.7 km/h 12.6 km/h 22.9 km/h 35.0 km/h 25 deg 5385 mm 4650 mm 8750 kg 3460 kg 5290 kg Size Tire 17.5-25 -12PR, L2
SPECIFICATIONS
Travel speed
01-3
GENERAL
Dumping reach (tip of cutting edge) Bucket dump angle Bucket tilt (SAE carrying position) Digging depth (10E dump angle) ENGINE Model Type Number of cylinders - bore x stroke Piston displacement Gross power @ 2400 rpm Maximum torque @ 1600 RPM High idle Low idle Starting motor Alternator Battery POWER TRAIN Torque converter Transmission Reduction gear Differential Final drive AXLE, WHEEL, AND TIRE Drive type Front axle Rear axle Standard tire Wheel rim Front tire inflation pressure Rear tire inflation pressure 985 (960) mm 45 deg 46 deg 290 mm
SPECIFICATIONS
S6D102E-1 diesel engine Direct injection (Aspiration, Turbo charged) 6 - 102 mm x 120 mm 5.88 R (359 in) 82 kW 426 NCm (314 lbf ft) 2600 rpm 850 rpm 24V, 4.5 kW 24V, 50A 12V, 110Ah x 2
3-element, 1-stage, single-phase (Komatsu TCA30-6Z) Spur gear, constant-mesh multiple-disc, hydraulic actuated, modulation type Spiral bevel gear Straight bevel gear, torque proportioning Planetary gear, single reduction
Front/rear wheel drive Fixed frame, semi-floating Center pin support type, semi-floating type 17.5-25 x 12 pr (L2) 25 x 13.00 294 kPa (3.0 kg/cm) 294 kPa (3.0 kg/cm)
01-4
GENERAL
BRAKES Main brakes Parking brake STEERING SYSTEM Type Structure HYDRAULIC SYSTEM Hydraulic pump type Delivery Control valves: Set pressure for work equipment Set pressure for steering Cylinders: Boom - qty. - bore x stroke Bucket - qty. - bore x stroke Steering - qty. - bore x stroke WORK EQUIPMENT Linkage type Bucket edge type Gear pump 144 R/min. Articulated type
SPECIFICATIONS
Front/rear wheel independent wet-type sealed disc brakes with hydraulic booster Thrust shaft (transmission shaft) braking, wet-type disc brake, mechanical type
Fully hydraulic power steering
Spool type 20.59 MPA (210 kg/cm) Spool type 18.64 MPa (190 kg/cm) Reciprocating piston 2 - 110 x 618 1 - 120 x 423 2 - 60 x 340
Single link (Z-bar linkage) Flat edge with bolt on cutting edge
01-5
GENERAL
WEIGHT TABLE
WEIGHT TABLE
Machine model Serial No. WA180-3 A80001 and up kg Engine (with air cleaner & muffler) Radiator Torque converter Transmission with torque converter Center drive shaft Front drive shaft Rear drive shaft Front axle Rear axle Axle pivot Wheel (each) Tire (each) Orbit-roll valve Priority valve Steering cylinder (each) Hydraulic tank Equipment / Steering pump Brake booster 540 80 35 480 11 12 6 387 393 69 71 106 8 6 14 53 10 11 Main control valve Boom lift cylinder (each) Bucket cylinder Engine hood with side panel Front frame Rear frame Bucket link Bellcrank Boom lift arm including bushings Bucket with bolt on cutting edge Counterweight Fuel tank Battery (each) Floor, cab assembly Cab (ROPS) Operators seat Machine model Serial No. WA180-3 A80001 and up kg 21 62 56 127 726 612 17 125 520 710 1210 80 30 1060 500 40
01-6
GENERAL
FUEL, COOLANT AND LUBRICANTS

PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS
Reservoir
Kind of fluid
Ambient Temperature
-22 -30 -4 -20 14 -10 32 0 50 10 68 20 86 30 104EF 40EC
Capacity Specified
22 R 5.8 US gal 4.8 UK gal
Refill
19.5 R 5.1 US gal 4.3 UK gal
Engine oil pan
SAE 5W-30 SAE 10W-30 SAE 15W-40 SAE 5W

Engine oil
Brake
1R 1R 0.26 US gal 0.26 US gal 0.22 UK gal 0.22 UK gal 28 R 7.4 US gal 6.6 UK gal 23.5 R 6.2 US gal 5.2 UK gal
Transmission case
SAE 10W
Hydraulic system Axle (front & rear) (each)
SAE 10W
80 R 41 R 21.1 US gal 10.8 US gal 17.6 UK gal 9.0 UK gal 14 R 3.7 US gal 3.1 UK gal 14 R 3.7 US gal 3.1 UK gal
Axle oil
See Note 1
Pins
Grease
NLGI No. 2
Fuel tank
Diesel fuel
ASTM D975 No. 2
170 R 44.9 US gal 37.4 UK gal 38.5R 10.1 US gal 8.5 UK gal
Cooling system Coolant
See 20.3 Coolant specification on page 3-13
35 R 9.2 US gal 7.7 UK gal
ASTM D975 No. 1 Other equipment will be necessary, when operating the machine at temperatures below -20EC (-4EF),therefore consult your distributor for your needs. Note 1: For axle oil, use only the recommended oil as follows. SHELL: DONAX TT or TD CALTEX: RPM TRACTOR HYDRAULIC FLUID CHEVRON: TRACTOR HYDRAULIC FLUID TEXACO: TDH OIL MOBIL: MOBIL 424 It is permissible to substitute engine oil SAE 30 API classification CD for axle oil. Although an increased in brake noise may occur, the durability of the axle is not be affected.
01-7
GENERAL
ENGINE OIL SPECIFICATIONS

Normal operation Oil performance recommendations are as follows: The use of a quality engine lubricating oil combined with appropriate oil and filter change intervals are critical factors in maintaining engine performance and durability. SAE 15W-40 multi-viscosity oil meeting the American Petroleum Institute (API) performance classification of CE/SG is recommended. NOTE: CC/CD or CD/SF oils may be used in areas where CE oil is not yet available but the oil change interval must be reduced to one half the interval given in the maintenance schedule A sulfated ash limit of 1.0 mass percent is suggested for optimum valve and piston deposit and oil consumption control. the sulfated ash must not exceed 1.85 mass percent. The sulfated ash limit of 1.85 mass percent has been placed on all engine lubricating oils recommended for use in the engine. Higher ash oils can cause valve and/or piston damage and lead to excessive oil consumption. The API service symbol displays the appropriate oil categories; the lower half may contain words to describe oil energy conserving features. The center section identifies the SAE oil viscosity grade. Oil viscosity recommendations are as follows: The use of a multi-graded lubricating oil has been found to improve oil consumption control and improve engine cranking in cold temperatures while maintaining lubrication at high operating temperatures. While SAE 15W-40 multi-viscosity oil is recommended for most operating climates, refer to the previous chart for oil viscosity recommendations for extreme climates. NOTE: limited use of low viscosity oils, such as 10W-30 may be used for easier starting and providing sufficient oil flow at ambient temperatures below -5EC (23EF). However, continuous use of low viscosity oil can decrease engine life due to wear.
Single graded oils may be used if multi-graded oil is not available. But be sure to use oil that matches the temperature shown in the table. Special break-in lubricating oils are not recommended for a new or rebuilt engine. Use the same type of oil during the break-in as specified for normal operation. Additional information regarding lubricating oil availability throughout the world is available in the "E.M.A. Lubricating Oils Data Book For Heavy Duty Automotive and Industrial Engines". The data book may be ordered from the Engine Manufacturers Association, 401 North Michigan Ave., Chicago, Il U.S.A. 60611. The telephone number is (312) 6446610. Arctic Operation If an engine is operated in ambient temperatures consistently below -23EC (-10EF) and there are no provisions to keep the engine warm when it is not in operation, use a synthetic API performance classification CE or CF-4 engine oil with adequate low temperature properties such as SAE 5W-20 or 5W-30. The oil supplier must be responsible for meeting the performance service specifications. IMPORTANT: The use of a synthetic base oil does not justify extended oil change intervals. Extended oil change intervals can decrease engine life due to factors such as; corrosion, deposits and wear.
01-8
GENERAL
DIESEL FUEL SPECIFICATIONS
DIESEL FUEL SPECIFICATIONS

and excessive smoke. Do not mix gasoline or alcohol with diesel fuel. This mixture can cause an explosion. Due to the precise tolerances of diesel injection systems, it is extremely important that the fuel be kept clean and free of dirt or water. Dirt or water in the system can cause severe damage to both the injection pump and nozzles. For normal service above -12EC (+10EF), the use of ASTM Grade No. 2-D diesel fuel with a minimum Cetane number of 40 is recommended. The use of No. 2-D diesel fuel will result in optimum engine performance under most operating conditions. Fuels with Cetane numbers higher than 40 may be needed in high altitudes or extremely low ambient temperatures to prevent misfires At operating temperatures below -12EC (+10EF), use ASTM Grade No. 1-D diesel fuel. The use of lighter fuels can reduce fuel economy. Where a winterized blend of Grade No. 2-D and No. 1-D fuels is available, it may be substituted for Grade No. 1-D fuel. However, it is the supplier's responsibility to provide the fuel for the anticipated ambient temperature. Use a low sulfur content fuel having a cloud point that is at least 10 degrees below the lowest expected fuel temperature. Cloud point is the temperature at which crystals begin to form in the fuel. The viscosity of the fuel must be kept above 1.3 cSt to provide adequate fuel system lubrication.
01-9
GENERAL
COOLANT SPECIFICATIONS
GENERAL Selection and maintenance of the engine coolant is important to long engine life. The following information provides recommendations for selecting the engine coolant and maintaining the coolant inhibitors. Heavy duty diesel engines require a balanced coolant mixture of water, antifreeze, and supplemental coolant additives. Supplemental coolant additive recommendations are included in the section entitled Inhibitors Conditioners. The coolant mixture must be drained and replaced at the specified service interval shown in the OPERATION & MAINTENANCE MANUAL, or every two years of operation, whichever comes first. WATER Use water which has a low mineral content. Water used in conjunction with antifreeze, coolant filters and inhibited water must meet the following standards: Total Hardness - Not to exceed 170 parts per million (10 grains/gallon maximum) to prevent scale deposits. Water containing dissolved magnesium and calcium (the usual reason for water hardness) above the specified amount will cause scale deposits to develop in the engine. Chlorides - Not to exceed 40 parts per million (2.5 grains/gallon maximum) to prevent corrosion. Sulfites - Not to exceed 100 parts per million (5.8 grains/gallon maximum) to prevent corrosion. Dissolved Solids - Not to exceed 340 parts per million (20 grains/gallon maximum) to minimize sludge deposits, scale deposits, corrosion or a combination of these. If any of the above requirements cannot be met, use distilled, de-ionized, or de-mineralized water. To determine if local water supplies meet these standards, water samples can be tested by water treatment laboratories. Softened water that is prepared using common salt (sodium chloride) contains excessive amounts of chlorides and should not be used. Never use water alone in the cooling system because corrosion will occur. ANTIFREEZE In climates where the temperature is above -37EC (34E F), use a coolant mixture that contains 50 percent antifreeze. Antifreeze is essential in any climate. It broadens the operating temperature range by lowering the coolant freezing point and by raising its boiling point. Do not use more than 50 percent antifreeze in the mixture unless additional freeze protection is required. Never use more than 68 percent antifreeze under any condition. An antifreeze concentration greater than 68% will adversely affect freeze protection and heat transfer rates. Antifreeze concentrations between 68 and 100% actually have a higher freezing point than a 68% antifreeze concentration and should not be used due to reduced heat transfer rates. Low silicate ethylene glycol antifreeze is recommended. The antifreeze should contain no more than 0.1% anhydrous alkali metasilicate. Low silicate antifreeze is recommended to avoid the formation of silica-gel (hydrogel). This gel formation can occur when the cooling system contains an over concentration of high silicate antifreeze and/or supplemental coolant additive. DO NOT use methanol or alcohol as an antifreeze because of its low boiling point. Antifreeze may retain its freeze protection for more than one season but coolant conditioners must be added to maintain corrosion protection. Antifreeze formulated with methoxy propanol, or propylene glycol, is not recommended for this system. Do not mix types of antifreeze solutions. Mixed solutions make it impossible to determine the protection against freezing. Antifreeze containing sealer or anti-leak additives should NOT be used in this system. Sealer or anti-leak additives will cause plugging problems in the cooling system. Check the solution periodically and at normal operating temperature, to be sure the cooling system has sufficient protection against freezing. The following table shows the approximate percentage of antifreeze solution required for various temperatures.
01-10
GENERAL
Approximate Freezing Point 0E C -7EC -12EC -18EC -23EC -29EC -34EC -40EC -46EC -51EC -57EC -62EC -68EC -69EC (+32EF) (+20EF) (+10EF) (0EF) (-10EF) (-20EF) (-30EF) (-40EF) (-50EF) (-60EF) (-70EF) (-80EF) (-90EF) (-92EF)
Percentage of Antifreeze Concentration by Volume 0 15 25 33 40 45 48 53 56 59 62 65 67 68
Specific Gravity at 16EC (60EF) 1.000 1.025 1.040 1.053 1.062 1.070 1.074 1.080 1.083 1.088 1.092 1.095 1.097 1.098
In tropical climates where antifreeze availability may be limited, use a corrosion inhibitor DCA4, to protect the engine cooling system. INHIBITORS/CONDITIONERS 1. All cooling system inhibitors, including those in antifreeze solutions, become depleted through normal operation. If the inhibitors in antifreeze are allowed to become depleted, the antifreeze becomes corrosive and attacks and coats the metallic surfaces of the cooling system which reduces heat transfer. Cooling system conditioners which contain these inhibitors must be added to maintain corrosion protection. 2. Soluble oil is not recommended for use in this engine as its use will reduce heat transfer. 3. There are no miracle additives that will increase heat transfer or prevent overheating. Conditioned water is still the best coolant. 4. DCA4 is recommended to inhibit corrosion in the cooling system for the following reasons: ! Improved compatibility with high silicate antifreezes to minimize hydro-gel formation if over concentration occurs. Provides engine protection in the following areas: - Solder corrosion/bloom - Copper corrosion/erosion/stress cracking - Oil fouling - Cylinder liner cavitation corrosion - Aluminum cavitation corrosion - Seal and gasket degradation
Maintenance of Cooling System Inhibitors Keeping the engine coolant properly inhibited will keep the engine and radiator free of rust, scale deposits and corrosion. New machines are delivered with antifreeze protection. Service at regular scheduled intervals specified in the OPERATION & MAINTENANCE MANUAL with a service DCA4 filter. Each time the coolant is drained and replaced, the coolant must be recharged with DCA4. New coolant can be correctly charged with supplemental coolant additives by using DCA4 filters or DCA4 concentrate listed in the table entitled, DCA4 Unit Guide. If coolant is added between drain intervals, additional DCA4 will be required. Coolant Testing for Conditioner Concentration When the cooling system is maintained as recommended, the conditioner concentration should be satisfactory. The DCA4 concentration must not fall below 1.0 unit per 3.8 R (1 US gal) or exceed 2 units per 3.8 R (1 US gal) of coolant. The only accurate method for testing chemical concentrations in coolant with mixed chemical compounds is a laboratory analysis. For this reason, the coolant inhibitor should be maintained as shown in the OPERATION & MAINTENANCE MANUAL. Inadequate concentration of the coolant additive
01-11
GENERAL
can result in major corrosive damage to cooling system components. Over concentration can cause formation of gel that can cause restriction, plugging of passages and overheating. Replenishing Coolant Conditioner Install a precharge DCA4 filter when the coolant is changed or a significant (more than 50%) coolant loss occurs. Install a service DCA4 filter as specified in the OPERATION & MAINTENANCE MANUAL When antifreeze is added, add coolant conditioner equal to 1.0 unit per 3.8 R (1 US gal) of antifreeze. Mixing of DCA4 and other supplemental coolant additives is not recommended because there is currently no test kit available to measure concentration levels with mixed chemical solutions. DCA4 Unit Maintenance Guide Use supplemental coolant additives (corrosion inhibitors) to protect the engine cooling system from corrosion. Antifreeze alone does not provide enough corrosion protection for a heavy duty diesel engine. Supplemental corrosion protection must be supplied through periodic additions of supplemental coolant additives to the coolant. To protect against corrosion, a new coolant charge must be brought up to 0.26 DCA4 unit per liter (one unit per U.S. gal) of coolant (initial charge). Maintain the correct DCA4 concentration by changing the service coolant filter at each engine oil and filter change interval. Each time the coolant is drained and replaced, the coolant must be recharged with supplemental coolant additives. Use the appropriate DCA4 spin-on filter listed in
following table. The coolant mixture must be drained and replaced as defined under General. The amount of replacement inhibitor is determined by the length of the service interval and the cooling system capacity. Refer to the DCA4 Unit Guide for the selection of the correct filter to replenish the DCA4. If coolant is added between drain intervals, additional DCA4 will be required. Check the coolant DCA4 concentration level anytime make-up coolant is added to the system. The DCA4 concentration must not fall below 0.13 units per liter or exceed 0.5 units per liter (0.5 units per U.S. gallon or exceed 2 units per U.S. gallon). DCA4 Unit Guide Fleetguard Part No. DCA4 Coolant Filter WF-2070 WF-2071 WF-2072 WF-2073 WF-2074 WF-2075 WF-2076 WF-2077 DCA4 Liquid DCA60L DCA80L DCA4 Powder DCA95 DCA4 Units
2 4 6 8 12 15 23 0
4 (1 Pint) 1760 (55 USgal)
20
DCA4 Precharge and Service Filters System Capacity Liters 19 to 26 26 to 38 38 to 57 57 to 76 76 to 114 114 to 190 US Gallons 5 to 7 7 to 10 10 to 15 15 to 20 20 to 30 30 to 50
Precharge Filter (See NOTE 1) WF-2072 WF-2073 WF-2074 WF-2075 WF-2076 (See NOTE 2)
Service Filter (See NOTE 3) WF-2070 WF-2071 WF-2071 WF-2071 WF-2072 WF-2073
01-12
GENERAL
NOTE 1 - After draining and replacing coolant, always precharge the cooling system to maintain the DCA4 concentration between 1.0 and 2.0 units per 3.8 R (1 US gal). When performing service which requires draining the cooling system, discard the coolant. Reusing coolant can introduce contaminates or over concentrated chemicals, resulting in premature failure of cooling system components. ! Install appropriate service filter listed in the above table based on cooling system capacity. Example: 95 gal (360 R) cooling system capacity -15 Units (1) WF-2075 Filter 80 Units
required to precharge the cooling system. Four bottles of powder, part number DCA95, will provide a sufficient amount of DCA4 units (80) to precharge the example cooling system. ! Install the appropriate service filter at the next and subsequent maintenance intervals.
NOTE 3 - Change the coolant filter at every engine oil and filter change interval to protect the cooling system.
Maintain a nominal concentration of 1.0 DCA4 unit per 3.8 R (1 US gal) of coolant in the system. Less than 0.5 unit per 3.8 R (1 US gal) indicates an under-concentrated coolant solution. More than 2.0 units per 3.8 R (1 USgal) indicates an over-concentrated coolant solution. To check the DCA4 concentration level, use the Fleetguard coolant test kit, CC2626. Instructions are included with the test kit.
The answer represents the additional units
DCA4 Unit Concentration Guide

Number of Solution A Drops to Cause Color Change
Coolant Condition Extremely under-concentrated - less than 0.4 DCA4 units per 3.8 R (1 US gal) Marginally under-concentrated - 0.45 to 0.8 DCA4 units per 3.8 R (1 US gal) Acceptable - 0.85 to 1.3 DCA4 units per 3.8 R (1 US gal) Highly acceptable - 1.35 to 2.0 DCA4 units per 3.8 R (1 US gal) Marginally over-concentrated - 2.1 to 3.3 DCA4 units per 3.8 R (1 US gal)
Action Required Initially charge the system to a minimum of 1.0 DCA4 unit per 3.8 R (1 US gal) Add DCA4 liquid units to maintain 1.0 DCA4 unit per 3.8 R (1 US gal) minimum or change the DCA4 coolant filter NONE NONE Review maintenance practice Drain 50% of the coolant and replace with water antifreeze mixture. Retest the system for correct DCA4 unit concentration.
0 to 10 Drops
11 to 16 Drops
17 to 25 Drops 26 to 35 Drops 36 to 55 Drops
Over 55 Drops
Extremely over-concentrated
01-13
GENERAL
The following may be purchased from your Komatsu International Company distributor. Cooling system test kit The Fleetguard Coolant Test Kit is used to check the coolant concentration of coolant additives in the cooling system. Part Number: CC-2626 1. 2. 3. 4. 5. Test strip bottles Solution #1 bottle Small plastic container Large plastic cup Syringe
01-14
10 STRUCTURE AND FUNCTION

POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 POWER TRAIN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 10-4 TORQUE CONVERTER, TRANSMISSION PIPING . . . 10-6 TRANSMISSION HYDRAULIC SYSTEM DIAGRAM . . . 10-8 TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM . . . 10-9 TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . 10-10 TORQUE CONVERTER OIL FILTER . . . . . . . . . . . . . 10-12 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REVERSE CLUTCH . . . . . . . . . . . . . . . . . . . FORWARD, 2ND CLUTCH . . . . . . . . . . . . . . 3RD, 4TH CLUTCH . . . . . . . . . . . . . . . . . . . . FORWARD 1ST . . . . . . . . . . . . . . . . . . . . . . . . . . . FORWARD 2ND . . . . . . . . . . . . . . . . . . . . . . . . . . FORWARD 3RD . . . . . . . . . . . . . . . . . . . . . . . . . . FORWARD 4TH . . . . . . . . . . . . . . . . . . . . . . . . . . REVERSE 1ST . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION CONTROL VALVE . . . . . . . . . . . . . . UPPER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . LOWER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION SOLENOID VALVE . . . . . . . . . . TORQUE CONVERTER OUTLET PORT VALVE PILOT REDUCING VALVE . . . . . . . . . . . . . . . . . . TRANSMISSION SOLENOID VALVE . . . . . . . . . . PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . MAIN REGULATOR VALVE . . . . . . . . . . . . . . . . . QUICK RETURN VALVE . . . . . . . . . . . . . . . . . . . . MODULATION FILL VALVE . . . . . . . . . . . . . . . . . DIRECTIONAL SELECTOR SPOOL . . . . . . . . . . EMERGENCY MANUAL SPOOL . . . . . . . . . . . . . OPERATION OF FORWARD 1ST . . . . . . . . . . . . ACCUMULATOR VALVE . . . . . . . . . . . . . . . . . . . TRANSMISSION CONTROL . . . . . . . . . . . . . . . . . . . . DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . TORQUE PROPORTIONING DIFFERENTIAL . . FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AXLE MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CENTER HINGE PIN . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13 10-15 10-15 10-16 10-16 10-18 10-19 10-20 10-21 10-22 10-23 10-24 10-25 10-26 10-27 10-28 10-29 10-30 10-31 10-32 10-36 10-38 10-39 10-40 10-42 10-44 10-45 10-46 10-46 10-47 10-48 10-49 10-51 10-52 10-54 10-56 10-57 10-58 10-59 CUSHION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62 STEERING VALVE (ORBIT-ROLL) . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. Steering wheel at neutral. . . . . . . . . . . . . . . 2. Steering wheel turned (turning to left) . . . . . CONNECTION between hand pump and sleeve . . . BRAKE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PARKING BRAKE CONTROL . . . . . . . . . . . . . . . . . . . PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . WORK EQUIP. HYDRAULIC SYSTEM DIAGRAM . . . WORK EQUIP. HYDRAULIC CIRCUIT DIAGRAM . . . 10-64 10-66 10-66 10-68 10-70 10-72 10-73 10-74 10-78 10-80 10-81 10-82 10-84 10-85
HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-86 OIL FILTER BYPASS VALVE . . . . . . . . . . . . . . . . . . 10-87 BREATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-88 MAIN CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . 10-90 2-SPOOL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90 3-SPOOL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-92 RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-94 SAFETY VALVE (WITH SUCTION) . . . . . . . . . . . . . 10-95 SUCTION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-96 Boom and bucket spool at NEUTRAL position . . . . . 10-97 Boom spool at RAISE position . . . . . . . . . . . . . . . . . 10-98 Boom spool at LOWER position . . . . . . . . . . . . . . . . 10-99 Boom spool at FLOAT position . . . . . . . . . . . . . . . . 10-100 Bucket spool at TILT BACK position . . . . . . . . . . . . 10-101 Bucket spool at DUMP position . . . . . . . . . . . . . . . . 10-102 WORK EQUIPMENT LEVER LINKAGE . . . . . . . . . . . . 10-103 WORK EQUIPMENT LINKAGE . . . . . . . . . . . . . . . . . 10-104 BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-106 BUCKET POSITIONER AND BOOM KICK-OUT . . . . . 10-107 BUCKET POSITIONER . . . . . . . . . . . . . . . . . . . . . . 10-108 BOOM KICK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . 10-108 PROXIMITY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATION OF THE PROXIMITY SWITCH . . . . Bucket TILT BACK switch . . . . . . . . . . . . . . . . Boom RAISE switch . . . . . . . . . . . . . . . . . . . . . ACTION OF THE PROXIMITY SWITCH . . . . . . . . 10-109 10-110 10-110 10-110 10-110
ROPS CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-111
10-1
STRUCTURE AND FUNCTION

AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . 10-112 AIR CONDITIONER AND HEATER PIPING . . 10-112 ELECTRIC CIRCUIT DIAGRAM . . . . . . . . . . . 10-113 E.C.S.S. (ELECTRONIC CONTROLLED SUSPENSION SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-114 E.C.S.S. HYDRAULIC, ELECTRICAL CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-115 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-116 ELECTRICAL WIRING ILLUSTRATION . . . . . . . . . . 10-119 ELECTRICAL WIRING DIAGRAM (1/2) . . . . . . . . . . . 10-120 CENTRAL PANEL (CLUSTER GAUGE) . . . . . . . . . . 10-122 SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . BRAKE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . ENGINE STARTING CIRCUIT . . . . . . . . . . . . . . . . . . ENGINE STOP CIRCUIT . . . . . . . . . . . . . . . . . . . . . . AUTOMATIC PREHEATING CIRCUIT . . . . . . . . . . . . QUICK HEATING SYSTEM (Q.H.S.) . . . . . . . . . Q.H.S. CONTROLLER . . . . . . . . . . . . . . . . . . . . HEATER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . RIBBON HEATER . . . . . . . . . . . . . . . . . . . . . . . . Q.H.S. WATER TEMPERATURE SENSOR . . . ELECTRICAL TRANSMISSION CONTROL . . . . . . . COMBINATION SWITCH . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION CUT-OFF FUNCTION . . . . . . . . . . PARKING BRAKE FUNCTION . . . . . . . . . . . . . . . . . . KICK-DOWN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . KICK-DOWN SWITCH . . . . . . . . . . . . . . . . . . . . KICK DOWN ELECTRIC CIRCUIT DIAGRAM . . KICK-DOWN SWITCH OPERATED . . . . . . . . . . KICK-DOWN SWITCH ACTUATION - CANCELED (1) . . . . . . . . . . . . . . . . . . . . . . . . . KICK-DOWN SWITCH ACTUATION - CANCELED (2) . . . . . . . . . . . . . . . . . . . . . . . . . KICK-DOWN SWITCH ACTUATION - CANCELED (3) . . . . . . . . . . . . . . . . . . . . . . . . . 10-123 10-123 10-123 10-122 10-125 10-126 10-126 10-128 10-128 10-129 10-129 10-130 10-131 10-132 10-134 10-135 10-135 10-136 10-137 10-138 10-139 10-140
TABLE OF CONTENTS
10-2
POWER TRAIN
POWER TRAIN
Outline ! The motive force from engine (3) passes through the engine flywheel and is transmitted to torque converter (2), which is connected to the input shaft of transmission (1). ! The transmission has six hydraulically actuated clutches, and these provide four speed ranges for both FORWARD and REVERSE. The transmission speed ranges are selected manually.
The motive force from the output shaft of the transmission passes through center drive shaft (6), front drive shaft (5) and rear drive shaft (7), and is then transmitted to front axle (4) and rear axle (8) to drive the wheels.
10-3
POWER TRAIN SYSTEM
POWER TRAIN SYSTEM
10-4
POWER TRAIN SYSTEM

Outline ! The motive force from engine (1) passes through the flywheel and is transmitted to torque converter (2). The torque converter uses oil as a medium. It converts the transmitted torque in accordance with the change in the load, and transmits the motive force to the input shaft of the transmission. In addition, the motive force of the engine passes through the pump drive gear of the torque converter, and is transmitted to hydraulic, steering pump (4), (3) and torque converter charging pump (5) to drive each pump. ! Transmission (6) operates the directional spool and speed spool of the transmission valve through the solenoid valves, and actuates the six hydraulically actuated clutches to select one of the four FORWARD or REVERSE speeds. The transmission speed range is selected manually. ! The output shaft of transmission (6) transmits the power to the front and rear axles. At the front, the power is transmitted to front axle (11) through center drive shaft (8), flange bearing (9), and front drive shaft (10). At the rear, the power is transmitted to rear axle (17) through rear drive shaft (16). ! The motive force transmitted to front axle (11) and rear axle (17) has its speed reduced by the bevel gear and pinion gear of differentials (12) and (18), and is then transmitted to the sun gear shaft through the differential mechanism. ! The motive force of the sun gear is reduced further by the planetary mechanism and is transmitted to the wheels through the axle shaft.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
Engine Torque converter Steering pump Hydraulic pump Torque converter charging pump Transmission Parking brake Center drive shaft Flange bearing Front drive shaft Front axle Front differential Front brake Front final drive Front tire Rear drive shaft Rear axle Rear differential Rear brake Rear final drive Rear tire
10-5
TORQUE CONVERTER, TRANSMISSION PIPING
TORQUE CONVERTER, TRANSMISSION PIPING
1. 2. 3. 4. 5. 6.
Transmission Oil filter Torque converter Torque converter charging pump Radiator Oil cooler
Outline ! The oil from the torque converter charging pump passes through the oil filter and flows to the brake booster. From the brake booster, it flows to the main regulator valve and is divided into three lines: the torque converter circuit, clutch circuit, and solenoid pilot circuit. ! The oil flowing to the torque converter circuit enters the torque converter. The oil pressure is adjusted by the torque converter outlet port valve, the oil is cooled by the oil cooler, lubricates the transmission and returns to the transmission case.
10-6
MEMORANDA
MEMORANDA
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM

(Engine low idling, directional lever at Neutral, Speed lever at 2nd)
10-8
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM

(Engine stopped)
1. Transmission case 2. Strainer 3. Torque converter charging pump 4. Oil filter 5. Priority valve 6. Main regulator valve 7. Torque converter 8. Torque converter outlet valve 9. PTO lubrication 10. Oil cooler
11. Transmission lubrication 12. Pilot reducing valve 13. Pilot oil filter 14. Quick return valve 15. Modulation fill valve 16. Accumulator 17. Solenoid valve 18. Speed spool 19. Directional spool 20. Emergency manual spool
21. 22. 23. 24. 25. 26. 27. 28.
Accumulator valve FORWARD clutch REVERSE clutch 4th clutch 3rd clutch 2nd clutch 1st clutch Brake booster
10-9
TORQUE CONVERTER
TORQUE CONVERTER
1. 2. Turbine Stator Drive case Pump
6. 8.
PTO gear (drive) Housing (transmission case)
Model: TCA30-6A Type: 3-element, 1-stage, 1-phase Stall torque ratio: 2.84
TORQUE CONVERTER
Path of motive force The torque converter is installed between the engine The e (4) from flywheel. c ) are each secure the rotation of the engine. The motive force of pump uses oil as a medium to rotate turbine (2) an transmit to transmission input shaft (11). The otive force of drive case (4) is used as the e O gear (drive) (6).
The oil supplied from the torque converter charging en l passage of stator shaft (8), and flows to pump (5). il is given centrifugal force by pump (5), enters turbine (2), and transmits the energy of the oil to the bine. t sh (11), so the motive force is transmitted to th transmission input shaft. The oil from turbine (2) is sent to stator (3), and the pump again. However, part of the oil i sent rom the stator through outlet port B to the
10-11
TORQUE CONVERTER OIL FILTER
TORQUE CONVERTER OIL FILTER

1. 2 3. 4. Relief valve Element Center bolt Drain plug
Specifications Filter mesh size: 10 microns Filtering area: 8900 cm Relief pressure: 0.34 MPa (3.5 kg/cm)
Operation ! The oil from the torque converter charging pump enters filter inlet port A. It is filtered from the outside of element (2) to the inside, and flows to outlet port B.
If element (2) becomes clogged with dirt, or the oil temperature is low and the pressure rises at inlet port A, the oil from inlet port A opens relief valve (1) and flows directly to outlet port B in order to prevent damage to the pump or element (2).
10-12
1. Transmission control valve 2. Oil filter 3. Accumulator valve
Transmission Parking brake lever 4th gear (Teeth 33)
7. 8. 9.
10-13
TRANSMISSION
10. Torque converter charging pump 11. Input shaft 12. Torque converter 13. FORWARD clutch 14. 4th clutch
15. 16. 17. 18. 19. 20.
3rd, 4th shaft Rear coupling Output shaft Front coupling Parking brake 3rd clutch
21. 22. 23. 24. 25. 26.
2nd clutch FORWARD, 2nd shaft REVERSE, 1st shaft 1st clutch REVERSE clutch Input gear (Teeth 34)
10-14

! ! The motive forc transmission input shaft and enters the transmission. e forward or reverse clutches and the fo and transmits the motive force from the input shaft to the output
CLUTCH
REVERSE 1ST CLUTCH
7. REVERSE cutch disc (x9) 8. REVERSE gear (Teeth 45) 9. REVERSE, 1st shaft 10. REVERSE ring gear (Teeth: 59) 5. 1st clutch disc (x5) 6. REVERSE clutch plate (x10)
a. REVERSE clutch oil port b. 1st clutch oil port c. Lubricating oil port
10-15

FORWARD, 2ND CLUTCH
TRANSMISSION
1. 2. 3. 4. 5. 6.
Spacer Thrust washer 2nd clutch plate (x6) 2nd clutch disc (x5) FORWARD clutch plate (x10) FORWARD clutch disc (9)
7. FORWARD gear (teeth: 47) 8. FORWARD 2nd shaft 9. FORWARD ring gear (teeth: 58) 10. 2nd ring gear (Teeth: 58) 11. 2nd gear (Teeth: 27, 49)
a. FORWARD clutch oil port b. 2nd clutch oil port c. Lubricating oil port
3RD, 4TH CLUTCH
1. 2. 3. 4. 5. 6.
Spacer Thrust washer 3rd clutch plate (x6) 3rd clutch disc (x5) 4th clutch plate (x6) 4th clutch disc (x5)
7. 4th gear (Teeth: 51) 8. 3rd, 4th shaft 9. 4th ring gear (Teeth: 59) 10. 3rd ring gear (Teeth: 59) 11. 3rd gear (Teeth: 40, 52)
a. 4th clutch oil port b. 3rd clutch oil port c. Lubricating oil port
10-16
TRANSMISSION
Operation of clutch When operated ! The oil sent from the transmission valve passes through the oil passage inside shaft (1), and goes to the rear face of piston (6) to actuate the piston. ! When piston (6) is actuated, separator plate (2) is pressed against clutch disc (3) and forms shaft (1) and clutch gear (4) into one unit to transmit the motive force. ! Oil is drained from oil drain hole (5) at this time, but this does not affect clutch operation since less oil is drained than supplied.
When not actuated ! If the oil from the transmission valve is shut off, the pressure of the oil acting on the rear face of piston (6) drops. ! The piston is returned to its original position by wave spring (7), so shaft (1) and clutch gear (4) are separated. ! When the clutch is disengaged, the oil at the rear face of the piston is drained by centrifugal force through oil drain hole (5), preventing the clutch from remaining partially engaged.
10-17
TRANSMISSION
Operation ! the D (13) and 1st oil pressure from the transmission valve. The power from the torque converter is transmitted input shaft (11) and input gear (26) t FORWAR gear (28). FORWARD clutch (13) i engaged, so the power is transmitted to REVERSE, 1st clutch (24) is engaged, so the rotation of REVERSE, r
driven gear (31) forms one unit with 2nd gear (32), so the power of 1st driven gear (31) passe thr 2nd gear (32), is transmitted to 3rd gear and output gear (34), and is then transmitted to output shaft (17).
Note:
Inp
gear (26) is always meshed with VERSE gear (27) and FORWARD gea (28).
10-18
TRANSMISSION FORWARD 2ND
Operation ! In the case of FORWARD 2nd gear, FORWARD clutch (13) and 2nd clutch (21) are connected by the oil pressure from the transmission valve. ! The power from the torque converter is transmitted from input shaft (11) and input gear (26) to FORWARD gear (28). FORWARD clutch (13) is engaged, so the power is transmitted to FORWARD, 2nd cylinder gear (35). ! 2nd clutch (21) is engaged, so the rotation of FORWARD, 2nd cylinder gear (35) rotates 2nd gear (32) and is transmitted to 3rd gear (33).
The power is transmitted from 3rd gear (33) and output gear (34) to output shaft (17). Input gear (26) is always meshed with REVERSE gear (27) and FORWARD gear (28).
Note:
10-19
STRUCTURE AND FUNCTION FORWARD 3RD
TRANSMISSION
Operation ! In the
case of FORWARD 3rd gear, FORWARD clutch (13) and 3rd clutch (20) are connected by the oil pressure from the transmission valve.
The power from the torque converter is transmitted from input shaft (11) and input gear (26) to FORWARD gear (28). FORWARD clutch (13) is engaged, so the power is transmitted to 3rd, 4th cylinder gear (36).
3rd clutch (20) is engaged, so the power of 3rd, 4th cylinder gear (36) is transmitted to 3rd gear (33). The power is then transmitted through output gear (34) to output shaft (17). Input gear (26) is always meshed with REVERSE gear (27) and FORWARD gear (28).
Note:
10-20
TRANSMISSION FORWARD 4TH
Operation ! In the case of FORWARD 4th gear, FORWARD clutch (13) and 4th clutch (14) are connected by the oil pressure from the transmission valve. ! The power from the torque converter is transmitted from input shaft (11) and input gear (26) to FORWARD gear (28). FORWARD clutch (13) is engaged, so the power is transmitted to 3rd, 4th cylinder gear (36). ! 4th clutch (14) is engaged, so the power of 3rd, 4th cylinder gear (36) is transmitted to 4th gear (37). The power is then transmitted to 4th gear (38), 4th shaft (39), and 4th gear (40).
The power of 4th gear (40) is transmitted to 4th gear (41), which forms one unit with 3rd gear (33), so the power passes through 3rd gear (33), is transmitted to output gear (34) and output shaft (17).
Note:
Input gear (26) is always meshed with REVERSE gear (27) and FORWARD gear (28).
10-21
STRUCTURE AND FUNCTION REVERSE 1ST
TRANSMISSION
Operation ! In the case of REVERSE 1st gear, REVERSE clutch (25) and 1st clutch (24) are connected by the oil pressure from the transmission valve. ! The power from the torque converter is transmitted from input shaft (11) and input gear (26) to REVERSE gear (27). REVERSE clutch (25) is engaged, so the power is transmitted to REVERSE, 1st cylinder gear (29).
1st clutch (24) is engaged, so the power of REVERSE, 1st cylinder gear (29) passes through 1st gear (30) and is transmitted to 1st driven gear (31). 1st driven gear (31) forms one unit with 2nd gear (32), so the power of 1st driven gear (31) passes through 2nd gear (32), is transmitted to 3rd gear (33) and output gear (34), and is then transmitted to output shaft (17).
10-22
TRANSMISSION CONTROL VALVE
1. 2. 3. 4.
Lower valve Upper valve Emergency manual spool Solenoid valve port
a. b. c. d. e.
Pilot oil pressure measurement port To oil cooler From pump Pump oil pressure measurement port Clutch oil pressure measurement port
10-23
STRUCTURE AND FUNCTION UPPER VALVE
1. 2. 3. 4. 5. 6. 7. 8.
Upper valve body Main regulator valve Pilot reducing valve Priority valve Modulation fill valve pressure adjusting screw Modulation fill valve Accumulator Quick return valve
9. 10. 11. 12. 13. 14. 15. 16.
Check valve Lower valve body Torque converter outlet valve FORWARD and REVERSE spool HIGH and LOW spool Speed range spool Solenoid valve Emergency manual spool
10-24
TRANSMISSION CONTROL VALVE LOWER VALVE
Outline ! The oil from the pump passes through the torque converter oil filter, enters the transmission valve, and is divided into the pilot circuit and the clutch actuation circuit. ! The priority valve gives priority to the oil sent to the pilot circuit, so the pilot pressure is always kept the same. ! The pressure of the oil flowing to the clutch actuation circuit is adjusted by the modulation fill valve and actuates the clutch. The oil which is relieved is sent to the torque converter. ! The quick return and modulation fill valve are interconnected during gear shifting.
They act to raise the clutch oil pressure smoothly, thereby reducing the shock when shifting gear. During traveling, the clutch pressure is kept the same. The pressure of the oil which flows to the circuit is adjusted by the pilot reducing valve. During gear shifting, the oil flows in accordance with ON-OFF position of the solenoid valves and actuates the FORWARD, REVERSE and speed spools. By switching the FORWARD, REVERSE, and speed spools, the oil regulated by the modulation fill valve is sent to the selected clutch to obtain the necessary gear combination.
10-25
STRUCTURE AND FUNCTION TRANSMISSION SOLENOID VALVE
1. 2. 3. 4. 5. 6. 7. 8.
Connector Valve body 1st, 4th solenoid valve 3rd solenoid valve REVERSE solenoid valve FORWARD solenoid valve Emergency manual spool Lock plate
STRUCTURE ! 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.
10-26
TRANSMISSION CONTROL VALVE TORQUE CONVERTER OUTLET PORT VALVE

Function ! The torque converter outlet port valve is installed in the outlet line of the torque converter and adjusts the maximum pressure of the torque converter.
Operation ! The oil at port a passes through the orifice in spool (1) and flows to port c.
When the pressure at port a rises, the pressure at port c also rises. This overcomes the tension of spring (2) and moves spool (1) to the left in the direction of the arrow to allow oil to flow from port a to port b.
If the pressure at port a becomes even higher, spool (1) is moved further to the left in the direction of the arrow, and the oil flows from port a to port b and drain port d. (Cold relief)
10-27
STRUCTURE AND FUNCTION PILOT REDUCING VALVE

Function ! The pilot reducing valve controls the pressure used to actuate the directional selector spool, H-L selector spool, range selector spool.
Operation ! The oil from the pump enters port a, passes through port b of pilot reducing spool (1), enters spool (2) in the lower valve, and fills the pilot circuit. The oil at port b passes through the orifice (3)and flows to port c.
When the pressure in the pilot circuit rises, the pressure at port c also rises. This overcomes the tension of spring (4) and moves pilot reducing spool (1) to the right in the direction of the arrow. For this reason, port a at port b are shut off, so the pressure at port c is maintained.
10-28
TRANSMISSION CONTROL VALVE TRANSMISSION SOLENOID VALVE

Function ! There are four solenoid valves installed to the transmission control valve. When the gear shift lever in the operator's compartment is operated, the solenoid valves are switched ON/OFF, and the oil is drained to actuate the gear shift spool. Operation 1. Solenoid valve OFF The oil from pilot reducing valve (3) flows to ports a and b of gear shift spools (1) and (2). The oil at ports a and b is stopped by solenoids (4) and (5), and gear shift spools (1) and (2) move to the right in the direction of the arrow. As a result, the oil from the pump flows to the 2nd clutch.
2. Solenoid valve ON When the gear shift lever is operated, the drain port of solenoid valves (4) and (5) opens. The oil at ports a and b of gear shift spools (1) and (2) flows from ports c and d to the drain circuit. Therefore, ports a and b become the low pressure circuit, and the gear shift spool is moved to the left in the direction of the arrow by the tension of spring (6). As a result, the oil at port e flows to the 4th clutch and the clutch is switched.
10-29
STRUCTURE AND FUNCTION PRIORITY VALVE

Function ! The priority valve gives priority to sending oil to the pilot circuit of the lower valve. When the pressure in the circuit goes above the set pressure, it acts as a main relief valve to protect the circuit.
Operation ! The oil from the pump is divided into two lines. One oil flow enters port a, passes around priority valve (2), goes through pilot reducing valve (1), and flows to the pilot circuit of the lower valve. The other oil flow goes to priority valve (2).
The oil flowing to priority valve (2) passes through orifice (3) and flows to port b. As a result, it pushes priority valve(2) to the left in the direction of the arrow against the force of spring (4), and flows to port c.
When the pressure at port b goes above the set pressure, priority valve (2) is pushed further to the left in the direction of the arrow, and the oil is drained from port d to protect the circuit. (The main relief function)
10-30
TRANSMISSION CONTROL VALVE MAIN REGULATOR VALVE

Function ! The main regulator valve controls the flow of oil to the clutch circuit, and sends any excess oil to the torque converter circuit.
Operation ! The oil from the pump enters port a of priority valve (1), and then passes from port c through modulation fill valve (3) and main orifice (2), and flows to the clutch circuit.
The oil passing through orifice (4) and entering port b moves the spool to the left in the direction of the arrow against the force of spring (5), so the oil passes through port c and flows to the torque converter circuit.
10-31
STRUCTURE AND FUNCTION QUICK RETURN VALVE

Function ! The pressure of the transmission clutch is raised smoothly by the modulating action. This reduces any shock when shifting gear and prevents the generation of peak torque and the power train. Therefore, it reduces operator fatigue and ensures a comfortable ride for the operator. At the same time, it also increases the durability of the power train. Operation 1. After starting engine, clutch fully engaged (clutch pressure at point A) (FORWARD 1st)
10-32

2. When shifting from FORWARD to REVERSE (clutch pressure at point B)
When the directional lever is moved from FORWARD to REVERSE, FORWARD solenoid (1) closes, REVERSE solenoid (2) opens, and directional spool (3) moves to the right in the direction of the arrow. FORWARD clutch (4) is connected to the drain circuit and the oil is drained. At the same time, the oil from the pump flows to REVERSE clutch (5), but while the oil is filling the clutch, the clutch pressure is low. As a result, the oil pressure at port a of quick return valve (6) also drops, so check valve (7) opens
! i
and the oil at port b flows to port a. At the same time, quick return valve (6) is moved to the left in the direction of the arrow by the pressure of the accumulator, and the oil from accumulator (8) is suddenly drained from port c. Accumulator (8) is returned fully to the left by the force of spring (9). To reduce the shock when shifting gear, the pressure in the clutch circuit must be completely lowered and accumulator (8) must move fully to the left.
10-33

3. Clutch pressure starting to rise (clutch pressure at point C)
The oil from the pump fills the REVERSE clutch and the pressure in the clutch circuit starts to rise. As a result, the pressure at port a rises, so quick return valve (6) is moved to the right in the direction of the arrow, and closes drain port c.
10-34

4. Start of accumulator action, clutch completely engaged (clutch pressure at point D)
Because of the differential pressure created by modulation fill valve (11), a constant flow of oil passes through 1st orifice (10) and enters accumulator (8). As this oil flows in, the accumulator piston gradually moves to the right in the direction of the arrow, and spring (9) is compressed, so the accumulator pressure rises. As this accumulator pressure rises, it raises the clutch pressure. Except in 1st, oil flows into the accumulator from 1st orifice + 2nd (3rd) orifice, so the modulating time is shorter than for 1st.
when accumulator piston (8) moves to the end of its stroke, the rise in the pressure at port d finishes, so the specified pressure is maintained and the REVERSE clutch is completely engaged. When the gear shift spool is operated, the action is the same as above.
10-35
STRUCTURE AND FUNCTION MODULATION FILL VALVE

Function ! The modulation fill valve adjusts the pressure and controls the amount of oil flowing to the accumulator while allowing the clutch pressure to rise.
Operation 1. Clutch completely engaged (point a)
2. Shifting from FORWARD to REVERSE ! The oil inside the accumulator is drained by the quick return valve, and accumulator piston (1) moves to the left. When this happens, the pressure in chamber c and Chamber d drops, and spring (2) moves modulation fill valve (3) to the right to open port a.
10-36

3. Clutch pressure starting to rise (point c point d) ! When the oil from the pump fills the clutch piston, the pressure in the clutch circuit starts to rise. When this happens, the drain circuit of the quick return valve is closed. ! When the drain circuit of the quick return valve closes, the oil passing through port a enters chamber d and pressure P2 in chamber d starts to rise. When the relationship between P1 and P2 becomes P2 > P1 + P3 (tension of spring (2)), the fill valve moves to the left, shuts off port a, and prevents the clutch pressure from rising suddenly.
At the same time as the oil from port a flows to the directional spool, the relationship is P2 > P1, so oil also passes through the orifice in the quick return valve and flows into chamber c. P1 rises and P2 also rises at the same time. This process is repeated while maintaining the relationship P2 = P1 + P3 (tension of spring (2)), and the clutch pressure rises. The oil from the torque converter outlet port circuit forms the pilot pressure to the modulation fill valve and flows to port e. The pressure at port e changes according to the engine speed. The relationship is P2 = P1 + P3 + P4 (changes according to engine speed), so if pressure P4 changes, pressure P2 also changes by the same amount. Therefore, pressure P2 rises at the same time by the same amount that pressure P4 changes, so it is possible to create oil pressure characteristics that matches the engine speed.
10-37
STRUCTURE AND FUNCTION DIRECTIONAL SELECTOR SPOOL

Operation 1. When at neutral ! Solenoid valves (4) and (5) are OFF and the drain port is closed. The oil from the pilot circuit passes through the oil hole in the emergency manual spool and fills ports a and b of the directional spool. In this condition, P1 + spring force (1) = P2 + spring force (2), so the balance is maintained. Therefore, the oil at port c does not go to the FORWARD or REVERSE clutch.
2. When at FORWARD ! When the directional lever is placed at the FORWARD position, solenoid valve (4) is switched ON and drain port d opens. The oil which is filling port a is drained, so P1 + spring force (1) < P2 + spring force (2). When this happens, the directional spool moves to the left, and the oil at port c flows to port e and is supplied to the FORWARD clutch.
10-38
TRANSMISSION CONTROL VALVE EMERGENCY MANUAL SPOOL

Function ! If there should be any failure in the electrical circuit and the directional solenoid valve does not work, this spool can be operated manually to engage the FORWARD or REVERSE clutch.
Operation 1. Emergency manual spool at neutral ! The oil from the upper valve (pilot reducing valve) passes around emergency manual spool (1), and is blocked by solenoid valves (2) and (3). ! When the operating condition is normal, the emergency manual spool is at the neutral position.
2. Emergency manual spool actuated (FORWARD) ! When emergency manual spool (1) is pushed in, port a and the drain port are connected, so the oil in chamber b is drained. As a result, directional spool (4) moves to the left in the direction of the arrow, and the oil flows to the FORWARD clutch to engage the clutch.
10-39
STRUCTURE AND FUNCTION OPERATION OF FORWARD 1ST
10-40

! ! The oil from pump (1) passes through priority valve (2) and is divided to the pilot circuit and clutch actuation circuit. When the gear shift lever is operated to FORWARD 1st, FORWARD solenoid (3) and gear shift solenoid (6) are actuated. The oil filling ports a and b is drained and directional spool (7) and gear shift spool (9) move to the left. When directional spool (7) moves, the oil flows from clutch pressure port c to port d, and engages the FORWARD clutch. Gear shift solenoid (5) is closed, and H-L spool (8) is pushed fully to the right, so the oil flows from clutch pressure port e to port f, passes through spool (9) and engages the 1st clutch. When the oil completely fills the clutch cylinder, the action of accumulator (10) and quick return valve (11) raises the oil pressure gradually, and when it reaches the set pressure, the FORWARD and 1st clutches are completely engaged.
! ! !
10-41
STRUCTURE AND FUNCTION ACCUMULATOR VALVE
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Piston (for 2nd clutch) Piston (for 1st clutch) Body Piston (for FORWARD clutch) Spring (for FORWARD clutch) Stopper (for FORWARD clutch) Cover Spacer (for FORWARD clutch) Spacer (for 1st clutch) Spacer (for 2nd clutch) Stopper (for 1st clutch) Spring (for 1st clutch) topper (for 2nd clutch) Spring (for 2nd clutch)
Outline ! The accumulator valve is installed in the FORWARD, 1st, 2nd clutch circuit. When the transmission shifts gear, the accumulator valve slowly reduces the oil pressure to the clutch that was first engaged in order to prevent loss of torque and to reduce the transmission shock when shifting gear. It temporarily stores the clutch oil pressure in order to allow gear shifting to be carried out smoothly without any time lag. (To make it possible to reduce the oil pressure to the clutch slowly, there are throttles installed in the directional spool, H-L spool and range spool of the transmission control valve.)
10-42

Operation 1. Shifting down when digging (kick-down F2 Fl) When the transmission is in F2, oil pressure is stored in the 2nd clutch accumulator. When the kick-down is operated, the Fl clutch is engaged, but the oil pressure in the accumulator is maintained for the 2nd clutch until the torque is transmitted to the 1st clutch. In this way, it is possible to shift gear smoothly without losing the torque.
2. Moving out after digging (Fl R2) When the transmission is in Fl, oil pressure is stored in the accumulator for the FORWARD clutch and 1st clutch. When shifting to R2 after completing digging operations, the R2 clutch is engaged, but the oil pressure for the FORWARD Clutch and 1st clutch is maintained in the accumulator. This makes it possible to reduce the loss of torque due to the reaction force to the product being handled, and to move back smoothly without shock.
10-43
TRANSMISSION CONTROL
TRANSMISSION CONTROL
1. 2. 3. 4.
Directional lever Gear shift lever Gear shift lever stopper Turn indicator, lamp, dimmer switch
Outline ! With the transmission control, an electrical signal is sent to the transmission solenoid valves when the directional and gear shift levers are operated. This opens or closes the solenoid valves and moves the spool inside the transmission valve.
10-44
DRAIVE SHAFT
DRIVE SHAFT
1. 2. 3. 4.
Front drive shaft Flange bearing Center drive shaft Rear drive shaft
Outline ! The motive force from the engine passes through the torque converter and the transmission. Some of it is transmitted from rear drive shaft (4) to the rear axle, while the rest goes from center drive shaft (3) through flange bearing (2) and front drive shaft (1) to the front axle.
The drive shaft has the following purpose in addition to simply transmitting the power. The drive shaft has a universal joint and sliding joint to enable it to respond to changes in the angle and length. This enables the drive shaft to transmit the motive force when the machine is articulated and to protect the components from damage from shock when the machine is being operated or shock from the road surface when the machine is traveling.
10-45
AXLE
AXLE
FRONT AXLE
10-46
AXLE FRONT DIFFERENTIAL
1. 2. 3. 4. 5. 6.
Side gear (No. of teeth: 12) Pinion gear (No. of teeth: 9) Shaft Bevel gear (No. of teeth: 47) Sun gear shaft Bevel pinion (No. of teeth: 13)
10-47
STRUCTURE AND FUNCTION REAR AXLE
AXLE
1. 2. 3. 4. 5. 6. 7. 8. 9.
Oil supply port Differential Differential housing Wet-type single-disc brake Final drive Axle housing Axle shaft Drain plug Level plug
10-48
AXLE REAR DIFFERENTIAL
1. 2. 3. 4. 5. 6.
Side gear (No. of teeth: 12) Pinion gear (No. of teeth: 9) Shaft Bevel gear (No. of teeth: 47) Sun gear shaft Bevel pinion (No. of teeth: 13)
10-49

Outline ! The motive force from the engine is transmitted to the front and rear axles via the torque converter, the transmission and the propeller shaft. ! In the axle, the motive force is transmitted from pinion gear (1) to bevel gear (5), shifted 90E and reduced, and transmitted to sun gear shaft (2) via differential (4). ! The motive force of the sun gear is further reduced by planetary gear-type final drive, and transmitted to the axle shaft and wheel.
AXLE
When moving straight forward ! When moving straight forward, the speed of rotation of the left and right wheels is equal, so pinion gear (4) in the differential assembly does not rotate, and the motive force of carrier (6) is transmitted equally to the left and right sun gear shafts (2) via the pinion gear (4) and side gear (3).
When slewing ! When slewing, the speed of rotation of the left and right wheels is unequal, so pinion gear (4) and side gear (3) in the differential assembly rotate according to the difference in the left and right rotation speeds, and the motive force of carrier (6) is transmitted to the sun gear shafts (2).
10-50
AXLE TORQUE PROPORTIONING DIFFERENTIAL

Function ! Because of the nature of their work, 4-wheel drive loaders have to work in places where the road surface is bad. In such places, if the tires slip, the ability to work as a loader is reduced, and also the life of the tire is reduced. The torque proportioning differential is installed to overcome this problem. ! In structure it resembles the differential of an automobile, but differential pinion gear (4) has an odd number of teeth. Because of the difference in the resistance from the road surface, the position of meshing of pinion gear (4) and side gear (3) changes, and this changes the traction of the left and right tires. Operation When traveling straight (equal resistance from road surface to left and right tires) ! If the resistance from the road surface to the left and right wheels is the same, the distance between pinion gear (4) and meshing point "a" of left side gear (7) is the same as the distance between pinion gear (4) and meshing point "b" of right side gear (3). ! Therefore the left side traction TL and the right side traction TR are balanced. When traveling on soft ground (resistance from road surface to left and right tires is different) ! On soft ground, if the tire on one side slips, the side gear of the tire on the side which has least resistance from the road surface tries to rotate forward. Because of this rotation, the meshing of pinion gear (4) and side gear changes. ! If left side gear (7) rotates slightly forward, the distance between the pinion gear and the meshing point "a" of the left side gear becomes longer than the distance between the pinion gear and the meshing port "b" of the right side gear. The position is balanced as follows. a x TL = b x TR The ratio between the distances to "a" and "b" can change to 1 : 1.38. ! Therefore when the ratio of the distances to "a" and "b" is less than 1 : 1.38 (that is, the difference between the resistance from the road surface to the left and right tires is less than 38%), the pinion gear will not rotate freely, so drive force will be given to both side gears, and the tires will not slip. Because of this effect, the tire life can be increased by 20 - 30%, and at the same the operating efficiency is also increased.
10-51
AXLE
FINAL DRIVE
1. 2. 3. 4. 5.
Sun gear shaft (Teeth 15) Ring gear (Teeth 69) Planetary gear (Teeth 26) Planetary carrier Axle shaft
Outline ! As the final function the final drive operates to reduce the rotative speed of the motive force from the engine and increases the driving force. ! Ring gear (2) is press-fitted in the axle housing and fixed in place by a pin. ! The motive force transmitted from the differential to the sun gear shaft (1) is reduced using a planetary gear mechanism, increasing the driving force. The increased driving force is transmitted to the tires via planetary carrier (4) and axle shaft (5).
10-52
MEMORANDA
MEMORANDA
10-53
AXLE MOUNT
AXLE MOUNT
10-54
AXLE MOUNT
1. 2. 3. 4. 5. 6.
Front axle Front frame Rear frame Rear axle Tension bolt Pivot
FRONT AXLE ! Front axle (1) receives the force directly during operations, so it is connected directly to front frame (2) by tension bolt (5). REAR AXLE ! The rear axle (4) has a structure which allows the center of the rear axle to float, so that all tires can be in contact with the ground when traveling over soft ground.
10-55
CENTER HINGE PIN
CENTER HINGE PIN
1. 2. 3. 4.
Front frame Rear frame Upper hinge pin Lower hinge pin
Outline ! The front frame (1) and rear frame (2) are connected through a bearing by the center hinge pin (3), (4). The steering cylinders are connected to the left and right front and rear frames, so when the cylinders are operated, the frame bends at the middle to give the desired angle, that is the desired turning radius.
10-56
STEERING PIPING
STEERING PIPING
1. 2. 3. 4. 5. 6. 7. 8.
Main control valve Steering valve (orbit-roll) Hydraulic tank Priority valve Hydraulic pump Steering pump Cushion valve Steering cylinder
10-57
STEERING COLUMN
STEERING COLUMN
1. Steering wheel 2. Steering column 3. Steering valve (orbit-roll)
10-58
PRIORITY VALVE
PRIORITY VALVE
Outline ! The priority valve is in the circuit between the steering pump and the steering valve. It acts to divide the flow of oil from the steering pump and send it to the steering valve or oil cooler circuit. It also sets the oil pressure in the circuit from the priority valve to the steering valve to 18.6 MPa (190 kg/cm) to protect the circuit.
1. Plug 2. Valve body 3. Spool 4. Return spring 5. Plug 6. Relief valve body 7. Spring seat 8. Valve spring 9. Poppet 10. Seat 11. Screen A. To steering valve B. To main control valve C. From steering valve D. Drain E. From pump
10-59

Operation 1. Steering wheel at neutral When the engine is stopped, spool. (3) are pushed fully to the left by the tension of spring (4). In this condition, the circuits between ports M and N are fully open, while the circuits between ports M and Q are fully closed. If the engine is started and the steering pump start to turn, the oil from the pump goes from port M to port N, and then enters port A of the steering valve. The oil entering port A is throttled by orifice a, so the pressure in the circuit rises. When this happens, the oil passing through orifices m in spool (3) enters port P. It then compresses spring (4), and moves spool (3) to the right in the direction of the arrow. This stabilizes the condition so that the circuits between ports M and Q are almost fully open and the circuits between ports M and N are almost fully closed. Therefore, the oil from the steering pump almost all flows to the work equipment circuit.
PRIORITY VALVE
2. Steering wheel turned to left When the steering wheel is turned to the left, an angle variation is generated between the spool and sleeve of the steering valve, and the oil flow is switched. (For details, see STEERING VALVE.) The oil from the pump flows from port M to port N, and enters port A. The degree of opening of the sleeve (port A) and spool (port B) of the steering pump creates a difference between the pressure up to port A and the pressure beyond port B. Some of the oil from port B flows to the Girotor E, and then goes to the front right cylinder. The remaining oil passes through orifice b, flows to port J, and then enters port R. When this happens, spool (3) stabilizes at a position where the differential pressure between the circuit up to port A and circuit beyond port B (pressure of port P - pressure of port R) and the load of spring (4) are balanced. It adjusts the degree of opening from port M to ports N and Q, and distributes the flow to both circuits. The ratio of this distributed flow is determined by the degree of opening of port A and port B, in other words, the angle variation between the sleeve and spool of the steering valve. This degree of opening is adjusted by the amount the steering wheel is turned.
10-60
PRIORITY VALVE
3. Steering cylinder at end of stroke If the operator tries to turn the steering wheel further when the steering cylinder has reached the end of its stroke, the circuit from port M through port N to port S is kept open and the pressure rises. When this pressure rises above 18.6 MPa (190 kg/cm), relief valve (10) opens and the oil is relieved to the hydraulic tank. Because of this flow of oil, a differential pressure is created on both sides of orifice r. Therefore, the balance is lost between the load of spring (4), and the pressure up to port A and the pressure beyond port B. As a result, the pressure up to port A becomes relatively higher. For this reason, the pressure at port P moves spool (3) even further to the right from the condition in Item 2. It stabilizes the condition at a position where the circuits between ports M and N are almost fully closed, and the circuits between ports M and Q almost fully open.
10-61
CUSHION VALVE
CUSHION VALVE
1. 2. 3. 4. 5.
Valve seat Valve body Spring Poppet Orifice
6. 7. 8. 9. 10.
Plug Spring Spool Plug Spring
11. Poppet
L. Steering cylinder R. Steering cylinder
Outline ! When There is a reaction to the sudden rise in the pressure of the steering cylinder, the cushion valve acts to prevent shock by relieving the momentary high pressure oil to another line. Function ! If high pressure oil suddenly enters from port R, the high pressure oil compresses spring (3), and pushes open poppet (4). It then passes through the center groove of spool (8), goes through poppet (11) of port L, and Flows to port L. ! At that time, the high pressure oil passes through
orifice (5) and goes to the pressure chamber of plug (6). When it becomes greater than the pressure at port L and force of spring (7), it pushes spool (8) fully to the left. This shuts off the flow of high pressure oil from port R through poppet (4) to port L. This temporary flow of oil has a cushion effect. The valve is not actuated any further, so there is no effect on the steering, and the steering operates as normal. ! When the pressure rises slowly and there is no need for any cushion effect, spool; (8) closes more quickly than poppet (4) opens so there is no unnecessary cushion action.
10-62
MEMORANDA
MEMORANDA
10-63
STEERING VALVE
STEERING VALVE (ORBIT-ROLL)
10-64
STEERING VALVE
Outline ! The steering valve is connected directly to the shaft of the steering wheel. It switches the flow of oil from the steering pump to the left and right steering cylinders to determine the direction of travel of the machine. ! The steering valve, broadly speaking, consists of the following components: rotary type spool (3) and sleeve (5), which have the function of selecting the direction, and the Girotor set (a combination of rotor (8) and stator (9), which acts as a hydraulic motor during normal steering operations, and as a hand pump (in fact, the operating force of the steering wheel is too high, so it cannot be operated) when the steering pump or engine have failed and the supply of oil has stopped.
Structure ! Spool (3) is directly connected to the drive shaft of the steering wheel, and is connected to sleeve (5) by center pin (4) (it does not contact the spool when the steering wheel is at neutral) and centering spring (12). ! The top of drive shaft (6) is meshed with center pin (4), and forms one unit with sleeve (5), while the bottom of the drive shaft is meshed with the spline of rotor (8) of the Girotor. There are four ports in valve body (2), and they are connected to the pump circuit, tank circuit, and the circuits at the head end and bottom end of the steering cylinders. The pump port and tank port are connected by the check valve inside the body. If the pump or engine fail, the oil can be sucked in directly from the tank by this check valve.
10-65
STRUCTURE AND FUNCTION OPERATION

1. Steering wheel at neutral.
STEERING VALVE
10-66
STEERING VALVE
When the steering wheel is at neutral, centering spring (12) makes spool (3) and sleeve (5) stop at a position where center pin (4) is at the center of the oblong hole in spool (3). At this point, pump port A of the sleeve and ports E, F, and G to the steering cylinder and Girotor, and vertical grooves B, C, and D of the spool are shut off. However, orifice a of pump port A is connected to orifice d (connected to drain port H) of the spool. Orifice b of port J from the priority valve is connected to vertical groove B of the spool. In addition, port K of the sleeve is connected to drain port L of the spool and vertical groove B.
By shutting off and connecting these ports and grooves, the oil from the pump passes from port A through orifices a and d, and is drained to the hydraulic tank. In addition, the oil which forms the pilot pressure of the priority valve passes from port J through orifice b, then through vertical groove B and port K, and is returned to the hydraulic tank from port L.
10-67

2. Steering wheel turned (turning to left)
STEERING VALVE
10-68
STEERING VALVE
When the steering wheel is turned to the left, spool (3), which is connected by the spline of the steering shaft, also turns to the left. The spool and sleeve (5) are interconnected by centering spring (12), so the spool compresses the centering spring. Therefore, a difference in the angle of rotation (angle variation) is generated between the spool and sleeve equal to the amount that the centering spring is compressed. When this happens, first, port A and vertical groove B are connected. Then vertical groove B and port E to the Girotor, and port E from the Girotor to vertical groove C are connected. Finally, vertical groove C and port G to the head end of the right cylinder are connected. In addition, vertical groove B is kept connected to orifice b of port J to the priority valve, but port K of the sleeve gradually closes the connection of vertical groove B and port L. Port F from the head end of the left cylinder is connected to vertical groove D (connected to drain port H) at the same time as port A and vertical groove B are connected. By shutting off and connecting the above ports and grooves, the oil from the pump enters vertical groove B from port A, then flows to port E to the Girotor, and turns the Girotor. The oil discharged from the Girotor enters vertical groove C from port E, and
flows from port G to the head end of the right cylinder. The oil entering vertical groove B passes through orifice b and flows to port J. From port J, it becomes the pilot pressure of the priority valve. The oil from the head end of the left cylinder enters vertical groove D from port F and is drained to the hydraulic tank. 3. Steering wheel stopped When the operation of the steering wheel is stopped, the difference in rotation between the spool and sleeve is returned to the neutral condition by the reaction of centering spring (12).
10-69
STRUCTURE AND FUNCTION CONNECTION BETWEEN HAND PUMP AND SLEEVE
STEERING VALVE
The diagrams above show the connections with the sleeve ports used to connect the suction and discharge ports of the Girotor.
If the steering wheel has been turned to the right, ports a, c, e, g, i and k are connected by the vertical grooves in the spool to the pump side. At the same time, ports b, d, f, h, j, and I are connected to the head end of the left steering cylinder in the same way. In the condition in Fig. 1, ports 1, 2, and 3 are the discharge ports of the Girotor set. They are connected to ports l, b, and d, so the oil is sent to the cylinder. Ports 5, 6, and 7 are connected and the oil flows in from the pump. If the steering wheel is turned 90E, the condition changes to the condition shown in Fig. 2. In this case, ports 1, 2, and 3 are the suction ports, and are connected to ports i, k, and c. Ports 5, 6, and 7 are the discharge ports, and are connected to ports d, f, and h.
10-70
STEERING VALVE
! In this way, the ports acting as the discharge ports of the Girotor are connected to the ports going to the steering cylinder, while the ports acting as the suction ports are connected to the pump circuit. Adjustment of discharge according to amount steering wheel is turned. For each 1/7 turn of the steering wheel, the inside teeth of the Girotor advance one tooth, and the oil from the pump is discharged in an amount that matches this movement. Therefore, the amount of oil discharged is directly proportional to the amount the steering wheel is turned.
Role of centering spring ! Centering spring (12) consists of four X-shaped leaf springs and two flat leaf springs. It is assembled between spool (3) and sleeve (5) as shown in the diagram on the right. When the steering wheel is turned, the spool compresses the spring, and a difference (angle variation) is generated in the turning angle of the spool and sleeve. Centering spring (12) consists of four X-Shaped leaf springs and two flat leaf springs. It is assembled between spool (3) and sleeve (5) as shown in the diagram on the right. When the steering wheel is turned, the spool compresses the spring, and a difference (angle variation) is generated in the turning angle of the spool and sleeve. As a result, the port of the spool and sleeve is connected and oil is sent to the cylinder. However, when the rotation of the steering wheel is stopped, the rotation of the Girotor also stops, so no more oil is sent to the cylinder, and the oil pressure rises. To prevent this, when the turning of the steering wheel is stopped, the action of the centering spring only allows it to turn by an amount equal to the difference in angle of rotation (angle variation) of the sleeve and spool, so the steering wheel returns to the NEUTRAL position.
10-71
BRAKE PIPING
BRAKE PIPING
Outline ! Brake booster (7) consists of a hydraulically actuated boosting mechanism. It is designed to reduce the operating force of the pedal, and to ensure a powerful braking force. ! When the brake pedal is depressed, the oil sent from the pump shuts off the transmission circuit inside the valve and actuates the piston to apply the front and rear brakes. A relief valve is installed in the circuit to protect the circuit from damage if any abnormal pressure should be generated in the oil sent from the pump.
1. 2. 3. 4. 5. 6. 7. 8. 9.
Front axle Right brake pedal Left brake pedal Rear axle Brake oil tank Rear brake Brake booster Transmission cut-off switch Front brake
10-72
BRAKE CONTROL
BRAKE CONTROL
10-73
BRAKE BOOSTER
BRAKE BOOSTER
Outline ! The brake booster is a boosting system to increase the braking force. It increases the pressure in the master cylinder in proportion to the operating force by using the oil pressure delivered from the oil pump.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Dust cover Spool Relief valve Cylinder cover Power piston Return spring (for power piston) Return spring (for connector) Connector Reaction spring Reaction piston Secondary piston Primary piston
10-74
BRAKE BOOSTER
Operation Brake OFF ! When the push rod connected to the brake pedal is returned, spool (2), connector (8), and power piston (5) are returned towards cylinder cover (4) by return springs (6) and (7). Therefore, primary piston assembly (12) and secondary piston assembly (11) of the master cylinder are each in their respective neutral positions. The respective pressures in the chambers E and F (the chambers connected to the discharge port) pass through the relief port and are released to atmospheric pressure chambers C and D in the reservoir. The oil from the pump flows from port A to port B and then flows into the transmission circuit. In addition, the oil in the master cylinder is connected to the front and rear axles.
Hydraulic pressure starting to rise ! When the brake pedal is depressed, the push rod connected to the pedal compresses reaction spring (9) and moves spool (2) forward. Connector (8) is pushed towards the power piston by return spring (7), so the passage between power piston (5) and spool (2) is restricted. A difference in pressure is generated between the front and rear walls of the power piston, so the power piston moves forward, pushes connector (8), and actuates secondary piston assembly (11) of the master cylinder.
10-75

Hydraulic force rising ! When secondary piston (11) moves forward and primary cup (13) closes relief port (14), pressure is generated in chamber E. Reaction piston (10) (piston with small diameter) built into secondary piston (11) moves to the rear and is in continuous contact with the tip of spool (2). The pressure generated in the master cylinder and bearing on the area of reaction piston (10) passes through push rod (16) and is transmitted to the pedal as the operating force. ! The pressure generated at chamber E of secondary piston (11) of the master cylinder is also generated at the same time in chamber F of primary piston (12). In addition, when the brake pedal is depressed, power piston (5) moves to the right, and the pressure of the oil in chamber E and chamber F rises, so the braking force of the front brake and rear brake is also increased.
BRAKE BOOSTER
Relief valve ! When the brake is being operated, if the pressure inside the power cylinder (port A) goes above the specified level, relief valve (3) is actuated. The oil is relieved to the transmission circuit to prevent abnormal pressure in the brake system. ! If there should be any failure in the hydraulic pump sending oil to the power cylinder, the operating force of the pedal is transmitted through spool (2) and connector (8), so the piston in the master cylinder can be actuated. However, when this happens, the operating force of the brake pedal is heavier than usual.
10-76
BRAKE BOOSTER
Brake actuated (oil leaking from front brake) ! The brake oil tanks from independent systems, so if there is any leakage of oil in either the front or rear brake systems, only one of the brakes (front or rear) will be applied. This increases the safety and ensures that the machine can always be stopped.
Brake pedal released ! When the pedal is released, spool (2) is returned by reaction spring (9), so the passage between spool (2) and power piston (5) is restricted. It is released to the same conditions as when not actuated (brake OFF), and the difference in pressure between front and rear chambers of power piston (5) is removed, so the power piston and connector (8) are acturned by return springs (6) and (7). Following this, the pistons of the master cylinders are also returned to the neutral position by their respective return springs. The relief ports are connected to the reservoir, and the pressure returns to atmospheric pressure.
10-77
BRAKE
BRAKE
1. Differential housing 2. Piston 3. Inner ring
4. Disc 5. Outer ring 6. Bearing carrier
7. Axle housing 8. Sun gear shaft
Function ! The brake is a wet-type, single disc brake. It consists of piston (2), inner ring (3), disc (4), and outer ring (5). ! The brake cylinder consists of differential housing (1) and bearing carrier (6). Piston (2) is assembled inside the brake cylinder.
Inner ring (3) is installed to the notched part of bearing carrier (6). Outer ring (5) is secured to axle housing (7) by pin. ! Disc (4) has a lining stuck on both faces. It is assembled between inner ring (3) and outer ring (5). It is connected by the spline of the sun gear shaft.
10-78
BRAKE
Operation Brake applied ! When the brake pedal is depressed, the rod of the master cylinder is pushed. Oil pressure P is generated, and this acts on the piston inside the brake cylinder to slide piston (6) slightly. Therefore, the rotation of disc (4), which is between inner ring (3) and outer ring (5), is stopped, and the brakes. are applied to stop the machine.
Brake released ! When the oil pressure is released, piston (6) moves back slightly because of the return force of piston O-ring (9). A gap is created between inner ring (3) and outer ring (5), so disc (4) is free. Grooves are cut in a lattice pattern on the lining stuck to disc (4). When the disc is rotating, oil flows in these grooves to cool the lining.
10-79
PARKING BRAKE CONTROL
PARKING BRAKE CONTROL
Outline ! When parking brake pedal (1) is depressed, control cable (3) pulls brake lever (4) up and actuates the multiple disc brake installed to the output shaft of the transmission. ! ! To release the parking brake, pull parking brake release lever (2). When the parking brake is applied, the neutralizer relay acts to shut off the electric current to the transmission solenoid valve and keep the transmission at neutral.
1. 2. 3. 4. 5.
Parking brake pedal Parking brake release lever Control cable Parking brake lever Transmission
10-80
PARKING BRAKE
PARKING BRAKE
Outline ! The parking brake is a mechanically operated wet type multiple disc brake which applies braking force to transmission output shaft (5). ! Lever (2) is connected to the control cable, and when the lever is pulled, ball (6), which is between cover (7) and piston (8) connected to the lever, moves on the slope of the piston groove. The piston pushes the discs and plates together, and applies braking force to output shaft (5).
1. 2. 3. 4. 5. 6. 7. 8.
Transmission Parking brake lever Disc Plate Transmission output shaft Ball Cover Piston
10-81
HYDRAULIC PIPING
HYDRAULIC PIPING
1. 2. 3. 4. 5. 6. 7. 8. 9.
Bucket cylinder Boom cylinder (R.H.) Steering valve Hydraulic tank Priority valve Hydraulic pump Steering pump Main control valve Boom cylinder (L.H.)
10-82
HYDRAULIC PIPING
Outline ! ! The hydraulic system consists of the work equipment circuit and the steering circuit. The work equipment circuit controls the operation of the boom, bucket, or other attachments. The oil from the hydraulic tank (4) is sent from the hydraulic and steering pump (6)and steering pump (7) to the priority valve (5). The amount of oil flow is controlled and sent to main control valve (8). If the bucket and boom spools of main control valve are at neutral, the oil passes through the drain circuit of the main control valve, is filtered by the filter inside hydraulic tank (4), and returns to the tank. When the work equipment control lever is operated, the bucket or boom spool of main control valve (8) move, oil flows from main control valve (8) to the boom cylinders (2) and (9) or to bucket cylinder (1), and operates the boom or bucket. The maximum pressure of the hydraulic circuit is controlled by priority valve (5) and the relief valve inside the main control valve. A safety valve (with suction) is installed in the bucket cylinder circuit to protect the circuit. Hydraulic tank (4) is a pressurized sealed typed and has a breather with a relief valve. It pressurizes the inside of the tank and also prevents negitive pressure in order to prevent cavitation of the pump.
10-83
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM

(Engine low idling, work equipment in HOLD)
10-84
1. 2. 3. 4. 5. 6.
Hydraulic tank Filter Steering pump Hydraulic pump Priority valve Steering valve (Orbit-rol valve)
7. 8. 9. 10. 11. 12.
Overload valve Steering cylinder Cushion valve Relief valve Safety valve (with suction) Bucket spool
13. 14. 15. 16. 17.
Boom spool Suction valve Bucket cylinder Boom cylinder Oil cooler (option)
10-85
HYDRAULIC TANK
HYDRAULIC TANK
Outline ! The oil from the hydraulic tank is sent from the pump through the priority valve and main control valve to each cylinder. It merges in the return circuit with the oil from various parts, is filtered by the oil filter, and returns to the tank. ! The oil filter filters the whole oil flow in the circuit. When the oil filter becomes clogged, the bypass valve is actuated to allow the oil to return directly to the tank and prevent damage to the filter.
1. 2. 3. 4. 5. 6.
Cap breather Air bleed plug Oil filter bypass valve Oil filer Oil level gauge Drain plug
10-86
HYDRAULIC TANK OIL FILTER BYPASS VALVE

When the filter is clogged ! By-pass valve (1) opens and the oil returns directly to the tank without passing through the filter (2). By-pass valve set pressure: 0.15 MPa (1.5 kg/cm)
When negative pressure is formed in the return circuit. ! By-pass valve (1) moves up and acts check valve. Check valve set pressure: 0.024 MPA (0.24 kg/cm)
10-87
STRUCTURE AND FUNCTION BREATHER
HYDRAULIC TANK
1. 2. 3. 4. 5. 6.
Cover Sleeve Spring Spring Poppet Filter element
Preventing negative pressure inside tank ! The tank is a pressurized sealed type, so if the oil level inside the hydraulic tank goes down, there will be negative pressure in the tank. If this happens, a sleeve (2) is opened by the difference between the pressure inside the tank and the atmospheric pressure, and air is let in to prevent negative pressure from forming inside the tank.
Preventing rise in pressure inside tank ! If the pressure in the circuit rises above the set pressure during operations because of the change in the oil level in the hydraulic cylinders or the rise in the temperature, the poppet (5) is actuated to release the pressure inside the hydraulic tank.
10-88
MEMORANDA - MEMORANDA -
10-89
MAIN CONTROL VALVE
MAIN CONTROL VALVE

2-SPOOL VALVE
A. B. C. D. E. F.
To bucket cylinder rod end To boom cylinder rod end Drain port (to tank) To boom cylinder bottom side To bucket cylinder bottom side From pump
10-90
MAIN CONTROL VALVE
1. 2. 3. 4. 5. 6. 7. 8.
Main relief valve Bucket spool Boom spool Magnet for boom Magnet for bucket Safety valve (with suction) Suction valve Check valve
10-91
STRUCTURE AND FUNCTION 3-SPOOL VALVE
MAIN CONTROL VALVE
A. B. C. D. E. F. G. H.
To attachment cylinder To bucket cylinder rod side To boom cylinder rod side Drain port (to tank) To boom cylinder bottom side To bucket cylinder bottom side To attachment cylinder From pump
10-92
MAIN CONTROL VALVE
1. 2. 3. 4. 5.
Main relief valve Attachment spool Bucket spool Boom spool Magnet for boom
6. 7. 8. 9.
Magnet for bucket Safety valve (with suction) Suction valve Check valve
10-93
STRUCTURE AND FUNCTION RELIEF VALVE
MAIN CONTROL VALVE
1. 2. 3. 4. 5.
Main valve Valve seat Pilot poppet Spring Adjustment screw
Function The relief valve is installed to the inlet portion of the main control valve. If the oil goes above the set pressure, the relief valve drains the oil to the tank to set the maximum pressure for the work equipment circuit, and to protect 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 in main valve (1), and fills port B. Pilot poppet (3) is seated in valve seat (2). ! If the pressure inside ports A and B reaches the set pressure of pilot poppet spring (4), pilot poppet (3) opens and the oil pressure at port B escapes from port D to port C, so the pressure at port B drops. When the pressure at port B drops, a difference in pressure between ports A and B is created by the orifice of main valve (1). The main valve is pushed open and the oil at port A passes through port C, and the abnormal pressure is released to the drain circuit. The set pressure can be changed by adjusting the tension of pilot poppet spring (4). To change the set pressure, remove the cap nut, loosen the locknut, then turn adjustment screw (5) to adjust the set pressure as follows. TIGHTEN to INCREASE pressure LOOSEN to DECREASE pressure
10-94
MAIN CONTROL VALVE SAFETY VALVE (WITH SUCTION)
1. 2. 3. 4. 5. 6.
Suction valve Main valve Main valve spring Pilot piston Suction valve spring Valve body
Function ! The safety valve is in the bucket cylinder circuit inside the main control valve. If any abnormal pressure is generated by any shock to the cylinder when the main control valve is at the neutral position, this valve relieves the abnormal pressure to prevent damage to the cylinder.
Operation Operation as safety valve ! Port A is connected to the cylinder circuit and port B is connected to the drain circuit. The oil pressure at port A is sent to port D from the hole in pilot piston (4). It is also sent to port C by the orifice formed from main valve (2) and pilot piston (4). Pilot piston (4) is secured to the safety valve, and the size of the cross-sectional surface (cross-sectional area) has the following relationship: d2 > d1 > d3 > d4. ! If abnormal pressure is created at port A, suction valve (1) is not actuated because of relationship d2 > d1>, but relationship between port A and port C is d3 > d4, so main valve (2) receives oil pressure equivalent to the difference between the areas of d3 and d4. If the oil pressure reaches the force (set pressure) of main valve spring (3), main valve (2) is actuated, and the oil from port A flows to port B.
10-95

Operation as suction valve ! If any negative pressure is generated at port A, port D is connected with port A, so there is also negative pressure at port D. The tank pressure of port B is applied to port E, so the suction valve (1) receives oil pressure a, which is equal to the difference in the area of d2 and d1 because of the tank pressure at port E. Therefore, oil pressure e moves the valve in the direction of opening, and oil pressure a acts to move suction valve (1) in the direction of closing. When the pressure at port A drops (and comes close to negative pressure), it becomes lower than hydraulic pressure e. The relationship becomes oil pressure e > oil pressure a + force of valve spring (5), and suction valve (1) opens to let the oil from port B flow into port A and prevent any negative pressure from forming at port A.
MAIN CONTROL VALVE
SUCTION VALVE
1. Main poppet 2. Sleeve 3. Spring
Function ! This valve acts to prevent any negative pressure from forming in the circuit.
Operation ! If any negative pressure is generated at port A (boom cylinder rod end) (when a pressure lower than tank circuit port B is generated), main poppet (1) is opened because of the difference in area between d1 and d2, and oil flows from port B at the tank end to port A at the cylinder port end.
10-96
MAIN CONTROL VALVE Boom and bucket spool at NEUTRAL position
Operation ! The oil from hydraulic pump (1) passes through the priority valve, and enters port A. The maximum pressure is set by relief valve (2). ! Bucket spool (3) is at the NEUTRAL position, so the bypass circuit is open and the oil in chamber A passes around the spool and flows to port B. Boom spool (4) is also at the NEUTRAL position, so the bypass circuit is open and the oil in chamber B passes around the spool, enters chamber C of the drain circuit, passes through the filter, and returns to the tank.
10-97
STRUCTURE AND FUNCTION Boom spool at RAISE position
MAIN CONTROL VALVE
Operation ! When the work equipment control lever is pulled, boom spool (4) is pulled out to the RAISE position. ! The oil from the pump flows through the by-pass circuit of the bucket spool and flows to the by-pass circuit of boom spool (4). The by-pass circuit is closed by the spool, so the oil from port B pushes check valve (5) open. The oil from port B then flows from port E to the bottom end of the cylinder. At the same time, the oil at the cylinder rod end flows from port D to drain port C and returns to the tank. As a result, the boom is raised.
10-98
MAIN CONTROL VALVE Boom spool at LOWER position
Operation ! When the work equipment control lever is pushed, boom spool (4) is pushed in to the LOWER position. ! The oil from the pump flows through the by-pass circuit of the bucket spool and flows to the by-pass circuit of boom spool (4). The by-pass circuit is closed by the spool, so the oil from port B pushes check valve (5) open. The oil from port B then flows from port D to the rod end of the cylinder. At the same time, the oil at the cylinder bottom end flows from port E to drain port C and returns to the tank. As a result, the boom is lowered.
10-99
STRUCTURE AND FUNCTION Boom spool at FLOAT position
MAIN CONTROL VALVE
Operation ! If the work equipment control lever is pushed beyond the LOWER position, boom spool (4) is pushed into the FLOAT position. ! The oil from the pump passes around the by-pass circuit of the bucket spool and flows to the boom spool by-pass circuit. The oil in the by-pass circuit is sent to the drain circuit by the spool and cannot push open check valve (5). Both the RAISE circuit E and LOWER circuit D of the boom cylinder are connected to the drain circuit, so the boom goes down under its own weight. ! When the bucket is in contact with the ground surface, the bucket can move up or down in accordance with the shape of the ground surface.
10-100
MAIN CONTROL VALVE Bucket spool at TILT BACK position
Operation ! When the work equipment control lever is pulled, bucket spool (3) is pulled out to the TILT BACK position. ! The by-pass circuit is closed by the spool, so the oil from port A pushes open check valve (7). The oil from port A then flows to port H of the bottom end of the cylinder. At the same time, the oil at the cylinder rod end flows from port G to drain port C, and returns to the tank. As a result, the bucket is tilted back.
10-101
STRUCTURE AND FUNCTION Bucket spool at DUMP position
MAIN CONTROL VALVE
Operation ! When the work equipment control lever is pushed, bucket spool (3) is pushed in to the DUMP position. ! The by-pass circuit is closed by the spool, so the oil from port A pushes open check valve (7). The oil from port A then flows from port G to the rod end of the cylinder. At the same time, the oil at the cylinder bottom flows from port H to drain port C, and returns to the tank, As a result, the bucket is tilted forward.
10-102
WORK EQUIPMENT LEVER LINKAGE
WORK EQUIPMENT LEVER LINKAGE
1. 2. 3. 4.
Bucket boom control lever Kick-down switch Lock lever Main control valve
10-103
WORK EQUIPMENT LINKAGE
1. 2. 3. 4. 5. 6.
Bellcrank Bucket cylinder Boom cylinder Boom Bucket link Bucket
10-104
10-105
BUCKET
BUCKET
1. Bucket (1.7 m3) 2. Bolt-on cutting edge (BOC)
10-106
BUCKET POSITIONER AND BOOM KICK-OUT
1. 2. 3. 4.
Bucket cylinder rod Lever Proximity switch Proximity switch
10-107
STRUCTURE AND FUNCTION 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 control lever is returned from the TILT position to the HOLD position, and the bucket is automatically set to the suitable digging angle. Lever (2) is secured to the bucket cylinder rod (1) by bolts. In addition, proximity switch (3) 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, lever (2) also moves to the left. Proximity switch (3) separates from lever (2) at the desired position, and the bucket control lever is returned to neutral.
! !
BOOM KICK-OUT
! The boom kick-out is an electrically actuated system. It acts to move the boom control lever to the HOLD position and stop the boom at the desired position before the boom reaches the maximum height. Plate is fixed to the boom. In addition, proximity switch (4) is fixed to the frame. When the boom is moved from the LOWER position to the RAISE position, the boom rises, and when it reaches the desired position, the proximity switch and lever come together and the system is actuated to return the boom control lever to the HOLD position.
10-108
PROXIMITY SWITCH
PROXIMITY SWITCH
Operation ! The proximity switches are installed to the boom and bucket cylinders by a support. In accordance with the operating condition, a pulse is generated from the sensor at the desired point when moving to the boom RAISE position and bucket TILT BACK position. This electric current is transmitted to a magnet, and the boom and bucket control lever is returned to neutral. Therefore, the main control valve also returns to neutral and the movement of the boom and bucket are stopped.
10-109
STRUCTURE AND FUNCTION OPERATION OF THE PROXIMITY SWITCH

Bucket TILT BACK switch ! If the bucket is dumped beyond the set position for the bucket positioner, the detector plate is above the detector surface of the bucket proximity switch, so the proximity switch sends the battery current to the magnet switch coil. ! When the bucket lever is operated to the TILT BACK position, the bucket spool is held at the TILT BACK position by the magnet at the bucket spool detent of the main control valve, and the bucket is tilted back. When the bucket tilts back and reaches the set position for the bucket positioner, the detector plate separates from the proximity switch detector surface. When this happens, the proximity switch cuts the electric current to the magent coil. The bucket spool is then returned to the neutral position by the return spring.
PROXIMITY SWITCH
Boom RAISE switch ! When the boom is lowered below the set position for the boom kick-out, the detector plate is above the detector surface of the boom proximity switch, so the proximity switch sends the battery current to the magnet switch coil. ! Now when the boom lever is operated to the RAISE position, the boom spool is held at the RAISE position by the boom spool detent magnet of the main control valve, and the boom rises. When the boom rises and reaches the set position for the boom kick-out, the detector plate seperates from the proximity switch detector surface. When this happens, the proximity switch cuts the electric current to the magnet coil. The boom spool is then returned to the neutral position by the return spring.
ACTION OF THE PROXIMITY SWITCH
POSITION Proximity switch Boom, Bucket Proximity Switch When detector is positioned at detection surface of proximity switch. Proximity switch sends electric current to magnet coil. Magnet is actuated. When detector is separated from detection surface of proximity switch. Proximity switch cuts electric current to magnet coil. Magnet is not actuated.
10-110
ROPS CAB
ROPS CAB
10-111
AIR CONDITIONER
AIR CONDITIONER
AIR CONDITIONER AND HEATER PIPING
1. 2. 3. 4. 5. 6. 7. 8.
Vent Air conditioner condenser Dry receiver Compressor Hot water inlet port Hot water outlet port Air conditioner unit Water valve
10-112
AIR CONDITIONER ELECTRIC CIRCUIT DIAGRAM

(Eagle air conditioner/ Heater)
NOTES:
1. Position the ambient temperature probe near waist high level, out of air flow and sun load. 2. Insert the sensing tube from present thermostat down into the evaporator coil, parallel to the coil face, between the 1st and 2nd rows, to a depth of the coil height minus 1 inch. Wire chart
Socket Size
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 10GA 18GA 18GA 18GA N/A 18GA 14GA 16GA 18GA 14GA 18GA 16GA 18GA 16GA 12GA N/A
Color
Red Red Black Red N/A Black Orange Dk. Green DK. Blue Black Brown White Tan Yellow Black N/A
Wire function
Battery positive in evap coil thermostat in ambient thermistor in evap coil thermostat in Not used ambient thermistor in Fan positive out Clutch out Ignition switch in Fan negative out Condenser blown fuse in Heat solenoid out Pressure switch detect in Condenser fan relay out Battery negative in Not used
10-113
E.C.S.S.
E.C.S.S. (ELECTRONIC CONTROLLED SUSPENSION SYSTEM)
Outline ! The E.C.S.S. is a system to suppress the travel vibration when traveling on unpaved surfaces, snow, or other rough road surfaces at high speed, or when traveling loaded. It is effective in reducing the vibration of the chassis and makes it possible to carry out stable travel operations.
1. 2. 3. 4. 5.
Accumulator (ACC1) Accumulator (ACC2) Solenoid valve Actuation selector switch Main control valve
10-114
E.C.S.S. E.C.S.S. HYDRAULIC, ELECTRICAL CIRCUIT DIAGRAM
System actuation table Actuation selector switch OFF Boom cylinder bottom pressure MPa (kg/cm2) 0 - (0 -) 0 - 5.9 (0 - 60) ON 5.9 - 14.7 (60 - 150) 14.7 - (150 -) Solenoid valve actuation SOL1 O O SOL2 O O SOL3 O Actuation of system Not actuated ACC1 actuated ACC2 actuated Not actuated
10-115
STRUCTURE AND FUNCTION OPERATION
E.C.S.S.
1. Boom cylinder 2. Actuation selector switch
3. Accumulator 4. Pressure switch
6. Solenoid selector switch 7. Main control valve
With this system, there are two interconnected accumulators (3) charged with gas under different pressures. These two accumulators are installed between the bottom end of boom cylinder (1) and main control valve (6). The two accumulators (3) are equipped with pressure switches (4) and solenoid selector valves (5) to open and close the oil circuit. There is also a further solenoid selector valve (5) between the head end of boom cylinder (1) and control valve (6) to open or close the flow of oil to the cylinder head. The pressures (ACC1, ACC2) of the gas in the two accumulators (3) and the set pressure (PSW1, PSW2) of the two pressure switches (4) are set as follows: ACC1 < Load pressure at bottom end when empty < ACC2 < Load pressure at bottom end when loaded. Load pressure at bottom end when empty < PSW1 < Load pressure at bottom end when loaded < PSW2.
! !
For this reason, when traveling unloaded, accumulator (3) ACC1 acts as a spring, and when traveling loaded, ACC2 acts as a spring. Even if the operator forgets to switch actuation selector switch (2) when operating, if the pressure at the bottom end goes above PSW2, solenoid selector valve (5) is automatically switched and the circuit of accumulator (3) is closed, so accumulator (3) is protected from any axcessive pressure generated at the bottom end.
10-116
E.C.S.S.
1. Actuation selector switch OFF ! Solenoid selector valves (1), (2), and (3) are at the shut-off position, so the system is not actuated.
2. Actuation selector switch ON, traveling unloaded, boom cylinder bottom pressure: 0 - 5.9 Mpa (0 - 60 kg/cm2) ! Accumulators ACC1 and ACC2 are both interconnected, but gas pressure of accumulator ACC2 > boom cylinder bottom pressure, so ACC2 is not actuated as a spring. Only accumulator ACC1 is acyuated as a spring.
10-117

3. Actuation selector switch ON, traveling loaded, boom cylinder bottom pressure: 5.9 - 14.7 Mpa (60 - 150 kg/cm2) ! Electricity flows to pressure switch (1) and solenoid selector valve (3) is at the shut-off position, so only accumulator ACC2 is actuated as a spring.
E.C.S.S.
4. Actuation selector switch ON, excess pressure generated, boom cylinder bottom pressure: above 14.7 Mpa (150 kg/cm2) ! Electricity flows to both pressure switches (1) and (2), and solenoid selector valves (1), (2), and (3) are at shut-off position, so the system is not actuated, and no excess pressure is brought to bear on accumulator ACC1 or ACC2.
10-118
ELECTRICAL WIRING ILLUSTRATION
ELECTRICAL WIRING ILLUSTRATION
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Central panel Bucket positioner proximity switch Head lamp Transmission cut-off switch Staring switch Combination switch Fuse box Parking brake switch Slow blow fuse Alternator Water temperature sensor Working lamp
13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
License lamp Rear combination lamp Battery Fuel level sensor Battery relay Transmission solenoid valve Directional lever Gear shift lever Wiper switch Horn Boom kick-out proximity switch
10-119
CENTRAL PANEL
CENTRAL PANEL (CLUSTER GAUGE)
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Service meter indicator Fuel gauge Turn signal pilot lamp Speedometer Head lamp high beam pilot lamp Coolant temperature gauge Torque converter oil temperature gauge Brake oil level warning lamp Working lamp pilot lamp Preheating pilot lamp
11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Working lamp switch Parking brake pilot lamp Engine oil pressure warning lamp Battery charge warning lamp Transmission cut-off selector lamp Emergency steering lamp Brake boost pressure warning lamp Transmission cut-off selector switch Emergency steering lamp Service meter
10-122
SENSOR
SENSOR
ENGINE OIL PRESSURE
1. 2. 3. 4. 5. 6.
Plug Contact ring Contact Diaphragm Spring Terminal
Function ! The engine oil pressure sensor is installed to the engine block and detects the oil pressure. If the oil pressure goes below the specified pressure, it lights up the engine oil pressure warning pilot lamp on the cluster gauge to warn the operator of the abnormality.
BRAKE OIL LEVEL
1. 2. 3. 4. 5. 6.
Cap Ring Float Connector Tank Diaphragm
Function ! The brake oil level sensor is installed to the top of the brake oil tank. When the brake oil goes below the specified level, the float goes down and the switch is turned on. This lights up the brake oil level lamp on the cluster gauge to warn the operator of the abnormality.
10-123
ENGINE STARTING CIRCUIT
ENGINE STARTING CIRCUIT
Function ! A neutral safety circuit is used to prevent the engine from starting if the directional lever is not at the N position. This ensures safety when starting the engine. Operation ! When the directional lever is placed at the N position, the N contacts of the directional lever switch are closed. ! When the starting switch is turned to the ON position, Electric current flows from battery (+) starting switch terminal B - BR battery relay. The battery relay is closed, so current flows in the following circuit: (1) battery(+) slow blow fusedirectional switch terminal N neutral relay terminals 1 - 2 ground, and the relay coil is excited. When this happens, neutral relay terminals 3 - 5 are closed. ! In addition, electric current flows from switch terminal ACCUMULATOR Fuel shut-off solenoid ground, and then releases the stop lever of the fuel injection pump to the FULL position to set the operating condition.
If the starting switch is turned to the START position, current flows from starting switch terminals B - C neutral relay terminals 5 - 3 starting motor terminal S ground, and a circuit is also formed from the battery battery relay starting motor terminal B, so the engine starts. If the directional lever is not at the N position, circuit (1) is not formed, so the engine does not start.
10-124
ENGINE STOP CIRCUIT
ENGINE STOP CIRCUIT
Function ! The system is equipped with an electrical fuel cut device ( Fuel shut-off solenoid) which makes it possible to start the engine by turning the switch ON or OFF. This improves the ease of operation. Operation ! When the starting switch is turned OFF, starting switch terminals B and ACC are opened. ! The current in the Fuel shut-off solenoid is shut off by the starting switch, so the coil is not excited. Therefore, the stop lever of fuel injection pump is released to the stop position and shuts off the fuel supply to the injection pump, causing the engine to stop.
10-125
AUTOMATIC PREHEATING CIRCUIT

QUICK HEATING SYSTEM (Q.H.S.)
OUTLINE ! To make it easier to start the engine in cold weather, a Q.H.S. (Quick Heating System) automatic preheating system is installed. This consist of a controller, a water temperature sensor, and a large capacity ribbon heater. ! The Q.H.S. automatically sets the preheating time to match the coolant temperature simply by turning the starting switch ON. It also acts to reduce the preheating time. ! When the starting switch is turned to the ON position, the preheating pilot lamp lights up, and the ribbon heater carries out preheating while the lamp is lit up. The water temperature sensor detects the water temperature and the preheating time is set by the controller. ! While the preheating pilot lamp is lit up, preheating is being carried out, so keep the starting switch at the ON position. When the engine reaches a temperature which makes it possible to start the engine, the preheating pilot lamp goes out, so the engine can be started.
When the starting switch is turned to the START position while preheating, it assumes the engine has started and immediately stops the preheating. Operation ! When the starting switch is turned to the ON position, A signal flows from the starting switch terminal ACC to Q.H.S. controller terminal 4. The controller instantaneously detects the water temperature and determines the length of time for lighting up the preheating pilot lamp and the preheating time for the ribbon heater. ! Controller terminal 5 is connected to the ground, and lights up the preheating pilot lamp. At the same time, it sends a signal from terminal 2 to the heater relay to actuate the heater relay and make the ribbon heater red hot. ! When the preheating end signal is sent from the controller, the heater relay is turned OFF and preheating is completed.
10-126

! The diagrams on the right show the actuation sequence. (Fig. 1, Fig. 2)
The diagrams on the right show lighting up time T1 for the preheating lamp and preheating/post heating time T2 according to the water temperature. (Fig. 3, Fig. 4)
10-127
STRUCTURE AND FUNCTION Q.H.S. CONTROLLER
1. Q.G.S. controller body 2. Lead wire 3. Connector
HEATER RELAY
10-128
AUTOMATIC PREHEATING CIRCUIT RIBBON HEATER
Q.H.S. WATER TEMPERATURE SENSOR
10-129
ELECTRICAL TRANSMISSION CONTROL
ELECTRICAL TRANSMISSION CONTROL
Function 1 2 Directional lever 3 4 5 6 7 8 Gear shift lever Transmission cut-off selector switch Transmission cut-off switch Parking brake switch Kick-down switch
Electrical control is used to actuate the transmission solenoid and select the F,R, or N position. If the directional lever is not at the N position, the engine will not start even if the staring switch is turned to the START position. This is to prevent any accident if the machine should start suddenly. (For details, see ENGINE STARTING CIRCUIT) When traveling in reverse, it lights up the backup lamp to warn people in the surrounding area. Electrical control is used to actuate the transmission solenoid and select the speed range. This is used to select between actuation and non actuation of the transmission cutoff function. When the left brake pedal is pressed, the transmission is returned to neutral and the normal brake is actuated (transmission cut-off function) To prevent seizure of the parking brake, the transmission is returned to neutral when the parking brake is applied. When traveling in F2, it is possible to operate the switch to shift down to F1 with-out moving the gear shift lever. If the gear shift lever is moved to the R or N position, the speed range is automatically returned to the original 2nd position.
10-130
COMBINATION SWITCH
COMBINATION SWITCH
Outline ! The directional lever has speed lever switch has individual part, the switch mechanism; the detent combination switch.
three positions and the four positions. As an does not have a detent mechanism is in the
Each switch is positioned by two pins, and is secured to the body by three screws. When each lever is operated to the desired position, the switch, which is interconnected by a shaft, acts to allow electric current to flow to that circuit only.
General locations, function 1 Directional lever switch 2 Speed lever switch 3 Speed lever stopper 4 Turn signal indicators 5 Self cancel 6 Turn signal indicators 7 Dimmer switch 8 Hazard switch 9 Emergency flashing pilot lamp
Switches between F, R, and N Selects speed range Stopper used to prevent speed lever from entering 3rd or 4th during operations Direction indicator lamps used when turning left or right Turn signal indicator lever automatically returns to central position after machines turns left or right Switches on clearance lamp, head lamp, parking lamp, etc. Selects high beam for travel and low beam for passing Makes both left and right turn signal indicator lamps flash at the same time Flashes at the same time as the emergency flashing lamp flashes
10-131
TRANSMISSION CUT-OFF FUNCTION
TRANSMISSION CUT-OFF FUNCTION

Outline ! If the transmission cut-off selector switch on the cluster gauge is turned ON (pilot lamp lights up), the transmission cut-off switch installed to the left brake pedal is actuated. When the left brake is operated, the brake is applied and the transmission is also shifted to neutral at the same time. ! If the transmission cut-off selector switch is turned OFF (pilot lamp goes out), the transmission is not shifted to neutral and the left brake operates in the same way as the right brake.
Operation 1. Transmission cut-off selector switch ON ! If the transmission cut-off selector switch is turned ON, a voltage of +24V is applied to the transmission F solenoid or R solenoid through the transmission cut-off switch to the neutralizer relay FORWARD relay or REVERSE relay. Electric current flows from the directional lever to the FORWARD relay or REVERSE relay, so the relay coil is excited and a circuit is formed.
When the left brake pedal is depressed, the transmission cut-off switch is turned OFF, and the electric current to the FORWARD relay or REVERSE relay is cut. As a result, the transmission is shifted to neutral in addition to the normal operation of the brake.
10-132
COMBINATION SWITCH
2. Transmission cut-off selector switch OFF ! If the transmission cut-off selector switch is turned OFF, a voltage of +24V is applied to the transmission F solenoid or R solenoid from the transmission cut-off selector switch neutralizer relay FORWARD relay or REVERSE relay. The transmission cut-off switch does not form part of this circuit. ! If the left brake pedal is depressed, the transmission is not shifted to neutral. The brake is simply applied as a normal brake.
10-133
PARKING BRAKE FUNCTION
PARKING BRAKE FUNCTION

Outline ! When the parking brake is applied, the transmission is kept at neutral. This means that even when the engine is run at full throttle, there is no load on the parking brake, and this prevents any dragging caused by mistaken operation.
Operation ! When the parking brake pedal is depressed, the parking brake switch is turned ON, an electric current flows from the neutralizer relay coil to the parking brake switch ground, and the neutralizer relay coil is excited. ! As a result, the neutralizer relay is actuated, so the circuit is cut. No electric current flows to the FORWARD relay or REVERSE relay and the transmission is placed in neutral.
10-134
KICK-DOWN SWITCH
KICK-DOWN SWITCH
KICK-DOWN SWITCH
Operation ! The kick-down (shifting down from 2nd 1st) is actuated only when traveling in F2. ! When traveling in F2, if it is desired to shift down to lst without operating the speed lever, operate the kick-down switch on the boom lever to ON to shift down to F1. ! After this, even if the kick-down switch is pressed, the transmission is kept at F1. Cancellation (or not actuated) ! When directional lever is at N ! When directional lever is at R ! When speed lever is not at 2nd ! When starting switch is OFF
10-135
STRUCTURE AND FUNCTION KICK DOWN ELECTRIC CIRCUIT DIAGRAM

Normal operation
KICK-DOWN SWITCH
Directional lever operated to F ! When the directional lever is operated to the F position, current flows from battery directional lever switch terminals 1 - 2 FORWARD relay terminals 5 - 6 ground. As a result, the FORWARD relay is actuated and terminals 1 and 2 and terminals 3 and 4 are connected. ! Next, electric current flows from battery transmission cut-off switch neutralizer relay terminals 3 - 6 FORWARD relay terminals 3 - 4 solenoid (1) ground, and solenoid (1) is actuated. Speed lever set to 2
Gear shift lever operated to 2nd ! When the gear shift lever is at the 2nd position, no electric current flows to solenoids (2), (3), or (4). In this condition, the transmission valve is set to F2 by the action of solenoid (1). ! If the kick-down switch is not pressed, no electric current will flow to the kick-down relay coil (relay terminals 5, 6). Therefore, the kick-down relay is not actuated and the transmission is held in F2. Solenoid actuation table F1 F2 F3 F4 N R1 R2 R3 R4 1 2 3 4 F F F F F F M F F F F F F F F F
10-136
KICK-DOWN SWITCH KICK-DOWN SWITCH OPERATED

(During operation or during travel when gear shift lever is at F2)
Kickdown switch pushed to ON position ! When the kickdown switch is pushed, current flows from battery directional lever switch terminal 1 gear lever switch terminal 6 FORWARD relay terminals 1-2 kickdown switch kickdown relay terminals 5 - 6 ground. As a result, the kickdown relay is actuated and terminals 1 and 2 and terminals 3 and 4 are connected. ! A circuit is formed from gear shift lever switch terminal 6 FORWARD relay terminals 1 - 2 kick-down relay terminals 1 - 2 terminals 5 - 6 ground. From this point, even if the kick-down switch is returned, the kick-down relay continues to be actuated (kick-down relay self-hold circuit). When the kick-down relay is actuated and terminals 3 and 4 are connected, electric current flows from battery kick-down relay terminals 3 - 4 solenoid (4) ground, and solenoid (4) is actuated. Solenoid (1) is also being actuated, so the speed range is set to F1.
! In this way, if the kick-down switch is pressed when the gear shift lever is at F2, the gear is shifted down to F1. The self-hold function of the kick-down relay then keeps the transmission in F1 even if the kick-down switch is released or pressed several times. Solenoid actuation table F1 F2 F3 F4 N R1 R2 R3 1 2 3 4 M F F F F M F F F F F F F F F F R4
10-137
STRUCTURE AND FUNCTION KICK-DOWN SWITCH ACTUATION - CANCELED (1)

(Directional lever at N or R)
KICK-DOWN SWITCH
If the directional lever is moved to the R position, the contacts of terminal F are turned OFF, so the current flowing from FORWARD relay terminals 5 - 6 ground stops flowing, the FORWARD relay is reset, and FORWARD relay terminals 1 and 2, and terminals 3 and 4 separate. When FORWARD relay terminals 1 and 2 separate, the electric current stops flowing from kick-down relay terminals 1 - 2 terminals 5 - 6 ground, the kickdown relay is reset, and the self-hold circuit is canceled. (The self-hold circuit is also canceled at the N position.) When the kick-down relay is reset, the electric current flowing from kick-down relay terminal 3 - 4 solenoid (4) ground stops flowing and the actuation of solenoid (4) is canceled. When the directional lever is moved to the R position, electric current flows from battery directional lever switch terminals 1 - 4 REVERSE relay terminals 5 - 6 ground, so REVERSE relay
terminals 1 and 2, and terminals 3 and 4 are connected, and solenoid (2) is actuated. ! Therefore, there is no electric current flowing to solenoids 1, 3, or 4, so the transmission is set to R2, the position of the gear shift lever. Solenoid actuation table F1 F2 F3 F4 N R1 R2 R3 R4 1 2 3 4 F F F F F F F F F F M F F F F F
10-138
KICK-DOWN SWITCH KICK-DOWN SWITCH ACTUATION - CANCELED (2)

(Gear shift lever at position other than 2nd)
If the gear shift lever is moved to any position other than 2nd, the current flowing from gear shift lever relay terminal 6 FORWARD relay terminals 1 - 2 kickdown relay terminals 1 - 2 terminals 5 - 6 ground stops flowing, and kickdown relay terminals 1 and 2, and terminals 3 and 4 separate. When kick-down relay terminals 1 - 2 separate, the self-hold circuit is canceled, and the kick-down is not actuated even if the gear shift lever is moved again to F2. At the same time, kick-down terminals 3 - 4 also separate, so the actuation of solenoid (4) is canceled.
! If the gear shift lever is placed in 3rd, electric current flows from gear shift lever switch terminal 7 solenoid (3) ground, and solenoid (3) is actuated. Solenoid (1) is being actuated, so the transmission is set to F3, the position of the gear shift lever. Solenoid actuation table F1 F2 F3 F4 N R1 R2 R3 1 2 3 4 F M F F F F F M F F F F F F F F R4
10-139
STRUCTURE AND FUNCTION KICK-DOWN SWITCH ACTUATION - CANCELED (3)

(Starting switch turned to OFF)
KICK-DOWN SWITCH
When the starting switch is turned to the OFF position, the battery power source is cut off by the battery relay, and the kickdown self-hold circuit is canceled. When the starting switch is at the OFF position, the kick-down switch is not actuated even if the kickdown switch is pressed ON.
10-140
20 TESTING AND ADJUSTING

Standard value table for engine . . . . . . . . . . . . . . . . 20- 2 Standard value table for chassis . . . . . . . . . . . . . . . . . 20- 4 Tools for testing, adjusting & troubleshooting . . . . . . . 20- 8 Measuring engine speed . . . . . . . . . . . . . . . . . . . . . . 20-10 Measuring engine lubrication oil pressure . . . . . . . . . 20-11 Measuring fuel filter inlet restriction . . . . . . . . . . . . . . 20-11 Measuring blow-by pressure . . . . . . . . . . . . . . . . . . . 20-11 Measuring compression pressure . . . . . . . . . . . . . . . 20-12 Measuring exhaust gas color . . . . . . . . . . . . . . . . . . . 20-13 Measuring coolant temperature . . . . . . . . . . . . . . . . . 20-14 Measuring and adjusting valve clearance . . . . . . . . . 20-14 Measuring accelerator pedal . . . . . . . . . . . . . . . . . . . 20-15 Measuring operating force, travel of speed lever . . . . 20-17 Measuring stall speeds . . . . . . . . . . . . . . . . . . . . . . . 20-18 Measuring torque converter, transmission, oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . 20-20 Method of operating emergency manual spool . . . . . 20-22 Testing and adjusting steering wheel . . . . . . . . . . . . 20-24 Measuring steering oil pressure . . . . . . . . . . . . . . . . . 20-26 Measuring operating force, travel of brake pedal . . . 20-28 Testing and adjusting brake pedal linkage . . . . . . . . 20-29 Measuring brake performance . . . . . . . . . . . . . . . . . . 20-31 Testing brake oil pressure . . . . . . . . . . . . . . . . . . . . . 20-32 Testing for brake disc wear . . . . . . . . . . . . . . . . . . . . 20-33 Bleeding air from brake system . . . . . . . . . . . . . . . . . 20-34 Measuring parking brake performance . . . . . . . . . . . 20-35 Testing and adjusting parking brake linkage . . . . . . . 20-36 Testing wear of parking brake disc . . . . . . . . . . . . . . 20-37 Measuring parking brake disc wear . . . . . . . . . . . . . . 20-38 Measuring work equipment control lever . . . . . . . . . . 20-39 Measuring stroke of work equipment valve spool . . . 20-42 Measuring work equipment hydraulic pressure . . . . . 20-43 Measuring work equipment . . . . . . . . . . . . . . . . . . . . 20-45 Testing and adjusting bucket positioner . . . . . . . . . . 20-47 Testing and adjusting boom kick-out . . . . . . . . . . . . 20-48 Troubleshooting TABLE OF CONTENTS . . . . . . . 20-101
See ENGINE SHOP MANUAL.
When using the standard value tables to make judgement for testing, adjusting, and troubleshooting, the following precautions are necessary: 1. The standard values in the tables 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 after the machine is operated, and when carrying out repairs. 2. The permissible values given in the tables are values estimated based on the results of various tests carried out on the machines shipped from the factory, so they should be used together with the information on the repair condition and other information such as the operating history of the machine when judging the condition of the machine. 3. These standard values do not form a basis for judging claims. When carrying out testing, adjusting, or troubleshooting, park the machine on level ground and use the safety pins and blocks to prevent the machine from moving When carrying out work together with co- workers, always use signals and do not let unauthorized people near the machine. When checking the coolant level, always wait for the coolant to cool down. If the radiator cap is removed when the coolant is still hot, the coolant will spurt out and cause burns. Be careful not to get caught in the fan, fan belt or other rotating parts.
20-1
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE - In Chassis

Machine model Engine model Item Measurement condition Unit WA180-3L Komatsu S6D102E-1 Standard value for new machine 2650 50 rpm Low idle Engine rating Intake manifold pressure Intake air restriction Lubricating oil pressure with SAE 15W-40 oil & coolant temperature in operating range Fuel filter inlet restriction Rated gross power / rated speed At T.C. stall and W.O.T. (Wide Open Throttle) At T.C. stall and W.O.T. at restriction indicator port Minimum at low idle Minimum at rated speed & load Maximum restriction at high idle Coolant temperature in operating range: C Service Tool orifice size: 5.613 mm At T.C. stall and W.O.T. With SAE 15W-40 oil Maximum at T.C. stall and W.O.T. Maximum operating temperature kW/rpm 850 25 88/2400 850 25 88/2400 Service limit value 2650 50
High idle Engine speeds
mm Hg
850-950 New element: 380 Used Element: 635 70 (0.70) 276 (2.81) 100
850-950
mm H 2O kPa (kg/cm) kPa (kg/cm) mm Hg
Max. 635 0.70 (0.70) 276 (2.81) 200
Blow-by pressure
mm H 2O
180
360
Exhaust back pressure Coolant temperature
mm Hg EC (EF)
77
77
100 (212)
100 (212)
20-2
STANDARD VALUE TABLE FOR CHASSIS
Machine model Engine model Item Measurement condition Unit
WA180-3L Komatsu S6D102E-1 Standard value for new machine 0.25 0.51 Service limit value 0.25 0.51
Valve clearance
Engine cold: Intake valves Exhaust valves C Coolant temperature in operating range C Torque converter oil temperature in operating range C Hydraulic oil at normal operating temperature
mm
Engine stall speeds: Torque converter Hydraulic Full
2500 100 rpm 2500 100 1950 200
2500 200 2500 200 1950 300
p For further detailed information, refer to Engine Shop Manual.
20-3

Cate gory Item Operating Force Accelerator pedal "1 Operating Angle deg. "2 L1 N-FORWARD Directional lever Operating Force N-REVERSE N-FORWARD Travel N-REVERSE 1st 2nd Operating Force 2nd3rd 3rd4th 1st 2nd Travel 2nd 3rd 3rd 4th Priority valve pressure
Transmission Valve
Measurement Condition
Unit N (kg)
Standard value Service limit for new machine value 49-98 (5-10) 48 3 30 2 147 (15) ------13.7 (1.4) 13.7 (1.4) 40 20 40 20 13.7 (1.4) 13.7 (1.4) 13.7 (1.4) 40 20 40 20 40 20
2.3 0.2 (23 2)
Stopper Height
mm
48 5 5.9 +4.9, -2.9 (0.6 +0.5, -0.3) 5.9 + 4.9, -2.9 (0.6 +0.5, -0.3) 40 10
N (kgf)
mm C C Engine stopped Torque converter oil temperature: 60-80EC (140-176EF)
40 10 5.9 +4.9, -2.9 (0.6 +0.5, -0.3)
Speed lever
N (kg)
5.9 +4.9, -2.9 (0.6 +0.5, -0.3) 5.9 +4.9, -2.9 (0.6 +0.5, -0.3) 40 10
mm
40 10 40 10
2.3 0.2 (23 2)
Pilot reducing valve pressure Clutch pressure Torque converter outlet port pressure Play Operating Force Low idling Operating time High idling
C C
Torque converter oil temperature: 60-80EC (140-176EF) Engine speed: Low idling
Mpa (kg/cm2)
1.0 0.1 (10 1) 2.3 0.2 (23 2) 0.38 0.05 (3.9 0.5)
1.0 +0.1, -0.2 (10+1,-2) 2.3+0.3,-0.4 (23+3,-4)

0.38 0.10 (3.9 1.0)
Steering wheel
C C C C C
Engine speed: Low idling Machine facing straight to front Flat, horizontal, straight, dry paved road surface Hydraulic oil temperature: 45-55EC (113-131EF) Engine speed: Low idling
mm N (kgf)
20 20
8.8 - 11.8 (0.9 - 1.2)
0 - 120
Max. 21.6 (Max. 2.2)
Max. 3.9 Sec. Max. 3.2
Max. 6.0 Max. 4.5
20-4

Cate gory Steering valve Item

Measurement Condition Unit Standard value
for new machine
Service limit value
Relief pressure
C Engine speed: High C Hydraulic oil temperature: 45-55EC (113-131EF)
Mpa (kgf/cm2)
18.6 0.69 (190 7)
18.6+0.7,-1.1 (190+7,-11)
Operating force
C Engine speed: Low idle C Engine water temperature gauge: white range
N (kgf)
206 (21)
---
"2 Wheel Brakes Operating angle "1
18.5 4 deg. 48
18.5 +8,-4
---
Performance
C Flat, horizontal, straight, dry paved road surface C Speed when applying brake: 20 km/h, braking delay: 0.1 sec C Brake pedal operating force: 294 N (30 kg) C Tire inflation pressure: Specified pressure C 4.1 Mpa (42 kg/cm2) in 5 min. C Thickness of disc C Tire inflation pressure: Specified pressure C Flat paved road with 1/5 (11E20') grade C Dry road surface Machine at operating condition
Max. 4.0
Max. 5.0
Drop in hydraulic pressure Wear of disc
Mpa (kg/cm2) mm
Max. 0.34 (Max. 3.5) 1.08 0.06
Max. 0.34 (Max. 3.5) Min. 0.7
Performance Parking brake
---
Stopped
---
Piston stroke (X) C Parking brake ON: a C Parking brake OFF: b
mm
1.85 0.28
Min. 3.5
20-5

Cate gory Item HOLDRAISE
Work equipment control lever

Measurement Conditions Unit Standard Value
Max. 29.4 (Max. 3.0) Max. 27.5 (Max 2.8)
Permissible Value
Max 44.1 (Max 4.5) Max 44.1 (Max 4.5) Max 44.1 (Max 4.5)
RAISE HOLD Operating force HOLDLOWER Boom LOWERHOLD LOWERFLOAT FLOATHOLD HOLDDUMP C Engine speed: Low idle C Hydraulic oil temperature: 45-55EC (113-131EF)
N (kgf)
Max. 29.4 (Max 3.0)
--Max. 46.1 (Max.4.7)

Max. 27.5 (Max.2.8)
--Max 66.7 (Max 6.8)

Max 44.1 (Max 4.5)
Work equipment control valve
Operating Force
Max 29.4 (Max 3.0) N (kgf) Max 29.4 (Max 3.0) Max 31.4 (Max 3.7) 80 15 80 15 mm 75 15 70 15 70 15 C Hydraulic oil temperature: 45 - 55EC C Engine speed: High idle Mpa (kg/cm2) 20.6 +0.4, -0.5 (210 +4, -5) 8 8 C Hydraulic oil temp: 45 55EC (113-131EF) C Engine speed: Low idle 15.5 mm 7 8
Max 44.2 (Max 4.5) Max 34.3 (Max 3.5) Max 34.3 (Max 3.5) 80 20 80 20 75 20 70 20 70 20 20.6 +0.4, -1.5 (210 +4, -15) -----------
Bucket
HOLDTILT
TILTHOLD
HOLDRAISE
Travel
C Engine speed: Low idle C Hydraulic oil temperature: 60 - 80EC (140-176EF)
Boom
HOLDLOWER
LOWERFLOAT
HOLDDUMP Bucket HOLDTILT
Main control valve
Relief pressure
Boom spool operating travel Bucket spool operating travel
HOLDRAISE HOLDLOWER HOLDFLOAT HOLDDUMP HOLDTILT
20-6

Boom lifting time Work equipment speed Boom lowering time Bucket dumping time w/ Standard bucket cylinder Bucket dumping time w/ large bucket cylinder
Bucket tilting time standard bucket Bucket tilting time large bucket At full stroke

4.8 0.3 2.5 0.5 1.1 0.3 C Hydraulic oil temp: 45 55EC (113-131EF) C Engine speed: High idle C Steering valve: Neutral C No load 1.3 Sec. 1.3 0.3 1.0 0.3 1.5 1.3 C Hydraulic oil temp: 45 55EC (113-131EF) C Leave for 5 minutes after stopping engine then measure for next 15 minutes C Bucket empty, boom, bucket horizontal C No load Max. 1.9 Max. 1.4 Max. 2.1 Max. 1.6 Max. 5.8 Max. 4.2 Max. 1.4 Max. 1.6
Work equipment
Bucket horizontal
At full stroke
Bucket horizontal
Hydraulic drift
Retraction of boom cylinder rod
Max. 17 mm Max. 17
Max. 20
Retraction of bucket cylinder rod
Max. 25
Proximity switch
Clearance of bucket positioner switch Clearance of boom kick-out switch C Hydraulic oil temp: 45 55EC (113-131EF) mm
3-5
---
3-5
---
20-7
TOOLS FOR TESTING ADJUSTING AND TROUBLE SHOOTING
TOOLS FOR TESTING, ADJUSTING & TROUBLESHOOTING

Check or measurement item Symbol Intake manifold pressure Intake air restriction Engine lubricating oil pressure Fuel filter inlet restriction Exhaust back pressure Measuring voltage and resistance values ------Commercially available 1 799-203- 8001 2 795-790-2500 Coolant and oil temperatures B 799-101-1502 799-101-5002 1 Oil pressure C 790-261-1203 2 799-401-2320 3 790-261-1311 790-261-1321 Digital hydraulic tester Hydraulic gauge Adapter Tool Number Tool Description Pressure gauge Water manometer Pressure gauge Vacuum gauge Mercury manometer Tester Remarks See engine shop manual See engine shop manual See engine shop manual See engine shop manual See engine shop manual --Digital display (799-2039000) L: 60-2000 rpm R: 60-19999 rpm See engine shop manual See engine shop manual Pressure gauge 2.45, 5.88, 39.2, 58.8 Mpa (25, 60, 400, 600 kg/cm2) Pressure gauge 0-68.6 Mpa (0-700 kg/cm2) 1.0 Mpa (10 kg/cm2) ----0 - 6.9 Mpa (0 - 70 kg/cm2) Kit part No. 795502-1205
Engine speeds
Digital optical tachometer Adapter kit Digital temperature gauge Analog hydraulic tester
Compression pressure
1 795-502-1590 2 795-502-1700 1 799-201-1541
Compression gauge Adapter Gauge Tube Adapter Nozzle Feeler Gauge Gear Handy smoke detector
Blow-by pressure
2 799-201-1571 3 799-201-1450 4 795-790-1950 F Commercially available 795-799-1130 799-201-9000 1
Kit Part No. 799-201-1504
------Discoloration 0-70% w/ standard color % x 1/10 Bosch index -------
Valve clearance
F1
Exhaust color
G 2 Commercially available 799-601-7400 Commercially available Smoke meter
Troubleshooting of wiring harnesses and sensors Operating Force
H I
T-adapter Push-pull scale
20-8

Check or measurement item Symbol Pushing force Stroke Brake oil pressure Clearance measurement Speed Boom holding tool Pushing angle Length measurement L O P Q R S J K
TOOLS FOR TESTING ADJUSTING AND TROUBLE SHOOTING

Tool Number Commercially available Commercially available 1 793-605-1001 2 790-101-1430 417-22-23250 Commercially available 793-463-1100 Commercially available Commercially available Tool Description Push gauge Scale Brake test kit Coupler Thickness feeler gauge Stop watch Stopper Angle gauge Slide calipers Remarks ----6.9 Mpa (70 kg/cm2) -------------
20-9
MEASURING ENGINE SPEEDS
MEASURING ENGINE SPEEDS

When removing or installing the measuring equipment, be careful not to touch any high temperature parts. i Measure the engine speed under the following conditions. Coolant temperature: Within operating range Torque converter oil temperature: 70 to 90EC (158 - 194EF) Hydraulic oil temperature: 45 to 55EC (113 - 131EF)
1. Install the digital optical tachometer using the instruction supplied with it. 1) Remove the cap 1 of engine speed output, and then install adapter assy A2. 2) Connect the tachometer A1 and adapter assy A2 with cable. When measuring engine speeds, be careful not to touch any high temperature parts or rotating parts. 2. Start the engine, and measure the engine speed when it is set to the conditions for measuring. 1) Measuring low idle and high idle speeds. 2) Measure the speed at near the rated speed. i When measuring speeds for items other than the above, such as torque converter stall, see the procedure for the item as described in this section.
20-10
MEASURING, OIL PRESS., FUEL FILTER RESTRICTION & BLOW-BY PRESS.
MEASURING ENGINE LUBRICATING OIL PRESSURE

Remove oil pressure sensor then install pressure gauge. i Refer to ENGINE SHOP MANUAL for tools and proper procedure.
MEASURING FUEL FILTER INLET RESTRICTION

i Refer to ENGINE SHOP MANUAL for tools and proper procedure.
MEASURING BLOW-BY PRESSURE

20-11
MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION PRESSURE

When removing or installing the measuring equipment, be careful not to touch any high temperature parts.
When measuring, be careful not to let your clothes get caught in any rotating part. 1. Before measuring the compression pressure, check the value clearances. Refer to Engine Shop Manual and adjust them if necessary. 2. Measurement conditions Engine water temperature: 40 - 60EC (104 - 140EF) 3. Remove the nozzle holder of the cylinder which is necessary to be measured. 4. Install adapter D2 and connect the compression pressure guage D1 5. Set the multi tachometer A. Refer to Measuring engine speeds. 6. Cut off fuel control rod and then fix the governor lever of fuel pump to no inspection position. After that, measure compression pressure of cylinder while starting engine by starter motor. Do not crank the starting motor for periods longer than 30 seconds. Allow 2 minutes between the 30 second cranking periods so the starting motor can cool. i i i Read scale of compression pressure guage after being stable. Measure and check the engine speed while measuring compression pressure. After measuring, install the nozzle holder again.
20-12
MEASURING EXHAUST COLOR
MEASURING EXHAUST COLOR

i
When measuring in the field when there is no air or power supply, use smoker the checker; when recording official data, use the smoke meter.
Measuring with handy smoke checker G1 When measuring the exhaust gas color, be careful not to touch the exhaust pipe or any other high temperature part.
i
Warm up the engine (oil temperature: 60EC 140EF) before measuring the exhaust gas color. 1) Fit filter paper in too[ G1. 2) Insert the exhaust gas intake port into the exhaust pipe, accelerate the engine suddenly, and at the same time operate the handle to catch the exhaust gas on the filter paper. 3) Remove the filter paper and compare it with the scale provided to judge the condition.
Measuring with smoke meter G2 When measuring the exhaust gas color, be careful not to touch the exhaust pipe or any other high temperature part. i Warm up the engine (oil temperature: 60EC 140EF) before measuring the exhaust gas color. 1) Insert the probe into the outlet port of the exhaust pipe, then tighten the clip to secure it to the exhaust pipe. 2) Connect the probe hose, accelerator switch plug, and air hose to tool G2. i The pressure of the air supply should be less than 1.5 MPa (15 kg/cm). 3) Connect the power cord to the AC100V outlet. i When connecting the cord, check first that the power switch is OFF. 4) Loosen the cap nut of the suction pump, then fit the filter paper. i Fit the filter paper securely so that the exhaust gas does not leak. 5) Turn the power switch. 6) Accelerate the engine suddenly, and at the same time, depress the accelerator pedal and operate the relief valve to catch the exhaust gas color on the filter paper. 7) Lay the filter paper used to catch the exhaust gas color on top of unused filter papers (10 sheets or more) inside the filter paper holder, and read the indicated value.
20-13
MEASURING COOLANT TEMPERATURE AND ADJUSTING VALVE CLEARANCE
MEASURING COOLANT TEMPERATURE

MEASURING AND ADJUSTING VALVE CLEARANCE

20-14
MEASURING COOLANT TEMPERATURE AND ADJUSTING VALVE CLEARANCE
MEASURING ACCELERATOR PEDAL

OPERATING FORCE OF ACCELERATOR PEDAL 1. Measuring 1) Set push-pull scale y at a position 150 mm from pedal fulcrum a i Put the center of the push-pull scale y in contact with a point 150 mm from the pedal fulcrum. 2) Start the engine than measure the maximum value when the pedal is moved from the pushed position (low idling) to the end of its travel (high idling).
2. TESTING 1) Stop the engine. 2) Disconnect the cable (1) at the bottom of the accelerator pedal, and check that the plate (2) and ball joint (3) at the bottom of the pedal move smoothly. i Carry out the above inspection, and adjust or replace parts if necessary. Then carry out the measurement of the operating force again to check that it is within the standard value.
20-15

OPERATING ANGLE OF ACCELERATOR PEDAL 1. Measuring 1) Stop the engine. 2) Put angle gauge R in contact with the accelerator pedal, and measure operating angle " (" =" 1-" 2) when the pedal is operated from low idle position " 1 to high idle position " 2.
MEASURING ACCELERATOR PEDAL
Adjusting 1) Open the inspection cover of the engine hood. 2) Set accelerator (1) to the FREE condition(lever (2) in contact with U-bolt (3)), adjust cable (5) so that the governor lever (4) is at the low idle position, then tighten nuts (6) and (7). Locknuts (6), (7): 46.6 12.3 Nm (4.75 1.25 kgm)
Locknut (9): 3.9 1.0 Nm (0.4 0.1 kgm) Mounting nut (10): 13.2 1.5 Nm (1.35 0.15 kgm)
3) Keep accelerator pedal (1) depressed, then adjust stopper bolt (8) so that the governor lever (4) is at the high idle position. i Screw in ball joint (3) at least 8 mm.
20-16
MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER
MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER
Measurement conditions Toque converter oil temperature: 60 - 80EC (140 - 176E F)
Block the tires securely.
OPERATING FORCE OF SPEED LEVER 1. Stop the engine. 2. Install push-pull scale y or a spring balance to center of the control lever knob, and measure the operating force when the lever is pulled in the direction of operation. i Carry out the measurement for each speed range.
TRAVEL OF SPEED LEVER 1. Stop the engine. 2. Make mark a at the center of the control lever knob, and measure the travel when the lever is operated in the direction of operation.
20-17
MEASURING STALL SPEEDS

Measurement conditions ! Engine water temperature: Within the white operating range on the engine water temperature gauge. ! Hydraulic oil temperature: 45 - 55EC (113 - 131EF) ! Engine speed: High idle ! Torque converter oil temperature: 60 - 80EC (140 - 176EF) Apply the parking brakes and block the tires
When measuring each stall speed be careful not touch any rotating part or parts that are extremely hot. i i Check that the low idle and high idle are the standard values. Before measuring each stall speed, remove cover (1) from the pickup port, install adapter A2 of tachometer A1, then connect the tachometer A1 and the adapter with a cable. Check that the engine speed is the standard value. If it is not within the standard range , check for loose linkage or play.
TORQUE CONVERTER STALL SPEED i Before starting the operation, check that the tires are chocked and release the parking brake.
1. Start the engine and run at low idle. 2. Place direction lever (4) at FORWARD OR REVERSE, and set speed lever (3) to the highest position. 3. Use the brakes to stop the machine, then use multitachometer A1 to measure the speed when the engine is at high idle. i i
Turn transmission cut-off selector switch (2) OFF and use the left brake . (Check that the pilot lamp goes out.) Do not keep the stall condition for more than 20 seconds. Make sure that the torque converter oil temperature does not exceed 120EC.
20-18

HYDRAULIC STALL SPEED 1. Start the engine and run at high idle. 2. Operate the bucket or boom lever (4), set the cylinder to the stroke end, and activate the work equipment valve relief. 3. Use multi-tachometer A1 To measure the engine i Do not keep the stall condition for more than 20 seconds. Operate the control lever quickly.
FULL STALL SPEED ! Measure the engine speed when the torque converter stall and the hydraulic stall are both carried out at the same time. i Before measuring the full stall, check that the torque converter stall and hydraulic stall speeds are normal. If either of the stall speeds are abnormal, correct the problem and measure again.
20-19
MEASURING TORQUE CONVERTER, TRANSMISSION OIL PRESSURE

i Measurement conditions C C Engine water temperature: within white range on engine water temperature gauge Torque converter oil temperature: 60 - 80EC (140 - 176EF) Apply the parking brake and put blocks under the tires.
Preparatory Work i The following preparatory work is necessary when measuring all oil pressures. Before starting the operation, check that there are blocks under the tires, then release the parking brake. C Remove cover (1) on the left side of the rear frame. C Turn transmission cut-off selector switch (2) OFF and use the left brake. (Check that the pilot lamp is OFF.) C Remove the plug from the measurement port of the transmission valve. C Install hydraulic tester kit C1 to the measurement port, extend the gauge to the operators compartment, then start the engine and measure the pressure. Check that no oil is leaking from any connection. After removing the measurement plug, always coat the plug with adhesive. Plug: sealing agent (LG-1)
i i
20-20
1. Measuring pilot pressure 1) Measurement port : 1 2) Start the engine and measure the oil pressure with the engine at high idle.
2. Measuring priority pressure 1) Measurement port : 2 2) Start the engine and measure the oil pressure with the engine at high idle.
3. Measuring all clutch pressures 1) Measurement port : 3 2) Start the engine and measure the oil pressure with the engine at high idle.
4. Measuring torque converter outlet port pressure 1) Measurement port : 4 2) Start the engine and measure the oil pressure at torque converter stall.
5. Adjusting modulating time Turn screw (A) to make the modulating time shorter or longer. 1) TIGHTEN screw to give PATTERN 1). 2) LOOSEN screw to give PATTERN 2).
i i i
The standard length is 6.75 mm (return fully, then screw in 4 turns Do not adjust excessively. After adjusting, always check that there are no abnormality in the pressure. Keep the range of the adjustment to within 1 turn
20-21
METHOD OF OPERATING EMERGENCY MANUAL SPOOL

Outline The transmission valve is controlled electrically, but if there should be any failure in the electrical system, or if there is any failure in the solenoid valve or spool and the machine cannot move, it is possible to operate the emergency manual spool to move the machine. This operation of the spool is designed only for use if the machine cannot be moved because of a failure in the transmission control, and it is necessary to move the machine from a dangerous working area to a safe place where repairs can be carried out. This spool must not be operated except when there has been a failure. When carrying out this operation, keep strictly to the order of operation and pay careful attention to safety when moving the machine. To prevent the machine from moving, lower the bucket to the ground, apply the parking brake, and put blocks under the tires. Always stop the engine before operating the spool.
1. Remove cover (1) from the left side of the rear frame. 2. Remove lock plate (2) from emergency manual spool (3) of the transmission valve. i The lock plate can be removed simply by loosening the mounting bolts. 3. Operate emergency spool (3) to the operating position according to the direction of movement of the machine (forward or reverse). i FORWARD: Push in the spool until it enters the detent. a = Approx. 8 mm REVERSE: Pull the spool until it enters the detent. b = Approx. 8 mm
20-22
4. Check that the area around the machine is safe, then remove the blocks from under the tires. 5. Sit in the operators seat and depress the left brake pedal (4) fully. 6. Start the engine, then release the parking brake and slowly let the brake pedal out to start the machine. When the engine is started, the transmission is also engaged and the machine will start, so always check carefully that the area around the machine and in the direction of travel is safe and keep the brake pedal depressed fully when starting the engine. 7. After moving the machine, stop the engine, then apply the parking brake and put blocks under the tires. 8. Return the manual spool to the neutral position and install the lock plate.
20-23
TESTING AND ADJUSTING STEERING WHEEL

Measuring steering wheel play i Measurement conditions C Engine: Stopped. C Vehicle posture: Facing straight.
Measuring procedure 1. Turn the steering wheel lightly clockwise and counterclockwise two or three times to check that the steering mechanism is in neutral, then put a mark a on the outer frame of the vehicle monitor. 2. Turn the steering wheel lightly clockwise, align the position where it stops with mark a, and place mark b on the steering wheel. 3. Turn the steering wheel lightly counterclockwise, align the position where it stops with mark a, and place mark c on the steering wheel. Measure the straight distance d between mark c and the position marked in step 2.
MEASURING OPERATING FORCE OF STEERING WHEEL i Measurement conditions C C C C C Road surface: Flat, horizontal, dry paved surface Engine water temperature: within white range on engine water temperature gauge Hydraulic oil temperature: 45 - 55EC (113-131EF) Tire inflation pressure: Specified pressure Engine speed: Low idling (bucket empty)
Measurement method 1. Install push-pull scale y to the steering wheel knob. 2. Start the engine. i After starting the engine, raise the bucket approx. 400 mm and remove the safety bar. 3. Pull push-pull scale y in the tangential direction and measure the value when the steering wheel moves smoothly. i Avoid measuring when the steering wheel starts to move.
20-24
MEASURING OPERATING TIME FOR STEERING WHEEL i C C C C C Measurement conditions Road surface: Flat, horizontal, dry paved surface Engine water temperature: Within green range on engine water temperature gauge Hydraulic oil temperature: 45 - 55EC (113-131EF) Tire inflation pressure: Specified pressure Engine speed: Low and high idle
Measurement method 1. Start the engine. i After starting the engine, raise the bucket approx. 400 mm and remove the safety bar. 2. Operate the steering wheel (1) to the end of its stroke to turn the machine to the left or right. 3. Measure the time taken to operate the steering wheel to the end of the stroke to the right (left). i Operate the steering wheel as quickly as possible without using force. i Carry out the measurements both at low idling and high idling, and to both the left and right.
20-25
MEASURING STEERING OIL PRESSURE

i C C Measurement conditions Hydraulic oil: 45 - 55EC (113 - 131EF) Engine speed: High idle
METHOD OF MEASURING MAIN RELIEF PRESSURE Loosen the oil filler cap to release the pressure inside the hydraulic tank, then turn the steering wheel several times to release the remaining pressure inside the piping. 1. Fit safety bar (1) to the frame. 2. Remove cover (3) at the bottom right of floor frame (2). 3. Remove measurement plu (4) for the right turn steering circuit. 4. Install hydraulic tester kit (A1) to the measurement port. 5. Start the engine, run the engine at high idle, then turn the steering wheel to the right and measure the pressure when the relief valve is actuated. i To measure the pressure when turning the steering wheel to the left, remove the plug (5)for the left turn steering circuit.
20-26

METHOD OF ADJUSTING MAIN RELIEF PRESSURE
Always stop the engine before adjusting the pressure. 1. Stop the engine. 2. Remove hose (2) and fitting (3) connected to port T of the priority valve (1). 3. Remove double screw (4). 4. Turn adjustment screw (5) to adjust. i Pressure adjustment for one turn of adjustment screw: Approx. 6.9 Mpa (70 kg/cm2). i Turn the adjustment screw to adjust the set pressure as follows. TIGHTEN to INCREASE pressure. LOOSEN to DECREASE pressure. i Tool 1" for turning adjustment screw: Size 7/32 inch, hexagonal i If the relief pressure cannot be measured accurately then do not try to adjust the pressure. Adjustment screw: (5): 4.5 2.3 Nm (0.46 0.23 kgm) Double screw (4): 14.7 2 Nm (1.5 0.2 kgm)
20-27
MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL
MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL

i C C Measurement conditions Engine water temperature: Within white range on engine water temperature gauge Engine speed: Low idle
Operating effort of pedal 1. Install push gauge (J) to the operators foot. i Align the center of the push gauge with a point 150 mm from the fulcrum of the pedal. 2. Start the engine, run at low idle, and measure the operating effort when the pedal is depressed. Travel of pedal 1. Install push gauge (J) to the operators foot. i Align the center of the push gauge a with a point 150 mm from the fulcrum of the pedal. 2. Start the engine and measure the pedal angle when running at low idle with a pedal depressed with a force of 206 N (21 kg). 3. Next, place angle meter (R) on the pedal and measure angle " with a pushing a force of 206 N (21 kg). It is also possiblle to measure " 1 and " 2 and calculate " = " 1 - " 2.
20-28
TESTING AND ADJUSTING BRAKE PEDAL LINKAGE
Testing 1. Check for play in linkage mounting pin (1), pin hole of lever (2), and lever bushing. 2. Measure length X1" of rod and check that it is within the standard value. i Standard length of rod X1": 175 mm i Measure the length from the center of pin (1) to the center of ball joint (6a). 3. Measure the distance of movement of rod (8) and check that clearance a is within the standard value. i Standard clearance a: 0 - 0.7 mm i When doing this, check that the brake pedal is in contact with the stopper. Adjusting 1. Adjusting link X1 1) Remove pin (1) and ball joint (6a), remove rod and loosen locknut (5), then turn yoke (6) and ball joint (6a) to adjust the length. 2) After adjusting the length of rod X1, connect it to the brake pedal.
20-29
2. Adjusting rod X2 1) Loosen locknut (7), turn rod (8) so that tip C of rod contacts the master cylinder piston, then turn rod (8) back 1/4 turn. i Standard length of rod X2": 154.3 i Movement for turn of rod: 0.75 mm 2) Tighten locknut (7) to hold in position.
3. Adjusting transmission cut-off switches (left pedal) 1) Loosen mounting screw of switch (9) and adjust switch (9) so that protrusion of the tip of the switch from the end face of the transmission cut-off switch plate is dimension b. i Dimensionb: 1.1 - 1.9 mm i When doing this, check that the switch is ON.
2) To adjust the cut-off timing, adjust plate (10) so that the dimension d from the center of the stopper bolt of plate (10) to the end face of plate (10) is 24 mm. i When doing this, check that plate (10) contacts portion e of the switch plate. i Adjust with the pedal in the FREE condition.
4. Adjusting Stop lamp switch (right pedal) Adjust with mounting nut (11) of stop lamp switch (12). 1) Adjust with nuts (11) so that the tip of the switch is dimension :f. i Dimension f: 3.5 - 5.0 mm When doing this, check that the switch is OFF. i Adjust with the pedal in the FREE. condition
20-30
MEASURING BRAKE PERFORMANCE
MEASURING BRAKE PERFORMANCE

i C C C C Measurement conditions Road surface: Flat, horizontal, dry paved surface Travel speed: 20 km/h when brakes are applied Delay in applying brakes: 0.1 sec Tire inflation pressure: Specified pressure
Measurement method 1. Start the engine and move the machine. 2. Set the speed lever to the highest speed position and drive the machine. 3. When the travel speed reaches 20 km/h, depress the left brake pedal with the specified operating force. Specified operating force: 294 N (30 kg) i Before carrying out this operation, determine the run-up path and the point for applying the brakes, then apply the brakes when the machine reaches that point. 4. Measure the distance from the point where the brakes were applied to the point where the machine stopped. i Repeat this measurement three times and take the average.
20-31
MEASURING BRAKE OIL PRESSURE
MEASURING BRAKE OIL PRESSURE

i C C Measurement conditions Engine water temperature: Within white range on engine water temperature gauge Brake pressure: 4.1 Mpa (42 kg/cm2)
Apply the parking brake and put blocks under the tires. Measuring 1. Raise the boom, set support (1A) or tool Q in position, then remove front cover (1). 2. Stop the engine. i When leaving the operators seat, apply the lock to the work equipment control levers securely. 3. Remove brake tube (2) on the side to be measured, then remove adapter (3). 4. After removing the adapter, install tool L1, L2. i Connect the quick coupler of tool L1, L2. 5. Loosen bleeder screw (4) and bleed the air. i Operate pump 2 to bleed the air. 6. Tighten the bladder screw, operate pump 2, raise the pressure to 4.1 Mpa (42 kg/cm2), then tighten stop valve 3. 7. After applying the pressue, leave for 5 minutes and measure the drop in the pressure. i If the hose is moved while measuring the pressure, the pressure will change, so do not move the hose. i When removing hydraulic test kit L1, L2 after testing, operate pump 2 to lower the pressure of L1, L2, then remove it. i After completing the operation, install the brake tube, then bleed the air from the brake circuit.
20-32
TESTING FOR BRAKE DISC WEAR

Apply the parking brake and chocks under the tires.
Measuring 1. Loosen drain plug (1) and drain the axle oil. Axle oil: 14R 2. Install measuring plug (2). 3. Lightly press the brake pedal. i Check that plate (4) and plate (5) are in tight contact with disc (3). Insert feeler gauge (O) between disc (3) and plate (4), and measure the clearance. 4. Fasten the drain plug and supply axle oil to the specified level through the oil supply port. Axle oil: 14R
20-33
BLEEDING AIR FROM BRAKE SYSTEM

Apply the parking brake and put blocks under the tires.
Procedure 1. Raise the boom, set support (1A) or boom drop prevention stopper Q in position, then remove front cover (1). 2. Remove cap (2) of the bleeder screw, insert vinyl hose (3) into the screw, and insert the other end in a container.
3. Start the engine.
4. Depress the brake pedal, then loosen the bleeder screw and bleed the air. Keep the brake pedal depressed, tighten the bleeder screw, then release the brake pedal slowly. i Add brake oil when necessary during the operation to keep brake oil tank full.
5. Repeat this operation, and when no more bubbles come out with the fluid from the hose, depress the pedal fully and tighten the bleeder screw while the oil is still flowing. i Repeat the operation to bleed the air from the other cylinders, and after completing the operation, check th elevel in the oil tank and add more oil if necessary. i To bleed the air completely, bleed the air first from the cylinder which is farthest from the brake pedal. i After bleeding the air, carry out a brake performance test then bleed the air again and check that there is no air in the circuit.
20-34
MEASURING PARKING BRAKE PERFORMANCE
MEASURING PARKING BRAKE PERFORMANCE

i C C C C Measurement conditions Tire inflation pressure: Specified pressure Road surface: Flat, dry paved road surface with slope of 1/5 grade (11E20'). Machine: Operating condition Operating effort: 392.3 N (40 kg)
Measurement method 1. Start the engine, set the machine facing in a straight line, then drive the machine up a 1/5 grade slope with the bucket empty. 2. Depress the brake, stop the machine, set the directional lever to the neutral position, then stop the engine. 3. Depress the parking brake pedal, then gradually release the brake pedal and check that the machine is held in position. i Carry out the measurement in two ways: Once with the machine facing uphill, and once more with the machine facing downhill.
20-35
TESTING AND ADJUSTING PARKING BRAKE LINKAGE
TESTING AND ADJUSTING PARKING BRAKE LINKAGE

Apply the parking brake and put blocks under the tires. Testing Depress the parking brake pedal with a force of approx. 294 N (30 kg). If the travel of brake pedal is more than 13 clicks, check for looseness of the control cable mount (pedal end and brake end). If any looseness is found, tighten and then adjust as follows. Adjusting linkage 1. Pull release lever (1) and release the parking brake. 2. Loosen locknut (2) and remove clevis pin (4). 3. Set lever (5) at the parking brake end in the release position. i With lever (5) at the FREE position, move the link up by the amount of play. 4. Screw in clevis (3), align the hole with the pin hole in lever (5) at the parking brake end, then assemble clevis pin (4) and tighten locknut (2). 5. After adjusting, depress parking brake pedal (6) with a force of approx. 294 N (30 kg), and check that the travel of the pedal is 7 - 11 clicks.
If it is impossible to adjust only at parking brake end 6. Loosen locknut (7) at pedal (6) end, then remove clevis pin (9). 7. Screw in clevis (8) and adjust so that the mounting dimension is X. i Standard dimension X: 148 mm
Adjusting parking brake switch 1. Adjust with nut (11) so that the mounting dimension at the tip of parking brake switch (10) is c. i Mounting dimension c of switch: 4 - 6 mm i When doing this, check that the parking brake switch is OFF.
20-36
TESTING PARKING BRAKE DISC WEAR
TESTING PARKING BRAKE DISC WEAR

Stop the machine on level ground, install the safety bar to the frame, lower the bucket to the gruond, stop the engine, then apply the parking brake and put blocks under the wheels. Check that there are blocks under the tires. Carry out this operation with the drive shaft still installed.
i i
Testing 1. Check that the parking brake is applied. 2. Remove plug (1). ! Width across flats of hexagon wrench: 6 mm 3. Insert calipers S into the measurement port (2) and measure dimension a from end face c of the cover (3) to the piston (4).
4. Release the parking brake. 5. Insert calipers S into the measurement port (2), and measure dimension b from end c face of the cover (3) to the piston (4). ! Piston stroke X = a - b If X is 3.5 mm, the brake disc is worn and must be replaced. i For details of method of replacing the brake disc, see
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION.
After measuring, check the transmission oil level.
20-37
MEASURING PARKING BRAKE DISC WEAR
MEASURING PARKING BRAKE DISC WEAR

Put blocks under the tires. i i If the braking effect is poor, or if the transmission has been overhauled, measure the wear of the parking brake disc. For details of method disassembling and assembling the parking brake see DISASSEMBLY AND ASSEMBLY OF TRANSMISSION.
Measuring To measure rthe thickness of brake disc (1), check that dimension w is greater than the value given below. i Dimension w: Min. 1.97 mm i For details of the procedure for adjusting the parking brake linkage, see TESTING AND ADJUSTING OF PARKING BRAKE PEDAL.
20-38
MEASURING WORK EQUIPMENT CONTROL LEVER

i Measurement conditions C Engine water temperature: Within white range on engine water temperature gauge. C Hydraulic oil temperature: 45 - 55EC C Engine speed: Low idling. Install the safety bar to the frame. Measurement method 1. Operating force of work equipment control lever Install push-pull scale 3 to the work equipment control lever and measure the operating force. i Install the push-pull scale to the center of the knob. i Operate the control lever at the same speed as for normal operations, and measure the minimum value for the force needed to operate the knob. 2. Travel of work equipment control lever Measure travel at each position when operating the work equipment control lever. i Mark a the lever knob and use scale K to measure. i If the travel is not within the standard value, check for play of the linkage and wear of the bushing.
Adjusting 1. Adjusting work equipment control lever linkage 1) Remove the right control box (1), top cover (2), and front cover (3). i Remove boot (4) first from the top cover. i When removing the top cover, be careful of the wiring for the switches.
20-39
2) Adjust with locknuts (8) and yoke (7) so that the length of work equipment control cable (5) is standard length a at main control valve (6) end. i Standard value a : 173 mm
3) With work equipment control lever (9) at the neutral position, loosen locknuts (12) and (13) at the bottom of ball joint (11) so that the levers can be locked by lock lever (10), then turn joint (14) to adjust length b. i Standard length b : 200.5 mm (4) After adjusting the length, tighten locknut (12), then secure joint (14) with locknut (13).
20-40
2. Adjusting stopper of work equipment control lever (1) To adjust boom RAISE stopper bolt (1). connect control cable (2). Then operate the work equipment control lever gradually to the RAISE position and adjust the length of stopper bolt (1) so that stopper bolt (1) contacts the control lever at the point where the control lever suddenly starts to feel heavy. (2) To adjust boom FLOAT stopper bolt (3), connect control cable (2). Then operate the work equipment control lever gradually to the FLOAT position and adjust the length of stopper bolt (3) so that stopper bolt (3) contacts the control lever at the point where the control lever suddenly starts to feel heavy. (3) To adjust bucket DUMP stopper bolt (4), connect control cable (5). Then operate the work equipment control lever gradually to the DUMP position and adjust the length of stopper bolt (4) so that stopper bolt (4) contacts the control lever at the point where the control lever suddenly starts to feel heavy.
20-41
MEASURING STROKE OF WORK EQUIPMENT VALVE SPOOL
MEASURING STROKE OF WORK EQUIPMENT VALVE SPOOL

Stop the machine on level ground, install the safety bar to the frame, lower the bucket to the ground, stop the engine, then apply the parking brake andput blocks under the wheels. i C C C Measurement conditions Engine water temperature: Within white range on engine water temperature gauge Hydraulic oil temperature: 45 - 55EC Engine speed: Stopped
Measuring 1. Adjusting stroke of valve spool 1) Put scale K in contact with spool (2) of main control valve (1) from the bottom of the front frame.
2) Measure the stroke of the valve spool when work equipment control lever (3) is moved to each position. i Carry out the measurement with two workers and give signals while carrying out the operation. i One worker operates the control lever, and the other worker measures the stroke.
20-42
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE

i C C C Measurement conditions Engine water temperature: Within white range on engine water temperature gauge Hydraulic oil temperature: 45 - 55EC Engine speed: High idle
Work equipment relief valve pressure measuring procedure Loosen the oil supply cap to release the pressure inside the hydraulic oil tank, then operate the control levers two or three times to release any pressure remaining in the piping. 1. Remove bucket cylinder circuit oil pressure measuring plug (1). 2. Install hydraulic test kit C1 to the measuring port. i Check that there is no oil leakage from any joints. i Use a hose which is long enough to reach the operators seat. 3. Start the engine, raise the boom about 400 mm, tilt back the bucket using the control lever, and measure the pressure when the relief valve is activated. i Be careful not to apply any sudden pressure to the pressure gauge. When removing the hydraulic pressure gauge, release the pressure inside the circuit in the same way as when it was installed.
Adjusting Apply the parking brake and put blocks under the tires. Always stop the engine before adjusting the oil pressure. 1. Raise the boom, set support (1A) or tool Q in position, then remove front cover (1).
20-43
2. Remove the relief valve cap nut (2) at control valve (3). 3. Loosen lock nut (4), and turn adjust screw (5) to adjust. i Pressure adjustment for one turn of adjustment screw: Approx. 2.5 Mpa (25 kg/cm2) i Turn the adjustment screw to adjust the set pressure as follows. TIGHTEN to INCREASE pressure LOOSEN to DECREASE pressure Do not carry out any adjustment if the relief pressure cannot be measured accurately.
20-44
MEASURING WORK EQUIPMENT

i C C C C C Measurement conditions Engine water temperature: Within white range on engine water temperature gauge Hydraulic oil temperature: 45 - 55EC Engine speed: High idle Steering position: Neutral No load
Measurement method 1. Boom RAISE time Set the bucket at the lowest position from the ground with the bucket tilted back fully, then raise it and measure the time taken for the bucket to reach the maximum boom height. 2. Boom LOWER time Set the bucket horizontal, then lower the boom from the maximum height and measure the time taken for the bucket to reach the lowest position from the ground.
3. Bucket DUMP time Raise the boom to the maximum height, and measure the time taken to move the bucket from the tilt position (bucket fully tilted back) to the dump position ( bucket fully tipped forward).
4. Bucket TILT time 1) Raise the boom to the maximum height, and measure the time taken to move the bucket to the tilt position (bucket fully tilted back). 2) Set the bucket horizontal to the ground and measure the time taken to move the bucket from the horizontal position to the tilt position (bucket fully tilted back).
20-45

MEASURING HYDRAULIC DRIFT WORK EQUIPMENT i C C C C C C Measurement conditions Engine water temperature: Within white range on engine water temperature gauge. Hydraulic oil temperature: 45 - 55EC (113 - 131EF) Stop the engine, leave for 5 minutes, then measure for 15 minutes. Boom: Horizontal Bucket: Horizontal No load
Apply the safety lock to the work equipment control levers. Never go under the work equipment. Measurement method 1. Set the boom and bucket in a horizontal position, then stop the engine. 2. Leave for 5 minutes, then start the measurement. 3. Wait for 15 minutes, then measure retraction amount A of the bucket cylinder rod and retraction amount B of the boom cylinder rod.
A: Retraction amount of bucket cylinder rod B: Retraction amount of boom cylinder rod
20-46
TESTING AND ADJUSTING BUCKET POSITIONER
TESTING AND ADJUSTING BUCKET POSITIONER

i C C Measurement conditions Engine water temperature: Within white range on engine water temperature gauge. Hydraulic oil temperature: 45 - 55EC (113 - 131EF)
1. Testing 1) With the engine stopped, check that clearance between switch (1) and bar (2) is the standard value. 2) Start the engine, run at high idle and check the actuation position. (Check three times and take the average value.)
2. Adjusting 1) Lower the bucket to the ground, operate the bucket to the desired digging angle, then return the lever to HOLD and stop the engine. 2) Adjust so that clearance between bracket (3) and detection bar (2) is a, then secure in position. i Clearance a : 0.5 - 2.0 mm
3) Secure support (4) to bucket cylinder bracket so the tip of detection bar (2) is in line with the center of the switch sensing surface. 4) Adjust the switch so the clearance between the switch sensing surface and detection bar (2) is b then secure in position. Switch mounting nut: 17.7 2 Nm (1.8 0.2 kgm)
Clearance: b 3 - 7 mm (The clearance must be less than 7 mm, and there must be no interference between the switch and detection bar (plate) After adjusting, operate the bucket lever and check that the bucket positioner is actuated at the desired position.
20-47
TESTING AND ADJUSTING BOOM KICK-OUT
TESTING AND ADJUSTING BOOM KICK-OUT (IF EQUIPPED)

i C C Measurement conditions Engine water temperature: Within white range on engine water temperature gauge. Hydraulic oil temperature: 45 - 55EC (113 - 131EF)
1. Testing 1) Stop the engine, and check that the clearance between switch (1) and plate (2) is the stand value. 2) Start the engine, run at high idle, and check the actuation position. (Check three times and take the average value.) 2. Adjusting 1) Raise the boom the desired position and mark it at the position where the center of the switch is at lower end of the plate. 2) Adjust the position of the plate so that the center of the switch (1) is in line with the bottom of plate (2), then secure in position. Plate mounting nut: 88.3 34.3 Nm (9 3.5 kgm) 3) Adjust the switch (1) so that the clearance a between the switch (1) sensing surface and plate (2) is the standard value, then secure the switch in that position.
20-48
TESTING AND ADJUSTING BOOM KICK-OUT
Proximity switch actuation pilot lamp (red) The proximity switch is equipped with a pilot lamp which shows when it is being actuated, so use this when adjusting.
20-49
TROUBLESHOOTING
MEMORANDA
MEMORANDA
20-50
TROUBLESHOOTING
TABLE OF CONTENTS
TROUBLESHOOTING
Points to remember when trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sequence of events in troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions when carrying out maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checks before troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Handling connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions when troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preventing recurrence of trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Method of using troubleshooting charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-103 20-104 20-105 20-113 20-114 20-115 20-117 20-119
Troubleshoting of engine system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-201 Troubleshooting of hydraulic and mechanical system (chassis related) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-401 Troubleshooting of Eagle Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-701
20-101
TROUBLESHOOTING
MEMORANDA
MEMORANDA
20-102
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted. When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near. If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause burns, so wait for the engine to cool down before starting troubleshooting. Be extremely careful not to touch any hot parts or to get caught in any rotating parts. When disconnecting wiring, always disconnect the negative (-) terminal of the battery first. When removing the plug or cap from a location which is under pressure from oil, water or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly. The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, an important point is to understand the structure and function of the machine. 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 after a 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 man hours, parts, or oil and grease. At the same time, it will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. 2. Points to ask the 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? 3. 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. 4. Check the stroke of the control valve spool. 5. Other maintenance items can be checked externally, so check any item that is considered to be necessary. 4. Confirming the failure. 1. 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. i When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. 5. Troubleshooting 1. Use the results of the investigation and inspection in Steps 2 - 4 to narrow down the causes of the failure, then use the troubleshooting flowchart to locate the position of the failure exactly. b The basic procedure for troubleshooting is as follows. 1. Start from the simple points. 2. Start from the most likely points. 3. Investigate other related parts or information. 6. Measures to remove root cause of failure. 1. Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. 2. To prevent this, always investigate why the problem occurred. Then, remove the root cause.
20-103
TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
20-104
TROUBLESHOOTING
PRECAUTIONS 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 mechanics 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).
PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT 1. Handling wiring harnesses and connectors. Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses.
a. Main failures occurring in wiring harness. i. Defective contact of connectors (defective contact between male and female). Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces.
20-105
TROUBLESHOOTING
ii.
Defective crimping or soldering of connectors. The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.
iii.
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.
iv.
High-pressure water entering connector. The connector is designed to make it difficult for water to enter (drop-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. Since 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, it water should get into the connector, the pins will be short-circuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it.
20-106
TROUBLESHOOTING
v.
Oil or dirt stuck to connector. If oil or grease is 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 dry with compressed air and spray it with a contact restorer. i When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. i
2.
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. Removing, installing, and drying connectors and wiring harnesses. a. Disconnecting connectors i. 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. i Never pull with one hand. b. When removing from clips i. When removing a connector from a clip, pull the connector in a parallel direction to the clip. i If the connector is twisted up and down or to the left or right, the housing may break.
20-107
TROUBLESHOOTING
c.
d.
Action to take after removing connectors i. After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil or water from getting in the connector portion. i If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector. Connecting connectors i. Check the connector visually ii. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). iii. Check that there are no deformation, defective contact, corrosion, or damage to the connector pins. iv. Check that there is no damage or breakage to the outside of the connector. i 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. i If there is any damage or breakage, replace the connector. v. Fix the connector securely vi. Align the position of the connector correctly, then insert it securely. vii. For connectors with lock stopper, push in the connector until the stopper clicks into position. viii. Correct any protrusion of the boot and any misalignment of the wiring harness. ix. For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. i If the connector cannot be corrected easily, remove the clamp and adjust the position. x. If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.
20-108
TROUBLESHOOTING
e.
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. i. Disconnect the connector and wipe off the water with a dry cloth. i 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.
ii.
Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. i 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.
iii.
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. i After completely drying the connector, blow it with contact restorer and reassemble.
20-109
TROUBLESHOOTING
3.
Handling control box a. 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. b. Do not open the cover of the control box unless necessary.
c. d. e.
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.
i.
ii.
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. 2. 3. 4. Always turn the power OFF before disconnecting or connecting connectors. Before carrying out troubleshooting, check that all the related connectors are properly inserted. i Disconnect and connect the related connectors several times to check. Always connect any disconnected connectors before going on to the next step. i If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated. When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. i If there is any change, there is probably defective contact in that circuit.
20-110
TROUBLESHOOTING
Points to remember when handling hydraulic equipment

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful. 1. Be careful of the operating environment. Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or in places where there is a lot of dust. Disassembly and maintenance work in the field. If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to confirm the performance after repairs, so it is desirable to use a unit exchange. Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dust proof workshop, and the performance should be confirmed with special test equipment.
2.
3.
Sealing openings. After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is a danger of dirt entering or of the surrounding area being made dirty by leaking oil. 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.
4.
Do not let any dirt or dust get in during refilling operations. Always keep the oil filler and the area around it clean, and always 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.
20-111
TROUBLESHOOTING
5.
Change hydraulic oil when the temperature is high. When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil.
6.
Flushing operations. After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil and secondary flushing is carried out with the specified hydraulic oil.
7.
Cleaning operations. After repairing the hydraulic equipment (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultra fine (about 3) particles that the filter built into the hydraulic equipment cannot remove, so it is an extremely effective device,
20-112
CHECKS BEFORE TROUBLESHOOTING

Item Standard value ---------------23 - 26 V ----Remedy
Checks before starting
Lubricating oil, cooling water
1. Check fuel level 2. Check for dirt or water in fuel 3. Check hydraulic oil level 4. Check hydraulic oil strainer 5. Check brake oil level 6. Check engine oil level 7. Check cooling water level 8. Check condition of dust indicator 9. Check air pressure 10. Check for loose or corroded battery terminals 11. Check for loose or corroded alternator terminals 12. Check for loose or corroded stating motor terminals 13. Check for abnormal noise or smell 14. Check for oil leakage 15. Bleed air from system 16. Check battery voltage (engine stopped) 17. Check level of battery electrolyte 18. Check for discolored, burnt, or bare wires 19. Check for missing wiring clamps, hanging wires 20. Checks for water leaking onto wiring (checks carefully water leakage at connectors and terminals) 21. Check for broken or corroded fuses 22. Check alternator voltage (engine running at over half throttle) 23. Noise when battery relay is operated (switch starting switch from ON to OFF)
Add fuel Clean, drain Add oil Clean, drain Add oil Add oil Add water Clean or replace Refer to troubleshooting Tighten or replace Tighten or replace Tighten or replace Repair Repair Bleed air Replace Add or replace Replace Repair Disconnect connector and dry connection
Item
Electrical Equipment
Other check items
Hydraulic mechanical components Electrical components
-27.5 - 29.5 V
Replace Replace
--
Replace
20-113
TROUBLESHOOTING
HANDLING CONNECTORS
HANDLING CONNECTORS
1. When removing connectors from clips, pull the connector in a parallel direction to the clip. If the connector is twisted to the left and right or up and down, the housing may break.
2. When disconnecting male and female connectors, release the lock and pull in a parallel direction with both hands. Never try to pull apart with one hand.
3. When the wiring harness clamp of the connector has been removed, always return it to its original condition and check that is no looseness of the clamp.
20-114
TROUBLESHOOTING
PRECAUTIONS WHEN TROUBLESHOOTING

1. SAFETY ! Stop the machine on level ground, and check that the safety pins and parking brake are correctly applied, and that the tires are blocked. ! When working in groups, use agreed upon signals and do not allow unauthorized persons near machine. Be careful not to get burned by hot parts or get caught in rotating parts. Always disconnect the cable from the negative (-) terminals of the battery before disconnecting any wiring. Always release the pressure before removing the plugs or caps of any place under hydraulic or air pressure, and connect all measuring tools correctly. b. Was there anything unusual before the machine broke down? c. Did the breakdown occur suddenly, or had there been signs of trouble before? d. What was the machine doing when break down occurred? e. Had the machine been repaired before the breakdown? If so, who carried out the repair, and when? f. Had the same kind of failure occurred before? 2) Check the following items which can be checked simply by visual checks etc. a. Check oil level. b. Check for leakage of oil from piping or hydraulic equipment. c. Check travel of control levers. d. Check stroke of spool in control valves. Reenact the failure and check the condition of the machine (particular conditions at the time of failure). a. Ask the user or operator if the decision about the failure was made based on measured values, or by comparison, or by feeling. b. Compare extent of failure with standard values. ! Check safety before carrying out any check. ! Did not make any check or measurement that will make the condition worse. Try to locate the possible causes for the failure. The transmission system consists of the transmission itself, the transmission control valve, and the transmission electrical control. In particular, when trouble occurs in the transmission system, the probable location of the failure can be divided as follows; ! Transmission itself, or transmission control valve. ! Transmission electric control.
! !
3)
2. METHODS FOR TROUBLESHOOTING Just because a failure occurs, do not immediately start to disassemble the machine. ! The machine may be disassembled in such a way that the problem cannot be located, so the cause of the problem will be unknown.
As a result, 4) ! ! The customer and operator will lose confidence in you. Time will be wasted, and unnecessary costs will be incurred for excess parts and greasing.
To avoid these problems, use the following procedure when troubleshooting. 1) Ask the customer and operator the following questions about the breakdown. a. Have there been any other problems apart from the one reported?
20-115
TROUBLESHOOTING
To decide which of the two is the location of the failure, refer to JUDGMENT ON POWER TRAIN. 5) Carry out troubleshooting using the troubleshooting charts. There are the following two types of troubleshooting charts. 1. TROUBLESHOOTING TABLE POWER TRAIN STEERING SYSTEM BRAKE AND AIR SYSTEM WORK EQUIPMENT SYSTEM 2. TROUBLESHOOTING FLOW CHART ELECTRICAL SYSTEM The troubleshooting charts consist of: 1) Items which can be checked easily. 2) Items which are likely to be the cause of such failures. Follow theses charts to carry out troubleshooting. At the same time, do not forget the following points. ! Check related items. ! Check that there are no other failures or breakdowns. 6) Investigate causes of breakdown ! Even if the breakdown is repaired, if the original cause of the problem is not removed, the same breakdown will occur again. To investigate and remove the original cause, see "Actions to take to prevent failures from occurring again". 3. PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR ASSEMBLING PARTS DURING TROUBLESHOOTING ! Carry out the various testing and adjusting while observing the items on quality control given in "Testing and Adjusting". !

When removing parts, check their condition of mounting, and distinguish between front and rear, left and right, and top and bottom. Check the match marks, or make match marks to prevent mistakes when installing. If part cannot be removed even when the nuts and bolts have been removed, do not use excessive force to remove it. Check the part to see if there is any problem with it and remove the problem before trying to disassemble the part. When installing or assembling, clean off all dust and dirt and repair any scratches or dents. Remove all grease or oil before coating with gasket sealant.
! !
20-116
TROUBLESHOOTING
PREVENTING RECURRENCE OF TROUBLE
PREVENTING RECURRENCE OF TROUBLE

! The troubleshooting table is used to establish the direct cause of damage or breakdown of a part or piece of equipment. It is not able to establish the root cause of the damage or failure, however. ! Also, this table only describes the action to be taken with the particular part or piece of equipment. It does not mention what action should be taken to prevent a recurrence of the root cause. ! In order to remove the root cause of a fault so as to prevent a recurrence, carefully investigate the real cause while referring to the following items. ! Regarding the method of checking and adjusting each part or piece of equipment, refer to "Testing and Adjusting" in the Shop Manual. Water: Oil storage tank, breather, etc. HYDRAULIC EQUIPMENT Sand: Oil replenishing or replacing 1. Oil checks method, etc. ! The fundamental cause of almost all faults Rubber: Cylinder packing, etc. occurring in hydraulic equipment is the Metal: Wear or damage to hydraulic inclusion of water, air or other foreign matter in equipment such as pump and the oil. Accordingly, it is necessary to check the motor, as well as transmission oil to see whether or not it contains any of the and torque converter, etc. above substances, and then take appropriate action. 3) Oil cleaning and replacement ! If a large amount of metal particles or 1) Oil checks other foreign matter is discovered in the ! Check for water contamination. oil, either wash the oil using an oil Check the oil for possible water refresher or replace it. contamination by means of a diesel If the oil is contaminated by water, it is engine oil checker or a hot plate. not possible to remove the water by ! Check for contamination of other means of an oil refresher. foreign matter. Remove the drain plug When washing the oil, also wash or and filter, then check the bottom of the replace the strainer and replace the tank and also the filter to see if any filter. foreign matter has collected there. Check the degree of contamination by 2. Cleaning fragments of damaged parts means of a contamination checker. ! If a part becomes damaged, fragments may ! Viscosity check pass into the oil line. It is thus necessary to Check the viscosity of the oil using a wash the oil. viscometer in order to confirm whether ! In addition, disassemble and wash such parts or not the oil is satisfactory. as valves and cylinders which are liable to 2) Check of contamination point collect metal fragments and other foreign If, as a result of the above checks, it is matter, thus helping to prevent a recurrence of discovered that the oil is contaminated by faults due to such fragments becoming lodged water or other foreign matter, it is in various parts of the engine or hydraulic necessary to find out where the equipment. contamination is occurring and also to take steps to prevent it.
20-117
TROUBLESHOOTING
MEMORANDA
MEMORANDA
20-118
TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING CHARTS

1. Category of troubleshooting code number
Troubleshooting code No. Component S-FF M-FF K-FF E-FF T-FF D-FF W-FF Troubleshooting of engine Troubleshooting of main monitor Troubleshooting of maintenance monitor Troubleshooting of electrical system Troubleshooting of hydraulic and mechanical system Troubleshooting of ECSS (Electronically Controlled Suspension System) Troubleshooting of work equipment
2. Method of using troubleshooting table for each troubleshooting mode.

1) Troubleshooting code number and problem. 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 the troubleshooting from the first check item in the failure mode .(See Example (2)) 3) Method of following troubleshooting chart. ! 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 condition box. (Note: The number at the top right corner of the condition box is an index number; it does not indicate the order to follow.) ! Following the YES or NO lines according to the results of the check or measurement will lead finally to the Cause column. Check the cause and take the action given in the Remedy column on the right .(See Example (3)) ! Below the [ ] condition box, there are the methods for inspection or measurement, and the judgement values. If the judgement values below the condition box are correct or the answer to the question inside the condition box is YES, follow the YES line. If the judgement value is not correct, or the answer to the question in NO, then follow the NO line. ! Below the condition box is given the preparatory work needed for inspection and measurement, and the judgement values. If this preparatory work is neglected, or the method of operation or handling is mistaken, there is the 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 the first item 1. 4) General precautions When carrying out troubleshooting for the failure mode (problem), precautions that apply to all the items are given at the top of the page and marked with a i. (See Example (4)) The precautions marked i are not given in the condition box, but must always be followed when carrying out the check inside the condition box. 5) Troubleshooting tools When carrying out troubleshooting, prepare the necessary 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).
20-119
TROUBLESHOOTING
< Example >
(1) M-15 Abnormality in buzzer

(2) (a) Buzzer does not sound when starting switch is turned ON (during self-check) (3)
(4) i Before carrying out troubleshooting, check that all the related connectors are properly inserted. i Always connect any disconnected connectors before going on to the next step.
20-120
TROUBLESHOOTING
3. Using troubleshooting chart for engine-related failure

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 inspection without using troubleshooting tools. Next, troubleshooting tools or direct inspection are used to check the high probability causes to make the final confirmation. [Question] Sections (A) and (B) in the chart below corresponds to the items where the answers can be obtained from the user. The items in (B) are items that can be obtained from the user, depending on the users level. [Check items] The serviceman carries out simple inspections to narrow down the causes. The items under (C) in the chart below correspond to this. The serviceman narrows down the causes from information (A) that he has obtained from the user and the results of (C) 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].
20-121
TROUBLESHOOTING
The basic method of using the troubleshooting chart is as follows. Items listed for [Questions] and [Check Items] that have a relationship with the Cause items are marked with F, and of these, causes that have a high probability are marked with F ". Check each of the [Questions] and [Check Items] in turn, and marke the F or F " 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 the final confirmation of the cause. 1. For [Confirm recent repair history] in the Question section, ask the user, and mark the Cause column with a to use as reference for locating the cause of the failure. However, do not use this when making calculation to narrow down the causes. 2. Use the 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 in necessary to determine the order for troubleshooting.
20-122
TROUBLESHOOTING

MEMORANDA
20-123
TROUBLESHOOTING
! 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 injection ! Excessive injection of fuel
20-124
TROUBLESHOOTING
20-125
TROUBLESHOOTING
4. 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 1. Steering does not work Symptom [Example] failure symptom. If the answers to the questions match the information given, follow the arrow to reach Ask the operator about the following points. the probable cause of the failure. ! Did the steering suddenly stop working? Consider the contents of the questions and consult the Breakage in steering equipment table while proceeding to Steps 2 and 3 to grasp the ! Had the steering gradually been becoming true cause. heavy? Internal wear of steering equipment, defective seal. Step 2. Checks before troubleshooting Before starting the main troubleshooting and measuring the hydraulic pressure, first check the Checks efore starting [Example] Checks before Starting items, and check for oil leakage and loose bolts. These checks may avoid ! Is the oil level and type of oil in the hydraulic time wasted on unnecessary troubleshooting. tank correct? The items given under Checks before Starting are ! Is there any leakage of oil from the steering items which must be considered particularly for that control valve? symptom before starting troubleshooting. 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. i 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 F', 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 F: Carry out the other troubleshooting items (where the same cause is marked with check if the symptom appears, then repair. If there are two F s: Go on to Step 3) to narrow down the possible causes.
20-126
TROUBLESHOOTING
3) 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 1) and if the symptom appears, mark that item. (In the chart on the right, the symptom appears again for item 5). 4) Find the appropriate cause from the cause column. In the same way as in Step 2), if the symptom appears, the F 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.) 5) Narrow down the possible causes. There is one common cause among the causes located in Steps 2) and 4). (One cause marked F, appears on the line for both items.) This cause is common to both the symptoms in troubleshooting Steps 1) and 3). i The causes which are not common to both troubleshooting items (items which are not marked F 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.) 6) Repeat the operations in Steps 3), 4) and 5) until one cause (one common cause) remains. i If the causes cannot be narrowed down to one cause, narrow the causes down as far as possible. 7) Remedy If the causes are narrowed down to one common cause, take the action given in the remedy column. The symbols given in the remedy column indicate the following: X: Replace,
: Repair, A; Adjust, C: Clean
20-127
TROUBLESHOOTING
MEMORANDA
MEMORANDA
20-128
TROUBLESHOOTING
TROUBLESHOOTING OF ENGINE SYSTEM
TROUBLESHOOTING OF ENGINE SYSTEM TABLE OF CONTENTS
S- 1 S- 2 S- 3 S- 4 S- 5 S- 6 S- 7 S- 8 S- 9 S-10 S-11 S-12 S-13 S-14 S-15 S-16
Starting performance is poor (Staring always take time) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine does not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine does not pick up smoothly (Follow up is poor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine stops during operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine does not rotate smoothly (hunting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine lacks output (no power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust gas is black (incomplete combustion) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil consumption is excessive (or exhaust gas is blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil becomes contaminated quickly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel consumption is excessive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil is in cooling water, or water spurts back, or water level goes down . . . . . . . . . . . . . . . . . . . . . . . . Oil pressure lamp lights up (drop in oil pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil level rises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water temperature becomes too high (overheating) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Abnormal noise is made . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vibration is excessive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-202 20-203 20-206 20-207 20-208 20-209 20-210 20-211 20-212 20-213 20-214 20-215 20-216 20-217 20-218 20-219
20-201
TROUBLESHOOTING
S-1 STARTING PERFORMANCE IS POOR (Starting always takes time)
S-1
General causes why starting performance is poor ! Defective electrical system ! Insufficient supply of fuel ! Insufficient supply of air ! Improper selection of fuel (At ambient temperature of -10EC or below, use ASTMD975 No. 1, and -10EC or above, use ASTM D975 No. 2 diesel fuel.) ! The specific gravity should exceed the value for the charging rate of 70% in the below table ! In cold weather the specific gravity must exceed the value for the charging rate of 75% in the below table.
20-202
TROUBLESHOOTING
S-2
S-2 Engine does not start

(1) Engine does not turn General cause why engine does not turn ! Internal parts of engine seized i If the internal parts of the engine are seized, carry out trouble shooting for Engine in power train. ! Failure in power train ! Defective electrical system
20-203
TROUBLESHOOTING
S-2
(Fuel is not being injected)
(2)
Engine turns but no exhaust gas comes out
Genereal causes why engine turns but no exhaust gas comes out ! Supply of fuel impossible ! Supply of fuel is extremely small ! Improper selectioon of fuel (particularlyin winter)
20-204
TROUBLESHOOTING
S-2
(3)
Exhaust gas comes out but engine does not start. (Fuel is being ejected)
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
20-205
TROUBLESHOOTING
S-3
(Follow up is poor)
S-3 Engine does not pick up smoothly
General causes why exhaust gas comes out but engine does not start ! Insufficient intake of air ! Insufficient supply of fuel ! Improper condition of fuel injection ! Improper fuel used
20-206
TROUBLESHOOTING
S-4
S-4 Engine stops during operations

General causes why engine stops during operations ! Seized parts inside engine ! Insufficient supply of fuel ! Overheating i If there is overheating and insufficient output, carry out troubleshooting for overheating. ! Failure in power train i If engine stops because of failure in power train, carry out troubleshooting for chassis.
20-207
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 ! Defective engine throttle controller mechanism (Engine throttle controller type)
20-208
TROUBLESHOOTING
S-6
S-6 Engine lacks output (no power)

General causes why engine lacks output ! Insufficient intake of air ! Insufficient supply of air ! Improper condition of fuel injection ! Improper fuel used (If non-specified fuel is used, output drops) ! Lack of output due to overheating i If there is overheating and insufficient output, carry out troubleshooting for overheating.
20-209
TROUBLESHOOTING
S-7
S-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black ! insufficient intake of air ! Improper condition of fuel injection ! Excessive injection of fuel
20-210
TROUBLESHOOTING
S-8
S-8 Oil consumption is excessive (or exhaust gas is blue)

i Do not run the engine at idle for more than 20 minutes continuously.. (Both low and high idle) General causes why oil consumption is excessive ! Abnormal combustion of oil ! External leakage of oil ! Wear of lubrication system
20-211
TROUBLESHOOTING
S-9
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
20-212
TROUBLESHOOTING
S-10
S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive ! Leakage of fuel ! Improper condition of fuel injection ! Excessive injection of fuel
20-213
TROUBLESHOOTING
S-11
S-11 Oil is in cooling water, or water spurts back, or water level goes down
General causes why oil is in cooling water ! Internal leakage in lubrication system ! Internal leakage in cooling system
20-214
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
20-215
TROUBLESHOOTING
S-13
S-13 Oil level rises

i 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 components
20-216
TROUBLESHOOTING
S-14
S-14 Water temperature becomes too high (overheating)

General causes why water temperature becomes too high ! Lack of cooling water (deformation, damage of fan) ! Drop in heat dissipation efficiency ! Defective cooling circulation system ! Rise in oil temperature of power train i Carry out troubleshooting for chassis
20-217
TROUBLESHOOTING
S-15
S-15 Abnormal noise is made

i Judge if noise is 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
20-218
TROUBLESHOOTING
S-16
S-16 Vibration is excessive

i 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, breakage) ! Improper alignment ! Abnormal combustion
20-219
TROUBLESHOOTING
MEMORANDA
MEMORANDA
20-220
TROUBLESHOOTING
HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED)
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED) TABLE OF CONTENTS

POWER TRAIN T-1 Machine does not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-2 Travel speed is slow, thrusting power is weak, lacks power on slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-3 Excessive shock when starting machine or shifting gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-4 Excessive time lag when starting machine or shifting gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-5 Torque converter oil temperature is high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING SYSTEM S-1 Steering wheel does not turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-2 Steering is heavy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-3 Steering wheel shakes or there is excessive shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-4 Deviates to one side when traveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-5 Turning radius is different between left and right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-6 Excessive shock to machine when steering wheel is turned fully to left or right . . . . . . . . . . . . . . . . . . . . .
20-402 20-404 20-406 20-407 20-408
20-409 20-410 .20-411 20-412 20-412 20-412
BRAKE SYSTEM A-1 Brakes do not work or braking effect is poor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-413 A-2 Brake is not released, brake drags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-414 WORK EQUIPMENT H-1 Boom does not rise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-2 Boom movement is slow or boom lacks lifting power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-3 When boom is raised, it moves slowly at a certain height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-4 Bucket cannot be pushed with boom cylinder (bucket floats). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-5 Excessive hydraulic drift of boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-6 Boom shakes during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-7 Boom drops momentarily when control lever is operated from HOLD to RAISE . . . . . . . . . . . . . . . . . H-8 Bucket does not tilt back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-9 Bucket movement is slow or tilt-back lacks power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-10 Bucket movement becomes slow during tilt-back operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-11 Bucket cannot be pushed with bucket cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-12 Excessive hydraulic drift of bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-13 Bucket shakes during loading operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-14 Bucket dumps momentarily when control lever is operated from HOLD to TILT . . . . . . . . . . . . . . . . . H-15 Boom, bucket control levers are heavy or do not move smoothly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-415 20-416 20-417 20-417 20-417 20-417 20-418 20-419 20-420 20-421 20-421 .20-421 20-422 20-422 20-423
Explanation of symbols in Table The following symbols are used on the Cause column to show the action to be taken to remove the cause. X: Replace,
Correct,
A: Adjust, C: Clean
20-401
TROUBLESHOOTING
T-1
POWER TRAIN T-1 Machine does not start

Ask the operator the following questions. ! Did the problem suddenly start? Yes = Internal part seized or broken ! Was there any abnormal noise when this happened? Yes = Component broken. Checks before troubleshooting ! Does the machine monitor function properly? ! Is the transmission oil level correct? ! Is the type of oil correct? ! Is the transmission filter or strainer clogged? ! Does the electrical circuit of the transmission control work properly? ! Is the transmission oil deteriorated? Does the oil smell of burning? ! Is there any damage or leakage of oil that can be seen externally? ! Is the drive shaft broken? ! Is the wheel brake or parking brake locked?
20-402
TROUBLESHOOTING
T-1
20-403
TROUBLESHOOTING
T-2
T-2 Travel speed is slow, thrusting power is weak, lacks power on slopes
Checking for abnormalities ! Measure digging operations and speed when traveling on level ground and on slopes, and check if there is actually an abnormality or whether it is just the feeling of the operator. Checks before troubleshooting ! Is the transmission oil level correct? Is the type of oil correct? ! Is the transmission filter or strainer clogged? ! Is there any oil leaking from the joints of the piping or valves? ! Is there any dragging of the wheel brake or parking brake? ! Is the tire inflation pressure and tread pattern normal? ! Is the method of operation correct?
20-404
TROUBLESHOOTING
T-2
20-405
TROUBLESHOOTING
T-3
T-3 Excessive shock when starting machine or shifting gear

Checking for abnormalities It is difficult to measure if the shock is excessive or normal, so judge that the shock is excessive in the following cases. ! When it is clear that the shock has become greater than before. ! When the machine is compared with another machine of the same class and the shock is found to be greater. Checks before troubleshooting ! Is the engine idling speed too high? ! Is there play in any of the drive shafts?
20-406
TROUBLESHOOTING
T-4
T-4 Excessive time lag when starting machine or shifting gear

Ask the operator the following questions. ! Was there excessive time lag? Was there any abnormality in the travel speed or thrusting force? Was there any lack of power when traveling up slopes? Yes = Go to T-2 Travel speed is slow, thrusting power is weak, lacks power on slopes Checks before troubleshooting ! Is the transmission oil level correct? ! Is the type of oil correct? ! Is there any oil leaking from the joints of the piping or valves?
20-407
TROUBLESHOOTING
T-5
T-5 Torque converter oil temperature is high

Ask the operator the following questions. ! Does oil temperature rise during torque converter stall and go down when there is no load? Yes = Selection of transmission range ! Does oil temperature rise only when carrying out scooping work? Yes = Improvement in method of operation Checks before troubleshooting ! Are the radiator water level and fan belt tension correct? ! Is the transmission oil level correct? ! Is the type of oil correct? ! Is the transmission filter or strainer clogged? Checking for abnormalities ! Measure the torque converter oil temperature. Is it actually high? Yes = Defective oil transmission gauge
20-408
TROUBLESHOOTING
S-1
STEERING SYSTEM S-1 Steering wheel does not turn

Ask the operator the following questions. ! Did the problem suddenly start? Yes = Steering equipment damaged or broken ! Was there previously any symptom, such as heavy steering? Yes = Wear of internal parts of steering equipment, defective seal Checks before troubleshooting ! Is the hydraulic oil level correct? ! Is the type of oil correct? ! Has the safety bar been removed from the frame?
There is a close connection between the steering circuit and the work equipment circuit, so if any abnormality is felt in the steering, check the operation of the work equipment also.
20-409
TROUBLESHOOTING
S-2
S-2 Steering is heavy

Ask the operator the following questions. ! Did the problem suddenly start? Yes = Steering equipment damaged or broken ! Was there previously any symptom, such as heavy steering? Yes = Wear of internal parts of steering equipment, defective seal Checks before troubleshooting. ! Is the hydraulic oil level correct? Is the type of oil correct? ! Is there any leakage of oil from the hydraulic hoses, valves, or cylinders? ! Is there any scuffing of the center hinge pin bearing or steering cylinder pin or bushing? ! Is the tire inflation pressure correct? Checking for abnormalities. ! Measure the operating force of the steering wheel and the time taken to turn the steering, and check the values in the Standard Value Table to see if there is really any abnormality.
20-410
TROUBLESHOOTING
S-3
S-3 Steering wheel shakes or there is excessive shock

Checks before troubleshooting ! Is the hydraulic oil level correct? Is the type of oil correct? ! Is there any play in the center hinge pin bearing or steering cylinder pin or bushing? ! Is there any variation in the tire inflation pressure? ! Is the steering wheel play correct? Checking for abnormalities ! Operate at a safe place and check how the steering wheel shakes and under what conditions. In cases where the steering wheel is heavy but does not shake, go to "T-7 Steering is heavy."
20-411
TROUBLESHOOTING
S-4, S-5, S-6
S-4 Deviates to one side when traveling

Cause ! Defect inside Orbit-Roll ! Oil leakage inside steering cylinder ! Variation in inflation pressure of tires
S-5 Turning radius is different between left and right

Cause ! Defective cylinder piston packing ! Defect inside Orbit-roll
S-6 Excessive shock to machine when steering wheel is turned fully to left or right
Cause ! Deteriorated, damaged, or missing front frame bumper
20-412
TROUBLESHOOTING
A-1
BRAKE SYSTEM A-1 Brakes do not work or braking effect is poor
Ask the operator the following questions ! Did the problem suddenly start? Yes = Brake equipment broken ! Did the problem gradually appear? Yes = Deterioration of seal, wear of lining, disc Checks before troubleshooting ! Is the brake oil level correct? ! Is the brake pedal play correct? ! Is there any leakage of oil from the brake tube or connector? ! Is there any deformation of the tube? Is the tire inflation pressure and tread pattern normal? Checking for abnormalities ! Measure the braking force and compare with the Standard Value Table to check if the braking effect is poor
20-413
TROUBLESHOOTING
A-2
A-2 Brake is not released, brake drags

Checks before troubleshooting ! Is the play of the brake pedal correct? Checking for abnormalities ! Does the machine travel smoothly under inertia on flat ground? ! Jack up the four wheels and check the rotating resistance of the tires.
20-414
TROUBLESHOOTING
H-1
WORK EQUIPMENT H-1 Boom does not rise
Ask the operator the following questions. ! Did the problem suddenly start? Yes = Equipment seized, damaged Was there any abnormal noise when this happened? (from where?) ! Was there previously any symptom, such as the speed becoming slow? Yes = Wear of internal parts, deterioration in spring Checks before troubleshooting ! Is the hydraulic oil level correct? ! Is the travel of the boom control lever and spool properly adjusted?
20-415
TROUBLESHOOTING
H-2
H-2 Boom movement is slow or boom lacks lifting power

Checks before troubleshooting ! Is the travel of the boom control lever and main control valve spool properly adjusted? ! Is there any seizure of the work equipment linkage? (Is there any abnormal noise?) Checking for abnormalities ! There is a strong connection between lifting power and speed, so this problem first appears as a lack of lifting speed. Measure the boom lifting speed when the bucket is loaded and use the Standard Value Table to judge if there is any abnormality.
20-416
TROUBLESHOOTING
H-3, H-4, H-5, H-6
H-3 When boom is raised, it moves slowly at a certain height

Checks before troubleshooting ! Can any deformation be seen in the boom cylinder? Cause ! Swelling or internal damage to boom cylinder tube i For other abnormalities when the boom is raised, go to "H-2 Boom movement is slow or boom lacks lifting power."
H-4 Bucket cannot be pushed with boom cylinder (bucket floats)

See "H-2 Boom movement is slow or boom lacks lifting power." Checks before troubleshooting ! Is the stroke of the boom spool in the main control valve properly adjusted? Cause ! Defective seating of suction valve at boom cylinder rod end of main control valve ! Oil leakage from boom cylinder piston seal
H-5 Excessive hydraulic drift of boom

Ask the operator the following questions. ! Did the problem suddenly start? Yes = Dirt caught in valve, broken part ! Did the problem gradually appear? Yes = Worn parts Checks before troubleshooting ! Is the boom spool at the neutral position? Yes = Seized link bushing, defect in spool detent Troubleshooting and Cause ! When measuring the hydraulic drift, is there any sound of oil leakage from inside the boom cylinder? Yes = Defective cylinder packing
H-6 Boom shakes during operation

When digging or leveling operations are carried out with the boom control lever at HOLD, the bucket and boom move up and down to follow the shape of the ground. Troubleshooting and Cause Measure the hydraulic drift of the boom and check if it is possible to lift the chassis with the boom cylinder. 1. If the hydraulic drift of the boom cylinder is outside the standard value, go to "H-5 Excessive hydraulic drift of boom." 2. If the chassis cannot be raised with the boom cylinder, go to "H-4 Bucket cannot be pushed with boom cylinder." 3. If the hydraulic drift of the boom is normal, operate the boom several times, and operate the boom cylinder to the end of its stroke. Is it now possible to raise the chassis with the boom cylinder? Yes = Vacuum had formed inside cylinder i However, if this problem appears frequently, the suction valve at the boom cylinder rod end is defective.
20-417
TROUBLESHOOTING
H-7
H-7 Boom drops momentarily when control lever is operated from HOLD to RAISE
Checking problem ! When the engine is run at low idling and the boom control lever is operated slowly from HOLD to RAISE, the boom goes down under its own weight. When the lever is operated fully to the RAISE position, the condition returns to normal. Cause ! Defective seating of check valve for boom spool in main control valve
20-418
TROUBLESHOOTING
H-8
H-8 Bucket does not tilt back

Ask the operator the following questions. ! Did the problem suddenly start? Yes = Equipment seized, damaged Was there any abnormal noise when this happened? (from where?) ! Was there previously any symptom, such as the speed becoming slow? Yes = Wear of internal parts, deterioration in spring Checks before troubleshooting ! Is the travel of the bucket control lever and spool properly adjusted?
20-419
TROUBLESHOOTING
H-9
H-9 Bucket movement is slow or tilt-back lacks power

Checks before troubleshooting ! Is the travel of the bucket control lever and main control valve spool properly adjusted? ! Is there any seizure of the work equipment linkage? (Is there any abnormal noise?) Checking for abnormalities ! Check if there is lack of tilt-back power during actual operations. ! Measure the operating speed of the bucket and use the Standard Value Table to check if there is any abnormality
20-420
TROUBLESHOOTING
H-10, H-11, H-12
H-10 Bucket movement becomes slow during tilt-back operation

Checks before troubleshooting ! Can any deformation be seen in the bucket cylinder? Cause ! Swelling or internal damage to bucket cylinder tube ! For other abnormalities when the bucket is operated, go to "H-9 Bucket movement is slow or tilt back lacks power."
H-11 Bucket cannot be pushed with bucket cylinder

See "H-9 Bucket movement is slow or tilt back lacks power." Checks before troubleshooting ! Is the stroke of the bucket spool in the main control valve properly adjusted? Cause ! Defective seating of safety valve (with suction valve) at bucket cylinder rod end of main control valve ! Oil leakage from bucket cylinder piston seal
H-12 Excessive hydraulic drift of bucket

Ask the operator the following questions. ! Did the problem suddenly start? Yes = Dirt caught in valve, broken part ! Did the problem gradually appear? Yes = Worn parts Checks before troubleshooting ! Is the bucket spool at the neutral position? Yes = Seized link bushing, defect in spool detent Checking for abnormalities ! Use the Standard Value Table to check if the hydraulic drift of the bucket is actually excessive. Cause ! Oil leakage inside bucket cylinder ! Defective seating of safety valve (with suction valve) at bottom end ! Defective oil tightness of bucket spool
20-421
TROUBLESHOOTING
H-13, H-14
H-13 Bucket shakes during loading operation (Main control valve at HOLD)
Checks before troubleshooting ! Is there play in the work equipment linkage pin, bushing? (Is there any abnormal noise?) Cause ! Defective bucket cylinder piston seal ! Defective operation of safety valve (with suction valve) at bucket cylinder rod end. If any other problem occurs at the same time, carry out troubleshooting according to the nature of the problem.
H-14 Bucket dumps momentarily when control lever is operated from HOLD to TILT
Checking problem ! When the engine is run at low idling and the bucket control lever is operated slowly from HOLD to TILT, the bucket dumps momentarily under its own weight. When the lever is operated fully to the TILT position, the condition returns to normal. Cause ! Defective seating of check valve for bucket spool in main control valve
20-422
TROUBLESHOOTING
H-15
H-15 Boom, bucket control levers are heavy or do not move smoothly
Checking for abnormalities ! Compare operating force of the lever with the value in the Standard Value Table to see if it is actually excessive.
20-423
TROUBLESHOOTING
MEMORANDA
MEMORANDA
20-424
TROUBLESHOOTING
TROUBLESHOOTING-EAGLE AIR CONDITIONER
TROUBLESHOOTING
Troubleshooting Setup: Controller on Temp. 60E F Defrost off, Fan on high Abbreviations: EC - Electric Condenser (A) Problem - EO error message display on the controller: Possible Cause 1. Open EC power circuit 2. Defective EC relay (circuit) Inspection Check the EC circuit breaker for power, voltage, and continuity Check for output voltage on the yellow wire, at the relay coil. Check the voltage and continuity across the relay contacts. Check for input voltage on the brown wire, at the controller. Applicable to systems without an EC Check for output voltage on the yellow wire, at the controller. Remedy a) Repair the wiring b) Replace open circuit breaker a) Repair the connections / wiring b) Replace the defective relay
3. Open EC voltage detection circuit 4. Improper wiring installation 5. Defective controller
a) Repair the wiring or connector a) See note #3 a) Replace the controller
(B) Problem - E1 error message display on the controller: Possible Cause 1. Abnormal A/C refrigerant pressure(s). * Cool weather operation may cause low pressure short cycling Inspection Check the refrigerant pressures with gauges. High side greater than: 320 psig (R12), or 350 psig (R134a). Low side less than: 3 - 6 psig.* Check for output voltage on the green wire at the compressor. Check the wire connections. Check for continuity across the pressure switch(es) and thermostat. Check the continuity of the clutch solenoid to ground. Check for an input voltage on the tan wire, at the controller. Check for output voltage on the green wire, at the controller. Remedy a) Check the condenser operation for air and refrigerant blockage b) Leak check system, repair the leaks and recharge the system c) Relocate the low pressure switch to the evaporator outlet a) Repair the connections/wiring b) Replace the defective switch(es) or the thermostat c) Replace the defective compressor clutch
2. Opened compressor clutch circuit
3. Opened pressure switch detection circuit 4. Defective controller
a) Repair the connections/ wiring a) Replace the controller
701
TROUBLESHOOTING
(B) Problem continued
False E1 error message / cold weather charging problems: (Occurs particularly when vapor charging in cold weather)
1.
E1 error message may occur during charging when the low pressure switch (LPS) opens at 3 psig. The suction side pressure must rise above 45 psig to reset the E1 error message.
2.
When the system is fully charged, the E1 error message should not appear under normal operating conditions. In order to continue charging, by-pass the LPS, turn the controller off then on, and set the controller to 60E F. This will reset the controller and force into the air conditioning mode. If the LPS cant be easily reached, disconnect the clutch wire at the compressor, and run a hot wire directly to the compressor clutch solenoid. Take care not to short out the controller clutch circuit. E1 error message may occur while charging, when the compressor is wired hot.
3.
4.
5.
(C) Problem - No Heat Possible Cause 1. Opened heat solenoid circuit. Poor connection, loss of voltage. Inspection Check for an output voltage on the white wire, at the heat solenoid valve. Check the solenoid continuity to ground. Check for coolant blockages in the heat solenoid valve and hoses. Check the direction of coolant flow (feel the hoses). Check for output voltage on the white wire, at the controller. Remedy a) Repair connections/wiring
2. Defective heat solenoid or improper installation.
a) Repair or replace the valve. b) Reverse the coolant hoses to the valve. a) Replace the controller
3. Defective controller
702
TROUBLESHOOTING
(D) Problem - No display, the blower fan will not turn off, when the power is turned on. Possible Cause 1. Fan wires shorted to ground or vehicle chassis Inspection Disconnect the controller from the external harness, Individually check the continuity of the orange and black fan wires to ground, in the external harness. Remedy a) Unground and repair the shorted wiring.
(E) Problem - Compressor clutch will not engage, unless defrost button is pushed. Possible Cause 1. Defective preset thermostat inside evaporator. Opened preset thermostat circuit. Broken thermostat wiring. Evaporator coil temperature too cold for a/c operation. 2. Ambient cab temperature too cool (below 60E F). Inspection Push, hold defrost / temperature decrease buttons simultaneously. Check display for OP or CL readout. Disconnect red leads, and check for continuity across thermostat terminals. Set controller at 68-70E F, in a/c mode. Warm-up ambient temperature probe with fingers or heat gun. Push, hold temp. Decrease/increase buttons simultaneously. Display will read 40F if probe is defective. Disconnect the controller, check for continuity across black probe leads. Check resistance of thermistor. Remedy a) If CL, go to step 2. b) If OP, repair connections or wiring to preset thermostat. c) Replace preset thermostat.
a) Verify if compressor clutch will pull in or not. b) If not go to step 3. a) If display reads 49F, at room temperature, replace thermistor. b) Repair connections/wiring. c) If 10K ohms +/- 20%, thermistor is good. If 100K-1M ohms, replace thermistor.
3. Opened ambient cab temperature probe (thermistor)
703
TROUBLESHOOTING
Notes:
1. Wire colors may vary with installation. Refer to the wiring schematic. 2. For 24V controllers, resistor (R17) must be clipped and removed from the circuit board. (Refer to figure below) If the resistor is not clipped on the 24V system, the controller display will light up, but the blower fan will not turn on.
3. For air conditioning systems that do not use an electric condenser, the blue and brown wires must be connected together, on the external harness. The brown wire must be connected to the battery voltage, or the EO error message will result. 4. Care must be taken during installation, not to pinch or cut wiring from the controller. Shorted wiring may result in damage to the controller. 5. Improper probe location of the evaporator coil thermostat sensor, or ambient cab temperature sensor, may cause short cycling of the compressor. 6. Eagle climate controllers are designed to use normally closed heat solenoid valves. 7. Disconnect the vehicle battery leads, if a machine is to be inactive, or put into storage, for a period of a week or more. The current drain from the controllers memory may result in a dead vehicle battery. An optional ignition relay may be installed to disable the controllers memory function, when the key switch is turned off.
704
TROUBLESHOOTING
WIRING DIAGRAM
NOTES: 1. Position the ambient temperature probe near waist high level, out of air flow and sun load. 2. Insert the sensing tube from present thermostat down into the evaporator coil, parallel to the coil face, between the 1st and 2nd rows, to a depth of the coil height minus 1 inch. Wire Chart CONNECTOR DETAIL
Scoket 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Size 10GA 18GA 18GA 18GA N/A 18GA 14GA 16GA 18GA 14GA 18Ga 16GA 18GA 16GA 12GA N/A Color Red Red Black Red N/A Black Orange Dk. Green Dk. Blue Black Brown White Tan Yellow Black N/A Wire function Battery positive in evap coil thermostat in ambient thermistor in evap coil thermostat in Not used ambient thermistor in Fan positive out Clutch out Ignition switch in Fan negative out Condenser blown fuse in Heat solenoid out Pressure switch detect in Condenser fan relay out Battery negative in Not used
705
30 DISASSEMBLY AND ASSEMBLY

CONTENTS
METHOD OF USING MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5 PRECAUTIONS WHEN CARRYING OUT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. Precautions when carrying out removal work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. Precautions when carrying out installation work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. Precautions when completing the operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6 30-6 30-7 30-8
SPECIAL TOOL LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-9 STARTING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-11 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-11 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-11 ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-12 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-12 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-12 FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-13 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-13 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-13 ENGINE OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-14 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-14 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-14 WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15 NOZZLE HOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16 THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17 TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-18 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-18 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-18 CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19 RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-23
30-1
DISASSEMBLY AND ASSEMBLY
TABLE OF CONTENTS
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31 ENGINE HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-32 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-32 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-33 EXHAUST MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-34 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-34 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-34 AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-35 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-35 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-35 TORQUE CONVERTER CHARGING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-36 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-36 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-36 TORQUE CONVERTER, TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-37 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-37 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-44 TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-45 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-45 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-47 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY OF PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY OF PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION CLUTCH PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I. DISASSEMBLY OF 1ST, REVERSE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II. DISASSEMBLY OF FORWARD, 2ND CLUTCH PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ill. DISASSEMBLY OF 3RD, 4TH CLUTCH PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY OF CLUTCH PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l. ASSEMBLY OF 1ST, REVERSE CLUTCH PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II. ASSEMBLY OF FORWARD, 2ND CLUTCH PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ill. ASSEMBLY OF 3RD, 4TH CLUTCH PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-49 30-49 30-58 30-60 30-63 30-75 30-75 30-77 30-79 30-81 30-81 30-86 30-90
TRANSMISSION CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-95 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-95 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-96 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-98 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-100 TRANSMISSION SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-102 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-102 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-102 TRANSMISSION ACCUMULATOR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-103 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-103 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-104 DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-105 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-105 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-107
30-2
TABLE OF CONTENTS
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-109 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-109 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-110 REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-111 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-111 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-115 DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-120 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-120 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-124 AXLE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-134 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-134 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-139 CENTER HINGE PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-147 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-147 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-155 PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-164 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-164 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-165 STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIN CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-166 30-166 30-168 30-169 30-172 30-177 30-177 30-179 30-180 30-182
STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-184 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-184 BRAKE BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-186 30-186 30-188 30-189 30-192
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-197 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-197 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-199 HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-200 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-200 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-201 HYDRAULIC FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-202 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-202 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-202 HYDRAULIC STEERING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-203 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-203 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-204
30-3
TABLE OF CONTENTS
BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-205 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-205 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-206 BOOM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-207 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-207 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-208 HYDRAULIC CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-209 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-209 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-211 WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-213 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-213 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-216 FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-219 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-219 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-220 COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL OF LEFT AND RIGHT COUNTERWEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION OF LEFT AND RIGHT COUNTERWEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL OF REAR COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION OF REAR COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-221 30-221 30-221 30-221 30-222
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-223 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-223 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-223
30-4
METHOD OF USING MANUAL
METHOD OF USING MANUAL

1.When removing or installing unit assemblies 1. 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. 2. Any special techniques applying only to the installation procedure are marked , and the 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 OF ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Title of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions related to safety when carrying out the operation 1. XXXX (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step in operation i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technique or important point to remember when removing XXXX (1) 2. - - - - (2) . . . . . . . . . . . . . . . . . . . . . . . . . indicates that a technique is listed for use during installation 3. 9 9 9 9 assembly (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quantity of oil or water drained
INSTALLATION OF ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Title of operation

! i ! i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carry out installation in the reverse order of removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technique used during installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technique or important point to remember when installing - - - - (2) Adding water, oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step in operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Point to remember when adding water or oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quantity when filling with oil and water
2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given together as PRECAUTION WHEN CARRYING OUT OPERATION, so be sure to follow these precautions when carrying out the operation. 3.Listing of special tools (1) For details of the description, part number, and quantity of any tools (A1, etc.) that appear in the operation procedure, see the SPECIAL TOOL LIST given in the manual.
30-5
PRECAUTION WHEN CARRYING OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] 1. Precautions when carrying out removal work ! ! ! ! ! ! ! ! ! ! If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering. When draining oil, prepare a container of adequate size to catch the oil. Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. 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.
i Precautions when handling piping during disassembling Fit the following blind plugs into the piping after disconnecting it during disassembly operations. 1. Hoses and tubes using sleeve nuts Nominal Plug (nut end) Sleeve nut (elbow end) Use the two items below as a set number 02 03 04 05 06 10 12 07376-50210 07376-50315 07376-50422 07376-50522 07376-50628 07376-51034 07376-51234 07221-20210 (Nut), 07222-00210 (Plug) 07221-20315 (Nut), 07222-00312 (Plug) 07221-20422 (Nut), 07222-00414 (Plug) 07221-20522 (Nut), 07222-00515 (Plug) 07221-20628 (Nut), 07222-00616 (Plug) 07221-21034 (Nut), 07222-01018 (Plug) 07221-21234 (Nut), 07222-01219 (Plug)
2. Split flange type hoses and tubes Nominal Flange (hose end) number 04 05 07379-00400 07379-00500
Sleeve head (tube end) 07378-10400 07378-10500
Split flange 07371-30400 07371-30500
30-6
3. If the part is not under hydraulic pressure, the following corks can be used. Dimensions Nominal Part Number number D d L 06 08 10 12 14 16 18 20 22 24 27 07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430 07049-02734 6 8 10 12 14 16 18 20 22 24 27 5 6.5 8.5 10 11.5 13.5 15 17 18.5 20 22.5 8 11 12 15 18 20 22 25 28 30 34
2. Precautions when carrying out installation work ! ! ! ! ! ! ! ! ! ! ! ! ! i 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 anti-friction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eye bolts, check that there is no deformation or deterioration, screw them fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side. When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: 1. Start the engine and run at low idle. 2. Operate the work equipment control lever to operate the hydraulic cylinder 4 - 5 times, stopping 100 mm from end of its stroke. 3. Next, operate all hydraulic cylinders 3 - 4 times to the end of their stroke, then stop the engine and loosen air bleed plug (1) to bleed the air from the hydraulic tank. After bleeding the air , tighten plug (1). 4. Following this raise the engine speed , repeat the procedure in Step 3) to bleed the air. Repeat this operation until no more air comes out from the plug hole. Plug: 11.3 1.5 Nm (1.15 0.15 kgm) 5. After doing this, run the engine at normal speed. i When using the machine for the first time after repair or long storage, follow the same procedure.
30-7
3. Precautions when completing the operations ! ! ! i ! If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the engine to circulate the coolant through the system. Then check the coolant 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 air from the system after reassembling the parts. For details, see TESTING AND ADJUSTING, Bleeding air. Add the specified amount of grease (molybdenum disulfide grease) to the work equipment related parts.
30-8
SPECIAL TOOL LIST
SPECIAL TOOL LIST

Nature of work Disassembly, assembly of transmission assembly Symbol A B 1 2 D Disassembly, assembly of transmission clutch pack assembly E 3 4 5 1 2 A Part no. Part Name Qty. 2 1 1 1 1 5 2 1 1 1 1 5 5 5 5 1 1 1 1 1 2 2 2 4 6 1 1 1 1 Wrench assembly 790-102-3820 790-102-1320 C 790-302-1290 Socket (with across flats: 70 mm) Socket (with across flats: 60 mm) 1 1 1 1 Steering Boom, Bucket Bucket Boom Steering Removal, installation of nylon nut Removal, installation of round head For adjusting shim Holder for oil seal when press fitting oil seal Removal of axle shaft bearing Checking for oil leaks Insertion of brake piston F-R 1st - 4th Positioning bearing of differential pinion Jig for setting piston seal Disassembly, assembly of clutch assembly Remarks Removal, installation of rear housing Removal, installation of clutch assembly 793-305-1600 Lifting tool 793-310-2100 Lifting tool 793-310-1300 Stand 793-310-1330 Plate 793-310-1360 Bar 793-310-1370 Pin 01541-01260 Nut 793-415-1110 Lifting tool 793-415-1120 Lifting tool 793-510-1600 Mandrel 793-520-2202 Installer 793-520-2110 ! Plate Disassembly, assembly of differential assembly B 01010-31640 ! Bolt 01010-31680 ! Bolt 01643-31645 ! Washer 799-101-5002 Hydraulic tester kit C A Disassembly of axle housing 1 A 2 3 1 Assembly of axle housing B C 2 3 793-605-1001 Brake tester 790-101-1102 Pump assembly 790-101-3100 Puller assembly 790-101-3110 ! Puller 790-101-3120 ! Bolt 790-101-3130 ! Nut 793-520-2730 Seal support 793-520-2740 Bolt 01016-30840 Adjustment bolt 793-510-1500 Holder 790-502-1003 or Cylinder repair stand 790-502-2000 790-101-1102 Pump 790-330-1100 Disassembly, assembly of hydraulic cylinder B
commercially Socket (with across available flats: 46 mm)
30-9

Nature of work Symbol Part no. 790-101-5021 Grip 01010-50816 Bolt D 790-201-1811 Push tool 790-201-1781 Push tool 790-201-1741 Push tool 790-201-5021 Grip 01010-50816 Bolt E Disassembly, assembly of hydraulic cylinder 1 790-201-1620 Plate 790-201-1590 Plate 790-201-1550 plate 790-720-1000 Expander 796-720-1660 Ring 07281-01159 Clamp F 2 796-720-1630 Ring 07281-00709 Clamp 796-720-1670 Ring 07281-01279 Clamp Note: Part Name Qty. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
SPECIAL TOOL LIST

Remarks Press fitting of coil bushing Kit Part no.: 790-201-1702 Boom Bucket Steering Insertion of dust seal Kit Part No.: 790-201-1500 Boom Bucket Steering Installation of piston ring Boom, bucket Steering Bucket
As for special tool of disassembly and assembly of engine components (engine oil cooler, fuel injection pump, turbocharger, nozzle holder, thermostats, cylinder head etc. ) Refer to ENGINE SHOP MANUAL
30-10
STARTING MOTOR
STARTING MOTOR
WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. WARNING! Disconnect the cable from the negative (-) terminal of the battery.
REMOVAL 1. Disconnect negative (-) terminal (1) of the battery located behind the radiator grille. 2. Open engine hood side cover and lock in position. 3. Remove washer tank and bracket (2) and two mounting bolts with nuts (3) from frame and position out of way. 4. Disconnect cable (4) and harness wires (5) and (6). 5. Remove ground connection (7) with two mounting bolts (8), then remove starting motor assembly.
INSTALLATION Install starting motor assembly in reverse order of removal Mounting bolt: 32 4 lbf.ft (43 6 Nm) (4.38 0.61 kgm)
30-11
ALTERNATOR
ALTERNATOR
REMOVAL 1. Disconnect negative (-) terminal (1) of the battery located behind the radiator grille. 2. Open engine hood side cover and lock in position. 3. Remove 5 mounting bolts of left fan guard half (2) and rotate down out of way. 4. Install 3/8" drive breaker bar (3) in belt tensioner. Lift up on breaker bar and remove belt (4) from alternator pulley. 5. Remove output (5) and ground (6) leads from back of alternator. 6. Remove bottom mounting bolt (7). Supporting the alternator, remove top mounting bolt (8) and remove the alternator from the machine.
INSTALLATION Install starting motor assembly in reverse order of removal Mounting bolt: 32 4 lbf.ft (43 6 Nm) (4.38 0.61 kgm)
30-12
FUEL INJECTION PUMP
FUEL INJECTION PUMP

WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. REMOVAL 1. Disconnect negative (-) terminal (1) of the battery located behind the radiator grille. Open engine hood right side cover and lock in position (3). Disconnect the throttle linkage (4). Disconnect the fuel inlet line (filter to pump line) (5). Disconnect the return (6) and drain lines (7). Disconnect the electrical wiring (8). Disconnect the six fuel lines (pump to injectors) (9). Remove the Fuel Injection Pump. Refer to ENGINE SHOP MANUAL.
2. 3. 4. 5. 6. 7. 8.
INSTALLATION Install fuel injection pump assembly in reverse order of removal
30-13
ENGINE OIL COOLER
ENGINE OIL COOLER

REMOVAL 1. Disconnect negative (-) terminal (1) of the battery located behind the radiator grille. 2. Open left gull wing side cover (2) on the engine hood and lock in position. 3. Drain the engine oil. Refer to OPERATIONAL & MAINTENANCE MANUAL. 4. Remove the alternator. Refer to ENGINE SHOP MANUAL. 5. Remove the turbocharger drain line (3). 6. Remove the Oil Filter. Refer to OPERATIONAL & MAINTENANCE MANUAL. 7. Remove the Engine Oil Cooler (4). Refer to ENGINE SHOP MANUAL.
INSTALLATION Install engine oil cooler in reverse order of removal.
30-14
WATER PUMP
WATER PUMP
WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. WARNING! Disconnect the cable from the negative (-) terminal (1) of the battery.
REMOVAL 1. Open engine hood left side cover and lock into position. 2. Drain water system (coolant) (2). Refer to OPERATION & MAINTENANCE MANUAL. Remove the Fan Belt from the Alternator and Belt Tennsioner. Refer to ALTERNATOR ASSEMBLY. Remove the alternator. Refer to ALTERNATOR ASSEMBLY. Remove the Water Pump (3). Refer to ENGINE SHOP MANUAL.
3.
4.
5.
INSTALLATION Install the water pump assembly in reverse order of removal. Refer to ENGINE SHOP MANUAL.
30-15
NOZZLE HOLDER
NOZZLE HOLDER
WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. REMOVAL 1. Remove hood. Refer to HOOD REMOVAL. 2. Remove air cleaner (1) and bracket (2). Refer to AIR CLEANER. 3. Remove muffler (3) and mount bracket (4). Refer to MUFFLER. NOTE: When the muffler bracket is removed, the air conditioner compressor and mount bracket comes off with it. 4. Remove turbocharger crossover tube (5) (air 5. Remove nozzel holder (6). Refer to ENGINE SHOP MANUAL. intake).
INSTALLATION Install nozzel holder in reverse order of removal. Refer to ENGINE SHOP MANUAL.
30-16
THERMOSTAT
THERMOSTAT
WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. REMOVAL 1. Drain water system of coolant (2). Refer to OPERATION & MAINTENANCE MANUAL. 2. Open engine hood, left side. 3. Disconnect screw clamp on thermostat and remove hose connection (3). 4. Remove thermostat. Refer to ENGINE SHOP MANUAL.
INSTALLATION Install thermostat in reverse order of removal. Refer to ENGINE SHOP MANUAL.
30-17
TURBOCHARGER
TURBOCHARGER
WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. REMOVAL 1. Open engine hood left side cover and lock into position (2). 2. Remove heat shield (3). 3. Disconnect muffler clamp (4), air intake clamp (5), oil drain line (6) and oil lube line (7). 4. Remove turbocharger. Refer to ENGINE SHOP MANUAL.
INSTALLATION Install turbocharger assembly in reverse order of removal. Refer to ENGINE SHOP MANUAL.
30-18
CYLINDER HEAD
CYLINDER HEAD
WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. REMOVAL 1. Remove hood. Refer to HOOD REMOVAL. 2. Remove air cleaner (1) and bracket (4). Refer to AIR CLEANER. 3. Remove muffler (3) and mount bracket (2). Refer to MUFFLER. NOTE: When the muffler bracket is removed, the air conditioner compressor and mount bracket comes off with it. 4. Remove turbocharger crossover tube (air intake). 5. Remove cylinder head. Refer to ENGINE SHOP MANUAL.
INSTALLATION Install cylinder head in reverse order of removal. Refer to ENGINE SHOP MANUAL.
30-19
RADIATOR
RADIATOR
WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. WARNING! Loosen the oil cap slowly to release the pressure inside the hydraulic tank. Then operate the control levers several times to release the remaining pressure in the hydraulic piping. REMOVAL 1. Engine hood and side covers. Refer to REMOVAL OF ENGINE HOOD. 2. DRAINING COOLANT Loosen radiator cap (1) to release internal pressure, and open drain valve (2) and drain coolant from system. When system is drained close the drain valve. If the coolant contains antifreeze, dispose of it properly. Coolant: 35R (9.2 US gals)
3. Fan guards. A) Remove left fan guard (3) and right fan guard (3A). Be careful not to damage radiator fins.
4. Rear cover. A) Remove cover (4) at the bottom rear of the radiator.
30-20

5. Removal of cooling lines. A) Close petcock (5) to shut off heater hose, remove lower radiator outlet tube (6) with hoses.
RADIATOR
B) Disconnect engine vent line (7), remove radiator inlet tube (8), and disconnect roading trans cooler line (9) from thermostat housing.
C) Disconnect torque converter cooler hoses (10) and (11) from radiator bottom tank. Radiator fan shroud may have to be disconnected from radiator and pushed aside to disconnect hoses (10) and (11).
6. Radiator removal. A) Disconnect radiator stay rod (12) at radiator, loosen at frame and rotate forward.
30-21

B) Install lifting eyes (13) and hook up hoist, remove radiator mounting bolts and rubber mounts (14), and lift radiator assembly from machine. Radiator: 110 lbs (50 kg)
RADIATOR
30-22

INSTALLATION Install radiator in reverse order of removal. Be careful not to damage the fins on the radiator assembly. Adjust so that the clearance between the shroud and fan is uniform. Install so that the clearance between fan and fan guard is uniform Temporarily tighten the mounting bolts and fix the position, then tighten fully. When installing the radiator, the difference in the clearance between the fan and radiator on the left and right must be within 3mm (0.118"). Install so that the clearance between the radiator fins and the front face of the fan is uniform at the top, bottom, left, and right. The difference between the left and right in the position of the radiator in the front-to-rear direction must be within 5mm ((0.197"). Tighten hoses without twisting. Radiator mounting bolts: 82 8 lbf.ft (112.8 9.8 Nm) (11.5 1.0 kgm) Radiator support mounting bolts: 82 8 lbf.ft (112.8 9.8 Nm) (11.5 1.0 kgm) Torque converter cooler hoses: 130 22 lbf.ft (176.4 29.4 Nm) (18.0 3.0 kgm)
RADIATOR
30-23
ENGINE
ENGINE
WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. WARNING! Loosen the oil cap slowly to release the pressure inside the hydraulic tank. Then operate the control levers several times to release the remaining pressure in the hydraulic piping. WARNING! Disconnect the cable from the negative (-) terminal of the battery. REMOVAL 1. Engine hood and side covers. Refer to REMOVAL OF ENGINE HOOD. 2. Radiator and piping. Refer to REMOVAL OF RADIATOR. 3. Machines with Air Conditioning. Note: There are shims (A) and (B) at bottom mounting bolt between welded spacer and compressor. When removing keep shims as they were removed. A) Disconnect wire (1) from harness at top of compressor, loosen lower mounting bolt (2) and adjusting bolt (3) allowing for removal of compressor belt (4).
B) Unclip compressor lines (5) at air cleaner, and cut tie straps (6). C) Remove hardware (2) and (7), keeping in mind the afore mentioned shims and position the compressor out of way.
30-24

4. Right side of engine. A) Disconnect fuel inlet hose (8) and fuel outlet hose (9) and remove muffler drain tube (10).
ENGINE
B) Disconnect the fuel cut-off sensor (11), oil pressure switch (12), and coolant lead (13). Unclamp harness at clamp (14).
C) Remove slow-blow fuse (15) from mounting bracket (16), open side door of fuse and disconnect harness lead (17). Replace screw, close door, and place fuse back in mounting bracket.
D) At intake manifold, disconnect heat switch cable (18) and unclamp at air cleaner bracket (19), and remove cable from frame relay (20).
30-25

E) Unclip engine harness from floor harness (21).
ENGINE
F) Unclip harness and cranking motor cable at throttle bracket (22) at rear of engine (23), and shut off petcock (24), and disconnect heater hose (25).
G) Disconnect throttle linkage rod at fuel pump lever (26), remove throttle bracket (22) and position assembly out of way.
H) Remove remote engine oil drain bracket (27) from trunnion.
30-26

5. Left side of engine. A) Disconnect fuel sending unit (28), remove output (29), ground (30) leads from back of alternator, and water temperature switch (31).
ENGINE
B) Disconnect harness ground cable (32), remove starter relay and bracket (33) from engine block.
C) Cut tie straps (34), remove mounting bolts from washer tank and bracket (35), and position out of way. Disconnect cranking motor leads (36) and (37).
D) Slide harness connector (38) from flywheel housing bracket and disconnect and remove engine harness. Disconnect cranking motor ground cable (39) at frame.
30-27

E) Remove air conditioning dryer and bracket (40) from frame and position out of way.
ENGINE
F) Disconnect heater hose (41) pass through clips (42) and position out of way.
6. Top of engine. A) Remove turbo-charger shield (43), and loosen muffler clamp (44) at turbo-charger.
B) Remove band (45), remove center mounting bolts (46), and lift off exhaust muffler (47).
30-28

C) Loosen clamps (48) on hose between air cleaner and turbocharger, remove bands (49), and lift off air cleaner (50).
ENGINE
7. Engine assembly. A) Set jack stand (51) under transmission (52) and adjust the height properly and set the stand into position.
B) Hook hoist to rear lifting eye (53), to front lifting eye (54), and to air conditioning compressor mounting bracket (55).
C) Remove torque converter housing to flywheel housing bolts (56).
30-29

D) Remove rear engine mounting bolts (57) from each side.
ENGINE
E) Using hoist guide the engine rearward to clear the torque converter housing, and lift from the machine. Be careful not to damage the fuel tank breather tube and the engine oil drain hose when removing the engine. Engine assembly: 1190 lbs (540 kg)
30-30

INSTALLATION 1. Install the engine assembly in reverse order of removal. Check that there is an o-ring installed to the mating face of the torque converter. Lubricate the outside circumference of O-ring: Soapy water When connecting the engine and torque converter, adjust the height so that the torque converter pilot goes in smoothly. Never use force when connecting. When assembling rear engine mounting bolts never use grease, oil, or soapy water on the rubber mounts. Mounting bolt: 550 61 lb/ft 745 83 Nm 76 8.5 kgm (Width across flats: 32mm) 2. Installation of radiator, refer to REMOVAL AND INSTALLATION OF RADIATOR. 3. Installation of engine hood, refer to REMOVAL AND INSTALLATION OF THE ENGINE HOOD. 4. Refilling with oils and coolant. Tighten radiator drain valve and open the two heater hose petcocks on the engine, and add the engine coolant through the radiator filler neck to the specified level. Check and if necessary add transmission oil through the oil filler neck on the transmission to the specified level. Check and if necessary add engine oil through the oil filler neck on the engine to the specified level. Run the engine (to operating temperature) and heater to circulate the oil and engine coolant through the system. Then check the engine coolant and oil, and the transmission oil levels again. Add oil or coolant if required.
ENGINE
30-31
ENGINE HOOD
ENGINE HOOD
REMOVAL 1. Remove pre-cleaner assembly (1) from hood, cap opening of air cleaner to prevent dirt from entering.
Install lifting eyes (A) and chain (B) on top of hood (2).
3. Remove overflow hose (3) for radiator sub-tank at radiator neck.
4. Open engine hood side covers and radiator grille and lock in position. Remove six engine hood mounting bolts (4) and four fender mounting bolts (5).
30-32

5. Disconnect wiring connectors (6) and (7) from engine hood.
ENGINE HOOD
Disconnect neg. (-) and (+) battery cables (8) and (9), and Unclip crossover light harness (10).
7. Remove the grease gun inside the left side of the engine compartment, then remove the clips (11).
8. Lift engine hood (2) approximately 6 in. (150 mm), check that there is no interference, then lift off slowly. Be careful not to hit the cab or rear wiper arm.
INSTALLATION Install engine hood in reverse order of removal. Engine hood: 68 lbs (150 kg)
30-33
EXHAUST MUFFLER
EXHAUST MUFFLER
REMOVAL 1. Engine hood and side covers. Refer to REMOVAL OF ENGINE HOOD.
2. Exhaust muffler. A) Remove turbo-charger shield (1), and loosen muffler clamp (2) at turbo-charger.
B) Remove band (3), remove center mounting bolts (4), and lift off exhaust muffler (5).
INSTALLATION 1. Install the exhaust muffler in reverse order of removal.
30-34
AIR CLEANER
AIR CLEANER
REMOVAL 1. Engine hood and side covers. Refer to REMOVAL OF ENGINE HOOD.
2. Air cleaner. A) Loosen clamps (1) on hose between air cleaner and turbocharger, remove bands (2), and lift off air cleaner (3).
INSTALLATION 1. Install the air cleaner assembly in reverse order of removal.
30-35
TORQUE CONVERTER CHARGING PUMP

REMOVAL WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. 1. Cover, wiring 1) Remove cover (1) under left center fender. 2) Remove clamp and wiring clamp (2) of air conditioner hose. 2. Hydraulic piping 1) Disconnect hose (3) between transmission strainer and torque converter charging pump from torque converter charging pump. 2) Disconnect tube (4) between torque converter charging pump and filter from torque converter charging pump. 3. Torque converter charging pump Remove mounting bolts, then remove torque converter charging pump (5).
INSTALLATION ! Carry out installation in reverse order to removal. Tube flange mounting bolt: 66.2 7.4 Nm (6.75 0.75 kgm) Tube flange mounting bolt: 30.9 3.4 Nm (3.15 0.35 kgm) Mounting bolt: Be careful not to get the O-ring Caught when installing 66.2 7.4 Nm (6.75 0.75 kgm)
30-36
TORQUE CONVERTER, TRANSMISSION

REMOVAL WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. Remove cover (1) at the top of the hydraulic tank on the right side, then remove covers (2) on the left and right under the floor.
WARNING! 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. ! Loosen plug (3) to prevent the oil inside the hydraulic tank from flowing out. Disconnect the cable from the negative (-) terminal of the battery.
Machines equipped with air conditioner ! Release the gas at a point far from the compressor. Loosen the hose connection slightly to release the gas. 1. Draining oil Loosen drain plug (3-1) and drain transmission oil. Transmission oil: 28.0 R
2. Cover 1) Sling left ladder rail (4), then remove mounting bolts, and lift off together with center fender (5). Carry out the operation in the same way on the right side. When lifting off the ladder, be careful of the center of gravity. Be careful not to damage the cab glass.
30-37
2) Disconnect connector for left brake oil level sensor. 3) Remove brake oil tank mounting bracket (8) together with oil tank (7) from under floor. Leave the oil hose installed to the brake oil tank and tie it to the top surface of the rear frame with wire. ! For machines equipped with an air conditioner, it can be placed on top of the condenser. When carrying out this operation, do not disconnect the brake oil hose. Move it to the side and tie it temporarily with wire. 3. Electric wiring ! Disconnect following electric wiring from connector. ! Disconnect front wiring (9) and rear wiring (10) from connectors (1 1), (12), (13), (14), (15), (16), and (17). ! For machines with cab, disconnect wiring for cab from connector. ! Disconnect ground wiring (18) from rear frame. ! Disconnect transmission cut-off switch (19) and wiring connector (20). ! Remove wiring clamp and bracket (21) from rear frame (22). Fit tags to identify the wiring. 4. Brake booster 1) Remove locknut of ball joint (24) and brake linkage (23), and pull out linkage rod. 2) Set block under brake booster (25), then remove mounting bolts (26).
30-38

5. Fuel control cable
then remove bracket (28) together with control cable. For machines equipped with cab ! Disconnect the washer hose from the tank, then coil up and bend the end of the hose. ! After removing the hose, fit a blind plug in the washer tank.
6. Transmission valve wiring Disconnect connectors (33) of transmission valve wiring. Fit tags to identify the wiring.
7. Work equipment control cable Disconnect work equipment control cables (34) at valve end. Fit tags to the cables before disconnecting. Remove the cable clamp.
30-39
8. Parking brake cable 1) Disconnect parking brake cable (38) from lever, and remove bracket (40) from front face of transmission (39). After removing the cable, tie it temporarily to the bottom surface of the floor with wire. 2) Disconnect speedometer cable (41). 3) Remove transmission oil filler tube (42).
9. Steering piping 1) Remove hoses (44) and (45) from steering valve (43). 2) Disconnect hoses (47), (48), and (49) between steering valve (43) and priority valve.
3) Remove hose (50) between steering valve and hydraulic tank. Fit blind plugs after disconnecting the hoses.
30-40
10. Floor frame, cab assembly Sling floor frame and cab assembly (51), then remove mounting bolts, and lift off. When raising the floor frame and cab assembly, pull the brake booster out gradually from the mounting bracket, and lift the cab slowly. The brake hose is not disconnected, so be careful not to catch the brake booster. Check that there is no interference from the hoses and wiring, then lift it off. When raising the floor frame and cab assembly, lift slowly for approx 40-50 mm, stop and check that there is no interference, then continue to lift. Floor frame, cab assembly: 680 kg Floor frame assembly: 155 kg 11. Drive shafts 1) Disconnect center drive shaft (52) at transmission end. 2) Remove rear drive shaft (53). 12. Hydraulic, steering pump 1) Disconnect hose (55) between hydraulic, steering pump and priority valve at priority valve end. 2) Loosen clamp of hose (56) between hydraulic tank and hydraulic, steering pump, then disconnect at tank end. Remove hose clamp (56-1) between the main control valve and the hydraulic tank first. 3) Remove mounting bolts of hydraulic, steering pump (57), then remove.
30-41

13. Hydraulic piping
1) Disconnect drain hose (60) of brake booster at transmission end. 2) Disconnect hose (61) between priority valve and main control valve, then remove hose support bracket (62) from rear frame.
3) Disconnect hose (58) between main control valve and hydraulic tank, then disconnect hose clamp (59). 14. Torque converter, transmission 1) Disconnect hose (63) between transmission valve and cooler from transmission valve (64). 2) Disconnect hose (65) between transmission and cooler from elbow under rear housing of transmission (68). 3) Remove oil filler tube (66) from transmission.
30-42

4) Set hydraulic jack (1) under engine. Adjust the height properly and support the engine.
5) Remove left and right transmission mount bolts (67) and (67-1).
6) Sling torque converter and transmission (68), and remove bolt connecting to engine (69). Sling at two points.
7) Lift off torque converter and transmission (68). Check that there is no interference from the hoses and wiring, then lift off. Be extremely careful that the torque converter and transmission does not hit the rear frame when lifting off. Torque converter, transmission: 480 kg
30-43

Check that the O-ring is inserted securely in the mating surface of the torque converter. Outside circumference of O-ring: Soapy water

INSTALLATION ! Carry out installation in the reverse order to removal.
Bend the cotter pin securely.
Adjust the parking brake. For details, see TESTING AND ADJUSTING, Adjusting parking brake.
Mounting bolt: 277 32 Nm (28.25 3.25 kgm)
When connecting the engine and torque converter, adjust the height so that the torque converter pilot goes in smoothly. Never use force when connecting. Tighten the mounting bolts a little at a time on the left and right, and be careful not to damage the O-ring. Mounting bolt: 66.2 7.4 Nm (6.75 0.75 kgm)
Be careful of the direction of the yoke, and align the pilot portion correctly to install. Mounting bolt: 66.2 7.4 Nm (6.75 0.75 kgm)
! Refilling with oil 1 ) Tighten drain plug and add transmission oil through oil filler to the specified level. Transmission oil: 28R 2) Tighten plug and add hydraulic oil through oil filler to the specified level.
Install the hoses without twisting or interference.
To position the transmission, adjust with the adjustment screw to make clearance "a the specified value, then tighten the mounting bolts. When assembling the rubber, never use grease, oil, or soapy water. Clearance "a": 1 - 2 mm Mounting bolt: 745 83.4 Nm (76 8.5 kgm) (Width across flats: 32 mm)
Hydraulic oil: 80R Run the engine to circulate the oil through the system. Then check the oil level again.
30-44
TORQUE CONVERTER
TORQUE CONVERTER
DISASSEMBLY 1. Turbine case assembly 1) Remove stator shaft and pump assembly (2) from turbine and case assembly (3).
2) Disassemble turbine and case assembly as follows. I) Remove pilot (4). ii) Remove snap ring (5).
iii) Push boss portion of turbine (6) and remove from case (7).
iv) Remove bearing (8) from case.
30-45

2. Stator 1) Remove snap ring (9). 2) Remove stator (10). 3. Stator shaft Using forcing screws (1), push from stator shaft (11) end, and disconnect from pump assembly (12).
TORQUE CONVERTER
4. Gear Remove gear (13) from pump (14). 5 Bearing Remove bearing (15) from gear (13).
30-46
TORQUE CONVERTER
TORQUE CONVERTER
ASSEMBLY 1. Bearing Install bearing (15) to gear (13). 2. Gear Install gear (13) to pump (14). Mounting bolt: 66.2 7.4 Nm (6.75 0.75 kgm)
3. Stator shaft 1) Install seal ring (16) to stator shaft (11). Seal ring: Grease (G2-LI) Make the extension of the seal ring uniform. 2) Push inner race end of bearing, and install pump assembly (12) to stator shaft (11).
4. Stator 1) Install stator (10). 2) Install snap ring (9).
5. Turbine, case assembly 1) Assemble turbine and case assembly as follows. i) Install bearing (8) to case. Press fit until the ring contacts the case. ii) Push inner race of bearing and install turbine (6) to case (7).
30-47

iii) Install snap ring (5). iv) Install pilot (4). Mounting bolt: Thread tightener (LT-2) Mounting bolt: 66.2 7.4 NM (6.75 0.75 kgm)
TORQUE CONVERTER
2) Install stator shaft and pump assembly (2) to turbine and case assembly (3). Mounting bolt: Thread tightener (LT-2) Mounting bolt: 30.9 3.4 NM (3.15 0.35 kgm)
30-48
TRANSMISSION
TRANSMISSION
DISASSEMBLY ! !
After removing transmission assembly (9) from the chassis, remove the left and right mount brackets first. Remove the PTO lubrication tube.
1. Hydraulic piping Disconnect hoses (1) and (2), and each tube. Be careful not to crush tube (3) during the operation. After removing the tubes, fit a cover to protect the thread.
2. Oil filter 1) After removing each hose, remove mounting bracket (5) of filter (4) with filter still installed.
2) Remove O-ring (8), cover (7), and speedometer pickup port assembly (6) of idler countershaft portion. After removing the speedometer pickup port assembly, be careful not to damage the gear portion of the idler countershaft.
30-49

3) Raise transmission assembly (9), and install to assembly stand. After installing the transmission assembly to the assembly stand, turn over, then set a support under the REVERSE and lst side. (To keep it parallel)
TRANSMISSION
3. Strainer, rear coupling 1) Pull out rear coupling (10). Fit a cover to prevent dirt or dust from entering. 2) Remove hose and tube (11) between strainer and pump.
4. Charging pump After removing hoses, remove charging pump assembly (12) and O-ring.
5. Transmission control valve 1) Remove accumulator valve (13). 2) Sling transmission control valve (14), then remove mounting bolts and lift off. After removing the mounting bolts, fit 2 guide bolts in the bolt holes. Transmission control valve: 46 kg
30-50

6. Rear housing 1) Install tool A to rear housing (15), then sling. Install tool A securely to prevent it from coming off.
TRANSMISSION
2) Using forcing screws, raise rear housing(15), then use tool A to lift off. Remove slowly and be careful not to damage the seal ring. When removing, install guide bolts to front housing (16) and lift off horizontally. Rear housing, torque converter assembly: .160 kg
7. Torque converter Lift off torque converter (17) from rear housing (15). Before removing, make match marks on the housing and torque converter mating face with a felt pen. When turning over the rear housing, remove pilot cap (18) or set the housing on blocks. Torque converter: 35 kg
30-51

8. Pump (torque converter, work equipment) 1) Remove snap ring (19) at torque converter pump mount.
TRANSMISSION
2) Turn over rear housing (15), and remove snap ring (21) of pump gear (20), then remove ring washer (22) and split spacer (23).
3) Insert screwdriver into stepped portion between rear housing (15) and shaft (24), then lever with screwdriver, push shaft down and pull it out.
30-52

4) Remove bearing (25) from shaft (24). Carry out the operation in the same way at the work equipment hydraulic pump end.
TRANSMISSION
9. Seal ring 1) Remove seal ring (26) from each clutch shaft. 2) Remove input shaft (27).
10. REVERSE, lst clutch assembly 1) Install tool B to REVERSE and lst clutch assembly (28). 2) Using tool B, lift off REVERSE and lst clutch assembly (28). Be careful not to hit the other gears when removing. REVERSE, lst clutch assembly: 30 kg
11. FORWARD, 2nd clutch assembly 1) Install tool B to FORWARD and 2nd clutch assembly (29).
30-53

2) Using tool B, lift off FORWARD and 2nd clutch assembly (29). When doing this, 3rd, 4th clutch assembly (30) and the gear are engaged, so pull up each part in turn to a point where the bearing comes out from the front housing. FORWARD, 2nd clutch assembly: 37 kg
TRANSMISSION
3) When bearing of 3rd, 4th clutch assembly (30) comes out from housing, pull to output shaft end and tie with wire. WARNING! Be careful not to get your fingers caught between the gear and housing when carrying out this operation.
12. 3rd, 4th clutch assembly 1) Install tool B to 3rd and 4th clutch assembly (30). Install the lifting tool before removing the wire. 2) Using tool B, lift off 3rd and 4th clutch assembly (30). 3rd, 4th clutch assembly: 42 kg
13. Idler countershaft assembly 1) Remove idler countershaft (31) from front housing (16).
30-54

2) Remove bearings (32) and (33), and gears (34) and (35) from shaft (31). If speedometer worm gear (36) is installed, remove it before carrying out the operation.
TRANSMISSION
14. Rear dust seal, oil seal Remove dust seal (37) and oil seal (38). 15. Coupling Remove mounting bolts, then remove front coupling (39), holder (40), and O-ring.
16. Parking brake assembly 1) Turn over front housing (16), and set support stand under housing. 2) Remove plug of portion "a" at parking brake front housing end, and be sure to assemble set bolt (I for securing piston. Set bolt for securing piston: P = 1.25, M = 8, L = 35 Washer: 01643-30825
3) Remove housing mounting bolts (42). Install a guide bolt to prevent the housing from failing. Before removing the parking brake assembly, sling the output gear to prevent the output shaft bearing cone from coming out from the bearing cup.
30-55

4) Tighten 2 forcing screws in forcing screw hole, and remove housing and piston assembly (43). Check that a set bolt is installed to hold the part in position. Using housing mounting bolts as forcing screws.
TRANSMISSION
5) Loosen mounting bolts of parking brake retainer assembly (44), and pull out left and right shims (45). For reference when installing, check the number and thickness of the shims.
6) Remove hub spline (46), then remove parking brake retainer assembly (44).
17. Output shaft gear 1) Loosen mounting bolts of gear cover (47) and leave them fitted temporarily, then turn over front housing (16).
30-56

2) Remove mounting bolt (48), then remove gear cover (47) from bottom of housing. WARNING! Be careful not to get your fingers caught between the gear and housing.
TRANSMISSION
3) Hold spline portion of output shaft gear assembly (49) and pull up. WARNING! Be extremely careful not to get your fingers caught between the gear and housing (16) when removing. Clearance (one side) between gear and housing: Approx. 20 mm If there is oil on the output shaft spline, wipe it off completely and be extremely careful when removing. 4) Remove bearing cone (51), snap ring (52), gear (53), and bearing cone (54) from shaft (50) in order.
18. Bearing cup Remove bearing cup of front housing with puller. Do not remove unless necessary.
30-57

DISASSEMBLY OF PARKING BRAKE
TRANSMISSION
1. Plate, disc 1) Remove holder bolts (6) from retainer assembly (44).
2) Remove separator plate (7), wave spring (8), and disc (9).
2. End plate Remove end plate (10), then remove hub spline (11).
3. Retainer Turn over retainer (4), and remove bearing cup (12) with puller.
30-58

4. Housing Remove 2 set bolts 03 for securing piston, then remove piston (13) and balls (14). If it is necessary to disassemble the lever portion, remove lock bolt (15), check the match marks on inner lever (16) and outer lever (17), then pull out the inner lever, and remove bearings (18) and oil seal (19).
TRANSMISSION
30-59

ASSEMBLY OF PARKING BRAKE 1. Housing 1) Press fit oil seal (20) and dust seal (21) to housing (5). Press-fitting dimension "a": 25.8 1.0 mm Press-fitting dimension "b": 18.3 1.0 mm Lip of oil seal: Grease (G2-LI) Coat with grease when assembling the housing. 2) Press fit needle bearing (18) and oil seal (19) to housing (5) to specified dimensions. Needle bearing press-fitting dimension c: 38.5 0.15 mm (lst) Needle bearing press-fitting dimension "d": 18.0 0.5 mm (2nd) Oil seal press-fitting dimension "e": 7.5 0.3 mm Lip of oil seal: Grease (G2-LI) 3) Insert outside lever (17) from oil seal end. Clean and remove all oil and grease from the bolt hole of the outside lever. 4) Align with match mark and assemble inside lever (16).
TRANSMISSION
5) Tighten lock bolt (15). Clean and remove all oil and grease from lock bolt and bolt hole. Be sure to assemble the washer. Lock bolt: Thread tightener (LT-2) Lock bolt: 30.9 3.4 Nm (3.15 0.35 kgm)
30-60

6) Fit balls (14) in groove of housing (5), install piston (13) from top, then temporarily tighten 2 set bolts (3), for securing piston. Assemble temporarily to prevent the piston from failing out during assembly. Set bolt for securing piston: P = 1.25, M = 8, L = 35
TRANSMISSION
2. Retainer Press fit bearing cup (12) to retainer (4). After press fitting the cup, check that there is no clearance at portion "a".
3. End plate Turn over retainer and assemble end plate (10), then assemble hub spline (11) to center. Use the hub spline as a guide when assembling the disc.
30-61

4. Separator plate, disc 1) Assemble separator plate (7), wave spring (8), and disc (9) in order in turn. Soak disc (9) in clean transmission oil for at least 2 minutes before assembling. Use one spring. Insert pins (22) into the guide of the separator plate spline.
TRANSMISSION
2) Tighten holder bolt (6) of separator plate (7) to retainer (4). Remove all oil and grease from the bolt thread and bolt hole. Holder bolt: Thread tightener (LT-2) Holder bolt: 53.9 19.6 Nm (5.5 2.0 kgm)
5. Brake housing, retainer Assemble temporarily parking brake retainer assembly (44) and parking brake housing and piston (43). When assembling housing and piston (43), do not remove the 2 set bolts (3) for holding the piston.
30-62
TRANSMISSION
TRANSMISSION
ASSEMBLY Press fit the oil seal and dust seal before assembling each clutch assembly. Press fit the bearing cup fully to the stepped portion of the housing so that there is no clearance. Keep the front housing horizontal. 1. Bearing cup Press fit bearing cup (55) to front housing (16). 2. Output shaft gear 1) Press fit bearing cone (54) to shaft (50), assemble gear (53) and snap ring (52), then press fit bearing cone (51). To prevent improper adjustment of the end play, press fit the cone securely up to the shoulder of the shaft. Fit the snap ring securely in the shaft groove.
2) Assemble output shaft and gear assembly (49 )to bearing cup portion of front housing (16). WARNING! Be careful not to get your fingers caught between the gear and housing when carrying out this operation. Clearance (one side) between gear and housing: Approx. 20 mm If there is oil on the output shaft spline, wipe it off completely and be extremely careful when assembling.
3) Insert gear cover (47) from under housing, rotate gear cover a half turn and align mounting bolt holes. WARNING! Be careful not to get your fingers caught between the gear and housing when carrying out this operation.
30-63

4) Remove all oil and grease from mounting bolt (48) and bolt hole, coat thread of mounting bolt of gear cover (47) with gasket sealant, then tighten. Mounting bolt: Thread tightener (LT-2) Mounting bolt: 110.3 12.3 Nm (1 1.25 1.25 kgm)
TRANSMISSION
3. Adjusting rotating torque of bearing 1) Assemble O-ring (44-1) to parking brake retainer assembly (44), and coat outside circumference thinly with grease. O-ring outside circumference: Grease G2-LI) 2) Turn over front housing (16), and install guide bolt, align with guide bolt, assemble brake retainer assembly (44), and temporarily assemble mounting bolts. When doing this, check that the bearing cone is properly fitted inside bearing cup a", then assemble.
3) Insert desired shim (45) from left and right of parking brake retainer assembly (44), then tighten mounting bolts. Mounting bolt: 110.3 12.3 Nm (1 1.25 1.25 kgm) Do not install the hub spline until Step 6).
30-64

To settle the bearing, rotate the shaft while tightening. After tightening, hit the end face of the shaft several times with a plastic hammer. Coat the bearing thoroughly with oil. Standard shim thickness "a": 0.85 0.83 mm Bearing: Transmission oil 4) Tighten coupling mounting bolts to shaft (50), then measure rotating torque. Rotating torque: 0.10 - 1.0 Nm (0.01 - 1.0 kgm) If no small torque wrench is available, it is also possible to measure as follows. Fit measurement plate (56) to shaft (50), tighten the coupling mounting bolts, then install a push-pull scale to the tip of plate (56), and carry out the measurement. ! Plate length : 100 mm ! Push-pull scale reading: 1.0 -9.8 NM (0.1 - 1.0 kgm) When measuring the rotating torque, do not measure at the beginning of the movement. Measure the torque when the shaft is rotating. If the rotating torque is not within the standard value, add or remove shims to adjust again. If the rotating torque is within the standard value, check that the end plate is "0. 5) Insert selected shim (45) from left and right of parking brake retainer assembly (44), then tighten mounting bolts uniformly. Insert the thim shims in the middle, and the thick shims on the outside when assembling. Mounting bolt: 110.3 12.3 Nm (1 1.25 1.25 kgm) 6) Align with parking brake disc spline, and assemble hub spline (46) to output shaft (50). Use a screwdriver to align the discipline. If the spline is not aligned, rotate lightly while assembling. Never push with force.
TRANSMISSION
30-65

4. Parking brake assembly 1) Assemble new gasket to mounting surface "b" for housing and piston assembly on parking brake retainer assembly (44).
TRANSMISSION
2) Align housing and piston assembly (43) with guide bolt and assemble. Check that the lock set bolt is assembled. When assembling, be careful not to damage the oil seal lip.
3) Tighten mounting bolts (42) of housing and piston assembly (43) on diametrically opposite sides. Mounting bolt: 110.3 12.3 Nm (1 1.25 1.25 kgm)
4) Remove lock set bolt and install plugs (41-1).
30-66

5. Coupling Coat oil seal lip portion thinly with grease, assemble coupling (39), then tighten O-ring (57), holder (40), and mounting bolt (58). Lip of oil seal: Grease (G2-LI) Mounting bolt: 277 32 NM. Slide the coupling several times to prevent the oil seal lip from turning over. Insert the O-ring into the shaft groove, and be careful not to get it caught. Check that the lock set bolt has been removed and the plug has been assembled in its place. 6. Rear oil seal, dust seal Turn over front housing (16), then press fit oil seal (38) and dust seal (37). Lip of oil seal: Grease (G2-LI) Press-fitting dimension "a": 29 1 mm Press-fitting dimension "b": 21.5 1.0 mm
TRANSMISSION
7. Idler countershaft 1) Assemble to shaft (31) so that oil groove of gear (34) is on inside, then press fit bearing (32). 2) Assemble to shaft (31) so that oil groove of gear (35) is on inside, then press fit bearing (33). Press fit the bearing securely to the face of the gear.
3) Assemble speedometer worm gear (36) to spline of shaft (31), then tighten mounting bolt (59). Remove all oil and grease from the mounting bolts and bolt holes. Mounting bolt: Thread tightener (LT-2) Mounting bolt: 30.9 3.4 Nm (3.15 0.35 kgm)
30-67

4) Assemble idler countershaft (31) to front housing (16). When assembling, be careful not to damage the speedometer worm gear.
TRANSMISSION
8. 3rd, 4th clutch assembly Using tool B, assemble 3rd and 4th clutch assembly (30) to housing, then move it towards output shaft end. Secure with wire in the same way as when disassembling. Do not fit the bearing at the bottom of the clutch into position.
9. FORWARD, 2nd clutch assembly 1) Using tool B, raise FORWARD and 2nd clutch assembly (29). Be careful that the stopper pin does not come out. 2) Mesh gear of 3rd, 4th clutch assembly (30) with gear of FORWARD, 2nd clutch assembly (29), then lower slowly. Do not fit the bearing at the bottom of the clutch into position.
WARNING! Be careful not to get your fingers caught in the gear.
3) After checking that each gear is engaged, press fit bearing at bottom of 3rd, 4th clutch assembly (30) to front housing. Check the meshing of each gear when press fitting the bearing. When doing this, the 3rd, 4th clutch gear and FORWARD, 2nd clutch gear must be meshed.
30-68

4) Press fit bottom bearing of FORWARD and 2nd clutch assembly (29) to front housing portion. Coat the bearing press-fitting portion of the front housing thinly with transmission oil. Bearing press-fitting portion: Transmission oil
TRANSMISSION
10. REVERSE, 1st clutch assembly Using tool B, press fit bottom bearing of REVERSE and 1st clutch assembly (28) to front housing. WARNING! Be careful not to get your fingers caught in the gear.
11. Seal ring 1) Press fit bearing (60) to input shaft (27), assemble gear (61) so that oil groove of gear is on bearing side, then secure with snap ring (62). 2) Press fit bearing (63) to input shaft (27). Bearing press-fitting portion: Transmission oil Fit the snap ring securely in the groove.
3) Assemble input shaft (27) to front housing (16).
30-69

4) Install seal rings (26) to each clutch. Coat the seal ring thoroughly with oil, then install, and check that it rotates lightly by hand. Seal ring: Oil (transmission oil)
TRANSMISSION
12. Pump (Torque converter, work equipment) 1) Press fit bearing (25) to shaft (24). Press fit so that there is no clearance at the stepped portion of the shaft. 2) Assemble gear (20) and snap ring (21) inside rear housing (15), and insert shaft (24) from pump mount end.
Install the gear so that the oil groove of the gear is on the pump mount side. 3) Assemble ring washer (22) and split spacer (23) to stepped portion of shaft (24), then install snap ring (21).
30-70

4) Turn over rear housing (15), and assemble snap ring (19) at pump mount end.
TRANSMISSION
Carry out the operation in the same way at the work equipment pump end.
13. Torque converter Using eyebolts, raise rear housing (15), set to mount of torque converter, then tighten mounting bolts (64). Install guide pins to the torque converter. Align the mounting bolt hole properly, and be careful of the meshing with the pump gear when installing. When installing, align the match marks made during assembly. Mounting bolt: 112.8 9.8 Nm (1 1.5 1.0 kgm) 14. Rear housing 1) Using tool A, raise rear housing (15), and assemble to front housing (16). Install guide bolts (M = 10, P = 1.5, R 150 mm) to the front housing. Mating surface of housing: Gasket sealant (Three Bond 1207B) Be careful not to coat with too much gasket sealant, and be sure that the gasket sealant is not squeezed out to the inside of the case.
30-71

When inserting the input shaft, be careful not to let the tip of the shaft contact portion "a" of the housing. Lower slowly until it meshes with the spline of the input shaft. Mesh the spline of the input shaft securely. Be careful not to damage the seal rings of each shaft. Housing mounting bolt: 112.8 4.9 Nm (11.5 0.5 kgm) 2) Install pilot cap (18). Remove all oil and grease from the mounting bolts and bolt holes. Cap mounting bolt: Thread tightener (LT-2) Pilot cap mounting bolt: 66.2 7.4 Nm (6.75 0.75 kgm) Remove tool A from rear housing (15).
TRANSMISSION
15. Transmission control valve 1) Install guide bolt to mount of control valve(14). Clean and removeall oil and grease from the mounting bolt thread and mounting bolt hole of the control valve. 2) Align with guide bolt, assemble gasket, then fit control valve (14) temporarily. Use a new part for the gasket. 3) Coat mounting bolts of control valve (14) with thread tightener, and tighten. Tighten the mounting bolts on diametrically opposite sides, and be careful not to tighten too much. The length of the mounting bolts is different, so be careful when using them. (1): L = 120 mm (2): L = 130 mm (3): L = 135 mm (4) : L = 115 mm (5): L=100 mm Mounting bolt: Thread tightener (LT-2) Mounting bolt: 34.3 4.9 Nm (3.5 0.5 kgm)
30-72

4) Assemble O-ring to accumulator valve (13), and install to transmission. Remove all oil and grease from the mounting bolts and bolt holes. Mounting bolt: Thread tightener (LT-2) Mounting bolt: 34.3 4.9 Nm (3.5 0.5 kgm)
TRANSMISSION
16. Charging pump Assemble O-ring to charging pump (12), and install to transmission. Be careful not to get the O-ring caught. Mounting bolt: 66.2 7.4 Nm (6.75 0.75 kgm)
17. Strainer, rear coupling 1) Install hose and tube (11) between strainer and pump. Be careful not to get the O-ring caught. Mounting bolt: 66.2 7.4 Nm (6.75 0.75 kgm)
2) Align center line of key groove to align rear coupling (10) with front coupling. Coat the oil seal lip portion thinly with grease. Slide the coupling to prevent the oil seal lip from turning over. Lip of oil seal: Grease (G2-LI)
30-73

18. Oil filter 1) Sling transmission assembly (9), and lift off from assembly stand. When standing the transmission assembly, be careful of the center of gravity (lift off slowly). 2) Install O-ring (8) to idler countershaft portion, then install speedometer pickup port assembly (6) and cover (7). Be careful not to get the O-ring caught. Do not use force to mesh the gears. Mounting bolt: 110.3 12.3 Nm (1 1.25 1.25 kgm) 3) Install oil filter (4) and bracket (5). Mounting bolt: 112.8 9.8 Nm (11.5 1.0 kgm) 19. Hydraulic piping Install hoses (1) and (2) and tube. Be careful not to crush tube (3) during the operation. Install the hoses without twisting, and be careful not to get the O-rings caught. ! Connect PTO lubrication tube. ! Install mount brackets to left and right of transmission assembly (9). ! Wipe the bracket mounting surface clean. Mounting bolt: 277 31.9 Nm (28.25 3.25 kgm)
TRANSMISSION
30-74
TRANSMISSION CLUTCH PACK

I. DISASSEMBLY OF 1ST, REVERSE CLUTCH
WARNING! When setting the clutch pack on the stand, be careful not to let your hands slip because of oil, and be extremely careful not to get your fingers caught between the stand and the clutch pack Set with the lst side facing up, and set on tool D1.
1. Bearing Remove bearing (1) with puller.
2. Gear Remove spacer (2), thrust washer (3), gear (4), needle bearing (5), and thrust washer (6). 3. End plate 1) Install tools D2 and D3, tighten nut D5, and remove ring (7). Set the spacer in position and push in the end plate. After removing the ring, remove tools D2 and D3.
30-75

2) Remove end plate (8).
4. Clutch plate Remove plate (9), disc (10), and spring (11) from housing. 5. Piston Blow air in through oil hole at 1st end of shaft and remove piston (12). If the piston is at an angle and does not come out, push the piston in and try again. If force is used to remove the piston, the inside circumference of the cylinder will be damaged.
6. Bearing Set with the REVERSE side facing up, and set on tool D1. Remove bearing (13) with puller. 7. REVERSE gear Remove spacer (15), thrust washer (16), needle bearing (17), REVERSE gear (18), and thrust washer (19). Disassemble the REVERSE gear in the same way as in Steps 3 - 5 for the 1st gear.
30-76

II. DISASSEMBLY OF FORWARD, 2ND CLUTCH PACK
Set with the 2nd side facing up, and set on tool D1. 1. Bearing Using puller, remove 2nd gear (37) together with bearing (35).
2. 2nd gear Remove spacer (39) and thrust washers (36), then remove needle bearings (38) from 2nd gear (37). Remove the inside thrust washer after removing the clutch plate.
3. End plate 1) Install tools D2 and D3, tighten nut D5, then remove ring (40). Set the spacer in position and push in the end plate. After removing the ring, remove tools D2 and D3. 2) Remove end plate (41).
30-77

4. Clutch plate Remove plate (42), disc (43), and spring (44) from housing.
5. Piston Blow air in through oil hole at 2nd end of shaft and remove piston (45). If the piston is at an angle and does not come out, push the piston in and try again. If force is used to remove the piston, the inside circumference of the cylinder will be damaged.
6. Bearing Set with the FORWARD side facing up, and set on tool D1. Remove bearing (46) with puller. When installing the puller, put the center in contact with the plate.
7. FORWARD gear Remove spacer (47), thrust washer (48), needle bearing (49), FORWARD gear (50), and thrust washer (51). Disassemble the FORWARD gear in the same way as in Steps 3 - 5 for the 2nd gear.
30-78

Ill. DISASSEMBLY OF 3RD, 4TH CLUTCH PACK Set with the 3rd side facing up, and set on tool D1. 1. Bearing Fit puller to bearing (53), then remove bearing (53).
2. 3rd gear Remove spacer (54), thrust washer (55), 3rd gear (56), and needle bearings (57). Remove the inside thrust washer at Step 4-2).
3. End plate 1) Install tools D2 and D3, tighten nut D5, then remove ring (58). Set the spacer in position and push in the end plate. After removing the ring, remove tools D2 and D3. 2) Remove end plate (59).
30-79

4. Clutch plate 1) Remove plate (60), disc (61), and spring (62) from housing. 2) Remove inside thrust washer (71).
5. Piston Blow air in through oil hole at 3rd end of shaft and remove piston (63). If the piston is at an angle and does not come out, push the piston in and try again. If force is used to remove the piston, the inside circumference of the cylinder will be damaged.
6. Bearing Set with the 4th side facing up, and set on tool D1. Using puller, remove bearing (64) and 3rd gear (65).
7. 4th gear Remove spacer (66), thrust washer (67), needle bearing (68), 4th gear (69), and thrust washer (70). Disassemble the 4th gear in the same way as in Steps 3 5 for the 3rd gear.
30-80

ASSEMBLY OF CLUTCH PACK l. ASSEMBLY OF 1ST, REVERSE CLUTCH PACK
WARNING! When setting the clutch pack on the stand, be careful not to let your hands slip because of oil, and be extremely careful not to get your fingers caught between the stand and the clutch pack. Set with the REVERSE side facing up, and set the shaft and housing assembly on tool D1.
1. Piston seal Assemble piston seal (71-1) to piston (71). When assembling a new piston seal, use seal shaping jig El or E2 for approx. 2 - 3 minutes, then assemble the piston seal. If the seal is installed to the piston without being shaped, the seal will be damaged. Inside surface of shaping jig: Oil (transmission oil)
2. REVERSE piston Assemble REVERSE piston (71). Be careful not to damage the piston seal. Sliding surface of piston seal: Oil (transmission oil)
3. Clutch plate Insert tool D4 in housing, then assemble plate (72), disc (73), and spring (74) in turn. Soak disc (73) in clean transmission oil for at least 2 minutes before assembling. Be careful not to let spring (74) and plate (72) rest on top of each other. Be careful not to let the plate or spring get caught in the ring groove of the clutch housing when assembling. A30 x 85 mm nail can also be used for tool D4.
30-81

4. End plate 1) Install tools D2 and D3, tighten nut D5 to push in end plate (76), then remove tool D4. Set the spacer in position and push in the end plate.
2) Assemble ring (77), then remove tools D2 and D3. Check that ring (77) is fitted securely in the groove. Check that the disc rotates smoothly by hand. 5. Thrust washer Install thrust washer (19). 6. REVERSE gear Use a screwdriver to align the spline on the inside of the plate, and assemble REVERSE gear (18). If the gear spline is not aligned, rotate lightly while assembling. Never push with force. 7. Bearing Assemble needle bearing (17), thrust washer (16), and spacer (15). Check that the end face of thrust washer (16) is level with or below the stepped portion of the shaft.
30-82

8. Bearing Press fit bearing (13). Press fit completely so that spacer (15) is in tight contact with the stepped portion of the shaft and bearing (13).
After press fitting the bearing, check that clearance "a" between thrust washer (16) and spacer (15) is within the specified range."a" = 0.07 - 0.93 mm
9. 1st piston 1) Turn over clutch pack. WARNING! When turning over the clutch pack, be careful not to get your fingers caught between the stand and clutch pack. 2) Assemble piston (12) in same way as for REVERSE piston. Sliding surface of piston seal: Oil (transmission oil)
10. Clutch plate Insert tool D4 in housing and assemble plate (9), disc (10), and spring (11) in turn. A 3i x 85 mm nail can also be used for tool D4. Assemble in the same way as for REVERSE.
30-83

11. End plate 1) Install tools D2 and D3, tighten nut D5 to push in end plate (8), then remove tool D4. Set a spacer in position and push in the end plate. 2) Assemble ring (7) and remove tools D2 and D3. Assemble in the same way as for REVERSE.
12. Thrust washer Install thrust washer (6). 13. lst gear Assemble 1st gear (2). Assemble in the same way as for REVERSE.
14. Bearing Assemble needle bearing (5).
15. Thrust washer, spacer Assemble thrust washer (4) and spacer (3). Check that the end face of thrust washer (4) is level with or below the stepped portion of the shaft.
30-84

16. Bearing Press fit bearing (1). Press fit completely so that the spacer is in tight contact with the stepped portion of the shaft and bearing (1).
After press fitting the bearing, check that clearance "b" between thrust washer (4) and spacer (3) is within the specified range. b = 0.04 - 1.16 mm
17. Clutch pack operating test Blow in compressed air through oil hole of shaft and check if each clutch is actuated. If the gear at the point where the air is blown in is held in position, the clutch is working normally.
30-85

II. ASSEMBLY OF FORWARD, 2ND CLUTCH PACK
WARNING!When setting the clutch pack on the stand, be careful not to let your hands slip because of oil, and be extremely careful not to get your fingers caught between the stand and the clutch pack. Set with the FORWARD side facing up, and set the shaft and housing assembly on tool D1.
1. Piston seal Assemble piston seal (83-1) to piston (83). When assembling a new piston seal, use seal shaping jig El or E2 for approx. 2 - 3 minutes, then assemble the piston seal. If the seal is installed to the piston without being shaped, the seal will be damaged. Inside surface of shaping jig: Oil (transmission oil)
2. FORWARD piston Assemble FORWARD piston (83). Be careful not to damage the piston seal. Sliding surface of piston seal: Oil (transmission oil)
3. Clutch plate Insert tool D4 in housing, then assemble plate (78), disc (79), and spring (80) in turn. Soak disc (79) in clean transmission oil forat least 2 minutes before assembling. Be careful not to let spring (80) and plate (78) rest on top of each other. Be careful not to let the plate or spring get caught in the ring groove of the clutch housing when assembling. A 3i x 85 mm nail can also be used for tool D4.
30-86

4. End plate 1) Install tools D2 and D3, tighten nut D5 to push in end plate (81), then remove tool D4. Set the spacer in position and push in the end plate. 2) Assemble ring (82) and remove tools D2 and D3 Check that ring (82) is fitted securely in the groove. Check that the disc rotates smoothly by hand.
5. Thrust washer Install thrust washer (51). 6. FORWARD gear Assemble FORWARD gear (50), then assemble needle bearing (49). If the gear spline is not aligned, rotate lightly while assembling. Never push with force.
7. Thrust washer Assemble thrust washer (48). Check that the end face of the thrust washer is level with or below the stepped portion of the shaft. 8. Bearing Assemble spacer 47), then press fit bearing (46). After press fitting the bearing, check that clearance "e" between thrust washer (48) and spacer (47) is within the specified range. e = 0.07 - 0.93 mm
30-87

9. 2nd piston 1) Turn over clutch pack. WARNING!When turning over the clutch pack, be careful not to get your fingers caught between the stand and clutch pack. 2) Assemble piston (45) in same way as for FORWARD piston. Sliding surface of piston seal: Oil (transmission oil)
10. Clutch plate Insert tool D4 in housing and assemble plate (42), disc (43), and spring (44) in turn. A 3i x 85 mm nail can also be used for tool D4. Assemble in the same way as for FORWARD.
11. End plate 1) Install tools D2 and D3, tighten nut D5 to push in end plate (41), then remove tool D4. Set a spacer in position and push in the end plate.
2) Assemble ring (40), then remove tools D2 and D3. Assemble in the same way as for FORWARD.
12. Thrust washer Install thrust washer (36).
30-88

13. 2nd gear Assemble 2nd gear (37), then assemble needle bearings (38). Assemble in the same way as for FORWARD.
14. Thrust washer, spacer Assemble thrust washer (36) and spacer (34). Check that the end face of thrust washer (36) is level with or below the stepped portion of the shaft.
15. Bearing Press fit bearing (35). Press fit completely so that spacer (34) is in tight contact with the stepped portion of the shaft and bearing (35). After press fitting the bearing, check that clearance "f" between thrust washer (36) and spacer (34) is within the specified range. f = 0.04 - 1.16 mm
16. Clutch pack operating test Blow in compressed air through oil hole at 2nd end and check if each clutch is actuated. If the gear at the point where the air is blown in is held in position, the clutch is working normally.
30-89

Ill. ASSEMBLY OF 3RD, 4TH CLUTCH PACK WARNING! When setting the clutch pack on the stand, be careful not to let your hands slip because of oil, and be extremely careful not to get your fingers caught between the stand and the clutch pack. Set with the 4th side facing up, and set the shaft and housing assembly on tool D1.
1. Piston seal Assemble piston seal (84-1) to piston (84). When assembling a new piston seal, use seal shaping jig E1 or E2 for approx. 2 - 3 minutes, then assemble the piston seal. If the seal is installed to the piston without being shaped, the seal will be damaged. Inside surface of shaping jig: Oil (transmission oil)
2. 4th piston Assemble 4th piston (84). Be careful not to damage the piston seal. Sliding surface of piston seal: Oil (transmission oil)
3. Clutch plate Insert tool D4 in housing, then assemble plate (85), disc (86), and spring (87) in turn. Soak disc (86) in clean transmission oil for at least 2 minutes before assembling. Be careful not to let spring (87) and plate (85) rest on top of each other. Be careful not to let the plate or spring get caught in the ring groove of the clutch housing when assembling. A 3i x 85 mm nail can also be used for tool D4.
30-90

4. End plate 1) Install tools D2 and D3, tighten nut D5 to push in end plate (88), then remove tool D4. Set the spacer in position and push in the end plate.
2) Assemble ring (89), then remove tools D2 and D3. Check that ring (89) is fitted securely in the groove. Check that the disc rotates smoothly by hand.
5. Thrust washer Install thrust washer (70). 6. 4th gear Assemble 4th gear (69), then assemble needle bearing (68). If the gear spline is not aligned, rotate lightly while assembling. Never push with force. 7. Thrust washer, bearing Assemble thrust washer (67), and spacer (66), then insert bearing (64) to shaft. Check that the end face of thrust washer (67) is level with or below the stepped portion of the shaft.
30-91

8. Bearing Press fit bearing (64). Press fit completely so that spacer (66) is in tight contact with the stepped portion of the shaft and bearing (64).
After press fitting the bearing, check that clearance "g" between thrust washer (67) and spacer (66) is within the specified range. ..g" = 0.07 - 0.93 mm
9. 3rd piston 1) Turn over clutch pack. WARNING! When turning over the clutch pack, be careful not to get your fingers caught between the stand and clutch pack. 2) Assemble piston (63) in same way as for 4th piston. Sliding surface of piston seal: Oil (transmission oil)
10. Thrust washer Install thrust washer (71). Assemble 3rd inside thrust washer (71) before assembling the clutch plate.
30-92

11. Clutch plate Insert tool D4 in housing and assemble plate (60), disc (61), and spring (62) in turn. A 3i x 85 mm nail can also be used for tool D4. Assemble in the same way as for 4th.
12. End plate 1) Install tools D2 and D3, tighten nut D5 to push in end plate (59), then remove tool D4. Set a spacer in position and push in the end plate. 2) Assemble ring (58), then remove tools D2 and D3. Assemble in the same way as for 4th.
13. 3rd gear Assemble 3rd gear (56), then assemble needle bearings (57). Assemble in the same way as for 4th.
14. Thrust washer, spacer Install thrust washer (55), then assemble space (54). Check that the end face of thrust washer (55) is level with or below the stepped portion of the shaft.
30-93

15. Bearing Press fit completely so that spacer (54) is in tight contact with the stepped portion of the shaft and bearing (53). After press fitting the bearing, check that clearance "h" between thrust washer (55) and spacer (54) is within the specified range. h = 0.04 - 1.16 mm
16. Clutch pack operating test Blow in compressed air through oil hole at 3rd end and check if each clutch is actuated. If the gear at the point where the air is blown in is held in position, the clutch is working normally.
30-94

REMOVAL WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. ! Remove inspection cover (1) of the left side of the rear frame. ! Remove cover (2) at the left side of the floor.
1. Electric wiring 1) Disconnect connectors (3), (4), (5), and (6) and wiring for transmission solenoid valve. 2) Disconnect torque converter oil temperature sensor connector (7). When disconnecting the wiring connectors, fit tags to identify the connectors.
2. Hydraulic piping Hose (8) between brake booster and transmission valve Hose (9) between transmission valve and oil cooler Disconnect hose (10) between torque converter oil filter and brake booster, and remove hose clamp. 3. Transmission valve Sling transmission valve (12) and remove mounting bolts, then lower under machine. WARNING! The working space is confined, so be extremely careful. To prevent the valve from falling, remove 2 mounting bolts, then install guide bolts and insert wooden blocks. Remove the valve with a upper valve and lower valve assembled. Disassemble the upper and lower valve after removing. When fitting a lifting tool, avoid the connectors and fit the tool securely to the valve body. Transmission valve: 46 kg (upper: 15.5 kg) (lower: 30.5 kg)
30-95

INSTALLATION
! Carry out installation in the reverse order to removal. WARNING! The working space is confined, so be extremely careful. Connect the wiring connector securely.
Install the hoses without twisting or interference. Nut of hose mouthpiece: 176.5 29.4 Nm (18 3 kgm) ! Width across flats of hose mouth piece nut: 36 mm
When installing the transmission valve, replace the gasket with a new part. When installing the transmission valve, use guide bolts to prevent it from falling. Secure with upper and lower valve set bolts (13) and (14). Remove all oil and grease from the valve mounting bolts and mounting bolt holes. The length of the mounting bolts is different, so be careful when using them. (1) L = 120 mm (2) L = 130 mm (3) L = 135 mm (4) L = 115 mm (5) L = 100 mm (6) L = 100 mm
To prevent distortion of the valve, tighten the transmission valve mounting bolts in the order shown in the diagram. Mounting bolt: Thread tightener (LT-2) Mounting bolt: 34.3 4.9 Nm (3.5 0.5 kgm)
30-96

MEMORANDA
30-97

DISASSEMBLY
30-98

1. Disconnection Remove mounting bolts, and disconnect upper valve (1) and lower valve (2), then remove gasket (3). 2. Disassembly of upper valve 1) Remove mounting bolts, remove cover (4), then remove gasket (5), pilot valve (6), priority spring (7), quick return valve assembly (8), accumulator piston (9), and spring (10). 2) Remove sleeve (11) from quick return valve assembly, then remove spring (12) and ball (13). 3) Remove plug (14) from sleeve (11). 4) Remove mounting bolts, remove cover (15), then remove gasket (16), main regulator valve (17), spring (18), priority valve (19), modulating valve assembly (20), accumulator shaft (21), and springs (22) and (23). 5) Remove load pistons (24) and (25) from main regulator valve (17) and priority valve (19). 6) Remove plug (26) from modulating valve assembly (20), then remove retainer (27), springs (28) and (29), sleeve (30), and O-rings (31). 7) Remove nut (32) and washer (33) from cover (15), then remove adjustment screw (34) and O-ring (35). 8) Remove plug (36) and main orifice (37) from upper valve (1). 3. Disassembly of lower valve 1) Remove mounting bolts, remove solenoid valve assembly (38), then remove spring (39), retainer (40), spring (41), and sleeve (42). 2) Remove mounting bolts, remove cover (43), then remove gasket (44), torque converter regulator valve (45), shim, (46), spring (41A), sleeve (42A), F-R selector valve (47), HL selector valve (48), range selector valve (49), springs (50), and spacers (51). 3) Remove mounting bolts, then remove pilot filter (52) and Orings (53). 4) Remove plug (54) from F-R selector valve (47). 5) Remove plugs (55) from lower valve (2) and cover (43). 6) Remove orifices (56) from lower valve (2).
30-99

ASSEMBLY
30-100

1. Assembly of lower valve 1) Install orifices (56) to lower valve (2). Screw in the orifice at least 2 mm from the valve body. 2) Install plugs (55) to lower valve (2) and cover(43). Plug: Sealant (LG-1 or LG-5)

set cover (15) in mounting position, and secure washer (33) and nut (32). For details of the adjustment procedure, see TESTING AND ADJUSTING. 3) Fit plug (26) to modulating valve (20), then assemble O-rings (31) to sleeve (30), and install springs (28) and (29) and retainer (27). 4) Install load pistons (24) and (25) to main regulator valve (27) and priority valve (19). 5) Assemble springs (22) and (23), accumulator shaft (21), modulating valve assembly (20), priority valve (19), spring (18), and main regulator valve (17), then set gasket (16) to mount, and install cover (15). Mounting bolt: 68.6 4.9 Nm (7.0 0.5 kgm) 6) Assemble plug (14) to sleeve (11), then set ball (13) and spring (12) to quick return valve (8), and assemble sleeve (11). 7) Assemble spring (10), accumulator piston (9), quick return valve assembly (8), priority spring (7), and pilot valve (6),, then set gasket (5) to mount, and install cover (4). Mounting bolt: 68.6 4.9 Nm (7.0 0.5 kgm) 3. Connection Set gasket (3) to mount, then connect lower valve (2) and upper valve (1). Mounting bolt: 31.4 2.9 Nm (3.2 0.3 kgm)
3) Install plug (54) to F-R selector valve (47). 4) Install O-rings (53) to pilot filter (52), then set in mounting position and tighten mounting bolts. Mounting bolt: 68.6 4.9 Nm (7.0 0.5 kgm) 5) Install H-L selector valve (48), range selector valve (49), spacers (51), springs (50), F-R selector valve (47), sleeve (42A), spring (41A), shim (46), and torque converter regulator valve (45), then set gasket (44) in position, and install cover (43). Mounting bolt: 68.6 4.9 Nm (7.0 0.5 kgm) 6) Install sleeve (42), spring (41), retainer (40), and spring (39), then set gasket mount, and install solenoid valve assembly (38) to lower valve (2). Mounting bolt: 68.6 4.9 Nm (7.0 0.5 kgm) 2. Assembly of upper valve 1) Install plug (36) and main orifice (37) to upper valve (2). Screw in the orifice at least 2 mm from the valve body. Plug: Sealant (LG-1 or LG-5) 2) Fit O-ring (35) to adjustment screw (34), then
30-101
TRANSMISSION SOLENOID VALVE
TRANSMISSION SOLENOID VALVE

DISASSEMBLY, ASSEMBLY
DISASSEMBLY 1. Remove mounting bolts from solenoid valve body (1), then remove solenoids (2) and O-rings (4). Remove the connector from the plate. 2. Remove plate (3) from valve body (1). 3. Remove lock plate (5), then remove emergency manual spool (6) and O-ring (7). 1) Remove orifice (8) from emergency manual spool (6). 2) Remove plate (9). 4. Remove plugs (10) from solenoid valve body (1). ASSEMBLY 1. Install plugs (10) to solenoid valve body (1). Plug: Sealant (LG-1 or LG-5) 2. Install orifice (8) and O-ring (7) to emergency manual spool (6), then secure with lock plate (5), and install
plate (9). 3. Install plate (3) to valve body (1). 4. Assemble O-rings (4) to solenoid valve (2), and tighten bolts. Be careful not to get the O-ring caught. Mounting bolt: 68.6 4.9 Nm (7.0 0.5 kgm)
30-102
TRANSMISSION ACCUMULATOR VALVE

DISASSEMBLY 1. Remove accumulator valve (4) from transmission assembly (3). 2. Remove O-rings (1) and (2) from accumulator valve (4). 3. Using pads, set accumulator valve body (9) in vice.
4. Remove mounting bolts (5) and (6), and assemble guide bolts A. ! M =10,P = 1.5,L = Approx. 40.mm 5. Remove bolts (7) and (8), then remove cover (10) together with guide bolts A. The internal parts will come off together with the cover, so be extremely careful not to damage them when removing.
6. Pull out valves (11), springs (12) and (14), stoppers (13) and (15), and spacers (16) and (17) from cover (10). Fit tags to each spring, stopper, spacer, and use for reference when assembling. Reference Spring FWD 1ST 2ND R = 145 R = 145 R = 145 Stopper R = 95 R = 95 R = 95 Spacer R = 40 R = 40 R = 50
30-103
7. Remove plugs (19) and (20) from cover (10). ! Plug : 5 mm (width across flats) Do not remove the plugs unless necessary. If plugs (19) and (20) have been removed, coat the thread with thread tightener as shown in the diagram below, then tighten the plugs. Be careful not to let the thread tightener drip on to the hatched portion when coating with thread tightener. Plug : Thread tightener (LG-1)
ASSEMBLY 1. Using pads, set accumulator valve cover (10) in vice. Be careful not to tighten the vice on the cover with excessive force. 2. Assemble spacers (17) and (16), stoppers (15) and (13), and springs (14) and (12) to accumulator valve cover (10), then insert valves (1 1) from top of each spring. 3. Fit O-rings (22) and (21) in each groove of accumulator valve body (9). Assemble the O-ring securely in the body groove. 4. Assemble accumulator valve body (9) perpendicularly from above cover (10), then temporarily install with guide bolts. Assemble the body carefully and be sure that the O-ring does not fall out. 5. Push in accumulator valve body (9), and remove guide bolts, then secure with standard bolt. Mounting bolt : 54 19.6 Nm (5.5 2.0 kgm) ! Mounting bolt : 8 mm (width across flats)
30-104
DRIVE SHAFT
DRIVE SHAFT
DISASSEMBLY 1. Front drive shaft 1) Shaft slip spline is permanently lubricated, and should not be disassembled.
2) Loosen bolt (2), then remove coupling (3) and retainer. Make match marks to prevent the coupling from being installed in a different direction. 3) Using a press, remove flange bearing (4).
30-105

2. Center drive shaft, rear drive shaft 1) Shaft slip spline is permanently lubricated, and should not be disassembled.
DRIVE SHAFT
3. Spider, bearing 1) Remove bolts (6) of spider and bearing assembly (5), and tap with plastic hammer to remove.
30-106
DRIVE SHAFT
DRIVE SHAFT
ASSEMBLY 1. Spider, bearing 1) Assemble so that the grease nipples face in the same direction. Repeat the same procedure for the front, center and rear drive shafts.
2) Set spider and bearing assembly (5) to drive shaft mount, and lock with bolts (6). Mounting bolt: 54 3 Nm (5.5 0.3 kgm) Bearing cap: Grease (G2-LI)
2. Front drive shaft 1) Press fit flange bearing (4). Do not hit the flange bearing directly with a hammer.
2) Align match marks, and tighten coupling (3) and retainer (9) with mounting bolt (2). Tighten the bolt to the specified tightening torque after installing to the machine. Spline portion: Grease (G2-LI) Mounting bolt: 279 29 Nm (28.5 3.0 kgm)
30-107

MEMORANDA
MEMORANDA
30-108
FRONT AXLE
FRONT AXLE
REMOVAL
WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the work equipment to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. 1. Jacking up the machine Put block (1) under front frame, and hold up machine. Raise the front frame with the bucket, and set blocks (1) in position with the tires raised slightly from the ground. 2. Tire, wheel Sling tire and wheel (1), remove mounting bolts, then lift off. Tire, wheel: 180 kg
3. Drive shaft Disconnect front drive shaft (2).
4. Axle 1) Disconnect brake tube (3).
30-109

2) Using jack and hoist, sling axle (4), remove mounting bolts (5), then lift off. Adjust the height of the jack when removing the mounting bolts. Axle: 387 kg 3) Pull out axle from machine. Use a hoist and jack to remove the axle.
FRONT AXLE
FRONT AXLE
Raise the front frame slightly with the bucket, and remove block (1).
Mounting bolt: 927 103 Nm (94.5 10.5 kgm) (Width across flats: 36 mm) Drive shaft: 65.7 6.9 Nm (6.7 0.7 kgm)
Be careful not to tighten the tube nut too far. Tube nut: 11.8 2.9 Nm (1.2 0.3 kgm)
When installing the axle, use the mounting bolts as a guide and align the mounting position. Mounting bolt: 740 73 Nm (75.5 7.5 kgm) (Width across flats: 36 mm) ! Bleeding air from brake system Bleed the air. For details, see TESTING AND ADJUSTING.
30-110
REAR AXLE
REAR AXLE
REMOVAL WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. WARNING! Open the side inspection cover and apply the lock. Loosen drain valve (1) and drain fuel.
1. Fuel tank 1) Disconnect fuel hose (2), fuel return hose(3), and fuel gauge wiring connector (4). 2) Remove return hose (5) from fuel filter. Remove the clamp of breather tube (5-1).
3) Remove inside cover (7), outside cover (8) and rubber of fuel oil filler port (6) at left side of rear frame.
4) Set transmission jack under fuel tank, and support fuel tank (9) lightly. 5) Remove mounting bolts, then lower transmission jack slowly and remove. When there is a clearance of approx. 50 mm from the rear frame, stop and check that there is no interference. The oil filler tube will hit the rear frame so move to the right and remove carefully. Fuel tank (dry): 70 kg 6) Pull out fuel tank (9) to right side of chassis.
30-111

2. Jacking up chassis 1) Remove engine oil drain valve (11) from rear axle pivot (10).
REAR AXLE
2) Set block (1) between left and right rear axles and rear frame. 3) Jack up chassis and put support stand under rear frame. Raise the rear frame with a garage jack, and when the tires come slightly off the ground, set stand in position.
3. Tire, wheel Fit sling around tire and wheel (12), then remove mounting bolts and lift off. Tire, wheel: 180 kg
4. Drive shaft Remove rear drive shaft (13). Make match marks to show the mounting position.
30-112

5. Brake, grease tube 1) Disconnect brake hose (14). 2) Remove grease tube (15) from rear axle pivot.
REAR AXLE
6. Axle 1) Secure pivot (10) to axle with chain or wire. Fix securely so that the pivot does not move. 2) Sling one end of axle (16), set garage jack under axle housing at other end, then remove mounting bolts. Adjust the height of the garage jack when r emoving. The pivot end will go down, so be extremely careful when removing the axle. Rear axle, pivot: 462 kg 3) Pull out axle assembly from chassis. Use a hoist and jack to pull out the axle assembly. After pulling the axle assembly out from the chassis, remove the chain or wire.
7. Rear pivot 1) Remove trunnion cap (16-1). Before removing the cap, remove the grease tube. If there are shims installed, check the number and thickness of the shims and use for reference when assembling. 2) Remove thrust plate (17).
30-113

3) Lift off rear pivot (18). Be careful that the hanging tool does not slip when lifting off the rear pivot. Rear pivot: 75 kg
REAR AXLE
4) Remove O-ring (19) and bushng (20) from pivot (18).
8. Front pivot Remove O-rings (22) and bushing (23) from pivot (21).
30-114
REAR AXLE
REAR AXLE
INSTALLATION 1. Front pivot Assemble O-rings (22) and bushing (23) to pivot (21). Assemble so that the chamfered side of the bushing is on the axle housing side. Set with the join of the bushing at the side. O-ring, bushing: Grease (G2-LI)
2. Rear pivot 1) Assemble O-ring (19) and bushing (20) to pivot (18). Set with the join of the bushing at the side. O-ring, bushing: Grease (G2-LI)
2) Raise pivot (18), and insert to mounting portion of axle. Be careful not to get the O-ring caught. 3) Install thrust plate (17) to mounting portion of axle. Wipe the mating surface of the thrust plate clean.
Assemble so that the i5 hole of thrust plate (17) is at the top. Outside circumference of pivot mount: Grease (G2-LI) Mounting bolt: 112.8 9.8 Nm (11.5 1.0 kgm)
30-115

To make axle and pivot parallel, turn over trunnion cap (161) and tighten down with 8 bolts uniformly. Mounting bolt: 68.6 9.8 Nm (7 1 kgm) Check that the clearance between the pivot and trunnion cap is uniform. Set on the mount on the machine body with the cap still reversed.
REAR AXLE
3. Axle Raise axle (16) with jack and hoist, set in mounting position and tighten mounting bolts. Use the bolts as guides when setting in the mounting position. When tightening the mounting bolts, do not tighten in one pass. Tighten the mounting bolts in three stages. After installing the axle assembly, remove the wire. Mounting bolt: 549 58.8 Nm (56 6 kgm) (Width across flats: 30 mm) 4. Adjusting shim at rear pivot 1) Using depth micrometer (1), measure dimension "a" of trunnion cap (16-1). Measure at 4 places at 90E angles and take the average. Clean the probe contact surface before measuring. ! Standard value "a": 12.2 - 12.33 mm
2) Assemble thrust washer (17) at rear pivot. Using depth micrometer (1), measure dimension "b" at 4 places at 90E angles and take the average. Clean the contact surfaces of the thrust plate. Clean the probe contact surface before measuring. ! Reference value "b": 12.10 - 12.30 mm Insert a feeler gauge around circumference "c" and at the joint of the thrust plate, and check that there is no clearance.
30-116

! ! Joint rear pivot and trunnion cap Standard clearance "d": 0.1 - 0.29 mm . a" - "b" - (0.1 - 0.29) = t (shim thickness) Shim size = 0.2 mm
REAR AXLE
3) Assemble selected shims between rear pivot (10) and trunnion cap (16-1), then install mounting bolts. Fill the trunnion cap with grease before installing. Trunnion cap: Grease (G2-LI) Mounting bolt: 112.8 9.8 Nm (11.5 1 kgm)
5. Brake, grease tube 1) Secure grease tube (15) with mounting clamp. 2) Connect brake hose (14). Be careful not to tighten the brake hose too much.
30-117

3) Install engine oil drain valve (11) in axle pivot (10).
REAR AXLE
6. Drive shaft Install rear drive shaft (13). Align the pilot correctly and install with the yoke facing in the correct direction. Mounting bolt: 31.4 2.9 Nm (3.2 0.3 kgm)
7. Tire, wheel Sling tire and wheel (12), set in mounting position, and tighten mounting bolts. Mounting bolts: 927 103 Nm (94.5 10.5 kgm) (Width across flats: 36 mm)
8. Lowering machine 1) Pull out block (2) from under rear frame and lower machine to ground. Raise the rear frame with a garage jack, and remove blocks (2) when the frame is raised slightly. 2) Remove block (1) between left and right rear axles and rear frame.
30-118

9. Fuel tank 1) Pull in fuel tank (9) under chassis. Pull in from the right side of the rear frame. 2) Operate transmission jack and raise fuel tank (9) slowly, then set in mounting position, and fit mounting bolts temporarily. When setting to the mount, move from the right to the left, raise, and stop at a point where the oil filler passes the rear frame, then check that there is no interference. 3) Position and tighten mounting bolt firmly. Mounting bolt: 110.3 12.3 Nm (11.25 1.25 kgm) 4) Install inside cover (7), outside cover (8), and rubber of fuel filler port (6) at left side of rear frame.
REAR AXLE
5) Install return hose (5) from fuel filter. 6) Install breather tube (5-1) and clamp. 7) Connect fuel hose (2), fuel return hose (3), and fuel gauge wiring connector (4). 8) Close drain valve (1).
10. Bleeding air from brake system Bleed air. For details, see TESTING AND ADJUSTING.
30-119
DIFFERENTIAL
DIFFERENTIAL
DISASSEMBLY 1. Brake tube Remove brake tube (1).
2. Differential cover Remove bleeder screw (2), then remove differential cover (3). Install the differential assembly in a stand. Remove the axle housing.
3. Cage 1) Screw in a forcing screw, then using guide bolt (4), remove cage (5). Check the number and thickness of the shims, and keep them in a safe place. Loosen mounting bolts of coupling, and temporarily install the cage. Cage: 17 kg 2) Remove O-ring from cage.
4. Brake piston Screw in forcing screws (3 places) to raise evenly, then remove piston (6). If the O-ring of the piston is not damaged, it is possible to install the bleeder screw and blow in air to remove the piston.
30-120

5. Bearing carrier Screw in forcing screws to raise bearing carrier evenly, and remove bearing carrier (7). Remove angle ring. Check the number and thickness of the shims, and keep them in a safe place. Mark the left and right bearing carriers to avoid confusing them.
DIFFERENTIAL
6. Differential carrier 1) Lift off differential carrier assembly (9) from differential housing (8). When removing the assembly, be careful that the lifting tool does not slip. Differential carrier assembly: 30 kg
2) Remove bevel gear (10), then remove bearing (11) from bevel gear.
3) Remove thrust washer (13) from differential carrier (12), then remove side gear (14).
30-121

4) Remove lock pins (15), pull out shaft (16), then remove pinion gears (17).
DIFFERENTIAL
5) Remove side gear (18).
7. Coupling 1) Remove mounting bolt (20), then remove holder (21), coupling (22) and O-ring (23). Do not remove the protector press fitted to the coupling unless necessary. 2) Remove oil seal (24).
30-122

3) Using a press, remove pinion gear (25) from cage, then remove bearing (26).
DIFFERENTIAL
4) Remove spacer (27) and bearing (28) from piinion gear (25).
5) Remove bearing cups (29) and (30) from cage (5).
30-123
DIFFERENTIAL
DIFFERENTIAL
ASSEMBLY 1. Pinion gear 1) Press fit bearing cone (28) in pinion gear (25), then assemble spacer (27). There must be no clearance at the contact faces of any parts.
2) Press fit bearing cups (29) and (30) in cage (5).
3) Assemble pinion gear (25) in cage (5), then press fit bearing cone (26). Apply pressure to the bearing at the specified load, and rotate the case to settle the bearing. Press load: 49 KN (5 ton) Bearing: Oil (axle oil) When rotating the case at the specified load, rotate lightly by hand. If the rotation is not smooth, replace the bearing and spacer, and again rotate lightly by hand.
30-124

4) Press fit oil seal (24) in cage (5). Assemble oil seal (24) evenly so that it has the specified depth "t". t = 6 0.5 mm Oil seal lip: Grease (G2-LI) Pinion gear shaft: Grease (G2-LI)
DIFFERENTIAL
2. Coupling Install coupling (22), O-ring (23) and holder (21) to pinion gear (25), then tighten mounting bolts. Tighten the mounting bolts partially. Tighten them fully after the completion of assembly. When inserting the coupling, be careful not to damage the seal. Mounting bolt: Thread tightener (LT-2) Mounting bolt: 279 29 Nm (28.5 3.0 kgm)
3. Differential carrier assembly 1) Install side gear (18) to differential carrier (12).
2) Install pinion gears (17) and shaft (16) to differential carrier (12), then insert lock pins (15). Gears, shafts: Oil (axle oil)
30-125

3) Assemble side gear (14) and thrust washer (13). Sliding surface of thrust washer: Oil (axle oil) 4) Press fit bearing (11) on bevel gear (10).
DIFFERENTIAL
5) Assemble bevel gear (10) in differential carrier (12), then tighten mounting bolts. Mounting bolts: Thread tightener (LT-2) Mounting bolts: 279 29 Nm (28.5 3.0 kgm) Coat the thrust washer with grease and stick it to the bevel gear to prevent it from falling off during installation. Align the lock of the washer correctly with the groove in the bevel gear.
4. Adjusting shim of cage 1) Assemble cage (5) without shims in differential housing (8). Mounting bolts: 112.8 9.8 Nm (11.5 1.0 kgm)
2) Insert measuring tool A in differential (8), and measure distance between end face of bevel pinion gear and tool A with an inside micrometer or a cylinder gauge. When inserting tool A in the differential housing, coat thinly with oil, and insert straight without twisting.
30-126

3) Selecting shims t = C - (L + D/2) t :Shim thickness A: 157.5 C: (A + a) - (B + b) B: 50.68 L: Actual value a: Error for distance A D: Diameter of tool A b: Error for distance B Use the actual value for distance D
DIFFERENTIAL
Shim thickness "t" must be within 0.5 -1.9 mm. The end face of the pinion gear is marked with an electric pen as follows. MD +0.10 [Distance a(mm)] (-0.01) [Distance b(mm)]
Always use the bevel pinion gear and bevel gear in a set with the same number.
4) Remove cage. 5. Bearing carrier Press fit bearing cups (32) and (33) in bearing carriers (7) and (31). Press-fitting portion of bearing cup: Oil (axle oil)
6. Adjusting bearing carrier shims 1) Raise differential carrier assembly (9), set in mounting position, then install left and right bearing carriers (7) temporarily. Assemble the differential carrier assembly with the bevel gear on the right as seen from the cage mount. Assemble the bearing carrier and adjust without the angle ring and shim.
30-127

2) Tighten carrier (31) at differential carrier end to specified tightening torque. Mounting bolts: 113 9.8 Nm (11.5 1.0 kgm)
DIFFERENTIAL
3) Tighten 4 mounting bolts of carrier (7) at bevel gear end. Rotate the bevel gear and coat the bearing with oil. Bearing: Oil (axle oil) To settle all the parts, rotate the bevel gear when tightening. Mounting bolts: 11.8 Nm (1.2 kgm)
4) Loosen 4 mounting bolts at bevel gear end until there is end play at bearing. 5) Tighten 4 mounting bolts uniformly again. Mounting bolts: 3.9 Nm (0.4 kgm) When doing this, check that there is end play at the bearing, and rotate the bevel gear when tightening.
6) Using a feeler gauge at 2 places in groove of bearing carrier (7) at bevel gear end, measure clearances T1 and T2 7) Selecting shims Shim thickness = (T1 + T2)/2 0.035 mm Combine the following shims to give the necessary shim thickness. 0.07 mm, 0.20 mm, 0.30 mm, 0.80 mm
30-128

8) Remove left and right bearing carriers (7),and assemble selected shims (32). Rotate the bevel gear and tighten the mounting bolts of the bearing carrier uniformly. Mounting bolts: 113 9.8 Nm (11.5 1.0 kgm)
DIFFERENTIAL
9) Using a spring balance, measure preload of bevel gear and check that it is within specified range. Preload: 7.8 - 25.5 Nm ( 0.8 - 2.6 kgm) (Target: 25.5 Nm (2.6 kgm)) If the preload is not within the specified range, change the shim thickness to adjust.
7. Cage 1) Assemble O-ring (34) in bearing cage. O-ring: Oil (axle oil)
2) Install guide bolt, assemble shims (35) selected in Step 4, and install cage (5). Mounting bolts: 113 9.8 Nm (11.5 1.0 kgm)
30-129

8. Adjusting backlash 1) Measure backlash of bevel gear with a dial gauge. First, measure with all the shims insertedat the bevel gear end. Measure the backlash at 3 places around the circumference of the bevel gear. The variation between the measurement must be within 0.1 mm.
DIFFERENTIAL
2) To obtain backlash within specified range,move some of the shims from bevel gear side to opposite side. When moving the shims, do not change the total shim thickness. The total shim thickness on the left and right must remain the same. Adjust the backlash as follows. If backlash is too LARGE, move shims from B to A If backlash is too SMALL, move shims from A to B
30-130
DIFFERENTIAL
9. Adjusting tooth contact Coat face of 7 or 8 teeth of bevel gear lightly with red lead. Hold the bevel gear by hand to act as a brake, rotate the pinion gear forward and backward and inspect the pattern left on the teeth. Tooth contact Cause 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. Procedure for adjustment Adjust the pinion gear by adjusting the shims at the cage. Adjust the bevel gear in the same way as when adjusting backlash.
Bevel pinion gear is too far from bevel gear.
1. 2.
Reduce shims at pinion gear to bring closer to bevel gear. Move bevel gear further away from pinion gear and adjust backlash correctly.
Bevel pinion gear is too close to bevel gear.
1. 2.
Increase shims at pinion gear to move away from bevel ear.. Move bevel gear closer to pinion gear and adjust backlash correctly.
Bevel gear is too close to pinion gear.
1. 2.
Reduce shims at pinion gear to bring closer to bevel gear. Move bevel gear further away from pinion gear and adjust backlash correctly.
Bevel gear is too far from pinion gear.
1. 2.
Increase shims at pinion gear to move away from bevel gear. Move bevel gear closer to pinion gear and adjust backlash correctly
When adjusting the bevel gear, do not change the preload of the bearing. Adjust by moving shims between the left and right. Always keep the same total thickness of shims.
30-131

10. Bearing carrier Remove bearing carrier (7), assemble angle ring (36) together with adjusted shims. Coat the angle ring with grease, and be careful not to drop it when installing. When installing bearing carrier (7), the angle ring may come out, so do not use a hammer to install the bearing carrier. Angle ring: Grease (G2-LI) Mounting bolt: 113 9.8 Nm (11.5 1.0 kgm)
DIFFERENTIAL
11. Brake piston 1) Assemble O-rings (37) and (38) securely in grooves of brake piston (6) and bearing carrier (7). Coat the brake piston and piston mount with grease to prevent theO-ring from twisting or breaking. Piston and piston mounting face: Oil (axle oil)
2) Install piston press fit tool B on housing, and tighten screws (39) evenly to press fit. Press fit the piston completely until it contacts the housing. The O-ring and piston will be damaged if a plastic hammer is used to press fit the piston.
12. Brake oil leakage test 1) Install bleeder screw. 2) Tighten screw (39) of piston press-fitting tool B completely, then loosen one turn. 3) Install hose of tool C to brake tube mount port (44), and bleed air from inside cylinder. 4) Operate pump and raise pressure to 1.4 MPa (14 kg/cm2). When the pressure is 1.4 MPa (14 kg/ cm2 ), leave for 5 minutes. The drop in pressure should be less than 0.34 MPa (3.5 kg/c m2).
30-132

5) If the test shows that there is no air leakage, raise pressure to 4.1 MPa (42 kg/cm2). When the pressure is 4.1 MPa (42 kg/ cm2), leave for 5 minutes. The drop in pressure should be less than 0.34 MPa (3.5 kg/c m2). If there is any oil leakage, remove the brake piston, check the O-ring for damage, then assemble again. After checking for brake oil leakage, insert the piston fully.
DIFFERENTIAL
13. Coupling Tighten mounting bolts of coupling (22) fully. Mounting bolt: Thread tightener (LT-2) Mounting bolts: 279 29 Nm (28.5 3.0 kgm)
14. Differential cover 1) Install differential cover (3) to housing. Use a guide bolt when installing to prevent thread tightener from entering the mounting hole of the bleeder screw. Cover contact surface: Gasket sealant (Loctite 515) Mounting bolts: 113 9.8 Nm (11.5 1.0 kgm)
2) Remove guide bolt, install bleeder screw (2). Check that there is no thread tightener stuck to the bleeder screw hole before installing.
30-133
AXLE HOUSING
AXLE HOUSING
DISASSEMBLY 1. Draining oil Loosen drain valve (1) and drain oil Axle oil: 14 R
2. Differential cover 1) Remove bleeder screw (2), then using forcing screw, remove differential cover (3). 2) Install axle assembly to stand.
3. Axle housing assembly 1) Sling axle housing (4), then remove housing mounting bolts. Put match marks on the housings to distinguish the left and right housings.
2) Disconnect axle housing, and remove shaft (5), brake disc (6) and brake ring. Be careful not to damage the surface of the brake disc. Axle housing: 88 kg
30-134

4. Brake outer ring Remove brake outer ring (7) and pin (8). Be careful not to damage the surface in contact with the brake disc.
AXLE HOUSING
5. Planetary carrier 1) Remove axle shaft mounting bolt, then remove planetary carrier (9).
2) Remove shims. Check the number and thickness of the shims, and keep them in a safe place.
6. Axle shaft 1) Stand housing and shaft assembly upright, then sling housing (10). 2) Tap end face of axle shaft (11) with a copper hammer to remove the shaft.
30-135

When the axle shaft has been pulled out a little way, pull out portion "a" of oil seal (12) with a screwdriver to prevent the oil seal from being damaged by bearing (13).
AXLE HOUSING
3) Remove bearing (13) and seal (12) from shaft (11) Never apply heat or use gas cutting to remove the bearing. (This will affect the hardening of the shaft and reduce the strength.)
Remove the bearing as follows. 4) When removing bearing (13) of shaft (11), use a screwdriver at point "b" of oil seal and sleeve (12), and push towards flange uniformly around circumference. 5) Make clearance "c" in order to fit claws of puller to connection of bearing (13) and sleeve (12A).
6) Install bolt (30) (5/8 - 18UNF, R = approx. 60mm) at point "d" to bearing puller A1. Screw in the bolt thread fully.
30-136

7) Set bearing puller A1 to clearance "c" between bearing (13) and sleeve (12A), then assemble bolt A2 and nut A3. When doing this, fix securely to prevent any play in the bearing puller.
AXLE HOUSING
8) Insert washer between bolt (30) and flange surface, turn in direction to loosen bolt (30), and remove bearing (13). The puller has only a small grip on the bearing, so be extremely careful not to let it come off the bearing. If the length of the thread of bolt (30) is too short, add extra washers to the flange surface to adjust the height of bolt (30), and remove bearing (13). Replace the oil seal and sleeve assembly with new parts.
7. Ring gear Using a puller, raise ring gear (14) evenly and remove.
8. Axle housing Remove bearing cups (15) and (16) from axle housing (10).
30-137

9. Planetary carrier 1) Drive in spring pin (17). Be careful not to drive in the spring too far.
AXLE HOUSING
2) Using a press, remove shaft (18).
3) Remove spring pin (17) from shaft (18).
4) Remove pinion gear (19) from planetary carrier (9), then remove bearing cone (20), spacer (21) and shims.
30-138
AXLE HOUSING
AXLE HOUSING
ASSEMBLY 1. Axle housing Press fit bearing cups (15) and (16) in axle housing (10). After press fitting the cups, check that there is no clearance at portion "a".
2. Ring gear Press fit ring gear (14) in axle housing (10), then insert pins (17). Cool ring gear (14) in dry ice to a temperature of about 30EC before press fitting. Align the pin holes of the housing and ring gear when assembling. Press fit the ring gear horizontally and be careful not to fit it at an angle.
3. Axle shaft 1) Using a press on axle shaft (11), press fit oil seal (12). Do not use a hammer as it may cause deformation. Coat the press-fitting portion of the sleeve surface "a" thinly with oil. Press-fitting portion of sleeve: Axle oil
30-139

Set bearing (13) on press stand, and press fit axle shaft (11). Be careful not to fit the bearing at an angle. Press-fitting portion of bearing: Axle oil
AXLE HOUSING
4. Housing, shaft 1) Stand shaft (11) upright and install too[ (B1). Using the adjustment bolt, adjust the height of the seal support. Set the top surface of tool B1 lightly in contact with seal (12) and make the clearance uniform. Secure tool B1 with tool B2 so that it does not come out of position.
2) Raise housing (10) horizontally, and insert carefully on shaft. Stop housing (10) before press fitting the oil seal.
3) Align housing (10) with press-fitting portion for oil seal, then lower housing slowly. Use the weight of the housing to insert it.
30-140

4) Remove tool B1.
AXLE HOUSING
5) Press fit bearing (13) on shaft (11). Rotate housing by hand and press fit until end play is 0.3 mm. Do not make the end play 0 mm. Press-fitting portion of bearing cone: Axle oil Press force: Approx. 19.6 KN (2 ton) After assembling the housing, the face of the seal must be level with the housing face. If there is any clearance "b" at part "a", it must be uniform and within the standard range. Standard range Clearance "b": 0.21 - 1.91 mm
5. Adjusting end play 1) Stand axle shaft and housing assembly (22) upright, and hold flange "a".
30-141

2) Install planetary carrier (9) to spline of axle shaft (11), then assemble shim adjustment tool C to portion "c" of planetary carrier, and install mounting bolts. Assemble planetary carrier (9) without the gear. Remove all thread tightener from the mounting bolts and the bolt holes of the axle shaft.
AXLE HOUSING
3) Rotate axle housing (10) and tighten mounting bolt (26) of retainer. Bolt: 55 Nm (5.6 kgm)
4) Using a depth micrometer, measure distance H from shim adjustment tool to end face of axle shaft. ! Shim thickness X = (H - t)
+O.15 +0.10
When selecting the shims take the nearest value to X + 0.10.
30-142

5) After selecting shims, loosen bolts, and remove planetary carrier (9).
AXLE HOUSING
6. Planetary carrier 1) Assemble bearing cone (20) on gear (19), then set spacer (21) and pinion gear (19) in carrier (9). Insert spacer (21) in the planetary carrier before assembling. There is no need to adjust with shims. Reference value for end play: 0 - 0.17mm
30-143

2) Check alignment of shaft hole of gear and planetary carrier again, then press fit shaft(18). Align the hole of spring pin (17) and shaft (18), then drive in the spring pin until it is level with the face of the carrier. Press force: 49 KN (5 ton) Shaft: Axle oil
AXLE HOUSING
3) Tap end face of shaft (18) and differential side of gear (19) to push back bearing (20) and allow gear to rotate smoothly. The gear must rotate smoothly.
7. Planetary carrier 1) Assemble shims (24) selected in Step 5 in planetary carrier (9) at axle shaft end face, then install mounting bolts. Remove all oil and grease from the mounting bolts and bolt mounting holes of the axle shaft. Mounting bolt: Thread tightener (LT-2) Mounting bolt: 279 29.4 Nm (28.5 3.0 kgm) Clean the end face of the shaft and the planetary carrier spline before installing. WARNING! When installing the planetary carrier, be careful not to get your fingers caught.
30-144

2) After settling bearing (23) fully, check "X" at drill hole "b" of axle housing (10). Reference value ! Rotation force "X": Approx. 26.5 N (2.7 kg) or less
AXLE HOUSING
3) Install stand of dial gauge to axle housing, and measure end play of planetary carrier at end face of planetary carrier. ! End play of planetary carrier: 0 - 0.098 mm If the end play is more than 0.098 mm, repeat Step 5 and adjust again.
8. Brake outer ring Assemble brake outer ring (7) in axle housing. Align pin and pin hole of outer ring to assemble. Be careful not to damage the surface of the brake outer ring.
9. Axle housing assembly 1) Assemble brake ring (27), brake disc (6) and shaft (5) in differential housing. Be careful not to damage the surface of the brake ring when assembling. Soak the brake disc for 2 to 3 minutes in clean axle oil before assembling.
30-145

2) Raise axle housing (10) horizontally, align spline groove and hole of pin (28), then assemble carefully. When assembling, be careful not to let the brake ring or disc come out of place. Remove all oil and grease, and clean the mounting surface to the differential housing and axle housing, then coat with an unbroken film of gasket sealant. Contact face of housing: Gasket sealant (Loctite 515) Mounting bolt of housing: 279 29 Nm (28.5 3.0 kgm) 10. Differential cover 1) Install differential cover (3) to differential housing. Coat with an unbroken film of gasket sealant. Be careful not to let the gasket sealant enter the mounting hole of the bleeder screw when assembling. Contact face of cover: Gasket sealant (Loctite 515) Mounting bolt of cover: 113 9.8 Nm (11.5 1.0 kgm) 2) Install bleeder screw (2). 11. Refilling with oil Tighten drain plug and add engine oil through oil filler and gauge (29) to the specified level.
AXLE HOUSING
30-146
CENTER HINGE PIN
CENTER HINGE PIN

REMOVAL WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. Before starting the operation, set a pallet under the bucket. Remove cover (1) at the top of the hydraulic tank on the right side, then remove covers (2) on the left and right under the floor.
WARNING! 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. ! Loosen plug (3) to prevent the oil inside the hydraulic tank from flowing out. Machines equipped with air conditioner ! Release the gas at a point far from the compressor. Loosen the hose connection slightly to release the gas. Disconnect the cable from the negative terminal of the battery.
1. Cover 1) Sling left side ladder rail (4), remove mounting bolts, then lift off together with center fender (5). Carry out the operation in the same way on the right side. When lifting off the ladder, be careful of the center of gravity. Be careful not to damage the cab glass. 2) Disconnect connector for left brake oil level sensor.
3) Remove brake oil tank mounting bracket (8) together with oil tank (7) from under floor. Leave the oil hose installed to the brake oil tank and tie it to the top surface of the rear frame with wire. ! For machines equipped with an air conditioner, it can be placed on top of the condenser.
30-147

2. Electric wiring Disconnect following electric wiring from connector. ! Connectors (11), (12), (13), (14), (15), (16), and (17) of front wiring (9) and rear wiring (10). For machines with cab, disconnect wiring for cab from connector. ! Disconnect ground wiring (18) from rear frame. ! Disconnect transmission cut-off switch (19) and wiring connector (20). ! Remove wiring clamp and bracket (21) from rear frame (22). Fit tags to identify the wiring.
CENTER HINGE PIN
3. Brake booster 1) Remove locknut of ball joint (24) of brake linkage rod (23), and pull out linkage rod. 2) Set block under brake booster (25), then remove mounting bolts (26).
4. Fuel control cable Disconnect fuel control cable (27) at engine end, then remove bracket (28) together with control cable. For machines equipped with cab ! Disconnect the washer hose from the tank, then coil up and bend the end of the hose. ! After removing the hose, fit a blind plug in the washertank.
30-148

5. Transmission valve wiring Disconnect each connectors (33) from transmission valve wiring. Fit tags to identify the wiring.
CENTER HINGE PIN
6. Work equipment control cable Disconnect work equipment control cables (34) at valve end. Fit tags to the cables before disconnecting. Remove the cable clamp.
7. Parking brake cable 1) Disconnect parking brake cable (38) from lever, and remove bracket (40) from front face of transmission (39). Check that there are blocks under the tires. After disconnecting the cable, tie it temporarily to the bottom surface of the floor with wire. 2) Disconnect speedometer cable (41). 3) Remove transmission oil filler tube (42).
30-149

8. Steering piping 1) Remove hoses (44) and (45) from steering valve (43). 2 )Disconnect hoses (47), (48), and (49) between steering valve (43) and priority valve.
CENTER HINGE PIN
3) Remove hose (50) between steering valve and hydraulic tank. Fit blind plugs after disconnecting the hoses.
9. Floor frame, cab assembly Sling floor frame and cab assembly (51), then remove mounting bolts (51-1) and lift off. When raising the floor frame and cab assembly, pull the brake booster out gradually from the mounting bracket, and raise the cab slowly. The brake hose is not disconnected, so be careful not to catch the brake booster. Check that there is no interference from the hoses and wiring, then lift off. When raising the floor frame and cab assembly, lift slowly for approx. 40 - 50 mm, stop and check that there is no interference, then continue to lift. Floor frame, cab assembly: 680 kg
Floor frame assembly: 155 kg Eyebolts for removing cab assembly M = 16mm, P = 2.0mm (4 bolts)
30-150

10. Steering cylinder 1) Disconnect hoses (52) and (53) between steering valve and steering cylinder from connection with tube. Disconnect both the left and right hoses. 2) Remove bottom lock bolt of steering cylinder, then remove pin (54).
CENTER HINGE PIN
11. Drive shaft Disconnect center drive shaft (55) at transmission end. When removing the drive shaft, set a block between the rear frame and the drive shaft to prevent the grease fitting from being crushed.
12. Electric wiring Remove clamp mounting bolts (56) and (56-1) of front frame wiring.
13. Brake tube Remove clamp of brake hose and tube (57) for front axle from frame.
30-151

14. Hydraulic piping Remove mounting bolts of dump and lift cylinder hose clamp brackets (60) and (60-1) for front frame (58) and rear frame (59) from frame.
CENTER HINGE PIN
15. Jacking up chassis 1) Adjust height of rear frame and set block (1) in position. 2) Adjust height of front frame on left and right, and set block (3) in position. Be extremely careful when adjusting the height of the frame.
3) Set support stand (2) to counterweight.
16. Lower hinge pin Remove lock bolt, then pull out lower hinge pin (61).
30-152

17. Upper hinge pin 1) Remove locknut (62) and washer (63). 2) Remove pin mounting bolts, then pull out upper hinge pin (64). There are shims between the retainer and frame, so check the number and thickness of the shims, and keep in a safe place.
CENTER HINGE PIN
18. Disconnection of frame 1) Remove safety bar, jack up front differential and palleter under bucket, then pull out to front of front frame. Carry out this operation with 2 workers and rotate the tires uniformly on the left and right. Be extremely careful to maintain the balance when carrying out this operation. Be careful not to let the spacer at the bottom of the upper hinge get caught in the rear frame, and insert a bar between the rear frame and front frame to raise the front frame while disconnecting. 2) After disconnecting frame, remove spacer (65). 19. Lower hinge 1) Remove washer (66). 2) Remove snap rings (67) and (68), then pull out bearing (69).
30-153
CENTER HINGE PIN
20. Upper hinge 1) Remove spacer (70). 2) Remove mounting bolt, then remove retainer (71). There are shims between the retainer and frame, so check the number and thickness of the shims, and keep in a safe place.
3) Remove dust seal (73) from retainer (72).
4) Remove bearing (74) and spacer (75) from front frame.
30-154
CENTER HINGE PIN
CENTER HINGE PIN

INSTALLATION 1. Upper hinge 1) Press fit bearing (74) and spacer (75) on front frame. The clearance between the bearing and spacer is adjusted, so do not change the combination. When replacing the bearing and spacer, replace as a set. When press fitting the bearing, press fit correctly and make sure that there is no clearance from the contact surface of the frame. Bearing: Grease (G2-LI) 2) Install dust seal (76) and spacer (70) from under front frame. Be careful not to damage the seal lip, and install with the lip on the outside. Outside circumference of dust seal: Thread tightener (Loctite 601) Seal lip: Grease (G2-LI) Inside circumference of spacer: Grease (G2-LI)
3) Press fit dust seal (73) on retainer (72). When press fitting the dust seal, fit with the lip on the outside. Seal lip: Grease (G2-LI)
4) Tighten retainer (72) with 4 mounting bolts, then insert shims so that clearance "a" between retainer and frame is standard value. Clearance "a": 0.1 - 0.2 mm Mounting bolt (when adjusting shim): 4.9 0.98 Nm (0.5 0.1 kgm) Mounting bolt: 66.7 6.9 Nm (6.8 0.7 kgm)
30-155

2. Lower hinge 1) Install snap ring (68), and press fit bearing (69).
CENTER HINGE PIN
2) Install snap ring (67), and install washer (66).
3. Connecting frame Jack up front differential, move front frame towards rear frame and align pin holes. WARNING! Use a bar to align the pin holes. Never use your fingers. Be careful not to bite into the lower spacer (65) of the upper hinge when connecting the frames. Align the pin holes correctly.
Install the safety bar.
30-156

4. Upper hinge pin 1) Insert upper hinge pin (64). 2) Fit washer (63) and tighten lock nut (62) to specified tightening torque. Select shims to give standard value for clearance "b" between rear frame and pin. Temporarily tighten the mounting bolt to act as a stopper when tightening the lock nut. Clearance "b": Max. 0.4 mm Lock nut: 559 49 Nm (57 5 kgm)
CENTER HINGE PIN
3) Assemble selected shims, and tighten mounting bolts of pin. Before tightening the mounting bolts, tighten the lock nut to the specified torque again. Mounting bolt: 113 9.8 Nm (11.5 1.0 kgm)
5. Lower hinge pin Insert lower hinge pin (61), and secure with lock bolt. Outside circumference of hinge pin: Grease (G2-LI)
30-157

6. Lowering chassis Remove blocks (1) and (3) from front and rear frame and support stand (2) from counterweight, then lower chassis.
CENTER HINGE PIN
7. Hydraulic piping Install mounting bolts of dump and lift cylinder hose clamp brackets (60) and (60-1) for front frame (58) and rear frame (59) to frame.
8. Brake tube Connect front axle brake hose (57) to tube.
9. Electric wiring Install clamp mounting bolts (56) and (56-1) .for front frame wiring.
30-158

10. Drive shaft Connect center drive shaft (55) to transmission. Be careful of the direction of the yoke, and align the pilot portion correctly to install. Mounting bolt: 65.7 6.9 Nm. (6.7 0.7 kgm)
CENTER HINGE PIN
11. Steering cylinder 1) Install pin (54) to bottom of steering cylinder, and secure with lock bolt. 2) Connect hoses (52) and (53) between steering valve and steering cylinder.
12. Floor frame, cab assembly 1) Raise floor frame and cab assembly (51), stop approx. 100 mm from mount, assemble mounting bracket (77) to brake booster (76), and keep suspended. 2) Check mounting condition of brake booster, then install cab assembly (51) to rear frame. Tighten floor mounting bolts (51-1) unIformly at left, right, front, and rear. Check that there is no interference with any hoses or wiring when installing. Mounting bolt: 274.6 29.4 Nm (28.0 3.0 kgm)
30-159

13. Steering piping 1) Connect hose (50) between steering valve and hydraulic tank. 2) Connect hoses (47), (48), and (49) between steering valve (43) and priority valve. 3) Connect hoses (44) and (45) to steering valve (43). Install the hoses without twisting or interference.
CENTER HINGE PIN
14. Parking brake cable 1) Install bracket (40) of parking brake cable (38) to front face of transmission, and connect parking brake cable (38) to lever. 2) Connect speedometer cable (41). 3) Install transmission oil filler tube (42). Adjust the parking brake. For details, see TESTING AND ADJUSTING.
15. Work equipment control cable Connect work equipment control cables (34) to each spool of valve. Install the clamp of the cable.
30-160

16. Transmission valve wiring Connect each transmission valve wiring connectors (33). When connecting, check the tags used to identify the wiring
CENTER HINGE PIN
17. Fuel control cable Connect fuel control cable (27) to engine end, and install bracket (28) to engine. For machines with cab ! Connect the washer hose to the tank end.
18. Brake booster 1) Remove block under brake booster (25), and install mounting bolts (26). Tighten the mounting bolts uniformly and be careful not to tighten them too much. Mounting bolt: 110.3 12.3 Nm (11.25 1.25 kgm)
2) Insert brake linkage rod (23) in boot portion of brake booster (25), and connect to linkage lever. 3) Connect ball joint (24) and tighten locknut. Locknut: 29.4 4.9 Nm (3.0 0.5 kgm)
30-161

19. Electric wiring Connect connectors to following electric wiring. ! Connectors (11), (12), (13), (14), (15), and (16) of front wiring (9) and rear wiring (10). ! Connector (17) of cab wiring ! Connect ground wiring (18) to rear frame. ! Connect transmission cut-off switch (19) and wiring connector (20). ! Install wiring clamp and bracket (21) to rear frame (22). When connecting, check the tags used to identify the wiring
CENTER HINGE PIN
20. Cover 1) Install brake oil tank mount bracket (8) together with oil tank (7) to bottom of floor. 2) Connect connector for left brake oil level sensor.
3) Sling left ladder rail (4), then raise together with center fender (5) and install. Carry out the operation in the same way on the right side. When raising the ladder to install it, be careful of the center of gravity. Be careful not to damage the cab glass.
30-162

21. Refilling with oil Tighten drain plug and add hydraulic oil through oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. Hydraulic oil: Add oil
CENTER HINGE PIN
22. Bleeding air from brake system ! If the hose has been disconnected from the brake booster, bleed the air from the brake system. For details of the procedure for bleeding air, see TESTING AND ADJUSTING. Install cover (1) at the top of the hydraulic tank on the right side, and covers (2) on the left and right under the floor.
30-163
PRIORITY VALVE
PRIORITY VALVE
REMOVAL WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. Turn the steering wheel to the left to articulate the chassis. Remove cover (1) at the top of the hydraulic tank on the right side, then remove covers (1-1) on the left and right under the floor. WARNING! 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. Loosen plug (2) to prevent the oil inside the hydraulic tank from flowing out.
1. Hydraulic piping Disconnect following piping. ! Hose (3) between hydraulic pump and priority valve. Remove rear right inspection cover (2-1), disconnect hydraulic pump, and remove hose (2-3) while still installed to the priority valve. This operation can also be carried out by removing connector mounting bracket (2-2) connecting the front wiring and rear wiring. To prevent damage to the mounting bolts, remove hose (2-3) after removing the priority valve. ! Hose (4) between priority valve and main control valve ! Hose (5) between steering valve and priority valve ! Hose (6) between priority valve and hydraulic tank ! Hose (7) between priority valve and steering valve Remove hose (7) after removing the priority valve.
30-164

2. Priority valve Remove mounting bolts (8), then remove priority valve (9). Remove hose (7) after removing the priority valve.
PRIORITY VALVE
PRIORITY VALVE
INSTALLATION
Carry out installation in the reverse order to removal.
Hose (4) mouthpiece: 176.5 29.4 Nm (18 3 kgm) (Width across flats: 36 mm) Hose (7) mouthpiece: 78.5 19.6 Nm (8 2 kgm) (Width across flats: 27 mm)
Install to the rear frame after installing hose (3) to the priority valve. Hose mouthpiece: 176.5 29.4 Nm (18 3 kgm) (Width across flats: 36 mm) Mounting bolt (8): 31.4 Nm (3.2 kgm) If the mount plate had to be removed, assemble as shown in the diagram on the right. Mounting bolt: 110.3 12.3 Nm (11.25 1.25 kgm)
30-165
STEERING VALVE
STEERING VALVE
REMOVAL WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. Remove cover (1) at the top of the hydraulic tank on the right side, then remove covers (1-1) on the left and right under the floor. WARNING! 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. Loosen plug (2) to prevent the oil inside the hydraulic tank from flowing out.
1. Column cover Remove steering column cover (4), then remove plugs (3) of bottom boot (5), and roll up.
2. Hydraulic piping Disconnect following hydraulic piping. ! Hose (6) between steering valve and priority valve ! Hose (7) between priority valve and steering valve ! Tubes (8) and (9) between steering valve and steering cylinder ! Hose (10) between steering valve and priority valve ! Hose (11) between steering valve and hydraulic tank Fit tags to identify the piping.
30-166

3. Steering valve Carry out the steering valve removal operation with 2 workers, give signals to each other, and be extremely careful when removing the steering valve. 1) Remove lock bolt (12) of spline connecting portion at steering column end. Be sure to remove lock bolt (12). If it is not removed, the lock bolt will catch in the column shaft lock groove, and the steering valve will not come out .
STEERING VALVE
2) Support from below, and remove bracket mounting bolt (14).
3) Remove steering valve (15). Remove the steering valve together with bracket (13). 4) Remove lock bolt (12-1) from steering valve (15), remove coupling (16) and mounting bolts (17), then remove bracket (13) and column assembly (18). Make match marks before removing column assembly (18) from the steering valve.
30-167
STEERING VALVE
STEERING VALVE
INSTALLATION ! Carry out installation in the reverse order to removal. Carry out the steering valve installation operation with 2 workers, give signals to each other, and be extremely careful when installing the steering valve.
Install the hoses without twisting or interference. Hoses (7), (8), (9), (11) Hose mouthpiece: 78.4 19.6 Nm (8 2 kgm) Width across flats of hose mouthpiece: 27 mm
When assembling the lock bolt, align with the column shaft groove and screw in. Lock bolt (12): 24.5 4.9 Nm (2.5 0.5 kgm)
Column shaft spline: Grease (G2-LI)
When assembling the lock bolt, align with the column shaft groove and screw in. Lock bolt (12-1): 28.4 3.9 Nm (2.9 0.4 kgm)
Tighten mounting bolts (17) on diametrically opposite sides. Mounting bolt (17): 41.7 17.2 Nm (4.25 1.75 kgm) (U3/8)
If the oil seal of the column assembly has been replaced, coat the oil seal lip with grease. Lip of oil seal: Grease (G2-LI) ! Refilling with oil Tighten drain plug and add hydraulic oil through oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
30-168
STEERING VALVE
STEERING VALVE
DISASSEMBLY Use a wire brush to remove all the dirt and dust stuck to the joint around the outside circumference of the unit. Carry out the operation in a clean place to prevent dirt or dust from sticking to the valve. As far as possible, hold the valve in a vice when disassembling.
DISASSEMBLY OF ROTOR 1. Set rotor side facing up, and hold mounting flange lightly in vice (1). Put a copper plate in contact with the vice and be careful not to tighten the vice too hard.
2. Remove screw (1), then remove end cap (2). 3. Remove O-ring (3) from end cap (2).
4. Pull out rotor set (4), then remove O-ring (5). Be careful not to drop the star inside the rotor set. 5. Remove spacer (6).
30-169

6. Remove drive shaft (7). 7. Remove spacer plate (8). 8. Remove O-ring (9) from housing (10).
STEERING VALVE
DISASSEMBLY OF CONTROL SIDE 9. Remove housing (10) from vice, and place on a clean cloth. Be careful not to damage the finished surface. 10. Raise tip of snap ring (11) with screwdriver, and remove from housing.
11. Turn spool and sleeve to place pin in a horizontal position, then push in spool and sleeve with your thumb, and remove bushing (12) from housing.
12. Remove X-ring seal (13) from bushing (12). 13. Remove dust seal (14) from bushing (12) with screwdriver. Be careful not to damage the bushing.
30-170

14. Remove 2 bearing races (15) and thrust needle (16) from spool and sleeve.
STEERING VALVE
15. Pull out spool and sleeve assembly (17) from housing (10) in the direction of the arrow. To prevent the spool and sleeve assembly from catching in the housing, rotate the spool and sleeve assembly slowly to the left and right when pulling out from the housing. 16. Pull out pin (18) from spool and sleeve assembly (17).
17. Push spool (20) inside sleeve (19) slightly to front, and remove 6 centering springs (21) from spool (20) carefully by hand. 18. Turn spool (20) slowly and pull out from rear of sleeve (19) (in the direction of the arrow).
19. Remove O-ring (22) from housing. 20. Remove set screw (23) from housing. 21. Screw a threaded bar into check sheet (24), and pull out check sheet (24). 22. Remove O-rings (25) and (26) from check sheet (24). 23. Tap housing, and remove ball (27) and retainer (28).
30-171
STEERING VALVE
STEERING VALVE
ASSEMBLY Check all parts for damage or burrs. Wash all metal parts in clean solvent and blow dry with air. Do not use a file or polish any part with rough sandpaper. Coat the O-rings with clean grease. (No need to put grease on new X-ring seals) Coat the O-ring for the rotor set with a small amount of grease.
ASSEMBLY OF CONTROL SIDE

1. Insert retainer (28) in housing with tweezers. Check that the retainer is not inserted at an angle. 2. Insert ball (27). 3. Fit O-rings (26) and (25) in check sheet (24), and push check sheet (24) into housing. Be careful to set the top and bottom of the check sheet facing in the correct direction. 4. Install set screw (23). Check that the set screw is set in slightly from the end face of the housing. Set screw: 11.8 Nm (1.2 kgm) Set screw: Loctite
5. Assemble spool (20) and sleeve (19) so that spring groove is on same side. Rotate the spool and slide it in. Grip the splined portion of the spool lightly and check that the spool rotates smoothly inside the sleeve. If there are match marks, check that the match marks are aligned.
30-172

6. Align spring groove positions of spool (20) and sleeve (19), and set on flat plate, then insert spring (21) in spring groove. Set so that the notches at both ends are at the bottom.
STEERING VALVE
7. Insert pin (18) in spool and sleeve assembly (17).
8. Insert spool and sleeve assembly (17) in housing (10) in the direction of the arrow. 1) Keep pin horizontal and rotate to left and right a little at a time to insert. Be extremely careful not to get it caught. 2) Make the spool and sleeve assembly flush with the rear end face of the housing. If it is inserted beyond the end face, the pin will fall out. 3) Check that spool and sleeve rotate smoothly inside housing.
9. Install O-ring (22) to housing (10). 10. Fit 2 bearing races (15) and thrust needle (16) in case (10).
30-173

11. Insert dust seal (14) in bushing (12). 12. Insert X-ring seal (13) in bushing (12). 13. Insert bushing (12) in spool, and rotate to install. ! Tap with a plastic hammer to assemble to the specified position. ! It must be in contact horizontally with the bearing race. 14. Fit snap ring (11) in housing.
STEERING VALVE
ASSEMBLY OF ROTOR 15. Hold flange of housing lightly in vice. Be careful not to tighten the vice too hard. Check that the spool and sleeve are set in slightly from the housing surface with fourteen holes.
16. Insert O-ring (9) in housing. 17. Put on spacer plate (8), and align positions of bolt hole and tap hole of housing.
30-174

18. Turn spool and sleeve assembly to make pin (18) and port surface of housing parallel, then mesh pin and yoke of drive shaft (7). To position accurately, draw a line on the end face of the drive shaft spline.
STEERING VALVE
19. Insert O-ring (5) in rotor set (4).
20. Make O-ring (5) end of rotor set to spacer plate end, then align insert portion of star of rotor (4) with drive. 1) Check that lines A, B, C, and D are all parallel. 2) Without removing joint of drive shaft (7), position bolt holes of rotor set. This procedure is very important for determining the valve timing of unit.
21. Insert spacer (6) inside rotor set. 22. Set end cap (2) on rotor set, and align bolt hole.
30-175

23. Coat thread of screw with grease, and tighten end cap. Install the handle to the spool, and check that the spool rotates. End cap mounting screw First step: 14.7 Nm (1.5 kgm) Second step: 27.0 1.5 Nm (2.75 0.15 kgm)
STEERING VALVE
30-176
MAIN CONTROL VALVE
MAIN CONTROL VALVE

REMOVAL WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. Raise the boom, set stand (1A) of boom holding stopper (U) in position, then remove front cover (1). Remove cover (2) at the top of the hydraulic tank on the right side.
WARNING! 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. Loosen plug (3) at the top of the hydraulic tank filter to prevent the oil inside the hydraulic tank from flowing out.
1. Drive shaft Disconnect drive shaft (4) at front axle end. After disconnecting the drive shaft, move it to the left and secure it with wire.
2. Electric wiring Disconnect electric wiring connectors (5) and (6) for main control valve. Fit tags with numbers to identify the wiring.
30-177

3. Control cable Pull out snap pin and remove pins (7), then remove control cables (8) from spools (9). Fit tags with numbers to identify the wiring.
MAIN CONTROL VALVE
4. Hydraulic piping Disconnect following hydraulic piping. ! Tubes (10) and (11) between main control valve and boom cylinder ! Hoses (12) and (13) between main control valve and the pilot solenoid valve for the tilt cylinders. ! Hose (14) between hydraulic pump and main control valve ! Hose (15) between main control valve and hydraulic tank ! Between main control valve and oil return hose (16)
5. Main control valve 1) Install eyebolt to front frame boss. Install the eyebolt to the boss portion securely. ! M = 12, P = 1.75 2) Using eyebolt installed to front frame, fit lifting tool and sling main control valve (18).
3) Remove mounting bolts (19) on top of mounting bracket of main control valve (18), then remove main control valve. Main control valve: 21 kg Loosen bottom bracket mounting bolts (20). When removing the main control valve, remove the top mounting bolts and lift off.
30-178
MAIN CONTROL VALVE
MAIN CONTROL VALVE

INSTALLATION Carry out installation in the reverse order to removal. Be careful of the direction of the yoke, and align the pilot portion correctly to install. Mounting bolt: 65.7 6.9 Nm (6.7 0.7 kgm) Install the snap pin securely.
Install the hoses without twisting or interference. Tube mouthpiece: 265 29.4 Nm (27 3 kgm) (Width across flats: 36 mm) Hose mouthpiece: 176.5 29.4 Nm (18 3 kgm) (Width across flats: 36 mm)
Align with the bottom bracket mounting bolts and install the main control valve. Be sure to tighten all of the bottom bracket mounting bolts. Mounting bolt: 110.3 12.3 Nm (11.25 1.25 kgm) ! Refilling with oil Tighten drain plug and add hydraulic oil through oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
30-179
MAIN CONTROL VALVE
MAIN CONTROL VALVE

DISASSEMBLY
30-180

1. Spool assembly 1) Remove mounting bolt (2) and plug (3) of detent assembly (1). 2) Holding spool (4) from moving, loosen bolt (5) inside detent assembly (1), then remove detent assembly (1). Remove joint (6) from spool (4). 3) Remove retainer (7), spring (8), retainer (9), oil seal (10) and plate (11). 4) Remove plate (12), then remove oil seal (10) and spool (4). 2. Main relief valve assembly 1) Remove main relief valve assembly (13). 2) Loosen nut (14), and screw out holder (15), then remove retainer (16), spring (17), poppet (18), seat (19) and spring (20). 3) Remove plug (21), then remove valve (22) from sleeve (23). Valve (22) and sleeve (23) are not available as individual parts, so replace them as a set. 3. Remove safety valve assembly (25) with suction valve and suction valve assembly (24). 4. Remove plug (26), then remove spring (27) and valve (28).
MAIN CONTROL VALVE
30-181
MAIN CONTROL VALVE
MAIN CONTROL VALVE

ASSEMBLY
30-182
MAIN CONTROL VALVE
1. Assemble valve (28) and spring (27) in body (29), and fit O-ring and tighten plug (26). Plug: 107.8 14.7 Nm (11 1.5 kgm) 2. Fit O-rings and install suction valve assembly (24) and safety valve assembly (25) with suction valve. Safety valve (with suction): 142.2 19.6 Nm (14.5 2 kgm) Suction valve: 142.2 19.6 Nm (14.5 2 kgm) 3. Main relief valve assembly 1) Assemble valve (22) in sleeve (23), then tighten plug (21). 2) Assemble spring (20), seat (19), poppet (18), spring (17) and retainer (16) in sleeve. 3) Screw nut (14) into holder (15), fit O-ring on holder, then install the holder into sleeve (23) and tighten nut (14). 4) Fit O-ring and backup ring and install main relief valve assembly (13). Main relief valve: 83.4 14.7 Nm (8.5 1.5 kgm) 4. Spool assembly 1) Assemble spool (4) in body, then install oil seal (10) and plate (12). 2) Pull out spool slightly, then assemble retainer (11), oil seal (10), retainer (9), spring (8), and retainer (7). 3) Holding spool from moving, turn bolt inside detent assembly (1), and install joint (6) to spool (4). Joint: 14.7 4.9 Nm (1.5 0.5 kgm) 4) Tighten bolt (5), then install detent assembly (1). 5) Tighten plug (3). Plug: 13.7 3.9 Nm (1.4 0.4 kgm)
30-183
STEERING CYLINDER
STEERING CYLINDER
REMOVAL WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. Remove cover (1-1) on the right under the floor. WARNING! 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. Loosen plug (1) to prevent the oil inside the hydraulic tank from flowing out.
1. Hydraulic piping 1) Disconnect steering cylinder rod hose (2) from steering cylinder tube. 2) Disconnect steering cylinder bottom hose (3) from steering cylinder tube.
2. Cylinder 1) Remove lock bolt at rod end, then remove pin (4). 2) Remove lock bolt at bottom end, remove pin (5), then remove cylinder (6). Be careful not to damage the rod plating.
30-184
STEERING CYLINDER
STEERING CYLINDER
INSTALLATION
! Carry out installation in the reverse order to removal.
Align the rod pin hole and assemble the shims so that clearance "b" between the cylinder and the frame is the specified value, then lock pin (4) with the mounting bolt. WARNING! Always use a bar when aligning the pin holes. Never insert your fingers. Clearance "b" = Max. 1.0 mm
Align the bottom pin hole and assemble the shims so that clearance "a" between the cylinder and the frame is the specified value, then lock pin (5) with the mounting bolt. WARNING! Always use a bar when aligning the pin holes. Never insert your fingers. Clearance "a" = Max. 1.0 mm ! Add hydraulic oil through oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
30-185
BRAKE BOOSTER
BRAKE BOOSTER
REMOVAL WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. Turn the steering wheel to the right to articulate the chassis.
1. Covers 1) Remove cover (1) under cab or on left and right sides of floor. 2) Remove cover (2) at left side of rear frame.
2. Machines equipped with air conditioner 1) Remove left ladder rail (3). Be careful not to catch the brake hose when removing the ladder rail. 2) Remove condenser front cover (4). Remove the hose clamp. 3) Remove condenser mounting brackets (5), and open condenser (6) to rear.
30-186

3. Brake piping 1) Disconnect hose (7) between brake booster and torque converter filter from brake booster. 2) Disconnect hose (8) between brake booster and transmission valve from brake booster. 3) Disconnect hoses (9) and (10) between brake oil tank and brake booster from brake booster. 4) Disconnect tubes (11) and (12) between brake booster and front and rear brake from brake booster. 5) Disconnect hose (13) between brake booster and transmission oil filler tube from brake booster.
BRAKE BOOSTER
4. Brake booster 1) Pull out ball joint (15) of brake linkage (14). 2) Remove 4 mounting bolts (16), then remove brake booster (17).
30-187
BRAKE BOOSTER
BRAKE BOOSTER
Be careful not to catch the brake hose when installing the ladder rail.
Install the hoses without twisting or interference. Be careful to assemble correctly when connecting the hoses between the brake booster and transmission.
Tube nut between front and rear brakes: 11.3 3.4 Nm (1.15 0.35 kgm) Hose clamp between brake oil tanks: 3.3 0.5 Nm (0.34 0.05 kgm)
Check that the cylinder rod is inserted in the brake booster piston groove. Ball joint nut: 29.4 4.9 Nm (3.0 0.5 kgm) Rod locknut: 110.3 12.3 Nm (11.25 1.25 kgm)
Mounting bolt (16): 110.3 12.3 Nm (11.25 1.25 kgm) ! Bleeding air Bleed the air from the brake system. For details, see TESTING AND ADJUSTING. Adjusting rod Adjust the rod. For details, see TESTING AND ADJUSTING.
30-188
BRAKE BOOSTER
BRAKE BOOSTER
DISASSEMBLY 1. Power master cylinder 1) Remove linkage rod (2) and dust cover from power master cylinder (1). Mask the tip of the piston of the linkage rod to protect it from damage.
2) Disconnect power cylinder (3) and master cylinder (4).
2. Piston assembly 1) Remove snap ring (5) from body (4), then remove secondary piston (6).
2) Remove stopper bolt (7), then hold brake oil hole (8) and stopper bolt hole (9) with finger. Blow in oil through brake oil hole (10) and remove primary piston (11). The piston may fly out, so do not blow the air in strongly.
30-189

3) Remove spring (12) from inside body (4). When removing the piston, be careful not to damage the inside diameter of the body or the sliding surface on the outside of the piston. If there is any problem with the primary or secondary pistons, replace the pistons as an assembly.
BRAKE BOOSTER
3. Fine disassembly of power cylinder 1) Remove dust cover (13). Remove the elbow first.
2) Push in cylinder cover (14), remove snap ring (15), then remove power piston (16), connector assembly (17), spring seat (18), and springs (19) and (20). WARNING! When removing the spring, the cylinder cover is pushed out by the spring, so remove carefully. 3) Remove power piston (16) from connector assembly (17).
4) Remove snap ring (21), disconnect spool (22) and connector, then remove thrust washer (23) and spring (24).
30-190

4. Relief valve Remove plug (25), then remove spring (26) and spool (27).
BRAKE BOOSTER
5. Power piston Remove seal ring (28) from piston (16).
30-191
BRAKE BOOSTER
BRAKE BOOSTER
ASSEMBLY 1. Elbow Install elbow (29) to power cylinder body (3).
2. Relief valve Insert spring (26) in spool (27), assemble in power body, then install plug (25).
3. Fine assembly of power cylinder 1) Assemble spring (24) in connector (31).
2) Insert spool (22) in connector (31), and assemble thrust washer (23), then secure with snap ring (21).
30-192

3) Set body (3) on block. 4) Insert springs (19) and (20), and spring seat (18) inside body (3). 5) Assemble connector assembly (17).
BRAKE BOOSTER
6) Assemble O-rings (32) and seal (33) in cylinder cover (14). Seal: Oil (brake oil)
7) Assemble seal ring (28) in power piston (16). Seal ring: Oil (brake oil)
30-193

8) Assemble power piston (16) and cylinder cover (14) to spool (22), then set guide shaft ..a in position. To prevent power piston (16) and cylinder cover (14) from dropping inside the body, stop them at the top of the body.
BRAKE BOOSTER
9) Push in guide shaft "a" with a press, bend springs (19) and (20), and keep in position. Keep snap ring (15) until the completion of assembly.
10) Lower power piston (16) only, and push in evenly on the left and right with both thumbs. When assembling the power piston, do not hit it in with a hammer. When assembling the power piston (16), apply the force evenly. Never use excessive force. 11) Check that there is no damage to O-ring of power piston (16), then assemble cylinder cover (14). 12) Secure cylinder cover (14) with snap ring (15).
30-194

13) Install dust cover (13).
BRAKE BOOSTER
4. Fine assembly of master cylinder 1) Insert primary piston (11) in body (4). Insert the piston carefully to prevent damage to the seal cup. Never force it into position. Body and piston: Oil (brake oil)
2) Push piston (13) and tighten stopper bolt (7) by hand. After tightening as far as possible by hand, tighten fully. Stopper bolt: 10.8 2.0 Nm (1.1 0.2 kgm)
3) Insert secondary piston (6) in body (4). Body and piston: Oil (brake oil) When assembling the piston, be careful not to damage the inside diameter of the body and the outside diameter of the piston. Be careful not to get the O-ring caught. 4) Push in secondary piston (6), then install C-ring (5). Fit the C-ring properly in the groove.
30-195

5. Power master cylinder 1) Connect power master cylinder (3) and master cylinder (4). Use a new O-ring for the connection of the master cylinder. Connecting bolt (34): 31.9 2.5 Nm (3.25 0.25 kgm)
BRAKE BOOSTER
2) Assemble linkage rod (2) to power master cylinder (1). For details of adjusting the brake linkage, see TESTING AND ADJUSTING.
30-196
PARKING BRAKE
PARKING BRAKE
REMOVAL If further disassembly is necessary, see DISASSEMBLY AND ASSEMBLY OF TRANSMISSION. WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. After putting blocks under the tires, release the parking brake. Loosen the plug of the transmission and drain the oil. Transmission oil: 28 R 1. Drive shaft 1) Disconnect drive shaft (1) from transmission end. Set block to the rear frame. 2) Using hexagonal wrench, remove 2 plugs on opposite sides, then install 2 piston lock set bolts Width across flats of hexagonal wrench: 6 mm Piston lock set bolt: p = 1.25, M = 8, L = 35
2. Coupling Remove mounting bolt (7), then remove holder (4), O-ring (5), and coupling (6). Make match marks on the coupling.
3. Parking brake housing Disconnect cable (9) from parking brake lever (8). Check that there are blocks under the tires, then disconnect the cable. Disconnect the cable with the parking brake released.
30-197

4. Parking brake 1) Remove all mounting bolts (10) of parking brake housing (11). 2) Tighten 2 forcing screws in forcing screw hole and remove parking brake housing (11). Use the housing mounting bolts as forcing screws. Do not remove bolts (20) used for installing retainer assembly (19). The working posture is poor and the housing is removed with the piston installed to the housing, so be extremely careful when removing. Install guide bolt to prevent the housing from failing. Be careful not to let the oil seal lip hit the shaft when removing. Parking brake housing: 15 kg
PARKING BRAKE
5. End plate 1) Remove separator plate bolt (14). 2) Remove separator plate (13), wave spring (15), and disc (16) in turn, then remove end plate (17). If it is necessary to remove hub spline (18), remove it as it is.
30-198
PARKING BRAKE
PARKING BRAKE
Be careful of the direction of the yoke, and align the pilot portion correctly to install. Mounting bolt: 65.7 6.9 Nm (6.7 0.7 kgm)
Soak the disc in clean transmission oil for at least 2 minutes before assembling. Use one spring. When assembling the separator plate, be careful that the hub spline does not rise up. Refilling with oil Install drain plug and add engine oil through oil filler to the specified level. Transmission oil: 28 R
Remove 2 piston lock set bolts and install the plug.
Be careful not to get the O-ring caught. Align with the coupling match mark, and assemble so that there is no misalignment of the front and rear couplings in the circumferential direction. Mounting bolt: 277 31.9 Nm (28.25 3.25 kgm)
If it is necessary to adjust the parking brake cable, see TESTING AND ADJUSTING.
After connecting the parking brake cable, bend the cotter pin securely.
Mounting bolt: 110.3 12.3 Nm (11.25 1.25 kgm)
The working posture is poor, so be extremely careful when installing the parking brake housing. Install a guide bolt to prevent the housing from falling. Use a new gasket. Be careful not to let the oil seal lip hit the shaft when installing.
Remove all oil and grease from the separator bolt thread and bolt hole. Tighten the separator bolts uniformly in turn. bolt: Thread tightener (LT-2) bolt: 53.9 19.6 Nm (5.5 2.0 kgm)
30-199
HYDRAULIC TANK
HYDRAULIC TANK
REMOVAL
WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. WARNING! 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. ! Loosen plug (1) at the top of the hydraulic tank filter to prevent the oil inside the hydraulic tank from flowing out. ! Remove covers (2) at the side first. 1. Ladder rail Lift off right ladder rail (3). Ladder rail: 22 kg
2. Hydraulic piping 1) Loosen clamp of hose (4) between hydraulic tank and pump, and disconnect when removing hydraulic tank. 2) Disconnect hose (5) between main control valve and hydraulic tank from hydraulic tank. ! Width across flats of hose mouthpiece (5): 36 mm 3) Disconnect hose (6) between steering valve and hydraulic tank and hose (7) between main control valve and hydraulic tank. ! Width across flats of hose mouthpiece (6): 27 mm 3. Hydraulic tank 1) Set palleter and stand under hydraulic tank (8). 2) Raise palleter slowly to support hydraulic tank (8).
30-200

3) Remove mounting bolts of hydraulic tank (8). Be sure to remove all the mounting bolts.
HYDRAULIC TANK
4) Pull out palleter and pull out hose between pumps while removing hydraulic tank (8). When removing the hydraulic tank, tip it to the outside and disconnect the hose. Hydraulic tank (dry): 53 kg
HYDRAULIC TANK
Mounting bolt: 112.8 9.8 Nm (11.5 1.0 kgm) ! Refilling with oil Add hydraulic oil through oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
30-201
HYDRAULIC FILTER
HYDRAULIC FILTER
REMOVAL Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. 1. Hydraulic piping Disconnect hydraulic hoses (1) and (2). ! ! Width across flats of hose mouthpiece (1): Width across flats of hose mouthpiece (2): 36 mm 27 mm
2. Cover Remove mounting bolts, then remove cover (3).
WARNING! The cover is under the tension of a spring, so be careful when removing it. Be careful not to damage the mating surface of the cover and the tank and O-ring (4).
3. Filter Remove spring (5) and bypass valve (6), then remove filter (7).
HYDRAULIC FILTER
Replace the O-ring with a new part. Fit the O-ring securely in the groove and be careful not to get it caught when assembling. After installing the hydraulic tank and connecting the hose, bleed the air from the hydraulic tank.
30-202
HYDRAULIC STEERING PUMP

REMOVAL WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. Disconnect the cable from the negative(-) terminal of the battery. 1. Cover, wiring 1) Remove cover (1) under right center fender. 2) Remove covers (3) and (4) top of hydraulic tank. Remove the wiring clamps. WARNING! 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. ! Loosen plug (2) to prevent the oil inside the hydraulic tank from flowing out.
3) Remove connector mounting bracket (7) connecting front wiring (5) and rear wiring (6), then move to side. Do not disconnect the connector at this point.
2. Hydraulic piping 1) Disconnect tube (8) between hydraulic tank and hydraulic, steering pump at hydraulic and steering pump end. 2) Disconnect hose (9) between hydraulic, steering pump and priority valve at hydraulic and steering pump end. 3. Pump Remove mounting bolts, then remove hydraulic and steering pump (10). WARNING! The working space is confined, so be extremely careful when removing.
30-203
HYDRAULIC, STEERING PUMP

INSTALLATION ! Carry out installation in the reverse order to removal. Be careful not to get the O-ring caught when installing the tube. Mounting bolt: 66.2 7.4 Nm (6.75 0.75 kgm)
Install the hoses without twisting or interference. Be careful not to get the O-ring caught when installing. Mounting bolt: 34.3 3.4 Nm (3.5 0.35 kgm)
Be careful not to get the O-ring caught when installing. Tighten the mounting bolts uniformly at the top and bottom. Mounting bolt: 110.3 12.3 Nm (11.25 1.25 kgm) ! Refilling with oil Run the engine to circulate the oil through the system. Then check the oil level again.
30-204
BUCKET CYLINDER
BUCKET CYLINDER
WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Then operate the control levers several times to release the remaining pressure in the hydraulic piping. REMOVAL 1. Bucket positioner Disconnect connector (1).
2. Rod pin Sling cylinder (7), then remove lock bolt, and remove pin (2). Sling at 2 points, and be careful of the center of gravity.
3. Hydraulic piping 1) Disconnect rod hose (3) from cylinder. ! Width accross flats of hose (3) mouthpiece: 36 mm 2) Disconnect bottom tube (4) at connection with hose (5) ! Width accross flats of hose (3) mouthpiece: 36 mm
30-205

4. Bucket cylinder 1) Remove lock bolt, then remove bottom pin (6). If there are shims installed, check the number and thickness of the shims, and keep in a safe place. 2) Lift off bucket cylinder (7). Be cafeful not to damage the cylinder rod portion. Bucket cylinder: 56 kg
BUCKET CYLINDER
INSTALLATION ! Carry out installation in the reverse order of removal.
WARNING! When aligning the position of the pin hole, use a bar. NEVER insert your fingers in the pin hole.
Bucket positioner For details of adjusting the bucket positioner, see TESTING AND ADJUSTING (section 20).
WARNING! When aligning the position of the pin hole, use a bar. NEVER insert your fingers in the pin hole. Align the pin hole at the cylinder bottom, assemble shims so that the total for clearance a between the cylinder and frame is within the standard value, then assemble pin (6) and lock with bolt. Clearance a: Max. 1.5 mm
30-206
BOOM CYLINDER
BOOM CYLINDER
WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Then operate the control levers several times to release the remaining pressure in the hydraulic piping. Set the support stand under the tip of the boom. REMOVAL 1. Rod pin 1) Sling boom cylinder (1), then remove lock bolt, and remove pin (2). If there shims installed, check the number and thickness of the shims, and keep in a safe place. 2) Start the engine, and use the control lever to retrack cylinder rod on side that was removed. Retract the rod to a point 20 mm before the end of the stroke. 2. Hydraulic piping 1) Disconnect rod tube (3) from connection of hose (4). 2) Disconnect bottom tube (5) from connection of hose (6). Do not forget to relieve the pressure in the hydraulic system before disconnecting tubes and hoses. After disconnecting the tubes and hoses, fit plugs to prevent the entry of dirt or dust.
3. Boom cylinder 1) Remove lock bolt, then remove bottom pin (7). If there shims installed, check the number and thickness of the shims, and keep in a safe place. 2) Lift off boom cylinder (1). Be careful of the center of gravity, and lift off slowly. Be cafeful not to damage the cylinder rod portion. Boom cylinder: 62 kg
30-207

INSTALLATION ! Carry out installation in the reverse order of removal.
BOOM CYLINDER
WARNING! When aligning the position of the pin hole, use a bar. NEVER insert your fingers in the pin hole. Start the engine, operate the control levers, extend the rod. Align the pin holes and assemble shims so that clearance b is within the standard value, then assemble pin (2) and lock with the bolt. Clearance b: Max. 2 mm
WARNING! When aligning the position of the pin hole, use a bar. NEVER insert your fingers in the pin hole. Align the pin hole at the cylinder bottom, assemble shims so that the total for clearance a between the cylinder and frame is within the standard value, then assemble pin (7) and lock with bolt. Clearance a: Max. 1.5 mm
30-208
HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
DISASSEMBLY 1. Set cylinder assembly (1) to tool A. 2. Raise lock portion of cylinder head (2), then using tool B, remove cylinder head (2) from cylinder.
3. Pull out cylinder head and piston rod assembly (3) from cylinder (4), and lift off. Oil will flow out when the piston rod assembly is removed from the cylinder, so place a container under the cylinder to catch the oil. 4. Remove cylinder (4) from tool A.
5. Set cylinder head and piston rod assembly to tool A, then using tool C, loosen nut (5).
Cylinder Boom Bucket Steering
Width across flats (mm) 60 70 46
6. Remove nut (5), then remove piston assembly (6), and retainer and cylinder head assembly (8) from rod (9). The retainer is for the steering cylinder only.
30-209

7. Disassembly of piston assembly 1) Remove wear ring (11). 2) Remove piston ring (12) from piston (13).
HYDRAULIC CYLINDER
8. Disassembly of cylinder head assembly 1) Remove snap ring (14), then remove dust seal (15). 2) Remove rod packing (16). 3) Remove bushing (17) from cylinder head (18). 4) Remove O-ring (19) and backup ring (20).
30-210
HYDRAULIC CYLINDER
HYDRAULIC 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 rod packing, dust seals or O-rings when assembling. 1. Assembly of cylinder head assembly 1) Using tool D, press fit bushing (17) to cylinder head (18). Be extremely careful not to deform the bushing when press fitting. 2) Install rod packing (16). Be sure to install the rod packing facing in the correct direction. 3) Using tool E, Install dust sea[ (15) to head (18). 4) Install snap ring (14). 5) Install backup ring (20) and O-ring (19). Do not try to force the backup ring into position. Warm it in warm water (50 - 60EC) before fitting it. 2. Assembly of piston assembly 1) Using tool F1, expand piston ring (12). Set the piston ring on the expander and turn the handle 8 - 10 times to expand the ring. 2) Remove piston ring (12) from tool F1, then assemble to piston (13). 3) Using tool F2, compress piston ring (12). 4) Assemble wear ring (11).
30-211

3. Set piston rod (9) to tool A. 4. Assemble cylinder head assembly (8) and retainer and piston assembly (6), and install nut (5). The retainer is for the steering cylinder only. 5. Using tool C, tighten nut (5). Rod thread: Thread tightener (LT-2) Nut: Cylinder Boom cylinder Bucket cylinder Steering Cylinder Width across flats (mm) 60 mm 70 mm 46 mm Tighening Torque Nm (kgm) 1765 176 (180 18) 2599 259 (265 26.5) 784 78 (80 8)
HYDRAULIC CYLINDER
6. Remove piston rod and head assembly from tool A, then set cylinder (4) to tool A. 7. Raise piston rod and head assembly (3), and assemble to cylinder (4). 8. Using tool B, tighten cylinder head nut (2). Cylinder head nut: Cylinder Boom Bucket Steering
Tightening torque Nm (kgm) 932 93 (95 9.5) 980 98 Nm (100 10) 441 44 (45 4.5)
9. Bend lock into notch at cylinder end. 10. Remove cylinder assembly (1) from tool A.
30-212
WORK EQUIPMENT
WORK EQUIPMENT
REMOVAL WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. 1. Bucket link 1) Remove bucket link mounting pin (1). Tie the bucket link to the tilt lever with wire. 2) Remove left and right bucket hinge mounting pins (2). WARNING! NEVER insert your fingers in the pin hole.
3) Drive machine in reverse and disconnect the bucket. Bucket (BOC): 710 kg
2. Bucket cylinder mounting pin Sling bucket cylinder (3), remove pin mounting (4), then disconnect cylinder rod and bellcrank. Set block between cylinder bottom and frame Bucket cylinder: 56 kg
3. Boom cylinder pin Sling boom cylinder (5), then remove mounting pin (6). Put support under the tip of the boom. Insert block on top of the axle, then lower the cylinder. If shims are inserted, check number and size of shims, and put in a safe place. Boom cylinder: 62 kg
30-213

4. Boom, bellcrank, bucket link 1) Remove bracket (7-1) of boom kick-out switch (7).
WORK EQUIPMENT
2) Sling boom bellcrank and bucket link (8), then remove mounting pins (9) of boom, then lift off the boom. Boom, bellcrank, bucket link: 662 kg
If there shims installed, check the number and thickness of the shims, and keep in a safe place.
5. Bellcrank, bucket link 1) Remove mounting pin (11) of bucket link (10), and remove from bellcrank. Bucket link: 17 kg Remove the wire holding the bucket to the bellcrank. WARNING! When the pin is removed, the bellcrank will move up suddenly, so keep your head and other parts away. If there shims installed, check the number and thickness of the shims, and keep in a safe place.
2) Sling bellcrank (12), remove mounting pin (13), then lift off from boom. Bellcrank: 125 kg
30-214

6. Dust seal, bushing 1) Remove dust seal (15) and bushing (16) from boom (14).
WORK EQUIPMENT
2) Remove dust seal (17) and bushings (18) from bellcrank (12).
3) Remove dust seal (19) and bushing (20) from bucket (10).
30-215
WORK EQUIPMENT
WORK EQUIPMENT
INSTALLATION WARNING! When aligning the position of the pin hole, use a bar. NEVER insert your fingers in the pin hole.
1. Dust seal, bushing Press fit bushings (16) to bucket link, bellcrank, and boom with press, and assemble dust seals (15) Bushing: Grease (G2-LI)
2. Bellcrank, bucket link 1) Align hole of boom (14) and bellcrank (12), and assemble shims so that clearance d is specified value, then assemble mounting pin (13), and lock with bolt. Clearance d: Max. 2.0 mm
2) Align hole of bellcrank (12) and bucket link (10), and assemble shims so that clearance e is specified value, assemble mounting pin (11), and lock with bolt. Clearance e: Max. 2.0 mm Secure the bucket link to the bellcrank with wire.
30-216

3. Boom, bellcrank, bucket link 1) Raise boom, bellcrank, and bucket link (8) and set in mounting position, align front frame and boom mount hole so that clearance a is specified value, then assemble mounting pin (9) and lock with bolt. Clearance a: Max. 1.5 mm After assembling the pins, set a stand under the tip of the boom.
WORK EQUIPMENT
2) Install bracket (7-1) of boom kick-out switch (7).
4. Boom cylinder Sling boom cylinder (5), start engine, align cylinder rod with boom mount hole, insert shims so that clearance f is specified value, then assemble mounting pin (6) and lock with bolt. Clearance f: Max.2.0 mm WARNING! When starting the engine, check that the directional lever is at neutral and that the parking brake is applied. Remove the block after assembling the mounting pins.
5. Bucket cylinder Sling bucket cylinder (3), adjust control lever and align pin hole, then assemble mounting pin (4), and lock with bolt. Remove the block after assembling the mounting pin.
30-217

6. Bucket Operate control lever and align hole of bucket mounting pin (2). Insert shims to make clearance b uniform on the left and right, then install mounting pin (2) and lock with bolt. Clearance b: Max. 1.5 mm
WORK EQUIPMENT
7. Bucket link Align hole of mounting pin (1) of bucket link (10). Insert shims to make clearance c uniform on the left and right, then install mounting pin (1) and lock with bolt. Clearance c: Max. 2.5 mm
8. Greasing Grease all pins
30-218
FUEL TANK
FUEL TANK
REMOVAL WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. WARNING! Disconnect the cable from the negative (-) terminal of the battery. 1. Open the side inspection cover and apply the lock, and open rear grill. 2. Loosen drain valve (1) and drain fuel.
3. Disconnect fuel hose (2), fuel return hose (3), and fuel gauge wiring connector (4). 4. Remove return hose (5) from fuel filter. Remove clamp of breather tube (5-1).
5. Remove cover (6).
6. Remove outer cover (8), inner cover (7), and rubber at oil filler port (6) on left side of rear frame.
30-219

3. Fuel tank 1) Set transmission jack under fuel tank, and support fuel tank (10) lightly.
FUEL TANK
2) Remove mounting bolts, then lower transmission jack slowly and remove. When there is a clearance of approx. 50 mm from the rear frame, stop and check that there is no interference. The oil filler tube will hit the rear frame, so move to the right and remove carefully. Fuel tank (dry): 80 kg
3) Pull out fuel tank (9) to right side of chassis.
FUEL TANK
Be sure to assemble the fuel hoses correctly.
When raising the transmission jack, maintain the balance, keep the fuel tank horizontal, and set in the mounting position. Tighten the bolts in turn on the left and right. Mounting bolt: 113 9.8 Nm (11.5 1.0 kgm) Refilling with oil Tighten drain plug and add fuel through fuel filler.
30-220
COUNTERWEIGHT
COUNTERWEIGHT
WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. REMOVAL OF LEFT AND RIGHT COUNTERWEIGHTS 1. Remove left (1) and right (2) counterweights. 1) Sling counterweights. 2) Remove mount bolts. Counterweight left: Counterweight right: 100 kg 170 kg
INSTALLATION OF LEFT AND RIGHT COUNTERWEIGHTS Install left and right in reverse order of removal. Mounting bolt (A): 549 59 N@m (56 6 kgm) Mounting bolt (B): 279 29 N@m (29 3 kgm)
REMOVAL OF REAR COUNTERWEIGHT 1. Removal of radiator grill. 1) Disconnect battery cables at the battery (3). 2) Disconnect electrical connections (4). 3) Disconnect backup warning horn (power and ground wires) (5). 2 Connect hoist (6) to radiator guard cover. 1) Disconnect gas spring cylinders at the frame (7). 2) Disconnect top mounting bracket.
3. TILT radiator guard cover from machine and set to the side.
30-221

4. Rear counterweight. Counterweight: 1210 kg
COUNTERWEIGHT
1) Using proper size hook and chain, hoist counter weight (to relieve pressure on mount bolts). 2) Remove four (4) mount bolts. WARNING! Rear counterweight may swing out from machine when the last bolt is removed. 3) Rest rear counterweight on a pallet (8).
INSTALLATION OF REAR COUNTERWEIGHT Install rear counterweight in reverse order of removal. Refer to ENGINE SHOP MANUAL. Mounting bolt: 927 98 N@m (95 10 kgm)
30-222
INSTRUMENT PANEL
INSTRUMENT PANEL
REMOVAL WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. Disconnect the cable from the negative (-) terminal of the battery. 1. Instrument panel Remove mounting bolts, then remove panel assembly (2) from instrument panel mount guard (1), and pull up. 2. Tachometer cable Disconnect tachometer cable (4) from housing (3). Remove the clip of the tachometer from the left side under the floor frame.
3. Electric wiring Disconnect following electric wiring connectors. ! Connectors (5) and (6) Remove the wiring from the clamp. 4. Panel 1) Remove panel assembly (2). 2) Remove each gauge from housing (3).
INSTRUMENT PANEL
After inserting the connectors, arrange the wiring so that there is no strain.
30-223

MEMORANDA
INSTRUMENT PANEL
30-224
40 MAINTENANCE STANDARD
Engine mount, transmission mount . . . . . . . . . . Torque converter, charging pump . . . . . . . . . . . Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission control valve . . . . . . . . . . . . . . . . . Accumulator valve . . . . . . . . . . . . . . . . . . . . . . . . Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional counterweight . . . . . . . . . . . . . . . . . . . Center hinge pin . . . . . . . . . . . . . . . . . . . . . . . . . Steering column . . . . . . . . . . . . . . . . . . . . . . . . . Steering cylinder mount . . . . . . . . . . . . . . . . . . . Priority valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake booster . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . Main control valve . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic cylinder . . . . . . . . . . . . . . . . . . . . . . . . Work equipment linkage . . . . . . . . . . . . . . . . . . . Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bucket positioner and boom kick-out . . . . . . . . . 40- 3 40- 4 40- 5 40- 6 40-18 40-22 40-23 40-25 40-28 40-30 40-31 40-32 40-34 40-35 40-36 40-37 40-38 40-39 40-40 40-42 40-46 40-48 40-50 40-51
40-1
MAINTENANCE STANDARD
MEMORANDA
MEMORANDA
40-2
ENGINE MOUNT, TRANSMISSION MOUNT
ENGINE MOUNT, TRANSMISSION MOUNT
40-3
unit: mm No. 1
Check item Standard clearance 0.05 - 0.10
Criteria Clearance limit 0.15
Remedy
Side clearance Clearance between inside diameter of plain bearing and outside diameter of gear shaft Depth for knocking in pin Rotating torque of spline shaft Discharge amount oil: EO10-CD oil temperature: 45-55E C
0.060 -0.119
0.200 Replace
Standard size 3 10
Tolerance 0 -0.5
2.0 -4.9 Nm (0.2 - 0.5 kgm) Rotating speed 3000 rpm Delivery pressure 2.9 MPa (30 kg/cm) Standard delivery Delivery amount amount limit 94 R/min 86 R/min
40-4
TORQUE CONVERTER
TORQUE CONVERTER
Unit: mm No. 1 Check item Standard size Outside diameter of pilot Inside diameter of retainer seal ring contact surface Wear stator shaft seal Width ring Thickness Backlash between PTO drive gear and drive gear 42 100 3 4 Criteria Tolerance -0.009 -0.034 +0.035 0 -0.01 -0.03 0.15 - 0.42 Repair limit 41.75 100.5 2.7 3.6 Replace Repair chrome plating or replace Remedy
40-5
TRANSMISSION
TRANSMISSION (1/3)
40-6

Unit: mm No.
TRANSMISSION
Check item Shaft 0 -0.012 0 -0.013 0 -0.012 0 -0.013 +0.025 +0.009 0 -0.015 -0.009 -0.025 0 -0.011
Criteria Tolerance Hole +0.021 -0.008 +0.018 -0.012 +0.021 +0.008 +0.018 -0.012 0 -0.012 +0.022 -0.013 +0.041 +0.025 +0.014 -0.011 Standard clearance -0.008 -0.033 -0.012 0.031 0.008 0.033 -0.012 0.031 -0.037 -0.009 -0.013 0.037 0.034 0.066 -0.011 0.025 Clearance limit -
Remedy
Standard size Clearance between 4th shaft and bearing (R) 30 Clearance between 4th shaft bearing (R) and housing Clearance between 4th shaft and bearing (F) Clearance between 4th shaft bearing (F) and housing Clearance between pump drive shaft and bearing Clearance between pump drive shaft bearing and housing Clearance between pump drive shaft and bearing Clearance between pump drive shaft bearing and housing 72 30 72 50 90 35 47
2 3 4 5 6 7 8
Replace
40-7
TRANSMISSION
TRANSMISSION (2/3)
40-8

Unit: mm No. Check item Standard size 50 2 3 4 5 6 7 8 9 Clearance between pump drive shaft bearing and housing Clearance between pump drive shaft and bearing Clearance between pump drive shaft bearing and housing Clearance between input shaft and bearing Clearance between input shaft bearing and housing earing Clearance between input shaft and bearing Clearance between input shaft bearing and housing Clearance between REVERSE, 1st clutch bearing (F) and housing 80 35 47 35 72 50 90 90 Shaft +0.025 -0.009 0 -0.013 -0.009 -0.025 0 -0.011 +0.009 +0.025 0 -0.013 -0.009 -0.025 0 -0.0151 0 -0.015 0 -0.015 0 -0.015 0 -0.015 0 -0.018 0 -0.015 Criteria Tolerance Hole 0 -0.012 +0.018 -0.012 +0.041 +0.025 +0.014 -0.011 0 -0.012 +0.018 -0.012 0 -0.012 +0.022 -0.013 +0.022 -0.013 -+0.022 -0.013 +0.022 -0.013 +0.022 -0.013 +0.026 -0.014 0 -0.015 Standard clearance -0.037 -0.009 -0.012 0.031 0.034 0.066 -0.011 0.025 -0.037 -0.009 -0.012 0.031 0.037 0.009 -0.013 0.037 --0.013 0.037 --0.013 0.037 -0.013 0.037 --0.013 0.037 -0.014 0.044 --0.013 0.037
TRANSMISSION
Remedy Clearance limit Replace -
Clearance between pump drive shaft and bearing
Clearance between 10 REVERSE, 1st clutch bearing (R) and housing Clearance between FORWARD, 2nd cl;utch 11 clutch bearing (F) and housing Clearance between 12 FORWARD, 2nd clutch bearing (R) and housing Clearance between 3rd, 4th 13 clutch bearing housing (F) and housing Clearance between 3rd, 4th 14 clutch bearing (R) and housing
90
110
90
130
90
40-9
TRANSMISSION
TRANSMISSION (3/3)
40-10

Unit: mm No. Check item Clearance between output shaft and bearing (F) Clearance between output shaft bearing (F) and housing Clearance between output shaft and bearing (R) Clearance between output shaft bearing (R) and housing Clearance between output shaft oil seal (F) and housing Clearance between output shaft oil seal (R) and housing Inside diameter of housing seal ring contact surface Width of shaft seal ring grove Width of seal ring Thickness of seal ring 8 Outside diameter of sliding portion of coupling oil seal (F) Outside diameter of sliding portion of coupling oil seal (R) Standard size 50 2 3 4 5 6 90 50 90 90 90 Shaft +0.031 +0.015 0 -0.015 +0.031 +0.015 0 -0.015 +0.170 +0.080 +0.170 +0.080
TRANSMISSION
Criteria Tolerance Hole 0 -0.012 -0.015 -0.040 0 -0.012 -0.015 -0.040 +0.054 0 +0.054 0 Tolerance +0.05 +0.076 0 0 -0.13 0 -0.1 0 -0.074 0 -0.074 Standard clearance 0.02 - 1.68 0.10 - 1.0 Nm (0.01 - 0.10 kgm) Standard clearance -0.043 -0.015 -0.040 - 0 -0.043 0.015 -0.040 - 0 -0.170 -0.026 -0.170 -0.026 Clearance limit Repair limit 0.05 (Amount of wear) 3.5 2.6 2.1 0.05 (Amount of wear) 0.05 (Amount of wear) clearance limit -
Remedy
Standard size 50 3.2 3.0 2.29 65
Replace
65 Standard size 0.85
between parking 10 Clearance brake housing and case Free rotation torque of output 11 shaft
Adjust shim
40-11
TRANSMISSION
REVERSE, 1ST CLUTCH
Unit: mm No. Check item Standard size 1 Clearance between piston and cylinder REVERSE Inside 85 Shaft +0.102 -0.090 -0.35 -0.040 +0.102 +0.090 -030 -0.35 +0.025 +0.009 +0.025 +0.009 +0.025 +0.009
Criteria Tolerance Hole +0.28 +0.15 +0.08 -0.05 +0.28 +0.15 +0.13 0 0 -0.012 0 -0.012 0 -0.012 Standard clearance 0.048 0.19 0.30 0.48 0.048 0.19 0.048 0.19 -0.009 -0.037 -0.009 -0.037 -0.055 -0.009 Clearance limit 0.24
Remedy
Outside 1ST Inside Outside
118 85 140 50
0.53 0.24 Replace 0.53 -
Clearance between piston and cylinder
Clearance at bearing press fitting portion of REVERSE clutch shaft Clearancet bearing press fitting portion of 1st clutch shaft Clearance at spacer press fitting portion of REVERSE, 1st clutch shaft
50
51
40-12

Unit: mm No. Check item 6 Thickness of seperator plate Distortion of separator plate 7 Thickness of friction plate Distortion of friction plate 8 9 Load of wave spring Thickness of REVERSE, 1st clutch spacer Standard size 1.8 3.0 902 N (92 kg) (Height: 2.975 mm) 5.0 3.0
TRANSMISSION
Criteria Tolerance 0.06 0.05 +0.05 -0.10 0.07 902 N ( 92 kg) 0.05 0.1 0.07 - 0.93 0.04 - 1.16 Repair limit 1.7 0.15 2.65 0.14 731 N (74.5 kg) 2.7
Remedy
Replace
of REVERSE, 1st 10 Thickness clutch thrust washer 11 End play of REVERSE gear 12 End play of 1st gear
40-13
TRANSMISSION
FORWARD , 2ND CLUTCH
Unit: mm No. Check item Standard size FORWARD 1 Clearance between piston and cylinder Inside 85 Shaft +0.102 +0.090 -0.35 -0.40 +0.102 +0.090 -0.30 -0.35 +0.025 +0.009 +0.025 +0.009 +0.025 +0.009
Criteria Tolerance Hole +0.28 +0.15 +0.08 -0.05 +0.28 +0.15 +0.13 0 0 -0.012 0 0.012 0 -0.03 Standard clearance 0.048 0.19 0.30 0.48 0.048 0.19 0.030 0.48 -0.037 -0.009 -0.037 -0.009 -0.055 -0.009 Clearance limit 0.24
Remedy
Outside Inside Outside
118 85 140 50
0.53 0.24 Replace 0.53 -
Clearance between piston and cylinder
Clearance at bearing press fitting portion of FORWARD clutch shaft Clearance at bearing press fitting portion of 2nd clutch shaft Clearance at spacer press fitting portion of FORWARD, 2nd clutch shaft
2ND
50
51
40-14

Unit: mm No. Check item 6 7 Thickness of FORWARD, 2nd clutch thrust washer Thickness of separator plate Distortion of separator plate Thickness of friction plate Distortion of friction plate 9 Load of wave spring Standard size .03 1.8 3.0 902 N (92 kg) (Height: 2.975 mm) 5.0
TRANSMISSION
Criteria Tolerance 0.1 0.06 0.05 +0.05 -0.10 0.07 90.2 N (9.2 kg) 0.05 0.07 - 0.93 0.04 - 1.16 Repair limit 2.7 1.7 0.15 2.65 0.14 731 N (74.5 kg) -
Remedy
Replace
of FORWARD, 10 Thickness 2nd clutch spacer play of FORWARD 11 End gear 12 End play of 2nd gear
40-15
TRANSMISSION
3RD, 4TH CLUTCH
Unit: mm No. Check item Standard size 1 Clearance between piston and cylinder Inside Outside 2 Clearance at outside diameter of bearing press-fitting portion of 4th clutch shaft Clearance at outside diameter of bearing press-fitting portion of 3rd clutch shaft Clearance at spacer press-fitting portion of 4th clutch shaft Clearance at spacer press-fitting portion of 3rd clutch shaft Thickness of separator plate Distortion of separator plate 7 Thickness of friction plate Distortion of friction plate 8 Load of wave spring 85 140 50 Shaft +0.102 +0.090 -030 -0.35 +0.025 +0.009 +0.030 +0.011 +0.025 +0.009 0.030 +0.011 1.8 3.0 -
Criteria Tolerance Hole +0.28 +0.13 0 0 -0.012 0 -0.015 0 -0.03 0 -0.03 Tolerance 0.06 0.05 +0.05 -0.10 0.07 Standard clearance 0.048 0.19 0.30 0.48 -0.037 -0.009 -0.045 -0.011 -0.055 -0.009 -0.060 -0.011 1.7 0.15 2.65 0.14 731 N (74.5 kg) Clearance limit 0.24 0.53 -
Remedy
3 4 5
60 51 61
Repair limit Replace
Standard size 6
902 N (92 kg) (Height: 2.975 mm) 90.2 N (9.2 kg)
40-16

Unit: mm No. Check item Thickness of 4th clutch thrust washer Standard size 3.0 3.0 5.0 5.0
TRANSMISSION
Criteria Standard clearance 0.1 0.1 0.05 0.05 0.07 - 0.93 0.04 - 1.16 Clearance limit 2.7 2.7
Remedy
of 3rd clutch thrust 10 Thickness washer 11 Thickness of 4th clutch spacer 12 Thickness of 3rd clutch spacer 13 End play of 4th gear 14 End play of 3rd gear
Replace -
40-17
40-18

Unit: mm No. Check item Standard size Clearance between pilot valve and body 19 Clearance between main regulator valve and body Clearance between main regulator valve and load piston Clearance between priority valve and body Clearance between priority valve and load piston Clearance between quick return valve and body Clearance between modulation fill valve and body Clearance between modulation fill valve and sleeve Clearance between modulation fill valve and sleeve Clearance between sleeve and body Clearance between accumulator valve and body 19 13.5 19 12.5 28 28 28 Tolerance Shaft -0.02 -0.03 -0.02 -0.03 -0.02 -0.03 -0.02 -0.03 -0.02 -0.03 -0.020 -0.028 -0.02 -0.03 -0.02 -0.03 -0.04 -0.05 -0.050 -0.075 -0.02 -0.03 Standard size Free length 12 13 14 15 16 17 18 19 Main regulator valve spring Priority valve spring Quick return valve spring Modulation fill valve spring (inner) Modulation fill valve spring (outer) Accumulator spring (outer) Accumulator spring (inner 1) Accumulator spring (inner 2) 82.55 69.5 48.0 41.8 43.6 99.6 35.6 40.8 Installed length 62.6 52.6 41.0 40.0 24.3 99.6 35.6 40.8 Hole +0.013 0 +0.013 0 +0.018 0 +0.013 0 +0.018 0 +0.013 0 +0.013 0 +0.033 +0.020 +0.041 +0.025 +0.025 0 +0.013 0

Criteria Standard clearance 0.020 0.043 0.020 0.043 0.020 0.048 0.020 0.043 0.020 0.048 0.020 0.041 0.020 0.043 0.040 0.066 0.065 0.091 0.050 0.100 0.020 0.043 Clearance limit 0.050 0.050 0.055 0.050 0.055 0.044 0.050 0.070 Remedy
2 3 4 5 6 7 8
9 10 11
30 41 28
0.100 0.110 0.050
Replace
Repair limit Free length Installed load 79.3 66.7 46.1 40.1 41.9 95.6 34.2 39.2 207 N (21.1 kg) 228 N (23.3 kg) 0.7 N (0.072 kg) 21.7 N (2.21 kg) 125 N (12.7 kg) -
Installed load 230 11.5 N (23.46 1.17 kg) 254 12.7 N (25.92 1.30 kg) 0.8 0.04 N (0.08 0.004 kg) 24.1 1.2 N (2.46 0.12 kg) 138 7 N (14.07 0.07 kg) 0 0 0
40-19
LOWER VALVE
Unit: mm No.
Check item Standar d size Shaft -0.02 -0.03 -0.02 -0.03 -0.02 -0.03 -0.02 -0.03 Standard size Free length Installed length 66.1 36 36.7
Criteria Tolerance Hole +0.013 0 +0.013 0 +0.013 0 +0.013 0 Standard clearance 0.020 0.043 0.020 0.043 0.020 0.043 0.020 0.043 Clearance limit 0.050 0.050 0.050 0.050
Remedy
1 2 3 4
Clearance between torque converter regulator valve and body Clearance between F-R selector spool and body Clearance between H-L selector spool and body Clearance between range selector spool and body
19 19 19 19
Repair limit Free length 67.5 46.8 46.1 Installed load 50 N (5.1 kg) 75.5 N (7.7 kg) 62.8 N (6.4 kg)
Replace
Installed load 55.7 2.7 N (23.46 1.17 kg) 83.4 4.2 N (8.5 0.43 kg) 69.8 3.5 N (7.12 0.036 kg)
5 6 7
Torque converter regulator valve spring F-R selector spool spring H-L range selector spool return spring
70.3 48.8 48.0
40-20
SOLENOID VALVE
Unit: mm No.
Check item Standar d size 14 Shaft -0.02 -0.03
Criteria Tolerance Hole +0.013 0 Standard clearance 0.020 0.043 Clearance limit 0.050
Remedy
Clearance between emergency manual spool and body
Replace
40-21
ACCUMULATOR VALVE
ACCUMULATOR VALVE
Unit: mm No.
Check item Standard size Shaft -0.035 -0.045 Standard size Free length Installed height 175 135 125
Criteria Tolerance Hole +0.025 0 Installed load 158 N (16.1 kg) 78.8 N (8.04 kg) 157.9 N (16.1 kg) Standard clearance 0.035 0.070 Clearance limit 0.08
Remedy
Clearance between piston and body
32
Repair limit Free length 177.4 139.2 139+.2 Installed load Replace
2 3 4
FORWARD clutch accumulator spring 1st clutch accumulator spring 2nd clutch accumulator spring
184.8 145 145
40-22
DRIVE SHAFT
DRIVE SHAFT
40-23

MEMORANDA
DRIVE SHAFT
40-24
DIFFERENTIAL
DIFFERENTIAL (1/2)
Unit: mm No. 1 2
Check item
Criteria 1.2 -3.9 Nm (0.12 - 0.40 kgm) (7.8 - 25.5 N (0.8 - 2.6 kg) 0.085 - 1.295
Remedy
Bevel gear free rotating torque Thickness of shim at differential side bearing carrier (one side) Thickness of shim for differential housing and gauge assembly Protrusion of pin
Replace 0.5 - 1.55 12
3 4
40-25
DIFFERENTIAL
DIFFERENTIAL (2/2)
40-26
Unit: mm No. Check item Standard size 1 Clearance at differential side bearing Outer race Inner race Clearance of bearing and pinion shaft gear end Clearance of bearing and pinion shaft coupling Outer race Inner race Outer race Inner race 105 65 110 50 90 40 25.18 260.4 Shaft 0 -0.020 +0.051 +0.032 0 -0.015 +0.039 +0.025 0 -0.015 +0.037 -0.026 -0.180 -0.193 -0.250 -0.450 -0.250 -0.450
DIFFERENTIAL
Criteria Tolerance Hole -0.024 -0.059 0 -0.015 -0.041 -0.076 0 -0.015 -0.040 -0.075 0 -0.012 +0.02 -0.02 +0.05 -0.05 +0.05 -0.05 0.15 - 0.030 0.15 - 0.35 Max. 0.172 Standard size 1.55 8 51.90 150 150 Tolerance 0.05 0 - 0.09 0.025 - 0.043 - 0.106 - 0.043 - 0.106 Repair limit 1.35 149.6 149.6 Standard clearance 0.059 -0.004 -0.066 -0.032 -0.076 -0.026 -0.051 -0.025 -0.75 -0.025 -0.049 -0.026 0.16 0.213 0.20 0.50 0.20 0.50 Clearance limit 0.3 -
Remedy
Replace
4 5
Clearance between pinion gear and spider Assembly portion of piston of differential housing (housing and piston) Assembly portion of piston of bearing carrier (piston, carrier) Backlash of bevel gear Backlash of differential gear End play of pinion gear
6 7 8 9
215.95
Adjust
Thickness of side gear 10 washer of outside diameter of 11 Wear lock pin of spacer between 12 Height pinion shaft bearings diameter of axle 13 Outside mount (rear differential) 14 Axle mount (rear differential)
Replace
40-27
FINAL DRIVE
FINAL DRIVE
40-28

Unit: mm No. Check item Clearance between axle housing and ring gear Standard size 276 2 Clearance of guide pin Clearance at axle housing bearing press-fitted section Clearance at axle housing bearing press-fitted section Outer race Inner race Outer race Inner race Housing Shaft 12 12.661 69.85 127 77.788 130 93.5 33.338 Shaft +0.100 +0.030 +0.025 +0.007 +0.077 +0.052 +0.050 +0.025 +0.025 0 +0.063 +0.038 0 -0.054 +0.025 +0.013
FINAL DRIVE
Criteria Tolerance Hole +0.100 0 +0.187 +0.125 -0.038 0 -0.013 0 -0.013 -0.051 +0.025 0 +0.063 0 +0.013 0 Max. 0.98 0.21 - 1.91 Standard clearance -0.100 0.07 0.100 0.180 -0.077 -0.014 -0.050 -0.016 -0.076 -0.013 -0.063 -0.013 -0.025 0 Clearance limit -
Remedy
Replace --
Axle shaft pressfitted section
6 7 8
Clearance between pinion gear bearing and shaft End play of axle shaft Clearance between oil seal and housing
40-29
AXLE MOUNT
AXLE MOUNT
Unit: mm No. Check item Standard size 1 Thickness of thrust plate 12.2
Criteria Tolerance 0.1 Tolerance Shaft -0.043 -0.106 -0.043 -0.106 Hole +0.550 +0.050 +0.550 +0.050 0.2 (each) Standard clearance 0.093 0.656 0.093 0.656 Repair limit +0.1 -0.5 Clearance limit -
Remedy
Standard size Clearance between hole and shaft at front support end 150 Clearance between hole and shaft at rear support end Thickness of axle mount shim 150
Replace
3 4
40-30
ADDITIONAL COUNTERWEIGHT
ADDITIONAL COUNTERWEIGHT
40-31
CENTER HINGE PIN
CENTER HINGE PIN
40-32

Unit: mm No. Check item Standard size 1 2 3 4 5 6 7 8 9 Clearance between upper hinge pin and rear frame Clearance between upper hinge pin and rear frame Clearance between upper hinge and bearing Clearance between upper hinge and spacer (top) Clearance between upper hinge and spacer (bottom) Clearance between front frame and upper hinge bearing Clearance between lower hinge pin and rear frame Clearance between front frame and bearing Clearance between bearing and hinge pin 66 50 50 50 50 105 69.85 88.9 69.85 Shaft -0.073 -0.103 -0.038 -0.068 -0.038 -0.068 -0.038 -0.068 -0.038 -0.068 0 -0.015 -0.05 -0.06 0 -0.020 -0.050 -0.060
CENTER HINGE PIN
Criteria Tolerance Hole +0.05 -0.05 +0.100 0 0 -0.012 +0.250 0 +0.250 0 -0.02 -0.12 +0.05 -0.05 +0.05 -0.05 +0.050 +0.028 Standard clearance 0.023 0.153 0.038 0.168 0.026 0.068 0.038 0.318 0.038 0.318 -0.120 -0.005 0 - 0.11 -0.05 0.07 0.078 0.113 Repair limit 0 -0.20 0.1 Standard clearance 0.1 - 0.2 Max. 0.4 Clearance limit Clearance limit -
Remedy
Replace
Wear of oil seal contact 10 surface of upper hinge spacer (top), (bottom) of 11 Height upper hinge spacer Clearance when adjusting 12 shims at upper hinge Thickness of shim between 13 upper hinge and retainer (rear frame portion)
Standard size 63.45 23 Standard size 1.3 0.8
Adjust -
40-33
STEERING COLUMN
STEERING COLUMN
40-34
STEERING CYLINDER MOUNT
STEERING CYLINDER MOUNT
Unit: mm No. Check item Standard size Clearance between mounting pin and bushing at connection of steering 35 cylinder rod and frame Clearance between mounting pin and bushing at connection of steering cylinder bottom and frame 35 Shaft -0.050 -0.080 -0.050 -0.080
Criteria Tolerance Hole +0.142 +0.080 +0.142 +0.080 Standard clearance 0.130 0.222 0.130 0.222 Clearance limit 1.0
Remedy
1 2
1.0 Replace
Width of boss 3 Connection between steering cylinder and front frame 45+ 0.8 0 45+ 0.8 0
Width of hinge
Standard clearance (clearance a + b) Max. 1.0 (after adjusting with shim) Max. 1.0 (after adjusting with shim)
48 1.5
Connection between steering cylinder and rear frame
48 1.0
40-35
PRIORITY VALVE
PRIORITY VALVE
Unit: mm No. Check item Standard size 1 Return spring Free length 63.4 Installed height 45
Criteria Repair limit Installed load 218.7 N (22.3 kg) Free length 62 1 Installed load 175 N 17.9 kg)
Remedy
Replace
40-36
BRAKE BOOSTER
BRAKE BOOSTER
Unit: mm No.
Check item Standar d size Tolerance Shaft -0.025 -0.064 0.025 0.064 -0.060 -0.106 Standard size Free length Installed height 35.1 48.3 86 80.25 40
Criteria Hole +0.062 0 +0.062 0 +0.074 0 Installed load 85.3 N (8.7 kg) 129.4 N (13.2 kg) 294 N (30 kg) 196 N (20 kg) 98 N (10 kg) Standard clearance 0.025 0.126 0.025 0.126 0.060 0.180 Clearance limit 0.15 0.15 0.20
Remedy
1 2 3
Clearance between primary piston and body Clearance between secondary piston and body Clearance between power piston and body
33.34 33.34 70
Repair limit Free length Installed load 85.3 12.7 N (8.7 1.3 kg) 129.4 18.6 (13.2 1.9 kg) 294 44.1 N (30 4.5 kg) 196 29.4 N (30 4.5 kg) 98 18.6 N (10 1.9 kg) Replace
4 Primary piston spring 5 6 7 8 Secondary piston spring Spring Spring Reaction spring
57.1 72.8 199.2 143.75 48
40-37
BRAKE
BRAKE
Unit: mm No.
Check item Standard size
Criteria Tolerance 0 -0.05 0.063 0.2 0.89 (min.) 0.12 Repair limit 5.8 7.4 0.4 0.3
Remedy
Thickness of inner ring Thickness of brake disc Depth of lining groove
6.6 8.697 0.838 1.08 19.5
Replace
2 3
Thickness of lining Thickness of outer ring
40-38
PARKING BRAKE
PARKING BRAKE
Unit: mm No.
Check item Standard size Thickness 1.7 2.2 0.45 0.5 1010 N (103 kg) (Height: 2.2 mm)
Criteria Tolerance 0.05 0.1 0.08 +0.175 0 0.075 98 N ( 10 kg) Repair limit 1.6 0.1 1.97 0.3 814 N (83 kg)
Remedy
Plate
Distortion Thickness Depth of lining groove
Replace
2 3
Brake disk Wave spring load
Lining thickness
40-39
HYDRAULIC PUMP
HYDRAULIC PUMP
40-40
MEMORANDA
HYDRAULIC PUMP
40-41
MAIN CONTROL VALVE
MAIN CONTROL VALVE

2-SPOOL VALVE
40-42
MAIN CONTROL VALVE
Unit: mm No.
Check item Standard size Free length 41.1 Installed length 32.6
Criteria Repair limit Free length 39.4 Installed load 259 N (26.4 kg)
Remedy
Relief valve spring 1
Installed load Replace 207 N (21.1 kg)
40-43
MAIN CONTROL VALVE
3-spool valve
40-44
MAIN CONTROL VALVE
Unit: mm No.
Check item Standard size Free length Installed length 32.6
Criteria Repair limit Free length 39.4 Installed load 207 N (21.1 kg) Installed load 259 N (26.4 kg)
Remedy
1 Relief valve spring
41.1
Replace
40-45
HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
Unit: mm No.
Check item Name of cylinder Standard size 70 70 40 Tolerance Shaft -0.030 -0.104 -0.030 -0.104 -0.025 -0.087
Criteria Hole +0.271 +0.075 +0.271 +0.075 +0.132 +0.006 Standard clearance 0.105 0.375 0.105 0.375 0.031 0.219 Clearance limit 0.675
Remedy
Clearance between piston rod and bushing
Boom Bucket Steering
Replace 0.675 0.519
40-46

MEMORANDA
MEMORANDA
40-47
40-48

Unit: mm
No. Check item Standard pin dia. 1 Clearance between pin and bushing at both ends of bucket link Clearance between pin and bushing at connection of boom and bucket Clearance between pin and bushing at connection of and boom and frame Clearance between pin and bushing at connection of bucket cylinder bottom and frame Clearance between pin and bushing at connection of bucket cylinder rod and bellcrank Clearance between pin and bushing at connection of bellcrank and boom Clearance between pin and bushing at connection of boom cylinder bottom and frame Clearance between pin and bushing at connection of boom cylinder rod and boom 50 50 Tolerance Shaft -0.025 -0.064 -0.025 -0.064 -0.030 -0.076 -0.030 -0.076 Hole +0.142 +0.080 +0.142 +0.080 +0.142 +0.080 +0.142 +0.080 Criteria
Remedy Standard clearance 0.105 0.206 0.105 0.206 0.110 0.218 0.110 0.206 Clearance limit 1.0 1.0
60
1.0
60
1.0
50
-0.025 -0.076 -0.030 -0.076 -0.030 -0.076 -0.030 -0.076
+0.142 +0.080 +0.174 +0.100 +0.174 +0.100 +0.174 +0.100 Width of hinge 83 +3 0 88 1.5 88 1.5 204 1.5 83 1.5 88 +3 0 88 +3 0 89 0.8
0.105 0.218 0.130 0.250 0.130 0.250 0.130 0.250
1.0
Replace (Replace also if there is scuffing of pin)
65
1.0
60
1.0
60 Width of boss
1.0
Standard clearance (Clearance a + b)

1.2 - 7.8 1.3 - 7.1 0.7 - 4.5 2.0 - 6.0 0.7 - 4.5 2.2 - 6.0 1.2 - 7.8 1.4 - 6.6 0.7 - 4.5 Clearance less than 2.0 mm Replace Clearance less than 1.5 mm Insert shims on both sides so that clearance is less than 0.5 mm on both left and right
9 10 11 12 13 14 15 16 17
Connection of boom and bucket Connection of bucket link and bucket Connection of bellcrank and bucket link Connection of bellcrank and boom Connection of bucket cylinder and frame Connection of boom cylinder and frame Connection of boom and frame Connection of boom and boom cylinder Connection of bucket cylinder and bellcrank
85 1.8 83 +2.2 -0.6 83 +2.2 -0.6 200 0.5 80 +0.8 0 85 +0.8 0 85 +1.8 0 85 +1.8 0 85 +0.8 0
88 09091.5
40-49
BUCKET
BUCKET
Unit: mm No. 1
Check item Standard size 22
Criteria Repair limit 15.5
Remedy Replace
Wear of cutting edge
40-50
Unit: mm No. 1 2 3
Check item
Criteria
Remedy
Clearance at bucket positioner switch Clearance at boom kick-out switch Clearance between lever and guide
3 - 7 mm (There must be no interference) Adjust 0.5 - 2.0 mm
40-51
MAINTENANCE STANDARDS
MEMORANDA
40-52
Komatsu America International Company 440 North Fairway Drive Vernon Hills, IL 60061-8112 U.S.A. Attn: Technical Publications Fax No. (847) 970-4186
PROPOSAL FOR MANUAL REVISION

FOR INTERNAL USE ONLY -- No. PMR
P NAME OF COMPANY: R O P O DEPARTMENT: S E R NAME: MANUAL NAME: MANUAL NO: MACHINE MODEL: S/N IF APPLICABLE: PAGE NO:
LOCATION: PHONE NO: DATE:
PROBLEM:
Attach photo or sketch. If more space is needed, use another sheet. FOR INTERNAL USE ONLY CORRECTIVE ACTION:
PFMR1 081696

Wheel Loader Shop Manual PDF

Caricato da

Informazioni sul documento

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Wheel Loader Shop Manual PDF

Caricato da

Copyright:

Formati disponibili

CONTENTS

Indication New page to be added Page to be replaced Page to be deleted

Action Add Replace Discard

20-701 20-702 20-703 20-704 20-705 20-706

30-158 FOLD-OUTS 10-120 10-121

PRODUCT PUBLICATIONS INFORMATION

DESCRIPTION PARTS BOOK - PAPER: Engine and Chassis

PARTS BOOK - MICROFICHE: Engine and Chassis BEPM002100

OPERATION & MAINTENANCE MANUAL: Engine and Chassis CEAM001300

SHOP MANUAL: Chassis Engine: CEBM001101 SEBM010002

REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS

America International Company

PURCHASE ORDER NO.

TYPE or PRINT ONLY

CITY, STATE, ZIP CODE COUNTRY

CURRENT PRICES WILL BE CHARGED

HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

Coat Oil, water

LT-2 Adhesive LT-3

50 g Adh 1 kg Hard agt 500 kg 250 g 50 cc 200 g

LT-4 Loctite 648-50 LG-1

Plastic container Tube

LG-7 Rust preven-tion lubricant Molybdenum disulfide lubricant

! General purpose type

Molybdenum disulfide grease

! Used for places with heavy load.

STANDARD TORQUE REQUIREMENTS

STANDARD TORQUE REQUIREMENTS

STANDARD TORQUE REQUIREMENTS

ELECTRIC WIRE CODE

ELECTRIC WIRE CODE

CLASSIFICATION BY COLOR AND CODE

Charging W White WR White/Red WB

Ground B Black ---------------------

Primary Color Code

Color Code Auxiliary Color Code

5 Color Code 6 Color --Red/Blue

2.205 2.598 2.992 3.386 3.780

FOREWARD Millimeters to Inches

1.969 2.362 2.756 3.150 3.543

2.008 2.402 2.795 3.189 3.583

2.047 2.441 2.835 3.228 3.622

2.087 2.480 2.874 3.268 3.661

2.126 2.520 2.913 3.307 3.701

2.165 2.559 2.953 3.346 3.740

2.205 2.598 2.992 3.386 3.780

2.244 2.638 3.032 3.425 3.819

2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

110.23 132.28 154.32 176.37 198.42

112.44 134.48 156.53 178.57 200.62

114.64 136.69 158.73 180.78 202.83

116.85 138.89 160.94 182.98 205.03

119.05 141.10 163.14 185.19 207.24

121.25 143.30 165.35 187.39 209.44

123.46 145.51 167.55 189.60 211.64

125.66 147.71 169.76 191.80 213.85

127.87 149.91 171.96 194.01 216.05

130.07 152.12 174.17 196.21 218.26

FOREWARD Liter to U.S. Gallon

1R = 0.2642 U.S. Gal

1 0.264 2.906 5.548 8.189 10.831