(SM) D155ax 3

SEBM005207
Shop
Manual
D155AX
Super Dozer
SERIAL NUMBERS D155AX=3 - 60001 mdw

This material is proprietary to Komatsu America international Company and is not to be reproduced, used, or
disclosed except in accordance with written authorization from Komatsu America International Company.
It is our policy to improve our products whenever it is possible and practical to do so. We resew the right to make
changes or add improvemet& at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication.
It is recommended that customers contact their distributor for information on the latest revision.
December 1997 Coovriaht 1997 Komatsu America Intemational Comoanv 00-l

0
CONTENTS
No. of page
01 GENERAL . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . ..~..................................... 01-I
‘IO STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..*............. 10-I
20 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-I
30 DISASSEMBLY AND ASSEMBLY . . . . . . ..m...................*.......... 30-I
40 MAINTENANCE STANDARD . . . . . . . ..n..................................... 40-I
8
5
E;
00-2
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The affected pages are indicated by the use of the
following marks. It is requested that necessary actions
Mark Indication Action required
must betakentothese pages accordingtothe listbelow.
be newly added Add

I O IPage to I
Pages having no marks are not revised atthistime.
LIST OF REVISED PAGES
Revision Revision Revision Revision Revision

Mark Pages number Mark Pages number Mark Pages number idark Pages number Jlark Pages number
0 oo- 1 IO- 8 IO-49 IO- 94 IO-136

oo- 2 IO-9 @ IO-50 IO- 95 10-137
oo- 2-l IO-10 IO-51 IO- 96 IO-138
oo- 2-2 10-11 @ IO-52 IO- 97 10-139
00- 2-3 10-12 IO-53 IO- 98 10-140
00- 2-4 0 IO-14 0 IO-54 IO- 99 IO-141
00- 2-5 IO-15 @ IO-55 10-100 IO-142
oo- 3 IO-16 @ IO-56 10-101 IO-143
oo- 4 0 IO-17 0 IO-57 IO-102 IO-144
oo- 5 IO-18 IO-58 IO-103 IO-145
00- 6 10-19 IO-60 IO-104 IO-146
oo- 7 IO-20 IO-61 lo-106 IO-147
00- 8 IO-21 IO-62 10-106-I IO-148
oo- 9 IO-22 IO-63 IO-107 IO-149
00-10 IO-23 @ IO-64 lo-108 IO-150 @
00-11 0 IO-24 @ IO-65 IO-109 IO-152 @
00-12 IO-25 10-66 IO-110 IO-153 @
00-13 0 10-25-l 0 IO-67 10-111 IO-156 @
00-14 0 10-25-2 0 IO-68 IO-112 IO-157 @
00-15 IO-26 IO-69 IO-113 IO-160
00-16 IO-27 IO-70 IO-114 IO-161
00-17 IO-28 IO-71 10-115 IO-162
00-18 IO-29 IO-72 IO-116 IO-163
00-19 IO-30 IO-73 IO-117 IO-164
Ol- 1 10-31 IO-74 IO-118 IO-165
Ol- 2 'IO-32 IO-75 IO-119 IO-166
Ol- 3 IO-33 IO-76 IO-120 IO-167
Ol- 4 IO-34 IO-77 IO-121 IO-168
Ol- 5 IO-35 IO-78 IO-122 IO-169
Ol- 6 IO-36 IO-79 IO-123 IO-170
0 Ol- 7 IO-37 IO-80 IO-124 IO-171
Ol- 8 IO-38 IO-81 IO-125 IO-172
0% 9 IO-39 IO-82 IO-126 IO-173
01-10 10-40 IO-83 IO-127 IO-174
01-11 10-41 IO-84 IO-128 IO-175
01-12 IO-42 IO-86 10-129 IO-176
IO- 1 IO-43 IO-87 IO-130 IO-177
IO- 2 IO-44 10-88 IO-131 IO-178
IO- 3 IO-45 IO-89 IO-132 10-179
IO- 4 IO-46 IO-90 IO-133 IO-180
IO- 5 IO-47 IO-91 IO-134 IO-181
IO- 6 IO-48 IO-92 IO-135 lo-182 CS
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IO-183 IO-234 20- 5 @ 20-144 @ 0 20-316 0

IO-184 IO-235 20- 6 @ 20-145 @ 0 20-316-2 0
IO-185 lo-236 20- 7 @ 20-201 @ 0 20-316-3 0
IO-186 IO-237 20- 8 @ 20-202 @ 0 20-316-4 0
10-187-I @ IO-238 20- 9 @ 20-203 @ 20-317 0
10-187-2 @ IO-239 20- 10 @ 20-204 @ 20-318 @I
10-187-3 @ lo-240 20- 11 @ 20-205 @ 20-319 @
10-187-4 @ IO-242 20- 12 @ 20-206 @ 20-320 @
10-187-5 @ lo-243 20- 13 @ 20-207 @ 20-321 @
10-187-6 @ IO-244 20- 14 @ 20-208 @ 20-322 @
10-188 @ IO-245 @ 20- 15 @ 20-209 @ 20-401 0
IO-189 lo-247 @ 20- 16 @ 20-210 @ 20-402 0
10-189-l @ 10-248-2 @ 20- 17 @ 20-211 @ 20-403 @
10-189-2 @ 0 10-248-3 @ 20-101 @ 20-213 @ 20-404 @
IO-190 10-248-4 @ 20-102 @ 20-214 @ 20-405 @
IO-191 0 10-248-50 20-103 @ 20-215 @ 0 20-406 @
IO-192 0 10-249 0 20-104 @ 20-215-l @ 20-407 @
IO-193 lo-251 0 20-105 0 20-215-2 @ 20-408 @
10-194 0 IO-252 0 20-106 @ 20-216 @ 20-409 @
10-195 IO-253 @ 20-107 @ 20-217 @ 20-410 @
IO-196 0 IO-254 @I 20-108 @ 20-217-I @ 20-411 ($
IO-197 10-254-I @ 20-109 @ 20-217-2 @ 20-412 @
IO-198 IO-255 20-109-l @ 20-218 @ 20-413 @
10-199 IO-256 20-110 @ 20-219 @ 20-414 @
10-200 lo-257 20-111 @ 20-220 @ 20-415 0
10-201 IO-258 20-112 @ 20-221 @ 20-416 @
IO-202 10-259 20-113 @ 20-222 @ 20-417 @ %
IO-203 IO-260 20-114 @ 20-223 @ 20-418 @ 2
IO-204 IO-261 0 20-115 0 20-224 @ 20-419 @ ;;
lo-205 IO-262 20-116 @ 20-225 @ 20-420 @
lo-206 lo-263 20-117 @ 20-226 @ 20-421 @
IO-207 lo-264 20-118 @ 20-227 @ 20-422 @
IO-208 IO-265 20-120 @ 20-228 @ 20-423 0
10-209 0 IO-266 0 20-121 @ 0 20-229 0 20-501 @
IO-210 0 IO-267 @ 20-122 @ 0 20-229-I 0 0 20-502 @
IO-211 0 IO-268 @J 20-123 @ 0 20-230 0 20-503 @
10-212 0 10-268-I 0 20-124 @ 20-231 @ 20-504 @
IO-213 0 10-268-2 @ 20-125 @ 20-232 @ 20-505 @
IO-214 IO-269 20-125-l @ 20-233 @ 20-506 @
lo-215 IO-270 20-126 @ 20-234 @ 20-507 @
IO-216 lo-271 @ 20-127 @ 20-235 @ 20-508 @
IO-218 @ 10-271-I @ 20-128 @ 20-236 @ 20-509 @
10-219 lo-272 @ 20-129 @ 20-237 @ 20-510 @I
IO-220 @ IO-273 20-130 @ 20-301 @ 20-511 @
IO-221 0 lo-274 0 20-131 @ 20-302 @ 20-512 @
IO-222 @ IO-275 20-132 @ 20-303 @ 20-513 @
IO-223 0 IO-276 0 20-133 @ 20-305 @ 20-514 @I
IO-224 @ IO-277 20-134 @ 20-306 @ 20-515 0
IO-225 IO-278 20-135 @ 20-307 @ 20-516 @
IO-226 @ 10-279 20-136 @ 20-308 @ 20-517 @
lo-227 lo-280 20-137 @ 20-309 @ 20-518 @
IO-228 @ IO-281 20-138 @ 20-310 @ 20-519 @
IO-229 @ 20- 1 @ 20-139 @ 20-311 @ 20-520 @
IO-230 0 20- 2 0 20-140 @ 20-312 @ 20-521 @
lo-231 0 20- 2-1 0 20-141 @ 20-313 @ 20-522 0
lo-232 0 20- 3 0 20-142 @ 0 20-314 @ 20-523 @
IO-233 20- 4 @ 20-143 @ 0 20-315 0 20-524 @
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20-546 @ 0 20-604 0 20-829 @ 30-43-3 30- 93 @
20-547 @ 20-701 @ 20-830 @ 30-43-4 30- 94 @
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20-549 @ 20-703 0 20-832 @ 30-43-6 30- 96 @
8 20-550 @ 20-704 @ 20-833 @ 30-43-7 30- 97 @
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20-569 @ 20-724 0 30- 14 @ 30-60 30-115 @
20-570 @ 20-725 @ 30- 15 @ 30-61 30-116 @
20-571 @ 20-726 @ 30- 15-1 @ 30-62 30-117 @
20-572 @ 20-727 @ 30- 15-2 @ 30-63 30-118 @
20-573 @ 20-728 @ 30- 16 @ 30-64 30-119 @
20-574 @ 20-729 @ 30- 17 @ 30-65 30-120 @
20-575 @ 20-730 @ 30- 18 @ 30-66 0 30-121 @
20-576 @ 20-801 @ 30- 19 @ 30-67 0 30-122 0
20-577 @ 20-802 @ 30- 20 @ 30-68 0 30-123 @)
20-578 @ 20-802-I @ 30- 21 @ 30-69 0 30-124 @)
20-579 @ 20-803 @ 30- 22 @ 30-70 0 30-125 0
20-580 @ 20-804 @ 30- 23 @ 30-71 30-126 @
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30-132 @ 30-155-20 @ 30-197 @ 30-249 @ 0 30-282
30-133 @ 30-155-21 @ 30-198 @ 30-250 @ 30-283
30-134 @ 30-155-22 @ 30-198-I @ 30-251 @ 30-284
30-135 @ 30-156 @ 0 30-198-2 0 30-252 @ 30-285
30-136 @ 30-157 @ 30-198-3 @ 30-253 @ 30-286
30-137 @ 30-158 @ 30-199 @ 30-254 @ 30-287
30-138 @ 30-159 @ 30-200 @ 30-255 @ 30-288
30-139 @ 30-160 @ 30-201 @ 30-256 @ 30-289
30-140 0 30-161 @ 30-202 @ 30-257 @ 30-290
30-141 @ 30-162 @ 30-203 @ 30-258 @ 30-291
30-142 @ 30-162-I @ 30-204 @ 30-259 @ 30-292
30-143 @ 30-163 @ 30-205 @ 30-259-I @ 30-293
30-144 @ 30-163-I @ 30-206 @ 30-259-2 @ 30-294
30-145 @ 30-163-2 @ 30-207 @ 30-259-3 @ 30-295
30-146 @ 30-163-3 @ 30-208 @ 30-259-4 @ 30-296
30-147 @ 30-163-4 @ 30-209 @ 30-259-5 @ 30-297
30-148 @ 30-163-5 @ 30-210 @ 30-259-6 @ 30-298
30-149 @ 30-163-6 @ 30-211 @ 30-259-7 @ 30-299
30-150 @ 30-163-7 @ 0 30-212 0 30-259-8 @ 30-300
30-151 @ 30-163-8 @ 30-213 @ 30-259-g @ 30-301
30-152 @ 30-163-g @ 0 30-214 0 30-259-10 @ 30-302
30-152-l @ 30-163-10 @ 30-215 @ 30-259-11 @ 30-303
30-152-2 @ 30-163-11 @ 30-216 @ 30-259-12 @ 30-304
30-152-3 @ 30-163-12 @ 30-217 @ 30-259-13 @ 30-305
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30-152-130 30-172 @ 30-224 @ 30-264 @ 30-314
30-152-140 30-173 @ 30-225 @ 30-265 @ 30-315
30-152-150 30-174 @ 30-226 @ 0 30-266 0 30-316
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30-155 @ 30-177 @ 30-229 @ 0 30-269 @ 40- 2
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SAFETY SAFETY NOTICE
SAFETY
r--
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The
service and repair techniques recommended by Komatsu and described in this manual
are both effective and safe. Some of these techniques require the use of tools specially
designed by Komatsu for the specific purpose.
To prevent injury to workers, the symbol A is used to mark safety precautions in this
manual. The cautions accompanying these symbols should always be followed care-
fully. If any dangerous situation arises or may possibly arise, first consider safety, and
take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to

keep tools and removed parts. Always keep
Mistakes in operation are extremely dangerous. the tools and parts in their correct places.
Read the Operation and Maintenance Manual Always keep the work area clean and make
carefully BEFORE operating the machine. sure that there is no dirt or oil on the floor.
1. Before carrying out any greasing or repairs, Smoke only in the areas provided for smok-
read all the precautions given on the decals ing. Never smoke while working.
which are fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK

wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons Before adding oil or making any repairs,
missing. park the machine on hard, level ground, and
. Always wear safety glasses when hitting block the wheels or tracks to prevent the
parts with a hammer. machine from moving.
. Always wear safety glasses when grind-
Before starting work, lower blade, ripper,
ing parts with a grinder, etc.
bucket or any other work equipment to the
3. If welding repairs are needed, always have a ground. If this is not possible, insert the
trained, experienced welder carry out the safety pin or use blocks to prevent the work
work. When carrying out welding work, al- equipment from falling. In addition, be sure
ways wear welding gloves, apron, hand to lock all the control levers and hang warn-
shield, cap and other clothes suited for welding signs on them.
ing work.
9. When disassembling or assembling, support
4. When carrying out any operation with two the machine with blocks, jacks or stands
or more workers, always agree on the oper- before starting work.
ating procedure before starting. Always in-
10. Remove all mud and oil from the steps or
form your fellow workers before starting any
other places used to get on and off the ma-
step of the operation. Before starting work,
chine. Always use the handrails, ladders or
hang UNDER REPAIR signs on the controls
steps when getting on or off the machine.
in the operator’s compartment.
Never jump on or off the machine. If it is
5. Keep all tools in good condition and learn impossible to use the handrails, ladders or
the correct way to use them. steps, use a stand to provide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19. Be sure to assemble all parts again in their
original places.
11. When removing the oil filler cap, drain plug Replace any damaged parts with new parts.
or hydraulic pressure measuring plugs, . When installing hoses and wires, be sure
loosen them slowly to prevent the oil from that they will not be damaged by contact
spurting out. with other parts when the machine is be-
Before disconnecting or removing compo- ing operated.
nents of the oil, water or air circuits, first
20. When installing high pressure hoses, make
remove the pressure completely from the
sure that they are not twisted. Damaged
circuit.
tubes are dangerous, so be extremely care-
12. The water and oil in the circuits are hot ful when installing tubes for high pressure
when the engine is stopped, so be careful circuits. Also, check that connecting parts
not to get burned. are correctly installed.
Wait for the oil and water to cool before
21 When assembling or installing parts, always
carrying out any work on the oil or water
use the specified tightening torques. When
circuits.
installing protective parts such as guards,
13. Before starting work, remove the leads from or parts which vibrate violently or rotate at
the battery. Always remove the lead from high speed, be particularly careful to check
the negative (-1 terminal first. that they are installed correctly.
14. When raising heavy components, use a hoist 22. When aligning two holes, never insert your
or crane. fingers or hand. Be careful not to get your
Check that the wire rope, chains and hooks fingers caught in a hole.
are free from damage.
23. When measuring hydraulic pressure, check
Always use lifting equipment which has
that the measuring tool is correctly assem-
ample capacity. bled before taking any measurements.
Install the lifting equipment at the correct
places. Use a hoist or crane and operate
24. Take care when removing or installing the
slowly to prevent the component from hit-
tracks of track-type machines.
ting any other part. Do not work with any
When removing the track, the track sepa-
part still raised by the hoist or crane. rates suddenly, so never let anyone stand at
15. When removing covers which are under in- either end of the track.
ternal pressure or under pressure from a
spring, always leave two bolts in position
on opposite sides. Slowly release the pres-
sure, then slowly loosen the bolts to remove.
16. When removing components, be careful not

to break or damage the wiring. Damaged
wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil
from spilling out. If any fuel or oil drips onto
the floor, wipe it up immediately. Fuel or oil
on the floor can cause you to slip, or can
even start fires.
18. As a general rule, do not use gasoline to

wash parts. In particular, use only the mini-
mum of gasoline when washing electrical
parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to full
effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a
service workshop. For ease of understanding, the manual is divided into the following chapters; these
chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give
an understanding of the structure, but also serves as reference material for troubleshooting.
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. Use the specifications given in the book
with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
VOLUMES REVISED EDITION MARK
Shop manuals are issued as a guide to carrying When a manual is revised, an edition mark
out repairs. They are divided as follows: (@@@....I is recorded on the bottom of the
Chassis volume: Issued for every machine model pages.
Engine volume: Issued for each engine series
Each issued as one
Electrical volume:
volume to cover all REVISIONS
Attachments volume:
I models
Revised pages are shown in the LIST OF RE-
These various volumes are designed to avoid VISED PAGES next to the CONTENTS page.
duplicating the same information. Therefore, to
deal with all repairs for any model , it is neces-
sary that chassis, engine, electrical and attach-
SYMBOLS
ment volumes be available.
So that the shop manual can be of ample prac-
DISTRIBUTION AND UPDATING tical use, important safety and quality portions
are marked with the following symbols.
Any additions, amendments or other changes
will be sent to KOMATSU distributors. Get the
most up-to-date information before you start any
work.
FILING METHOD
1. See the page number on the bottom of the Symbol 1 Item Remarks
page. File the pages in correct order.
Special safety precautions are
--LI a
Following examples show how to read the
Safety necessary when performing
page number. the work.
Example 1 (Chassis volume):
Special technical precautions
10 -3 or other precautions for pre-
* Caution serving standards are neces-
Item number (IO. Structure sary when performing the
and Function) work.
Consecutive page number for
Weight of parts of systems.
each item. Caution necessary when se-
Weight lecting hoisting wire, or when
Example 2 (Engine volume): working posture is important,
etc.
12 - 5
TT T Places that require special at-
Unit number (I. Engine) tention for the tightening
Item number (2. Testing and torque during assembly.
Adjusting) Places to be coated with ad-

Consecutive page number for hesives and lubricants, etc.
each item.
@I
Places where oil, water or fuel
Oil, water must be added, and the ca-
Additional pages: Additional pages are indi- pacity.
I
cated by a hyphen (-1 and number after the
Places where oil or water
page number. File as in the example. - : Drain must be drained, and quan-
Example: tity to be drained.
1o-4 12-203
1o-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may
Heavy parts (25 kg or more) must be cause the rope to slip off the hook during
lifted with a hoist, etc. In the DISAS- hoisting, and a serious accident can re-
SEMBLY AND ASSEMBLY section, sult. Hooks have maximum strength at
every part weighing 25 kg or more is the middle portion.
indicated clearly with the symbol &
. If a part cannot be smoothly removed from

the machine by hoisting, the following checks
should be made:
I) Check for removal
the part to the relative
2) Check for existence
of all bolts fastening
parts.
of another part caus-
100% 88%
;EB
79% 71% 41%
SAM)0479
3) Do not sling a heavy load with one rope

ing interference with the part to be re- alone, but sling with two or more ropes
moved. symmetrically wound onto the load.
A Slinging with one rope may cause

turning of the load during hoisting,
untwisting of the rope, or slipping of
WIRE ROPES
the rope from its original winding
1) Use adequate ropes depending on the
position on the load, which can re-
weight of parts to be hoisted, referring to
sult in a dangerous accident.
the table below:
Wire ropes 4) Do not sling a heavy load with ropes form-

(Standard “Z” or “S” twist ropes ing a wide hanging angle from the hook.
When hoisting a load with two or more
without galvanizing)
ropes, the force subjected to each rope
Rope diameter r Allowable load will increase with the hanging angles. The
table below shows the variation of allow-
mm kN tons
able load kN {kg) when hoisting is made
IO 9.8 1.0 with two ropes, each of which is allowed
11.2 13.7 1.4 to sling up to 9.8 kN (1000 kg) vertically,
at various hanging angles.
12.5 15.7 1.6
When two ropes sling a load vertically, up
14 21.6 2.2
to 19.6 kN (2000 kg) of total weight can be
16 27.5 2.8 suspended. This weight becomes 9.8 kN
18 35.3 3.6 (1000 kg} when two ropes make a 120”
20 43.1 4.4 hanging angle. On the other hand, two

ropes are subjected to an excessive force
22.4 54.9 5.6
as large as 39.2 kN 14000 kg) if they sling
30 98.1 10.0
a 19.6 kN 12000 kg} load at a lifting angle
40 176.5 18.0 of 150”.
AII LY
50 274.6 28.0
60 392.2 40.0
* The allowable load value is estimated to

be one-sixth or one-seventh of the break-
ing strength of the rope used.
I
2) Sling wire ropes from the middle portion
30 60 90 120 150
of the hook. Lifting angle (decree) SAD00480
00-7
FOREWORD COATING MATERIALS
COATING MATERIALS
Ir The recommended coating materials such as adhesives, gasket sealants and greases used for
disassembly and assembly are listed below.
Ir For coating materials not listed below, use the equivalent of products shown in this list.
Category K omatsu code Part No. o’w Container Main applications, features
-
l Used to prevent rubber gaskets, rubber
LT-IA 790-129-9030 150 g Tube
cushions, and cock plug from coming out.
-
l Used in places requiring an immediately
effective, strong adhesive. Used for plas-
20 9 ‘olyethylene
LT-1 B 790-129-9050 tics (except polyethylene, polyprophylene,
(2 pes.) container
tetrafluoroethlene and vinyl chloride), rub-
ber, metal and non-metal.
-
l Features: Resistance to heat and chemi-
‘olyethylene cals
LT-2 50 g container l Used for anti-loosening and sealant pur-
pose for bolts and plugs.
-
790-129-9060 idhesive: l Used as adhesive or sealant for metal, glass
(Set of adhe- 1 kg and plastic.
LT-3 sive and lardening Can
hardening agent:
agent) 500 g
Adhesives -
‘olyethylens l Used as sealant for machined holes.
LT-4 790-129-9040 250 g
container
-
Holtz l Used as heat-resisting sealant for repair-
790-126-9120 75 g Tube
MH 705 ing engine.
-
l Quick hardening type adhesive
Three bond ‘olyethylene l Cure time: within 5 sec. to 3 min.
790-i29-9i4a 50 g Used mainly for adhesion of metals, rub-
1735 container l
bers, plastics and woods.

-
l Quick hardening type adhesive
l Quick cure type (max. strength after 30 min-
Aron-alpha ‘olyethylene
790-129-913a 29 utes)
201 container
l Used mainly for adhesion of rubbers, plas-
tics and metals.
-
l Features: Resistance to heat, chemicals
Loctite ‘olyethylene
79A-129-911f 50 cc l Used at joint portions subject to high tem-
646-50 container
peratures.
-
l Used as adhesive or sealant for gaskets
LG-1 790-129-901a 200 g Tube
and packing of power train case, etc.
-
Features: Resistance to heat
Used as sealant for flange surfaces and
Gasket bolts at high temperature locations, used
sealant 790-129-907c to prevent seizure.
LG-3 1 kg Can
Used as sealant for heat resistance gasket
for high temperature locations such as en-
gine precombustion chamber, exhaust
pipe, etc.
00-8
FOREWORD COATING MATERIALS
Category Komatsu code Part No. o’ty Container Main applications, features
l Features: Resistance to water, oil

l Used as sealant for flange surface, thread.
I LG-4
17go-12g-go201 2oo ’ 1 Tube 1
l
l
Also possible to use as sealant for flanges
with large clearance.
Used as sealant for mating surfaces of fi-
nal drive case, transmission case.
l Used as sealant for various threads, pipe

Polyethylene joints, flanges.
LG-5 790-129-9080 1 kg
container l Used as sealant for tapered plugs, elbows,
nipples of hydraulic piping.
l Features: Silicon based, resistance to heat,

Gasket cold
sealant LG-6 09940-00011 250 g Tube l Used as sealant for flange surface, tread.
l Used as sealant for oil pan, final drive case,
etc.
l Features: Silicon based, quick hardening

type
LG-7 09920-00150 150 g Tube l Used as sealant for flywheel housing, in-
take manifold, oil an, thermostat housing,
etc.
Three bond l Used as heat-resisting sealant for repairing

1790-129-90901 100 g I Tube I engine.
1211
I I I I I
I
l Used as lubricant for sliding portion (to pre-

LM-G
Molybde- 1 ogg40-ooo51 1 ” 9 1 Can 1 vent from squeaking).
num
disulphide l Used to prevent seizure or scuffling of the
lubricant LM-P 09940-00040 200 g Tube thread when press fitting or shrink fitting.
l Used as lubricant for linkage, bearings, etc.
I I I I I
SYG2-4OOLl l General purpose type

SYG2-350LI
G2-LI SYG2-4OOLI-A Various Various
SYG2-16OLI
SYGA-16OCNLI
l Used for normal temperature, light load

SYG24OOCA bearing at places in contact with water or
Grease
SYG2-350CA steam.
GP-CA SYGZ-4OOCA-A Various Various
SYG2-16OCA
SYGA-16OCNCA
I I I I
t
1Mf!$Er/ SYG2-400M 1 (r{r ISelows type1

l Used for places with heavy load
00-9
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUES OF BOLTS AND NUTS

Use these torques for metric bolts and nuts. (Always use torque wrench).
Thread diameter Width

of bolt across flats
m-
mm mm Nm km
6 10 13.2f 1.4 1.35kO.15

8 13 31f3 3.2kO.3
10 17 66f7 6.7kO.7
12 19 113flO 11.5+1
14 22 177+19 18f2
16 24 279+30 28.5f3
18 27 382f39 39f4
20 30 549f59 56f6
22 32 745f83 76f8.5
24 36 927f103 94.5+ 10.5
27 41 1320f140 135+15
30 46 1720f190 175f20
33 50 2210+240 225f25
36 55 2750f290 280+30
39 60 3290f340 335f35
Thread diameter Width

of bolt across flats
mm mm Nm bm
6 10 7.85f 1.95 0.8kO.2
8 13 18.6f4.9 1.9f0.5
IO 14 40.2f5.9 4.1k0.6
12 27 82.35f7.85 8.4f0.8
TIGHTENING TORQUE OF HOSE NUTS

Use these torques for hose nuts.
Thread diameter Width across flat Tightening torque

Nominal No.
mm mm Nm kgm
02 14 19 24.5? 4.9 2.5f0.5
03 18 24 49k19.6 5f2
04 22 27 78.5f 19.6 8f2
05 24 32 137.3k29.4 14f3
06 30 36 176.5f29.4 18f3
10 33 41 196.lf49 20f5
12 36 46 245.2f 49 25+5
14 42 55 294.2* 49 30+5
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS

Use these torques for split flange bolts.
mm mm Nm km
10 14 65.7+ 6.8 6.7f0.7

12 17 112k9.8 11.5fl
16 22 279f29 28.5f3
00-l0
TIGHTENING TORQUE OF O-RING BOSS CONNECTOR

Use these torques for O-ring boss connector

Nominal No.
mm mm Nm kgm
02 14 34.3k 4.9 3.5kO.5
03,04 20 Varies depending on 93.1 k 9.8 9.5f 1
05,06 24 type of connector. 142.lf 19.6 14.5+2
IO,12 33 421.4+ 58.8 43+6
14 42 877.1f132.3 89.55 13.5
TIGHTENING TORQUE OF O-RING BOSS CONNECTOR

Thread diameter Width across flat Tighteni 4 J torque

Nominal No.
mm mm Nm kgm
08 8 14 7.35k1.47 0.75kO.15
10 10 17 11.27f 1.47 1.15f0.15
12 12 19 17.6451.96 1.8f0.2
14 14 22 22.54-1:1.96 2.3f 0.2
16 16 24 29.4f 4.9 3f 0.5
18 18 27 39.2+ 4.9 4f0.5
20 20 30 49f 4.9 5f0.5
24 24 32 68.6k9.8 7fl
30 30 32 107.8+_ 14.7 11+ 1.5
33 33 - 127.4f 19.6 13f2
36 36 36 151.9f24.5 15.5f2.5
42 42 - 210.7f29.4 21.5f3
52 52 - 323.4f 44.1 33f 4.5
- - -
TIGHTENING TORQUES OF FLARE NUT

SAW0483

mm mm Nm kgm
I I I
14 19 24.5+4.9 2.5f0.5
18 24 49f 19.6 5+2
22 27 78.5+ 19.6 8f2
24 32 137.3k29.4 14f3
30 36 176.5529.4 18f3
33 41 196.1+49 2055
36 46 245.2f 49 25f5
42 55 294.2+49 30f5
00-l 1
TIGHTENING TORQUE FOR 102 SERIES ENGINE (BOLT AND NUTS)

Use these torques for metric bolts and nuts of 102 Series Engine.
Thread diameter Tightening torque

mm Nm kgm
6 IO?2 1.02 f 0.20
8 24 + 4 2.45 f 0.41
IO 43 f 6 4.38 + 0.61
12 77 f 12 7.85 + 1.22
TIGHTENING TORQUE FOR 102 SERIES ENGINE (EYE JOINTS)

Use these torques for metric eye joints of 102 Series Engine.

mm Nm kgm
6 8f2 0.81 f 0.20
8 10 f2 1.02 + 0.20
10 12 f2 1.22 f 0.20
12 24 f 4 2.45 f 0.41
14 36 f 5 3.67 f 0.51
TIGHTENING TORQUE FOR 102 SERIES ENGINE (TAPERED SCREWS)

Use these torques for inches tapered screws of 102 Series Engine.

inches Nm kgm
l/16 3fl 0.31 f 0.10
118 8+2 0.81 + 0.20
l/4 12f2 1.22 f 0.20
318 15 f 2 1.53 f 0.41
112 24 f 4 2.45 + 0.41
314 36 f 5 3.67 f 0.51
1 60 i 9 6.12 f 0.92
00-l 2
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
rJmlnle~l CaylezjD. Curre;$rating
N~t~a~;aof Dia. ;Ifnstr$nds Cross se4tion rn Applicable circuit
m I I
0.85 11 ~~1 0.88 1 2.4 1 12 1 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1
5 65 0.32 5.23 4.6
15 84 0.45 13.36 7.0 59

I I I I I Starting (Glow plug)
40 85 0.80 42.73 11.4
60 127 0.80 63.84 13.6
100 217 I 0.80 109.1 I 17.6 I 230 I Starting
CLASSIFICATION BY COLOR AND CODE
Circuits
pr- Zlassi-
\
ication
Charging Ground Starting Lighting Instrument Signal Other
pri_ Code W B B R
1
marY t Color White Black Black Red
WR - BW RW
2
White & Red - Black & White Red & White Yellow & Red IGreen & White IBlue & White
WB - BY RB YB I GR I LR
3
White & Black - Black & Yellow Red & Black Yellow & Black Green & Red I I Blue & Red
4ti Code WL - BR RY YG GY LY
4
iary
t Color White & Blue - Black & Red Red & Yellow Yellow & Green Green & Yellow Blue & Yellow
I
Code WG - - RG YL GB LB
5
Color Red & Green Yellow & Blue Green & Black Blue & Black
Code RL YW GL -
6
Color - I-I - Red & Blue Yellow&White Green & Blue -
00-l 3
FOREWORD CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For
details of the method of using the Conversion Table, see the example given below.
EXAMPLE
. Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as @, then draw a horizontal
line from @.
(2) Locate the number 5 in the row across the top, take this as @I, then draw a perpendicular line
down from 0.
(3) Take the point where the two lines cross as 0. This point @ gives the value when converting
from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

(I) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches 1 mm = 0.03937 in
0 1 2 3 4 5 ; 6 7 8
0 0 0.039 0.079 0.118 0.157 0.197; 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591; 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 j 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 i 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 i 1.811 1.850 1.890 1.929
@ j
.. . . . . .. . ..1.969
. . ..50 .2.008 .2.047 . 2.087 .2.126 ~2.165 2.205 2.244 2.283 2.323
a-- 60
. .. . . . . . .
I 2.362
. .. . . . . .. .
2.402
.. .. . . .. ..
2.441
. .. . . . . . . .
2.480
.. . . . . .. .
2.520 2.559 2.598 2.638 2.677 2.717
2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-14
FOREWORD CONVERSIONTABLE
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
- - - - -
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
\
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
,
90 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
I
198.42 d 1 1
00-15
Liter to U.S. Gallon

lt = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon

.._- _._..,.,, . ... . _...
0
I 1
I 2
3 I 4 I 5 I 6 17 I 8I g
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-16
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
\
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-l 7
kg/cm* to lb/in*
1 kg/cm2 = 14.2233 lb/in2
T
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 365 1380 1394 1408
100 1422 1437 451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-18
FOREWORD CONVERSION TABLE
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade tempera-
ture reading or vice versa is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values,
and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8”F
“C “F “C “F “C “F “C “F 1
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 46 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 66 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-19
01 GENERAL
Specification drawing .................................... Ol- 2

Specifications ................................................. Ol- 4
Weight table .................................................. .Ol-10
Table of fuel, coolant and lubicants ............ .Ol-12
01-l
GENERAL SPECIFICATION DRAWING
SPECIFICATION DRAWING
l Semi U-tiltdozer + giant ripper
- Unit:mm
3210 2510
I . s
8155 :
& f
SD000304
l U-tiltdozer + giant ripper
3210 2510
I-
8550
SDD00305
01-2
GENERAL SPECIFICATION DRAWING
. Semi U-tiltdozer + multi-shank ripper
Unit: mm
G.L
. U-tiltdozer + multi-shank ripper
SDW0378
GENERAL SPECIFICATIONS
SPECIFICATIONS
Machine model D155AX-3
Serial number 60001 - 60279 60280 and up

f
Bare tractor kg 28,400
I
With semi U-dozer + variable multi-shank ripper kg 38,500
+ ROPS + cab + air conditioner + side cover
Minimum turning radius (center of machine) m 1.05

Gradeability deg 30
Stability (front, rear, left, right) deg 35
-
Continuous speed control
e
E Low speed - high speed km/h 0 - 11.2
2
-
Continuous speed control
8
t Low speed - high speed km/h 0 - 13.9
5
CT
Bare tractor kPa{kg/cm*} 77.47{0.79}

With semi U-dozer + variable multi-shank rip- kPa{kg/cm*} 104.92{1.07}
per + ROPS + cab + air conditioner + side
cover
With U-dozer + variable multi-shank ripper + kPa{kg/cm*} 105.90{1.08}
ROPS + cab + air conditioner + side cover
Bare tractor mm 4,975
With semi U-dozer + variable multi-shank rip- mm 8,155

per
With U-dozer + variable multi-shank ripper mm 8,550
Bare tractor mm 2,695
With semi U-dozer + variable multi-shank rip- mm 3,955

per
With U-dozer + variable .multi-shank ripper mm 4,265
To top of exhaust pipe mm 3,395
To top of cab mm 2,555

(to top of control lever)
GENERAL SPEClFldATlONS
With cab installed mm 3,365
With ROPS canopy installed mm 3,500
With canopy installed mm 3,500
Track gauge mm 2,100
Length of track on ground (mm) mm 3,210
Track shoe width (standard) mm 560
Minimum ground clearance mm 485
(To bottom surface of undercover)
Name S6D140-1 SAGD 140-2

I-cycle, watercooled, 4cycle, water-cooled,
Type of engine n-line, vertical type, di- in-line, vertical type, di-
‘ect injection, with tur- rect injection, with tur-
locharger bocharger, aftercooler
No. of cylinders - Bore x Stroke mm 6-140x165 6-140x165
Piston displacement e ICC1 15.24{15,240) 15.24{15,240}
Flywheel horsepower kW/rpm{HP/rpmI 225/l ,900{302/1,9001
t? Max. torque Nm/rpm{kgm/rpmI 1,432/l ,250{146/1,250)

5
E Max. speed at no load rpm 2,050
5 Min. speed at no load rpm 700
Min. fuel consumption ratio g/kWh{g/HPhI 205U531
Starting motor 24V, IlkW
Alternator 24V, 35A
Battery 12V, 170Ahx2
Radiator core type D-7
Planetary gear, multiple disc clutch + hydro-

static transmission,hydraulically actuated
HMT (electrical type), force-feed lubrication
gear pump, forward 3-speed, reverse 3-
speed (automatic transmission)
01-5
a

I
Variable swash plate type (HPV160)
Max. delivery pressure : 41.2 MPa {420 kg/cm*}
Theoretical delivery : 298 e /min/1,861 rpm
Variable swash plate type (HMV160+160)

Max. pressure: 41.2 MPa (420 kg/cm*}
.E
s Bevel gear shaft Spiral bevel gear, force-feed lubrication gear pump
5
2 Differential planetary gear type, driven by hydraulic mo-
a H HSS steering system tor, manual type, hydraulically actuated
s -
Wet type, multiple clutch disc, spring boosted, hydrauli-
S Master brake
cally actuated, pedal operated
Spur gear l-stage, planetary gear l-stage, splash type

Final drive
lubrication pump
Suspension Rigid, balancing beam type
2 each side
6 each side
Assembly type, single grouser, 41 each side, pitch: 228.6

Track shoe (560 mm)
mm
Power train + lubrication pump (tandem) Gear type (SAL(3)100+80)
Scavenging pump (tandem) Gear type (112)
Gear type (104)

HMT, PPC charge pump (tandem with scavenging
Max. delivery pressure : 4.4 MPa 145 kg/cm*}
pump (112))
Theoretical delivery : 206 e /min/1,982 rpm
Fixed swash plate type (HMF160)

HSS motor Max. pressure: 41.2 MPa I420 kg/cm*}
Rated flow (theoretical value) : 299 e /min
Variable swash plate type (HPVIGO)

CLSS load sensing type
Max. delivery pressure : 36.3 MPa {370 kg/cm3
01-6
@
Machine model D 155AX-3

f
Type 3+1+1 tandem, spool type, hydraulically assisted type

. For HSS
. For blade lift HSS + ripper tilt + ripper lift + blade lift + blade tilt
. For blade tilt
. For ripper lift
. For ripper tilt
.
,
Type Reciprocal, piston type
Cylinder bore mm 120
Piston rod outer diameter mm 75
Max. piston stroke mm 1,347
Max. distance between pins mm 3,187
Min. distance between pins mm 1,836
Max. piston stroke mm 160
01-7
a

I
Hydraulic tank Box type (control valve externally installed)
Type Hydraulic semi U-tiltdozer, hydraulic U-tiltdozer
Blade support method Brace type (right tilt cylinder)
Blade lifting height (from ground level) mm 1,250
Blade lowering depth (from ground level) mm 590
Max. blade tilt mm 1,000
Blade cutting angle variation deg *6
Blade capacity m3 11.7 <SAE 8.8>
Blade width mm 3,955
Blade height mm 1,720
Blade cutting angle deg 52

8
5
Blade lifting height (from ground level) mm 1,250
Z
Blade lowering depth (from ground level) mm 590
Max. blade tilt mm 1,080
Blade cutting angle variation deg +6
Blade capacity m3 13.2 <SAE 11.8>
Blade width mm 4,265
Blade height mm 1,720
Blade cutting angle deg 52
Max. tilt mm 1,000
Max. pitch angle deg 6
Max. pitch-back angle deg 6
Max. tilt mm 1,080
Max. pitch angle deg 6
Max. pitch-back angle deg 6
01-8
@

- f I
Max. digging depth mm 870
Max. lifting height mm 925
Ripping angle of point deg 34.5 - 60
Max. beam width mm 2,260
Shank positions Jo. of holes 2
5
E
.-Q
i! Max. digging depth mm 1,220

2
P Max. lifting height mm 925
Ripping angle of point deg 34.5 - 60
Max. beam width mm 1,535
Shank positions 40. of holes 3
01-9
8
GENERAL WEIGHT TABLE
WEIGHT TABLE
a This weight table is a guide for use when transporting or handling components.
Unit: kg
Machine model D 155AX-3
Engine, damper assembly 1,340 1,395
l Engine assembly 1,220 1,275
l Damper assembly 117 117
l Universal joint 18 18
l Engine mount parts (wiring) 3 3
Radiator assembly (including built-in oil cooler) 306
Hydraulic cooler 104 (88 as individual part)
Fuel tank assembly (when empty) 235
Fuel tank assembly (when full) 660
. Power train unit assembly 2,705
. HMT assembly (including PTO) 1,164
. HSS assembly 891
. HMT control valve assembly 87
. Brake valve assembly 15
. PPC charge filter assembly 22
. PPC charge valve assembly 21
. Power train filter assembly 20
. Scavenging pump, PPC charge pump 36
. Power train, lubrication pump 27
. Hydraulic, HSS pump 106
. HSS motor 64
. HMT pump 102
. HMT motor 158
Final drive assembly 1,372x2
Sprocket teeth (12X9)x2
Hull frame assembly 3,182
Track group assembly (each side) 3,755
Track frame 1,224
Idler assembly 410
Recoil spring assembly 508
Bogie, track roller assembly 410x3
Track roller assembly (single flange xl) 97x3
Track roller assembly (double flange xl) 109x3
Carrier roller assemb1.y 45x2
01-10
@
GENERAL WEIGHT TABLE
Unit: kg
Track shoe assembly (560 mm, wet type) 2,558x2
Pivot shaft assembly 116x2
Equalizer bar 229
Hydraulic tank assembly 102

Hydraulic filter assembly 19
Main control valve 112
(HSS + blade lift + blade tilt + ripper lift + ripper tilt)
Engine underguard 183
Transmission underguard 228
Operator’s seat 42
Semi U-tiltdozer assembly 4,903
l Blade 2,818
l Straight frame 690x2
l Tilt brace 98x1
l Center brace 92x2
l Tilt cylinder assembly 190
8 Semi U-tilt + pitch dozer assembly 5,007

c l Blade 2,818
b l Straight frame 690x2
l Center brace 92x2
l Tilt cylinder assembly 190
l Pitch cylinder assembly 215
Blade lift cylinder assembly 165x2
Multi-shank ripper assembly 3,710
l Bracket, beam 2,014
l Shank 266x3
l Lift cylinder assembly 119x2
l Tilt cvlinder assembly 122x2
Giant ripper assembly 3,135
l Bracket, beam 1,728
l Shank 333x1
l Lift cylinder assembly 119x2
l Tilt cylinder assembly 122x2
l Pin puller cylinder assembly 7
ROPS assembly 480
Cab 285
ROPS canopy 698
Canopy 105
Dashboard 83
Floor frame 310
Side cover 130
Air conditioner assembly 110
01-11
8
GENERAL TABLE OF FUEL, COOLANT AND LUBRICANTS
TABLE OF FUEL, COOLANT AND LUBRICANTS
KIND OF AMBIENT TEMPERATURE I CAPACITY (t,

RESERVOIR
FLUID
Engine oil pan
Power train case
Final drive case (each side) Engine oil
0’“““““l
Hydraulic system
-1 Gear oil
Bogie (each) 1 1 1 / 1 / 1 1 1 0.21 - 0.23 1 0.21 - 0.23 i-

I
Add antifreeze
* AsrMD975No.1
NOTE:
(I) When fuel sulphur content is less than 0.5 %, (2) When starting the engine in an atmospheric
change oil in the oil pan every periodic main- temperature of lower than O”C, be sure to
tenance hours described in this manual. use engine oil of SAEIOW, SAEIOW-30 and
Change oil according to the following table if SAEl5W-40 even though an atmospheric tem-
fuel sulphur content is above 0.5 %. perature goes up to 10°C more or less in the
day time.
(3) Use API classification CD as engine oil and if
Change interval of oil API classification CC, reduce the engine oil
Fuel sulphur content
in engine oil pan change interval to half.
0.5to 1.0% l/2 of regular interval (4) There is no problem if single grade oil is mixed
with multigrade oil (SAEIOW-30, 15W-401, but
Above 1.0 % l/4 of regular interval be sure to add single grade oil that matches the
temperature in the table on the left.
(5) We recommend Komatsu genuine oil which
ASTM: American Society of Testing and Material
has been specifically formulated and ap-
SAE: Society of Automotive Engineers
proved for use in engine and hydraulic work
API: American Petroleum Institute
equipment applications.
Specified capacity:Total amount of oil including oil for components and oil in piping.
Refill capacity:Amount of oil needed to refill system during normal inspection and maintenance.
01-12
0
10 STRUCTURE AND FUNCTION
Radiator ........................................................ IO- 2 Suspension ................................................... IO-144

Oil cooler ...................................................... IO- 4 Work equipment hydraulic piping diagram IO-146
Engine control .............................................. IO- 6 PPC control piping diagram ........................ IO-149
Power train ................................................... IO- 8 Work equipment control ............................. IO-150
Power train system ...................................... IO- 9 Work equipment, HMT and HSS
Power trai unit mount ................................. IO- 10 hydraulic system diagram .................... IO-152
Overall drawing of power train unit ........... IO- 11 Work equipment, HMT and HSS
Power train hydraulic piping diagram.. ...... IO- 12 hydraulic circuit diagram ...................... IO-153
Power train hydraulic system drawing ....... IO- 14 Hydraulic tank and filter.. ............................ IO-160
Power train hydraulic circuit diagram ........ IO- 15 Hydraulic, HSS pump.. ................................ IO-162
Damper, universal joint ............................... IO- 16 Accumulator ................................................. IO-177
HMT system ................................................. IO- 18 EPC solenoid valve ...................................... IO-178
HMT control ................................................. IO- 24 PPC lock valve.. ............................................ IO-181
8
PTO ............................................................... IO- 26 PPC valve ..................................................... IO-182
c
HMT .............................................................. IO- 28 Main control valve ....................................... IO-188
z
‘HMT control valve ....................................... IO- 46 Operation of main control valve.. ............... IO-190
Lubrication relief valve ................................ IO- 58 HSS motor ................................................... IO-212
HMT pump assembly .................................. IO- 60 Operation of steering, work equipment
HMT motor assembly.. ................................ IO- 78 control circuit.. ....................................... IO-218
Operation of HMT system.. ......................... IO- 94 Piston valve .................................................. 1O-228
PPC, EPC, HMT charge filter ....................... IO-100 Quick drop valve .......................................... IO-229
PPC, EPC, HMT charge valve.. .................... IO-101 Cylinder stay ................................................ 1O-230
HMT oil cooler bypas valve ........................ IO-104 Work equipment .......................................... IO-231
Steering, brake control ................................ IO-106 Pin puller switch .......................................... IO-235
Bevel gear shaft, HSS, brake ...................... IO-107 Pin puller solenoid valve.. ........................... IO-236
Operation of HSS.. ....................................... IO-I 12 Tilt/Pitch selector switch .............................. 1O-238
Brake valve.. ................................................. IO-123 Pitch solenoid valve ..................................... 1o-239
Scavenging pump strainer.. ........................ IO-132 Cab mount ................................................... IO-242
Power train pump strainer.. ........................ IO-133 Cab.. .............................................................. IO-243
Power train oil filter.. ................................... IO-134 Air conditioner ............................................. IO-245
Final drive ..................................................... IO-135 Electrical wiring diagram.. ........................... IO-247
Radiator guard ............................................. IO-138 Electrical circuit diagram ......................... .lO-248-2
Main frame, under guard.. .......................... IO-139 Machine monitor system ............................ IO-251
Track frame .................................................. IO-140 Sensors.. ....................................................... IO-255
Recoil spring ................................................ IO-142 Engine control system.. ............................... IO-259
Track roller bogie ......................................... IO-143 HMT control system .................................... IO-266
10-l
8
STRUCTURE AND FUNCTION RADIATOR
RADIATOR
SKCOOOOZ
1. Radiator core assembly 9. Fan

2. Fan guard 10. Outlet hose
3. Reservoir tank 11. Drain plug
4. Lower tank (power train oil cooler built-in) 12. Inlet hose (for circulating at low water
5. Overflow hose temperature)
6. Water filler cap 13. Cushion
7. Air bleed hose 14. Breather cap
8. Inlet hose 15. Valve
1o-2
STRUCTURE AND FUNCTION RADIATOR
A-A
B-B
SKD00003
Outline
Radiator
l The radiator is provided with a reservoir tank
I
to make it easier to check and maintain the
radiator water level.
. The power train oil cooler is built into the
lower tank. *
Relief
(MPa (kg/cm?) 0.09 (0.9)
Pressure pressure
valve Vacuum
pressure (MPa (kg/cm211 0.005 (0.05)
1o-3
STRUCTURE AND FUNCTION OIL COOLER
OIL COOLER
1. Swing hinge
2. Hydraulic cooler
3. Power train oil cooler
A. Power train oil cooler outlet port

6. Power train oil cooler inlet port
Outline
. The power train oil cooler is built into the
lower tank.
Z SKDOOOD5
. The hydraulic cooler can be tilted, so it is easy
to clean.
Cooling method Built into lower Air coo,ed

, tank I
Heat dissipation area 1.829 m2 39.7 mz
1o-4
STRUCTURE AND FUNCTION OIL COOLER
SKD00400
Procedure for tilting hydraulic cooler

1. Remove top pin bolt (3) and nut (2) and bot- 1. Bolt
tom pin bolt (5) from mounting hole A, then 2. Nut
pass them through A and B and install them. 3. Pin bolt
* The diagram- shows the condition of the 4. Hydraulic cooler
pin bolt when tilted. 5. Pin bolt
2. Remove 4 top bolts (I) and 4 bottom bolts (6). 6. Bolt
3. In this condition, use bolts (3) and (5) as the A. Holes used when installing (chassis side, top,
fulcrum and tilt hydraulic cooler (4). bottom: 2 places)
* When installing again, carry out the pro- B. Holes used when tilting (oil cooler side, top,
cedure in the reverse order to removal, bottom: 2 places)
and return the pin bolt to its original po-
sition.
1o-5
STRUCTURE AND FUNCTION ENGINE CONTROL
ENGINE CONTROL
SEW0007
1. Decelerator pedal Outline

2. Fuel control dial . The engine speed is controlled electrically by
3. Engine throttle controller fuel control dial (2) and mechanically by
4. Governor motor decelerator pedal (I).
5. Rod l The operation signal of fuel control dial (2)
6. Fuel injection pump enters engine throttle controller (3). A drive
signal is then sent to governor motor (4) to
control fuel injection pump (6).
Dial, pedal positions
0: LOW IDLING
0: HIGH IDLING
0: HIGH IDLING
0: LOW IDLING
10-6
STRUCTURE AND FUNCTION POWER TRAIN
POWER TRAIN
1 2 7n in 14 II
SKDOOOIO ;;
Outline
. The power generated by engine (I) has its The rotation of the pair of HSS gears on the
torsional vibration dampened by damper (21, left and right is controlled by HSS motor (14).
and then passes through universal joint (31, The steering is carried out by generating a
and is transmitted to PTO (8). difference in speed on the left and right.
Here the power is divided into two. One part It is also possible to use the HSS mechanism
goes directly to transmission (IO), and the to rotate the left and right sides in opposite
other part goes through PTO (8) and is trans- directions to carry out counterrotation turns.
mitted to HMT pump (20), HMT motor (19) . Brake (15) of the HSS is used only for braking
and transfer (11). the machine. Brake (15) is a wet type, multiple
. Transmission (IO) uses a combination of a disc clutch, spring boosted type.
planetary gear system and hydraulic clutches The power sent from brake (15) is transmit-
to reduce the speed and carry out gear shift- ted to final drive (16).
ing (forward 3 speeds, reverse 3 speeds). The . Final drive (16) consists of a single stage spur
two sets of clutches selected in accordance gear and single stage planetary gear system.
with the change in the load are engaged and It reduces the speed and rotates sprocket (17)
transmit the power to the differential. Here to drive track shoe (18) and move the ma-
the two lines of power are merged and the chine.
power is transmitted to bevel gear (12).
. The power transmitted to the bevel gear shaft
is transmitted to HSS (Hydrostatic Steering
System) (13).
10-8
STRUCTURE AND FUNCTION POWER TRAIN SYSTEM
POWER TRAIN SYSTEM
SKDOOOll
: S6D140-1
1. Engine
2. Damper
Serial No.: 6000160279
[Serial No.: 60208 and up : SA6D140-2 1 11.
12.
Transfer
Bevel gear
3. Universal joint 13. HSS unit
4. PPC charge pump (104) 14. HSS motor (HFMIGO)
5. Scavenging pump (I 12) 15. Brake
6. Power train lubrication pump (SAL(3)-80) 16. Final drive
7. Power train pump (SAL(3)-100) 17. Sprocket
8. PTO 18. Track shoe
9. Hydraulic, HSS pump (HPVIGO) 19. HMT motor (HMVl60+160)
IO. Transmission 20. HMT pump (HPVIGO)
1o-9
8
STRUCTURE AND FUNCTION POWER TRAIN UNIT MOUNT
POWER TRAIN UNIT MOUNT
A-A
SKDOOOll
1. Cap (front) 6. Cap (rear)

2. Mount bolt 7. Front mount
3. Cushion 8. Rear mount
4. Clamp
5. Mount bolt
10-10
STRUCTURE AND FUNCTION OVERALL DRAWING OF POWER TRAIN UNIT
OVERALL DRAWING OF POWER TRAIN UNIT
9 8 u
12 13 14 15
8
X
2
0
SKD00013
1. Scavenging pump (112) Outline

2. PPC charge pump (104) l The power train unit can be broadly divided
3. Power train lubrication pump (SAL(3)-80) into PTO (12), HMT unit (13), and HSS unit
4. Power train pump (SAL(3)-100) (14). Therefore, after the power train unit has
5. Hydraulic, HSS pump (HPVIGO) been removed, it can be disassembled into
6. HMT control valve the PTO, HMT unit, and HSS unit.
7. Brake valve l The HMT unit consists of the transmission,
8. HMT motor (HMV160+160) HMT pump and HMT motor.
9. HMT pump (HPVIGO) . The HSS unit consists of the bevel pinion unit,
10. Power train pump strainer bevel gear shaft, HSS motor, planetary gear
11. Scavenging pump strainer system, and brake.
12. PTO
13. HMT unit
14. HSS unit
15. HSS motor (HMFIGO)
10-11
0
STRUCTURE AND FUNCTION POWER TRAIN HYDRAULIC PIPING DIAGRAM
POWER TRAIN HYDRAULIC PIPING DIAGRAM
7 8 9
A’ B d d E F 6 ‘H
1. PPC charge pump (104)

2. Scavenging pump (112)
3. Power train lubrication pump (SAL(3)-80)
4. Power train pump (SAL(3)-100)
5. PPC charge valve
6. PPC charge filter
7. Hydraulic filter
8. Hydraulic tank
9. HMT control valve
10. Last chance filter
11. Brake valve
12. HMT motor (HMV160+160)
13. Centralized pressure detection port
14. HMT oil cooler bypass valve
15. HMT pump (HPVIGO)
16. Power train oil strainer
17. Power train oil filter
18. Power train oil cooler (built into radiator lower tank)
19. Hydraulic cooler
A. Brake pressure pickup port

B. 1st clutch pressure pickup port
C. 2nd clutch pressure pickup port
D. 3rd clutch pressure pickup port
E. F clutch pressure pickup port
F. R clutch pressure pickup port
G. HMT pilot pressure pickup port
H. HMT lubrication pressure pickup port
Ii 16
SKD00016
10-12
STRUCTURE AND FUNCTION POWER TRAIN HYDRAULIC SYSTEM DRAWING
POWER TRAIN HYDRAULIC SYSTEM DRAWING

(Engine started, joystick at neutral, max. speed setter at low speed)
II
1
1I
ml 1 I 27
I
ABCDEFGH
i f f-7
IA IB
I&F] 22
SAD00019
10-14
0
STRUCTURE AND FUNCTION POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 1. Power train oil pan

IA. HMT case
IB. HSS case
2. Oil strainer
3. Power train pump (SAL(3)-100)
4. Power train oil filter
5A. Main relief valve
5B. Last chance filter
5C. Pilot reducing valve
5D. Forward clutch solenoid, selector valve
5E. Reverse clutch solenoid, selector valve
5F. 2nd clutch solenoid, selector valve
5G. 1st clutch solenoid, selector valve
5H. 3rd clutch solenoid, selector valve
51. Forward/reverse pressure compensation
PTO relief valve
r-- 5J. 2nd pressure compensation relief
5K. Ist/3rd pressure compensation relief
5L. Forward clutch modulating valve
5M.Reverse clutch modulating valve
5N. 2nd clutch modulating valve
50. 1st clutch modulating valve
18Y
5P. 3rd clutch modulating valve
50. Power train oil cooler relief valve
6. Reverse clutch
7. Forward clutch
8. 2nd clutch
‘,__,___--_-,j ,
9. 3rd clutch
i I IIIII!
10. 1st clutch
11. Power train oil cooler
u 12. HMT lubrication relief valve
13. HMT lubrication
24 14. PTO lubrication
15. Brake valve
15A. Solenoid valve
15B. Brake valve
15C. Parking brake valve
16. R.H. brake
I 16
17. L.H. brake
6 7 8 9 10 1
-_-__ I I Y I I- 18. Power train lubrication pump (SAL(3)-80)
Iracking 19. R.H. brake disc lubrication
xessure:
I. 103+0.02MP a
20. Bevel gear shaft lubrication
I
1.054.2k&m~
‘) 21. L.H. brake disc lubrication
22. Oil strainer
23. Scavenging pump (112)
24. PPC charge pump (104)
25. Pin puller solenoid valve (for giant ripper)
26. Pin puller cylinder
’
\i
I
I ‘- I I I 27. Centralized pressure detection port

A. Brake pressure pickup port
B. 1st clutch pressure pickup port
C. 2nd clutch pressure pickup port
D. 3rd clutch pressure pickup port
E. F clutch pressure pickup port
F. R clutch pressure pickup port
:lAlA
L______________J !
SAD00020 G. HMT pilot pressure pickup port
H. HMT lubrication pressure pickup port
10-15
0
STRUCTURE AND FUNCTION DAMPER, UNIVERSAL JOINT
DAMPER, UNIVERSAL JOINT

%1. : Serial No. 60280 and up
B-B
ii 10 9
A-A
lo-16
@
STRUCTURE AND FUNCTION DAMPER, UNIVERSAL JOINT
1. Breather
2. Dipstick
3. Drain plug
4. Input shaft
5. Flywheel
6. Outer body
7. Coupling
8. Universal joint
9. Cover
10. Rubber coupling
11. Inner body
Outline
. The damper dampens the torsional vibration
caused by the change in the engine torque
and the impact torque generated when accel-
erating suddenly or when carrying out heavy-
duty digging. In this way it acts to protect the
transmission and other parts of the power
train.
l This damper has few component parts: it uses
a rubber coupling, so the vibration is absorbed
8 by the internal damping effect of the rubber
z material and by the friction damping effect
6 provided by the deformation.
Operation
. The power from the engine passes through
flywheel (5) and is transmitted to outer body
(6).
The torsional vibration of the engine is ab-
sorbed by rubber coupling (IO), and the power
is transmitted to inner body (11). It then passes
through universal joint (81, and is transmitted
to the HMT.
10-17
0
STRUCTURE AND FUNCTION HMT SYSTEM
HMT SYSTEM
Outline
PTO HMT
. HMT stands for Hydro Mechanical Transmis- -7 --------->
sion.
l The HMT consists of a combination of hy-
draulic speed control (piston pump, motor)
and a mechanical transmission (hydroshift
transmission). In this way, the transmission
provides the continuous speed control of the
hydraulic speed control system together with
the high efficiency of the hydroshift transmis-
sion.
. The power generated by the engine is divided SKD00379
into two for the hydraulic system and me-

chanical system by the PTO. The hydraulic
system provides continuous speed control.
All of the remaining power flows to the me-
chanical system to increase the transmission Engin
Transmission
efficiency. O”tput
Structure
l The HMT system consists of the components
shown in the diagram on the right (HMT sys-
SKD00380
tem diagram).
l The HMT controller carries out gear shifting
of the mechanical transmission in accordance
with commands from the joystick (steering/
directional change lever). In addition, it also
changes the speed of the hydraulic motor
(HMT motor) to carry out continuous control
of the travel speed.
. In addition, the HMT controller detects both
the engine speed and the angle of opening of
the engine throttle, and controls the travel
speed so that the machine can always carry
out operations at the optimum efficiency points
of the engine.
lo-18
HMT SYSTEM DIAGRAM
Max. speed I
<;, Engine speed ,;p 7 , 1
7-
HMT
1
motor
I
control
valve
HM
I spe
-
ie
I
I -1 *
!Sprocket Brake 1
HSS motor
10-19
Differences between HMT and TORQFLOW transmission
HMT TORQFLOW transmission
<
Structure of
equipment
SKD00383
4 mechanical transmission (hydroshift) and
iydraulic gear shifting system (pump, mo- The torque converter (fluid coupling) and me-
:or) are aligned in parallel. :hanical transmission are aligned in series.
Flow of energ Ion

Engine
from engine
output
SKD00380
1) Most of the engine power passes through VI of the engine power passes through the
the mechanical transmission where there orque converter, and the resulting loss of
is little loss, so a high drawbar pull is ob- energy means that the drawbar pull is lower s
tained with a little loss of power. han with the HMT. 5
z
2) The hydraulic speed change system acts

to increase or decrease the speed of the
mechanical transmission output shaft.
Drawbar c wbar
P
transmission
Explanation
I
Travel ipeed Travel speed
The action of the hydraulic gear shifting sys-

em to increase or decrease the speed ex-
ends the drawbar pull performance of the
rydroshift transmission in A to ranges B and
.
,.
I other words, it makes it possible for the
lydroshift transmission performance to
nove freely between B and C.
1O-20
Effect of HMT as seen from machine drawbar

pull performance curve Drawbarpull (WI
. 1 .Ol
As exolained in the reasons in Sections (1) \
and (i) of “Differences between HMT and
TORQFLOW transmission”, the drawbar pull
in F2 with the HMT is greater than in F2 with
TORQFLOW transmission, and the range is
also greater. As a result, higher production
can be obtained.
Drawbarpull (HP/T) Travel speed (km/h)

SKD00285
1o-21
Basic flow for machine control with HMT

1. The machine travels forward, in reverse, or
stops according to the position of the joystick
(directional).
2. If the joystick is moved to the FORWARD or
REVERSE position, the travel speed will rise
to the travel speed (speed ratio) set with the
procedures below (Fig. 1, Fig. 2).
3. If the joystick is returned to the NEUTRAL
position when the machine is traveling, de-
celeration will take place in the reverse order
from acceleration.
Fig. 1
Input Control output
Position of’oystick
(directional / c 1. Determines target speed ratio
Max..speed setter
posrtion
-V engine speed
E;ii;e throttle opening _
F, R, Ist, 2nd, 3rd

--, solenoid ON/OFF
signal
2. Moves HMT pump, HMT motor swash plate
Engine speed sensor ft angle and switches transmission clutch
signal to give target speed ratio. HMT pump servo
The speed ratio is calculated from the mo- - drive current
tor speed sensor signal and engine speed
, (
xsignal, and the speed range at that point I
HMT motor servo
, r drive current
Fig. 2
Example of movement when accelerating from speed ratio 0 -+I.0
Symbol for Condition of Movement of HMT pump, motor Clutches engaged

condition machine Pump wash plate angle IMotor wash plate angle 1 1 2 13 1F
Motor speed ratio
Accelerating in F3 @Max. Reduced-Max. 0 0
@+@ Accelerating in F3 @Max.-+@0.4 Max. 0 0

I I I I I I I
Completion of
@ GO.4 Max. 0 0
acceleration
1o-22
Change in volume ratio of HMT pump, motor when static

. The diagram shows the graph for the condition of the HMT pump and HMT motor.
HMT motor speed ratio

HMT motor speed
1.5 engine speed
I
1.0
REVERSE 1.5 FORWARD

Speed ratio
HMT output speed
engine speed
Engagement
of clutches
speedrange/ R2 Rz(N)Fl F2 F3
0 0
0
Cluthes
engaged loool
0 000 0
0
Change in HMT pump volume ratio
Change in HMT motor volume ratio
, - Speed ratio
-1.5 -1.0 -0.5 0 0.5 1.0 1.5 SDW0389
1 O-23
0
STRUCTURE AND FUNCTION HMT CONTROL
HMT CONTROL
Serial No.: 60001 - 60806
* For details of the operation of the joystick for the steering system, see STEERING, BRAKE CONTROL.
SKD00043
1. Safety lever Lever positions

2. HMT control valve 0: NEUTRAL
3. Joystick (directional) 0: FORWARD
4. Speed control switch 0: REVERSE
5. Max. speed setter (forward) 0: FORWARD MIN. SPEED
6. Max. speed setter (reverse) 0: FORWARD MAX. SPEED
7. Brake valve @: REVERSE MIN. SPEED
8. Cable Q): REVERSE MAX. SPEED
9. HMT controller 8: LO (possible to set travel speed)
10. Limit switch (for safety lever) @: HI (cancels travel speed setting ana oecomes
max. travel speed. Or cancels max. speed and
sets to set speed.)
@: FREE
0: LOCK
1o-24
a
STRUCTURE AND FUNCTION HMT C6NTROL
Outline
The HMT is controlled by joystick (2) and max.
speed setters (5) and (6).
The joystick is used to shift between forward
and reverse.
There are separate max. speed setters for for-
ward and reverse. They are each used to set
the speed between the minimum speed and
the maximum speed and to provide continu-
ous speed control inside that range.
If speed control switch (4) is operated when
the machine is traveling, it is possible to
change the travel speed. If the switch is
pressed, the set travel speed is canceled and
the transmission is shifted to the maximum
travel speed. When the switch is pressed
again, it will return to the original set speed.
A safety mechanism is employed: if safety
lever (1) is not placed at the LOCK position,
limit switch (IO) is not actuated and the en-
gine cannot be started.
1o-25
Serial No.: 60807 and up

* For details of the operation of the joystick for the steering system, see STEERING, BRAKE CONTROL.
SWD02419
1. Safety lever Lever positions

2. HMT control valve 0: NEUTRAL
3. Joystick (directional) 0: FORWARD
4. Max. speed setter (forward) 0: REVERSE
5. Max. speed setter (reverse) 0: FORWARD MIN. SPEED
6. Brake valve 0: FORWARD MAX. SPEED
7. Cable @: REVERSE MIN. SPEED
8. HMT controller 0: REVERSE MAX. SPEED
9. Limit switch (for safety lever) @: FREE
@: LOCK
10-254
0
Outline
. The HMT is controlled by joystick (2) and max.
speed setters (5) and (6).
The joystick is used to shift between forward
and reverse.
There are separate max. speed setters for for-
ward and reverse. They are each used to set
the speed between the minimum speed and
the maximum speed and to provide continu-
ous speed control inside that range.
. A safety mechanism is employed: if safety
lever (I) is not placed at the LOCK position,
limit switch (IO) is not actuated and the en-
gine cannot be started.
1o-25-2
a
STRUCTURE AND FUNCTION PTO
PTO
SKD00041
lo-26
STRUCTURE AND FUNCTION PTO
B-B D-D
.I3
SKD00042
1. Power train, power train lubrication pump Outline

mount The PTO divides the power from the engine into
2. Scavenging pump, PPC charge pump mount two. One part drives the pumps (including the
3. PTO lubrication tube HMT pump), and the other becomes the trans-
4. HMT pump mount mission input.
5. Hydraulic, HSS pump mount
6. Coupling
7. Input shaft
8. PTO drive gear (48 teeth)
9. Idler gear shaft
10. Idler gear (61 teeth)
11. PTO case
12. HMT pump drive gear (49 teeth)
13. Pump drive gear (49 teeth)
(Power train, power train lubrication,
hydraulic, HSS pump)
14. Pump drive gear (46 teeth)
(Scavenging pump, PPC charge pump)
lo-27
STRUCTURE AND FUNCTION HMT
HMT
B-B
A-A
I I \ A. To reverse clutch
I 8 7 B. To forward clutch
C. To 2nd clutch
D. To 3rd clutch
E. To 1st clutch
F. Scavenging pump delivery port (from pump)
G. From oil cooler
SKD00044
H. Power train pump suction port (to pump)
I. Scavenging pump suction port (to pump)
J. Scavenging pump delivery port (to HSS case)
K. Power train pump suction port (from HSS case)
lo-28
1. Lubrication relief valve

2. Scavenging pump strainer
3. Power train oil strainer
NO.1 NO.2 NO.3 NO.4 NO.5
1 4. Lubrication tube (to PTO)
Clutch ( b 5. HMT motor
Reverse Forward 2nd 3rd 1st 6. Transfer case
7. HMT case
8. Lubrication tube (to rear half of HMT)
9. Lubrication tube (to transfer)
11. Transfer drive gear (41 teeth)
12. Speed sensor
13. Transfer idler gear (26 teeth)
14. Transfer driven gear (47 teeth)
15. Input shaft
16. Reverse sun gear (28 teeth)
17. Reverse planet pinion (22 teeth)
18. Pinion shaft
19. Reverse carrier (72 teeth)
20. Reverse ring gear (72 inner teeth, 105 outer teeth)
21. Disc
22. Plate
23. Piston
24. Reverse ring gear (72 teeth)
25. Forward carrier (72 teeth)
26. Forward planet pinion (21 teeth)
27. Forward ring gear (74 inner teeth, 105 outer teeth)
28. Forward sun gear (31 teeth)
29. 2nd hub (85 teeth)
30. 3rd-1 ring gear (70 teeth)
31. 3rd-1 planet pinion (20 teeth)
32. 3rd-1 ring gear (70 inner teeth, 105 outer teeth)
33. 3rd-1 carrier (70 teeth)
34. 3rd-1 sun gear (30 inner teeth, 70 outer teeth)
35. 3rd-2 ring gear (70 teeth).
36. 3rd-2 planet pinion (20 teeth)
37. 1st hub (105 teeth)
38. Differential-l carrier (43 inner teeth, 108 outer teeth)
39. Differential input ring gear (108 teeth)
40. Differential-l ring gear (93 teeth)
41. Differential-2 carrier (93 teeth)
42. Differential-2 ring gear (87 teeth)
43. Differential input ring gear (47 inner teeth,
108 outer teeth)
44. Output shaft
45. Differential-2 planet pinion (22 teeth)
46. Differential-2 sun gear (43 teeth)
47. Differential-l sun gear (41 teeth)
48. Differential-l planet pinion (21 inner teeth)
49. Differential-l planet pinion (22 outer teeth)
50. 1st clutch housing
51. 3rd-2 sun gear (30 teeth)
52. 3rd-2 carrier
69_ j , ,:9/ _;8 57 56 ,:I _,54c, 53 52 51 50 49 48 47 46 45
53. 3rd clutch housing
-- -I-
54. Intermediate shaft
Planetary line lReverse/ pt’ward[ 13rd - 1 1 13rd - 2 1 Differential-l 1IDifferential-2 55. 2nd housing
56. 2nd clutch housing
c-c SKD00045 57. Forward clutch housing
58. Reverse clutch housing
59. Return spring
60. Torque pin
1 O-29
Outline
1. Structure
. The HMT is a forward 3 speed, reverse 3
speed transmission using a combination of
planetary gear system and disc clutches.
. The HMT pump drive PTO is at the input shaft
end of the HMT, and the transfer for the
HMT motor hydraulic power input is at the
output end. The hydraulic power and me-
chanical power are combined at the plan-
etary differential and are output to the HSS.
Speed range and clutches actuated
Joystick Speed No. 1 No. 2 No. 3 No. 4 No. 5 Actuated

(directional) range Re- For- mode
verse ward 2nd 3rd 1st
* Actuation mode
HMT: Hydro Mechanical Transmission
(Power transmission using hydraulic
power + mechanical power + differ-
ential)
HST: Hydro Static Transmission
(Power transmission using hydraulic
power + differential)
No. of plates and discs used
1O-30
* The diagram shows the condition in F2.
1 6
: Mechanical power
: Hydraulic power
: Combined power
SKDO0046
2. Power transmission
. The power transmitted from the engine 1. Input shaft
through the damper to the universal joint then 2. HMT pump
enters PTO assembly (3) from input shaft (I). 3. PTO assembly
Inside the PTO, the power is divided into two: 4. HMT motor
one drives transmission assembly (81, and the 5. Transfer
other drives HMT pump (2) and the other 6. Output shaft
pumps. 7. Planetary differential
. The hydraulic power generated by HMT pump 8. Transmission assembly
(2) is converted again to rotating energy by
HMT motor (4) and enters transfer (5).
The power entering transmission assembly (8)
is shifted to each gear range by a planetary
gear.
. The power (hydraulic power) of the HMT mo-
tor transmitted to the transfer and the power
(mechanical power) transmitted from the trans-
mission assembly are combined at planetary
differential (7), rotate output shaft (6), and are
transmitted to the HSS.
By using a power transmission mechanism
combining hydraulic power and mechanical
power it is possible to obtain smooth speed
changes without any loss of power or with-
out any shock when shifting gear.
10-31
SKDO0047
3. Oil flow 1. HSS case

. The oil actuating clutches (6) of the transmis- 2. Strainer
sion, and the lubricating oil for PTO lubrica- 3. Power train pump
tion (IO) and transmission lubrication (11) are 4. Oil filter
sucked up from HSS case (1) by power train 5. HMT control valve
pump (3) and are sent to all parts before be- 6. Transmission clutch
ing drained to HMT case (12). 7. Brake valve
The accumulated oil drained to the HMT case 8. Brake cylinder
is sucked up by scavenging pump (14), passes 9. Oil cooler
through a passage inside the HMT case, and 10. PTO lubrication
is returned to HSS case (1). 11. Transmission lubrication
12. HMT case
13. Strainer
14. Scavenging pump
1O-32
Operation
1. Operation of disc clutch 23
. The disc clutch is installed in order to lock 59
ring gear (20) in position. It consists of piston
(231, plate (221, disc (211, torque pin (601, and
piston return spring (59). 60
The inner teeth of the disc are meshed with
the outer teeth of the ring gear. 22
The plate is meshed with torque pin (601, which
is locked to housing (58) and the protruding 21
notched portion on the outside diameter of
the plate.
20
SKD00048
Clutch engaged (locked)

. The oil from the control valve passes through 59
the port of housing (58) and is forcibly sent
to the back of piston (23).
60
The piston pushes plate (22) against disc (211,
and the friction stops the rotation of the disc.
It also locks ring gear (20), which is meshed 22
with the inner teeth.
21
58
SKD00049
Clutch disengaged (released)

. When the oil from the control valve is shut
off, piston (23) is returned to its original posi-
tion by piston return spring (59). The friction
60
between plate (22) and disc (21) is released,
and ring gear (20) is placed in neutral.
SKD00050
1o-33
2. Forward IST
38 39 40
w : Mechanical 49 47 46
power
w : Hydraulic power
: Combined power
IRotates y;e vtotates IRotates

freely) freelyl freelyJ
1o-34
Forward IST
* The direction of rotation given in the follow-
ing explanation is the direction as seen from
the rear of the machine.
. In the case of forward Ist, the No. 3 clutch
(for 2nd) and No. 5 clutch (for 1st) are en-
gaged.
. The power transmitted to input shaft (15) all
passes through the PTO drive gear and is used
as the power to drive the HMT pump. The
hydraulic power transmitted from the HMT
pump to the HMT motor passes through the
transfer and is input to the differential.
l The hydraulic power transmitted to differen-
tial input ring gear (39) rotates differential-l
carrier (38) and differential-2 sun gear (461,
which is interconnected with it.
. If differential-2 sun gear (461, which is the hy-
draulic power, rotates counterclockwise in the
same direction as the input shaft, differential-
2 ring gear (42) also rotates counterclockwise
and is output.
. Differential-l sun gear (47) is interconnected
with 1st hub (37), so it is fixed in position
8 when No. 5 clutch (for 1st) is engaged.
5 ’ As a result, the rotation of differential-l car-
Z rier (38) is reduced by differential-l planet pin-
ions (48) and (491, and is transmitted to differ-
ential-l ring gear (40).
. In the differential-2 line, differential-2 sun gear
(46) rotates at the same time as differential-l
carrier (381, and differential-2 carrier (41) ro-
tates at the same time as differential-l ring
gear (40). The power is further reduced by the
action of these two differential portions, and
is transmitted to differential-2 ring gear (42).
l When the rotation of differential-2 sun gear
(46) becomes faster, the rotation of differen-
tial-2 ring gear (42) also becomes faster and
the machine accelerates.
. The power transmitted to differential-2 ring
gear (42) is transmitted from output shaft (44)
to the HSS.
. When this happens, No. 3 clutch (for 2nd) is
engaged, so forward carrier (251, 2nd clutch
housing (561, 2nd hub (29), and intermediate
shaft (54) rotate at the same time as differen-
tial-2 carrier (41). In this way, they are syn-
chronized so that the forward clutch is en-
gaged smoothly when the gear is shifted from
forward 1st to forward 2nd.
1o-35
3. Reverse 1st
w
: Mechanical
: Hydraulic
: Combined
power
power
power
Planetary line lEl[

freely)
;I L
3rd-1
mtates
freely)
3rd -2
(Rotates
freely1
Differential-l Differential -2
46
lo-36
Reverse 1st
. In the case of reverse Ist, No. 3 clutch (for
2nd) and No. 5 clutch (for 1st) are engaged in
the same way as for forward 1st.
. The operation of the transmission is the same
as for forward Ist, but the direction of rota-
tion of the HMT motor is the opposite of for-
ward Ist, so the rotation of output shaft (44)
is also in the opposite direction.
. If differential-2 sun gear (46), which is the hy-
draulic power, rotates clockwise in the oppo-
site direction as input shaft (15L differential-2
ring gear (42) also rotates clockwise and is
output.
. When the rotation of differential-2 sun gear
(46) becomes faster, the rotation of differen-
tial-2 ring gear (42) also becomes faster and
1o-37
4. Forward 2nd
25 28
w : Mechanical power
: Hydraulic power
: Combined power
(Rotates (ROtZlteS (Rotates Fiotates

freely) freely) freely) freely)
1 O-38
Forward 2nd
In the case of forward 2nd, No. 2 clutch (for-
ward) and No. 3 clutch (for 2nd) are engaged.
The power transmitted to input shaft (15) is
divided in two inside the PTO into the me-
chanical power, which drives the transmis-
sion directly, and the hydraulic power, which
is transmitted from the HMT pump to the HMT
motor and transfer.
. The mechanical power is transmitted from
input shaft (15) to forward sun gear (28). For-
ward ring gear (27) is locked because No. 2
clutch (forward) is engaged, so the rotation of
forward sun gear (28) is reduced and trans-
mitted to forward carrier (25).
. In addition, because No. 3 clutch (for 2nd) is
engaged, the rotation of forward carrier (25)
is transmitted from 2nd clutch housing (56) to
2nd hub (291, intermediate shaft (541, and dif-
ferential-2 carrier (41).
. Differential No. 2 carrier (411, which is the
mechanical power, rotates counterclockwise
in the same direction as the input shaft.
. The hydraulic power input to the transfer
8 passes through differential input ring gear (391,
5 and rotates differential-l carrier (38) and dif-
s ferential-2 sun gear (46), which is connected
to it.
. If differential-2 sun gear (46) rotates clockwise
because of the hydraulic power, differential-2
ring gear (42) rotates counterclockwise in the
opposite direction, and increases in speed, so
If differential-2 sun gear (46) rotates
counterclockwise, the speed of differential-2
ring gear (42) is reduced, and the machine
decelerates.
. When this happens, No. 5 clutch (for 1st) is
not engaged, so differential-l sun gear (47) is
rotated together with differential-l planet pin-
ions (48) and (491, and the differential-l line
rotates freely.
. In the differential-2 line, the mechanical power
transmitted to differential-2 carrier (41) and
the hydraulic power transmitted to differen-
tial-2 sun gear (46) are combined and the
power is transmitted to differential-2 ring gear
(42).
. The power transmitted to differential-2 ring
gear (42) is transmitted from output shaft (44)
to the HSS.
1o-39
5. Reverse 2nd
38 39
hi
-
$
E
56 29 54 48 49 47 46
kZZ?2Z3 : Mechanical power
w : Hydraulic power
: Combined power
_I-
Planetary Ii1 :nti,
-
(Rotates motates motates (Rotates
freely) freely) freely) freely) SKD00058
1O-40
Reverse 2nd
In the case of reverse 2nd, No. 1 clutch (re- In the differential-2 line, the mechanical power
verse) and No. 3 clutch (for 2nd) are engaged. transmitted to differential-2 carrier (41) and
The power transmitted to input shaft (15) is the hydraulic power transmitted to differen-
divided in two inside the PTO into the me- tial-2 sun gear (46) are combined and the
chanical power, which drives the transmis- power is transmitted to differential-2 ring gear
sion directly, and the hydraulic power, which (42).
is transmitted from the HMT pump to the HMT The power transmitted to differential-2 ring
motor and transfer. gear (42) is transmitted from output shaft (44)
The mechanical power is transmitted from to the HSS.
input shaft (15) to reverse sun gear (16). Re- When this happens, output shaft (44) rotates
verse carrier (19) is locked because No. 1 clutch in the opposite direction from forward 2nd.
(reverse) is engaged, so the rotation of re-
verse sun gear (16) is reduced and transmit-
ted to reverse ring gear (24).
REVERSE ring gear (24) is connected to for-
ward carrier (25) so the rotation is transmitted
to forward carrier (25).
When this happens, forward carrier (25) ro-
tates in the opposite direction from forward
2nd. The operation beyond this point is the
same as for forward 2nd.
. In addition, because No. 3 clutch (for 2nd) is
engaged, the rotation of forward carrier (25)
8 is transmitted from 2nd clutch housing (56) to
E 2nd hub (291, intermediate shaft (54), and dif-
s ferential-2 carrier (41).
. Differential No. 2 carrier (41), which is the
mechanical power, rotates clockwise in the
opposite direction from the input shaft.
passes through differential input ring gear (391,
and rotates differential-l carrier (38) and dif-
ferential-2 sun gear (461, which is connected
to it.
. If differential-2 sun gear (46) rotates counter-
clockwise because of the hydraulic power, dif-
ferential-2 ring gear (42) rotates clockwise in
the opposite direction, and increases in speed,
so the machine accelerates.
If differential-2 sun gear (46) rotates clockwise,
the speed of differential-2 ring gear (42) is
reduced, and the machine decelerates.
. When this happens, No. 5 clutch (for 1st) is
not engaged, so differential-l sun gear (47) is
rotated together with differential-l planet pin-
ions (48) and (49), and the differential-l line
rotates freely.
10-41
6. Forward 3rd
fZ?ZZZB : Hydraulic power
: Combined power
1O-42
Forward 3rd
In the case of forward 3rd, No. 2 clutch (for- . If differential-l carrier (38) and differential-2
ward) and No. 4 clutch (for 3rd) are engaged. sun gear (46) are rotated counterclockwise by
The power transmitted to input shaft (15) is the hydraulic power, differential-2 ring gear
divided in two inside the PTO into the me- (42) increases in speed, so the machine accel-
chanical power, which drives the transmis- erates.
sion directly, and the hydraulic power, which If differential-2 sun gear (46) rotates clock-
is transmitted from the HMT pump to the HMT wise, the speed of differential-2 ring gear (42)
motor and transfer. is reduced, and the machine decelerates.
The mechanical power is transmitted from . The power transmitted to differential-2 ring
input shaft (15) to forward sun gear (28). For- gear (42) is transmitted from output shaft (44)
ward ring gear (27) is locked because No. 2 to the HSS.
clutch (forward) is engaged, so the rotation of
forward sun gear (28) is reduced and trans-
mitted to forward carrier (25).
The rotation of forward carrier (25) is trans-
mitted from 2nd clutch housing (56) to 3rd-1
ring gear (30). 3rd-1 carrier (33) is locked be-
cause No. 4 clutch (3rd) is engaged, so the
rotation of 3rd-1 ring gear (30) passes through
3rd-1 planet pinion (31), is increased, and is
transmitted to 3rd-1 sun gear (34).
. 3rd-1 sun gear (34) is connected to 3rd-2 ring
gear (35), so the rotation is further acceler-
8 ated in the 3rd-2 line, and is transmitted to
5 .
3rd-2 sun gear (51).
z The rotation of 3rd-2 sun gear (51) is transmit-
ted to differential-l sun gear (47), which is
connected to it.
. 3rd-2 sun gear (51) and differential-l sun gear
(47), which are the mechanical power, rotate
counterclockwise in the same direction as the
input shaft.
passes through differential input ring gear (39),
ferential-2 sun gear (46), which is connected
to it.
. In the differential-l line, the mechanical power
transmitted to differential-l sun gear (47) and
tial-l carrier (38) are combined. This power is
then reduced and is transmitted to differen-
tial-l ring gear (40).
. In the differential-2 line, the rotation transmit-
ted to differential-2 carrier (41), which is con-
nected to differential-l ring gear (40), and the
rotation of differential-2 sun gear (46) are com-
bined again and the power is transmitted to
differential-2 ring gear (42).
1o-43
7. Reverse 3rd
24 25 31 30 33
i HMT motor
1 HMTpump \i----+
I
15 w II
II
r;l I I A7
m : Hydraulic power
: Combined power
Planetary line /$iiZl E zil
motates
freely)
1o-44
Reverse 3rd
. In the case of reverse 3rd, No. 1 clutch (re- In the differential-2 line, the rotation transmit-
verse) and No. 4 clutch (for 3rd) are engaged. ted to differential-2 carrier (41), which is con-
. The power transmitted to input shaft (15) is nected to differential-l ring gear (401, and the
divided in two inside the PTO into the me- rotation of differential-2 sun gear (46) are com-
chanical power, which drives the transmis- bined again and the power is transmitted to
sion directly, and the hydraulic power, which differential-2 ring gear (42).
is transmitted from the HMT pump to the HMT If differential-l carrier (38) and differential-2
motor and transfer. sun gear (46) are rotated clockwise by the
l The mechanical power is transmitted from hydraulic power, differential-2 ring gear (42)
input shaft (15) to reverse sun gear (16). Re- increases in speed, so the machine acceler-
verse carrier (19) is locked because No. 1 clutch ates.
(reverse) is engaged, so the rotation of re- If differential-2 sun gear (46) rotates
verse sun gear (16) is reduced and transmit- counterclockwise, the speed of differential-2
ted to reverse ring gear (24). ring gear (42) is reduced, and the machine
. Reverse ring gear (24) is connected to for- decelerates.
ward carrier (25) so the rotation is transmitted The power transmitted to differential-2 ring
to forward carrier (25). gear (42) is transmitted from output shaft (44)
When this happens, forward carrier (25) ro- to the HSS.
tates in the opposite direction from forward When this happens, output shaft (44) rotates
3rd. The operation beyond this point is the in the opposite direction from forward 3rd.
same as for forward 3rd.
. The rotation of forward carrier (25) is trans-
mitted from 2nd clutch housing (56) to 3rd-1
8 ring gear (30). 3rd-1 carrier (33) is locked be-
5 cause No. 4 clutch (3rd) is engaged, so the
z rotation of 3rd-1 ring gear (30) passes through
3rd-1 planet pinion (311, is increased, and is
transmitted to 3rd-1 sun gear (34).
. 3rd-1 sun gear (34) is connected to 3rd-2 ring
gear (351, so the rotation is further acceler-
ated in the 3rd-2 line, and is transmitted to
3rd-2 sun gear (51).
l The rotation of 3rd-2 sun gear (51) is transmit-
ted to differential-l sun gear (471, which is
connected to it.
. 3rd-2 sun gear (51) and differential-l sun gear
(471, which are the mechanical power, rotate
clockwise in the opposite direction from the
input shaft.
passes through differential input ring gear (391,
ferential-2 sun gear (46), which is connected
to it.
. In the differential-l line, the mechanical power
transmitted to differential-l sun gear (47) and
tial-l carrier (38) are combined. This power is
then reduced and is transmitted to differen-
tial-l ring gear (40).
1o-45
HMT CONTROL VALVE
HMT CONTROL VALVE
2A
2B
2D
2E
D E 3
D-D
SDD00063
1 O-46
STRUCTURE AND FUNCTION HMT CONTROL VALVE
1. Valve seat
2. Solenoid valve assembly
4 5 6 7 8 9 10
2A. Forward solenoid
2B. 2nd solenoid
2C. 1st solenoid
2D. 3rd solenoid
2E. Reverse solenoid
4. 2nd selection detection switch
5. Reverse selection detection switch
6. Valve body
7. Reverse clutch selector valve
11 8. 2nd clutch selector valve
9. Forward clutch selector valve
10. Forward selection detection switch
12
11. 1st clutch selector valve
12. 1st selection detection switch
13. 3rd selection detection switch
14. 3rd clutch selector valve
13 16. Pilot reducing valve
17. Valve body
18. Forward/reverse clutch pressure compensation
relief valve
19. 2nd clutch pressure compensation relief valve
20. Ist/3rd clutch pressure compensation relief
valve
21. Main relief valve
22. Valve body
16 15 J 14
23. 3rd clutch modulating valve
25. 2nd clutch modulating valve
26. Reverse clutch modulating valve
27. Forward clutch modulating valve
18
27
A. To reverse clutch
B. To forward clutch
26 C. To 2nd clutch
D. To 1st clutch
E. To 3rd clutch
25
F. From power train pump
G. To power train oil cooler
H. Inlet port
20
I. Outlet port
24 J. To brake valve
23
B-B
1o-47
Outline
. The HMT control valve consists of the following filters and valves.

3. Pilot reducing valve
4. Pressure compensation relief valve (3 sets)
0. For directional clutch
0. For 2nd clutch
0. For IstI3rd clutch
5. Gear shift solenoid valve (clutch selector valve
and selector switch, 5 sets each)
0. For reverse clutch
0. For forward clutch
0. For 2nd clutch
0. For 3rd clutch
0. For 1st clutch
6. Modulating valve (5 sets)
0. For reverse clutch
0. For forward clutch
0. For 2nd clutch
@. For 3rd clutch
0. For 1st clutch
LAST CHANCE FILTER

Outline
. Last chance filter (2) is installed between the
upstream side of main relief valve (3) and the
upstream side of pressure compensation re-
lief valve (I).
All the oil entering the control valve is passed
through this filter to prevent any failure caused
by dirt in the system.
l This filter is a maintenance-free filter, and does
not require replacement.
valve
From pump SE000065
1O-48
MAIN RELIEF VALVE

Outline
. The main relief valve sets the actuating pres-
sure of the HMT control valve and brake valve.
. The brake actuating pressure is sent to the
brake valve through the HMT case and the
passage inside the HSS case.
Operation
. The oil from the power train pump enters
port A of main relief valve (1). It then passes
through orifice a and enters port B. When the
oil from the pump fills the circuit, the pres-
sure starts to rise.
. When the pressure in the circuit rises, the oil
entering port B pushes piston (2). The reac-
tion force compresses spring (4), moves spool
(3) to the left in the direction of the arrow, and
opens ports A and C. When this happens, the a\
oil from the pump is relieved from port A to 3\
port C, and it then flows from port C to the 4
power train oil cooler relief valve.
The oil pressure in the circuit at this is 3.1 r1
MPa (32 kg/cm?.
C’ Y
cz
n
To power train un
oil cooler relief
valve &A; B
From pump SED00066
1o-49
PILOT REDUCING VALVE

Outline
. Pilot reducing valve (I) is in the circuit divided
from the last chance filter outlet port and
pressure compensation relief valve.
The pilot reducing valve sets the pilot pres-
sure to move the gear shift solenoid valve
and actuate the 5 sets of gear shift valve
spools in accordance with the signal from the 1
HMT controller.
. The pilot reducing valve sets the pressure
in the pilot circuit to 1.2 MPa (12 kg/cm*) in
order to protect the solenoid valve.
. In addition, the pressure at the inlet port of
the pilot reducing valve is always kept at
about 2.43 MPa (25.3 kg/cm? by the pres-
sure compensation relief valve. In this way, it
is possible to actuate the gear shift valve
spool without suffering any effect from the SED00067
temporan/ drop in pressure in the transmis-

sion circuit when shifting gear.
Operation From la
. The oil from the last chance filter enters port filter ou
B from port A of pilot reducing valve (I). It

then flows from port B to the clutch selector
valve.
To clutch 3 ‘4
selector valve +
. When the flow from the pump increases and

the pressure rises, the oil passing through
From last chance
orifice a and entering port C pushes piston filter outlet port d
(4). The reaction force compresses spring (2)
and moves valve (3) to the left in the direction
of the arrow.
When this happens, the circuit between ports
A and B is closed, and the oil from the pump
does not flow beyond port B. The pressure in
the circuit at this point is 1.2 MPa (12 kg/cm? .
. When the gear shifting operation is carried To clutch
selector valve SED00069
out, the solenoid valve is connected to the
drain circuit, so the pressure in the pilot cir-
cuit beyond port B drops. When this happens,
valve (3) is returned to the right in the direc-
tion of the arrow by the tension of spring (2),
the passage between ports A and B is opened,
and oil flows in to keep the pressure in the
pilot circuit constant.
1O-50
PRESSURE COMPENSATION RELIEF VALVE

Outline
. To prevent loss of torque and shock when
shifting gears, gear shifting in the HMT is car-
ried out without relative rotation of the clutch.
To achieve this, it is necessary to disengage/
engage the clutches for gears before/after gear To forward,
reverse clutch
sifting simultaneously when performing gear- selector valve
shifting operation. In addition, if the pressure
drops for the clutches not involved in gear To 2nd clutch
selector valve
shifting at that time, clutch slippage will oc-
cur, so the pressure of the clutches not in-
To Ist, 3rd club
volved in the gear shifting must be kept above selector valve
a certain value while shifting gears.
For this reason, a pressure compensation re-
lief valve is installed between each clutch port
and the main relief valve. This acts to main-
tain the oil pressure above the set value.
. The forward and reverse clutches and the 1st
and 3rd clutches are never disengaged/en- To power train oil u
codler relief valve
gaged at the same time, so a common pres- ;
From pump SED00070
sure compensation relief valve is used for the
forward and reverse clutches and for the 1st
and 3rd clutches.
The same valve is used for the 3 sets (for- 1. Forward/reverse pressure compensation
8
ward/reverse, Ist/3rd, 2nd) of the pressure relief valve
5
compensation relief valve. 2. 2nd clutch pressure compensation relief valve
z
Example of clutch condition when shifting from 3. Ist/3rd clutch pressure compensation relief
Fl - F2 valve
l As shown in the graph, the 1st and 2nd clutch 4. Last chance filter
pressures are kept constant during filling time 5. Main relief valve
A for the forward clutch, and at point B, the
synchronized meshing of the forward and 2nd A: Forward clutch filling time
Oil
clutches is completed. pressure B: Point of completion of simultaneous
disengagement/engagement
In this way, a pressure compensation relief 4
valve is installed to prevent the pressure from
dropping when gear shifting and to enable %ch 1 1 1 ( rt
the gear shifting to be carried out smoothly.
Oil O I I
pressure If\
I I I
Clutch engaging condition I I
I
I
I
I
I
2nd
clutch
* 0'
I I I
=-t
Oil
pressure
1 I I I
I i i/i
A
SDD00071
10-51
Operation
When normal
. In normal conditions other than when shifting
gear, the oil pressure (the same as the main
relief pressure) inside port A is higher than To clutch’
the cracking pressure 2.48 MPa (25.3 kg/cm*)
of the pressure compensation relief valve, so
the oil from port A passing through orifice a
and entering port B pushes piston (I). The
reaction force compresses spring (31, moves
valve (2) to the left in the direction of the
arrow, and opens the passage between ports
A and C. As a result, port A and the clutch are
connected through port C.
. Regardless of which clutches are engaged, all
three pressure compensation relief valves are
in this condition.
+
Shifting gear from F2 - F3 From pump SE000072
. When shifting to 3rd, the main relief pressure
of port A goes down while the oil from port C
is filling the 3rd clutch. At the same time, the
pressure of the forward and 2nd clutches at
ports D and E also go down.
If the pressure goes below the cracking pres-
sure 2.48 MPa (25.3 kg/cm*) of the pressure
compensation relief valve, the pressure at port
B of the pressure compensation relief valve
also goes down. As a result, the force push-
ing spring (3) goes down, the passage be-
tween ports A and C closes, and this stops the
pressure at port C from dropping any further.
. In this way, the drop in the oil pressure of the
clutches which are not involved in gear shift-
ing is prevented when performing gear shift-
ing opeartion, and this prevents slipping of
the clutches.
4
Frompump SEDO9073
1o-52
GEAR SHIFT SOLENOID VALVE

r----- 2. Last chance filter
relief valve
5. 2nd pressure compensation relief valve
6. Ist/3rd pressure compensation relief valve
7. Forward clutch solenoid, selector valve
8. Reverse clutch solenoid, selector valve
9. 2nd clutch solenoid, selector valve
10. 1st clutch solenoid, selector valve
11. 3rd clutch solenoid, selector valve
Tooil cooler
I 16. 3rd clutch modulating valve
.A I
SO000074
Outline
. There are five sets of gear shift solenoid valves One set each of the gear shift solenoid valves
(including the clutch selector valve and selec- and clutch selector valves with the same struc-
tor detection switch) in the circuit between ture is used for each clutch, and all the valves
the pilot reducing valve and-the drain circuit. are actuated in the same way.
In addition, the circuit between the pilot re- Selector valve detection switch (for self diag-
ducing valve and the solenoid valves is con- nosis) is installed at the end of the stroke of
nected to the pilot port of the five sets of the clutch selector valve. When the solenoid
clutch selector valves. valve is actuated and the clutch selector valve
. Of the five sets of solenoid valves, two sets or moves and contacts the switch at the end of
three sets of solenoid valves are actuated by its stroke, the signal from HMT controller is
the signal from the HMT controller. As a re- grounded, and the fact that the clutch selector
sult, the oil from the pilot reducing valve is valve has been actuated is fed back to the
connected to the drain circuit, and the pilot HMT controller. If this signal does not match
pressure for the clutch selector valve is drained the command signal that the HMT controller
to engage the clutches. has sent to the solenoid, the HMT controller
judges that there is a failure in the HMT con-
troller valve, and carries out self diagnosis.
l Speed ranges and clutches actuated
Clutch No. 1 No. 2 No. 3 No. 4 No. 5

Re- For-
verse ward 2nd 3rd 1st
Forward 3rd 0 0
Forward 2nd 0 0
Forward 1st 0 0
stop 0 0
Reverse 1 st 0 0
Reverse 2nd 0 0
Reverse 3rd 0 0
1o-53
Operation
1. When no electricity is passing through sole-
noid valve (solenoid valve closed)
. The oil from the pilot reducing valve enters
pilot port E of clutch selector valve (I), passes
through orifice a, and enters port D. Solenoid
valve (2) is closed, so after port D is filled, the
oil pressure at pilot pot-t E and port D be-
comes the same. Clutch selector valve (I) is
pushed fully to the left in the direction of the
arrow by the force of spring (31, and stops. At
the same time, the passage between ports A
and B opens, and port C closes, so the oil
inside clutch (6) is drained and the clutch is
disengaged.
In this condition, clutch selector valve (I) is
(Disengaged) SED00075
not contacting selector detection switch (41,
so the selector detection switch is open.
Therefore, the HMT controller detects that this
clutch selector valve is not being actuated.
2. When electricity is passing through solenoid

valve (solenoid valve open)
. The oil from the pilot reducing valve enters
pilot port E of clutch selector valve (I), passes
through orifice a, and enters port D. Solenoid
valve (2) is open, so the oil entering port D
passes through solenoid valve (2) and is
drained, so the oil pressure at port D becomes
lower than the pressure at pilot port E. Be-
cause of this difference, clutch selector valve
(I) is pushed to the right in the direction of
the arrow, compresses spring (31, and stops.
At the same time, the passage between ports
B and C opens, and port A closes, so the oil reducing valve
supplied through the pressure compensation
valve fills clutch (6) and the clutch is engaged. (Engaged) SED00076
In this condition, clutch selector valve (I) is

contacting selector detection switch (4), so the
selector detection switch is closed.
Therefore, the HMT controller detects that this
clutch selector valve is being actuated.
1o-54
MODULATING VALVE
_-_---
r---- 2. Last chance filter
relief valve
5. 2nd pressure compensation relief valve
6. Ist/3rd pressure compensation relief valve
7. Forward clutch solenoid, selector valve
8. Reverse clutch solenoid, selector valve
9. 2nd clutch solenoid, selector valve
10. 1st clutch solenoid, selector valve
11. 3rd clutch solenoid, selector valve
16. 3rd clutch modulating valve
To oil
i ql i I
‘-T------ -2 I
SD000074
x,
z Outline
. Modulating valves are provided in the circuits
from the clutch selector valves to the clutches.
There is one for each clutch, and it carries out
modulation of the clutch pressure.
l The modulating valve is installed to prevent Modulating time
the generation of excessive peak pressure /
caused by oil hammer at completion of filling
the clutch when shifting gear according to the MPa
signal from the HMT controller. It acts to gradu- (kg/cm*)
ally raise the pressure applied to the piston 3.9
until it reaches the set value. (40)
l The graph on the right shows the passage of
? 2.9
time and the rise in the oil pressure with the
:, (30)
modulating valve. For example, when shifting P
h 2.0
from forward 1st (HST) to forward 2nd, the oil
5 (20)
from the pump passes through the forward
clutch selector valve and flows to the forward ; 1.0
(10)
clutch to fill the circuit to the clutch piston
port.
The time taken to fill the circuit to the clutch
piston port is called the filling time. The oil
Time SDD00077
pressure is 0 to 0.3 MPa (0 to 3 kg/cm*).
The time taken for the oil pressure to rise to
the set pressure after the circuit to the clutch
piston port is filled is called the build-up time.
The combination of the filling time and build-
up time is called the modulating time.
1o-55
Operation
1. Clutch filling
The oil from the clutch selector valve passes
through port A of valve seat (I) and fills the
clutch circuit. However, the oil pressure at this
point is a low 0 to 0.3 MPa (0 to 3 kg/cm21 so
relief valve (3) is pushed to the left in the
direction of the arrow by spring (51, stops when
it comes into contact with the seat surface of
valve body (2), and remains in contact with
the seat surface. \
t
From clutch
; ‘3 5
2. At moment of completion of filling

When the clutch circuit is completely filled,
the oil pressure at port A rises, and relief valve
(3) compresses spring (5) and moves to the
right in the direction of the arrow.
When this happens, the passage between
ports A and B opens, and the oil at port A
passes through drain port B and is drained
inside the HMT case to prevent the genera-
tion of peak pressure in the clutch circuit.
From-clutch
3. During modulation
The oil from the clutch selector valve contin-
ues to be relieved from port A of valve seat
(I) to port B. However, part of the oil passes
through orifice a, enters port C, and pushes
piston (4) to the right in the direction of the
arrow. When this happens, the pressure at
port C also rises together with the increase in
the reaction force of spring (5). In this way,
the oil pressure at port A rises together with
the oil pressure at port C, and the oil pressure 1’ t ‘a
From-clutch
in the clutch circuit gradually rises. selector valve
4. Completion of modulation
When piston (4) moves completely to the right,
the oil from port A passing through orifice a
and entering port C stops flowing, and the
difference in pressure between port A and
port C disappears.
As a result, the difference in the area of Al
(the area receiving the pressure at the left
end) and A2 (the area receiving the pressure
at the right end) pushes relief valve (3) to the
left in the direction of the arrow. It is pushed
against the seat surface of valve (2), closes A: t i ‘3 ‘AZ ‘4
the passage between ports A and B, and com- From clutch
selector valve
pletes the modulation.
1O-56
POWER TRAIN OIL COOLER RELIEF VALVE

Outline
. The power train oil cooler relief valve acts to
protect the oil cooler from abnormal pressure
by relieving the pressure if the pressure in the
oil cooler inlet port circuit goes above the set
pressure.
Operation
l The oil from the main relief valve enters port
A of power train oil cooler relief valve (I).
. If the oil pressure inside port A is below the
set pressure, the power train oil cooler relief
valve is not actuated, and all the oil flows
from port C to the power train oil cooler.
l When the temperature is low or when the oil
cooler is clogged, and the oil pressure inside
port A goes above the set pressure, the oil
pressure pushes valve (2). The reaction force
compresses spring (3) to push valve (2) to the
left in the direction of the arrow and opens
the passage between ports A and B.
When this happens, the oil is relieved from
port A to drain port B and is drained inside
8 the HMT case.
5 l
The cracking pressure of the power train oil t
cooler relief valve is 1.4 MPa (14 kg/cm*). From main To oil cooler
S relief valve
SDD00082
1o-57
STRUCTURE AND FUNCTION LUBRICATION RELIEF VALVE
LUBRICATION RELIEF VALVE
A-A 1. Piston
2. Spring
A. From oil cooler

B. Drain
C. Drain
Outline
. The oil leaving the oil cooler passes through
the lubrication relief valve and carries out Iu-
Unit: MPa (kg/cm?
brication of the PTO and HMT.
. The lubrication relief valve is installed to the
front face (input side) of the HMT case and
prevents any abnormal pressure in the lubri-
cation circuit.
lo-58
STRUCTURE AND FUNCTION HMT PUMP ASSEMBLY
HMT PUMP ASSEMBLY

HPVIGO
SDDOOl15
1. Servo valve connector

2. Piston pump
3. Servo piston
4. Servo valve
5. Suction safety valve
6. Charge safety valve
1O-60
0
SDDOO116
A. PSVO port (servo basic pressure)

8 B. PR port (charge safety valve relief preSSLIEd
5 C. PA, PB port (PA, PB pump pressure detection
z
plug)
D. PC port (charge pressure)
E. PB port (pump inlet/outlet)
F. PA port (pump inlet/outlet)
G. PD2 port (pump drain port)
H. PCS port (to charge pressure sensor)
Outline
l This pump consist of a variable capacity swash
plate type piston pump, servo valve, suction
safety valve, and charge safety valve.
* “Front” indicates the shaft mount end.
1O-61
1. Piston pump
F _
G H I
A. PSVO port (servo basic pressure)

B. PB port (pump inlet/outlet)
C. PA port (pump inlet/outlet)
D. PD2 port (pump drain port)
E. PA, PB port (PA, PB pump pressure detection
plug)
F. PR port (charge safety valve relief pressure)
G. PSVA port (servo valve output)
H. PSVB port (servo valve output)
I. PSVI port (servo valve basic pressure)
J. PC port (charge pressure) Y
SDD00117
K. PCS port (to charge pressure sensor)
1O-62
14 13
A-A
B-B SOD001 18
1. Shaft 8. Piston
2. Case 9. Cylinder block
3. Cradle 10. Valve plate
4. Rocker cam 11. End cap
5. Servo piston 12. Bearing
6. Slider 13. Spline
7. Shoe 14. Bearing
lo-63
2 3 45 6 7 8 9 IO 11
14 B A 13
A-h SDDODl 19
Outline
l The rotation torque transmitted to the pump . Rocker cam (4) has plane A, and shoe (7) is
shaft is converted to hydraulic energy and always pressed against this surface as it slides
pressurized oil is discharged according to the in a circle.
load. Rocker cam (4) sends high pressure oil to the
. It is possible to change the delivery amount space between cylindrical surface B and cra-
(normal delivery - 0 - reverse delivery) dle (3) fixed to the case (2), to form a hydro-
by changing the swash plate angle. static bearing and carries out a rocking move-
ment.
Structure . Piston (8) carries out motion relative to the
l Cylinder block (9) is supported to shaft (I) by axial direction inside each cylinder chamber
a spline (13), and shaft (I) is supported by of cylinder block (9).
front and rear bearings (12) and (14). l Cylinder block (9) carries out rotation relative
. The end of piston (8) has a concave ball shape, to valve plate (IO) while sealing the pressu-
and shoe (7) is caulked to it to form one unit. rized oil, and this surface ensures that the
Piston (8) and shoe (7) form a spherical bear- hydraulic balance is maintained correctly. The
ing. oil inside each cylinder chamber of cylinder
block (9) is sucked in and discharged through
valve plate (IO).
1O-64
Operation
1. Operation of pump
l Cylinder block (9) rotates together with shaft
(I), and shoe (7) slides on plane A.
When this happens, angle a of center line X
of rocker cam (4) to the axial direction of cyl-
inder block (9) changes. This angle a is called
the swash plate angle. 1 4789 E
PA PB
1) With swash plate angle a formed by the
angle between center line X of rocker cam t t
(4) to the axial direction of cylinder block
(91, plane A acts as a cam for shoe (7). In
this way, piston (8) slides inside cylinder
block (91, and as a result, a difference is
generated between volumes E and F in-
side the cylinder block. The amount of
suction and discharge is equal to differ-
ence F - E. SKD00120
In other words, cylinder block (9) rotates,

and the volume of chamber F becomes
smaller, so oil is discharged during this
process. At the same time, the volume of
chamber E becomes larger and oil is
sucked in as the volume increases.
2) When center line X of rocker cam (4) is
the same as the axial direction of cylinder PA PB
block (9) (s-wash plate angle = O), the dif-
ference between volumes E’ and F’ inside
cylinder block (9) is 0, so no oil flows in or
out, and no pumping is carried out.
3) With swash plate angle a formed by the
angle between center line X of rocker cam
(91, plane A acts as a cam for shoe (7). In
this way, piston (8) slides inside cylinder
block (9), and as a result, a difference is
generated between volumes E” and F”
inside the cylinder block. The amount of
PA PB
ence E” - F”.
and the volume of chamber E” becomes
process. At the same time, the volume of
chamber F” becomes larger and oil is
sucked in as the volume increases. When
the swash plate angle changes, the suc-
tion/discharge action of ports PA and PB
‘A ‘F”
is reversed. SKD00122
1 O-65
2. Control of discharge amount

1) If swash plate angle a becomes larger,
the difference between volumes E and F
becomes larger, and oil delivery Q is in-
creased. Swash plate angle a is changed
by servo piston (5).
Servo piston (5) carries out reciprocal
movement in a straight line (-1 accord-
ing to the command from the valve. This
straight-line movement is transmitted to
rocker cam (4) through slider (6), and
rocker cam (41, which is supported on the
cylindrical surface by cradle (2) slides on
the cylindrical surface ( C direction).
In the case of the pump, swash plate an-
gle a is a maximum of *20”.
A-A SW00123
4 5 6
c-c SDD00124
B-B SDD00125
1O-66
2. Servo valve
A-A B-B
SKD00126
1. Connector 10. Lever 2

2. Solenoid valve B 11. Body
3. Connector 12. Screw
4. Solenoid valve A 13. Arm
5. Shaft 14. Spool
6. Coil
7. Base A. PSVI port (servo valve basic pressure)
8. Lever 1 B. PSVB port (servo valve output)
9. Spring C. PSVA port (servo valve output)
1O-67
5 6 14
SKD00127
Operation
1) When pressurized oil (servo basic pressure)
does not enter from the charge pump or when
there is no signal current flowing to solenoid
valve coil (61, the servo valve and actuator
(15) are not actuated.
1O-68
SKD00128
2) When the signal current flows to solenoid

valve coil (6) and it is excited, solenoid pro-
pulsion force fl is generated and shaft (5)
pushes spool (14) to the right in the direction
of the arrow. Lever 2 (IO), which is intercon-
nected with spool (14), uses screw (12) as a
fulcrum and rotates clockwise while pulling
spring (9).
3) When spool (14) moves, the passages between
ports A and B and ports C and D open, and
pressurized oil from the charge pump passes
through ports A and B and flows to port F of
actuator (15).
At the same time, the oil at port G passes
through ports D and E and is drained.
lo-69
a---J-J-
\6 SKD00129
4) Servo piston (16) is moved to the right in the

direction of the arrow by the pressurized oil
entering port F, and the swash plate angle of
the variable pump becomes larger by an
amount equal to stroke a of the servo piston.
At the same time, arm (131, which is con-
nected to servo piston (16) rotates using screw
(12) as a fulcrum, and lever 1 (8) is moved to
the left.
Servo piston (16) stops in a position where
solenoid propulsion force fl is balanced with
spring force f2.
1O-70
5) The stroke of the actuator (servo piston), which

changes the delivery amount of the variable
Solenoid A (ON)
pump, is controlled by the servo valve.
The relationship between the stroke of the
actuator and the signal current of the sole-
noid valve is as shown in the diagram. Signal Current (A)
Solenoid B (ON)
- SKD00130
10-71
STRUCTURE AND FUNCTION HMT PUMP ASSEMB LY
5A 5B 5C 5D 5E 5F 5G
LIL‘1
!i;
16
SED00131
1. Charge pump
2. HMT pump
3. Oil cooler
5A. Valve
5B. Piston
5C. Sleeve
Function 5D. Poppet
. There are two suction safety valves installed 5E. Valve seat
to the HMT pump, and they have the follow- 5F. Spring
ing functions. 5G. Pressure adjustment screw
1) High pressure relief valve (one turn adjusts pressure by
The valve restricts the maximum pressure approx. 13.7 MPa (140 kg/cm?
inside the HMT circuit in order to protect 6. HMT motor
the HMT circuit and to restrict the maxi-
mum drawbar pull of the machine.
2) Suction safety valve
The valve ensures the flow of charge oil
to the HMT circuit and prevents the charge
oil from flowing into the pump high pres-
sure side (delivery side).
1 O-72
0
STRUCTURE AND’ FUNCTION HMT PUMP ASSEMBLY
Operation when acting as high pressure relief

valve
(Valve at piston pump delivery side)
. Port A is connected to the pump circuit and
port B is connected to the charge circuit. The
pressurized oil also fills port C through drill
hole a in piston (5B). In addition, poppet (5D)
is in tight contact with valve seat (5E).
. If abnormal pressure is generated in the cir-

cuit and the oil pressure at port A and C
reaches the pressure set by spring (5F), pop-
pet (5D) is pushed to the right in the direction
of the arrow, and the oil at port C is relieved
from port D to port B to reduce the oil pres-
sure at port C.
SEW0133
l When the oil pressure at port C goes down, a A 5A 5B C

differential pressure is generated between port
A and port C by orifice b in piston (5B). Valve
(5A) is pushed to the right in the direction of
the arrow by the oil pressure at port A, and
the oil at port A is relieved to port B.
In this way, the circuit is prevented from reach-
ing any higher pressure.
SED00134
1o-73
Operation when acting as suction safety valve

I) When HMT pump delivery is 0
. The HMT circuit is sealed, and the charge pres-
sure oil does not flow to the HMT circuit.
Therefore, the charge pressure oil from the
charge pump all passes through charge safety
valve (4) and is drained from oil cooler (3) to
the tank.
2) When HMT pump delivery is discharged from

port PA
(II Valve at piston pump delivery side
l When pressure oil is discharged from
port PA of HMT pump (21, port PA
becomes the high-pressure side. This
pressure oil at port PA passes through
drill hole a in piston (5B) and flows to
port A.
When this happens, valve (5A) is
pushed to the left in the direction of
the arrow against sleeve (5C) because
of the difference in area (Al>A2).
Therefore, the pressure oil from charge
pump (I) is prevented from flowing
in.
Ff SED00136
SD00137
1o-74
(2) Valve at piston pump suction side

. Port PB becomes the suction side, so
it becomes the low-pressure side.
Because of the difference in area
(Al>A2), valve (5A) is pushed to the
right in the direction of the arrow by
the charge pressure oil and the seat
of sleeve (5C) opens.
As a result, the charge pressure oil at
port B passes through the gap and
flows to port PB to carry out the charge
function for the HMT circuit.
. When the HMT pump discharges oil, SED00138
all the oil in the charge circuit flows to

the HMT circuit.
1o-75
4 C A 5
4A 4B 4c 4D 4E 4F
L!-!-l
SED00139
1. Charge pump
2. HMT pump
3. Oil cooler
4A. Valve
Function 4B. Spring
. The charge safety valve is installed to the HMT 4C. Valve seat
pump (between the suction safety valve and 4D. Poppet
the oil cooler). It acts to restrict the maximum 4E. Spring
pressure in the charge circuit in order to pro- 4F. Pressure adjustment screw
tect the charge circuit. 5. Suction safety valve
Set pressure: 3.7 MPa (38 kg/cn?lbt 204 fi/min) 6. HMT motor
1O-76
0
Operation
. Port A is connected to the charge circuit, and
port B is connected to the tank drain circuit.
The pressure oil passes through orifice a in
valve (4A) and fills port C. Poppet (4D) is in
tight contact with valve seat (40
& SEDOOl40
. If abnormal pressure is generated in the cir-

cuit or the shuttle valve of the HMT motor is
at neutral, and the pressure oil at ports A and
C reaches the pressure set by spring (4E), pop-
pet (4D) is pushed to the right in the direction
of the arrow, and the oil at port C is relieved
to port D to reduce the pressure of the oil at
port c.
I
I
A C
m SED00141
l When the pressure of the oil at port C goes 4A B 4D 4E

down, a differential pressure is created be-
tween ports A and C because of orifice a in
valve (4A). Valve (4A) is pushed to the right in
the direction of the arrow by the oil pressure
at port A, and the oil at port A is relieved to
port B.
In this way, the pressure in the charge circuit
is prevented from going any higher.
. Drain port D at the poppet portion is drained

to the HMT pump case, so the back pressure SED00142
of drain port B is not added to the charge
relief pressure, and the valve always displays
the set relief characteristics.
1o-77
HMT MOTOR ASSEMBLY
HMT MOTOR ASSEMBLY

HMVl60+160
l--A
D
Y
SAD00143
1 O-78
STRUCTURE AND FUNCTION HMT MOTOR ASSEMBLY
8 9
A-A
SAD00144
1. Servo valve connector

2. Piston motor (front)
3. Servo piston (front)
4. Servo valve (front)
5. Servo valve (rear)
6. Servo piston (rear)
7. Piston motor (rear)
8. Charge relief valve
9. Shuttle valve
A. PT3 port (motor drain port)

B. PSVO port (servo basic pressure)
C. PTI port (charge relief pressure)
D. MA port (motor inlet/outlet port)
E. MB port (motor inlet/outlet port)
Outline
. This motor consists of a variable capacity
swash plate type piston motor, servo valve,
charge relief valve, and shuttle valve.
t “Front” indicates the shaft mount end.
1o-79
Piston motor
A
F G H
I J K
SAD001 45
A. PT3 port (motor drain port) G. PSBI port (front servo valve output)
B. PSVO port (servo basic pressure) H. PSVI port (front servo valve basic pressure)
C. PTI port (charge relief pressure) I. PSB2 port (rear servo valve output)
D. MA port (motor inlet/outlet port) J. PSA2 port (rear servo valve output)
E. MB port (motor inlet/outlet port) K. PSV2 port (rear servo valve basic pressure)
F. PSAI port (front servo valve output)
1 O-80
12345678 9 IO 11 12
15 14 13
A-A
16 4
\
c-c 3 B-B
SAD00146
1. Shaft 9. Cylinder block

2. Case (front) 10. Valve plate
3. Cradle 11. End cap
4. Rocker cam 12. Case (rear)
5. Servo piston 13. Bearing
6. Slider 14. Spline
7. Shoe 15. Bearing
8. Piston 16. Shuttle valve
lo-81
I \\\T
15 B A 14 13
A-A SAD0001 47
Outline
. The pressurized oil sent from the pump is Rocker cam (4) sends high pressure oil to the
converted to rotation energy and is transmit- space between cylindrical surface B and cra-
ted to the output shaft. dle (3) fixed to cases (2) and (121, to form a
. It is possible to change the motor output rota- hydrostatic bearing and carries out a rocking
tion torque by controlling the swash plate an- movement.
gle. . Piston (8) carries out motion relative to the
Structure axial direction inside each cylinder chamber
. Cylinder block (9) is supported to shaft (I) by of cylinder block (9).
spline (14), and shaft (I) is supported by front . Cylinder block (9) carries out rotation relative
and rear bearings (13) and (15). to valve plate (IO) while sealing the pressu-
. The end of piston (8) has a concave ball shape rized oil.
and shoe (7) is caulked to it to form one unit. This surface ensures that the hydraulic bal-
Piston (8) and shoe (7) form a spherical bear- ance is maintained correctly. The oil inside
ing. each cylinder chamber at the rotation end (cyl-
. Rocker cam (4) has plane A, and shoe (7) is inder block) is sucked in and discharged
always pressed against this surface as it slides through the gap at the port (valve plate).
in a circle.
1 O-82
Operation
1. Operation of motor
l The pressurized oil sent from the pump
enters cylinder block (9) and pushes pis-
ton (8) from the back face.
In the case of the motor, the center line of
rocker cam (4) is always at an angle (swash
plate angle a) to the axial direction of cyl-
inder block (9). As a result, if we take the
example of one of pistons (8), oil pressure
is applied to the back face of the piston as
shown in the diagram on the right, and
piston axial force FO is generated. SAD001 49
. With shoe (7), which is joined to piston (8)

by the spherical surface, reaction force FR
in a direction at right angles to plane A is
generated. The combined force of FO and 47 8 9 E
FR is FP, and this becomes the force to
rotate cylinder block (9).
. Shaft (I), which is meshed to cylinder
block (9) by spline (14) transmits this rota-
tion torque to the output side. Cylinder
block (9) rotates, and while the condition
changes from volume E to volume F, pres-
surized oil from the pump flows into the
cylinder chamber, and pressure P is gen-
erated according to the load. On the other i ‘A 14 F
hand, when the condition goes beyond SAD00149
volume F and changes to volume E, the

oil is pushed out and returned to the
pump.
2. Rotation speed, torque control

If swash plate angle a becomes larger, the Q=qN
difference between volumes E and F inside (q=E-F) Q: Total flow
q: Flow for one rotation
cylinder block (9) becomes larger, and incom-
N: Rotation speed
ing oil flow q for each rotation is increased. T_pg P: Pressure
Therefore, for the same oil flow, the larger 2n:
T: Rotation torque
swash plate angle a becomes, the slower ro-
tation speed N becomes.
If swash plate angle a becomes larger, FO
becomes larger in relation to axial force FP,
and rotation torque T also becomes larger.
The method of changing the swash plate an-
gle of the motor is the same as for the pump.
(For details, see “Control of discharge amount”
for “OPERATION OF HMT PUMP”.)
In the case of the motor, swash plate angle a
is a maximum of 20” and a minimum of
approx. 6.5”.
lo-83
3. Relationship between direction of input flow,

swash plate angle, and direction of output
MA MB
rotation
The direction of swash plate angle a is con- It
stant, so the direction of output rotation
changes according to the direction of the in-
put flow of pressurized oil (direction of deliv-
ery from pump).
I) When oil flows in from port MA
The output shaft rotates clockwise as seen
from the end of the shaft at the mount
end. SAD00255
21 When oil flows in from port MB

The output shaft rotates counterclockwise
as seen from the end of the shaft at the
mount end.
SAD00256
8
2
z
1 O-84
2. Servo valve
Front end
1 2 B4
8 9
12 11 10 9 ‘11
A-A B-B
1. Connector IO. Screw

2. Solenoid valve 11. Arm
3. Shaft 12. Spool
4. Coil
5. Base
6. Lever 1
7. Spring A. PSVI port (servo valve basic pressure)
8. Lever 2 B. PSVB port (servo valve output)
9. Body C. PSVA port (servo valve output)
lo-86
Rear end
12 11 10 9 ‘IO
A-A B-B
1. Connector IO. Arm

2. Solenoid valve 11. Screw
3. Lever 1 12. Body
4. Spring
5. Lever 2
6. Base
7. Coil A. PSVI port (servo valve basic pressure)
8. Shaft B. PSVB port (servo valve output)
9. Spool C. PSVA port (servo valve output)
lo-87
Outline
. The motor servo valve increases the motor
output speed by making the volume of the
motor smaller.
. The motor servo valve does not distinguish
between the normal and reverse angle of the
swash plate (there is a solenoid on only one
side).
However, there are separate motor servo
valves for the front motor and rear motor.
SKD00259
Operation Rear
l The operation is more or less the same as for
the pump servo valve, so for details, see
SERVO VALVE for the HMT pump.
. The stroke of the actuator (servo piston) which

changes the speed of the variable motor is
controlled by the servo valve.
The relationship between the stroke of the
actuator and the solenoid valve signal current
is as shown in the diagram.
0; Signal current (A)
1O-88
3. Shuttle valve
Function
l The shuttle valve acts to switch the shuttle
valve spool according to the pressurized oil in
the HMT high-pressure circuit, and to return
the oil in the HMT low-pressure circuit through
the oil cooler to the tank. The shuttle valve is
installed to the HMT motor assembly.
Operation
When HMT pump swash plate angle is at
neutral position
The swash plate angle of the pump is at the
neutral position, so the delivery from HMT
pump (2) is 0. When this happens, the same
oil pressure is applied to ports A and B at
both ends of shuttle valve spool (7), so spool
(7) remains at the neutral position.
The pressurized oil from charge pump (I)
passes through charge safety valve (41, which
is assembled to the pump, and is drained from
oil cooler (3) to the tank.
SAD00262
21 When HMT pump is discharging oil from port

PA
. The pressurized oil from HMT pump (2) en-
ters port MA from port PA, passes through
orifice a of shuttle valve spool (7), then enters
port A. Spool (7) is pushed to the right in the
direction of the arrow by the pressurized oil
at port A, so the passage between ports MB
and C is opened and the oil is connected to
charge relief valve (8).
. When this happens, the relationship of the
set pressure of charge relief valve is as fol-
lows.
Set pressure of Set pressure of

charge safety charge relief
valve (4) valve (8) I
. As a result, the pressurized oil from charge

pump (I) flows from port C through charge
relief valve (81, where the set pressure is lower.
It is then relieved and is drained from oil cooler
(3) to the tank.
lo-89
0
3) When HMT pump is discharging oil from ,5

port PB
. The pressurized oil from HMT pump (2) en-
ters port MB from port PB, passes through
orifice b of shuttle valve spool (71, then enters
port B. Spool (7) is pushed to the left in the
direction of the arrow by the pressurized oil at
port B, so the passage between ports MA and
C is opened and the oil is connected to charge
relief valve (8).
. When this happens, the relationship of the set
pressure of charge relief valve is as follows.
. As a result, the pressurized oil from charge

pump (I) flows from port C through charge
relief valve (81, where the set pressure is lower.
It is then relieved and is drained from oil cooler
(3) to the tank.
8 SAD00264
8
5
z
1O-90
0
PB
11 MB
1. Charge pump
2. HMT pump
3. Oil cooler
6. HMT motor
7. Shuttle valve
8A. Valve
8B. Spring
8C. Valve seat
8D. Poppet
8E. Spring
8F. Pressure adjustment screw
Function
l The charge relief valve is installed to the HMT
motor. It acts to maintain the minimum pres-
sure at the HMT circuit low-pressure side and
ensure the suction performance of the HMT
pump.
Set pressure: 1.8MPa (18 kg/cm? (at 120.4Vmin)
Operation
l When oil is being discharged from port PA or
port PB of the HMT pump, the oil at the low-
pressure side flows from port MA or port MB
through shuttle valve (7) and enters inlet port
A of charge relief valve (8).
l The pressurized oil entering port A passes

through orifice a in valve (8A) and fills port C.
SAD00266
Poppet (8D) is in tight contact with valve seat
(80
10-91
0
. If the pressure oil at port C reaches the pres-

sure set by spring (8E), poppet (8D) is pushed
to the right in the direction of the arrow, and
the oil at port C is relieved to port D to reduce
the pressure of the oil at port C.
. When the pressure of the oil at port C goes

down, a differential pressure is created be-
tween ports A and C because of orifice a in
valve (8A). Valve (8A) is pushed to the right
in the direction of the arrow by the oil pres-
sure at port A, and the oil at port A is relieved
to port B.
In this way, the pressure in the charge circuit
is maintained at the set pressure of charge
relief valve (8). This charge pressure main-
tains the supply of oil inside the HMT closed
circuit. A a
SAW0268
. Drain port D at the poppet portion is drained

to the HMT motor case, so the back pressure
of drain port B is not added to the charge
relief pressure, and the valve always displays
the set relief characteristics.
1o-92
STRUCTURE AND FUNCTION OPERATION OF HMT SYSTEM
OPERATION OF HMT SYSTEM

1. Joystick at NEUTRAL, machine stopped
NEUTRAL
FORWARD
REVERSE
\ 1 I
G
aA 14
F 13
. E
To PPC valve
1
-
,C 11IIT -----
I I ; .---7
SARI0269
1. Hydraulic tank
2. Charge pump
3. HMT, PPC charge filter
4. Accumulator
5. HMT, PPC charge valve
6. Charge pressure sensor
7. HMT pump
7A. Suction safety valve
7B. Suction safety valve
7C. Charge safety valve
7D. Servo piston
7E. Solenoid B
7F. Solenoid A
7G. Servo valve
8. HMT motor assembly
8A. Shuttle valve
8B. Charge relief valve
9. HMT motor (front)
9A. Servo piston
9B. Solenoid
9C. Servo valve
10. HMT motor (rear)
IOA. Servo piston
IOB. Solenoid
8 IOC. Servo valve
2 11. Oil cooler bypass valve
& 12. Hydraulic cooler
13. HMT controller
14. Joystick (directional)
Operation when joystick is at NEUTRAL and ma-

chine is stopped
l When joystick (14) is at NEUTRAL, there is no In addition, when this happens, there is no
electric signal from HMT controller (13) to HMT electric signal from HMT controller (13) to HMT
pump solenoids (7E) and (7F). Servo valve motor solenoids (9B) or (IOB). Servo valves
(7G) and servo piston (7D) are both at neutral, (9C) and (IOC) are at neutral, and servo pis-
so the swash plate angle of HMT pump (7) is tons (9A) and (IOA) are at the end of their
0, and the delivery from ports PA or PB is also stroke, and the swash plate angle of HMT
0. motor (8) is the maximum.
In this condition, shuttle valve (8A) is at the
l The pressurized oil from charge pump (2) neutral position and no oil flows to port G.
passes through HMT, PPC charge valve (5)
and enters the charge circuit. The pressurized To ensure the suction performance of HMT
oil entering port A is set to the maximum pump (7), the charge pressure in the HMT
pressure for the charge circuit 3.7MPa (38 kg/ charge circuit is always detected by charge
cm? by charge safety valve (7C). When the pressure sensor (61, and feedback is sent to
HMT pump is at neutral, all the oil flow is HMT controller (13).
relieved from port D, passes through oil cooler
bypass valve (11) and hydraulic cooler (12),
and is drained to hydraulic tank (I).
1o-95
1
c
L
017x03
Operation when joystick is at FORWARD, and

machine is traveling forward
. When joystick (14) is moved to the FORWARD
position, an electric signal flows from HMT
controller (13) to solenoid B (7E). Servo valve
(7G) and servo piston (7D) move in the direc-
tion of the arrow, change the swash plate
angle of HMT pump (71, and discharge pres-
surized oil from port PB.
l When oil is discharged from port PB, suction

safety valve (7A) is closed by the pressure at
port B. Therefore, the pressurized oil in the
charge circuit at port A enters port C from
suction safety valve (7B) and supplies oil to
the HMT circuit.
. When the swash plate angle of HMT pump (7)

is moved to the maximum position and the
travel speed is raised further, an electric cur-
rent flows from HMT controller (13) to sole-
noids (9B) and (IOB), servo valves (9C) and
(IOC) and servo pistons (9A) and (lOA) move
in the direction of the arrows. This moves the
swash plate angle of HMT motor (81, increases
the motor speed, and accelerates the machine.
l The pressurized oil leaving port PB enters port
MB of HMT motor (8) and rotates the HMT
motor. The return oil flows from port MA to
port PA, and circulates inside the HMT closed
circuit.
At the same time, shuttle valve (8A) is moved
in the direction of the arrow by the pressu-
rized oil at port F, and the passage between
ports E and G at the low-pressure side is
opened.
When this happens, the minimum pressure
1.7 MPa (18 kg/cm*) at the low-pressure side
is maintained by charge relief valve (8B) to
pump. The excess pressurized oil is relieved
from charge relief valve (8B) to port H, passes
through oil cooler bypass valve (11) and hy-
draulic cooler (12) and is drained to hydraulic
tank (I 1.
l The relief pressure of charge relief valve (8B)
1.1 MPa (11 kg/cm*) is lower than the relief
pressure of charge safety valve (7C) 2.7 MPa
(28 kg/cm*). As a result, the charge pressure
oil flowing into the HMT circuit is relieved by
charge relief valve (8B).
1o-97
3. Joystick at REVERSE, machine is traveling reverse

I
NEUTRAL
11
I H
FORWARD
REVERSE
\ 1 I
G
8A 14
1
1
16
\I ! I
7F I 1//,
I
I
To PPC valve
m m ‘.I I
/
1OA
MA
r
* Direction of rotation of HMT motor

When port MA is high pressure: Clockwise as seen from motor mount
When port MB is high pressure: Counterclockwise as seen from motor mount
1 O-98
Operation when joystick is at REVERSE, and

machine is traveling in reverse
. When joystick (14) is moved to the REVERSE
position, an electric signal flows from HMT
controller (13) to solenoid A (7F). Servo valve
(7G) and servo piston (7D) move in the direc-
tion of the arrow, change the swash plate
angle of HMT pump (71, and discharge pres-
surized oil from port PA.
. When oil is discharged from port PA, suction

safety valve (7B) is closed by the pressure at
port C. Therefore, the pressurized oil in the
charge circuit at port A enters port B from
suction safety valve (7A) and supplies oil to
the HMT circuit.
. When the swash plate angle of HMT pump (7)

is moved to the maximum position and the
travel speed is raised further, an electric cur-
rent flows from HMT controller (13) to sole-
noids (9B) and (IOB), servo valves (9C) and
(IOC) and servo pistons (9A) and (lOA) move
in the direction of the arrows. This moves the
8 swash plate angle of HMT motor (8), increases
5 the motor speed, and accelerates the machine.
g
l The pressurized oil leaving port PA enters port
MA of HMT motor (8) and rotates the HMT
motor. The return oil flows from port MB to
port PB, and circulates inside the HMT closed
circuit.
At the same time, shuttle valve (8A) is moved
in the direction of the arrow by the pressu-
rized oil at port E, and the passage between
ports F and G at the low-pressure side is
opened.
When this happens, the minimum pressure
1.7 MPa (18 kg/cm21 at the low-pressure side
is maintained by charge relief valve (8B) to
pump. The excess pressurized oil is relieved
from charge relief valve (8B) to port H, passes
through oil cooler bypass valve (I I) and hy-
draulic cooler (12) and is drained to hydraulic
tank (1).
. The relief pressure of charge relief valve (8B)
1.1 MPa (11 kg/cm21 is lower than the relief
pressure of charge safety valve (7C) 2.7 MPa
(28 kg/cm2). As a result, the charge pressure
oil flowing into the HMT circuit is relieved by
charge relief valve (8B).
1o-99
STRUCTURE AND FUNCTION PPC, EPC, HMT CHARGE FILTER
PPC, EPC, HMT CHARGE FILTER
‘B
B-B
SAD001 76
1. Plug A. To PPC, EPC relief valve

2. Cover B. To filter bypass valve
3. Spring C. From charge pump
4. Plate
5. Element
6. Case
Performance
Mesh size (pm) 30
Filtering area (cm*) 5400

Oil flow U/mid I 203
10-100
STRUCTURE AND FUNCTION PPC, EPC, HMT CHARGE VALVE
PPC, EPC, HMT CHARGE VALVE
T PC
D-D
B-B ‘3 c-c SAD001 77
1. Accumulator check valve PI. From charge pump

2. Filter bypass valve PC. To HMT charge
3. PPC, EPC, HMT charge valve T. To hydraulic tank
Unit: MPa (ka/cm2)

Set pressure
ppC EPc HMT Cracking pressure 3.3 (34)
Cl. To main control valve
charge vi;lve Set pressure 4.1 (42)
Cl’.To HMT pump, motor servo
C2. To EPC solenoid valve Filter bypass Cracking differential
0.63 (6.4)
valve pressure
C2’.To PPC valve
C3. To accumulator Accumulator
Cracking pressure 0.051 (0.52)
check valve
P. From charge filter
10-101
Outline
This valve has the following three valves built in. l The PPC, EPC, HMT charge valve keeps the
. The accumulator check valve prevents the EPC solenoid valve pressure, PPC valve pres-
pressure stored in the accumulator from flow- sure and HMT pump and motor servo pres-
ing anywhere except to the EPC solenoid valve sure at the specified pressure and relieves
and PPC valve when the engine is stopped. any excess oil. The relieved oil flows to the
. The filter bypass valve acts to keep the differ- HMT pump and motor and becomes the
ential pressure between the pressures at the charge pressure for the pump and motor. It
charge filter inlet port and outlet port to be- also sets the maximum pressure in the cir-
low the set value. cuit.
Operation
PPC, EPC, HMT charge valve
. The oil from the charge pump passes through
the charge filter and enters chamber A. When
the pressure of the oil from chamber A pass-
ing through orifice b and entering chamber C
becomes greater than the set load of spring
(21, spool (I) moves to the right and connects main control valve
ports A and D. The oil from the charge pump

flows from chamber A through chamber D
and becomes the charge pressure for the HMT
pump and motor.
. If the pressure in chamber A becomes low,

the circuit between A and D is closed and the
pressure in chamber A is maintained. In this
way, the PPC valve pressure, EPC solenoid t
To HMT charge
valve pressure and HMT pump and motor
servo pressure are maintained.
Accumulator check valve

. Accumulator check valve (3) is provided to
prevent the accumulator pressure from drop-
ping when the engine is stopped.
To HMT servo,
main control valve
t
To HMT charge
10-102
Filter bypass valve

l The oil from the charge pump passing through
the charge filter and entering chamber A
passes from chamber A through orifice e and
enters chamber F of the filter bypass valve.
From charge pump
At the same time, the oil from the charge
pump entering chamber G of the filter bypass
valve directly passes through orifice h and
enters chamber J.
. If the charge filter becomes clogged and the
oil pressure in chamber F drops, and a differ-
ential pressure greater than the set pressure
is generated between chamber F and cham-
ber J, spool (4) moves to the left, connects
ports G and K, and the oil from the charge
pump is drained to the hydraulic tank.
e
SAD00282
10-103
STRUCTURE AND FUNCTION HMT OIL COOLER BYPASS VALVE
HMT OIL COOLER BYPASS VALVE
SAD00272
1. Plug Outline
2. Valve l This valve is installed in the circuit between
3. Shim the HMT pump and HMT motor oil return
4. Plug circuit and the oil cooler. If any abnormal
5. Spring pressure is generated in the oil flowing to the
6. Body oil cooler, this valve acts to return the oil di-
rectly to the hydraulic tank.
A. From HMT pump
B. To hydraulic tank
C. From oil cooler
D. To oil cooler Set pressure
E. From HMT motor Cracking pressure (MPa (kg/cm?)) 0.487 (4.97)
10-104
STRUCTURE AND FUNCTION STEERING, BRAKE CONTROL
STEERING, BRAKE CONTROL

* For details of operation of the joystick for the
transmission system, see HMT CONTROL.
* For details of the steering EPC valve, see EPC
VALVE.
lo-106
STRUCTURE AND FUNCTION STEERING, BRAKE CONTROL
1. EPC valve Lever, pedal positions

2. Brake pedal 0: NEUTRAL-
3. Rod 0: LEFT COUNTERROTATION TURN
4. Safety lever 0: RIGHT COUNTERROTATION TURN
5. Joystick (steering) 0: STRAIGHT TRAVEL FORWARD
6. Brake lever (from brake pedal) 0: LEFT TURN FORWARD
7. Solenoid (for brake valve) 8: RIGHT TURN FORWARD
8. Brake valve 0: STRAIGHT TRAVEL REVERSE
9. HSS motor 8: LEFT TURN REVERSE
10. Parking brake lever (from safety lever) @: RIGHT TURN REVERSE
11. Cable @: BRAKE RELEASED
12. HMT controller 0: BRAKE APPLIED
13. Limit switch (for safety lever) 0: FREE
14. Potentiometer (for brake pedal) 0: LOCK
8
x,
Outline
z l
The electrical signal from joystick (5) passes
through HMT controller (12) and EPC valve
(I), actuates HSS motor (9) and operates the
steering.
. If joystick (5) is moved slightly to the left when
it is being pushed to the FORWARD position,
the machine will turn gradually to the left. If
the joystick is moved fully to the left, the ma-
chine will turn sharply to the left.
. If joystick (5) is moved to the left when it is at
the NEUTRAL position, the machine will carry
out a left counterrotation turn.
. Brake pedal (2) actuates the spool of brake
valve (8) and actuates the left and right brakes
at the same time.
. Safety lever (4) is interconnected with brake
valve (81, and acts also as a parking brake.
. When the gear shift is operated, the electric
signal from HMT controller (12) flows to sole-
noid (7) and operates the brake.
10-106-l
STRUCTURE AND FUNCTION BEVEL GEAR SHAFT. HSS, BRAKE
BEVEL GEAR SHAFT, HSS, BRAKE
32 34
34 33 3i 3i 30 29 i8 i7
B-i3
SDDooo85
10-107
STRUCTURE AND FUNCTION BEVEL GEAR SHAFT, HSS, BRAKE
1. Cover
2. Output shaft
3. Bearing cage
4. Spring
5. Brake piston
6. Plate (1 on each side)
7. Brake plate (4 on each side)
8. Brake disc (5 on each side)
9. Brake outer drum
10. Brake inner drum
11. Nut
12. Bearing A
13. Shim (for adjusting preload of bevel gear)
14. Bevel gear shaft
15. Bevel gear (35 teeth)
16. Bearing B
17. Carrier
18. Ring gear
19. Planet pinion gear
20. Hub
21. Sun gear
22. Shim (for adjusting bevel pinion gear)
23. Bearing cage
24. Bearing
25. Nut (for adjusting preload of bearing)
26. Bevel pinion gear (21 teeth)
27. Gear E (for right sun gear drive)
28. Gear D
29. Shaft
30. HSS motor
31. Pinion gear
32. Gear A
33. Gear C
34. Gear B (for left sun gear drive)
A-A
lo-108
Outline
Bevel gear shaft Brake
. With the bevel gear shaft, the power output The brakes are installed to carry out braking
from the HMT has its rotating speed reduced of the machine, and are interconnected with
and is sent at right angles to the left and right brake inner drum (IO).
by the meshing of the bevel pinion and bevel The brake is a wet type, multiple disc clutch,
gear. spring boosted type, and is hydraulically op-
. The bevel gear shaft system employs spiral erated using pressurized oil from the brake
bevel gears for the bevel pinion and bevel valve, which is interconnected with the brake
gear, and employs a forced lubrication sys- pedal.
tem using the oil inside the case. The lubrication is a forced lubrication type
l The bevel gear shaft system consists of bevel using oil from the oil power train lubrication
gear (151, which is meshed with bevel pinion pump circuit, which passes through the hous-
(26), bevel gear shaft (141, and bearings (12) ing and cage, and is sent to the discs and
and (16), which support the bevel gear shaft. plates.
The brake consists of brake inner drum (IO)
HSS (which is interconnected with carrier (17) and
. The HSS (Hydrostatic Steering System) con- brake outer drum (911, disc (81, plate (7), brake
sists of a transfer portion, which reverses the outer drum (91, piston (51, spring (41, bearing
direction of the rotation of HSS motor (30) on cage (31, which support these, brake cover (I),
the left and right and transmits it to sun gear and output shaft (2).
(21), and a planetary gear system, which in- Brake outer drum (9) and brake cover (I) are
creases or decreases the speed of the input, fixed to the HSS case.
and then outputs it. Output shaft (1) is connected to brake inner
The direction of steering of the machine is drum (IO) by a spline.
changed by stopping the rotation of the HSS When the engine stops, the back pressure of
motor or by changing the direction of rotation the brake piston drops, so the brake is auto-
from the normal direction to the reverse di- matically applied. However, it is dangerous if
rection. the brake is released when the engine is
. The transfer portion uses a spur gear reduc- started again and the pressure in the circuit
tion mechanism. rises, so when the parking the machine, al-
. A forced lubrication system using the oil from ways place the parking brake at the LOCK
the power train lubrication pump is employed position.
for lubricating the transfer.
. A forced lubrication system using the oil from
the power train lubrication pump is employed
for lubricating the planetary gear.
. The transfer portion consists of HSS motor
pinion (311, gear A (32), gear C (331, shaft (29),
gear D (281, gear E (271, gear B (341, and cover
(I), which supports these.
l The planetary gear consists of sun gear (21),
planet pinion (191, hub (20), and carrier (17)
;y$ch is interconnected with brake inner drum
10-109
Flow of power for HSS
28 27
/ / I LTZZZI : Mechanical power

32 31 30
m : Hydraulic power
.: Combined power
SKD00113
10-110
STRUCTURE AND FUNCTION BEVEL GEAR SHAFT. HSS. BRAKE
. The power from the HMT passes through

bevel pinion gear (26) and bevel gear (15),
and is transmitted to bevel gear shaft (14). It
then goes from bevel gear shaft (14) through
hub (201, ring gear (181, carrier (171, and brake
inner drum (IO), and is transmitted to left and
right output shafts (2).
. When the steering is operated, HSS motor
(30) rotates and the power is transmitted from
pinion gear (31) to gear A (321, where it is
divided to the left and right.
The power sent to the left is transmitted from
gear A (32) to gear B (34), sun gear (211, and
planet pinion gear (19). It is combined with
the power from the HMT at the planetary gear
portion, and is transmitted from carrier (17) to
output shaft (2).
The power sent to the right is transmitted
from gear A (32) through gear C (33), gear D
(281, and gear E (27) to right sun gear (21) in
order to reverse the rotation of the power
from the HSS motor. (The flow of power
beyond this point is the same as on the left
side.) .
8 . The braking force is applied by braking the
2 rotation of inner drum (IO) (which is intercon-
z netted with carrier (17)) at brake outer drum
(9), which is fixed to the HSS case.
10-111
STRUCTURE AND FUNCTION OPERATION OF HSS
OPERATION OF HSS
1. When joystick is at NEUTRAL
Traveling straight forward
* The direction of rotation of the HSS motor
and gears is as seen from the left side of the
machine.
I
7 r
32
@ HMT output speed @ HMT output speed EBZZl : HMT power

@ Left bevel gear shaft output speed @ Right bevel gear shaft output speed
10-112
Traveling straight forward

When the joystick is at the NEUTRAL position,
HST motor (30), and transfer gear (33) and left
and right sun gears (21) of the planetary gear
portion, which are interconnected with the HSS
motor, are stopped.
In this condition, the power from bevel gear shaft
(14) is input to hub (201, passes through ring gear
(18) and planet pinion (191, and is transmitted to
carrier (17). It then passes through brake inner
drum (IO), which forms one unit with the carrier,
and is transmitted to output shaft (2).
Therefore, the left and right output speeds are the
same and the machine travels in a straight line.
. Direction of rotation of HSS motor
Turn Left turn Right turn Neutral

Joystick
position direction
Travel Neutral Forward Reverse Neutral Forward Reverse All
93 5%
Direction of
rotation of Counter- Counter- Clock- Clock- Clock- Co;;er- Stopped
clock- clock- wise wise wise
HSS motor
8 wise wise wise
5
z a% Counterrotation turn
10-113
2. Joystick operated to TURN RIGHT
Forward
27 21
32
@ HMT output speed @ HMT output speed E??Z7ZZ : HMT power

@A ccc Iera t‘o
I n f rom HSS motor @ Deceleration from HSS motor FZZBZZ3 : HSS motor power
@ ;L bgl gear shaft output speed 8 Ri ht bevel gear shaft output speed : Combined power
+ (Q-o, SDD00088
10-114
Forward
When the machine is traveling forward, bevel gear
shaft (14) and hub (201, which is connected to it,
rotate clockwise.
If the joystick is operated to the RIGHT TURN
position when the machine is traveling forward,
HSS motor (30) rotates clockwise, the rotation
passes through gear A (321, and gear B (34) on
the left side of the machine rotates clockwise,
while gear E (27) on the right side of the machine
is rotated counterclockwise by gear C (33). In
other words, the rotation of the HSS motor is
transmitted to sun gears (21) as rotation in oppo-
site directions on the left and right by the transfer
portion.
This rotation acts on the left and right planetary
gear mechanisms. The speed of carrier (17) on
the left is accelerated from the speed when
traveling in a straight line by the amount of the
power from the HSS motor. On the other hand,
the speed of carrier (17) on the right is deceler-
ated from the speed when traveling in a straight
line, so a difference in rotation is generated in the
output on the left and right. The output speed on
8 the right is lower, so as a result, the machine
E travels forward and turns to the right.
0’
10-115
Reverse
30
HMT output speed HMT output speed m : HMT power

@A ccc Iera t’Ion f rom HSS motor 6)_ Deceleration from HSS motor m : HSS motor Dower
@ Left bevel gear shaft output speed gear shaft output speed : Combined power
SDDOOOS9
(O+O)
lo-116
Reverse
When the machine is traveling in reverse, bevel
gear shaft (14) and hub (ZO), which is connected
to it, rotate counterclockwise.
If the joystick is operated to the RIGHT TURN
position when the machine is traveling in reverse,
HSS motor (30) is rotated counterclockwise in the
opposite direction from when traveling forward
by the function of the HMT controller. The rota-
tion passes through gear A (32), and gear B (34)
on the left side of the machine rotates counter-
clockwise, while gear E (27) on the right side of
the machine is rotated clockwise by gear C (33).
In other words, the rotation of the HSS motor is
portion.
the left is accelerated from the speed when
the speed of carrier (17) on the right is deceler-
ated from the speed when traveling in a straight
line, so a difference in rotation is generated in the
the right is lower, so as a result, the machine
travels in reverse and turns to the right.
10-117
3. Joystick operated to TURN LEFT
Forward
27 21
0 HMT output speed @ HMT output speed EZZ%l: HMT power

@D ece Iera t’o
I n f rom HSS motor @Acceleration from HSS motor i?%ZZZi : HSS motor power
@ Left bevel gear shaft output speed @ Ri ht bevel gear shaft output speed : Combined power
(0-O) t8+o, SDDOOOSO
lo-118
Forward
When the machine is traveling forward, bevel gear
shaft (14) and hub (20), which is connected to it,
rotate clockwise.
If the joystick is operated to the LEFT TURN posi-
tion when the machine is traveling forward, HSS
motor (30) rotates counterclockwise, the rotation
passes through gear A (321, and gear 6 (34) on
the left side of the machine rotates counterclock-
wise, while gear E (27) on the right side of the
machine is rotated clockwise by gear C (33). In
other words, the rotation of the HSS motor is
portion.
the right is accelerated from the speed when
the speed of carrier (17) on the left is decelerated
from the speed when traveling in a straight line,
so a difference in rotation is generated in the
8 the left is lower, so as a result, the machine trav-
5 els forward and turns to the left.
;3
10-119
Reverse
17 34 14 27 21 20
0 HMT output speed @ HMT output speed m : HMT power

@ Deceleration from HSS motor 0 Acceleration from HSS motor BZBZB : HSS motor power
@ ;o”_bE;l gear shaft output speed @ yi&; beyl gear shfat output speed : Combined power
1 2 SDD00091
10-120
Reverse
When the machine is traveling in reverse, bevel
gear shaft (14) and hub (20), which is connected
to it, rotate counterclockwise.
If the joystick is operated to the LEFT TURN posi-
tion when the machine is traveling in reverse,
HSS motor (30) is rotated clockwise in the oppo-
site direction from when traveling forward by the
function of the HMT controller. The rotation passes
through gear A (32), and gear B (34) on the left
side of the machine rotates clockwise, while gear
E (27) on the right side of the machine is rotated
counterclockwise by gear C (33). In other words,
the rotation of the HSS motor is transmitted to
sun gears (21) as rotation in opposite directions
on the left and right by the transfer portion.
the right is accelerated from the speed when
the speed of carrier (17) on the left is decelerated
from the speed when traveling in a straight line,
so a difference in rotation is generated in the
8 output on the left and right. The output speed on
5 the left is lower, so as a result, the machine trav-
z els in reverse and turns to the left.
10-121
Operation of brake
1. Brake released
When the brake pedal is at the RELEASED
position, the brake valve is also at the NEU-
TRAL position, so oil flows to back pressure
port A of brake piston (5).
When the oil pressure rises, the piston is
pushed to the left in the direction of the ar-
row, compresses spring (41, and releases the
pressure pushing disc (8) and plate (7) into
tight contact. When this happens, the power
transmitted from bevel gear shaft (14) through
the HSS to brake inner drum (IO) is transmit-
ted to output shaft (2), and is then transmitted
to the final drive.
SDD00092
2. Brake applied (brake pedal depressed) 2 4 A5 78 9

When the brake pedal is depressed, the brake
valve is switched, and the oil at port A, which
was applying back pressure to piston (5), is
connected to the drain circuit.
In this condition, piston (5) is pushed to the
right in the direction of the arrow by the ten-
sion of spring (41, so disc (8) and plate (7) are
brought into tight contact with the stopper of
brake outer drum (9). The brake outer drum
is joined to the HSS case and is locked in
position.
Therefore, the rotation of brake inner drum
(IO) (in other words, output shaft (2)) is braked
when the disc and plate are brought into tight
contact.
By adjusting the amount the brake pedal is
depressed, it is possible to adjust the hydrau-
lic pressure applied to piston (51, thereby ad-
justing the braking force.
10-122
STRUCTURE AND FUNCTION BRAKE VALVE
BRAKE VALVE
15 14 D C B A 13
A-A
Outline
. The brake valve is in the circuit between the
power train pump through the main relief
valve and the brake piston inside the HSS
unit. It consists of the main brake valve, park-
ing brake valve, and solenoid valve.
. When the brake pedal is depressed, the pres-
1. Main brake lever surized oil flowing to the brake piston is shut
2. Parking brake lever off, so the brake piston pushes the disc and
3. Solenoid valve plate into tight contact because of the force of
4. Plug the spring, and the brake is applied. In the
5. Body case of the HSS, the brake is used only for
6. Spring braking the machine, so the left and right
7. Seat brakes are actuated at the same time.
8. Brake valve . In addition, in the conditions given below, the
9. Piston signal from the HMT controller actuates the
10. Spring (small) solenoid valve and brakes the machine.
11. Spring (large) l When switching between forward and re-
12. Shaft (main brake) verse and the machine cannot be stopped
13. Shaft (parking brake) with the engine brake.
14. Spring . When traveling downhill and the travel
15. Plug speed is reduced by operating the max.
speed setter.
l When the engine speed drops during op-
A. T2 port (drain) erations and the HMT clutch is disengaged
B. BR port (to brake piston) to prevent the engine from stalling.
C. P port (from power train pump) . When the joystick is at NEUTRAL and the
D. Tl port (drain) machine is stopped.
lo-123
Operation
1. Brake released (parking brake OFF, brake pedal RELEASED, solenoid EXCITED)
10 11 12 Solenoid valve 13
Check valve
‘J ‘K
ti G F c ~uuuuu
SKD00095
lo-124
l When the brake pedal is released (not being

depressed), each valve is pushed to the set
position by the tension of the spring.
. The solenoid valve is excited by the signal
from the HMT controller, and push pin (13) is
pushed out to the left in the direction of the
arrow. Valves (IO) and (12) move and close
the passage between ports J and K. At the
same time, the passage between ports I and J
is opened, and the oil at port C is drained, so
shaft (7) is pushed fully to the right in the
direction of the arrow by spring (5).
. The pressurized oil from the power train pump
passes through the main relief valve and en-
ters port B. It then passes through ports F
and E, flows to the back pressure port of the
brake piston, and pushes the piston to the left
in the direction of the arrow to compress the
brake spring and release the brake. The oil
pressure at this point is balanced at 2.7 MPa
(28 kg/cm?, and this is possible to measure
at pressure detection port P.
. If the oil pressure at port F goes above the set
pressure, the pressure of the oil entering port
8 A through orifice a also rises. This pushes
3 brake valve (3) to the left, throttles the pas-
z sage between ports B and F, and controls the
oil pressure.
10-125
2. Brake applied (parking brake OFF, brake pedal DEPRESSED, solenoid EXCITED)
IO 11 12 Solenoid valve 13
Check valve
From power train pump
D 8
10-126
. The solenoid valve is excited in the same way

as in Item 1.
l When the brake pedal is depressed, shaft (7)
is pushed to the left in the direction of the
arrow, and compresses spring (5). The reac-
tion force pushes brake valve (3) to the left in
the direction of the arrow. Therefore, the pas-
sage ports B and F are closed, and the pres-
surized oil from the power train pump stops
at port B. Seat (2) is also pushed to the left in
the direction of the arrow, and the passage
between ports F and H is opened. When this
happens, the pressurized oil forming the back
pressure of the brake piston is pushed back
by the force of the brake spring and enters
port F from port E. Some of the return oil
passes through ports F and H and is drained
from port G; the rest of the oil passes from
port F through orifice a and enters port A.
l When the pressure at port F goes down, the
pressure at port A also goes down, so force
of the spring (I) pushes brake valve (3) back
to the right in the direction of the arrow. The
passage between ports F and H is closed and
the passage between ports B and F is opened,
so the pressurized oil at port B flows to port F.
In this way, the oil pressure is maintained and
the pressure beyond port F does not go down
any further.
. If the brake pedal is depressed further, the
above operation is repeated, and when the
valve reaches the end of its stroke, the brake
is completely applied.
l The oil pressure beyond port F is determined
by the tension of spring (5), which changes
the load according to the amount the brake
pedal is depressed. Therefore, if the brake
pedal is depressed a short distance the oil
pressure beyond port F is set to a high pres-
sure, and the brake is partially applied. If the
brake pedal is depressed a large distance, the
oil pressure is set to a low pressure and the
brake is applied.
lo-127
3. Parking brake ON (brake pedal RELEASED, safety lever at LOCK, solenoid EXCITED)
10 11 12 Solenoid valve 13
Check valve
c
To main relief (’
valve
+
9 F
1O-l 28
. The solenoid valve is excited in the same way

as in Item 1. In addition, shaft (7) is pushed
fully to the right in the direction of the arrow
by spring (5).
. If the safety lever (for the HMT control lever)
is placed at the LOCK position, shaft (8) is
pushed to the left in the direction of the ar-
row. The passage between ports F and E is
closed, and the passage between ports E and
D is opened. Therefore, the pressurized oil
from the power train pump enters port F and
stops.
. The pressurized oil flowing to the brake pis-
ton port and forming the back pressure passes
from port E through port D and is drained.
Shaft (8) remains pushed to the left in the
direction of the arrow, so the back pressure of
the brake piston port continues to drop. The
brake piston is pushed to the right in the di-
rection of the arrow by the brake spring, so
the brake is completely applied, and this con-
dition is maintained.
. Even when the engine is started again, this
condition is maintained.
10-129
4. HMT deceleration operated (brake pedal RELEASED, parking brake OFF, solenoid DEENERGIZED)
IO 11 I2 Solenoid valve 13
Check valve
c
To main
valve
+
Brake piston
& rhnnrln
1 2 aA
by--. ,:’
;:j:
:*,:‘,:> .,%:_,,::4:$
,,/,~,
,;,~:,:::.;,;,;,~:,~,~;,~;,~;;:;,;
.,,,,, -Jj - ’ ’
gzyg
f--l-
;:;
;:;
:;
:,,
‘:;;;
:;;;:
:;I;:,
14 8 :;,
E D b ::
;:;.
SKD00098
10-130
l Shafts (7) and (8) are being pushed fully to

the right in the direction of the arrow by the
spring.
. When the deceleration is operated, and the
solenoid valve is deenergized by the signal
from the HMT controller, push pin (13) is
pushed back to the right in the direction of
the arrow.
When this happens, valves (IO) and (12) are
pushed by the tension of spring (II). They
move to the right in the direction of the ar-
row, open the passage between ports J and
K, and close the passage between ports I and
J.
. The pressurized oil from the power train pump
passes through ports K and J and enters port
L from port C. It pushes cylinder (14) and
becomes the force pushing shaft (7) to the left
in the direction of the arrow. When cylinder
(14) contacts portion b, shaft (7) stops. The
oil pressure at this point is balanced at 1.0
MPa (IO kg/cm*).
As a result of this oil pressure, the same op-
eration is carried out as in Item 2 when the
brake is applied, and the brake is controlled.
10-131
STRUCTURE AND FUNCTION SCAVENGING PUMP STRAINER
SCAVENGING PUMP STRAINER
1. PPC charge pump (rear)

2. Scavenging pump (front)
3. PTO drive gear
4. Pump drive gear
SKDOOlOO
5. PTO case
6. Strainer
A. Scavenging pump suction port

B. Scavenging pump delivery port
Outline
l Scavenging pump (2) is driven by PTO drive
gear (3). It acts to return the oil accumulated
in the HMT case to the HSS case. * “Front” indicates the shaft mound end.
. The strainer is made of punched metal with
2 mm diameter holes.
1O-l 32
STRUCTURE AND FUNCTION POWER TRAIN PUMP STRAINER
POWER TRAIN PUMP STRAINER
3A 3B 3c
A-A
SKDOOOSS
1. Power train lubrication pump (rear)

(SAL(3)-80) Performance
2. Power train pump (front) I
Mesh size (pm) 100
(SAL(3)-100)
3. Power train pump strainer assembly Filtering area (cm? 2,100
3A. Magnet Pressure resistance (MPa (kg/cm2)) 0.2 (2.0)
3B. Strainer
3C. Shaft
A. From HSS case * “Front” indicates the shaft mount end.

B. To power train pump
10-133
STRUCTURE AND FUNCTION POWER TRAIN OIL FILTER
POWER TRAIN OIL FILTER
IB
ID
IE
. IF
1. Power train oil filter assembly

Performance
IA. Cover
IB. Body Cracking pressure (MPa (kg/cm*)) 0.103~0.02(1.05~0.2)
1C. Element Mesh size (pm) 30
ID. Valve Filtering area (cm? 10026
IE. Spring
Filter flow Wmin) 169
IF. Drain plug
A. To transmission case
B. From power train pump
10-134
STRUCTURE AND FUNCTION FINAL DRIVE
FINAL DRIVE
I-*
I
16 SDDOO102
Outline
. The final drive is a single stage spur gear, l Floating seal (4) is installed to the rotating
single stage planetary gear reduction type. The sliding portion of the sprocket to prevent the
lubrication is of splash type using the rotation entry of dirt or sand and to prevent leakage of
of the gears. lubricating oil.
The final drive can be removed and installed
as a single unit.
10-135
15 14 13 12 11 SDD00103
1. Sun gear (16 teeth) 9. No. 1 pinion (19 teeth)

2. Carrier 10. No. 1 gear (81 teeth)
3. Ring gear (65 teeth) 11. Sprocket hub
4. Floating seal 12. Sprocket teeth
5. Cover 13. Hub
6. Cover 14. Planet pinion (24 teeth)
7. Final drive case 15. Pinion shaft
8. Bearing cage 16. Pivot shaft
10-136
PATH OF POWER TRANSMISSION
. The power from the bevel gear and steering Then, the rotating force of sun gear (I) forms
clutch is transmitted to No. 1 pinion (9). It the rotating force of carrier (21, which sup-
then passes through No. 1 gear (IO), which is ports the planet pinion, and is transmitted to
meshed with the No. 1 pinion, and is trans- sprocket hub (II).
mitted to sun gear (I) to rotate it. The direction of rotation of carrier (2) is the
The rotation of sun gear (I) is transmitted to same as that of sun gear (I).
planet pinion (141, but ring gear (31, which is The rotating force transmitted to sprocket hub
meshed with the planet pinion, is fixed to cover (11) is transmitted to sprocket teeth (12).
(5), so the planet pinion rotates on its own
axis and moves around the sun gear along
the ring gear.
10-137
STRUCTURE AND FUNCTION RADIATOR GUARD
RADIATOR GUARD
D4
A-A B-B c-c D-D
SAD00150
1. Radiator mast Outline

2. Radiator guard l The radiator guard and main frame are joined
3. Hinge by pins at four points (front, rear, left, right).
. The radiator mask is joined to the radiator
guard by four bolts and a hinge is installed so
that the radiator mask can be opened and
closed when cleaning the radiator. The radia-
tor mask is designed so as not to come off
the radiator even if the four bolts are removed.
1O-l 38
STRUCTURE AND FUNCTION MAIN FRAME, UNDERGUARD
MAIN FRAME, UNDERGUARD
A-A B-B c-c

SKDOOlBl
1. Engine mount Outline

2. Power train unit mount . The main frame is constructed from one sheet
3. ROPS mount of metal.
4. Power train underguard l The main frame and underguard are con-
5. Engine underguard nected with bolts, and the underguard can be
divided into two parts (front and rear).
. A hinge is installed to the underguard, so
that it will not come off the main frame even
if the bolts are removed.
. A large inspection window is installed to the
rear underguard to facilitate checking the in-
ternal parts.
1o-139
STRUCTURE AND FUNCTION TRACK FRAME
TRACK FRAME
2 3
SKWQ152
Outline Track roller, bogie

. The track rollers are mounted on an X-shaped
bogie. This increases the actual ground con-
tact area between the track shoes and the
ground on rough surfaces, and helps increase
\I Positioning of track roller flange
and bogie
Bogie Inner Outer Outer Inner Inner Outer

the drawbar pull.
. Track roller D S S D D S
The X-shaped bogies are equipped with rub-
ber pads to absorb the shock from the ground D: Double
surface. S: Single
10-140
STRUCTURE AND FUNCTION TRACK FRAME
A-A
1. Equalizer bar
2. Idler
3. Track frame
4. Carrier roller
5. Sprocket
6. Sprocket guard
7. Bogie assembly
8. Track roller
9. Track roller guiding guard
10. Pivot shaft
10-141
STRUCTURE AND FUNCTION RECOIL SPRING
RECOIL SPRING
A-A
SKD00154
1. Yoke Outline
2. Nut . Recoil spring (4) is used to adjust the track
3. Retainer tension by pumping in or releasing grease
4. Recoil spring from lubricator (I I) to move rod (5) forward
5. Rod or backward. The recoil spring also acts to
6. Spring cylinder dampen any sudden shock brought to bear
7. Retainer on the idler.
8. Piston
9. Grease chamber cylinder
10. Pin
11. Lubricator
(for pumping in and releasing grease)
lo-142
STRUCTURE AND FUNCTION TRACK ROLLER BOGIE
TRACK ROLLER BOGIE
11 10 9 8
SK020155
1. Rubber mount Outline

2. Track roller . One track roller is mounted to each of inner
3. Inner bogie bogie (3) and outer bogie (4) to ensure that
4. Outer bogie the track roller and track shoe are always in
5. Cartridge pin contact.
6. Floating seal . Rubber mount (I) is used to absorb the ma-
7. Bushing chine vibration caused by contact with the
8. Plug ground.
9. Washer
10. Washer
11. Bogie mount cap
10-143
STRUCTURE AND FUNCTION SUSPENSION
SUSPENSION
SKDoO156
Outline
l The front of the track frame rocks up and
down using the rear pivot shafts (3) and (4) as
a fulcrum.
Equalizer bar (I) rocks using center pin (2) as
a fulcrum. The left and right track frames are
connected by side pin (5).
10-144
STRUCTURE AND FUNCTION SUSPENSION
B-B
I. Equalizer bar
2. Center pin
3. Left pivot shaft
4. Right pivot shaft
5. Side pin
6. Spherical bushing
7. Greasing tube
10-145
STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM

SEMI U-DOZER
SKD00159
1. Blade 8. Hydraulic filter

2. Tilt cylinder 9. Hydraulic tank
3. Right lift cylinder 10. Hydraulic, HSS pump
4. Left lift cylinder 11. Charge filter
5. EPC solenoid valve 12. HMT pump
6. Accumulator 13. Charge, scavenging pump
7. Main control valve 14. PPC, EPC, HMT charge valve
10-146
MULTI-SHANK
1. Main control valve

2. Divider block
3. Ripper tilt cylinder
4. Ripper lift cylinder
10-147
GIANT RIPPER
. The diagram shows a machine equipped with
a pin puller cylinder
1
5 SEW0394
1. Main control valve
2. Divider block
3. Ripper tilt cylinder (right)
4. Ripper lift cylinder (right)
6. Pin puller cylinder
6. Ripper lift cylinder (left)
7. Ripper tilt cylinder (left)
8. Pin puller solenoid valve
9. Brake valve
a. To HSS case
lo-148
STRUCTURE AND FUNCTION PPC CONTROL PIPING DIAGRAM
PPC CONTROL PIPING DIAGRAM

BLADE, RIPPER CONTROL
\/
SAD00166
1. EPC solenoid valve 6. Ripper control PPC valve

2. Accumulator 7. PPC lock valve
3. Charge filter 8. Scavenging pump
4. Blade control PPC valve 9. Charge pump
5. Main control valve IO. PPC, EPC, HMT charge valve
10-149
STRUCTURE AND FUNCTION WORK EQUIPMENT CONTROL
WORK EQUIPMENT CONTROL

* The diagram shows a machine equipped with
pitch dozer and pin puller cylinder. 8
/;-\0
z
Work equipment safety lever
Blade control lever
3. Tilt/pitch selector switch
4. Ripper control lever
5. Pin puller switch
6. Proximity switch
(Serial No.: 60001 - 60279)
8 7. Detent (to hold lever)
(Serial No.: 60001 - 60279)
\
8. PPC lock valve
SAD001 67
Lever positions
0: Blade HOLD Outline
0: Blade LOWER . The work equipment control employs a PPC
0: Blade FLOAT method which uses a PPC valve to move each
0: Blade RAISE control valve spool.
0: Blade LEFT TILT/PITCH . When safety lever (I) is placed at the LOCK
8: Blade RIGHT TILT/PITCH position, it becomes impossible to operate
0: Ripper HOLD blade control lever (2) from the HOLD posi-
8: Ripper RAISE tion to the LOWER directions. In addition,
0: Ripper LOWER proximity switch (6) is installed to prevent
@: Ripper TILT IN the engine from starting when the blade con-
0: Ripper TILT BACK trol lever is at the FLOAT position.
0: FREE . Work equipment safety lever (I) is intercon-
0: LOCK nected with PPC lock valve (81, and at the
@: Pitch selector switch OFF LOCK position, the oil in the PPC circuit is
0: Pitch selector switch ON stopped.
10-150
8
STRUCTURE AND FUNCTION HYDRAULIC TANK AND FILTER
HYDRAULIC TANK AND FILTER
lo-160
STRUCTURE AND FUNCTION HYDRAULIC TANK AND FILTER
B-B
Ii A-A E-E
SAW0173
Set value
1. Sight gauge
Hydraulic
2. Hydraulic filter assembly tank
3. Oil filler cap tank
I
4. Hydraulic tank Low (4?,1 89
5. Filter case
6. Cover Breather
7. Air bleed plug cap
8. Element
9. Suction valve
10. Spring
11. Drain plug (for removing Mesh size (pm) I 30
dirt) Hydraulic
12. Breather cap filter
13. Pressure valve
14. Strainer
A. From main control valve Strainer

B. To hydraulic tank
STRUCTURE AND FUNCTION HYDRAULIC, HSS PUMP
HYDRAULIC, HSS PUMP
1 Pd2 Pa
PP
kl
Z Y SDD00358
1. Piston pump assembly Outline

2. Control valve assembly . This pump consists of a variable capacity
Pa. Delivery port swash plate type piston pump and a control
Ps. Suction port valve.
Pd2. Pump drain port
PLS. Load pressure signal port (LS pressure)
PP2. Pump pressure port
lo-162
1. Piston pump
HPVIGO
PP PNC
Pa. Delivery port

Ps. Suction port
PP. Pump pressure signal port
PNC. Control pressure detection port
lo-163
B-B
A-A SDDO0360
1. Shaft 7. Rod
2. Case 8. Piston
3. Cradle 9. Cylinder block
4. Rocker cam IO. Valve plate
5. Shoe 11. End cap
6. Servo piston 12. Impeller
lo-164
SDDOOSSl
Outline
. The rotation and torque transmitted to the high pressure oil at cylindrical surface B of
pump shaft is converted to hydraulic energy cradle (31, which is fixed to the case, and car-
and pressurized oil is discharged according to ries out a sliding movement.
the load. . Piston (8) carries out motion relative to the
. It is possible to change the discharge amount axial direction inside each cylinder chamber
by changing the swash plate angle. of cylinder block (9).
l The cylinder block (9) carries out rotation rela-
Structure tive to valve plate (IO) while sealing the pres-
l Cylinder block (9) is supported by shaft (I) by surized oil, and this surface ensures that the
a spline C, and shaft (I) is supported by the hydraulic balance is maintained correctly. The
front and rear bearings. oil inside each cylinder chamber of cylinder ’
. The end of piston (8) has a concave ball shape block (9) is sucked in and discharged through
and shoe (5) is caulked to it to form one unit. valve plate (IO).
Piston (8) and shoe (5) form a spherical bear- . Impeller (12) is fixed to shaft (I), and rotates
ing. together with the shaft. It makes it easier for
. Rocker cam (4) holds plane A, and shoe (5) is the oil sucked in from the suction port to be
always pressed against this surface as it slides sucked in and sends it into the cylinder cham-
in a circle. ber by centrifugal force.
Rocker cam (4) forms a static bearing sending
lo-165
OPERATION
II. Operation of pump
Cylinder block (9) rotates together with shaft
(I), and shoe (5) slides on plane A.
When this happens, rocker cam (4) moves
along cylindrical surface B, so angle a of center
line X of rocker cam (4) to the axial direction
of cylinder block (9) changes.
This angle a is called the swash plate angle.
1 4 A 5 9
SD000362
0) With swash pale angle a formed by the

angle between center line X of rocker cam
(91, plane A acts as a cam for shoe (5).
In this way, piston (8) slides inside cylin-
der block (91, and as a result, a difference
is generated between volumes E and F
inside the cylinder block. The amount of
ence F - E.
and the volume of chamber E becomes
process. At the same time, the volume of 1 4 A 5 ‘F
SDD00363
chamber F becomes larger and oil is
sucked in as the volume increases.
(ii) When center line X of rocker cam (4) is X 9 E’

the same as the axial direction of cylinder
block (9) (swash plate angle = O), the dif-
ference between volumes E’ and F’ inside
cylinder block (9) is 0, so no oil flows in or
oh, and no pumping is carried out.
SDW0364
lo-166
2) Control of discharge amount

(8 If swash plate angle a becomes larger,
the difference between volumes E and F
becomes larger, and oil discharge Q is
increased. Swash plate angle a is changed
by servo piston (6). Servo piston (6) car-
ries out reciprocal movement in a straight
line (w) according to the command from
the LS valve. This straight-line movement
is transmitted to rocker cam (4) through
rod (7), and rocker cam (4), which is sup-
ported on the cylindrical surface by cradle
(3) slides on the cylindrical surface. F SDD00366
(ii) The area receiving the pressure is differ-

ent at the left and right sides of servo
piston (6), and the chamber receiving the
pressure at the small diameter piston end
is always connected with main pump pres-
sure PP. Output pressure PNC of the LS
valve is applied to the chamber receiving
the pressure at the large diameter piston
end (which receives pressure of the pump).
The movement of servo piston (6) is con-
trolled by the relationship of the size of
pump pressure PP and the pressure at the
large diameter piston end, and the com-
parative size of the area at the large diam-
eter piston end and small diameter piston
end.
(iii) The LS valve acts to control the move-

ment of the servo piston.Main pump pres-
sure PP~ (which is taken from the upstream
side of the control valve) and pressure
PLS (LS pressure) (which is taken from the
control valve outlet port) enter the LS
valve.
The differential pressure (AP = PP~ - PLS) 0
between the LS pressure PLS and control
pump upstream main pump pressure PP2
is called the LS differential pressure. The LS differential pressure AP=PP~-PLS
relationship with discharge amount Q is SDDO03ffi
as shown in the diagram on the right.
lo-167
2. Contrat valve
/ PP
PNC
SDD00367
PP. Pump pressure signal port

Pr. Control drain port
PLS. Load pressure signal port (LS pressure)
PNC. Control pressure detection pot-t
PP2. Pump pressure port
1O-l 68
A-A
B-B
c-c
1. Valve body 6. Spring 11. Spool

2. LS valve 7. Plug 12. Spring
3. Variable throttle valve 8. Locknut 13. Plug
4. Plug 9. Block 14. Locknut
5. Spool 10. Plug
1o-1 69
i-1
\
.,’ I - -,
&
:: pLs s,,‘,~;,~;,::~:~;,~,,~,~;,~;,;
:;
T,‘,‘, ‘, *s,,, LS pressure) PP2
;,>;,; ;*: ;*:s*,
IId
I l-l
Operation
(11 Operation of LS valve
1) C&rol valve at HOLD
. The LS valve is a three-way . Spool (4) is pushed to the left and port d and
selector valve.
The control valve upstream main pump pres- port c are connected. Pump pressure PP en-
sure PP~ and pressure PLS (LS pressure) from ters the large diameter piston end from port f
the control valve outlet port come to both and piston (I) is moved to the left by the
ends ‘of the valve. Spool (4) of this LS valve is difference in area of piston (I) so that the
being pushed by the force of spring (3) from swash plate angle becomes the minimum.
the LS pressure receiving end. The position
of spool (4) is determined by the size of LS
pressure PLS + spring force F and main pump
pressure (self pressure) PP.
. Main pump pressure PP is always flowing to
ports d and e. LS pressure PLS enters cham-
ber g from port a.
. Before the engine is started, servo piston (I)
is being pushed to the right by spring (5) of
rod (2). (See diagram on right)
. After the engine is started, when the work
equipment control lever is at HOLD, the LS
pressure PLS is 0 MPa (0 kg/cm*). (It is con-
nected to the drain circuit through the pas- SOD00370
sage inside the control valve spool.)
10-170
*(Direction of large 0) SDD00371
2) Operation (to right) of pump delivery to give

larger delivery
. When LS differential pressure APLS (which is . Because of the movement of spool (41, port c
the difference between the control valve up- and port b are connected and circuit c - f
stream main pump pressure PP~ and LS pres- becomes drain pressure Fr.
sure PLS) becomes smaller (for example, the l Circuit c - f, in other words, the pressure at
area of the opening of the control valve be- port f at the large diameter piston end of servo
comes larger, and the control valve upstream piston (I) becomes the drain pressure, so servo
pump pressure PP~ becomes smaller), spool piston (I) is pushed from the small diameter
(4) is pushed to the right by the combined piston end to the large diameter piston end.
force of LS pressure PLS and the force of spring Rod (2) moves to the right together with this
(3). Control valve upstream main pump pres- movement and changes the swash plate an-
sure PP~ also enters chamber h. At this point, gle to make it larger.
the combined force of the LS pressure PLS
and spring (3) is greater than the force of
control valve upstream main pump pressure
PP~, so spool (4) moves the full stroke to the
right.
10-171
e I L -
*(Direction of smaller 0) SDD00372
3) Operation (to left) of pump delivery to give

smaller delivery
. Next is the explanation for when servo piston . Main pump pressure PP also enters port e at
(I) moves to the left (delivery becomes the small diameter piston end, but servo pis-
smaller). When LS differential pressure APLS ton (I) is pushed from the large diameter pis-
becomes larger (for example, the area of the ton end to the small diameter piston end be-
opening of the control valve becomes smaller, cause of the difference in the area at the large
and the control valve upstream pump pres- diameter piston end and the small diameter
sure PP~ becomes larger), spool (4) is pushed piston end.
to the left by the force of control valve up- . As a result, rod (2) moves to the left and
stream pump pressure PP2. changes the swash plate angle to make it
. Because of the movement of spool (41, main smaller.
pump pressure PP flows in from port d to port
c, and enters the large diameter piston end
from port f.
lo-172
SDD00373
4) When servo piston is balanced

. With the LS valve, if control valve upstream diameter piston end is equal to oil pressure
main pump pressure PP~ and the combined PNC at the large diameter end x the area re-
force of LS pressure PLS in chamber g and ceiving pressure at the large diameter piston
force F of spring (3) are in balance (PP~ = LS + end. Normally, the difference in area between
F), servo piston (I) stops at the intermediate the large diameter piston and small diameter
position for the swash plate. (If force F of piston is approx. 2:1, so the pressure at the
spring (3) is converted to hydraulic force, it is large diameter piston end is approx. l/2 of
approx. 2 MPa (20 kg/cm*). pump pressure PP.
. If the LS pressure which fulfills the above bal- 5) Control valve upstream main pump pressure
anced condition (control valve upstream main PP~ is more or less equal to main pump deliv-
pump pressure - spring force) enters port a, ery pressure PP, but it is lower by the amount
oil pressure PP~ entering from port J and the of pressure lost between the main pump dis-
force from LS pressure PLS + force F of spring charge port and the control valve. By taking
(3) are balanced and pressure of a certain size this control valve upstream main pump pres-
enters portf from port c. sure PP~ instead of main pump delivery pres-
. When this happens, servo piston (I) stops at sure PP to control the LS valve, it is possible
the point where the force pushing the small to remove any effect caused by the loss of
diameter piston balances the force pushing pressure between the main pump discharge
the large diameter piston. port and the control valve. This makes it pos-
In other words, in this condition, pump pres- sible to provide precise control.
sure PP x area receiving pressure at small
10-173
(21 Operation of variable throttle valve

II Properties of variable throttle valve
. Because the main pump controls its own
pressure, there is a tendency for the response
speed of the swash plate to be quick at high
pressure and slow at low pressure.
The variable throttle valve has been installed
between the LS valve and the port at the large
diameter end of the servo piston for the fol-
lowing reasons.
To reduce the swash plate speed between
MIN and MAX at high pressure; to reduce
the impact force on the rod and other parts
of the main pump; and to prevent exces-
sive response.
To prevent cavitation at the suction port
caused by the sudden increase in the suc-
tion volume when changing from MIN to
MAX.
. The characteristics of the variable throttle valve

are as shown in the diagram at the right.
It has the function and property of maintain-
ing the response during operations at low pres-
sure by making the area of the opening smaller
at high pressure and the area of the opening
larger at low pressure, and by preventing the
above problems @ and @ at high pressure.
Main pump pressure PP

SDDCfJ374
10-174
SDD00375
21 Pump delivery pressure HIGH

. Main pump pressure PP passes through port l When spool (4) moves to the left, the area of
b from LS valve (5) and enters chamber f of the opening from port a to port c is throttled,
variable throttle valve (6). so the oil flow entering the large diameter
l When main pump pressure PP is high, if the end of servo piston (I) from port d is reduced,
force pushing spool (4) becomes greater than and the speed of servo piston (1) changing
the force of spring (3) because of the differ- position becomes slower.
ence in area at the diameter of the land por-
tion at both ends of chamber f, spool (4) moves
to the left.
10-175
3) Pump delivery pressure LOW

l When main pump pressure PP is low, even if In this condition, the area of the opening from
main pump pressure PP passes from port b to port a to port c becomes larger and the speed
chamberf, the pressure is low, so the force is of servo piston (I) changing position becomes
less than the force of spring (31, and spool (4) faster in order to transmit outlet port PNC as it
is kept pushed to the right by the force of is from LS valve (5).
spring (3).
lo-176
STRUCTURE AND FUNCTION ACCUMULATOR
ACCUMULATOR
FOR PPC VALVE
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications:
Type of gas: Nitrogen
Gas volume: 300 cc
Max. actuation pressure: 3.1 MPa (32 kg/cm21
Min. actuation pressure: 1.2 MPa (12 kg/cm?
Function
. The accumulator is installed between the PPC
charge pump and the PPC valve. Even if the
engine is started with the work equipment
still raised, the pressure of the nitrogen gas
compressed inside the accumulator sends the
pilot pressure to the main control valve to
actuate it and enable the work equipment to
move down under its own weight.
Operation Before actuation After actuation

l After the engine is stopped, when the PPC
valve is at neutral, chamber A inside the blad-
der is compressed by the oil pressure in cham-
ber B.
l When the PPC valve is operated, the oil pres-
sure in chamber B goes below 2.9 MPa (30
kg/cm*), and the pressure of the nitrogen gas
in chamber A expands the bladder, so the oil
in chamber B acts as the pilot pressure and
actuates the main control valve.
10-177
STRUCTURE AND FUNCTION EPC SOLENOID VALVE
EPC SOLENOID VALVE

FOR STEERING
‘.
A-A
P C2 SAD00178
1. EPC valve for turning (for turning right when Cl. To steering control valve (for turning right)
traveling forward) C2. To steering control valve (for turning left)
2. EPC valve for turning (for turning left when P. From charge pump
traveling forward) T. To hydraulic tank
3. Connector
4. Block
5. Body
6. Spool
7. Spring
8. Push pin
9. Coil
IO. Plunger
10-178
Function
l The EPC solenoid valve consists of the pro- MPa
portional solenoid valve portion and the oil (kg/cW
pressure block. 3 2.9-

* When the steering lever is operated, an elec- 2 (30)
tric signal is sent to the HMT controller. From Z

the HMT controller, an electric signal is sent E 2.5-
Q (25)
to the EPC valve according to the amount that
the steering lever is moved.
g (20)
l When signal current i is received from the
HMTcontroiler, an EPC output is generated in
6 15-
proportion to the size of the current, and the
steering valve pilot pressure is output. s ‘Ij’
g l.O-
2 10)
a’
2
a 0.5-
zi (5)
0
0 200 400 600 800 1000 (mA)
Current i
SYD00311
Operation
1. When signal current is 0 (coil deenergized)
l When there is no signal current flowing from
the controller to coil (91, coil (9) is deenergized.
. For this reason, spool (6) is pushed to the
right in the direction of the arrow by spring
(7).
l As a result, port P is closed, and the pressu-
rized oil passing through the PPC, EPC, HMT
charge valve from the charge pump does not
flow to the control valve.
At the same time, pressurized oil from the
control valve flows from port C through port
T and is drained to the tank.
HMT charge valve
SAD00179
10-179
2. When signal current is small (coil excited, Main control valve

during fine control)
. When a small signal current flows to coil (91,
coil (9) is excited and a propulsion force push-
ing to the left in the direction of the arrow is
generated in plunger (IO).
. Push pin (8) pushes spool (6) to the left in the
direction of the arrow and pressurized oil flows
from port P to port C.
. The pressure at port C rises and the force
acting on face a of spool (6) + the spring load
of spring (7) becomes greater than the pro-
pulsion force of plunger (IO). When this hap-
pens, spool (6) is pushed to the right in the
direction of the arrow, port P and port C are
shut off, and at the same time, port C and
port T are connected.
. As a result, spool (6) moves to the left or right -EPC*
to a position where the propulsion force of HMT charge valve
plunger (IO) is balanced with the pressure at
port C + the spring force of spring (7).
. Therefore, the circuit pressure between the SAD00180
EPC valve and the control valve is controlled

in proportion to the size of the signal current.
3. When signal current is large (coil is excited,

full power control)
l When the signal current flows to coil (91, coil
(9) is excited.
. The signal current at this point is the maxi-
mum, so the propulsion force of plunger (IO)
is also the maximum.
. Because of this, spool (6) is pushed to the left
in the direction of the arrow by push pin (8).
. As a result, the maximum flow of pressurized
oil from port P flows to port C and the circuit
pressure between the EPC valve and the con-
trol valve becomes the maximum.
At the same time, port T is closed and no oil
flows to the tank.
From PPC * EPC *

HMT charge valve
SAD00181
lo-180
STRUCTURE AND FUNCTION PPC LOCK VALVE
PPC LOCK VALVE
1. Lever
2. End cap
3. Bail
4. Seat
5. Body
SYD00312
Outline
. The PPC lock valve is installed in the PPC
circuit between the PPC charge valve and PPC
valve. If the work equipment safety lever is
placed at the LOCK position, the PPC lock valve
is actuated together with the work equipment
safety lever. This stops the oil in the PPC cir-
cuit and makes it impossible to operate the
work equipment.
lo-181
STRUCTURE AND FUNCTION PPC VALVE
PPC VALVE
For blade, and ripper Serial No.: 60001 - 60279
For Ripper Serial No.: 60280 and up
a B-+ b
h-r- SYD00313
a. P port (from charge pump) d. P4 port (blade LOWER/ripper RAISE)

b. T port (to hydraulic tank) e. PI port (blade LEFT TILT/ripper TILT BACK)
c. Pz port (blade RIGHT TILT/ripper TILT IN) f. p3 port (blade RAISE/ripper LOWER)
1O-l 82
8
uu
A-A B-B
D-D
E-E
SYD00314
1. Spool 7. Joint
2. Metering spring 8. Plate
3. Centering spring 9. Retainer
4. Piston IO. Body
5. Disc 11. Filter
6. Nut (for lever joint)
lo-183
Operation
1) At neutral Blade lift Blade tilt
Ports A and B of the control valve and ports

PI, P2, P3, and P4 of the PPC valve are con-
nected to drain chamber B through fine con-
trol hole f of spool (1).
SYD00315
Ripper tilt Ripper lift
SYD00316
SYD00317
lo-184
2) During fine control (neutral + fine control)

When piston (4) starts to be pushed by disc
(5), retainer (9) is pushed; spool (I) is also
pushed by metering spring (2), and moves
down.
When this happens, fine control hole f is shut
off from drain chamber D, and at almost the
same time, it is connected to pump pressure
chamber PP, so pilot pressure oil from the
charging pump passes through fine control
hole f and goes from port PI to port A.
When the pressure at port PI becomes higher,
spool (I) is pushed back and fine control hole
f is shut off from pump pressure chamber PP.
At almost the same time, it is connected to
drain chamber D to release the pressure at
port PI.
When this happens, spool (I) moves up or
down so that the force of metering spring (2)
is balanced with the pressure at port PI. The
relationship in the position of the spool (I)
and body (IO) (fine control hole f is at a point
midway between drain hole D and pump pres-
sure chamber PP) does not change until re-
tainer (9) contacts spool (I).
Therefore, metering spring (2) is compressed
proportionally to the amount of movement of
the control lever, so the pressure at port PI
also rises in proportion to the travel in the
control lever.
In this way the control valve spool moves to a
position where the pressure in chamber A (the
same as the pressure at port PI) and the force
of the control valve spool return spring are
balanced.
lo-185
3) During fine control

(when control lever is returned)
When disc (5) starts to be returned, spool (I)
is pushed up by the force of centering spring
(3) and the pressure at port PI.
When this happens, fine control hole f is con-
nected to drain chamber D and the pressure
oil at port PI is released.
If the pressure at port PI drops too far, spool
(1) is pushed down by metering spring (21,
and fine control hole f is shut off from drain
chamber D. At almost the same time, it is
connected to pump pressure chamber PP, and
the pump pressure is supplied until the pres-
sure at port Pl recovers to a pressure that
corresponds to the lever position.
When the spool of the control valve returns,
oil in drain chamber D flows in from fine con-
trol hole f in the valve on the side that is not
working.
The oil passes through port P2 and enters
chamber B to fill the chamber with oil. SYD00319
4) At full stroke
When disc (5) pushes down piston (4) , and
retainer (9) pushes down spool (I), fine con-
trol hole f is shut off from drain chamber D,
and is connected with pump pressure cham-
ber PP.
Therefore, the pilot pressure oil from the charg-
ing pump passes through fine control hole f
and flows to chamber A from port PI, and
pushes the control valve spool.
The oil returning from chamber B passes form
port P2 through fine control hole f and flows
to drain chamber D.
SYD00320
10-186
STRUCTURE AND FUNCTION WC VALVE
For blade Serial No. : 60279 and up
C d
SKD00534
a. P port From PPC charge valve port P

(through PPC lock valve)
b. T port (To hydraulic tank)
c. P2 port (To blade TILT valve port PB2)
d. P4 port (To blade LIFT valve port PA3)
e. PI port (To blade TILT valve port PA21
f. P3 port (To blade LIFT valve port PB3)
10-187-l
8
1. Spool 6. Nut (for lever joint)

2. Metering spring 7. Joint
3. Centering spring 8. Plate
4. Pistion 9. Retainer
5. Disc 10. Body
lo- 187-2
@
STRUCTURE AND FUNCTION PPC VALUE
Operation
I) At neutral
(i) PPC value for blade lift
Potts PA3 and PB3 of the blade lift control
valve, and ports P3 and P4 of the PPC valve
are connected to drain chamber D through
fine control hole f in spool (1).
LIFT CONTROL
VALVE
SAD01489
(ii) PPC valve for blade tilt

Ports PA2 and PB2 of the blade tilt control
valve, and ports PI and P2 of the PPC valve
are connected to drain chamber D through
fine control hole f in spool (I).
~~~
SAD01490
lo- 187-3
@
STRUCTURE AND FUNCTION PPC VALUE
2) During fine control (neutral- fine control)

When piston (4) starts to be pushed by
disc (51, retainer (9) is pushed; spool (I)
is also pushed by metering spring (21,
and moves down.
When this happens, fine control hole f
is shut off from drain chamber D, and at
almost the same time, it is connected to
pump pressure chamber PP, so pilot
pressure oil from the charging pump
passes through fine control hole f and
goes from port P4 to port PA3.
When the pressure at port P4 becomes
higher, spool (I) is pushed back and fine
control hole f is shut off from pump pres-
sure chamber PP.
At almost the same time, it is connected
to drain chamber D to release the pres-
sure at port P4.
When this happens, spool (I) moves up
or down so that the force of metering
spring (2) is balanced with pressure at
port P4.
The relationship in the position of the
spool (I) and body (IO) (fine control hole
SAD01491
f is at a point midway between drain
hole D and pump pressure chamber PP)
does not change until retainer (9) con-
tacts spool (I).
Therefore, metering spring (2) is com-
pressed proportionally to the amount of
movement of the control level, so the
pressure at port P4 also rises in propor-
tion to the travel in the control lever.
In this way the control valve spool
moves to a position where the pressure
in chamber PA3 (the same as the pres-
sure at port P4) and the force of the
control valve spool return spring are
balanced.
lo- 187-4
63
31 During fine control

(when control lever is returned)
When disc (5) starts to be returned, spool
(1) is pushed up to the force of centering
spring (3) and the pressure at port P4.
When this happens, fine control hole f
is connected to drain chamber D, and
the pressure oil at port P4 is released.
If the pressure at port P4 drops too far,
spool (I) is pushed down by metering
spring (2), and fine control hole f is shut
off from drain chamber D. At almost
the same time it is connected to pump
pressure chamber PP, and the pump
pressure is supplied until the pressure
at port P4 recovers to a pressure that
corresponds to the lever position.
When the spool of the control valve re-
turns, oil in drain chamber D flows in
from fine control hole f’ in the valve on
the side that is not working.
The oil passes through port P3 and en-
ters chamber PB3 to fill the chamber
with oil.
41 At full stroke
When disc (5) pushes down piston (4),
and retainer (9) pushes down spool (I),
fine control hole f is shut off from drain
chamber D, and is connected with pump
pressure chamber PP.
Therefore, the pilot pressure oil from the
charging pump passes through fine con-
trol hole f and flows to chamber PA3
from port P4, and pushes the control
valve spool.
The oil returning from chamber PB3 from
port P3 through fine control hole f’ and
flows to drain chamber D.
SAD01493
lo- 187-5
@
51 Blade operated to FLOAT

When piston (4) at port P4 (LOWER side)
is pushed by disc (5) and moves down,
protrusion a of the piston contacts ball
(11) during the downward stroke. (The
detent starts to be actuated.)
If piston (4) is pushed further, ball (II)
pushes up collar (121, which is being
held by detent spring (13), and moves
to the outside, so the ball passes over
protrusion a of the piston. At this point,
piston (4’) at the opposite side is pushed
up by the spring (14).
As a result, the oil inside chamber F
flows through b and c and enters cham-
ber E, and piston (4’) follows disc (5).
Passage d is interconnected with port
P4, so it is under more or less the same
pressure as port P4.
Chamber E is normally interconnected
with drain chamber D, but when ball
(11) passes over protrusion a of the pis-
ton, passage d and chamber E (which
were shut off) are interconnected and
pressurized oil flows. At the same time,
the control valve also moves to the
FLOAT position, so the blade circuit is
set to the FLOAT condition. The pressu-
rized oil inside chamber E pushes up
piston (4’), so even of the lever is re-
leased, it is held at the FLOAT position.
61 Blade released from FLOAT

When disc (5) is returned from the
FLOAT position, it is pushed down by a
force greater than the pressure of the
oil in chamber E.
For this reason, chamber E is shut off
from passage d and is connected to the
drain chamber. Therefore, the oil pres-
sure inside chamber E is lost, and the
FLOAT, position is released.
lo- 187-6
@
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
MAIN CONTROL VALVE

Serial No.: 60001 - 60279
A”\ / z
T ,PB5
PA5
PA4
PA3
PA2
PA1
WI
A2 Al P Bl B2
SAD00192
Al. To HSS motor PA4. From ripper PPC valve port P3

A2. To blade tilt cylinder head PA5. From ripper PPC valve port PI
A3. To blade lift cylinder head PBI. From EPC solenoid valve
A4. To ripper lift cylinder head PB2. From blade PPC valve port P2
A5. To ripper tilt cylinder head PB3. From blade PPC valve port P3
Bl. To HSS motor PB4. From ripper PPC valve port P4
B2. To blade tilt cylinder bottom PB5. From ripper PPC valve port P2
B3. To blade lift cylinder bottom P. Pump port
B4. To ripper lift cylinder bottom L. LS port (to HSS pump port LS valve)
B5. To ripper tilt cylinder bottom T. Drain port
PAI. From EPC solenoid valve a. Pump pressure detection plug
PA2. From blade PPC valve port PI b. LS pressure detection plug
PA3. From blade PPC valve port P4 C. PPC basic pressure port
1o-188
8
D-D \
18
A-A B-B
\
N-N 22
E-E F-F
G-G
19 19
M-M
K-K
H-H J-J
1. Valve block SAD00193
9. Pressure compensation valve 17. Back pressure valve
2. Ripper tilt spool 10. Steering priority valve 18. Unload valve
3. Ripper lift spool 11. LS relief valve (for work equipment) 19. Suction valve
4. Blade lift spool 12. LS check valve (for work equipment) 20. Check valve (spool built in)
5. Blade tilt spool 13. LS check valve (for steering) 21. Preset check valve
6. Steering spool 14. Main relief valve 22. LS bypass valve
7. Valve body 15. LS relief valve (for steering)
8. Load check valve 16. Back pressure check valve
lo-189
b
85
PA6
PA4 PB4
PA3 PB3
PA2 PB2
g
x,
PA1 PBl z
SAD01495
Al. To HSS motor PA4. From ripper PPC valve port P3

A2. To blade tilt cylinder head PA5. From rioter PPC valve port PI
A3. To blade lift cylinder head PBI. From EPC solenoid valve
A4. To ripper lift cylinder head PB2. From blade PPC valve port P2
A5. To ripper tilt cylinder head PB3. From blade PPC valve port P3
61. To HSS motor PB4. From ripper PPC valve port P4
B2. To blade tilt cylinder bottom PB5. From ripper PPC valve port P2
B3. To blade lift cylinder bottom P. Pump port
B4. To ripper lift cylinder bottom L. LS port (to HSS pump port LS valve)
B5. To ripper tilt cylinder bottom T. Drain port
PAI. From EPC solenoid valve a. Pump pressure detection plug
PA2. From blade PPC valve port PI b. LS pressure detection plug
PA3. From blade PPC valve port P4 C. PPC basic pressure port
10-189-l
8
12
D-D \
18
A-A \ B-0
‘7 20
\ N-N 22
E-E F-F
G-G
I 9. 19
K-K
1. Valve block 12. LS check valve (for work equipment)

2. Ripper tilt spool 13. LS check valve (for steering)
3. Ripper lift spool 14. Main relief valve
4. Blade lift spool 15. LS relief valve (for steering)
5. Blade tilt spool 16. Back pressure check valve
H-H J-J
6. Steering spool 17. Back pressure valve SAD01496
7. Valve body 18. Unload valve
8. Load check valve 19. Suction valve
9. Pressure compensation valve 20. Check valve (spool built in)
10. Steering priority valve 21. Preset check valve
11. LS relief valve (for work equipment) 22. LS bypass valve
lo- 189-2
@
STRUCTURE AND FUNCTION OPERATION OF MAIN CONTROL VALVE
OPERATION OF MAIN CONTROL VALVE
SAD001 94
FUNCTION
. When the main spool is at the HOLD position,
it drains the excess oil discharged by the
pump, and prevents the pressure from being
formed in the circuit from rising.
OPERATION
1. AT HOLD (OPERATION OF UNLOAD VALVE)
I) When the main spool is at the HOLD position, 3) When FO becomes lamer than set load FS of
the pump pressure passes from chamber A spring (21, the spool moves to the right and
through throttle (4) to chamber D. Chambers connects the passage between chamber A and
C and c’ are connected to the drain circuit. chamber B, so the oil from the pump is
drained. Therefore, spool (I) is balanced at a
2) When oil is supplied from the pump, the pres- position that matches the supply of oil from
sure in chamber D rises, and spool (I) is the pump.
pushed to the right by pressure FO which is Actually, the amount of oil supplied from the
determined by the cross-sectional area of pis- pump is small, so the pressure in the circuit is
ton (3) receiving the pressure. almost the same as the set load of spring (2).
10-190
2. CONTROL OF OIL FLOW
EPC solenoid valve
(1) Steering valve

. Use of the CLSS circuit (Closed Center Load to chamber C. Chamber G is drained through
Sensing System) makes it possible to control chamber H to chamber F. When this happens,
the oil flow by adjusting the area of opening the pump pressure is acting on the left end of
of the spool driven by the EPC solenoid valve spool (3) of the steering priority valve, so it
regardless of the load. pushes against the load of spring (4) and
1) At HOLD moves to the right to the maximum stroke
When the spool is at the HOLD position, the position. In this condition, the area of the open-
pump pressure is sent from chamber A ing to spool (I) of the steering valve is at its
through the notch in spool (3) of the steering minimum.
priority valve, and passes through chamber B
10-191
EPC solenoid valve P
SAD00196
. APLS = differential pressure between ports K and J = 2.0 MPa (20 kg/cm?
. APLS’ = differential pressure between ports I and D
. APLS ‘=.APLS
When turning to left

; When the steering lever is operated to turn
the machine to the left, pilot pressure PBI
acts on the right end of spool (I) through the
EPC solenoid valve, and when the pressure
becomes greater than the set load of spring
(21, the spool starts to move to the left. It
becomes balanced at a position that matches
EPC output pressure PBI.
lo-192
Chamber C and chamber D are connected, differential pressure of spool (I) becomes
and the oil from the pump flows through ports larger, so spool (3) moves in the direction to
A, B, C, and D to HSS motor (6). At the same throttle the oil flow; on the other hand, if the
time, the load pressure in chamber D passes oil flow is too small, spool (3) moves in the
through LS orifice (5) and chamber H, and is direction to increase the oil flow.
sent to chamber G. It is also sent from the LS
circuit 0 to pump servo valve (7). 0 In addition, pump servo valve (7) is controlled
so that the differential pressure between pump
The condition of the pressure of spool (3) is pressure P and LS pressure LS (LS differential
chamber B pressure 4 chamber C pressure, pressure: APLS) remains constant, so a suit-
and chamber G pressure g chamber D pres- able amount of oil flows to ensure that the
sure, so spool (3) is controlled by the differen- loss of pressure at the control valve (APLS’) is
tial pressure of spool (1) (chamber C pressure equal to APLS. The loss of pressure in the
- chamber D pressure), and balances with control valve is determined by the area of the
spring (4). opening of the main spool, so the oil flow
In other words, if the oil flow is too large, the matches the opening of the spool.
Spool stroke
A A PLS’
Constant spoolstroke
A PLS’ constant _ _ _ - - -
2.0 MPa
(20kg/cm2)
< z-
po EPCoutput
Area of opening of spoo? pressurePi
SYD00322 SYD00323
@ The return oil flow from the HSS motor passes

through chamber E and chamber F, and is
drained. (When this happens, back pressure
valve (8) is opened to the maximum by the LS
pressure.)
10-193
(2) Work equipment valve

Blade lift, blade tilt valve
Ripper lift, ripper tilt valve
* The diagram shows the blade lift valve.
///,/,/,, /,, / I I I ‘, ; -, ; ‘, ‘, ‘, ‘, ‘, ’ ,-
SAD00197
10-194
1) When spool (1) of the work equipment valve

is at the HOLD position, the pump pressure
(unload pressure) is sent to chambers D and
Dl. The pressure is not formed in chambers H
and HI, so pressure compensation valve spool
(3) and steering priority valve spool (4) are
pushed completely to the right.
2) The pump pressure passes through chambers

A and B of steering priority valve (4), and is
sent to chamber C of the main control valve.
From here it goes through chamber D and
chamber E to chamber F.
3) In the same way as for Item (I) Steering valve,

the position of pressure compensation valve
spool (3) is determined to match the opening
of spool (I) of the work equipment valve, and
the oil flow is determined so that the pressure
loss of the control valve becomes equal to the
differential pressure ALS of LS valve (7).
10-195
STRUCTURE AND FUNCTION OPERATION OF MAIN CONTROL VALVE I
(3) Meter-out control when blade moves down under its own weight, and suction function using back-
pressure valve (work equipment lever at LOWER)
Blade lift
PPC valve
SAD00198
If the blade moves down under its own weight,

the oil flow of return oil from cylinder is con-
trolled by the area of the opening of main
spool (I).
A back pressure that matches the oil flow is

formed in drain passage C of the control valve
by back-pressure valve (3), so oil is supplied
to the cylinder from suction valve (2) to pre-
vent a vacuum from forming in the circuit.
1) When the spool port is opened by PPC

output pressure PA3, because of the
weight of the blade, the oil at the cylinder
head passes through ports A, 6, C, and D,
and is drained to the tank.
When this happens, the flow of return oil
from the lift cylinder is throttled by the
area of opening between ports A and B,
so the downward speed is controlled.
2) When the blade moves down under its

own weight, LS pressure is not formed,
so a back pressure that matches the valve
characteristics of back-pressure valve (3)
is formed in chamber C.
The oil flowing from the cylinder head
end passes from the drain circuit through
suction valve (2) and is supplied to the
bottom end of the cylinder.
The oil discharged from the pump passes
through ports Al, Bl, Cl, Dl, and El, and
is supplied to the cylinder bottom.
10-197
(4) Meter-out control when blade moves down under its own weight (work equipment lever at FLOAT)
Blade lift A3 83 Al
lo-198
. When the lift valve is at FLOAT, the cylinder

port and drain port are connected to put the
circuit in a no-load condition.
. When the lift valve is in the FLOAT condition,

the pump passage and cylinder ports A3 and
B3 are separated so that the other control
valves can be operated.
1) When the work equipment control lever is

at the FLOAT position, if pressure PA3
becomes 3.4 MPa (35 kg/cm? or more, lift
spool (I) is moved to the maximum stroke
position.
2) In this condition, ports A3 and B3 and the

LS passage 0 are all connected to the
drain circuit, so there is no load on the lift
cylinder.
3) If the cylinder is driven by the weight of

the blade, the oil entering from A3 flows
to ports A, B, Bl and Al, while the rest of
the oil flows through ports C and D, and
is drained.
When this happens, the oil flow is throt-
tled by the area of opening between ports
A and B of spool (I), and the cylinder
speed is controlled.
4) The pump circuit chamber E and ports A3

and B3 are separated, and pump pressure
P is formed, so it is possible to carry out
compound operations with other control
valves.
10-199
3. AT RELIEF
(11 Steering valve
* The diagram shows the condition at relief for steering LS relief valve (5).
N L ‘5
SAD00200
API = AP3 + AP4 = Differential pressure between ports M and E

AP2 = Differential pressure between ports E and N
AP3 = Differential pressure between ports M and B
AP4 = Differential pressure between ports B and E
ALS = API + AP2 = Differential pressure between ports M and N = 2.0 MPa (20 kg/cm*)
1O-200
. It specifies the maximum pressure when the

HSS is operated.
I) If the pressure of HSS motor (7) becomes

higher, steering LS relief valve (5) will crack
and oil will be drained from LS circuit 0.
(Ports E, F, G, J, K, and L)
As a result, there will be a drop in pres-
sure in LS passage 0 starting from LS
sensing hole F, and AP2 will become
larger.
2) For the same reason, if the pressure in

chambers I and H drops, spool (2) will
push against spring (3) and move to the
right, and will make the opening between
chambers I3 and C smaller, so the flow to
chambers B and C will be throttled and
AP4 will become larger.
3) Because of the pump swash plate control,

the system circuit is balanced at a circuit
pressure which makes the pressure loss
generated by the flow at steering LS relief
valve (5) API + AP2 equal to LS differen-
tial pressure (ALS).
When this happens, pump LS valve (6)
detects the differential pressure generated
by LS relief valve (51, and moves the pump
swash plate from the maximum to the
minimum position. The pump swash plate
is balanced at a position where the LS
differential pressure is 2.0 MPa (20 kg/cm*).
4) When the pump is at the minimum swash

plate angle (minimum oil flow), if the mini-
mum oil flow is greater than the LS relief
oil flow + leakage at any part, the pres-
sure is confined in the pump circuit (be-
tween the pump and chambers A and B),
so the LS differential pressure rises. If this
differential pressure goes above the set
pressure for unload valve (4), the unload
valve is actuated to relieve the excess oil
flow and balance the circuit.
10-201
I21 Blade lift, blade tilt, ripper lift, ripper tilt

* The diagram shows the condition of work equipment LS relief valve (5) with the blade tilt aIt the end
of its stroke. Blade lift
PPC valve
0
L.H. TILT
\’
EPC solenoid valve fz
PPC, EPC, HMT(

charge valve
SAD00201
API = AP3 + AP4 = Differential pressure between ports M and P

AP2 = Differential pressure between ports P and N
AP3 = Differential pressure between ports M and B
AP4 = Differential pressure between ports B and P
ALS = AP1 + AP2 = Differential pressure between ports M and N = 2.0 MPa (20 kg/cm2)
1O-202
1) If blade tilt valve (I) is moved, and the pres-

sure of tilt cylinder (8) becomes higher, work
equipment LS relief valve (5) will crack and oil
will be drained from LS circuit 0. (Ports P, F,
G, J, K, and L)
As a result, there will be a drop in pressure in
LS passage 0 starting from LS sensing hole
F, and AP2 will become larger.
2) For the same reason, if the pressure in cham-

bers I and H drops, spool (2) will push against
spring (3) and move to the right, and will
make the opening between chambers B and
C smaller, so the flow between chambers B
and C will be throttled and AP4 will become
larger.
3) Because of the pump swash plate control, the

system circuit is balanced at a circuit pressure
which makes the pressure loss generated by
the flow at work equipment LS relief valve (5)
API + AP2 equal to LS differential pressure
(ALS).
When this happens, pump LS valve (6) de-
8 tects the differential pressure generated by LS
2 relief valve (5), and moves the pump swash
s plate from the maximum to the minimum
position. The pump swash plate is balanced
at a position where the LS differential pres-
sure is 2.0 MPa (20 kg/cm*).
4) When the pump is at the minimum swash

plate angle (minimum oil flow), if the mini-
mum oil flow is greater than the LS relief oil
flow + leakage at any part, the pressure is
confined in the pump circuit (between the
pump and chambers A and chamber B
through steering priority valve (7)), so the LS
differential pressure rises. If this differential
pressure goes above the set pressure for un-
load valve (41, the unload valve is actuated to
relieve the excess oil flow and balance the
circuit.
lo-203
(31 Steering + work equipment valve

(compound operations)
* The diagram shows the condition of LS relief valves (4) and (5) at steering stall with the blade tilt
at the end of its stroke.
Blade lift
PPC valve
L.H. TILT \
0
I
EPC solenoid valve
‘C
SAD00202
A=P-P2
APO = Differential pressure between ports H and K
PressureAPZ = LSO + APO
lo-204
. When steering valve (I) and work equipment

valve (2) are relieved at the same time, the
pump pressure is separated by pressure com-
pensation valve (3) in the work equipment
valve, and the port pressure is maintained at
a constant value.
1) If HSS motor (6) reaches the stall condi-

tion, the load pressure increases and LS
relief valve (4) for the steering valve is
actuated, so the system is cut off (for de-
tails, see Item (I) Steering valve).
2) When this happens, the pump pressure P

is maintained at 38.2 MPa (390 kg/cm?,
and this is sent to chamber G of the work
equipment valve.
3) When work equipment valve (2) is oper-

ated and the load on the work equipment
valve is greater, work equipment LS relief
valve (5) is actuated, and drain oil flow 01
flows to LS circuit. As a result, a differen-
tial pressure is generated on the left and
8 right sides of pressure compensation valve
5 (3) by LS throttle M of spool (2), and it
z moves the full stroke to the right. When
this happens, the opening between cham-
bers D and E is throttled to the minimum
size (pump pressure separated).
4) Oil flow Ql is determined by pump pres-

sure P and the total pressure loss A (P -
LSO) of ports C, D, E, F, G, I, J, and K.
Furthermore, pressure P2 (the pressure in
chamber H) becomes the total (LSO + APO)
of the circuit pressure loss of ports H, I, J,
and K, and the set pressure of work equip-
ment LS relief valve (5).
1O-205
4. Compound operations
(I) Steering valve + work equipment valve
* The diagram shows the condition when the steering and blade lift valve are operated at the same
time.
Blade lift P2
I __..,I
SAD00203
1 O-206
l The steering valve is equipped with a steering 3) When pump swash plate does not reach
priority valve (31, so if the steering valve and maximum angle
the downstream work equipment valve are When the maximum oil flow from the
operated at the same time, priority is given to pump is greater than the sum of the flow
the flow of oil to the steering valve, and the demanded by the steering valve and work
rest of the oil discharged from the pump goes equipment valve, an amount of oil that
to the work equipment valve. matches the opening of steering spool (I)
flows to the steering valve; an amount of
1) When steering spool (1) is operated by oil decided by the pump pressure and load
EPC solenoid valve output pressure PBI pressure and area of opening of the spool
and the oil flows, a differential pressure is flows to the work equipment valve.
created between chambers C and D. Steer-
ing priority valve (3) is controlled by this 4) When the pump swash plate is at maxi-
differential pressure, and at the same time, mum angle
the pump swash plate angle is controlled When the maximum flow of oil from the
at APLS = 2.0 MPa (20 kg/cm*), and the pump is smaller than the sum of the oil
flow of oil to the steering valve is fixed. flow demanded by the steering valve and
See Item 2-H) Steering valve. work equipment valve.
@ When steering valve load d work equip-
2) In this condition, if downstream blade lift ment valve load
valve (2) is operated, the pump pressure . An amount of oil that matches the open-
momentarily drops. ing of steering spool (I) flows to the steer-
At this point, the differential pressure being valve, and the remaining oil flows to
tween chambers C and D becomes the work equipment valve.
smaller, and steering priority valve (3) is
moved to the left by the pressure in cham- @ When steering valve load > work equip-
ber E in the direction to throttle the open- ment valve load
ing to the work equipment valve. . Pump pressure P is determined by the
At the same time, APLS becomes smaller, steering valve load, but in this condition,
so the pump swash plate angle moves in if the downstream work equipment valve
the maximum direction to supply an oil where the load is smaller is operated, the
flow to make up the amount that the pres- difference in pressure will cause the oil to
sure drops. try to flow to the work equipment valve,
so the pump pressure will drop.
. When this happens, steering priority valve
A (3) increases the size of the opening to
Opening to steering valve
the steering system, while at the same
time reducing the size of the opening to
the work equipment in order to ensure
the flow of oil to the steering system.
. In this condition, the flow of oil is divided
Opening to work
equipment valve in proportion to the difference in pressure
between differential pressure P - PI and
differential pressure P - P2.
The bigger PI - P2 is, the smaller the flow
> of oil to the steering system becomes.
Stroke
SYDoO324
1O-207
(2) Compound operation of work equipment

valve
* The diagram shows the condition when the
blade lift and tilt valves are operated at the
same time.
Blade lift Blade tilt

PPC valve PPC vave
SAD00204
1 O-208
. It consists of a parallel circuit, so when com- 4) When pressure P2 = pressure P3

pound operations are carried out, the oil flow P - P2 G P - P3, so an oil flow proportional
is divided according to the size of each spool to the size of the spool opening is distrib-
opening. uted to each spool.
I) When tilt spool (I) and lift spool (2) are at

the HOLD position or are operated, steer-
ing priority valve (3) is pushed completely
to the right, and the size of the opening to
the downstream area is at its maximum.
2) Tilt spool (I) and lift spool (2) are actuated

by PPC valve output pressure PA2 and
PR3, and each is balanced at a position
that matches its own pilot pressure.
3) When pressure P2 5 P3
Lift valve load pressure P3 is sent to pump
LS valve (4) through LS passage 0.
@ When pump swash plate does not reach

maximum angle
When the maximum flow of oil from the
pump is greater than the total of the oil
flow demanded by the tilt valve and lift
valve, an oil flow that matches the open-
ing of the spool flows to both the tilt valve
and lift valve.
@ When the pump swash plate is at maxi-

mum angle
When the maximum flow of oil from the
pump is smaller than the total of the oil
flow demanded by the tilt valve and lift
valve, the flow of oil to the tilt valve and
lift valve is divided according to differen-
tial pressure PO - P2 and differential pres-
sure PO - P3. In other words, more oil
flows to P2 where the load is small.
* In cases where the blade is raised in the

air and the tilt valve and lift valve (for
raise) are operated at the same time, the
tilt valve load pressure is smaller than the
lift valve load pressure, so the flow of oil
to the tilt valve is given priority. In addi-
tion, the oil flow demanded by the tilt
valve is smaller, so the condition is just as
if priority was given to the oil flow for the
tilt valve.
1 O-209
5. Unload valve preset system

* The diagram shows the condition with preset check valve (3) open immediately after blade lift valve is
operated.
Blade lift
PPC valve P3
-8
l This improves the response of the system in-

cluding the pump swash plate and pressure
compensation valve by sending the pilot pres-
sure (basic pressure of PPC valve and EPC
solenoid valve) to the LS circuit, and compen-
sating the rise of the LS circuit pressure.
(1) When lift spool (1) is at the HOLD position,

pilot pressure PI (basic pressure of PPC valve
and EPC solenoid valve) is sent through pre-
set check valve (3) to the chamber F of the
pressure compensation valve. This pressure
is called preset pressure P2.
At the same time, unload pressure P is being
sent to chamber B, but PI + FO > P (FO: load
of spring (4)), so pressure compensation spool
(2) moves to the left and the size of the open-
ing between A and B becomes the maximum.
(2) When spool (1) is switched, unload pressure

P flows immediately through chambers A, B,
C, D, and E to lift cylinder (8), so the pressure
at the port starts to rise and the time lag be-
comes smaller.
8
2 (3) At the same time, preset pressure P2 is sup-
& plied to LS circuit 0 by the timing of the spool,
and the pressure in the LS circuit rises. Be-
cause of this, unload valve (7) closes, and oil
is sent further to pump LS valve (6) to im-
prove the response of the pump swash plate
angle. This makes it possible to reduce the
response time for giving the necessary oil flow.
Check valve (5) is built into the spool to pre-
vent preset pressure P2 from venting in force
from the cylinder port.
(4) When cylinder port pressure P3 rises and be-

comes greater than preset pressure P2, it
pushes up check valve (5), and oil is sent to
chamber F of the pressure compensation valve
and pump LS valve (6) to give the basic APLS
control.
When this happens, pressure P3 at the cylin-
der port is prevented from entering the PPC
pump circuit by preset check valve (3).
1o-21 1
STRUCTURE AND FUNCTION HSS MOTOR
HSS MOTOR
\
‘C
Specifications
1. HSS motor assembly Type 1 HMFIGO

2. Brake valve assembly
Theoretical displacement (cc/rev) 1 160.8
A. PB port (from main control valve) Rated pressure (MPa (kg/cm?) 1 41.2 (420)
B. PA port (from main control valve)
Rated speed (rpm) 1 1,860
C. T port (to hydraulic tank)
10-212
x-x
SAD00249
1. Output shaft 8. Cover

2. Motor case 9. Spool return spring
3. Plate 10. Counterbalance valve
4. Piston 11. Check valve spring
5. Cylinder 12. Check valve
6. Valve plate 13. Safety valve
7. End cover
10-213
OPERATION OF BRAKE VALVE

l The brake valve consists of check valve (12),
counterbalance valve (IO), and safety valve
(131, and forms a circuit such as that shown
on the right.
. The function and operation of each compo-
nent is as given below.
1. Counterbalance valve, check valve

SYDO0325
Function
. When operating the steering on slopes, the
weight of the machine produces a force in the
downward direction which makes the machine
try to turn faster than the speed of the HSS
motor. Because of this, if the engine is run at
low speed and the steering is operated, the
HSS motor will overrun, and this will create
an extremely dangerous condition.
To prevent this, this valve is installed to carry
out the steering in accordance with the en-
gine speed (pump discharge volume).
Operation when oil is supplied

. When the steering lever is operated, the pres-
surized oil from the control valve is supplied
to port PA. It pushes open check valve (12a),
and flows from HSS motor inlet port MA to
HSS motor outlet port MB.
However, the outlet port side of the HSS mo- SYDO0326
tor is closed by check valve (12b) and spool
(IO), so the pressure at the side where the oil
.
is being supplied rises.
The pressurized oil at the side where the oil is
1 Controlvalve I
being supplied flows from orifice El of spool

(IO) into chamber Sl. And when the pressure
in chamber Sl becomes greater than the spool
switching pressure, spool (IO) is pushed to
the right.
In this way, port MB and port PB are con-
nected, so the outlet port side of the HSS
motor is opened and the HSS motor starts to
turn.
SYD00327
10-214
Action of brakes when operating steering on

downhill slopes
l When the steering is operated on downhill
slopes, if the machine attempts to run away,
the HSS motor will rotate under no load, and
the oil pressure at the inlet port of the HSS
motor will drop. This drop in pressure will
pass through orifice El, so the pressure in
chamber Sl will also drop.
If the pressure in chamber Sl drops below
the spool switching pressure, spool (IO) is
pushed to the left in the direction of the arrow
by spring (9), and outlet port MB is throttled.
As a result, the pressure at the outlet port
rises, and this creates a resistance to the rota-
tion of the HSS motor which prevents the
motor from overrunning.
In other words, the spool moves to a position
where it balances the pressure at outlet port
SYDOO328
MB with the force resulting from the weight
of the machine and the pressure at the inlet
port. In this way, it throttles the outlet port
circuit and controls the motor to a speed that
matches the amount of oil discharged from
8 the pump.
2
z 2. Safety valve
Function To port 1
l When the operation of the steering stops,
t
counterbalance valve (IO) closes the circuit at
the inlet and outlet ports of the HSS motor,
but the HSS motor continues to turn because
of inertia. As a result, the pressure at the out-
let port of the HSS motor becomes extremely
high, and this will damage the HSS motor
and the piping. The safety valve acts to re-
lease this abnormal pressure to the inlet port
of the HSS motor to protect the equipment
from damage.
To port T
Operation
t
l When the operation of the steering is stopped,
the check valve of the counterbalance valve
closes chamber E (or chamber F) in the outlet
port circuit, but the pressure at the outlet port
side continues to rise because of inertia.
e SYDO0330
10-215
. If the pressure in chamber E (or chamber F)

goes above the set pressure, the force of 7t/4
(Dl2 - D22) x pressure resulting from the dif-
ference in area of Dl and D2 (or the force of
7c/4 (D32 - D12) x pressure resulting from the
difference in area of D3 and Dl) becomes
greater than the force of the spring and moves
the poppet to the right. The oil then flows to
chamber F (or chamber E) in the circuit on the
opposite side. D2 sYDoo331
DI
lo-216
STRUCTURE AND FUNCTION OPERATION OF STEERING, WORK EQUIPMENT CONTROL CIRCUIT
OPERATION OF STEERING, WORK EQUIPMENT CONTROL CIRCUIT

At blade RAISE
* %I. : Serial No. : 60280 and up
L I BLADE LIFT BLADE TILT RIPPER TILT RIPPER
BLADE LIFT BLADE TILT
R R
PA5
:,1
p-3 i P’2
:,:
:::
:::
:::
I,,
I ’ <
,
SAD00390
1O-218
@
Operation
. If blade control lever (I) is operated to the
RAISE position, the spool of PPC valve (2),
which is connected directly to the lever, is
driven.
When this happens, the pilot pressure enter-
ing PPC valve (2) from charge pump (3) is
sent to port PB3 of blade lift spool (4).
l Spool (4) is pushed to the left by the pilot

pressure, so ports A and B and port C and D
are connected. The oil at port PA3 passes
through PPC valve (2) and is drained to hy-
draulic tank (5).
. When this happens, the pressurized oil from

hydraulic and HSS pump (6) enters port P,
passes through unload valve (7) and steering
priority valve (8). It then passes through ports
A and B, and enters the cylinder head end of
blade lift cylinders (9) and (IO), and raises
blade (II). At the same time, the oil at the
cylinder bottom passes through ports C, D,
and T, and is drained to hydraulic tank (5).
lo-219
At blade L.H. TILT

\
I Xl RI~R LIFT
P’4 i IP 1
P3 T P2
ill I
~~1//11//1/111,,,,/
1//1//1/,,11,,,,,,,
SAD00391
1O-220
63
Operation
. If blade control lever (I) is operated to the
LEFT TILT position, the spool of PPC valve (21,
driven.
sent to port PA2 of blade tilt spool (4).
l Spool (4) is pushed to the right by the pilot

are connected. The oil at port PB2 passes
draulic tank (5).

A and B, and enters the cylinder bottom end
of blade tilt cylinder (91, and tilts blade (IO) to
the left. At the same time, the oil at the cylin-
der head passes through ports C, D, and T,
and is drained to hydraulic tank (5).
10-221
RIPPER
At ripper RAISE
Xl
P3 T P2
/1//,,,,//,,,,
~111/,,/,/,,,,
SAD00392
1o-222
@
Operation
. If ripper control lever (I) is operated to the
RAISE position, the spool of PPC valve (21,
driven.
sent to port PB4 of ripper lift spool (4).
. Spool (4) is pushed to the left by the pilot

draulic tank (5).
l When this happens, the pressurized oil from

A and B, and enters the cylinder head end of
ripper lift cylinders (91, and raises ripper (IO).
At the same time, the oil at the cylinder bot-
tom passes through ports C, D, and T, and is
drained to hydraulic tank (5).
1O-223
At ripper TILT IN
Ir %I. : Serial No. : 60280 and up
Xl RIPPER TILT RIPPER LIFT

7-h-n Ilr
P4 I PIP1 I
P3T P2
SAD00393
lo-224
@
Operation
. If ripper control lever (1) is operated to the
TILT IN position, the spool of PPC valve (21,
which is connecteb directly to the lever, is
driven.
sent to port PB5 of ripper tilt spool (4).

draulic tank (5).
l When this happens, the pressurized oil from

A and B, and enters the cylinder bottom end
of ripper tilt cylinders (91, and tilts ripper (IO)
in. At the same time, the oil at the cylinder
head passes through ports C, D, and T, and is
drained to hydraulic tank (5).
1o-225
STEERING
At FORWARD LEFT TURN
Ir %I. : Serial No. : 60280 and up
Xl
1
P4 I PIP1 I
P3T P2
SAD00254
1 O-226
c3
Operation
l When the joystick is operated to the FOR-
WARD, left turn position, an electric signal
flows to EPC solenoid valve (I) and excites
the solenoid.
ing EPC solenoid valve (I) from charge pump
(2) is sent to port PBI of steering spool (3).

through EPC valve (I) and is drained to hy-
draulic tank (4).

A and B, and enters port PA of the HSS motor
assembly. It then passes through counterbal-
ance valve (8) and rotates HSS motor (9). (It
rotates counterclockwise as seen from the left
side of the machine.)
At the same time, the oil at port PB passes
through ports C, D, and T, and is drained to
hydraulic tank (4).
1O-227
STRUCTURE AND FUNCTION PISTON VALVE
PISTON VALVE
(BLADE LIFT CYLINDER)
Outline
. The piston valve is installed on the piston in
the blade lift cylinder. When the piston reaches
its stroke end, the valve releases the oil from
the hydraulic pump to reduce the oil pressure
being exerted on the piston.
When the blade is tilted, the blade is subject
to a tortional force owing to the uneven posi-
tion of the pistons in the two cylinders; that is
the piston one side is still moving while the
piston on the other side has reached its stroke
end.
The piston valves are installed to prevent the
tortional force from occurring. When one of
the pistons reaches its stroke end, its piston
valve opens to relieve the oil pressure.
In addition the piston valve relieves the shock
which occurs when the piston comes into con-
tact with the cylinder head or the bottom and
serves to reduce the subsequent surge pres-
sure in the cylinder by letting the oil escape
from the cylinder before the piston reaches
its stroke end.
Operation
Piston valve CLOSED
Pressurized oil from the hydraulic pump acts
on piston (2) and piston valve (3).
The piston valve (3) is pushed in the direction
of the arrow until piston valve seat (4) comes
into snug contact with the tapered section;
thereby, this causing the pressure in the cylin-
der to rise and moving piston (2) in the direc-
tion of the arrow.
SAD00206
Piston valve OPEN
Just before piston rod (I) reaches the end of
its stroke, the tip of valve (6) contacts the
cylinder bottom, so valve (6) and piston valve
(3) stop at that position and do not move
further. Only piston (2) moves further.
When this happens, the oil at the cylinder
head, which was sealed by piston valve (31,
escapes from piston valve seats (4) and (51,
and the pressure inside the cylinder stops ris-
ing.
1 O-228
0
STRUCTURE AND FUNCTION QUICK DROP VALVE
QUICK DROP VALVE

(BLADE LIFT CYLINDER)
Structure
The quick drop valve consists of valve body (I),
spool (21, check valve (31, and spring (4).
The quick drop valve serves to increase the blade
lowering speed and to reduce the occurrence of
vacuum when the blade is lowering, thereby short-
ening the time lag before digging is started.
The blade lowering speed, which is generally de-
termined by the pump discharge, can be made
faster with the quick drop valve.
1. Valve body
2. Spool
3. Check valve SYD00333
4. Spring
Operation
1. Start of lowering
When the blade lever is operated to LOWER,
the oil from the control valve enters the cylin-
8 der bottom through port A and pushes the
5 piston. In the meantime, the oil in the cylinder
Z head is pushed out into the piston, enters
valve port B, and flows into the tank from port
C.
2. While lowering
Pressurized oil from the cylinder head flows
into port C through port B.
At this time, the oil flow is restricted by an
orifice a provided along the way, causing a
differential pressure before and after the ori-
fice. .
When the differential pressure becomes
greater than the force of spring (41, it com-
presses the spring and moves spool (2) and
check valve (3) to the right.
When the spool and the check valve have
moved, part of the oil flowing from the cylin-
der head to the tank enters the passage to the
cylinder bottom together with the oil from the
control valve.
Thus, the blade lowering speed increases in
accordance with the amount of oil that flows
to the bottom of the cylinder and reduces the
formation of vacuum at the bottom of the
cylinder. 2 3 4 SBD00739
1 O-229
0
STRUCTURE AND FUNCTION CYLINDER STAY
CYLINDER STAY
1 2 3456
SAD00208
1. Grease nipple
2. Yoke
3. Oil seal
4. Bushing
5. Bushing
6. Grease nipple
1O-230
STRUCTURE AND FUNCTION WORK EQUIPMENT
WORK EQUIPMENT
SEMI U-DOZER
1. End bit
2. Cutting edge
3. Blade
A. Center brace
5. Tilt cylinder
6. Straight frame
7. Trunnion
8. Brace Semi U-dozer
Blade width (mm) 3,955
Blade height (mm) 1,720
Max. lifting height (mm) 1,250
Max. lowering depth (mm) 590
Max. tilt (mm) 1,000
Cutting angle (de@ 52”
Variation in cutting angle (deg) k6”
Tilt cylinder position I Right
lo-231
U-DOZER
1. End bit SE000210
2. Cutting edge
3. Blade
4. Center brace
5. Tilt cylinder
6. Straight frame
7. Trunnion
8. Brace U-dozer
I
Blade width (mm) I 4,265
Cutting angle (de@ 52”
Variation in cutting angle (deg) k6”
Tilt cylinder position I Right
lo-232
MULTI-SHANK RIPPER
SEDCO212
1. Mount bracket
2. Tilt cylinder
3. Lift cylinder
4. Beam
5. Shank
6. Protector
7. Ripper point
8. Arm
izayy
Max. lowering depth of point (mm)
Point digging angle (de@ 34.5” - 60.9”

I
Beam length (mm) 1 2,260
1O-233
GIANT RIPPER
. Machine equipped with pin puller
1. Bracket
2. Tilt cylinder
3. Lift cylinder
4. Beam
5. Pin puller cylinder 8 SED00213
6:Shank
7. Protector
8. Ripper point
9. Arm
Giant ripper
-
Max. lifting height of point (mm) 925
Max. lowering depth of point (mm) I 1,220
Point digging angle (deg) 34.5" - 60"
Beam length (mm) 1,535
1 O-234
STRUCTURE AND FUNCTION PIN PULLER SWITCH
PIN PULLER SWITCH
Structure of circuit
SE000245
Function 1. Connector
. The pin puller solenoid valve is controlled by 2. Wire
turning the pin puller switch ON/OFF. This 3. Switch
changes the oil circuit to the pin puller cylin- 4. Knob
der and sets the shank mounting pin to the
PUSH IN or PULL OUT position.
1 O-235
STRUCTURE AND FUNCTION PIN PULLER SOLENOID VALVE
PIN PULLER SOLENOID VALVE
1. Plug A. To pin puller cylinder bottom

2. Spring B. To pin puller cylinder head
3. Spring retainer P. From power train pump
4. Valve body T. To steering case
5. Spool
6. Spring retainer
7. Spring
8. Push pin
9. Solenoid assembly
1O-236
STRUCTURE AND FUNCTION PIN PULLER SOLENOID VALVE
Operation
From power train pump Pin puller switch
1. Pin puller switch at PUSH IN position I at PUSH IN position
When the pin puller switch is set to the PUSH
IN position, no electric current flows to sole-
noid (9) and it is deenergized.
Then, ports P and A and ports B and P of
spool (5) open, and the oil from the power
train pump flows from port P to port A, and
enters the bottom end of pin puller cylinder
(IO).
When the oil enters the bottom end of the
cylinder and the pressure in the circuit starts
to rise, the cylinder extends and pushes shank
mounting pin (11) into shank (12).
SYD00336
2. Pin puller switch at PULL OUT position

When the pin puller switch is set to the PULL
OUT position, electricity flows to solenoid (9)
and it is excited.
Then, the solenoid pushes out push pin (8)
and spool (5) moves to the left in the arrow
direction.
At this point, ports P and A and ports B and T
close, and ports P and B and ports A and T
open, so the oil from the power train pump
flows from port P to port B and enters the
head end of pin puller cylinder (IO).
When the oil enters the cylinder head end
and the pressure in the circuit rises, the cylin-
der retracts and pulls shank mounting pin (I I)
out of shank (12).
SYD00337
1O-237
STRUCTURE AND FUNCTION TILT/PITCH SELECTOR SWITCH
TILT/PITCH SELECTOR SWITCH
;I
1 2
1. Switch
2. Knob
3. Wire
4. Connector
SDD00241
Function
l The tilt/pitch selector switch is installed to the
blade control lever. When the tilt/pitch selec-
tor switch is turned ON/OFF, it controls the
pitch solenoid valve and opens or closes the
flow of oil to the pitch cylinder.
lo-238
STRUCTURE AND FUNCTION PITCH SOLENOID VALVE
PITCH SOLENOID VALVE
P x
From charge pump

I/ ---- I--l
PT
SED00242
Outline
. The pitch solenoid valve is installed between 1. Main spool assembly
the pitch cylinder and tilt cylinder. It acts to 2. Pilot solenoid valve assembly
open or close the oil pressure circuit to the 3. Connector
pitch cylinder according to the signal from the
tilt/pitch selector switch. A. To pitch cylinder bottom
B. To pitch cylinder head
P. From main control valve
T. To blade tilt cylinder bottom
X. From charge pump
Y. To hydraulic tank
1 O-239
STRUCTURE AND FUNCTION PITCH SOLENOID VALVE
Operation -
From main -
Tilt/pitch selector switch OFF control valve 5
l When tilt/pitch selector switch (I) is not being
operated (OFF), no electricity flows to sole-
noid valve (21, so it is deenergized. In this To main -
condition, main spool (3) opens ports P and control valve
T, and closes ports A and B. Therefore, no oil
flows to pitch cylinder (4). Only blade tilt cyl-
inder (5) moves, and the blade is tilted.
SKD00243
Tilt/pitch selector switch ON From main _

l When tilt/pitch selector switch is operated control valve
(ON), electricity flows to solenoid valve (2), so
it is excited. When this happens, main spool
(3) opens ports P and A, and ports T and B.
Therefore, the hydraulic circuit is connected
to the head end of pitch cylinder (4) and the
bottom end of blade tilt cylinder (5). As a
result, when blade tilt cylinder (5) is retracted,
pitch cylinder (4) is also retracted, and the
blade is pitched.
SKD002bb
1 O-240
STRUCTURE AND FUNCTION CAB MOUNT
CAB MOUNT
A-A
o lo o
SED00246
Outline
1. Cab suspension cylinder (left) . The floor frame and cab are mounted by cab
2. Tie rod suspension cylinders (1) and (3), using point
3. Cab suspension cylinder (right) B as the fulcrum. A rubber bushing is also
inserted in point B to prevent noise and vi-
bration.
. Inside the cab suspension cylinder, there is a
spring and oil. The shock absorbing ability of
the spring and the throttling effect of the oil
when it passes through the throttle inside the
cylinder act to absorb the shock when the
chassis drops and improve the riding comfort
for the operator during machine travel.
lo-242
STRUCTURE AND FUNCTION CAB
CAB
CAB ASSEMBLY
1 2
lZ
_._-__,
4
I SKD00215
1. Front wiper
2. Front glass
3. Rear wiper
4. Door
lo-243
STRUCTURE AND FUNCTION CAB
ROPS GUARD
SDD00247
1. ROPS guard Outline

. The ROPS guard is installed to protect the
operator if the machine should roll over.
lo-244
STRUCTURE AND FUNCTION AIR CONDITIONER
AIR CONDITIONER
AIR CONDITIONER PIPING
SKD00216
1. Air conditioner compressor 7. Hot water pick-up piping A. Recirculated air

2. Condenser 8. Hot water return piping B. Fresh air
3. Window defroster 9. Side defroster
4. Air conditioner unit 10. Receiver tank
5. Vents 11. Refrigerant piping
6. Blower motor
1 O-245
0
STRUCTURE AND FUNCTION ELECTRICAL WIRING DIAGRAM
ELECTRICAL WIRING DIAGRAM
24 23 22 21 44
SAD00283
1. EPC solenoid valve 11. Backup alarm relay 23. Fuse box 35. Horn
2. HMT charge pressure sensor 12. Power cut relay for 2nd/3rd, F/R solenoid 24. Battery relay 36. Front lamp
3. Horn switch 13. Battery relay cut relay 25. Governor motor 37. Engine water temperature sensor
4. Tilt/pitch selector switch 14. Rear lamp 26. Parking detection limit switch 38. Electrical intake air heater relay
5. Proximity switch (for detecting FLOAT position) 15. Pin puller solenoid (for giant ripper) 27. Brake pedal potentiometer 39. HMT controller
(Serial No. : 60001 - 60279) 16. Backup alarm 28. Monitor panel 40. Ripper lamp
6. Proximity switch relay 17. Washer tank 29. Key switch 41. Ripper point lamp
(Serial No. : 60001 - 60279) 18. Battery 30. Glow switch 42. Hydraulic oil temperature sensor
7. Pin puller switch (for giant ripper) 19. Power cut relay for 1st solenoid 31. Rear lamp switch 43. Engine speed sensor
8. Engine throttle potentiometer 20. Neutral safety relay 32. Front lamp switch 44. Engine oil pressure sensor
9. Fuel control dial 21. Overrun warning relay 33. Monitor alarm 45. Starting motor
10. Fuel level sensor 22. Engine throttle controller 34. Bimetal timer 46. Alternator
lo-247
8
STRUCTURE AND FUNCTION ELECTRICAL CIRCUIT DIAGRAM
CAB ELECTRICAL CIRCUIT DIAGRAM
otor Right Wiper mot :or

Fret Wiper motor
-..-._-__-
Siaer lighter
Additional
lamn
CN-9
CN-22
To battery CN-20 &

power source I CN-*rT
ox
ii
CN-361
Window washer
motor L. H. Wiper Front wiper R. H. Wiper Rear wiper Front IamP Rear lamp
(Front window) switch switch switch switch switch switch
Window washer
motor
(L. H. window)
CN-363
Ibn~;w washer 0.85LY
0.858
(R. H. window)
Window washer
motor
(Rear window)
CN-364
CN-4
Cab room IamP Rear sneaker Rear sneaker Ad ditional I amp

(R. H. 1 Pi ckun
Rear wiper motor
1 O-249
a
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
MACHINE MONITOR SYSTEM
/r Sensor signal > /
I I I I/
A
L
Power source
Each sensor Buzzer signal
&
Buzzer
i-
Controller Battery
SDDO0221
l The machine monitor system uses sensors The machine monitor system consists of the
installed at various parts of the machine to monitor panel, controller, sensors, warning
observe the machine condition. It processes buzzer and power source.
this information swiftly and displays it on the The monitor panel and sensors are connected
panel to keep the operator informed of the with wiring harnesses, and the power supply
machine condition. for the monitor panel is taken from the bat-
The information displayed on the panel can tery. If any abnormality occurs in the machine
be broadly divided into the following catego- (detected by the sensor), the monitor and
ries. warning lamp flash and the buzzer sounds to
protect the machine. The buzzer can be
1. The monitor group, which informs the stopped temporarily by operating the cancel
operator when there is an abnormality in switch.
the machine.
2. The gauge group (coolant temperature,
power train oil temperature, fuel level),
which always displays the condition of the
machine.
1o-251
MONITOR PANEL
1 2 3 4 5
1. Service meter
2. Service meter indicator
3. Engine coolant temperature gauge
4. Power train oil temperature gauge
5. Fuel level gauge
6. Alarm buzzer cancel switch indicator
7. Alarm buzzer cancel switch
8. Warning lamp
9. HMT hydraulic oil temperature caution
10. Electronic system caution (HMT,
engine throttle controller)
11. HMT charge pressure caution
12. Engine preheating caution
13. Engine oil pressure caution
14. Engine overrun caution
15. High/low speed selection display
(speed max. button ON/OFF status
display) (For Serial No. : 60001 - 60806)
16. Battery charge caution
17. Engine coolant temperature caution
17 16 15 14 13 12 11 10 9 8 7 6
SDD00222
Outline
l The monitor panel consists of the monitor 2. CAUTION items
group, which gives a warning if any abnor- These light up or flash when there is any ab-
mality occurs in the machine, and the service normality.
meter and gauge group, which displays the The warning lamp and alarm buzzer flash or
condition of the machine. The service meter sound togeter depending on the item that is
and fuel level gauge are driven directly by a abnormal.
signal from the machine, but for the other * The flashing interval for the monitor and warn-
items, a microcomputer installed in the panel ing lamp is approx. 0.8 seconds each repeated
processes the signal from various sensors and ON and OFF.
displays the result.
The items displayed on the indicator type 3. Alarm buzzer cancel switch
gauges and monitor portion are as shown in If any abnormality is detected and alarm buzzer
the table in MONITOR PANEL DISPLAY. sounds, it is possible to stop the buzzer tem-
In addition, if there is any abnormality in the porarily by pressing the buzzer cancel switch.
HMT system or governor control system, a In this case, the alarm buzzer cancel switch
signal is sent from the HMTcontroller, and the indicator lights up. If the cancel switch is
warning lamp flashes, and the alarm buzzer pressed again after the buzzer has been
sounds. stopped, the buzzer will sound again and the
cancel indicator will go out. If another abnor-
Operation mality is detected when the buzzer has been
1. Turning on power (turning starting switch to temporarily stopped, the alarm buzzer will
ON) sound again and the cancel switch will go
I) All caution monitor items light up for 3 out.
seconds.
2) The warning lamp lights up for 3 seconds
and the alarm buzzer sounds for 1 sec-
ond.
lo-252
a
Monitor panel display (gauge group)
Meter Engine coolant temperature ‘ower train oil temperature Fuel level
Gauge scale
SY D0034’ SYD00342 SYD00340
4. Gauge display portion

This consists of analog type meters with an indicator. The coolant temperature and power train oil
temperature gauges are driven by a microcomputer, and the area showing the normal operating
range of the machine is made larger to make operations at the limit of the range easier.
The red zone for the water and oil temperature is a warning area which uses a caution LED, caution
lamp, and caution buzzer.
8
2
z Connector terminal (signal table)
Connector No. Connection Connector No. Connection
l-l Power source 24V 2-l Engine water temperature
l-2 GND 2-2 Power train oil temperature
l-3 - 2-3 Fuel level sensor
l-4 Charge (alternator terminal R) 2-4 GND
l-5 Starting switch (c) 2-5 HMT hydraulic oil temperature

Preheating signal -
l-6 2-6
(heater relay output)
l-7 I Lamp switch I 2-7 I Alarm output
l-8 I Engine oil pressure I 2-8 I -

l-9 High/low selector display
I 2-9 I -
I-IO I HMT charge pressure sensor I 2-10 I Network
I-II I Overrun warning I 2-11 I -

1-12 I - I 2-12 I -
1-13 I Model selection 0 I
1-14 I Model selection 1 I
1-15 Model selection 2
1-16 HMT system abnormality
1 O-253
0
Monitor panel display (monitor group)
Display Display Display

LED lamp r Caution
Buzzer
Symbol lamp Remarks
category item range Iisplay display xltput
Display
color
Below 102” Turn off Turn off OFF

Engine
coolant 102” - 107°C Flashes Red Flashes OFF
temperature
SKDO0622 Above 107°C Flashes Flashes ON
u 0
tl!
0
HMT
hydraulic oil
temperature
Below
Above
120”
120°C
Turn off
Flashes
ON
Red
Turn off
Flashes
OFF
ON
:when engine Turn off

When there
is stopped)
Batten/ is defective
Red OFF
charge charging Flashes
(below IOV) Iwhen engine Flashes
SKD00624
is running)
ON
0 :when engine Turn off OFF
Warning
Ll
e8 Engine oil
pressure
Below
specified
value
is stopped)
Flashes
(when engine
is running)
Red
Flashes ON
Engine When engint According

is over- Flashes Red Flashes ON to S-NET
overrun
running signal
SKD00626
Turn off
(when engine Turn off OFF
Below is stopped)
HMT charge
specified Red
pressure Flashes
value
(when engine Flashes ON
SKDO0627
is running)
When elec- According

Electronic tronic syster Flashes ON
Flashes Red to S-NET
system is abnormal signal
SKD00628
Pilot
L! 0w
SKD00629
Preheating
When
preheating
ON Green Turn off OFF
Cl
0
According
Hi/Lo When travel
ON Green Turn off OFF to S-NET
a Selection speed is set
signal
kd
SKD00630
%I. For Serial No. : 60001 - 60806
1 O-254
0
l- LED lamp T Caution

Display Display Display lamp 3uzzer
Symbol Remarks
category item range Display display xltput
Display
color
[Et!]
SKD00631
Service
meter 0 - 99999.9h - - -
rime on
t:he clock
Service
meter
Service When service Flashes when

meter meter service meter Green
indicator is running is running
SKDW632
Switches
n0
SKD00633
Buzzer
cancel switch
indicator
When buzzer
IS canceled
Flashes while
buzzer remains
canceled
Yellow OFF
Switches
Items Actuation Symbol
Buzzer cancel OFF tf ON lx0

a
M8ixL
SKD00634
10-254-l
0
STRUCTURE AND FUNCTION SENSORS
SENSORS
l The signals from the sensors are input di-
rectly to the machine monitor panel.
l With the engine oil pressure sensor, if the
contacts are open and the signal wire is dis-
connected from the chassis ground, the panel
judges that the signal is normal.
Display category Type of sensor Sensor method When normal When abnormal
Caution Engine oil pressure Contact OFF(Open) ONKlosed)
Caution, gauge Engine coolant temperature Resistance - -
Gauge Power train oil temperature Resistance - -
Gauge Fuel level Resistance - -
HMT pump, motor oil temperature Contact ON(Closed) OFF(Open)

Caution
HMT charge pressure Contact ON(Closed) OFF(Open)
8
3
S
lo-255
ENGINE OIL PRESSURE SENSOR
1 234 5 6 1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Thermistor
SYD00343
Function
. The engine oil pressure sensor is installed at pressure goes below the specified pressure,
the front on the left side of the cylinder block. the curve of the diaphragm becomes smaller,
When the engine oil pressure is above the so the contact and contact link come into con-
specified value, diaphragm (4) bends, so contact and the circuit is turned ON. The monitor
tact (3) and contact ring (2) are separated and panel display and warning lamp flash, and
the circuit is turned OFF. When the engine oil the alarm buzzer sounds.
ENGINE COOLANT TEMPERATURE SENSOR

POWER TRAIN OIL TEMPERATURE SENSOR
SYD00344
Function
l The engine coolant temperature sensor is in- l The power train oil temperature sensor is in-
stalled to the thermostat housing on the right stalled between the HMT control valve and
side of the engine. It detects the temperature the oil cooler. It operates in the same way as
with thermistor (3) and sends a signal to the the engine coolant temperaturesensor.
monitor panel.
The monitor panel moves the gauge indicator
to the range that corresponds to the signal,
and if it is above the specified temperature,
the monitor panel display and warning lamp
flash, and the buzzer sounds.
lo-256
FUEL LEVEL SENSOR
f%3
E
7 F
B 2
Y 1
u
A-A Structure of circuit
SYDO0345
1. Connector Function
2. Float l The fuel level sensor is installed to the center
3. Arm of the front face of the fuel tank. Float (2)
4. Body moves up and down in accordance with the
5. Spring level of the remaining fuel.
6. Contact The movement of the float passes through
7. Spacer arm (3), which actuates a variable resistance,
and this sends a signal to the monitor panel
to display the level of the remaining fuel.
1O-257
HMT PUMP, MOTOR OIL TEMPERATURE SENSOR
SYCOO346
Function
l The HMT pump and motor oil temperature 1. Switch
sensor is installed to the HMT motor drain 2. Case
outlet block. The temperature is detected by 3. Wire
switch (I), and if the oil temperature goes 4. Connector
above the set value, the switch is turned OFF.
When this happens, the monitor panel dis-
play and warning lamp flash, and the alarm
buzzer sounds.
HMT CHARGE PRESSURE SENSOR
- Structure of circuit
SED00223
Function
l This sensor is installed to the PPC, EPC, HMT 1. Switch
charge valve outlet port. If the charge pres- 2. Case
sure drops below the set pressure, switch (I) 3. Wire
is turned OFF. When this happens, the moni- 4. Connector
tor panel display and warning lamp flash, and
the alarm buzzer sounds.
lo-258
STRUCTURE AND FUNCTION ENGINE CONTROL SYSTEM
ENGINE CONTROL SYSTEM

SYSTEM DIAGRAM
Outline
l The engine can be started and stopped sim- When starting switch (5) is turned ON, electric
ply by operating the starting switch. power enters engine throttle controller (2), and
. The engine control system is a dial type. The fuel injection pump (4) moves to the position
input signal from fuel control dial (I) enters set by fuel control dial (1). In this condition,
engine throttle controller (2). From engine the starting motor is cranked and the engine
throttle controller (2), the signal is output to starts when the starting switch is turned.
governor motor (3), and governor motor (3) If starting switch (5) is turned to the OFF posi-
operates the linkage to move the lever of en- tion when the engine is running, governor
gine fuel injection pump (4). In this way, the motor (3) moves the lever of the injection
engine speed is set by the position of fuel pump to the engine stop position. Even when
control dial (1). the starting switch is turned to the OFF posi-
. If starting switch (5) is not at the ON position, tion, power cut relay (6) continues to function
engine throttle controller (2) is not actuated, so that electricity is supplied to engine throt-
so the engine cannot be started simply with tle controller (2). After the engine is stopped,
fuel control dial (1). engine throttle controller (2) stops the signal
output from power cut relay (6) to stop the
supply of power to engine throttle controller
(2).
1O-259
OPERATION OF SYSTEM
Starting engine
l When the starting switch is turned to the
START position, the starting signal is sent to
the starting motor. The starting motor then
rotates and the engine starts.
When this happens, the engine throttle con-
troller confirms the signal voltage from the
fuel control dial and sets the engine speed to
the set speed.
Governor motor
SKDCO2S7
Engine speed control

Fuel control dial
l The fuel control dial sends a signal voltage to
the engine throttle controller according to the
angle (position) of the dial.
The engine throttle controller uses this signal
voltage to calculate the angle (position) of the
governor motor, and drives the governor
motor to that angle (position).
When this happens, the actuation angle of
the governor motor is detected by the
potentiometer to observe the governor mo-
tor. vemor motor
Stopping engine
. If the engine throttle controller detects that
.I_. - ..._.I._. ,-
n
-kI*1
_ Stating switch
the starting switch is at the STOP position, it

drives the governor motor so that the gover-
nor is at the NO INJECTION angle (position),
and stops the engine.
l When this happens, to ensure the electric
power inside the system until the engine com-
pletely stops, the engine throttle controller it-
self drives the battery relay.
Governor motor
1O-260
ENGINE THROTTLE CONTROLLER
Red lamp flashes

when normal
CN,SMl
SYD00347
Input/ output signals

CN-SMI
No. Name of signal

Input/
output
No. Name of signal
I Input/
output I
1. Chassis power source (24V) Input 12.1 GND I Input I
1 2. 1Chassis power source (24V) 1 lnPut 1 13. Battery relay output I output I
-
I 5. I Potentiometer power source (5V) I output 1
6. Starting switch ON signal (ACC) input 17. I Governor motor potentiometer signal I Input I
7. Fuel control dial Input
I 8. I Model selection I I but I

9. Model selection 3 Input
10. Motor drive A (+) output 21. Motor drive B (-1 1output 1
11. Motor drive B (+) output
lo-261
CONTROL FUNCTION OF ENGINE

(Input signal) (Output signal)
THROTTLE CONTROLLER
. The engine throttle controller receives the in-
put signals shown in the diagram on the right,
internally processes them, then sends an out-
put signal to the governor motor and battery
relay.
0
Gwemorpatenticmater,,~ ,, _ Battery relay
I,
@otwwmmsignal) (drive signal)
SAD00290
, Governor controller outwt characteristics

11 Engine speed setting function using fuel con-
trol dial.
The controller sends an output signal so that
rotation angle b of the governor motor
matches input voltage a for the angle of the
fuel control dial. Rotation angle b is fed back
to the controller by the potentiometer signal,
and the actuation of the governor motor is
always observed.
2) Engine stop function using starting switch

signal
When the starting switch is turned to the OFF
position, the engine throttle controller detects
this and drives the battery relay to provide
the electric power. At the same time, it drives
the governor motor and returns the injection
pump lever to the STOP position.
lo-262
Internal structure of engine throttle controller

. The inside of the controller consists of the
input circuit, microcomputer, and drive circuit
as shown in the diagram on the right. Each
of these parts has the following function.
I) Input circuit
e G
This receives the signals from the fuel control
I _ ----_--
dial (throttle signal) and starting switch (start
signal), and sends these to the microcomputer. SYD00350
In this portion, the noise is removed from the
signal and the wave pattern of the signal is
regulated.
It also provides the electric power (approx.
5V) for the fuel control dial and governor
potentiometer.
21 Microcomputer
This calculates the governor motor angle from
the input signal sent from the input circuit,
and sends the governor motor drive pulse
signal to the drive circuit.
s
E 3) Drive circuit
z The direction of flow of electricity to the gov-
ernor motor is switched by the pulse signal
sent from the microcomputer to rotate the
motor clockwise or counterclockwise.
Note: Self-diagnostic function
If any abnormality occurs in the elec-
tric system, a signal is sent to the HMT
controller to display the system which
has the failure.
1 O-263
FUEL CONTROL DIAL

1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
HIGH A-!
6. Connector
Front of machin
1
Low A--cl
6 Jf!!
A-A
2
e’
i
3
a2
Structure
R
1
of circuit
lo 0
EI
3 SYDOO351
(%)
Hi
100
Function
. There is a potentiometer installed under the u
knob, and when the knob is turned, the F
m
potentiometer shaft also rotates. This rota-
tion changes the resistance value of the vari-
able resistor inside the potentiometer 5
and ::
sends the desired throttle signal to the engine a
throttle controller. t7M I I tzm )
The hatched area in the graph on the right is 0 0.25 1 4 4.75 5 Voltage(V)
Throttle voltage characteristics
the abnormality detection area, and the en-
gine speed is set to low idling. SYD00352
lo-264
GOVERNOR MOTOR
1. Potentiometer
2. Cover
3. Shaft
4. Dust seal
5. Bearing
6. Motor
7. Gear
8. Connector
A-A
\
8 SYWO353
Function Operation
l The motor is rotated by the drive signal from When motor is stopped
the engine throttle controller and controls the . Electricity passes through both the A phase
governor lever of the fuel injection pump. and B phase of the motor.
. The motor, which is the power source, em-
ploys a stepping motor. Motor rotating
In addition, a feedback potentiometer is in- . A pulse current is applied to the A phase and
stalled to observe the actuation of the motor. B phase by the engine throttle controller and
. The rotation of the motor passes through the the motor rotates synchronously with the
gear and is transmitted to the potentiometer. pulse.
1 O-265
HMT CONTROL SYSTEM
%I. For Serial No. : 60807 and up

HMT CONTROL SYSTEM
SYSTEM EQUIPMENT LOCATION DIAGRAM
25. Joystick (steering stroke)

signal 2 potentiometer
26. Joystick (directional change stroke)
27. Joystick
28. Speed max. button
42 (For Serial No. : 60001 - 60806)
43 signal 1 potentiometer
30. FORWARD max. speed setter
31. REVERSE max. speed setter
44 32. REVERSE max. speed setter
potentiometer
45 33. FORWARD max. speed setter
potentiometer
46 34. Engine throttle controller
/ \ 35. Parking detection limit switch
48 Z
-47 SWD0.2422
36. Governor motor
37. HMT controller
38. 2nd selection detection switch
39. REVERSE selection detection switch
40. FORWARD selection detection switch
17. HMT motor solenoid valve B 41. FORWARD selection solenoid valve
1. Right steering solenoid 9. Brake pedal potentiometer
18. HMT 42. 2nd selection solenoid valve
2. EPC solenoid valve assembly 10. Throttle potentiometer
3. Left steering solenoid 19. HMT pump solenoid valve B 43. 1st selection detection switch
11. Brake valve solenoid
20. HMT pump solenoid valve A 44. 3rd selection detection switch
4. PPC, EPC, HMT charge valve 12. HSS motor
21. HMT pump 45. 1st selection solenoid valve
5. PPC, EPC, HMT charge filter 13. Brake valve
22. Engine speed sensor 46. 3rd selection solenoid valve
6. HMT charge pressure sensor 14. HMT motor speed sensor
23. Engine flywheel housing 47. REVERSE selection solenoid valve
7. Power train pump 15. HMT motor solenoid valve A
8. Power train oil temperature sensor 24. Joystick (directional change stroke) signal 1 potentiometer 48. HMT control valve
16. HMT motor
1 O-266
a
STRUCTURE AND FUNCTION HMT CONTROL SYSTEM
EQUIPMENT AND FUNCTIONS

: 60001 - 60806
Serial No.
Name of signal Equipment used Function Details of control Name of actuator Equipment used
Detects angle of engine throttle and HMT pump solenoid A

Potentiometer
Throttle signal sets target engine speed according to Output signal to move HMT pump,
(analog) HMT pump solenoid B
b motor swash plate angle and change Solenoid proportional valve
pump delivery HMT motor solenoid A
Potentiometer vents unnecessary movement of pump HMT motor solenoid B

Brake pedal signal
(analog) swash plate and prevents pressure in
closed circuit from going down Solenoid input/output signal to switch
F selector solenoid valve
b oil pressure of F clutch ON u OFF
Directional change stroke I
signal 1
Potentiometer Command signal to move machine
I t I
b Solenoid input/output signal to switch
Directional change stroke (analog) forward or in reverse R selector solenoid valve
oil pressure of R clutch ON H OFF
signal 2
Solenoid input/output signal to switch Solenoid valve
Steering lever signal 1 Command signal to determine left or 1st selector solenoid valve
Potentiometer oil pressure of 1st clutch ON H OFF (ONttOFF)
right turn when steering is operated l.
(analog) I
Steering lever signal 2 I
Solenoid input/output signal to switch
FORWARD max. speed set- 2nd selector solenoid valve
oil pressure of 2nd clutch ON e OFF
ter signal Potentiometer Signal to set optimum travel speed
. .
REVERSE max. speed set- (analog) when traveling forward or in reverse Solenoid input/output signal to switch
3rd selector solenoid valve
ter signal b oil pressure of 3rd clutch ON w OFF
HMT
Signal to switch between limited travel controller
High/low selector switch Contact type (knob switch) Output signal to determine stroke of Left steeringEpCvalve
speed set by max. speed setter and . .
signal (ONHOFF) b EPC valve to match steering lever po- - Solenoid proportional valve
max. travel speed Right steering EPC valve
sition
Parking brake lever signal 1 Signal to judge if parking brake is ON Auxiliary brake output signal to stop
Limit switch Solenoid valve
or OFF and to determine if to allow machine when direction is switched,
(ON-OFF) Brake valve solenoid
engine to start brake output signal when clutch is fully (ONHOFF)
Parking brake lever signal 2
disengaged
Engine speed signal 1 Signal to detect actual engine speed Output signal to prevent engine from
Electromagnetic pickup starting when levers are not at neutral
and control swash plate angle of HMT Neutral relay
(pulse) position or parking brake lever is not
Engine speed signal 2 pump and motor
at LOCK position
Stepping motor Signal to detect actual motor speed

HMT motor speed signal Output signal to sound backup alarm
(pulse) compared with target motor speed
bd when in reverse 1 Backupa’arm re’ay 1
Transmission F-R signal Relay output signal to cut electric Relay
Contact type 1st power source cut relay (ONtiOFF)
and detect if oil pressure is entering D power when 1st solenoid is shorted
Transmission lst, 2nd, 3rd (ONHOFF)
signal Relay output signal to cut electric 2nd,3rd F,R power SOurce
b power when 2nd/3rd. FIR solenoid is cut relay
shorted
Signal to detect if oil is being supplied
Pressure switch
HMT charge pressure signal properly to HMT pump, motor closed Warning output signal to warn opera-
(ON-OFF)
““”
tor when HMT pump, motor has ex- Overrun warning relay
ceeded speed limit
Signal to change HMT pump or motor Output signal to warn of abnormal-

Power train oil temperature Thermistor control (prevent gear shift shock) be- * ity in HMT charge pressure
signal (analog) cause modulating pressure is applied
Engine Monitor panel
due to change in oil temperature Output signal to warn of abnormal-
throttle
b ity in HMT controller, engine throttle
controller
Power source controller
Serial No. : 60807 and UD

Name of signal Equipment used Function Details of control Name of actuator Equipment used
Detects angle of engine throttle and HMT pump solenoid A

Potentiometer
Throttle signal sets target engine speed according to Output signal to move HMT pump, HMT pump solenoid B
(analog)
that angle b motor swash plate angle and change Solenoid proportional valve
pump delivery HMT motor solenoid A
When brake pedal is operated, it pre-
Potentiometer vents unnecessary movement of pump HMT motor solenoid B
Brake pedal signal
(analog) swash plate and prevents pressure in
closed circuit from going down Solenoid input/output signal to switch F selector solenoid valve
l oil pressure of F clutch ON ti OFF
Directional change stroke I I ! _
signal 1
Potentiometer Command signal to move machine b Solenoid input/output signal to switch
(analog) forward or in reverse R selector solenoid valve
Directional change stroke oil pressure of R clutch ON ++ OFF
signal 2 I I
Solenoid input/output signal to switch Solenoid valve
Steering lever signal 1 Command signal to determine left or 1st selector solenoid valve (ON++OFF)
Potentiometer oil pressure of 1st clutch ON t) OFF
(analog) right turn when steering is operated
Steering lever signal 2 I I I
Solenoid input/output signal to switch

-ORWARD max. speed set- 2nd selector solenoid valve
oil pressure of 2nd clutch ON tj OFF
:er signal Potentiometer Signal to set optimum travel speed
I !
qEVEl?SE max. speed set- (analog) when traveling forward or in reverse Solenoid input/output signal to switch
3rd selector solenoid valve
:er signal l oil pressure of 3rd clutch ON t) OFF
HMT
controller Output signal to determine stroke of Left steering EPC vah,e
Parking brake lever signal 1 b EPC valve to match steering lever po- Solenoid proportional valve
Signal to judge if parking brake is ON sition Right steering EPC valve
Limit switch
or OFF and to determine if to allow
(ONtlOFF) Auxiliary brake output signal to stop
engine to start Solenoid valve
machine when direction is switched,
Parking brake lever signal 2 Brake valve solenoid
brake output signal when clutch is fully (ONtiOFF)
disengaged
Engine speed signal 1 Output signal to prevent engine from

Signal to detect actual engine speed
Electromagnetic pickup starting when levers are not at neutral
and control swash plate angle of HMT Neutral relay
(pulse) position or parking brake lever is not
Engine speed signal 2 pump and motor
at LOCK position
Stepping motor Signal to detect actual motor speed

-lMT motor speed signal Output signal to sound backup alarm
(pulse) compared with target motor speed Backup alarm relay
when in reverse
Relay
Transmission F-R signal Signal to detect position of each spool Relay output signal to cut electric
Contact type 1st power source cut relay (ON-OFF)
and detect if oil pressure is entering b power when 1st solenoid is shorted
rransmission 1st. 2nd, 3rd (ONtiOFF) I I I
determined speed range
signal Relay output signal to cut electric 2nd13rd F/R power SOurce
b power when 2nd/3rd, F/R solenoid is CUt relay
shorted
Signal to detect if oil is being supplied 1
Pressure switch
iMT charge pressure signal (ON_OFFI properly to HMT pump, motor closed Warning output signal to warn opera-
circuit tor when HMT pump, motor has ex- Overrun warning relay
ceeded speed limit
I
Signal to change HMT pump or motor Output signal to warn of abnormal-
Power train oil temperature Thermistor control (prevent gear shift shock) be- , / , 1 ‘-4 ity in HMT charge pressure 1
signal (analog) cause modulating pressure is applied
Engine Monitor panel
due to change in oil temperature Output signal to warn of abnormal-
1 I
ity in HMT controller, engine throttle
‘-1 controller
Power source
1O-268
0
EXPLANATION OF SYSTEM
a) Directional, gear shift, acceleration, deceleration system
Serial No. : 60001 - 60806
Clutch selection detection switch

I IYI II
I,
HMT pump solenoid
_
//
(F.R-123) //
/I HMT motor solenoid
I,
// u
x //
Engine throttle potentiometer I,
I,
I, HMT control valve
,, I
k HMTcontroller I,II solenoid
II I, (F,R 1,2,3)
Engine speed sensor I, I, l
I,
I,
I,
II
HMT motor speed sensor Monk panel Alarm buzzer

//
I/
I EPC valve solenoid I I
II
I Power source I, SDD00225
Outline
. The HMT control system has as its basic If there should be any failure in the above
function the functions of shifting between input signal and output signal system, it also
forward and reverse, shifting gear, and ac- functions to limit the movement of the ma-
celerating or decelerating in each speed chine according to the condition of the fail-
range. The input signals consist of input ure.
signals from the operator when the joystick If there is any abnormality in the joystick
(directional change stroke), max. speed set- (steering stroke) input signal or EPC sole-
ter, and speed max. button switch are oper- noid output signal, it also functions to limit
ated, and the machine condition signals from the movement of the machine according to
the clutch selection detection switch, engine the condition.
throttle potentiometer, engine speed sen- The abnormality information is connected
sor, HMT motor speed sensor, and power to the monitor panel and alarm buzzer, and
train oil temperature sensor. The HMT con- the warning lamp (which shows the abnor-
trol valve solenoids, HMT pump solenoid mality condition of each signal) and the
and HMT motor solenoid are actuated by alarm buzzer are actuated to warn the op-
these to automatically control the gear shift- erator.
ing and acceleration or deceleration accord-
ing to the load.
10-268-l
0
Serial No. : 60807 and up
F-J
Joystick (directional chanae storke)
I/
II
I, HMT PUMP solenoid
Clutch selection detection switch + 1 I
(F, rf. 1I 2. 31
I/
I,
II HMT motor solenoid
I
Engine throttle potentiometer 7+ /I
HMT control valve
HMT control Ier
HMT motor speed sensor
I, ,,
Power train oil temperature sensor I, 1st Power cut relay 8
!!
&
0
2nd.3rd Power cut relay
I,
I,
I,
I EPC valve solenoid I II
Power source
I,
I,
SW002427
Outline
l The HMT control system has as its basic If there should be any failure in the above
function the functions of shifting between input signal and output signal system, it also
forward and reverse, shifting gear, and ac- functions to limit the movement of the ma-
celerating or decelerating in each speed chine according to the condition of the fail-
range. The input signals consist of input ure.
signals from the operator when the joystick If there is any abnormality in the joystick
(directional change stroke) and max. speed (steering stroke) input signal or EPC sole-
setter are operated, and the machine condi- noid output signal, it also functions to limit
tion signals from the clutch selection detec- the movement of the machine according to
tion switch, engine throttle potentiometer, the condition.
engine speed sensor, HMT motor speed sen- The abnormality information is connected
sor, and power train oil temperature sen- to the monitor panel and alarm buzzer, and
sor. The HMT control valve solenoids, HMT the warning lamp (which shows the abnor-
pump solenoid and HMT motor solenoid are mality condition of each signal) and the
actuated by these to automatically control alarm buzzer are actuated to warn the op-
the gear shifting and acceleration or decelerator.
eration according to the load.
10-268-2
a
b) Steering system
I,
1
hyt_k (steering I, - EPC valve
HMT controller
-- solenoid
HSS motor
//
t
HSS pump
SDD00226
Outline
l The signals input by the joystick (steering
stroke) are changed to signals enabling con-
trol of the steering control EPC valve sole-
noid, and are output to set the turning speed
according to the position of the joystick in
steering stroke.
. From the EPC valve, there is a hydraulic con-
nection to the control valve and HSS pump.
1 O-269
cl Brake system
Monitorpanel
Power source
I
t
Joystick (directional e Brake valve
change stroke) --U-- solenoid
I I,I, * HMT controller

I r---+4 I
Max. speed setter
LA+-4
I I
I,
I,
[I 1
d b SDD00227
8
E
Outline
The brake valve solenoid is actuated by the HMT output to actuate the brake valve solenoid.
system in the following four ways. Note: The brake valve solenoid is connected
. When the joystick is at neutral in directional hydraulically to the brake valve.
change stroke, an output signal is output to
actuate the brake valve solenoid according to
the input signal in order to stop the machine
securely.
. When switching between forward and reverse,
an output signal is output to actuate the brake
valve solenoid while there is a difference be-
tween the direction of travel of the machine
and the position of the joystick in order to
stop the machine quickly and enable the ma-
chine to start off smoothly after the direction
is changed.
. When traveling downhill, if the machine travel
speed is reduced by the max. speed setter, an
output signal is output to actuate the brake
valve solenoid as an auxiliary brake.
. To prevent the engine from stalling, when the
engine speed has suddenly dropped and is
near the low idling speed, all the HMT clutches
may be disengaged. To stop the machine
temporarily in such a case, an output signal is
1 O-270
d) Engine start system

Serial No. 60001 - 60279
Power source
Starting switch //
Starting motor +
safety relay
r/
Starting motor
SDD00228
Outline
l The parking detection limit switch is installed ment raised and the work equipment control
near the safety lever (parking lever). When lever still at the FLOAT position, there is dan-
the safety lever is not at the LOCK position ger that the work equipment will fall. To pre-
and the joystick (both in directional change vent this, a limit switch is provided to detect
and steering strokes) is not at the neutral po- the FLOAT position and prevent the engine
sition, there is danger that the machine may from being started.
move if the engine is started. To prevent this, If the work equipment safety lever is set to
electric current flows from the neutral safety the LOCK position, the work equipment (blade)
relay to the HMT controller, the neutral safety control lever is automatically returned to the
relay contacts open, and the engine is con- HOLD position, and the detection switch is
trolled by the HMT controller so that it cannot canceled to make it possible to start the en-
start. gine.
The neutral safety relay is also connected to Note: To provide a safety backup, there are
the proximity switch relay. two parking detection switches, and if
l There is a detent in the FLOAT position for any abnormality occurs in either of the
the work equipment control lever to make it two switches, an error is displayed by
possible to hold the control lever in position. the HMT controller.
If the engine is started with the work equip-
lo-271
@
Serial No. 60280 and up
Safety lever Parking detection

limit switch 1 Neutral
0 -H-
safety relay
0 I HMT
controler
I
Parking detection -
limit switch II c/Y-
0
0 I I/
I ’ I I
Starting motor
safety relay
Starting motor
1 Starting switch 1
SAD01 505
Outline
l The parking detection limit switch is installed Note: To provide a safety backup, there are
near the safety lever (parking lever). When two parking detection switches, and
the safety lever is not at the LOCK position if any abnormality occurs in either of
and the joystick (both in directional change the two switches, an error is displayed
and steering strokes) is not at the neutral by the HMT controller.
position, there is danger that the machine
may move if the engine is started. To pre-
vent this, electric current flows from the
neutral safety relay to the HMT controller,
the neutral safety relay contacts open, and
the engine is controlled by the HMT con-
troller so that it cannot start.
The neutral safety relay is also connected to
the proximity switch relay.
10-271-l
63
e) Alarm system and other systems
HMT
chatx2epiessuresensor HMTcontmller A!armtxQzef
Brake pedal
HMTpumpso!enoii
potentiometer
EnginethmtUeconiml!er
Sensors, actuators
1 Power source I,I/
Outline
. The HMT pump and motor form a closed cir- . If any abnormality should occur in any sensor
cuit, so oil is constantly supplied to the closed or actuator (solenoid valve, etc.) or the HMT
circuit by the charge pump to compensate for controller, the condition is output if necessary
any internal leakage. If the amount supplied through the HMT controller to the monitor
becomes low, there is danger of breakage of panel warning lamp and alarm buzzer to warn
the pump or motor, so a sensor is installed to the operator of the abnormality.
detect the charge pressure. l The nature of the abnormality is displayed on
If the charge pressure drops below the set the HMT controller display using letters and
pressure, a signal is sent from the HMT charge numbers.
pressure sensor to the HMT controller, the . A brake pedal potentiometer is installed to
caution and warning lamps on the monitor the brake pedal, and when the brake pedal is
panel light up and the alarm buzzer sounds to being depressed, there is no need for the HMT
warn the operator of the condition. pump to set the swash plate to the full angle.
. If any abnormality should occur in the engine Therefore, the input signal from the brake
throttle controller of the engine control sys- pedal otentiometer is used to control the HMT
tem, the signal showing the condition passes pump solenoid valve and restrict the move-
through the HMT controller and is output to ment of the HMT pump swash plate.
the monitor panel warning lamp and alarm
buzzer to inform the operator of the abnor-
mality.
lo-272
HMT CONTROLLER
1. Display window
2. Connector
CNl CN2 CN3 SDD00230
1 O-273
HMT CONTROL SYSTEM EQUIPMENT

THROTTLE SIGNAL POTENTIOMETER
BRAKE PEDAL SIGNAL POTENTIOMETER
1. Potentiometer
2. Shaft
3. Connector
circuit
?&DO0231
Function
. The throttle signal potentiometer is joined by detects the opening angle of the engine throt-
a link to the intermediate lever of the fuel tle from this voltage.
control linkage. When the fuel injection pump The brake pedal signal potentiometer is in-
lever moves, shaft (2) rotates and changes stalled to the support shaft of the brake pedal.
the resistance value. A fixed voltage is ap- When the brake pedal is depressed, shaft (2)
plied between pins 1 and 3, and a voltage is rotates and changes the resistance value. A
sent to the HMT controller according to the fixed voltage is applied between pins 1 and 3,
movement (opening angle of the throttle) of and a voltage is sent to the HMT controller
the injection pump lever. The HMT controller according to the angle to which the pedal is
depressed. zz
X
JOYSTlCK POTENTIOMETER (DIRECTIONAL CHANGE STROKE SIGNALS 1.2) z

JOYSTlCK POTENTIOMETER (STEERING STROKE SIGNALS 1,2)
1I. Joystick (steering stroke)

FAR ’ h signal 2 potentiometer
3. Joystick (directional change
1 stroke) signal 1
potentiometer
I SW I Pot1 Pot2 Pot3 Pot4
4. Joystick (directional change
PO
stroke) signal 2
lJ+jl~~~~
potentiometer
%I. For Serial No.: 60001- ‘60806
Structure of circuit SWD02428
Function
l These potentiometers are installed to the joy- When the joystick is moved to the left or right,
stick. When the joystick is moved forward, steering stroke potentiometers (I) and (2) ro-
directional change stroke potentiometers (3) tate and change the resistance value. A fixed
and (4) rotate and change the resistance value. voltage is applied between pins @ and @,
A fixed voltage is applied between pins @ and @ and @, and the voltage is sent to the
and @, and @ and 0, and the voltage is sent HMT controller according to the amount of
to the HMT controller according to the move- movement in steering stroke.
ment of the lever. To provide a safety backup, two potentio-
meters each are installed.
1 O-274
a
FORWARD MAX. SPEED SElTER POTENTIOMETER

(FORWARD MAX. SPEED SElTER SIGNAL)
1. Lining
2. Knob
3. Plate
6 5 4. Arm assembly
5. Shaft
circuit 6. Potentiometer
SDD00233
7. Connector
Function
. This potentiometer is installed to the max. and a voltage is sent to the HMT controller
speed setter (FORWARD). When the lever is according to the angle of the lever. This volt-
moved, shaft (5) of the potentiometer rotate age value is used to set the travel speed to
and changes the resistance value. A fixed match the lever position.
voltage is applied between terminals 1 and 2,
REVERSE MAX. SPEED SElTER POTENTIOMETER

(REVERSE MAX. SPEED SElTER SIGNAL)
1. Knob
2. Lining
a
OSR ,
3. Potentiometer
3
0.58 2 4. Shaft
Structure of 5. Arm assembly
2&=&---~
3
circuit 6. Plate
7. Connector
Function
. This potentiometer is installed to the max. and a voltage is sent to the HMT controller
speed setter (REVERSE). When the lever is according to the angle of the lever. This volt-
moved, shaft (4) of the potentiometer rotate age value is used to set the travel speed to
and changes the resistance value. A fixed match the lever position.
voltage is applied between terminals 1 and 2,
1 O-275
SPEED MAX. BUlTON (HIGH/LOW SELECTOR SWITCH SIGNAL)

For Serial No. : 60001 - 60806
1. Switch
2. Knob
3. Insert
4. Insert
Structure of
circuit
SDD00235
Function
. This button is installed to the tip of the joy- l This switching is possible only when the joy-
stick. When the button is pressed, the circuit stick is at the FORWARD or REVERSE posi-
is turned ON, and when it is pressed again, tion. When it is at the neutral position, the
the circuit is turned OFF. When the button is maximum speed is returned automatically to 8
turned ON, the HMT controller overrides the the value set by the max. speed setter. 5
. When the starting switch is turned from the Z
machine travel speed limitation set by the max.
speed setter; when it is turned OFF, the HMT OFF position to the ON position, the maxi-
controller reactivates the maximum travel mum speed is set to the default speed (the
speed limitation. speed set by the max. speed setter).
PARKING DETECTION LIMIT SWITCH (PARKING BRAKE LEVER SIGNALS I,21
1. Roller
5 2 2. Stopper
3. Diaphragm
3 0.758
4. Microswitch
5. Plug
4 6. Plunger
=*
7. Connector
6 Structure of circuit
Function
l This switch is installed to the governor motor the circuit is closed, and a signal is sent to the
bracket on the left side of the floor frame. It is HMT controller to show that the parking brake
joined to the parking brake lever (safety lever) is being actuated. For safety backup, there
by a link, and when it is at the LOCK position, are two switches installed.
lo-276
a
ENGINE SPEED SENSOR,

(ENGINE SPEED SIGNALS 1.2)
1. Magnet
c 0.75fG
0.75fB
,
SYD00354
2.
3.
4.
5.
Terminal
Case
Boot
Connector
Function
l This sensor is installed to the top left of the pulse as a pulse signal to the HMT controller.
engine flywheel. It generates electricity from The HMT controller counts these pulses and
the change in magnetism created as the en- calculates the engine speed.
gine flywheel gear passes, and sends this
8
HMT MOTOR ROTATION SENSOR (HMT MOTOR ROTATION SIGNAL)
2
z
1. Shaft
2. Sensor
3. Connector
(red) 3
alblcld 1 I I
T Structure of circuit
L
Output wave shape SED00237
Function
. This sensor is installed to the opposite side of . The HMT controller counts these pulses and
the HMT motor shaft. When the HMT motor calculates the rotating speed of the motor.
rotates, shaft (I) rotates. There is a perma- The electric current generated in coils A and B
nent magnet buried in the shaft, and electric- is offset in phases as shown in the diagram.
ity (AC) is generated in coil A and B. This The controller judges the direction of rotation
electricity is sent to the HMT controller as a from this offset.
pulse signal.
1 O-277
CLUTCH SELECTION DETECTION SWITCH

(F, R SPOOL SIGNAL)
(1st. 2nd, 3rd SPOOL SIGNAL)
777
Function 1. Terminal
l This switch is installed to the HMT control 2. Case
valve. When the tip of this spool contacts the 3. Nut
switch terminal, the switch is turned ON and 4. Connector
a signal is sent to the HMT controller to show
that the spool has moved.
HMT PRESSURE SENSOR

(HMT CHARGE PRESSURE SIGNAL)
1. Switch
Function
. 2. Case
This is installed to the PPC, EPC, HMT charge
3. Wire
valve outlet port. When the charge pressure
4. Connector
goes below the set pressure, switch (I) is
turned OFF. The monitor panel display and
warning lamp flash and the alarm buzzer
sounds.
1 O-278
POWER TRAIN OIL TEMPERATURE SENSOR
1. Connector
2. Plug
3. Thermistor
-
Structure of circuit SYDO0356
Function
l This sensor is installed in the circuit from the
HMT control valve to the oil cooler. It sends
the change in the oil temperature to the HMT
controller to change the control of the HMT
pump and motor to prevent shock when shift-
ing gear.
8
5
z TRANSMISSION F, R SELECTION SOLENOID VALVE
TRANSMISSION IST, 2ND, 3RD SELECTION SOLENOID VALVE
1. Nut
2. Core assembly
3. Coil assembly
4. Plunger
5. Spring
6. Pin
7. Spring
8. Valve seat
9. Body
10. Connector
11. Screen
Es
0 0
$
O&O
00 Structure of circuit
0 0
Function
l The command voltage from the HMT control-
ler is used to turn the pilot pressure ON and
OFF to actuate the speed range spool. When
electricity is flowing, the spool is actuated.
lo-279
HMT PUMP PROPORTIONAL VALVES A, B

HMT MOTOR PROPORTIONAL VALVES A, B
1. Case
2. Coil
3. Shaft
4. Plunger
5. Sleeve
6. Filter
7. Connector
‘7
c
6 5
Function 8
. The HMT pump proportional solenoid valve two proportional solenoids. 5
is actuated by the command current from the l The HMT motor proportional solenoid valve z
HMT controller and pushes the pilot valve of is actuated by the command current from the
the HMT pump servo valve to change the HMT controller and pushes the pilot valve of
swash plate angle of the pump. The pump the HMT motor servo valve to change the
swash plate angle becomes larger in propor- swash plate angle of the motor. The motor
tion to the current and the pump delivery is swash plate angle becomes smaller in pro-
increased. The pump discharges oil in the portion to the current and the volume of the
normal and reverse directions, so there are motor is reduced.
EPC SOLENOID VALVE
1. Spool
2. Spring
3. Coil
4. Spring
c
SDDO0239
Function
. The EPC output pressure is generated in pro-
portion to the command current from the HMT
controller. It outputs the pilot pressure to the
main control valve (steering).
1 O-280
BRAKE VALVE SOLENOID VALVE
1. Cover
2. Coil
3. Spring
4. Plunger
5. Valve seat holder
6. Valve seat
7. Spring
8. Valve seat
9. Cap
10. Connector
fL J 11. Cable
A. From pump
b
B. To brake valve
C. To brake
SYD00398
Function
. This valve uses the command voltage from
the HMT controller to turn the oil pressure to
s the brake valve ON or OFF. When electric
5 current flows to the brake valve solenoid, the
z brake is released, and when the flow of elec-
tricity stops, the brake is applied. (For details,
see STRUCTURE AND FUNCTION, BRAKE
VALVE.)
RELAYS
Relay to ensure safety when

Neutral relay
starting engine
Backup alarm relay Relay to drive backup alarm
Relay to cut power when abnor-

1st power cut relay
maky occurs in 1st power
1 I Relay to cut power when ab-

Znd, 3rd, F, R power
Structure of circuit normality occurs in Znd, 3rd,
cut relay
SED00240 F, R power circuit.
Function
Relay to output signal to moni-
l The relays use the command voltage from Overrun warning re-
tor panel circuit (overrun warn-
the HMT controller to open or close the con- lay
ing display)
tacts of the electric circuit.
lo-281
20 TESTING AND ADJUSTING
STANDARD VALUE TABLES ................................................................................................................. .20- 2

Standard value table for engine related parts ............................................................................... .20- 2
Standard value table for chassis related parts.. ............................................................................. .20- 3
Standard value table for electrical parts .......................................................................................... 20- 7
Standard value table for machine monitor.. ................................................................................... .20- 14
TESTING AND ADJUSTING .................................................................................................................. .20-101
TROUBLESHOOTING .............................................................................................................................. 20-201
Ir The following precautions are necessary when using the standard value tables for testing and adjusting, or
for troubleshooting.
1. The values in the table are for new machines, and are obtained from reference to values when shipping from
the factory. Therefore, they should be used as target values for judging the progress of wear, or when
repairing the machine.
2. The standard values for judging failures are based on the results of various tests when shipping the machine
from the factory. These values should be used as reference together with the repair condition and operating
record of the machine to make judgements on failures.
3. The values in the table should not be used for judging claims.
a When carrying out testing,

pins and block the tracks.
adjusting or troubleshooting, stop the machine on level ground, install the safety
When carrying out work together with other workers, use agreed signals and do not allow unauthorized
a
persons near the machine.
A When checking the water level, always wait for the water to cool down. If the radiator cap is removed when
the water is still hot, the water will spurt out and cause burns.
A Be careful not to get caught in the fan or other rotating parts.
20-l
0
STANDARD VALUE TABLE STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS

Serial No. : 60001 - 60271
Engine T S6D140-1
Standard value for Service limit value

Item Measurement conditions Unit
new machine
High idling 2,050 + 50 2,050+50

Engine speed Low idling rpm 700 5 50 700 + 50
Rated speed 1.900 -
)
Exhaust temperature Whole speed range
(turbocharger inlet port (ambient temperature: “C
temperature) 20°C)
kPa
Air supply pressure At rated output
mmHc
At sudden acceleration Bosch Max. 6.0 Max. 8.0
Exhaust gas color
At high idling index Max. 1.0 Max. 2.0
Valve clearance Intake valve 0.43 -

mm
(normal temperature) Exhaust valve 0.8 -
Oil temperature:
Compression pressure 40 - 60°C MPa Min 3.14 Min 2.16
(SAESO oil) Engine speed: :Kglcm’ IMin321 {Min 221
200 - 250 rpm
(Water temperature:
Blow-by pressure kPa Max. 0.98 Max. 1.96
Operating range)
(SAE30 oil) mmHX {Max. 1001 {Max. 2001
At rated output
(Water temperature:
Operating range)
Ei
At rated output 0.29 - 0.49 Min 0.2
(SAE30) {3.0 - 5.01 {Min 2.01
At low idling MPa 0.1 - 2.67 Min 0.07
Oil pressure Kg/cmi 1
(SAE30) {I .O - 27.2) IMin 0.7}
(SAEIOW) 12.5 - 4.51 IMinl.81
At low idling Min 0.1 Min 0.07
(SAEIOW) {Min l.O} {Min 0.71
Whole speed range

Oil temperature “C 80- 110 120
(inside oil pan)
Fuel injection timing Before top dead center 0

27 2 1 27 2 1
Deflection when pressed

Alternator belt tension with finger force of 15 -
approx. 59 N (6 kg)

Air conditioner compres- -
with finger force of approx. 10 I
sor belt tension approx. 59 N (6 kg)
mm
Fan belt tension -

Dimension A: 50 t 5
(auto tension)
20-2
a
STANDARD VALUE TABLE STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
Engine SAGDI 40-2
Standard value for Service limit value

Item 1fleasurement conditions Unit new machine
High idling 2,050 + 50 2,050+50

Engine speed Low idling rpm 700 _’ ‘0” 700 _’ ‘0”
Rated speed 1,900
Exhaust temperature Whole speed range

(turbocharger inlet port (ambient temperature: “C Max. 680 Max. 700
temperature) 20°C)
kPa Min. 85.3 Min. 67.9
Air supply pressure At rated output nmHg ,_ {Min. 6401 {Min. 5101
At sudden acceleration 3osch Max. 6.0 Max. 8.0
Exhaust gas color
At high idling index Max. 1.0 Max. 2.0
Valve clearance Intake valve 0.43

mm
(normal temperature) Exhaust valve 0.8
Oil temperature:
Compression pressure 40 - 60°C MPa Min 3.14 Min 2.16
(SAE30 oil) Engine speed: Wcm7 {Min321 {Min 221
200 - 250 rpm
(Water temperature:
Blow-by pressure kPa Max. 0.98 Max. 1.96
Operating range)
(SAE30 oil) nml+.Q) {Max. 1001 {Max. 200)
8 At rated output
5
(Water temperature:
z
Operating range)
(SAE30) (3.0 - 5.0) {Min 2.01
At low idling MPa 0.1 - 2.64 Min 0.07
Oil pressure
(SAESO) <s/cmZlt {I .O - 27.21 {Min 0.71
(SAEIOW) I2.5 - 4.51 IMinl.81
At low idling Min 0.1 Min 0.07
(SAEIOW) {Min 1.0) IMin 0.71
Whole speed range 120

Oil temperature “C 80- 110
(inside oil pan)
Fuel injection timing Before top dead center 0

12: g::g 12T ;::cJ
Alternator belt tension with finger force of 15
approx. 59 N (6 kg)

Air conditioner compres
with finger force of approx. 10
sor belt tension approx. 59 N (6 kg)
mm
Fan belt tension -

Dimension A: 50 2 5
(auto tension)
20-2-l
0
STANDARD VALUE TABLE STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Cat6 Standard value Service limit

Item Measurement conditions
son I Unit Ifor new machine value
l Engine oil pressure :
Within operating range
l Engine oil temperature :
Steering relief +
Within operating range
blade raise stall speed
l Hydraulic oil temperature : 45 - 55 “C
vm
Fuel control lever
Decelerator pedal
l Engine stopped 1st tf 2nd 13+ 5

Gear shift l Center of lever knob deg 132 5
2nd H 3rd 13 * 5
l Engine stopped 452 15 45It 15

Directional
l Center of lever knob
45+15 45+15
Total Right turn 85 2 25 85 = 25

travel
Left turn 85 2 25 85 + 25
l Engine at low idling
l Center of lever knob Until steering
clutch is com-
pletely disen- 37 37
gaged
Total travel 79* 10 79+ 10

l Engine at low idling Position until
Brake pedal
l Center of pedal brake oil pres-
sure becomes 0 61 61
mm
kg/cm*
HOLD + RAISE 80+ 15 805 15

Blade lever l Center of lever knob HOLD -$ LOWER
Serial No.: 60001 - 6027’ I l Hydraulic oil tem- 602 10 602 10
perature : 45 - 55°C HOLD +
Left, right tilt 52+ 10 52* 10
HOLD + RAISE 8Ok 15 802 15

Blade lever
: ;ydEu$ ;;;;$ob HOLD -+ LOWER 60 + 10 6Ok 10
perature : 45 - 55°C HOLD +
Left, right tilt 602 10 602 10
l Engine at low idling HOLD j RAISE 80+ 15 8Ok 15
Ripper lever l Center of lever knob
perature :‘45 - 55°C HoLD + LoWER
~
Fuel control lever
Decelerator pedal l Engine speed : low idling (850 2 5Orpm) 9;0’_29$I 147
Center of oedal I I + 1151
l
I
1st + 2nd
Y
0
2nd + 3rd
E Gear shift
0
-J 2nd + 1st
3rd -+ 2nd
Standard value Service limit

I for new machine value
3.04 k 0.29 2.64
Engine at low idling 1 131.0 2 3.0) 127.01
R clutch pressure
3.23 + 0.29 2.84
Engine at high idling 1 t33.0 + 3.01 129.0)
3.04 + 0.29 2.64
f31.0 f 3.01 i27.01
1st clutch pressure
3.23 -r-0.29 2.84
133.0 + 3.01 (29.01
Power train oil 3.04,* 0.29 2.64
Engine at low idling / f31.0 + 3.0) i27.01
2nd clutch pressure temperature:
70 - 80°C Engine at high idling 3.23 + 0.29 2.84
(33.0 + 3.01 l29.01
3.04 2 0.29 2.64
Engine at low idling 1 (31.0 f 3.01 (27.01
3rd clutch pressure
3.23 T 0.29 2.84
Engine at high idling 1 133.0 f 3.01 (29.0)
Transmission lubrica- 0.25 2 0.1 0.25 k 0.1
tion pressure {2.6 f 1.0) 12.6 + 1.0)
1.08 2 0.2 1.08 + 0.2
Transmission pilot (II.0 * 2.01 Ill.0 k 2.01
pressure 1.08 2 0.2 1.08 + 0.2
Engine at high idling
(Il.0 + 2.0) Ill.0 t 2.0)
HMT pump relief 41.2'-qa Min 36.26
pressure . Hydraulic oil temperature: 45 - 55°C
HMT charge pressure
~~~
Load sensing pressure
Power train oil

-. ._
l Engine at low idling i22.01
Brake actuating
temperature: 2.16
pressure
70 - 80°C Engine at high idling j22.01
PPC, HMT servo charge 0.29
Engine at high idling : 31 $F$
valve relief pressure
Steering relief pressure Engine at high idling 1 ’ ,._Jd” 1:: 201
1.96 :&Y
Engine at low idling 1 --~-
‘pi?: ! 20.58 * 0.98
Blade lift relief I LG.” +
- irII8 (210 2 101
pressure Hydraulic oil 20.58 2 0.98 20.58 f 0.98
temoerature: Ensine 1210 2 IO] I210 2 101
Blade tilt relief

pressure
. ““‘=I pg ; g8
; ys8
t 0.98
20.58
I210 2
20.58
1210
20.58
r 0.98
101
2
5
f
0.98
IO]
0.98
Ripper lift relief c IO) 1210 c IO]
pressure ‘“i.8 z yb98
I I &_.” _I: YJ8 +
l HIydraulic oil temperature: 45 - 55°C .I_ _
. Extend piston rod fully and discon- ivlax. j 12
nect hose at head end
cc/min Max. 2.7 11
l Engine at high idling
l Measure oil leakage during one -4
Max. 2.7 I I I
minute relief
20-4
@
Cate
YJn/
Item
‘ravel speed
.I Measurement
Level road surface

Engine at high idling
Engine water
temperature:
Within operating
range
conditions
FORWARD
1st - 3rd
Jnit
n/s
Standard value
lr new machine
0 - 11.2 + 0.6
iervice limit
value
0 - 11.2 2 0.6
Run-up distance:
REVERSE
IO-30 m 0 - 13.9 f 0.7 0 - 13.9 + 0.7
Measurement 1st - 3rd
distance: 20 m
3lade lift 200 250
TYDOOOOl
pHydraulic oil temperature: 46 - 55°C

* Engine stopped
bHydraulic drift at center of blade cutting
edge when raised 800 mm from grow I
150 200
31ade tilt
l Hydraulic TYDOOOO2
150 200
oil temperature: 45 - 55°C
0 Engine stopped
. Hvdraulic drift at edge of blade I
Work
Hydraulic driR
of chassis 80 80
. Hydraulic oil temperature: 45 - 55°C

l Engine stopped
l Hydraulic drift at center of idler with
blade pushed against ground
Work
eauioment
Hydraulic drif
of chassis 80 80
TYwooo4
l Hydraulic oil temperature: 45 - 55°C

l Engine stopped
l Hydraulic drift at center of sprocket
with ripper pushed against ground
20-5
0
Cate
go171
Item
T Work
Measurement conditions Unit
Standard value
x new machine
service limit
value
;%l,nt &j==g
~-//j-+-//f-l 3-5 3-5
A I
Blade (lift)
‘i L I I I
TYD00005
l Engine at high idling 1 - 1.5 1 - 1.5

l Hydraulic oil temperature:
45 - 55°C
l Blade: No load
l Ground level - Max. height
2.7 + 0.5 3.5
Blade (tilt)
BEngine at high idling TYD00006 2.3 f 0.5 3.0

1Hydraulic oil temperature:
45 - 55°C
bBlade: No load
pLeft tilt - Right tilt
set
JVork
equipment
oosture
2.5 ” 0.5 4.0
qipper (lift)
p Engine at high idling 3.0 ” 1.0 5.0

pHydraulic oil temperature:
45 - 55°C
DLowest shank hole
pGround level - Max. heiaht
Work equipment
posture
3.0 + 1.0 5.0
Ripper (tilt)
mEngine at high idling 2.5 2 1.0 4.5

) Hydraulic oil temperature:
l Lowest shank hole
l Tilt in - Tilt back
20-6
0
Cate- Standard value Service limit

WV for new machine value
. Engine at high idling
. Hydraulic oil temperature: 45 - 55°C
. Raise blade to maximum height, then
Blade lower blade and measure time taken 1.5 f 0.5 2.5
from point where blade contacts
ground to point where idler comes
off ground
l Engine at high idling

Hvdraulic oil temoerature: 45 - 55°C
z
l
l Raise ripper to maximum height, then

Ripper lower ripper and measure time taken 0.5 - 1.0 1.5
from point where ripper contacts
ground to point where sprocket
comes off ground
20-7
0
STANDARD VALUE TABLE STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS
STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS
n Measurement
I
L- Name of (Zonnector Judgment table
1 component No. conditions
If the condition is as shown in the table 1) Turn starting
below, it is normal switch OFF.
2) Disconnect
sx5 connector.
Fuel control dial
i (male) ._If.itiil

2) Disconnect
SM2 connector.
Potentiometer (male)
El

2) Disconnect
Between (1) - (2) 2.5 - 7.5 kR connector.
Between (3) - (4) 2.5 - 7.5 kO

SM3
Motor (male) Between (I) - (3) No continuity
Between (1) - (4) No continuity
Between (2) - (3) No continuity

below, it is normal switch ON.
2) Insert T-adapter.
Power source
voltage Between (I) - (12) 20 - 30 V
Between (2) - (12) 20 - 30 v

Fuel control dial SMI

)I
Between (7) - (16) (high idling)

Between (17) - (16) (low idling) 2.9 - 3.3 v
Potentiometer
Between (17) - (16) (high idling) 0.5 - 0.9 v
Between (5) - (16) 4.75 - 5.25 V
20-8
0
Name of CZonnector lspectio Measurement
I
Judgment table
component No. method conditions
Network SMI
Between (14),(15) - (12) 4-8V

Governor motor 2) Insert T-adapter.
Between (IO) - (20) 1.8 - 4.6 V
Between (11) - (21) 1.8 - 4.6 V

SMI
Between (13) - (12) 20 - 30 v
Battery relay
* Only for 4.0 seconds after the starting
switch is turned ON --f OFF. In all other
cases: 0 V
20-9
0
sys-
tern
Name of
component
Connector
No. I 1
I;P& Judgment
If the condition is as shown

table
in the table
Measurement
conditions
1) Turn starting
2) Disconnect
Between (1) - (2) 500 - 1,000 n connector.
Between (1) - chassis Min. 1 MQ

Engine speed sensor CNOIO
(I)
Measure with AC range 1) Start engine.
2) insert T-adapter.
Engine speed sensor CN009
(2) Between (I) - (2) 0.5 - 3.0 v
1) Screw in until speed sensor contacts ring

gear, then turn back 3/4 turns.
2) Sensor should work normally when
adjusted as above.
If the condition is as shown in the table

below, it is normal
1 Between (I) - (2) A Phase 1 2.5 - 7 Q
Between (3) - (2) B Phase 2.5 - 7 Q Turn starting

HMT motor CN122 switch OFF.
speed sensor (male) Disconnect
Measure with AC range
connector.
Between (1) - (2) A Phase o-3v I

1 Between (3) - (2) B Phase 1 o-3v I
If the condition is as shown in the table I) Turn starting

below, it is normal All resistances switch OFF.
2) Disconnect
Between THRTL (3) - (1) connector.
Throttle THRTL
Ei 4-6KQ
potentiometer (male)
Brake pedal BKPT Sianal

potentiometer (male)
Between THRTL (2) - (1)
El
FORWARD speed
control FMAX Between BKPT (2) - (3)
potentiometer (F) (male) 0.25 - 7 KQ
Between FMAX (3) - (2)
REVERSE speed
RMAX Between RMAX (3) - (I)
control
(male)
potentiometer (R)
Sianal
0.25 - 7 KQ
Between FMAX (3) - (I)
Between RMAX (3) - (2)
20-10
0
sysi- Name of onnectol spectio

r
Judgment table Measurement
ten 1 component No. I
nethod conditions
PUPA I
HMT pump ‘ !) Disconnect
Between (2) - (I 1 IO-20R
solenoids (A) (B) !Ya:eg) connector.
(male) Between (2),(l) - chassis Min. 1 MR

MRA below, it is normal switch OFF.
HMT motor 2) Disconnect
Between (I) - (2) IO-200 connector.
solenoids (A) (B) %aaBe’
(male)
Between (l),(2) - chassis Min. 1 MR

STA below, it is normal switch OFF.
HSS steering 2) Disconnect
EPC solenoids ‘;%’ Between (I) - (2) I 7-15a I connector.
(A) (B) (male)
Between (l),(2) - chassis 1 Min. 1 MQ

CNBRAK 2) Disconnect
Brake solenoid (male) Between (I) - (2) 30 - 80 R connector.
,
, Between (l),(2) - chassis Min. 1 MR
, -
)
l Spool solenoids If the condition is as shown in the table 1) Turn starting
1st spool SOL (male below, it is normal switch OFF.
2nd spool SOL (male 2) Disconnect
3rd spool Between (1) - (2) 5-20d connector.
‘SOL (male
F spool SOL (mak
R spool Between (1 j,(2) - chassis Min. 1 MQ
SOL (mak

2) Disconnect
Ambient temperature Resistance
connector.
Power train PLTP
oil temperature Approx. 29 kR
(male) 35°C
sensor I
I
Approx. 52 kQ
20°C
I
I
Approx. 80 W
10°C
If the condition is as shown in the table

1) Engine stopped
below, it is normal
or started.
2) Disconnect
CRGP connector.
HMT charge
pressure sensor (male)
Between (2) - chassis

(Engine stopped) Min. 1 MR
20-11
0
syc j-
T
tenl-l
-
Name of
component
lonnector
No.
spectic
nethoc
Judgment table Measurement
conditions
CNOOI
Power source 2) Insert T-adapter.
voltage 1 Between CNOOI (8),(16) - (711 20 - 30 V 1
CN003
Between CN003 (6) - (21) 20 - 30 v

/Between 1 4.75
(14) - (15) (Powersource) - 5.25 V I
Throttle CN2H2 (ToFlera-
potentiometer Max. 2.1 V
Between (7) - (15) (At full
3.45 - 3.5 v
throttle)

Brake pedal 2) Insert T-adapter.
CN2H2 1Between (14) - (15) (Powersource)/ 4.75 - 5.25 V 1
potentiometer I
Between (3) - (15) $?$$ 2.6 - 2.7 V

Between CN2H2 (14) - (15) 2) Insert T-adapter.
(Power source) 4.75 - 5.25 V g
I
Max. speed CN2H2 5
setter z
potentiometer CNOOI
If the condition is as shown in the table below

1) Turn starting
when the left lever is operated to FORWARD or
REVERSE, it is normal switch ON.
I 2) Insert T-adapter.
(1) - (15) 2.5 2 0.25 V
E;;pional Neutral
(5) - (15) 2.5 + 0.25 V
potentiometer CN2H2
(F;bJ’I ) (1) - (15) 3.75 - 4.25 V
FORWARD
high idling
(FNRZ) (5) - (15) 0.75 - 1.25 V
REVERSE
high idling
If the condition is as shown in the table below

when the left lever is operated to the left or right, 1) Turn starting
it is normal switch ON.
1 Neutral m
Steering lever
poteny;jmeter CN2H2
(2) - (15) 3.92 - 4.42 V
and RIGHT
(2) high idling
(6) - (15) 0.58 - 1.08 V
(2) - (15) 0.58 - 1.08V

LEFT
high idling
(6) - (15) 3.92 - 4.42 V
-
20-12
0
sys
terr
Name of
comoonent rCZonnector
No.
Judgment
Fthe condition is as shown

table
in the table
Measurement
conditions
1) Turn starting
below. it is normal switch ON.
CNOOI 2) Insert T-adapter.
3rake solenoid Brake released 20 - 30 V
Between
(14) - (7)
Brake applied Max. 1 V
f the condition is as shown in the table 1) Turn starting

5 Clutch
solenoid
Max. 1 V
1st spool CNOOI
2nd spool CNOOI
3rd spool CNOOI
spool CN003 20 - 30 v
L spool CNOOI

Ielow, it is normal switch ON.
l Spool switch CH2Hl
1st spool Max. 1 V
2nd spool
CNOOI
Zrd spool ( GND 1
R spool 20 - 30 v
R (8) - (7) j
I.F the condition is as shown in the table 1) Turn starting
I
I:)elow. it is normal switch ON.
HMT charge 2) Inset-t T-adapter.
CHZHI
pressure Between
CN003
sensor CNPHI (6)
_ CNO03 (2l),+!j#$&
1

IDelow, it is normal switch ON.
Travel speed
CNSHI 2) Insert T-adapter.
selector Between Switch ON Max. 1 V
CN2H2
switch CNZHI (1)
- CN003 (21) Switch OFF 20 - 30 v
i
>elow. it is normal switch ON.
2) Inset-t T-adapter.
’ (SWI,
Between Switch ON Max. 1 V
PSWI CN2Hl (4) -
Brake switch
PSW2
y$&(15)
Between
CN2Hl (2) _ Switch OFF 20 - 30 v
CN2H2 (15)
20-13
0
sys- Name of Judgment table Measurement

tern component conditions
I 1 If the condition is as shown in the table 1) Turn starting
al below, it is normal switch OFF.
FE
Pin-puller CN246 2) Disconnect
z; Between (1) - (2) 40 - 80 Sz connector.
solenoid (male)
8%
Z? Between (l),(2) - chassis Min. 1 ML?
I I ’ I 1
al below, it is normal switch OFF.
2: 2) Disconnect
Blade pitch SOL-1 Between (1) - (2) 40 - 80 z2
solenoid (male) i.j connector.
53 Between (l),(2) - chassis Min. 1 MD
20-14
0
STANDARD VALUE TABLE STANDARD VALUE TABLE FOR MACHINE MONITOR
STANDARD VALUE TABLE FOR MACHINE MONITOR
Measurement
SF Name of Con Judgement table
ten comoonent r conditions
I I
Check, caution If the condition is as shown in Tables 1 and 2, the monitor

Dortion buzzer Pisnel is normal 1) Start engine.
signal 2) Insert T-adapter.
Tiable 1 (Check, caution portion)
The H and L in the \
table above are the Monitor auxiliary signal input
following voltages.
% 1 Enaine oil
p&sure signal
H: 3.5 - 30 V
L: Approx. 0 V
R 2 Starting signal
H: 3.5 - 30 V
L: Approx. 0 V
Once the starting Preheating -
signal is H, it then CNPl(6)
changes to L. How-
ever, the starting sig-
Engine oil
nal is stored in
pressure
memory inside the
monitor panel as H
CNPl(8) K-i H I H I-H
until the starting
switch is turned OFF. Battery charge
% 3 Alternator signal CNPl(4)
H: 27.5 - 30 V I H I H M-H
L: Max. 5 V -
% 4 Sensor signal T able 2 (Buzzer signal) 1) Turn starting
H: 3.5 - 30 V switch ON.
L: Approx. 0 V Start;t:v$cvh ON
2) Insert T-adapter
CNPl(1) - (2)
or connect
(+24 V input) Starting ;;itch OFF
short connector.
When connector CN402

CNPP (7) (alarm buzzer is removed, buzzer
output) - (4) sounds or the following
cycle is repeated
Disconnect CN402 Over 20 V: 0.8 set
(coolant temperature 3 V: 0.8 set
sensor) tf connect
short connector to When short connector is
CN402 connected, buzzer stops
or voltage is 20 - 30 V
Coolant Sensor Turn starting

temoerature resistance switch OFF,
insert dummy
resistance, or
measure resist-
ance of sensor.
Turn starting
switch ON and
check display.
Coolant CF4402 1 120°C IApprox.2.3 k0 Disconnect
temperature (ITIale) connector.
SYD00341
20-l 5
0
Name of onnecto Judgement table

Measurement
component No. conditions
Power train 1) Turn starting

Sensor
oil tempera- switch OFF,
resistance
ture insert dummy
resistance, or
‘ower train oil :N45: 50°C Approx. 17 kQ measure
emperature male1 SC 95’C 102-c resistance of
95°C Approx.4.3 kQ sensor.
2) Turn starting
120°C Approx.2.3 M switch ON and
Ii$r check display.
130°C Approx.1.8 kQ 3) Disconnect
SYD00342
connector.
Fuel level :N42:

male1
SYcQO340
F the condition is as shown in the table 1) Turn starting

lelow, it is normal switch OFF.
2) Disconnect
l
Oil temperature or connector

Coolant temperature When normal
coolant temperature (coolant
sensor
:N40i 1 OO’C Approx. 3.8 kQ temperature
Fargla;t temperature
male] I sensor).
:N455 9bC Approx. 5 kQ . Disconnect
Power train oil tem-
male) I connector
perature sensor
35°C Approx. 29 kR (power train
(Power train oil tem-
I oil tempera
perature gauge)
2O’C Approx. 22 kS2 ture sensor).
10°C Approx. sb kQ
If the condition is as shown in the table 1) Start engine.

celow, the sensor is normal
Engine oil pressure :N40: Engine oil pressure 0.05

No continuity
sensor MPa(O.SKg/cm*)or above
GLID
Engine oil pressure below Continuity
0.05 MPa(0.5Ka/cm2)

below. the sensor is normal switch OFF.
Fuel level sensor CN423 (male) (I) - (2)

(fuel gauge)
Full Approx. 12 R or below
Empty Approx. 85 - 110 Q I
Nhen engine is running

(112 throttle or above] 1) Start engine.
-+28t2V
c If the battery is old, or after starting in cold
areas, the voltage may not rise for some
Alternator time.
20-M
0
Measurement
SF- Name of Judgement table
tern component conditions
z
.!i
below, the sensor is normal switch OFF.
5 CN452 4
E Hydraulic oil ~
E temperature (male) .g
.-
t
.z
20-17
0
Tools for testing, adjusting, and troubleshooting ................................................................................ 20-102

Measuring engine speed ......................................................................................................................... 20-103
Measuring exhaust color ........................................................................................................................ 20-104
Adjusting valve clearance ....................................................................................................................... 20-105
Measuring compression pressure.. ........................................................................................................ 20-106
Measuring blow-by pressure .................................................................................................................. 20-107
Measuring engine oil pressure.. ............................................................................................................. 20-108
Testing and adjusting fuel injection timing ........................................................................................... 20-109
Testing and adjusting alternator belt tension ....................................................................................... 20-l 10
Testing and adjusting air conditioner compressor belt tension ......................................................... .20-l 10
Measuring exhaust temperature ............................................................................................................ 20-I 11
Measuring air supply pressure (boost pressure). ................................................................................. 20-I 12
Measuring engine speed at steering relief + blade RAISE ................................................................... .20-113
Adjusting fuel control linkage.. ............................................................................................................... 20-I 14
Adjusting decelerator pedal .................................................................................................................... 20-I 17
Testing and adjusting throttle potentiometer.. ..................................................................................... 20-l 18
0”
Adjusting joystick (steering, directional lever),
E
z max. speed setter, parking brake lever linkage ...................................... 20-I 20
Adjusting brake pedal linkage.. .............................................................................................................. 20-122
Testing and adjusting brake pedal potentiometer ................................................................................ 20-123
Adjusting work equipment control linkage ........................................................................................... 20-124
Testing and adjusting work equipment, steering control pressure ................................................... .20-126
Measuring steering EPC solenoid valve output pressure ................................................................... .20-127
Measuring ON-OFF solenoid valve output pressure ............................................................................ 20-128
Measuring work equipment PPC valve output pressure ...................................................................... 20-l 29
Adjusting PPC valve ................................................................................................................................ 20-130
Measuring power train oil pressure ....................................................................................................... 20-131
Measuring and adjusting HMT pump main (high pressure) relief pressure ................................. 20-133
Measuring and adjusting HMT charge pressure ................................................................................... 20-134
Measuring and adjusting charge valve relief pressure
(HMT servo, PPC circuit charge pressure). ............................................ .20-135
Measuring and adjusting work equipment, steering pressure ............................................................ 20-136
Bleeding air from hydraulic cylinder ...................................................................................................... 20-138
Releasing remaining pressure in hydraulic circuit ............................................................................... 20-138
Bleeding air from HMT pump.. ............................................................................................................... 20-139
Checking location of cause of hydraulic drift of blade and ripper ....................................................... 20-140
Measuring leakage inside cylinder. ........................................................................................................ 20-141
Adjusting semi-U tiltdozer ...................................................................................................................... 20-l 42
Adjusting clearance of idler ................................................................................................................... -20-144
Simple procedure for testing brake performance ................................................................................. 20-145
20-101
0
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING

Checkor measurement item ;ym bol Part No. Part Name Remarks
799-203-8001 Multi-tachometer L : 60 - 2,OOOrpm

1 Digital display
6210-81-4110 Adapter
Engine speed
H : 60 - 19,999rpm
A
799-203-8901 Clamp set
2 Kit Part No. : 799-203-9000
6210-81-4111 Gear box
Adjusting fuel injection timing
A A 795-471-1200 Gauge assembly 0.01 - IOmm (meter)
Coolant and oil temperatures B 799-101-1502 Thermometer - 99.9 - 1299°C (sensor)
-
2.5,5.9,39.2,58.8MPa
799-101-5002 Hydraulic tester pressuregauge:{25,60,400,600kg/cm3
1
790-261-1203 Digital hydraulic tester
1.0 MPa
2 799-40 I-2320 Hydraulic gauge {I 0 kg/cm?
Both male and female 14 x 1.5
790-261-1311 (female PT l/8)
Oil pressure C 3 Adapter
790-261-1321 (female PT l/8)
790-261-1360 Adapter (female PT 118)
4 790-261-1370 Nut 14 x 1.5 blind
07003-31419 Gasket For blind

-
1 795-502-I 590 Gauge assembly 0 - 6.9 MPa 10 - 70 kg/cm*)
795-502-I 500 Adapter assembly (Kit Part No. : 795-502-1205)

Compression pressure D
_ B
2 l 795-502-1510 l Adapter
5
l 795-502-1520 l Plate _ z
-
1 799-201-1504 Blow-by checker
Blow-by pressure E
2 799-201-1590 Gauge 0 - 9.8 kPa (0 - lOOOmm.H,OI
-
Valve clearance F
Commercrally
Feeler gauge -
available
Discoloration 0 - 70 % (with
1 799-201-9000 Handy Smoke Checker
I 1 standard color)
Exhaust color G 2 Commercially (Discoloration x l/IO 4 Bosch
available Smoke meter
)
Air supply pressure
-101.3- 199.9kPa f-760- 1,50OmmHg}
(boost pressure)
0 - 294N (0 - 30 kg1
Operating force
0 - 490N IO - 50 kg]
Commercially
Stroke, hydraulic drift J available Scale
Commercially
Work equipment speed K available Stop watch
Measuring voltage and
resistance values L 1 79A-264-0210 1 Tester
~9-601-7100 1 T-adapter assembly
1 799-601-7010 1 For Xl
Troubleshooting of For SWPIPP

wiring harnesses and
For SWP14P
sensors
2 Adapter
799-601-7320 For SWPIGP
799-601-7080 For M2
799-601-7360 For relay 5P

Measuring wear of -
sprocket tooth P 1 791-627-1160 1 Wear gauge
20-102
@
TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE SPEED

Be careful not to touch any hot parts when re-
moving or installing the measuring tools.
* Measure the engine speed under the following
conditions.
l Coolant temperature: Within operating range
l Hydraulic temperature: 45 - 55°C
l Power train oil temperature: 70 - 90°C
1. Install sensor @ of multi-tachometer A to the
speed pickup port, then connect to multi-tachom-
eter A.
2. Start the engine and measure the engine speed
at high idling and low idling. \ ’ TLDOOOOS
* When measuring items other than above, see
the measurement procedure for each item.
TLDOOOlO
zo- 103
0
TESTING AND ADJUSTING MEASURING EXHAUST COLOR
MEASURING EXHAUST COLOR

l When measuring in the field where there is no
air or electric power supply, use Handy Smoke
Checker Gl; when recording formal data, use
Smoke Meter G2.
Ir Raise the coolant temperature to the operat-
ing range before measuring.
ABe careful not to touch any hot parts when re-
moving or installing the measuring tools.
1. Measuring with Handy Smoke Checker Gl.

I) Install filter paper to Handy Smoke Checker
Gl.
’ 2) Insert the exhaust gas suction port into the
exhaust pipe, accelerate the engine suddenly,
and operate the handle of Handy Smoke
Checker Gl at the same time to collect the
exhaust gas on the filter paper.
3) Remove the filter paper and compare it with
the scale supplied to judge the condition.
2. Measuring with Smoke Meter G2
I) Insert the probe @ of Smoke Meter G2 into
the outlet port of the exhaust pipe, and
tighten the clip to secure it to the exhaust
pipe.
2) Connect the air hose and the socket of the
probe hose and accelerator switch to Smoke
Meter G2.
* Keep the pressure of the air supply be-
low 1.5 MPa (15 kg/cm* 1.
3) Connect the power cord to the AC 100 V
socket.
Jc When connecting the cord, check that
the power switch of Smoke Meter G2 is
OFF.
4) Loosen the cap nut of the suction pump, I TLD00012
and fit the filter paper.
* Fit the filter paper securely so that the
exhaust gas cannot leak.
5) Turn the power switch of Smoke Meter G2
ON.
6) Accelerate the engine suddenly, and depress
the accelerator pedal of Smoke Meter G2 at
the same time to collect the exhaust gas
color on the filter.
7) Place the filter paper used to catch the ex-
haust gas color on top of at least 10 sheets
of unused filter paper inside the filter paper
holder, and read the value shown.
I TLDOOl40
20-104
0
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE
CLEARANCE
1. Remove the cylinder head cover.
2. Rotate the crankshaft in the normal direction to
align the 1.6 TOP line on vibration damper (I)
with pointer (2) when the No. 1 cylinder is at
compression top dead center. When rotating,
check the movement of the intake valves of the
No. 6 cylinder.
* When the No. 1 cylinder is near the com-
pression top dead center, the intake valve of
the No. 6 cylinder moves (the overlap posi-
tion with the exhaust valve).
3. When No. 1 cylinder is at compression top dead
center, adjust the valves marked 0. Next, ro-
tate crankshaft one turn (360’ ) in the normal Valve arrangement
direction and adjust the valve clearance of the
remaining valves marked 0.
4. To adjust the clearance, loosen locknut (4) of
adjustment screw (3), insert feeler gauge F be-
tween crosshead (5) and rocker arm (6), and
adjust with the adjustment screw until the clear-
ance is a sliding fit.
5. Tighten the locknut to hold the adjustment screw
in position.
g w Locknut : 49 + 2.9 Nm I4.9 t 0.3 kgm1
5 * After adjusting No. 1 cylinder at compression TDD00714
s top dead center, it is also possible to turn the
crankshaft 120” each time and adjust the clear-
ance of the valves of each cylinder according to
4 3 6 5
the firing order.
. Firing order : l-5-3-6-2-4
* After tightening the locknut, check the clearance
again.
TLD00014
TLD00015
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION
PRESSURE
AWhen measuring the compression pressure, be
careful not to touch the exhaust manifold or
any other hot parts or get caught in the fan belt
or any other rotating parts.
1. Adjust the valve clearance.
For details, see ADJUSTING VALVE CLEAR-
ANCE.
2. Warm up the engine so that the oil temperature
is 40 - 60” C.
3. Remove the fuel injection tube and inlet con-
nector, then remove the nozzle holder assem-
bly from the cylinder which is to be measured.
4. Install adapter D2 to the nozzle holder mount,
then connect pressure gauge Dl.
5. Set multi-tachometer A in position.
Ir For details, see MEASURING ENGINE
SPEED.
6. Disconnect the fuel control rod, set the gover-
nor lever of the injection pump to the NO IN- D* \
JECTION position, then crank the engine with
the starting motor and measure the compres-
sion pressure.
Measure the compression pressure at the point
I I III1 I I
where the pressure gauge indicator remains
TLD00017
steady.
When measuring the compression pressure,
measure the engine speed to confirm that it is
within the specified range.
After measuring the compression pressure, in-
stall the nozzle holder assembly.
20-l 06
0
TESTING AND ADJUSTING MEASURING BLOW-BY
MEASURING BLOW-BY
PRESSURE
* Raise the coolant temperature to the operating
range before measuring.
1. Install blow-by checker El to the end of engine

breather hose (I), then connect gauge E2.
2. Run the engine at near rated output, and meas-

ure the blow-by pressure.
4L When measuring, be careful not to touch
any hot parts or rotating parts.
* The blow-by should be measured with the \\
TLDOOOZO
engine running at rated output.
* Near rated output
. Measure the engine speed at steering relief
+ blade RAISE (end of RAISE stroke), and
run at near the rated output.
. If it is impossible to check at rated output or
stall speed, measure at high idling.
In this case, the blow-by value will be about
80% of the value at rated output.
* Blow-by varies greatly according to the con-
dition of the engine. Therefore, if the blow-
by value is considered abnormal, check for
problems connected with defective blow-by,
such as excessive oil consumption, defec-
tive exhaust gas color, and prematurely dirty
or deteriorated oil.
20-107
0
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL

PRESSURE 1
* Measure the engine oil pressure under the fol-
lowing conditions.
l Coolant temperature : Within operating range
1. Remove engine pressure pickup plug (I) F’T l/8),
then install the adapter of oil pressure gauge kit
Cl and oil pressure gauge C2 (1.0 MPa (IO kg/
cm2)).
2. Start the engine, and measure the oil pressure

at low idling and high idling.
20-108
0
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING

FUEL INJECTION TIMING
Serial No. : 60001 - 60271
1. Testing
I) Rotate the crankshaft 30 - 40” in the reverse
direction from No. 1 cylinder TOP.
2) Rotate the crankshaft slowly in the normal

direction and align pointer (2) and the I.J.
(injection timing) line on crankshaft pulley
(I).
TLD00013
3) Check that injection pump line “a” and cou-

pling line “b” are aligned.
TLD00141
2. Adjusting
* If the lines are not correctly aligned, loosen
nut (3). move the coupling to align the lines,
then tighten the nut.
m Nut: 66.2 = 7.4 Nm {6.75 2 0.75 kgm}
TLDOOO143
20-109
8
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
1. Remove No. 1 nozzle holder assembly (II.

For details, see REMOVAL OF NOZZLE HOLDER
ASSEMBLY.
2. Remove injection pump coupling cover.
3. Align No. 1 cylinder with the compression top ‘I
dead center line (1:6).
* When doing this, check that the fuel injec-
tion timing line on the fuel injection pump is
near the line on the fuel injection pump body.
4. Set dial gauge AA to the nozzle holder hole BLD00325
where the nozzle holder assembly has been re-
moved. (See the diagram.)
* Set the magnet stand of dial gauge AA in a
stable place where installation can be car-
ried out.
5. Set the scale on dial gauge AA to 0 when the
piston is at the top dead center.
Ir Rotate the crankshaft in the normal direc-
tion and in the reverse direction in turn to C
align the top dead center.

Ir Record the value indicated by the short indi-
cator on dial gauge .
:
6. Rotate the crankshaft approx. 45” inthe reverse
direction from the No. 1 cylinder TOP position. BLDOO326
7. Rotate the crankshaft again slowly in the nor-
mal direction and set to specified dimension “c”.
* Specified dimension ‘cl’: 2.36’:;:, mm
(BTDC: 22”)
* Always rotate the crankshaft in the normal
direction to align the position.
* Continue to rotate in the normal direction,
and when the No. 1 cylinder reaches the
TOP (top dead center) position (the indicator
on the dial gauge rotates in reverse), check
that the dial gauge reading is OT$$ mm. If it
is not within O:~;$mm, carry out Steps 4 and
5 again.
8. Check that fuel injection timing line “a” on the TLD00141
fuel injection pump is aligned with line “b” on
the coupling.
9. After adjusting fuel injection timing, install noz-
zle holder assembly.
For details, see REMOVAL OF NOZZLE HOLDER
ASSEMBLY.
20-109-l
8
TESTING AND ADJUSTING ALTERNATOR BELT TENSION lTESTING
TESTING AND ADJUSTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION

ALTERNATOR BELT TENSION
1. Testing
. Measure the deflection of the belt when it is
pressed at a force of approx. 59 N (6 kg1 at a
point midway between the alternator and
fan pulley.
* Deflection (standard value) a : 15 mm
2. Adjusting
1) Loosen alternator mount bolt (I).
2) Loosen locknut (21, then turn adjustment nut
(3) and adjust the belt tension.
3) After adjusting the belt tension to the stand-
ard value, tighten locknut (21, then tighten
alternator mount bolt (I).
TLD00027
TESTING AND ADJUSTING AIR

CONDITIONER COMPRESSOR
BELT TENSION
1. Testing
. Measure the deflection of the belt when it is
pressed at a force of approx. 59 N (6 kg1 at a
point midway between the compressor pul-
ley and engine drive pulley.
* Deflection (standard value) b :
Approx. 10 mm
ii TLD00028
2. Adjusting
1) Loosen 4 compressor mount bolts (I).
2) Loosen locknut (2), then turn adjustment nut
(3) and adjust the belt tension.
3) After adjusting the belt tension to the stand-
ard value, tighten locknut (21, then tighten
mount bolt (I).
20-110
8
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
MEASURING EXHAUST
TEMPERATURE
AThe temperature sensor must be installed to the
exhaust manifold, so if the machine has been
operated, wait for the manifold temperature to
drop before installing the sensor.
* Raise the coolant temperature to the operating

range before measuring.
1. Remove plug (I) from the exhaust manifold, and

install temperature sensor B.
. Temperature sensor B: 6215-1 I-8180
(cable length 610 mm)
::215-II-8170
(cable length 490 mm)
2. Connect to digital temperature gauge B with the
wiring harness.
Measurement procedure
. When measuring the maximum value for the
exhaust temperature
Carry out actual work and measure the maxi-
mum value during operation.
Ir Use the PEAK mode (it can store the
maximum value in memory) of the tem-
perature gauge function.
Note:
The exhaust temperature varies greatly accord-
ing to the ambient temperature (temperature of
the engine intake air), so if any abnormal value
is obtained, carry out temperature compensa-
tion.
Ir Compensation value = Measured value + 2 x
(20°C - ambient temperature)
20-l 11
@
TESTING AND ADJUSTING MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)
MEASURING AIR SUPPLY

PRESSURE (BOOST
PRESSURE)
A caught
Be careful not to touch any hot parts or get
in .pa any rotating parts when measur-
ing or when removing or installing the measur-
ing tools.
1. Remove air supply pressure measurement plug

(I) (PT’/s), then install the coupler inside oil pres-
sure gauge kit Cl.
2. Connect the oil pressure measurement hose to

the coupler and pressure gauge H (1,500 mmHg).
Note: Operate the engine speed at midrange or

above, and use the self-seal portion of the
gauge to bleed the oil inside the hose.
. Insert the gauge about half way, repeat the
action to open the self-seal portion, and
bleed the oil.
* If there is oil inside the hose, the gauge will
not work, so always bleed the oil.
3. Run the engine at near rated output, and read

the pressure indicated by the gauge.
* Near rated output
. Run at near the rated output.
For details, see Measuring engine speed at
steering relief + blade RAISE (end of RAISE
stroke).
* The air supply pressure (boost pressure) should
be measured with the engine running at rated
output. However, when measuring in the field, a
similar value can be obtained at steering relief +
blade RAISE.
20-112
0
TESTING AND ADJUSTING MEASURING ENGINE SPEED AT STEERING RELIEF + BLADE RAISE
MEASURING ENGINE SPEED

AT STEERING RELIEF + BLADE
RAISE
* Measure the speed under the following condi-
tions.
. Coolant temperature: Within operating range
. Power train oil temperature: Within operat-
ing range
Hydraulic oil temperature: Min. 45 - 50°C
A’ Make sure that there is no one near the ma-
chine before starting measurements.
Install multi-tachometer A.
* For details, see MEASURING ENGINE SPEED.
Depress the decelerator pedal, set the fuel con-
trol dial to FULL, and run the engine at full throt-
tle.
Depress the steering brake securely, operate the
steering lever to relieve the steering circuit, and
operate the blade RAISE (operate the blade le-
ver to the end of the RAISE stroke beforehand)
at the same time.
Release the decelerator pedal, run the engine at
full throttle, and measure the engine speed, at
this point.
* After completion of the measurement, re-
turn the steering lever swiftly to neutral, and
run the engine at high idling to lower the oil
temperature.
A Precautions
1) Depress
when relieving the steering
the decelerator pedal before setting
the fuel control dial to the FULL position.
2) Release the decelerator pedal to run the en-
gine at full throttle. However, for safety rea-
sons, always keep your right foot on the
decelerator pedal until the completion of the
measurement operation so that you can de-
press the decelerator pedal immediately in
an emergency.
20-113
0
TESTING AND ADJUSTING ADJUSTING FUEL CONTROL LINKAGE
ADJUSTING FUEL CONTROL LINKAGE
-_-
1' TLD00044
TLD00045
20-114
0
* When adjusting fuel control linkage, adjust throt-

tle potentiometer at the same time.
1. Disconnect connector (CN-KUMI) (13).
2. Adjust distance “a” between the pins of loose

spring (I) to the dimension given below.
* Dimension “a”: 323.5 mm
3. Connect rods (2), (31, and (4) so that distances
“b”, “c”, and “d” are the dimensions given be-
low.
j, Dimension “b”: 62 mm
Dimension “c”: 575 mm
TWD00901
Dimension “d”: 502 mm
4. Adjust adjustment height “e” of adjustment
spring (5) to the dimension given below.
* Adjustment height “e”: 10 mm
5. Adjust the angle of rod (6) so that clearance “f”
between rod (6) and power train oil filter (7) is
the dimension given below, then secure the rod
in position.
* Clearance “f”: Min. 10 mm
6. Check that turnbuckle (8) end of rod (6) is at
position B of 4-hole lever (9).
7. Start the engine, turn the fuel control dial gradu-
8 ally to the FULL position, then shorten turnbuckle
E (8). I TLC00046
;5 8. Make a clearance between the FULL stopper and

injection pump governor lever (IO).
9. Extend turnbuckle (81, and check that injection
pump governor lever (IO) contacts the FULL stop-
per.
Ir When doing this, check that loose spring
(11) does not extend more than 1 mm.
10. Set the fuel control dial to the low idling posi-
tion, and if the alarm buzzer does not sound
when the engine speed is above 750 rpm, set to
position A of 4-hole lever (9) and adjust as fol-
lows.
I) Turn the fuel control dial gradually to the
FULL position, then shorten turnbuckle (8) C
to make a clearance between the FULL stop-

per and injection pump governor lever (IO).
2) Extend turnbuckle (81, and check that injec-
tion pump governor lever (IO) contacts the
FULL stopper. TLD00145
* When doing this, check that loose spring
(11) does not extend more than 1 mm.
3) Run the engine at high idling, turn turnbuckle
(12) +. 1 turn, and secure it in position at the
point where the alarm buzzer sounds.
+r If the alarm buzzer does not sound when
the turnbuckle is turned f 1 turn, turn it
2 2 turns - + 5 turns and secure it at the
position where the alarm buzzer sounds.
4) Turn the fuel control dial to the low idling
position and check that the engine speed is
650 - 750 rpm.
11. Turn the fuel control dial to the low idling posi-
tion, set 4-hole lever (9) to position C when the
engine speed is below 650 rpm, and adjust in
the same way as for Step 10 above.
12. Turn the fuel control dial to the low idling posi-
tion and check that the engine speed is 650 -
750 rpm.
13. Extend turnbuckle (8) one turn.
Ir Stabilize the high idling speed.
14. After adjusting fuel control linkage, connect con-
necter (CN-KUMI).
20-116
@
TESTING AND ADJUSTING ADJUSTING DECELERATOR PEDAL
ADJUSTING DECELERATOR
PEDAL
Install so that distance “g” between the pins of
rod (I) is the dimension given below.
Ir Dimension “g”: 62 mm
Start the engine and turn the fuel control dial to
the FULL position.
In this condition, depress decelerator pedal (2)
fully, then turn turnbuckle (3) to adjust to the
following speed.
Adjust stopper bolt (4) so that decelerator pedal
(2) contacts stopper bolt (4) when the engine is
TLD00042
at high idling.
-k High idling speed: 2,050 + 50 rpm
TESTING AND ADJUSTING TESTING AND ADJUSTING THROlTLE POTENTIOMETER

THROTTLE POTENTIOMETER
I-
I I
l. Testing
1) Disconnect connector (CN-KUMI) (1).
- -d=x
2) Set the joystick and Max. speed setter to the 1
neutral position, start the engine, and check
that the high idling and low idling positions
of the fuel control dial are as shown in Table 1.
TLD0004.9
Table 1
Fuel control Normal value for potentiometer

dial position Engine speed Buzzer voltage (reference)
High idling - Sounds when normal 3.45 - 3.50 V
Low idling Below 700 rpm Sounds when abnormal Min. 2.1 V
2. Adjusting
I) If the buzzer does not sound at the high
idling position when checking Step 1 above,
shorten turnbuckle (2) to adjust to a position
where the buzzer sounds.
2) In the same way, if the buzzer sounds at the
low idling position, adjust the position of
the hole of the 4-hole lever of the control
linkage. For details, see ADJUSTING FUEL
CONTROL LINKAGE.
Ir After adjusting, connect connector (CN-
KUMI).
! -_/___.__
Connector (CN-KUMI)
TLD00050
BLD00327
20-118
@
ADJUSTING JOYSTICK (STEERING, DIRECTIONAL LEVER),
TESTING AND ADJUSTING MAX. SPEED SETTER. PARKING BRAKE LEVER LINKAGE
ADJUSTING JOYSTICK (STEERING, DIRECTIONAL LEVER),

MAX. SPEED SETTER, PARKING BRAKE LEVER LINKAGE
_~
1 I
i i
_-
\ ‘-_/’ L/
,e--
/
-
11
v a
20-120
0
ADJUSTING JOYSTICK (STEERING, DIRECTIONAL -LEVER),
TESTING AND ADJUSTING MAX. SPEED SElTER, PARKING BRAKE LEVER LINKAGE
Adjusting parking brake lever linkage
* Tighten the locknuts of the rods and cables se-

curely, and bend the cotter pins securely.
1) Connect push-pull cable (2) to brake valve
lever (1) and yoke (3). When doing this,
check that dimensions “a” and “b” are as
shown below.
* Dimension “a”: 219 mm
Dimension “b”: 169 mm
In addition, make the insertion amount
at the rod end 12 mm and the insertion
amount into yoke (8) 11 mm.
2) Put lever (5) in contact with stopper bolt (41,
then adjust stopper bolt (4) so that parking
brake lever (6) is 424 mm above the floor,
then secure in position.
3) Set parking brake lever (6) to the FREE posi-
tion, connect rod (91, then adjust rod (9) again
so that dimension “b” of the push-pull cable
is 169 mm.
4) Set parking brake lever (6) to the LOCK posi-
tion, and’check that the travel of brake valve
lever (I) is 37 mm.
5) With parking brake lever (6) at the LOCK
position, adjust at the oblong hole of the
switch mount bolt so that lever (IO) pushes
the movable portion of safety switch (II) in
by dimension “h”.
j, Dimension “h”: 2.8 mm
Note : The steering lever, directional lever and Max.

speed setter is an electric lever, so it does not
need adjustment.
TLD00057
20-121
0
TESTING AND ADJUSTING ADJUSTING BRAKE PEDAL LINKAGE
ADJUSTING BRAKE PEDAL

LINKAGE
I -I- ,
TLD00061
Ir Tighten the locknuts of the rods and cables se-

curely, and bend the cotter pins securely.
1. Adjust height “b” of damper (2) so that the travel
of brake pedal (I) is dimension “a”.
Ir Brake pedal travel “a”: 79 mm
Ir Damper standard height “b”: 39 mm
2. Adjust the length of rod (3) to dimension “c”,
then install to lever (4).
* Dimension “c”: 1,264 mm
3. Adjust the length of rod (5) to dimension “d”,
then install to lever (6).
+ Dimension “d”: 174 mm
4. Push rod (3) towards the rear of the machine
with a force of 9.8 - 19.6 N (I - 2 kg), and put it
lightly in contact with the brake spool inside the
brake valve. Then turn only joint (7) and con-
nect rod (3) and rod (5).
5. With brake pedal (I) at the brake RELEASED
position, adjust the length of the rod so that the
play of the brake pedal is 1 - 5 mm at the center
of the pedal. 3
5 7 8
* Turn joint (7) and (8) in the same direction
at the same time to adjust the length of the
rod.
6. With brake pedal (I) at the brake RELEASED
position, check that lever (6) contacts damper I TLD00063
(2).
20-122
0
TESTING AND ADJUSTING TESTING AND ADJUSTING BRAKE PEDAL POTENTIOMETER

BRAKE PEDAL
POTENTIOMETER
1. Testing
I) Insert a T-adapter in brake pedal potentio-
meter connector (CN-BKPT) (1).
2) Turn the starting switch to the ON position,
release the brake pedal, then measure the
voltage between pins No. 2 and 3.
* Normal voltage (standard value): 2.6 - 2.7 V
(Reference)
Voltage when brake pedal is depressed: 1.7 -
2.0 v
2. Adjusting
. If the voltage is not within the standard value,
loosen bolt (21, and turn potentiometer (3)
to adjust so that the voltage is within the
standard value.
n I
TLD00066
20- 123
0
TESTING AND ADJUSTING ADJUSTING WORK EQUIPMENT CONTROL LINKAGE
ADJUSTING WORK EQUIPMENT CONTROL LINKAGE

Serial No. : 60001 - 60271
, :
/I
12
\
\
--
-.-
7 ‘I
20-124
@
1. Extend detent assembly (I) to the end of its

stroke (where detent enters), install rod end (2)
and joint (31, then adjust so that the length is
dimension “a”.
* Dimension “a”: 259 mm
2. After adjusting, temporarily install detent assem-
bly (I) to bracket (4). (Leave it temporarily as-
sembled.)
3. Install work equipment control lever (5) to PPC
valve (61, then adjust at the neutral position so
that the clearance from the inspection window
is dimension “b”.
* Clearance “b”: 28 mm
4. Move work equipment control lever (5) to the
end of its stroke in the FLOAT direction, then
connect detent assembly (I) to lever (5) with
joint (3). (Check that the detent is entered in
this condition.)
5. Operate the tilt at the FLOAT position and check
that the detent does not come out.
6. In this condition, tighten the mounting bolts of
joint (21, and install cover (13).
7. With work equipment control lever (5) at the
FLOAT position, adjust the mounting position of
8 the proximity switch so that clearance “c” be-
tween the lever and proximity switch (7) is 3 TAD00071
E
s mm.
8. Set the length of rod (8) to dimension “d”, then
connect PPC lock valve (9) and work equipment
lock lever (IO).
* Dimension “d”: 330 mm
9. Set the length of rod (11) to dimension “e”,
then connect lever (12).
* Clearance “e”: 63.5 mm
* Adjust dimension “e” so that clearance “f”
is 0.5 - 1 mm when the lock is applied.
10. Operate work equipment lock lever (IO) from
the FREE position to the LOCK position and check
that the work equipment control lever is returned
from the FLOAT position to the HOLD position.
11. Set work equipment lock lever (IO) to the LOCK
position and check that work equipment lock
lever (IO) does not return to the FREE position
when work equipment control lever (5) is oper-
ated.
w TAD00072
20-125
0
ELD00328
1. Set the length of rod (I) to dimension “a”, 3. Operate work equipment lock lever (3) from
then connect PPC lock valve (2) and work the FREE position to the LOCK position and
equipment lock lever (3). check that the work equipment control lever
* Dimension “a”: 330 mm is returned from the FLOAT position to the
2. Set the length of rod (4) to dimension “b”, HOLD position.
then connect lever (5). 4. Set work equipment lock lever (3) to the
* Clearance “b”: 63.5 mm LOCK position and check that work equip-
* Adjust dimension “b” so that clearance ment lock lever (6) does not return to the
“c” is 0.5 - 1 mm when the lock is ap- FREE position when work equipment con-
plied. trol lever (3) is operated.
20-125-l
03
TESTING AND ADJUSTING WORK EQUIPMENT,
TESTING AND ADJUSTING STEERING CONTROL PRESSURE

WORK EQUIPMENT, STEERING
CONTROL PRESSURE
1. Measuring
Ir Oil temperature when measuring: 45 - 55°C
A Lower the work equipment to the ground and
stop the engine. Loosen the oil filler cap slowly
to release the pressure inside the hydraulic tank.
Then set the safety lock lever to the LOCK posi-
tion.
1) Remove control pressure pickup plug (I) (PT
I
l/s) and install
(5.88MPa {SO kg/cm2)).
oil pressure gauge Cl
I 1 TAD00077
2) Set the safety lever to the FREE position,

start the engine, and measure with the en-
gine at high idling.
Ir When testing for internal leakage of the
equipment in the control circuit, use the
parts given below to shut off the circuit
for the following sections when measur-
ing the relief pressure.
I I
No.
Section of hydraulic
circuit shut off
Component that
can be checked I
Control pump outlet Control pump
1
Port - / \ Ll
PPC valve inlet port for Blade control PPC TAD00078
2 valve
blade control
3 PPC valve inlet port Ripper control PPC

for ripper control valve
4 Steering EPC solenoid Steering EPC

valve inlet port solenoid valve
2
Charge relief Charge relief
‘3 valve
+ valve outlet port
4
* For details of adjustment, see ADJUSTING

CHARGE VALVE RELIEF PRESSURE.
20-126
8
TESTING AND ADJUSTING MEASURING STEERING EPC SOLENOID VALVE OUTPUT PRESSURE
MEASURING STEERING EPC

SOLENOID VALVE OUTPUT
PRESSURE
* Oil temperature when measuring: 45 - 55°C
1. Disconnect hose (I) from the steering EPC sole-
noid valve output circuit.
2. Install adapter C3 in place of the elbow.
3. Install oil pressure gauge Cl (5.9 MPa (60 kg/
cm2)) to adapter C3.
4. Run the engine at full throttle, operate the joy-
stick to the left or right, and measure the oil
pressure. 1’ TAD00080
. When operated to left
Left EPC solenoid valve output pressure:
Min. 3.5 MPa (36 kg/cm*)
Right EPC solenoid valve output pressure:
Min. 0 MPa (0 kg/cm*)
l When operated to right
Left EPC solenoid valve output pressure:
Min. 0 MPa (0 kg/cm*)
Right EPC solenoid valve output pressure:
Min. 3.5 MPa (36 kg/cm*)
TAD00081
20-127
0
TESTING AND ADJUSTING MEASURING ON-OFF SOLENOID VALVE OUTPUT PRESSURE
MEASURING ON-OFF Brake valve solenoid

SOLENOID VALVE OUTPUT r
PRESSURE
1. Measuring brake valve solenoid output pres-
sure
I) Connect oil pressure gauge Cl to brake oil
pressure measurement nipple.
2) Set the joystick to the neutral position, re-
lease the brake pedal, then measure the
brake oil pressure (brake valve solenoid out-
put pressure) when the parking brake is at
the LOCK position and at the FREE position.
TAD00083
LOCK position: 0 MPa (0 kg/cm?
FREE position: Pin-puller solenoid valve outlet hoses
1.0 f 0.5 MPa (IO -c 5 kg/cm?
2. Measuring output pressure of pin-puller sole-
noid valve
A Lower the shank to the ground when measuring
the output pressure of the pin-puller solenoid
valve.
1) Disconnect pin-puller solenoid valve outlet
hoses (I) and (21, then use adapter C3 in the
oil pressure gauge kit to install oil pressure
gauge Cl (5.9 MPa (60 kg/cm*)).
2) Operate the pin-puller to the PULL OUT and
PUSH IN positions, and measure the output
pressure of the pin-puller solenoid valve. 0
. Measuring output pressure of .
pin-puller
. sorenora
Oil pressure when operating pin puller ralve - . .
to PULL OUT (solenoid ON)
Head end:
3.1 + 0.3 MPa (32 ? 3 kg/cm2)
Bottom end: 0 MPa (0 kg/cm?
. Oil pressure when operating pin puller
to PUSH IN (solenoid OFF)
Head end: 0 MPa (0 kg/cm*)
Bottom end:
3.1 f 0.3 MPa (32 + 3 kg/cm?
3. Measuring output pressure of blade pitch sole-

noid valve
1) Disconnect the power pitch solenoid valve
outlet hose, then use the adapter in the oil
pressure gauge kit to install the oil pressure
gauge (5.9 MPa (60 kg/cm*)).
2) Operate the power pitch and measure the
output pressure of the power pitch solenoid
valve.
. When pitch is operated (front, rear) (so-
lenoid ON): Actuating pressure
. When pitch is not operated (front, rear)
(solenoid OFF): 0 MPa (0 kg/cm*)
20-128
a
TESTING AND ADJUSTING MEASURING WORK EQUIPMENT PPC VALVE OUTPUT PRESSURE
MEASURING WORK
EQUIPMENT PPC VALVE
OUTPUT PRESSURE
1. Disconnect the hose of the circuit to be meas-
ured (see diagram below).
2. Install adapter C3 in place of the elbow.
3. Install oil pressure gauge Cl (5.9 MPa (60 kg/
cm?) to adapter C3.
4. Run the engine at full throttle, operate the con-
trol lever of the circuit to be measured, and
measure the oil pressure.
L
‘.c3 TAD00089
Ripper lift (LOWER)
8
X Ripper tilt (TILT IN)
I-
& Blade lift (LOWER)
Blade tilt (right)
(RAISE)
I v
P3 L
0
@DI
PPC lock val
PPC charge valve
Blade tilt (left)
TAO00090
20-129
0
TESTING AND ADJUSTING ADJUSTING PPC VALVE
ADJUSTING PPC VALVE

If there is excessive play in the work equipment
lever, adjust as follows.
ii Lower the work equipment to the ground and
stop the engine. Then loosen the oil filler cap
slowly to release the pressure inside the hy-
draulic tank.
1. Remove the PPC valve.
2. Remove boot (I).
3. Loosen locknut (41, then screw in disc (3) to
adjust the play.
* Lever play : 0.5 - 3 mm (at a point approx.
75 mm from tip of lever knob)
* When locknut (4) is tightened, the play of
the lever is slightly reduced, so allow for
this when adjusting.
4. Secure disc (3) in position and tighten locknut
(4) to the specified torque.
w Locknut : 112.7 + 14.7 Nm (11.5 f 1.5 kgm)
5. Install boot (I) with boot stopper (2).
TAD00091
20-130
0
TESTING AND ADJUSTING MEASURING POWER TRAIN OIL PRESSURE
MEASURING POWER TRAIN

OIL PRESSURE
When measuring the hydraulic pressure, remove
all the sand and dirt from around the nipple and
plug.
Raise the power train oil temperature to 70 -
80°C before measuring.
a The FORWARD clutch pressure, REVERSE clutch
pressure, and 3rd clutch pressure cannot be
measured with the machine stopped, so check
the measurement procedure before carrying out
the measurement.
I \ \ TAD00092
Table of locations of centralized pressure pickup
points for measuring oil pressure and gauges
to use
TAD00097
1. Measuring transmission oil pressure

1) Measuring main relief pressure
i) When measuring the main relief pres-
sure, install oil pressure gauge Cl to nip-
ple (I).
ii) Set the joystick to the neutral position,
and measure the main relief pressure
with the engine at low idling and high
idling. ,
2) Measuring transmission lubrication pressure TAD001 44
i) When measuring the transmission lubri-

cation pressure, install oil pressure gauge
Cl to nipple (2).
and measure the transmission lubrica-
tion pressure with the engine at low
idling and high idling.
3) Measuring transmission pilot pressure
i) When measuring the transmission pilot
pressure, install oil pressure gauge Cl
to nipple (3).
and measure the transmission pilot pres-
sure with the engine at low idling and
high idling.
20-131
0
TESTING AND ADJUSTING MEASURING POWER TRAIN OIL PRESSURE
4) Measuring 1st clutch, 2nd clutch pressure l Combination of speed ranges and clutches used
i) When measuring the clutch pressure, in-
stall oil pressure gauge Cl to nipple (8)
for measuring the 1st clutch oil pressure
and nipple (7) for measuring the 2nd
clutch oil pressure.
and measure the 1st clutch pressure and
2nd clutch pressure with the engine at
low idling and high idling.
5) Measuring F clutch, R clutch, 3rd clutch pres-
sure
This measurement can also be carried
Ai out when the machine is traveling.

Set the machine on level ground.
i) Jack the machine up with the blade and * Actuation mode
ripper. HMT: Hydro Mechanical Transmission (Hy
ii) When measuring the clutch pressure, in- draulic power + mechanical power +
stall oil pressure gauge Cl to nipple (5) power transmitted by differential)
for measuring the F clutch oil pressure, HST: Hydro Static Transmission (Hydraulic
nipple (4) for measuring the R clutch oil power + power transmitted by dif
pressure, and nipple (6) for measuring ferential)
the 3rd clutch oil pressure.
iii) Set the Max. speed setter to the FMAX
position and the joystick to the FOR-
WARD position, rotate the track, and
measure the F clutch and 3rd clutch pres-
sure with the engine at low idling and
high idling.
A The machine is jacked up so be ex-
tremely careful of the rotation of the
tracks when measuring.
iv) Set the Max. speed setter to the RMAX
position and the joystick to the REVERSE
position, rotate the track, and measure
the R clutch pressure with the engine at
A The machine is jacked up so be ex-
tremely careful of the rotation of the
tracks when measuring.
Table 1 Unit: MPa (kg/cm*)

2. Measuring brake oil pressure
1) When measuring the brake oil pressure, in- Joystick
stall oil pressure gauge Cl to nipple (2). FORWARD or Steering to
2) Measure the brake oil pressure with the brake Neutra’ REVERSE left or right
pedal depressed and released, with the en- Parking LOCK 0 0 0
gine at low idling and high idling, and with brake
the joystick operated to the neutral, F, R, lever FREE ‘&:“;F Min. 2.2 (22) Min. 2.2 (22)
left, and right positions.

* Check that the values are as shown in Table 2 Unit: MPa (kg/cm?
Tables 1 and 2.
Depressed 0
Brake pedal
Released Min. 2.2 (22)
20-132
0
MEASURING AND ADJUSTING HMT PUMP MAIN
TESTING AND ADJUSTING (HIGH PRESSURE) RELIEF PRESSURE
MEASURING AND ADJUSTING

HMT PUMP MAIN (HIGH
PRESSURE) RELIEF PRESSURE
1. Measuring
AStop the machine on level ground, lower the
work equipment completely to the ground, ap-
ply the parking brake, then stop the engine.
1) When measuring the HMT pump main (high
pressure) relief pressure, remove measure-
ment plugs (I) and (2), and install oil pres-
sure gauge Cl (58.8 MPa (600 kg/cm?).
* Port PA: REVERSE (1)
Ir Port PB: FORWARD (2)
2) Start the engine, depress the decelerator
pedal, and turn the fuel control dial to the
FULL position.
3) Set the joystick to the neutral position.
4) Set the speed control lever to the halfway Cl
position.
5) Depress the brake pedal, set the parking
brake to the FREE position, and operate the
joystick to FORWARD.
6) Release the decelerator pedal slowly, run the
engine at full throttle, and measure the re-
lief pressure at that point.
7) Depress the decelerator pedal and operate
the joystick to REVERSE.
8) Repeat the procedure in Step 6) to run the
engine at full throttle and measure the relief
pressure.
2. Adjusting
1) Loosen locknut (4) of HMT pump main (high
pressure) relief valve (3), then turn adjust-
ment screw (5) to adjust.
* Turn the adjustment screw as follows.
l To INCREASE pressure, turn CLOCK-
WISE
. To DECREASE pressure, turn
BKD00330
COUNTERCLOCKWISE
* Amount of adjustment for one turn of
adjustment screw:13.72 MPa WI kg/cm3
m Locknut : 34.3 2 4.9 Nm 13.5 z 0.5 kgml
Ir After completion of adjustment, repeat
the procedure in Step 1 to check the set
pressure again.
I I I TAD00101
TESTING AND ADJUSTING MEASURING AND ADJUSTING HMT CHARGE PRESSURE

HMT CHARGE PRESSURE 1
1. Measuring
work equipment completely to the ground, then
apply the parking brake.
1) Remove HMT charge pressure measurement
plug (I), and install oil pressure gauge Cl
(5.88 MPa I60 kg/cm*)).
2) Set the joystick to the neutral position.
3) Run the engine at full throttle, and measure
the HMT charge pressure.
2. Adjusting
1) Loosen locknut (3) of HMT charge safety
valve (21, then turn adjustment screw (4) to \
adjust. \ ’
* Turn the adjustment screw as follows. c
l To INCREASE pressure, turn CLOCK- 1’
WISE
l To DECREASE pressure, turn
COUNTERCLOCKWISE
j, Amount of adjustment for one turn of
adjustment screw: 1.55 MPa 115.8 kg/cm3
w
*
Locknut : 68.6 + 9.8 Nm I7.0 I 1.0 kgm}
After completion of adjustment, repeat I TAD001 02
the procedure in Step 1 to check the set

pressure again.
I I II TAD001 03
TAD001 04
20-134
8
MEASURING AND ADJUSTING CHARGE VALVE RELIEF PRESSURE
TESTING AND ADJUSTING (HMT SERVO, PPC CIRCUIT CHARGE PRESSURE)

CHARGE VALVE RELIEF
PRESSURE (HMT SERVO, PPC
CIRCUIT CHARGE PRESSURE)
1. Measuring
Oil temperature when measuring: 45 - 55°C
Stop the machine on level ground, lower the
i
work equipment completely to the ground, then
apply the parking brake.
1) Remove plug (2) (l/s) of charge valve relief -1 J \‘- I
valve (HMT servo, PPC circuit charge pres- I 7

sure), and install oil pressure gauge Cl (5.9 2 TAD00105
MPa (60 kg/cm*)).
2) Set the joystick to the neutral position, then
start the engine and measure the charge
valve relief pressure (HMT servo, PPC circuit
charge pressure).
TAD00106
2. Adjusting
1) Remove plug (3) of charge valve relief valve
(HMT servo, PPC circuit charge pressure) (21,
then change number of shims (4) to adjust.
* Amount of adjustment for 1 shim: 0.04
MPa (0.4 kg/cm*)
(INCREASE the number of shims to IN-
CREASE the pressure.)
20- 135
a
TESTING AND ADJUSTING STEERING PRESSURE

WORK EQUIPMENT, STEERING
PRESSURE
work equipment to the ground, then apply the
parking brake.
Ir When installing the hydraulic gauge, remove all
the sand and dirt from around the plug.
1. Measuring hydraulic pressure

1) Remove plug (1) for measuring the pump
discharge pressure and plug (2) for measur-
- TAD00112
ing the load sensor pressure, and install oil
pressure gauge Cl (Work equipment: 39.2
MPa (400 kg/cmz) , steering oil pressure 58.8
MPa (600 kg/cm?).
2) Operate the blade tilt cylinder to the end of
its stroke to relieve the circuit, and measure
the work equipment oil pressure with the
engine at low idling and high idling.
3) Relieve the blade lift cylinder circuit and
measure the oil pressure with the engine at
Ilr Block the blade lift cylinder circuit with a
blind plug when measuring.
4) Set the joystick at neutral, the parking brake @
TAD00113
lever at the FREE position, and depress the
brake pedal. Then run the engine at high
idling, operate the steering lever fully to the
left or right, and measure the steering pres-
sure when the circuit is relieved.
/3
2. Adjusting work equipment load sensing relief
pressure
. Loosen locknut (4) of work equipment load

sensing relief valve (3), then turn adjustment
screw (5) to adjust. TAD00114
WISE
. To DECREASE pressure, turn COUN-
TER-CLOCKWISE
t Amount of adjustment for one turn of
adjustment screw: 17.5 MPa (179 kg/cm*)
w Locknut : 34.3 + 4.9 Nm (3.5 + 0.5 kgm)
* After completion of adjustment, repeat
the procedure in Step 1 to check the work
equipment relief pressure and load sens-
ing pressure again.
I TAD00115
20 136
0
TESTING AND ADJUSTING STEERING PRESSURE
3. Adjusting steering load sensing relief pressure
. Loosen locknut (7) of steering load sensing

relief valve (61, then turn adjustment screw
(8) to adjust.
WISE 6
l To DECREASE pressure, turn /
COUNTERCLOCKWISE
Sr Amount of adjustment for one turn of
adjustment screw: 15.1 MPa (154 kg/cm*)
I TAD001 16
m Locknut : 73.5 + 4.9 Nm (7.5 = 0.5 kgm)
* After completion of adjustment, repeat
the procedure in Step 1 to check the
steering relief pressure and steering load
sensing pressure again.
TAD001 17
20-137
0
BLEEDING AIR FROM HYDRAULIC CYLINDERS-
TESTING AND ADJUSTING RELEASING REMAINING PRESSURE IN HYDRAULIC
BLEEDING AIR FROM

HYDRAULIC CYLINDERS
* After replacing or installing hydraulic cylinders
or hydraulic piping, bleed the air from the hy-
draulic cylinders as follows:
1. Start the engine and run at idling for about 5

minutes.
2. Run the engine at low idling, and raise and
lower the blade or ripper 4 - 5 times.
* Stop the piston rod about 100 mm from the
end of the stroke. Never operate it to the
relief position.
3. Run the engine at full throttle and repeat the
procedure in Step 2. Then run the engine at
low idling and ooerate the piston rod to the end
of the stroke to relieve the circuit. .
RELEASING REMAINING
PRESSURE IN HYDRAULIC
CIRCUIT
A This machine is equipped with an accumulator
(the accumulator may lose its effect if it is left
for a long time), but the remaining pressure in
the piping between the control valve and hy-
draulic cylinders cannot be released simply by
operating the control levers.
When removing this piping, pay careful atten-
tion to the following points.
1. Run the engine at low idling, lower the work
equipment to the ground, taking care not to
relieve the circuit at the end of the stroke, then
stop the engine.
Ir If the engine is stopped when the hydraulic
cylinder has been relieved at the end of the
stroke, wait for at least 5 or 10 minutes be-
fore starting the operation.
2. When removing the piping, loosen the piping
sleeve nut gradually to release the pressure re-
maining inside the piping. Wait for the oil to
stop spurting out before removing the piping.
20-138
0
TESTING AND ADJUSTING BLEEDING AIR FROM HMT PUMP
BLEEDING AIR FROM HMT

PUMP
Hydraulic oil temperature: 45 - 55°C
Check that the hydraulic oil is at the specified
level.
When the HMT pump or HMT motor have been
removed or replaced, or when the hydraulic pip-
ing has been removed, always bleed the air as
follows:
Loosen air bleed plug (bleeder) (I) at the top of
the HMT pump.
Wait for 15 minutes, then start the engine and
run it at idling.
When oil comes out from the air bleed plug
hole, tighten the air bleed plug.
20-139
0
CHECKING LOCATION OF CAUSE OF HYDRAULIC
TESTING AND ADJUSTING DRIFT OF BLADE AND RIPPER
CHECKING LOCATION OF
CAUSE OF HYDRAULIC DRIFT Blade lift cylinder
OF BLADE AND RIPPER
* If hydraulic drift occurs in the blade and ripper
(cylinder), check as follows to see if the cause is
in the cylinder packing or in the control valve.
1. Inspection posture
1) Blade lift cylinder
. Push the blade against the ground to
raise the chassis.
* The piston has a valve so do not oper-
ate to the end of the stroke.
2) Blade tilt cylinder 1 TAD00123
. Extend the tilt cylinder rod fully (maxi-

mum tilt), then push the blade against
Blade tilt cylinder
the ground to raise the chassis.
3) Ripper lift cylinder
. Push the ripper against the ground to
raise the rear of the chassis.
2. Inspection
1) Set the cylinder of the circuit to be checked
in the inspection posture, then stop the en-
gine.
* For details of the inspection posture, see
Items I) - 4).
2) Operate the control lever in the direction to
extend the cylinder rod. Ih TAD00124
* For details of the inspection posture, see

Items I) - 4).
Ripper lift cylinder
3) Operate the control lever in the direction to
extend the cylinder rod.
. If the downward movement becomes
faster, the packing is defective.
. If there is no change, the control valve
is defective.
* If there is no more pressure in the accu-
mulator, run the engine for approx. 10
seconds to charge the accumulator be-
fore carrying out the operation.
Reference: TAD00125
If the cause of the hydraulic drift is in the packing,

the speed of downward movement in the above balance will be made in proportion to this
operation will become faster for the following rea- at a certain pressure (this differs accord-
sons. ing to the amount of leakage). .
I) With the work equipment in the posture given 3) When the pressure becomes balanced, the
above, (holding pressure applied to the bottom speed of downward movement becomes
end), the oil will leak from the bottom end to slower. In this condition, if the lever is
the head end. However, the volume at the head operated as shown above, the circuit at
end is smaller than at the bottom end (by an the head end is connected to the drain
amount proportional to the area of the rod), so circuit (the bottom end is closed by a check
if the oil flows in from the bottom end, the valve), and the oil at the head end flows
internal pressure at the head end will rise. to the drain circuit to increase the speed
2) If the internal pressure at the head end rises, a of downward movement.
20-140
0.
TESTING AND ADJUSTING MEASURING LEAKAGE INSIDE CYLINDER
MEASURING LEAKAGE INSIDE

CYLINDER
. If the hydraulic drift exceeds the standard value,
check if the cause of the hydraulic drift is in the
cylinder or in the control valve.
1. Measurement posture
1) Blade tilt cylinder
. Fully extend the rod of the cylinder to
be measured, and lower the end of the
blade to the ground.
2) Ripper lift cylinder
. Remove the shank pin and extend the
lift cylinder fully.
* The blade lift cylinder has a built-in
piston valve, so measurement is im-
possible. Disconnecthose
End of stroke
2. Measuring
I) Disconnect the head piping, and block the
piping at the chassis end with a blind plug.
a Be careful not to disconnect the piping
at the bottom end.
Start the engine, run the engine at high
idling, and apply the relief pressure to the
bottom end of the cylinder.
Wait for 30 seconds, then measure the
amount of leakage over the next 1 minute.
20-141
0
TESTING AND ADJUSTING ADJUSTING SEMI-U-TILTDOZER
ADJUSTING SEMI-U-TILTDOZER
t If the blade has been removed or disassembled,
adjust as follows.
1. Adjusting blade tilt

I) After installing the blade, adjust with handle
(I) so that dimension “a” is the following
dimension.
* Dimension “a”: 1,389 mm
2) Check the left and right tilt.
Amount of tilt Unit: mm
Right tilt Left tilt
Bl B2 1 TAD00127
450 450
3) If the tilt is not the same on the left and

right sides, adjust with handle (I) as fol-
lows to give the same tilt on both sides.
. B2 > Bl: Carry out fine adjustment to
make dimension “a” shorter Right tilt
. B2 c Bl: Carry out fine adjustment to
make dimension “a” longer
Bl B2
I
Left tilt
I TAD00128
20-142
0
TESTING AND ADJUSTING ADJUSTING SEMI-U-TILTDOZER
2. Procedure for adjusting with shims when as-

sembling blade
1) After assembling the blade, use shims to
adjust the clearance at tilt portion (2), center
portion (31, and lif? portion (4).
Shim adjustment Unit: mm
Clearance a b C
-
2 TAD00129
Standard clearance IMax. ImmlMax. ImmlMax. Imm
Standard shim 4 4 4
thickness
2) Apply grease to the adjustment locations and

check that the parts rotate smoothly.
& Adjustment portions (2), (31, (4):
Grease (G2-LI)
‘4 TAD00130
TAD00131
TAD00150 TAD001 49
20-143
TESTING AND ADJUSTING ADJUSTING CLEARANCE OF IDLER
ADJUSTING CLEARANCE OF
IDLER
Ir If the idler side guides, top and bottom guides,
and guide plate wear, and the idler is at an
angle or there is play to the side, adjust as
follows.
1. Adjusting in sideways direction

1) Drive the machine for 1 or 2 m on level
ground, then measure clearance “a” (left,
right, inside, outside: 4 places).
2) If clearance “a” is more than 4 mm, loosen
bolt (I) and adjust with shim (2) as follows.
Ir Clearance on one side: 0.5 - 1.0 mm
Ir Do not loosen bolt (I) more than 3 turns.
* The maximum adjustment amount is 6
mm.
2. Adjustment in vertical direction

l Shim adjustment cannot be used for adjust-
ment in the vertical direction, so measure
the clearance between the track frame and
guide plate (3). If the clearance is more
than 8 mm, replace with a new guide plate
(3) and wear plates (welded) (41, (51, and (6).
TAD00132
20-144
0
TESTING AND ADJUSTING SIMPLE PROCEDURE FOR TESTING BRAKE PERFORMANCE
SIMPLE PROCEDURE FOR

TESTING BRAKE
PERFORMANCE
* Carry out the measurement under the following
conditions.
. Coolant temperature: Within operating range
. Power train oil temperature: 70 - 90°C
1. Stop the machine on a level surface and set the
blade and ripper to the travel posture.
2. Run the engine at low idling, set the parking
brake to the FREE position and depress the brake
pedal.
TAD00135
3. Set the Max. speed setter to a mid-way position
(equivalent to F2).
4. Depress the decelerator pedal, set the fuel con-
trol dial to the FULL position.
5. Release the decelerator pedal gradually and raise
the engine speed to full throttle. Check that the
machine does not start to move.
A When measuring,
the decelerator
keep your right foot on
pedal, and if the machine
starts to move, immediately depress the
pedal and return the gear shift lever to the
neutral position.
zo- 745
0
TROUBLESHOOTING
Points to remember when troubleshooting ......................................................................................... 20-202
Sequence of events in troubleshooting ................................................................................................ 20-203
Points to remember when carrying out maintenance ........................................................................ 20-204
Checks before troubleshooting .............................................................................................................. 20-213
Type of connector and position of installation.. ................................................................................. .20-214

Connector arrangement diagram ......................................................................................................... .20-216
Connection table for connector pin numbers ...................................................................................... 20-218
Explanation of function of electrical system control mechanism ..................................................... 20-228
Monitor panel, HMT controller display method .................................................................................. 20-230
Method of using judgement table.. ....................................................................................................... 20-235
Method of using troubleshooting charts.. ........................................................................................... .20-236
Troubleshooting of engine throttle controller system (E mode) ....................................................... 20-30 1
Troubleshooting of engine system (S mode) ...................................................................................... 20-40 1
Troubleshooting of electrical system (E mode). ................................................................................. .20-501

8 and mechanical system (H mode) .................................................... .20-701
Troubleshooting of hydraulic
5
z Troubleshooting of machine monitor system (M mode) .................................................................. .20-801
20-201
0
TESTING AND ADJUSTING Points to remember when troubleshooting
POINTS TO REMEMBER WHEN TROUBLESHOOTING
A Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
A 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.
A If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
A Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
A When disconnecting wiring, always disconnect the negative (-) terminal of the battery first.
A When removing the plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and function.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry 3) Other inspection items.

to disassemble the components. 4) Other maintenance items can be checked ex-
If components are disassembled immediately any ternally, so check any item that is considered
failure occurs: to be necessary.
. Parts that have no connection with the fail- Confirming failure
g
ure or other unnecessary parts will be disas- Confirm the extent of the failure yourself, and
E
sembled. judge whether to handle it as a real failure or as
;;
. It will become impossible to find the cause a problem with the method of operation, etc.
of the failure. Sr When operating the machine to reenact the
It will also cause a waste of manhours, parts, or troubleshooting symptoms, do not carry out
oil or grease, and at the same time, will also lose any investigation or measurement that may
the confidence of the user or operator. make the problem worse.
For this reason, when carrying out troubleshoot- Troubleshooting
ing, it is necessary to carry out thorough prior Use the results of the investigation and inspec-
investigation and to carry out troubleshooting in tion in Items 2 - 4 to narrow down the causes of
accordance with the fixed procedure. failure, then use the troubleshooting flowchart to
2. Points to ask user or operator locate the position of the failure exactly.
I) Have any other problems occurred apart from Ir The basic procedure for troubleshooting is
the problem that has been reported? as follows.
2) Was there anything strange about the ma- 1) Start from the simple points.
chine before the failure occurred? 2) Start from the most likely points.
3) Did the failure occur suddenly, or were there 3) Investigate other related parts or infor-
problems with the machine condition before mation.
this? Measures to remove root cause of failure
4) Under what conditions did the failure occur? Even if the failure is repaired, if the root cause of
5) Had any repairs been carried out before the the failure is not repaired, the same failure will
failure? occur again.
When were these repairs carried out? To prevent this, always investigate why the prob-
6) Has the same kind of failure occurred be- lem occurred. Then, remove the root cause.
fore?
3. Check before troubleshooting
1) Check for symptoms of any abnormality in
the machine.
2) Check the CHECKS BEFORE STARTING items.
20-202
0
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
Offme, shop
TEW00180 &%a TEW00181 Jobsite
step 1
Examination, confirmation of symptoms
When a request for repairs is received, first

ask the following points. Ring I Ring I
. Name of customer
- Type, serial number of machine
- Details of jobsite, etc.
Ask questions to gain an outline of the prob-
lem.
- Condition of failure
- Work being carried out at the time of the TEW00182
failure
- Operating environment
- Past history, details of maintenance, etc.
‘I
step 2
Determining probable location of cause TEW00183
1) Look at the troubleshooting section of the

shop manual to find locations ’
of possible
causes.
- Hydraulic pressure gauge kit, etc.

2) Look in the parts book and prepare the nec-
essary replacement parts. 1) Before starting troubleshooting, locate and
2) See the Troubleshooting Section of the shop
Fie-enacting failure
(- Drive
fai,“re,
and
the condition
operate the
and judge
machine
if there
to confirm
is really a
TEWOO183
7/
Ask operator questions to confirm details of

I?$StJf Yilure.
- Was there anything strange about the ma-

chine before the failure occurred?
. Did the failure occur suddenly?
. Had anv repairs been carried out before the
TEW00189 III failure?’
I TEW0019(
20-203
0
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
To maintain the performance of the machine over a long period, and to prevent failures or other
troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and re-
pairs must be carried out. This section deals particularly with correct repair procedures for mechatronics
and is aimed at improving the quality of repairs. For this purpose, it gives sections on “Handling
electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
1. POINTS TO REMEMBER WHEN HANDLING

ELECTRIC EQUIPMENT
1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted 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 fre-
quently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely care-
ful when handling wiring harnesses.
TEW00191
Main failures occurring in wiring harness

@ Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely to
Improper insertion
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.
I TEW00192
@ Defective crimping or soldering of connec-

tors
The pins of the male and female connectors
are in contact at the crimped terminal Crimped portion
or
soldered portion, but if there is excessive
force brought to bear on the wiring, the plat-
ing at the joint will peel and cause improper
connection or breakage.
I TEW00193
20-204
0
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 solder-
ing may be damaged, or the wiring may be
broken.
High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof structure),
but if high-pressure water is sprayed directly
on the connector, water may enter the con-
nector, depending on the direction of the
water jet. #
As already said, the connector is designed
to prevent water from entering, but at the
same time, if water does enter, it is difficult b.
for it to be drained. Therefore, if water should
get into the connector, the pins will be short-
circuited by the water, so if any water gets
in, immediately dry the connector or take
other appropriate action before passing elec-
tricity through it.
Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face 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 connec-
tor, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a con- TEW00196
tact restorer.
Ir When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
Ir 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 clean-
ing with compressed air.
20-205
0
2) Removing, installing, and drying connectors and

wiring harnesses
l Disconnecting connectors
Hold the connectors when disconnecting.
When disconnecting the connectors, hold the
connectors and not the wires. For connec-
tors 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 con- TEW00197
nectors apart.
* Never pull with one hand.
When removing from clips

When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
* If the connector is twisted up and down
or to the left or right, the housing may
break.
TBW004B5
0 Action to take after removing connectors

After removing any connector, cover it with
a vinyl bag to prevent any dust, dirt, oil, or
water from getting in the connector portion.
Ir If the machine is left disassembled for a
long time, it is particularly easy for im-
proper contact to occur, so always cover
the connector.
TEW00198
20-206
0
0 Connecting connectors
Check the connector visuallv.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation, de-
Clicks into position
fective contact, corrosion, or damage to
the connector pins.
3) Check that there is no damage or break-
age to the outside of the connector.
+ If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry cloth.
If any water has got inside the connec-
il TEW00199
tor, warm the inside of the wiring with a

dryer, but be careful not to make it too
hot as this will cause short circuits.
* If there is any damage or breakage, re-
place the connector.
0 Fix the connector securely.

Align the position of the connector correctly,
then insert it securely.
For connectors with lock stopper, push in
the connector until the stopper clicks into
position.
Correct any protrusion of the boot and any

misalignment of the wiring harness
For connectors fitted with boots, correct any
protrusion of the boot. In addition, if the
wiring harness is misaligned, or the clamp
is out of position, adjust it to its correct po-
sition.
* If the connector cannot be corrected eas-
ily, remove the clamp and adjust the
position.
0 If the connector clamp has been removed,

be sure to return it to its original position.
Check also that there are no loose clamps. TBWKM97
20-207
0
l 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 wa-
ter or steam directly on the wiring harness.
If water gets directly on the connector, do as

follows.
@ Disconnect the connector and wipe off the
water with a dry cloth.
* If the connector is blown dry with com-
pressed air, there is the risk that oil in
the air may cause defective contact, so
remove all oil and water from the com-
pressed air before blowing with air.
@ Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dryer
to dry the connector.
Ir 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 connec-
tor.
0 Carry out a continuity test on the connector.

After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any short circuits between pins
caused by water.
* After completely drying the connector,
blow it with contact restorer and reas-
semble. T-adapter
20-208
0
3) Handling control box

The control box contains a microcomputer
and electronic control circuits. These control
all of the electronic circuits on the machine,
so be extremely careful when handling the
control box.
Do not open the cover of the control box
unless necessary.
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 con-
trol box in a place where it is exposed to
rain.
Do not place the control box on oil, water,

or soil, or in any hot place, even for a short
time.
(Place it on a suitable dry stand).
Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors con-
nected to the control box. Fit an arc welding
ground close to the welding point.
II TEW00206
2. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connect connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
* If the power is turned ON with the connectors still disconnected, unnecessary abnormality
displays will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or
current), move the related wiring and connectors several times and check that there is no
change in the reading of the tester.
* If there is any change, there is probably defective contact in that circuit.
20-209
0
TROUBLESHOOTING POINTS TO REMEMBIER WHEN CARRYING OUT MAINTENANCE
3. POINTS TO REMEMBER WHEN HANDLING

HYDRAULIC EQUIPMENT
With the increase in pressure and precision of hy-

draulic equipment, the most common cause of fail-
ure 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.
11 Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2) Disassembly and maintenance work in the field

If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is also
difficult to confirm the performance after repairs,
so it is desirable to use unit exchange. Disas-
sembly and main-tenance of hydraulic equip-
ment should be carried out in a specially pre-
pared dustproof workshop, and the performance
should be confirmed with special test equipment.
TEW00207
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 en-
tering. If the opening is left open or is blocked
with a rag, there is danger of dirt entering or of
the surrounding area being made dirty by leak-
ing oil so never do this.
Do not simply drain oil out on to the ground,
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
I TEWOOZOS
41 Do not let any dirt or dust get in during refilling

operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
TEW00209
20-210
0
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 pos-
sible of the old hydraulic oil must be drained
out. (Do not drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the hy-
draulic oil.
6) Flushing operations
After disassembling and assembling the equip-
ment, 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 sec-
ondary flushing is carried out with the specified
hydraulic oil.
Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the ma-
chine, carry out oil cleaning to remove the sludge
or contaminants in the hydraulic oil circuit.
The oil cleaning equipment is used to remove
the ultrafine (about 31.~1particles that the filter
built into the hydraulic equipment cannot re-
move, so it is an extremely effective device.
20-211
0
TESTING AND ADJUSTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
Judgement
Item Action
value
1. Check fuel level, type of fuel - Add fuel
2. Check for impurities in fuel - Clean, drain
3. Check hydraulic oil level Add oil
4. Check hydraulic strainer Clean, drain
3. Check power train oil level Add oil
5. Check engine oil level Add oil
7. Check coolant level - Add water
9. Check dust indicator for clogging Clean or replace
9. Check power train oil filter Replace
10. Check hydraulic filter Replace
11. Check final drive oil level Add oil
12. Check for looseness, corrosion of battery terminal, wiring Tighten or replace
13. Check for looseness, corrosion of alternator terminal, wiring Tighten or replace
14. Check for looseness, corrosion of starting motor terminal, Tighten or replace
wiring
15. Check operation of gauges Repair or replace
16. Check for abnormal noise, smell Repair
17. Check for oil leakage Repair
18. Carry out air bleeding Bleed air
19. Check battery voltage (engine stopped) 24 - 26 V Replace
20. Check battery electrolyte level - Add or replace
21. Check for discolored, burnt, exposed wiring - Replace
22. Check for missing wiring clamps, hanging wiring - Repair
23. Check for water leaking on wiring (pay particularly careful - Disconnect connec-
attention to water leaking on connectors or terminals) tor and dry
24. Check for blown, corroded fuses - Replace

4fter running fol
25. Check alternator voltage (engine running at l/2 throttle Several minutes Replace
or above) 27.5 - 29.5 v
26. 0@qTerating sound of battery relay (starting switch - -
20-213
0
TESTING AND ADJUSTING TYPE OF CONNECTOR AND POSITION OF INSTALLATION
TYPE OF CONNECTOR AND POSITION OF INSTALLATION

Serial No. : 60001 - 60271
Sr The Address column in this table shows the address in the connector pin allocation drawing
(3-dimensional drawing).
:onnector ConnectorNo. of
Place of use Address;
No. type pins
CN-OOI MIC 17 HMT controller Q-8
EN-2Hl AMP040 20 HMT controller P-8
EN-2H2 IAMP 16 1HMT controller 1 P-8 CN-217 M 2 Buzzer c-5
CN-003 I MIC / 21 I HMT controller 1 P-8 CN-220 M 2 Diode (battery relay drive) H-l
Intermediate connector
CN-004 I M I 2 I Diode I Q-8 CN-223 X I (rear lamp) J-4
CN-005 M 2 Diode R-8 CN-224 M 1 Rear lamp J-6
CN-006 M 2 Diode S-8 CN-243 M 1 Ripper lamp Q-8
CN-007 I M I 2 I Diode R-8 CN-244 ;o$,;r 1 Backup alarm J-6

Intermediate connector J-3
CN-009 I X / 2 I Engine speed sensor 2 I p-2 CN-245 x 2 lrinnar lamn1 S-F;
CN-OIO I X I 2 I Engine speed sensor I I p-2 1 CN-246 1 X 1 2 1Pin-puller solenoid / J-4

CN-247 X 1
CN-248 M 1 Ripper point lamp (opt) S-7
r&:262 I x I 2 I Horn switch I E-8

CN-014 1Relay I 5 1Backup alarm relay I l-8 1 CN-263 I X I 2 I Pin-puller switch I -
Intermediate connector D_8
CN-015 I Relay I 5 I Neutral safety relay I H-l
~~-016 I Relay I 5 1Overrun warning relay I H-8
Intermediate connector B-2 ~
CN-101 swp I2 (floor - engine) N-8
CN-103 X 2 Starting motor M-l
E E-l
D-l
L-7
1 CN-362
1 CN-363
I KES I 2 1Washer tank left
I KES I 2 1Washer tank right
I J-3
I J-2
CN-1 10 ;o;gc;r
1 intermediate connector
I K-7
M-7
T~,“,‘~II;;; dual pres- A_7
CN-151 X 3 Proximity switch E-8 CN-393 KES 3
CN-153 1SWP I 6 llntermediate 1 H-l CN-394 KES 4 Blower resistor C-6
CN-201 I X I 2 llntermediate connector1 N-l
CN-203 1 M 1 1 IFront lamp (right) I L-6 ..,,
CN-204 M 1 Front lamp (left) K-4
CN-205 - 1 Horn L-5

Engine water tempera- Q_1
CN-211 I KES 1 4 IRear lamp switch 1 C-6 CN-402 X 2 ture
Engine oil pressure sen-
CN-212 1 KES I 3 IBi-metal timer 1 B-4 CN-403 - 1 sioT
__. P-l
Intermediate connector B-3
CN-213 I KES I 4 IGIOW switch I c-7 CN-406 swp I2 (P/L - right fender) N-7
Intermediate connector ;I: 2 ;;:“e[~ee$a~;~;;ector J-5
CN-214 swp I6 (monitor - floor ) CN-422 X
20-214
03
Connector Connector
NO.of
Place of use Address Place of use Addres:
No. type pins
CN-423 X 2 Fuel level sensor H-8 ZN-RSOLI X I 2 I R solenoid 1 Q-3
ZN-ISOL X 2 1st solenoid O-8
ZN-2SOL X 2 2nd solenoid R-3
=N_3SOLI I 2 I3rd solenoid I O-8

CN-PI AMPO4C 16 Monitor panel
CN-P2 AMP040 12 Monitor panel
Pitch control switch (opt)
S eed control lever CN-SMP I X I 3 I Governor motor 1 F-l

CN-FMAX X 3 FgRWARD F-8
S eed control lever G-8 I G-1
CN-RMAX X 3 REVERSE CN-SM3 I x I 4 I Governor motor
1 CN-FNR / SWP 1 14 IJoystick 1 F-8

Intermediate connector J-7
CN-LEVER swp I6 (lever wiring harness) >
S-6
Intermediate connector I-l
CN-EMGCY swp I4 (prolix switch joint) S-6
CN-PUPA X 2 HMT pump solenoid A Q-2 IN-CAB-l ,‘a,$$,, 1 Cab power F-8
CN-PUPB X 2 HMT pump solenoid B Q-2 IN-CAB-2 ,‘anrez, 1 Cab power D-l
1CN-MRA 1 X 2 1HMT motor solenoid Ai R-3
1 CN-STB 1 X 1 2 ISteering EPC valve B 1 C-5

CN-PLTP X 2 ;,o;&tr,a,i&, \;$- N-7
CN-SOL-l X 2 Blade pitch solenoid c-3

, Assembly mode con- s_7
CN-KUMI X nectar
CN-RESET X 1 Controller memory clear S-8
CN-BRAK X 2 Brake solenoid s-5

3 HMT motor speed sen-
CN-MREV X nnr s-5
m X 1 1 12nd spool switch I s-4
1CN-3SW 1 X I 1 13rd spool switch I s-3

ICN-FSOL~ x I 2 IF solenoid 1 R-3

* The Address column in this table shows the address in the connector pin allocation drawing
(3-dimensional drawing).
Place of use Address Place of use Address
CN-001 1 MIC 1 17 IHMT controller Q-8 CN-216 1 KES I 4 1Front lamp switch C-6
CN-2Hl IAMP 20 I HMT controller P-8 CN-217 M 2 Buzzer c-5
CN-2H2 AMP040 16 HMT controller P-8 CN-220 M 2 Diode (battery relay drive) H-l
Intermediate connector J_4
CN-003 MIC 21 HMT controller P-8 CN-223 X I (rear lamp)
CN-004 1 M I 2 /Diode Q-8 CN-224 M 1 Rear lamp J-6
CN-005 I M ) 2 IDiode u-8 CN-243 I M I 1 I Ripper Lamp 1 Q-8
~~-006 1 M I 2 IDiode S-8 CN-244 ~~;‘p$r 1 Backup alarm J-6
CN-007 1 M I 2 IDiode I R-8 CN-245 X 2

Intermediate
(ripper lamp)
connector J-3
S-6
CN-009 X 2 Engine speed sensor 2 P-2 CN-246 I x 1 2 I Pin-puller solenoid I J-4
CN-010 X 2 Engine speed sensor 1 P-2 CN-247 X 1
CN-248 M 1 Ripper point lamp (opt) S-7
CN-262 I X I 2 I Horn switch E-8
CN-263 I X I 2 (Pin-puller switch I -

Intermediate connector D-8
CN-014 Relay 5 Backup alarm relay l-8 CN-264 swp 6 (horn switch)
CN-015 Relay 5 Neutral safety relay H-l CN-351 X 1 Air conditioner clutch Q-l
;;nt;-nner;liate connector Q-
CN-016 I Relay I 5 I Overrun warning relay I H-8 CN-360 KES 4
I I I I

CN-101 SWP 12 (floor - engine) CN-361 KES 2 Washer tank front J-2
N-8
Electrical intake air

CN-108 Terminal 1 heater terminal B L-7 CN-391 I KES I 4 I Air conditioner relay I A-4
Electrical intake air K_7
CN-109 Terminal 1 heater terminal C
CN-110 I &$zr I 1 1Intermediate connector I M-7
CN-153 SWP 6 Intermediate H-l
CN-201 X 2 Intermediate connector N-1
CN-203 1 M I I IFront lamp (right) I ~43 CN-396 I KES I 3 I Air conditioner switch I A-8
CN-204 I M I I IFront lamp (left) 1 K-4 CN-397 I M I 2 I Diode 1 B-5
~~-205 I - I I IHorn I L-5 CN-398 KES 4 Magnet relay A-5
CN-402 X 2 Engine water tempera- Q-1
ture
1 Engine oil pressure sen- P-l
CN-403 -
sor
CN-406 swp I2 (P/L - right fender) N-7
Intermediate connector ,44: ~;;~;~e;deila~;~;;ector J_5
CN-214 SWP 16 (monitor - floor ) CN-422 X 2
Intermediate connector A:
CN-215 SWP 8 (monitor - f)onr 1 CN-423 I X I 2 I Fuel level sensor I ~-8
20-215-l
@
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No. SWP type connector

of
pins Male (female housing) Female (male housing)
3 6
TEW00235 BLPOO033
4 8
8 4
TEW00237 TEW00238
12
0
0
._
_.__
______
i@iii!3 1
5
4
9 12
BLPOQO35
1 4 8 11 11 8 4 1
14
3 7 10 i4
14 10 7 3
TEW00240
4 1
1 4
5
5 8
16
9 2
9
BLPOuO36
20-219
0
No.
of
T M type connector
b E!$
1
3
1
2
BLPooO39
El Y
1
B
TEwoo243 TEW00244
3
;5
2 4 4 2
TEW00245 TEW00246
1 4
3 .6 TEW0024.6
TEW00247
BLPOOO41
20-220
0
No.
of
T S type connector
4’ ‘8 8 4
TEW0024-9 TEW00250
1 6
IO
j io TEW00251
BLP00042
1 6 6 1
12
5 12
BLPUOO43 TEW00254
1 8
L I
16
7 16 16 7
BLPCO044 TEW00256
20-22 1
0
No.
of
T MIC connector

1
3
uou
BLPOOQ45 BLFQOO46
1 BLPOCQ47 BLPOW46
7 1
13 8
13
I 1
i I BLPOO046 BLP000150
17
1
r
17
1 j BLPUW51 BLPW052
21
TEWOI3260
i j TEW00259
20-222
0
No. AMP040 type connector

of
4 8
8 4
BLWCO53
5 1
BLW0054
2 12 6
8 12
X
I-
s KI
1’ 7
BLFUOO55 7 i BLPOCO56
16 8
16
-8
BLpoOO57
20
11 1
TEW00234
20-223
0
No.
of
T AMP070 type connector
1 7
6 4
BLPOOOW
BLPooO59 14 6
9 1
12
8
BLPmO61 \ BLPOilO62
8
20-224
0
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No. c,f
pins
T L type connector
Male (female housing) Female (male housing)
aI
q
m
2
EE!d
TEW00258
20-225
8
No. Automobile connector

of
2
PH BLFO0063
I
BLPOO064
3 2
BLPOO065
1 2
4 BLPOO067
BLPOOO66
BLPOOO70
5 8
BLPW071 BLPOoO72
20-226
0
No. Relay connector

of
2 1
1 3 6 5 6 3
BLPuOO73 BLWOO74
6 4 3 6 5
ET
BLPOOO75 BLPoOO76
20-227
0
EXPLANATION OF FUNCTION OF ELECTRICAL
TESTING AND ADJUSTING SYSTEM CONTROL MECHANISM
EXPLANATION OF FUNCTION
OF ELECTRICAL SYSTEM
CONTROL MECHANISM
The electrical system control mechanism con-
sists of the monitor panel, HMT controller, and
engine throttle controller. The monitor panel
activates an alarm buzzer when abnormalities
occur in machine monitor, caution lamp system
or controllers. The engine throttle controller con-
trols engine speed only and does not output
any signal to the HMT controller.
The HMT controller carries out control of the
machine only. It receives signal (I) - (8) and (14)
and outputs signal to solenoids A - I in order to
control the travel speed and control engine speed
close to the target value. The functions of sig-
nals which are input / out to / from the HMT
controller are as follows:
l Input signal (a) outputs a signal which controls
safety function at engine starting.
l Input signal (c) outputs abnormality warning
to the monitor when HMT circuit charge pres-
sure drops. If machine were to continue to work
under this condition, a failure would result.
l Input signals (9) - (13) are used by HMT con-
troller for self-diagnosis.
l Input signal (b) outputs oil temperature signal
for adjustment of clutch engagement time ac-
cording to oil temperature.
l Input signal (14) outputs signals J and K to the
solenoids, when joystick (steering) is operated,
to operate steering system.
l Output signals L and M are output when an
abnormality occurs which makes it necessary to
stop the machine when it is traveling and to
return the transmission valve spool to the neu-
tral position.
l When this happens, output signal N is also
output to automatically actuate the brake. The
brake is also actuated by input signal (8).
When an abnormality occurs

1) The engine throttle controller transmits the
abnormality code through the S-NET to the
HMT controller and transmits a warning to
the monitor panel.
2) The HMT controller displays the abnormality
code on the display, and also sends a warn-
ing to the monitor panel through the S-NET.
20-228
0
Serial No. : 60001 6027 1

I Engine oil Pressure sensor
HMT P”~P charge ~reSS”re Sensor
-c I
Ensine water temoerature

sensor
Throttle potentiometer
Power train oil

temperature sensor
Brake Pedal potentiometer
Fuel level sensor
Directional lever potentiometer (2) Backup alarm relay
Steering lever potentiometer (1)

L
Steering lever potentiometer (2)

-3 bI-
piig
Is4 Speed control Potentiometer(F)

P\-
HMT pump servo solenoid (A)
HMT Pump servo solenoid(B)

SDeed control potentiometer (RI EI-
HMT motor solenoid (A)
C
HMT motor solenoid (6)
c)-
Steering EPC solenoid (A)
J -
Steerina EPC solenoid (8)
K
E
R clutch solenoid
F
1st clutch solenoid
C;
2nd clutch solenoid
ti-
Power train oil temuerature sensor 3rd clutch
-3 solenoid
@ I
Brake solenoid
bd-
Start signal
BR C
Battery relay drive -0:
- I
3rd SPOOI switch
TKD00715
20-229
0
%I. For Serial No.: 60001 - 60806

Engine oil pressure sensor

I
HMT PUIIIP charge ~res~“re sensor
gg
B Brake pedal potentiometer $
Directional lever twtentiometer(l1
rqF$
Oirecticnal lever potentiometer (2)
Steering lever Dotentiometer(l)

L
IEI Steering lever ootentiometer(2)

M
Sueed control potentiometer(F)

A
Speed control Potentiometer(R) B
Travel speed selector switch

C
____________________-_-_------_---J
;
D
Parking brake switch(l) =
-a o
J
Engine speed sensor (1) F

-3
b_J HMT motor speed sensor

-8
OE
-
F SPOOI switch
R SDOOI switch
ACC
Start sional
BR C
TVD00902
20-229-l
0
TESTING AND ADJUSTING MONITOR PANEL, HMT CONTROLLER DISPLAY METHOD
MONITOR PANEL, HMT CONTROLLER DISPLAY METHOD

1. Monitor panel
l When the starting switch is turned ON, all lamps and caution lamps light up for 3 seconds
and at the same time the alarm buzzer sounds for 1 second. Following this, they all return
to the normal display.
2. HMT controller
1) Self-diagnostic display
l The content of the self diagnosis is displayed in a 2-digit code using LEDs (light emitting diodes).
*....*If the self diagnosis detects any abnormality, it lights up the HMT system abnormality
display on the monitor panel and actuates the warning lamp and alarm buzzer.
2) Method of re-enacting abnormality display

. It is possible to re-enact and examine the abnormality display as follows.
[3 system: The moment the starting switch is turned ON -> OFF
11 system: Starting switch ON (engine stopped)
w system: Engine started
q system: Operation carried out to actuate actuator
Self diagnosis (abnormality) display code table
Iisplay Warning
Abnormal system and content of abnormality &t Memory Remarks
code BuzzerLamp
Drop in HMT charge pressure or disconnection in sen-
10 sor signal line moo0
11 HMT charge pressure sensor system remains closed II 0 0 0
12 Travel speed selector switch system remains ON q 0 - - For SerialNo.: 60001-60806
14 1 Throttle ootentiometer signal voltage is 4.68 V or above lolololol

15 Throttle potentiometer signal voltage is 0.29 V or below 11 0 0 0
16 Speed control lever (F) potentiometer signal is 4.68 V q 0 0 0
or above
17 S$~e~o;ontrol lever (F) potentiometer signal is 0.25 V q 0 0 0
18 ~xx?x?vontrol lever (RI potentiometer signal is 4.68 V q 0 0 0
19 S$e5~~o;ontrol lever (R) potentiometer signal is 0.29 V q 0 0 0
IA Brake pedal potentiometer signal is 4.68 V or above 0 0 0 0

Power train oil temperature sensor signal voltage is 0.29
Ic V or below 0 0 - -
Id
Abnormality in both directional lever potentiometer sig- q 0 0 0
nal systems
IE
Directional lever potentiometer
V or above
(I) signal voltage is 4.68
q 0 0 0
IF
Directional lever potentiometer
V or below
(I) signal voltage is 0.29
q 0 0 0
20 Brake pedal potentiometer signal is 0.29 V or below 0 0 0 0
20-230
0
Display Warning
Abnormal system and content of abnormality eE:ct Memory. Remarks
code BuzzerLamp
25 $eerer;~lever potentiometer (I) signal voltage is 0.29 V q 0 0 0

26 ~~;~qelever potentiometer (II) signal voltage is 4.68 V q 0 0 0
27 zF;;l;jvlever potentiometer (II) signal voltage is 0.29 V q 0 0 0
28 Abnormality in both engine speed sensor systems moo0
29 Abnormality in engine speed sensor (I) signal voltage moo0
2A Abnormality in engine speed sensor (II) signal voltage moo0
I 2c I Abnormality in HMT motor speed sensor I~lololol
1 2d 1 Abnormality in HMT motor speed sensor I~lololol

30 Disconnection in 1st clutch solenoid output system moo0
31 Short circuit in 1st clutch solenoid output system moo0

32 Disconnection in 2nd clutch solenoid output system n 0 0 4
1-33I Short circuit in 2nd clutch solenoid output system Imlololol

1 34 1 D’Isconnection in 3rd clutch solenoid output system lolololol
35 Short circuit in 3rd clutch solenoid output system DO00
38 Disconnection in brake solenoid output system 0 0 0 0
39 Short circuit in brake solenoid output system q 0 0 0

3A Disconnection in R clutch solenoid output system q 0 0 0
8
3c Short circuit in R clutch solenoid output system no00
2
Z 3d Disconnection in F clutch solenoid output system no00
3E Short circuit in F clutch solenoid output system no00
40 Does not come ON when F spool switch solenoid is ON q 0 0 0
1 41 I Does notcome ON when Fspool switch solenoid isON I q I 0 I 0, I 0 I

I 42 I Does not come ON when R spool switch solenoid is ON I q I 0 I 0 I 0 I
43 Does not come ON when R spool switch solenoid is ON q 0 0 0
44 Does not come ON when 1st spool switch solenoid is ON moo0

45 Does not come ON when 1st spool switch solenoid is ON n 0 0 0
I 46 I Does not come ON when 2nd spool switch solenoid is ON I H I 0 I 0 I 0 I
1 47 1 Does notcome ON when 2nd spool switch solenoid isON 1n 10 10 I 0 I

48 Does not come ON when 3rd spool switch solenoid is ON moo0
49 Does not come ON when 3rd spool switch solenoid is ON q 0 0 0
4F Disconnection in HMT pump servo solenoid output system 0 0 0

0
50 I Short circuit in HMT pump servo solenoid output system Idololol

51 I Disconnection in HMT motor servo solenoid (A) system I q I 0 10 10 I
52 Short circuit in HMT motor servo solenoid (A) system no00
53 Disconnection in HMT motor servo solenoid (B) system q0 0 0

54 Short circuit in HMT motor servo solenoid (B) system q 0 0 0
55 1 Disconnection in steering EPC solenoid system lmlololol
20-231
0
Iisplay Re- Warning

Abnormal system and content of abnormality Remarks
code enact MemoryBuzzerLamp
56 Short circuit in steering EPC solenoid system •l 0 0 0
57 Drop in power source voltage (17V or below) a 0 0 0
59 Disconnection in parking switch (I) signal system 0 0 - -
5A Disconnection in parking switch (2) signal system 0 0 - -

~u_m0.;fcJirectional lever potentiometers (I) and (II) is not
5c al 0 0 0
Sim of steering lever potentiometers (I) and (II) is not 5
5E f 0.5 v 0 0 0 0
Signal for engine speed sensor (I) is lower than signal
60 I 0 0 0
for sensor (II)
(II) is lower than signal
61 Signal for
for sensor
engine
(I)
speed sensor
n 0 0 0
Misalignment in signal for directional potentiometer (I)

6A 0000
system when starting signal is ON
Misalignment in signal for directional potentiometer (II)
6c startrng signal is ON 0 0 0 0
system when
Misali nment in signal for steering potentiometer sys-
6d starting signal is ON 0 0 0 0
tem (I a when
Misali nment in signal for steering potentiometer sys-
6E cl000
tem (I a when starting signal is ON
6F 1st fixed, 2nd start are both impossible q 0 0 0
70 Stays on when F spool switch solenoid is OFF •l 0 0 0
71 Stays on when F spool switch solenoid is OFF q 0 0 0
72 Stays on when R spool switch solenoid is OFF a 0 0 0
73 Stays on when R spool switch solenoid is OFF no00
74 Stays on when 1st spool switch solenoid is OFF n 0 0 0
76 Stays on when 2nd spool switch solenoid is OFF
78 Stays on when 3rd spool switch solenoid is OFF a 0 0 0
79 Stays on when 3rd spool switch solenoid is OFF moo0
8A Monitor panel alarm II 0 0 0

S-NET communication error (between monitor panel
8d and HMT controller) 0 0 0 0
governor con-
8E S-NET
troller
communication error
and HMT controller)
(between
q 0 0 0
96 Ab4z;mality in governor motor feedback potentiometer m 0 0 0

98 1 Abnormality in fuel control dial signal (outside range) lmlololol
Short circuit in batte relay out ut system (occurs at .X
A5
moment of switching % N + OF P)
0 0 0
A7 Disconnection in governor motor output system q 0 0 0
A8 Short circuit in governor motor output system lmiololol
20-232
0
3) Saving self-diagnostic display in memory

Once an abnormality has been detected, even if the abnormality is removed, the self-diagnostic
display keeps the display until the starting switch is turned OFF.
. Even if two or more failures occur at the same time, all of the failures are displayed in the self-
diagnostic display.
Display method: Starting in order with the display of the code for the abnormality which
occurred first, all the abnormalities are displayed, and finally the display
returns to the first code.
This is repeated continuously.
4) Saving failure code in memory

The HMT controller is equipped with a function to save the failure codes (self-diagnostic
display codes) in memory and to keep them in memory even after the starting switch is turned
OFF. (Up to a maximum of 10 codes)
In this way, if the starting switch is turned to ACC and the power for the HMT controller is
turned ON, it is possible to check the abnormalities that have occurred so far.
Method of saving and displayins failure codes u SYmbol:BIank (no disDlav)
TKD00717
Example of display of failure code in memory (now is normal but abnormalities 18 and 17 occurred in Past)
I Strtins I
Display interval ~,~,-$“,eEfs3,t”,eetss,i
TKD00718
20-233
@
Continuous display
when norma I
-- OlSPlaY $ 88 lee
-v
: g Continuous display
None
- - when normal
2:
1 Display interval k5 seci
_I
TKD00719
This system can answer question such as “When did the failure occur?” or “Which failures have
been repaired?“. To make it possible to make full use of the memory function, the following
operation must always be followed.
5) Method of erasing failure code from memory

After troubleshooting has been carried out and the failure has been repaired, if the self-
diagnostic display returns to the normal display, always erase the HMT controller failure codes
from memory as follows.
Turn the starting switch ON and when the past items in memory have all been displayed, make
sure that the display is 0.0.
Pull out and reinsert the connector (black l-pin) with the reset connector number near the
controller. (Keep the starting switch at the ON position when doing this.)
After turning the starting switch OFF, turn it ON again and check that all the past items in
memory have been erased.
(If the memory has been cleared, the display will show 8.8. for 5 seconds and then will 8
change immediately to the 0.0 normal display.)
2
z
20-234
@
TESTING AND ADJUSTING METHOD OF USING JUDGEMENT TABLE
METHOD OF USING JUDGEMENT TABLE

This judgement table is a tool to determine if the problem with the machine is caused by an
abnormality in the electrical system or by an abnormality in the hydraulic or mechanical system. The
symptoms are then used to decide which troubleshooting table (E-00, H-00) matches the symptoms.
The judgement table is designed so that it is easy to determine from the self-diagnostic display which
trouble-shooting table to go to.
Ir The abnormality display (warning) given by the monitor panel leads directly to troubleshooting of
the machine monitor (M-00).
(See the list of contents for troubleshooting of the machine monitor system)
[Method of using judgement table]

. A 0 mark is put at the places where the failure mode and self-diagnostic display match, so check
if the warning lamp on the monitor panel is lighted up.
. If the warning lamp is lighted up and an abnormality code is displayed on the HMT controller:
......Go to the troubleshooting code at the bottom of the judgement table ($1 (E-00).
. If a problem has appeared but the warning lamp is not lighted up and no abnormality code is
displayed on the HMT controller:
......Go to the code on the right of the judgement table (+) (H-00).
. If there is no 0 mark, go directly to the code on the right of the judgement table (-+I.
<Example> Failure mode “Travel speed does not change when travel speed selector switch is
operated”.
Procedure: Check if the self-diagnostic error code is being displayed on the monitor panel
(by a lighted warning lamp) or is being displayed on the HMT controller display.
20-235
0
TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

1.Cateaorv of troubleshootina code number
Troubleshooting
Component
Code No.
E-00 Troubleshooting of engine throttle controller system
E-000 ~~~ 1~Troubleshooting of HMT controller system

H-00 Troubleshooting of hydraulic, mechanical system
M-00 Troubleshooting of machine monitor system
s-00 1 Troubleshooting of engine related parts
2. Method of using troubleshooting table for each troubleshooting mode

Troubleshooting code number and problem
The title of the troubleshooting chart gives the troubleshooting code and failure mode (prob-
lem with the machine).
General precautions
When carrying out troubleshooting for the failure mode (problem), precautions that apply to all
items are given at the top of the page and marked with *.
The precautions marked * are not given in the I, but must always be followed when
carrying out the check inside the I-1.
Distinguishing conditions
Even with the same failure mode (problem), the method of troubleshooting may differ accord-
ing 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), b)), so go to the appropriate $
section to carry out troubleshooting. b
If the troubleshooting table is not divided into sections, start troubleshooting from the first
check item in the failure mode.
Method of following troubleshooting chart
YES
l Check or measure the item inside I-E, and according to the answer follow either
NO
the YES line or the NO line to go to the next I-1. (Note: The number written at the top
right corner of the II is an index number; it does not indicate the order to follow.)
. Following the YES or NO lines according to the results of the check or measurement will
lead finally to the Cause column.
Check the cause and take the action given in the Remedy column on the right.
. Below the [I there are the methods for inspection or measurement, and the judge-
ment values. If the judgement values below the _ are correct or the answer to the
question inside the II is YES, follow the YES line; if the judgement value is not
correct, or the answer to the question is NO, follow the NO line.
. Below the 1-I is given the preparatory work needed for inspection and measurement,
and the judgement values. If this preparatory work is neglected, or the method of opera-
tion or handling is mistaken, there is danger that it may cause mistaken judgement, or the
equipment may be damaged. Therefore, before starting inspection or measurement,
always read the instructions carefully, and carry out the work in the correct order.
Troubleshooting tools
When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For
details, see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.
Installation position, pin number
A diagram or chart is given for the connector type, installation position, and connector pin
number connection. 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).
20-236
0
TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING CHARTS
<Example>
0 M-5 Abnormality in buzzer
@ + Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on to the next step.
+ Of the Caution items, the buzzer does not sound if there is an abnormality in the battery charge.
@ a) Caution item flashes but buzzer does not sound
Cause Remedy
1 YES
Defective monitor panel Replace
1Does buzzer sound II
when CNP2 Defective contact or
(female) (71 is disconnection in wiring
connected to harness between fuse 3 - Repair or
chassis ground?
CN215 (2) - CN217
replace
*Connect CNP2 No (female) (1). or between
(female) (7) to CN217 (female) (2) - CNP2
chassis ground. (female) (7)
-Turn starting
switch ON.
20-237
0
TROUBLESHOOTING OF ENGINE THROTTLE
CONTROLLER SYSTEM
(E MODE)
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF

ENGINE THROTTLE CONTROLLER SYSTEM . . .. . . . . . . .. .. .. . . . . . . .. .. . . . . . . . . .. . . . . . . . .. .. . . . . . . .. .. . . . . . . . .. .. . .. . . . . . . . 20-302
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND
PROBLEMS ON MACHINE . . . . . . .. . . . . . . . . .. . . . . . . . .. . . . . . . .. . . .. . . . .. .. . . . . . . . .. . . . . . .. . .. . . . . . .. . . . . . . . . .. . . . . . . . . .. .. . . . . . . . . . .. . . . 20-303
JUDGEMENT TABLE FOR ENGINE THROll-LE GOVERNOR, ENGINE RELATED PARTS . . . . . . . . .. . . . . . . . 20-305
ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE THROTTLE CONTROLLER SYSTEM . . . .. . . . . . . . . . . .. . . . . . . . 20-306
E-l. Abnormality in engine throttle controller power source.. ......................................................... .20-307
E-2. f8El S-NET communication error (between governor controller and

HMT controller) is displayed ..................................................................................................... .20-308
E-3. 1961 Abnormality in feedback potentiometer system is displayed ........................................... .20-309
E-4. 1981 Abnormality in fuel control dial signal system is displayed.. ............................................ .20-310
E-5. [A51 Short circuit in battery relay drive system is displayed .................................................... .20-311
E-6. [E71 Disconnection in governor motor drive system is displayed ............................................ .20-312
E-7. [A81 Short circuit in governor motor drive system is displayed ............................................... .20-313
E-8. Engine does not start.. .................................................... . ............................................................. .20-314

8 .20-317
X E-9. Engine speed is irregular (Idling speed is irregular or there is hunting) .................................
b
E-10. Lack of output (engine high idling speed is too low). ................................................................ .20-318
;;
E-II. Engine does not stop .................................................................................................................... .20-320
20-301
0
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLE-
TROUBLESHOOTING SHOOTING OF ENGINE THROlTLE CONTROLLER SYSTEM
POINTS TO REMEMBER WHEN CARRYING OUT

TROUBLESHOOTING OF ENGINE THROTTLE CONTROLLER
SYSTEM
1. Points to remember when there is abnormality which is not displayed by user code
The engine on the D155AX-3 is controlled by an engine throttle controller.
The problems that may occur with this system include the following.
1. Low idling speed is too high (too low)
2. High idling speed is too low
3. There is hunting
4. Engine does not stop
If any abnormality occurs, and the abnormality is displayed on the HMT display, use the trouble-
shooting table to determine the appropriate troubleshooting flow chart from El to E8. However, if
there is any abnormality in the engine and no abnormality display is given, it is necessary to
determine whether the problem is in the mechanical system or in the electrical system. If the
linkage between the governor motor and the injection pump is not properly adjusted, problems 1
to 4 listed above may occur.
Therefore, if there is no abnormality display, but one of problems 1 to 4 above has occurred, carry
out troubleshooting as follows.
Defective adjustment of governor motor

YES 2 YES
If linkage batwaa” T linkage
governor motor and % See TESTING AND ADJUSTING.
If linkage between injection pump is
governor motor and r disconnected, does -
injection pump is
disconnected and Go to troubleshooting E-9 - E-11 of
pump lever is
electrical system
operated by hand
or is fixed with switch at ON, operate fuel control
wire, does
dial and working mode switch. Go to troubleshooting S-l -S-l6 of
condition return to
normal? NO engine system
X If engine does not stop,

push govern~pr lever to
STOP position and check
if engine stops.
Disconnect the linkage as explained above, or check the adjustment and go to the troubleshooting
flow chart for the mechanical system or electrical system.
% For details of the procedure for adjusting the linkage, see TESTING AND ADJUSTING.
2. Points to remember if abnormality returns to normal by itself
In the following cases, there is a high probability that the same problem will occur again, so it is
desirable to follow up this problem carefully.
1) If any abnormality returns to normal by itself, or
2) If the connector is disconnected and the T-adapter is inserted, or if the T-adapter is removed
and the connector is returned to its original position when carrying out troubleshooting of the
failure, and the abnormality is no longer displayed.
3) After completing troubleshooting, always erase the user code from memory.
3. Abnormality code memory retention function
When displaying the abnormality code in memory and carrying out troubleshooting, note down
the content of the display, then erase the display. After trying to re-enact the problem, carry out
troubleshooting according to the failure code that is c displayed.
(There are cases where mistaken operation or abnormalities that occur when the connector is
disconnected are recorded by the memory retention function. Erasing the data in this way saves
any wasted work.)
20-302
0
TROUBLESHOOTING ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE

npr- Condition when normal
Abnormal system Nature of abnormality Action by controller Problem that appears on machine
;l;W (voltage, current, resistance) when abnormality is detected when there is abnormality
Abnormality in network re- 1. Short circuit, disconnection in network wiring harness 1. The abnormality in the governor con- If the abnormalities in the following five modes
3E ception system (between 2. Abnormality in HMT controller troller cannot be transmitted to the occur, the abnormality is not displayed on the
HMT controller and gover- 3. Abnormality in engine throttle controller HMT controller HMT controller and monitor panel even if the
nor controller) operator feels the abnormality.
1. Short circuit in wiring harness between SMI (5) - (16), (5) - (17), (16) - (17) Resistance Calculates position of motor and carries 1. F$acci;ion of engine speed control may be re-
2. Short circuit in wiring harness between SM2 (1) - (2), (I) - (3), (2) - (3) SMI (female) SM2 (male)
value out control from value of voltage imme-
3. Short circuit in wiring harness between SX5 (1) - (2), (1) - (3), (2) - (3) (5) - (17) (l)-(2) 0.25 - 7 kQ diately before abnormality occurred For example:
4. Short circuit in wiring harness between SMI (5) - (7), (7) - (16) 1) Engine does not change to high idling speed
5. Disconnection in wiring harness between SMI (5) - SM2 (I) (17) - (16) (2) - (3) 0.25 - 7 kR (a little too low)
Abnormality in feedback 6. Disconnection in wiring harness between SMI (17) - SM2 (2) 2) Engine does not change to low idling speed
36 (5)-(16) - 2-3kQ
potentiometer system 7. Disconnection in wiring harness between SMI (16) - SM2 (3) (a little too high)
8. Defective governor motor potentiometer - (I) - (3) 4-6kS2 3) Engine may not stop
9. Defective contact of SMI, SM2 connectors * The governor motor moves in the direction
Between each to stop the engine, but motor may not move
Min. 1 MQ
pin and chassis - completely to the position to stop the en-
gine.
4) There are cases of hunting
1. Short circuit in wiring harness between SMI (5) - (16), (5) - (17), (16) - (17) Resistance Maintains engine speed at position of 1. Does not become partial speed when set at
SMI (female) SX5 (male) fuel control dial immediately before ab- FULL position
2. Short circuit in wiring harness between SM2 (I) - (2), (I) - (3), (2) - (3) value
3. Short circuit in wiring harness between SX5 (I) - (2), (I) - (3), (2) - (3) normality occurred 2. Does not reach high idling when set at partial
(5) - (7) (l)-(2) 0.25 - 7 kR
4. Short circuit in wiring harness between SMI (5) - (7), (7) - (16) speed
Abnormality in fuel control 5. Disconnection in wiring harness between SMI (5) - SX5 (I) (7) - (16) (2) - (3) 0.25 - 7 kR 3. There are cases of hunting
38 6. Disconnection in wiring harness between SMI (17) - SX5 (2) 4. Lacks output (max. speed of engine is too
dial input value
7. Disconnection in wiring harness between SMI (16) - SX5 (3) (5)-(16) - 2-3kQ low)
8. Defective fuel control dial - (1) - (3) 4-6kQ
9. Defective contact of SMI, SX5 connectors
Between each
Min. 1 MQ
pin and chassis -
If excess current flows between SMI (13) - battery relay drive relay Between SMI (13) and chassis: 20 - 30 V Sets drive current of battery relay drive Engine does not stop
Abnormality (short circuit) Ir This occurs only when turning starting switch to OFF, and stop- * Holds with the motor in the stop position for relay to 0
45
in battery relay drive system ping engine 4 set, returns to the low idling position, then
turns the battery relay OFF.
1. Disconnection inside governor motor Resistance 1. When there is a disconnection in both the A
2. Disconnection in wiring harness between SMI (IO) - SM3 (I) SM3 (male) SMI (female) phase and B phase at the same time, the prob-
value
3. Disconnection in wiring harness between SMI (11) - SM3 (3) E. Takes no particular action lem is the same as for a short circuit in the
(l)-(2) (IO) - (20) 2.5 - 7 Q
4. Disconnection in wiring harness between SMI (20) - SM3 (2) governor motor system
5. Disconnection in wiring harness between SMI (21) - SM3 (4) (3) - (4) (II)-(21) 2.5 - 7 R 2. When there is a disconnection in only one of A
6. Defective contact of SMI, SM3 connectors phase or B phase
(1) - (3) (IO) - (11) Min. 1 MZZ
Abnormality (disconnec- 1) Engine does not stop
47 2) Stops moving at position immediately before
tion) in motor drive system (l)-(4) (IO) - (21) Min. 1 MS1
failure, so engine speed cannot be controlled
Between pins Between Pins 3) There are cases of hunting
(I), (2), (3), (4) (lo), (‘I), (12), Min. 1 MQ
and chassis
%$53) and
Hold: 0.7 A
Motor drive current: Start: o.84 A
1. Short circuit inside governor motor Resistance Sets motor drive current to 0 1. If during operation
2. Wiring harness between SMI (IO) - SM3 (I) short circuiting SM3 (male) SMI (female)
value 1) Sets to low idling
with wiring harness between SMI (20) - SM3 (2) 2) Engine does not stop
(1) - (2) (IO) - (20) 2.5 -7 Q
3. Wiring harness between SMI (II) - SM3 (3) short circuiting 3) There are cases of hunting
with wiring harness between SMI (21) - SM3 (4) (3) - (4) (11) - (21) 2.5 - 7 Q 2. When stopped
4. Wiring harness in Items 2 and 3 short circuiting with chassis 1) Engine starts, but stays at low idling
Abnormality (short circuit) ground (1) - (3) (IO)-(11) Min. 1 MQ 2) Engine does not stop after starting
\8
in motor drive system 3) There are cases of hunting
(I) - (4) (IO) - (21) Min. 1 MQ
;y;;;$;l;) @%i$$, Min. 1 MR

and chassis
chassis
Hold: 0.7 A
Motor drive current: Start: o.84 A
20-303
a
JUDGEMENT TABLE FOR ENGINE THROlTLE
TROUBLESHOOTING GOVERNOR, ENGINE RELATED PARTS
JUDGEMENT TABLE FOR ENGINE THROTTLE GOVERNOR,

ENGINE RELATED PARTS
Failure mode
IS excesswe, or
exhaust gas is blue
20-305
0
ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE
TROUBLESHOOTING THROTTLE CONTROLLER SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE THROTTLE

CONTROLLER SYSTEM
CNOII CNZHZ
Monitor panel &qo”4op]e, (SWPlP) (0401B) HMT controller
11 S-NET
CNPP
(04012) Fuel control
S-NET 10 CNSX5fM3) dial
3
3
-3
Motor drive (B)
Motor drive (A)
Model selection 4
Model selection 2
Governor actuator
Feedback
CNSMZ(X3) rw--,,,e,,i,,;e~-l
Throttle power
source 6)
Network circuit + I
Network circuit sig I
Battely relay drive
GND
Motor drive (B)
Motor
Model
drive
selection
(A)
3
ri
Model selection 1
Throttle command
Key switch ON signal

Throttle power
VB (chassis
@
power source)
VB (chassis a 0
power source)
I I
TDD00159
20-306
0
TROUBLESHOOTING E-l
E-l. Abnormality in engine throttle controller power source

* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Ir Always connect any disconnected connectors before going on the next step.
Sr Check that fuse 2 is not blown.
Sr If no sound is heard from the battery relay when the starting switch is turned ON t) OFF, carry out
Troubleshooting E-8.
Cause Remedy
Defective engine throttle

Replace
controller
Defective contact, or
disconnection in wiring Replace wiring
harness between fuse 2 harness
and SMI (female) (1). (2)
See E-8
NO
E-l. Related electrical circuit diagram
Engine throttle CNSMl

Batteryrelay Battery
controller (MIC21) Fuse CN104(L2)
M
c
1
TDD00160
20-307
0
TROUBLESHOOTING F-7
E-2. [8El S-NET communication error (between governor controller and
HMT controller) is displayed
* Always connect any disconnected connectors before going on the next step.
Cause Remedy
YES
Defective HMT controller Replace
2
Is voltage
Defective governor
between CN2H2 Replace
controller
(11) and chassis between SMl
Yt
normal? (female) (14). (15) Wiring harness between
* Turn starting 3 SMl (female) (14),(15)-PI
Replace wiring
switch ON. Is resistance (fernale)( P2 (female)
harness
‘*4-8V between CN2H2 . Turn startina (IO) short circuiting with
- (female) (11) and switch OFF.- chassis ground
controller LED
NO SMl (female) (14, * Disconnect SMI,
(15) normal? Pl, P2, and
CN2H2. disconnection in wiring
* Turn starting harness between CN2H2
* Min. 1 MD Replace wiring
switch OFF. (female) (11) - CNOll
* Turn starting * Disconnect harness
(female) (7) - SMI (female)
switch ON. CN2H2, SMl, Pl, and P2. (14). (15), or short circuit
. Between wiring harnesses: Max. 1 R with chassis ground
* Between wiring harness and chassis:
Min. 1 Ma -
See E-158
NO
E-2. Related electrical circuit diagram
CNPI CN214 CNOI 1 CN2H2

(04012) (SWPIG) (SWPIZ) (04016) HMT controller
Monitor panel

controller (MIC21)
I \ I
S-NET @
S-NET cj$ 1
TDD00161
20-308
0
TROUBLESHOOTING E-3
E-3. 1961 Abnormality in feedback potentiometer system is displayed
+ Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Remedy
YES
1 Defective controller
Wiring harness between

SMI (female) (5) and SM2
2 Replace wiring
YES (female) (I) short circuiting
Is resistance at 4- harness
with chassis ground, or
YE SMI (female) Is resistance contact with power source
side as shown in YES between SMl wiring harness
Table I? - (female) (16) and -
SM2 (female) (3) Defective contact, or
* Turn starting 3
- normal? disconnection in wiring
switch OFF. Is resistance Replace wiring
1 -Turn starting - harness between SMI
- Disconnect SMI between SM 1 harness
No (female) (16) and SM2
Is resistance at and SX5. - (female) (17) and - switch OFF.
* Disconnect SMI (female) (3)
SM2 (male) side No SM2 (female) (2)
and SM2.
normal? Defective contact, or
- Max. 1 R
* Turn starting disconnection in wiring
switch OFF. harness between SMI Replace wiring
* Turn starting
* Disconnect SMI NO (female) (17) and SM2 harness
switch OFF.
* Disconnect SM2. and SM2. (female) (2). or short circuit
* Max. 1 R with chassis ground
Replace
NO
Table 1
8
2 SM2(female) SMl(female)
Resistance
value
z
When measuring the item marked % from the SMI (female) end, disconnect connector SX5.
(This is because the power source circuit is connected in parallel to the above potentiometer.)
Engine throttle CNSMT

controller (MIC21) CNSM2(X3)
source
Governor motor
Governor motor
potentiometer potentiometer
Potentiometer GND
Fuel control dial SIG
Fuel control dial
TDD00162
20-309
0
TROUBLESHOOTING E-4
E-4. 1981 Abnormality in fuel control dial signal system is displayed

Always connect any disconnected connectors before going on the next step.
Cause Remedy
YES
Defective controller Replace

SMI (female) (5) and SX5
4 YES (female) (I) short circuiting Replace wiring
Is resistance at with chassis ground, or harness
YE _ SMl (female) Is resistance contact with power source
side as shown in YES between SMI wiring harness
Table l? - (female) (16) and -
SX5 (female) (3) Defective contact, or
* Turn starting 3 normal?
_ disconnection in wiring
switch OFF. Is resistance Replace wiring
1 * Disconnect SMI between SMI
* Turn starting - harness between SMl harness
No (female) (16) and SX5
and SM2. - (female) (7) and - switch OFF.
* Disconnect SMI (female) (3)
SX5 (male) side No SX5 (female) (2)
and SX5.
* Max. 1 D
*Turn starting disconnection in wiring
switch OFF. harness between SMl Replace wiring
-Turn starting
- Disconnect SMl NO (female) (7) and SX5 harness
switch OFF.
* Disconnect SX5.
kc ?eplace
Table 1
Resistance
I SM2 (female)
I
SMI (female)
I
value
Between %Between
4-6kS1
(1) and (3) (5) and (16)
Between each pin

Min. 1 ML2
Between each Din and chassis
When measuring the item marked % from the SMI (female) end, disconnect connector SM2.
(This is because the power source circuit is connected in parallel to the above potentiometer.)
3
Governor motor
Governor motor 3
potentiometer Q-J-p potentiometer
Potentiometer GND 3

CNSX5(X3)
Fuel control dial
3 I
TDD00162
20-310
0
TROUBLESHOOTING E-5
E-5. [A51 Short circuit in battery relay drive system is displayed

Note: When the engine is stopped, this problem occurs only when the starting switch is turned ON 3 OFF.
* The engine does not stop.
g Stop the engine before starting the inspection. (Push the fuel control lever on the injection pump
to the NO INJECTION position.)
wiring harness between

harness
Is resistance SMI (female) (13) and
YES between SMI relay (SX7) (1)
(female) (13) and Wiring harness between
1
- chassis normal? SMl (female) (13) and
Is resistance
between relay
6x7) (1) and (2) -
*Turn starting
switch OFF.
NO
relay 6x7) (I) short
circuiting with chassis
I
Replace wiring
harness
. Disconnect SMl ground

normal?
and relay 6X7).
* Turn starting * Min. 1 MR
switch OFF. Defective relay (SX7) Replace
NO
* Measure with
relay as
individual part.
*270-320R
8
5 % In Item 1, it is also possible to check by replacing the relay.
z In this case, if the condition returns to normal, the relay is
defective. If there is no change (the abnormality is still
displayed), go on to Item 2.
Battery relay drive relay
CNSX7
To battery (+)
CNSMI
Engine throttle
controller (MIC21)
I \ I
Batten/ relay drive I
I
CN220(M2)
a.
@+ To alternator terminal R
TDD00163
20-311
0
TROUBLESHOOTING E-6
E-6. [E7] Disconnection in governor motor drive system is displayed

Ir During operation:
1) If there are disconnections simultaneously in both A and B phases:
@ The engine speed changes to low idling @ The engine does not stop
2) If there is a disconnection in only one of A or B phases:
The engine speed stays the same as before the problem occurred
* If the problem occurs when the engine is stopped:
1) The engine can be started but the engine speed stays at low idling
2) The engine starts but will not stop
a Stop the engine before starting the inspection. (Push the fuel control lever on the injection pump
** to the NO INJECTION position.)

Before carrying out troubleshooting, check that all the related connectors are properly inserted.
2 YES Defective engine throttle

Replace
controller
I Is resistance II I
YES between each pin
1 of SMI (female) as Defective contact, or
Is resistance shown in Table l? disconnection in wiring Replace wiring
between each pin NO harness of system where harness
- * Turn starting
of SM3 (male) as resistance is defective
switch OFF.
shown in Table l?
- Disconnect SM 1.
* Turn starting I Defective governor motor Replace
switch OFF. NO
* Disconnect SM3.
Table 1
Engine throttle CNSMT

i- \ I I I I Governor motor
TDD00164
20-312
0
TROUBLESHOOTING E-7
E-7. [A81 Short circuit in governor motor drive system is displayed

* If the problem occurs when the engine is running, the force of the spring has the following effect:
1) The engine changes to low idling
2) The engine will not stop
Ir If the problem occurs when the engine is stopped:
1) The engine can be started but the engine speed stays at low idling
2) The engine starts but will not stop
A Stop the engine before starting the inspection. (Push the fuel control lever on the injection pump
Sr Always connect any disconnected connectors before going on the next step.
I Cause Remedy
2
~- YES Defective engine throttle
Is resistance Replace
between each pin controller
, YES of SMl (female) Contact with other wiring
and between each harness or short circuit
Is resistance
pin and chassis as
between each pin with chassis ground in Replace wiring
shown in Table l? NO
of SM3 (male) and wiring harness of system harness
between each pin - Turn starting where resistance is
and chassis as switch OFF. defective
shown in Table l? - Disconnect SMl.
* Defective governor motor Replace
-Turn starting NO
switch OFF.
s - Disconnect SM3.
5
s
Table 1
SM3 (female) Resistance

SMI (female)
value
(I) - (2) (10) - Cm 2.5 - 7 sz
(3) - (4) (11) - (21) 2.5 - 7 sz
(I) - (3) (IO) - (11) Min. 1 MR
(I) - (4) (10) - (21) Min. 1 MQ

Pins(i),(2),(3),(4) Pins(lOL(1lL(20).
Min. 1 MQ
and chassis (2l)and chassis

controller (MIC21) CNSM3fX4)
Governor motor
$0
TDDO0164
20-3 13
0
TROUBLESHOOTING E-6
E-8. Engine does not start

Serial No. : 60001 - 60271
If the starting motor does not turn or it turns stiffly.
(If the starting motor turns normally, but the engine will not start, go to S-2.)
Check that abnormal displays 1641 and 1651 are not being displayed.
Check that fuse 10 is not blown.
Carry out troubleshooting with the work equipment control lever at HOLD,
the joystick at N, and the parking brake lever at the LOCK position.
6
Does engine start
YE
*Turn starting
switch to START.
NO
terminal (3) and

chassis normal?
I * Turn starting
switch to START.
4 I *20-30V
(14) and chassis
* Turn starting
switch to START. I 1
YE :S between CN214
NO
(12) and chassis
.20-30V
NO
YE from relay when

NO
* Turn starting YES

switch OWFF.
Is voltage between“II
battery relay
NO terminal BR and 14 YES
chassis normal?
Is resistance
between CN214
-Turn starting
. Voltage: ND (female) (12) and
switch ON.
Min. 24 V (11) normal?
-2O-30V
* Specific gravity: * Disconnect CN214 NO
Min. 1.26 and turn starting
switch ON.
IO
20-314
a
TROUBLESHOOTING E-8
Cause Remedy
Defective diode(CN220) Replace
alternator terminal
Defective neutral safety

Replace
NO relay KIN019
*Max. 13V
*Turn starting
switch ON
Defective starting motor Replace
+
YES wirina harness of
r Defective contact of
power source wiring Correct
YE NO harness
disconnection in wiring
I Replace wiring
Turn starting harness between CN103
harness
switch to START. NO (female) (1) -CNlOl (IO) -
(SX2) terminal (6) 20-30V proximity relay terminal (6)
YES Defective proximity

Replace
switch relay (SX2)
*Turn starting
switch to START. Does engine start“I1
Nail
*20-30V
Defective proximity
Replace
switch

proximity switch relay
Replace wiring
terminal (2) and CN151
harness
* Turn starting (female) (2) short circuiting
switch to START. with chassis ground
* Disconnect CN151.
-2O-30V
Replace wiring
harness between safety
harness
relay terminal (3) and
CN214 (male) (14)
Defective starting switch

Replace
(between Band C)
harness between fuse (IO harness
and CN214 (male) (12)
Defective battery relay Replace
Replace wiring
harness between CN214
harness
(female (III-CN105 (2)-
battery relay terminal B, F

Replace
(between Band BR)
Charge or
Drop in battery capacity
replace
20-3 15
0
TROUBLESHOOTING E-8

Serial No. : 66001 - 60271
Proximity switch relay
Neutral safety Proximity switch

re
CN151 (X2)
I I I
Start ins motor
I/ CNlOl
(SWP121
CN 103 (X2)
safety relay
CN105 (L2) Fuse

I ’
Start ina switch I!@ 1
2
CN220 (M2)
Battery rela!
CNI 05 (L2) (g
M -3 a
3
CN2 14
B ISWPI 61
Battery I
TVD00903
20-316
0
TROUBLESHOOTING E-8
E-8. Engine does not start

If the starting motor does not turn or it turns stiffly.
(If the starting motor turns normally, but the engine will not start, go to S-2.)
Check that abnormal displays 1641 and 1651 are not being displayed.
Check that fuse 10 is not blown.
Carry out troubleshooting with the work equipment control lever at HOLD,
the joystick at N, and the parking brake lever at the LOCK position. YES
YE
f Turn starting
switch to START.
YE S 1
chassis normal?
uo-
I
4
* Turn starting
switch to START.
*20-30V
(14) and chassis
0 g
* Turn starting
switch to START.
X
*20-30V
(12) and chassis
N
.20-30V
Is a sound heard I
YEiS from relay when NO
batterv relav is I
turned OFFj
YES
*Turn starting
switch OWOFF.
11 YES
specific gravity of
nce
CN214
,_^\
id
* Voltage:
Min. 24 V
* Specific gravity: * Disconnect CN214 NO
Min. 1.26 and turn starting
switch ON.
N0
20-316-2
0
TROUBLESHOOTING E-8
Cause Remedy
7 YES
Defective diode (CN220) leplace
Is voltage between
alternatorterminal
R and chassis
ground normal? Defective neutral safety
leplace
. Max. 13 V NO relay (CN015)
*Turn starting
switch ON
9 YES
Defective starting motor ieplace
Is power source
YES wiring harness of
8 motor properly
connected? Defective contact of
Is voltage
power source wiring Zorrect
between CN103 * Turn starting NO harness
- (1) and chassis - switch OFF.
-Turn starting harness between CN103 leplace wiring
switch to START. NO (female) (1) - CNIOI (IO) - larness
.20-30V proximity relay terminal (6)
disconnection in wiring leplace wiring
harness between safety rarness
relay terminal (3) and
CN214 (male) (14)
ieplace
(between B and C)
disconnection in wiring qeplace wiring
harness between fuse (IO: larness
and CN214 (male) (12)
Defective battery relay seolace
qeplace wiring
rarness
(female (11) -CN105 (2) -
battery relay terminal B, 5

(between Band BR) Xeolace
Charge or
Drop in battery capacity
.eplace
20-316-3
a
TROUBLESHOOTING E-8

Neutral safety Starting motor

relay CN015
@ -3 $J
(gp-$j DI
(g Start ina motor
CNlOl CN103 (X2)
safety relay
(SWP12)
CNOI I
(SWPI 2)
3 u
-3
CN220 IM2)
Starting switch
CN105 (L2)
Battery
TVDO0904
20-316-4
0
TROUBLESHOOTING E-9
E-9. Engine speed is irregular (Idling speed is irregular or there is hunting)

t Before carrying out troubleshooting, check that all the related connectors are properly inserted.
t Always connect any disconnected connectors before going on the next step.
Remedy
-
Does condition
2
YES
PDefective adjustment of
linkage
-
become normal
\IES when linkage
between governor
motor and pump is Defective injection pump
adjusted?
-
(see S mode)
- NO
1 % See TESTING
1 AND ADJUSTING.
il
1 Does engine stop
when linkage is Defective governor motor leplace
disconnectedand
motor lever is YE between SMI (6)
Potentiometer 4 and (12) normal Defective contact of
wiring harness between ;eplace wiring
starting switch ACC - arness
* Turn starting YE SMI (171 and (161 - During operation:
switch ON. 20-30V
Fuel control dial 3
. At low idling: -
between SMl (7)
and (16) normal 2.6 - 3.2 V
NO
. At low idling: -
4.0 - 4.75 v
Starting switch
CN214
Fuse
CNSX5(M3)
I I I
Fuel control dial
GND
Governor
Feedback SIG potentiometer
Throttle power
source (-)
CNSM2(X3)
TDD00166
20-3 17
0
TROUBLESHOOTING E-10
E-10. Lack of output (engine high idling speed is too low)

Sr Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Starting signal 5 YES
Potentiometer 4 ‘fjZj(H_
1Is injection pump 1

* During operation: NO
20-30V
Fuel control dial 3 stable?
. Start engine * Start engine.

- Fuel control dial
between SMI (7) *At low idling: IO
and (16) normal 2.9 - 3.3 v
at FULL position.
*At high idling:
* Start engine. 0.5 - 0.9 v
*At low idling: I
4.0 - 4.75 v NO
*At high idling:
0.25-l.OV
2 YES
% See TESTING Does condition
AND ADJUSTING. become normal
when linkage
between governor
motor and pump is
adjusted?
- NO
% See TESTING
AND ADJUSTING.
20-3 18
0
Cause Remedy
See S mode -
Defective governor motor qeplace
Defective contact of
?eplace wiring
starting switch ACC -
larness
CN214 (15) -SMl
(female) (6)
See E-3 -
See E-4 -
Defective adjustment of
Idjust
governor motor linkage
See S mode -

Starting switch
CN214
Fuse (SWPIG)
@
@$
I CNSX5(M3)
Engine throttle CNSM’

controller (MIC21)
Fuel control dial
GND
Governor
Feedback SIG
potentiometer
Throttle power
source (-1
CNSM2(X3)
TDD00166
20-3 19
0
TROUBLESHOOTING E-l 1
E-l 1. Engine does not stop

A Stop the engine before starting the inspection. (Push the fuel control lever on the injection pump
Ir Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Read the precautions for TESTING AND ADJUSTING, Adjusting fuel control linkage before starting
troubleshooting.
YES
1
1Does engine stop 1
* Turn starting
switch ON + OFF
2 YE
f Does condition
Decome normal
when linkage is
adjusted?
% See TESTING
Relay drive signal
AND ADJUSTING
switch is OFF, is
YE
voltage between
Potentiometer 4
When starting *When starting
YES switch is OFF, is switch is OFF:
- voltage between . 20-30V
SMOl (17) and (16) NO
Starting signal 3 (When ON -+ OFF:
P normal?
When starting for approx. 4 seconds)
*When engine is
switch is OFF, is
- voltage between - stopped’
P ’ SMl (6) and (12)
2.9 - 3.3 v 0
normal?
*When starting
switch is OFF:
NO
Max. 1 V
20-320
0
TROUBLESHOOTING E-l 1
Cause Remedy
Defective injection pump -

see S mode)
* Defective adjustment of
hdjust or
linkage
orrect
- Loose spring caught
YES
Defective relay fSX7) leplace
8
Does condition
YI ; become normal
- when relay 6x7) is -
interchanged with 9 YES
Defective governor motor leplace
other relay? Is voltage
1 * Replace with L between relay Defective contact, or
backup alarm NO fSX7) (3) and disconnection in wiring
relay KN104). chassis normal? harness between relay leplace wiring
NO (SX7) (3) and CN105 arness
* Turn starting
(male) (2) or CN220
switch ON.
(female) (1)
*Turn starting .20-30V
z
switch ON. Defective contact, or
*20-30V disconnection in wiring leplace wiring
NO harness between relay amess
ISX7) (5) and fuse (10)
leplace wiring
harness between relay
arness
(SX7) (I) and SMl
(female) (13)
Defective engine throttle

leplace
controller
See E-3 -
ieplace wiring
starting switch ACC -
larness
CN214 (15) - SMI
(female) (6)
20-321
CD
TROUBLESHOOTING E-II
E-l 1. Related electrical circuit diagram
Battery relay drive relay
CNSX7
To battery (+)
CN220(M2)
r
To starting switch terminal BR Battery relay
*~~$ZL!nator terminal R
Starting switch
CN214
Fuse
CNSX5(M3)
Engine throttle Fi,g;I

controller
Fuel control dial
GND
Governor
Feedback SIG
potentiometer
Throttle power
source C-1
TDD00166
20-322
a
TROUBLESHOOTING OF ENGINE SYSTEM
(S MODE)
Method of using troubleshooting charts .. . . . . . . . .. .. . . . . . . .. . . . . . . . . .. . . . . . . .. .. . . . . . . . . . .. . . . . . . . .. .. . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . 20-402
s- 1 Starting performance is poor (starting always takes time) ................................................. .20-406
s- 2 Engine does not start ............................................................................................................... .20-407
@ Engine does not turn ......................................................................................................... .20-407
@ Engine turns but exhaust gas does not comes out (fuel is not being injected)..........20-40 8
@ Exhaust gas comes out but engine does not start (fuel is being injected). ................ .20-409
s- 3 Engine does not pick up smoothly (follow-up is poor). ....................................................... .20-410
s- 4 Engine stops during operation ................................................................................................ .20-411
s- 5 Engine does not rotate smoothly (hunting). .......................................................................... .20-412
S- 6 Engine lacks output (no power) .............................................................................................. .20-413
s- 7 Exhaust gas is black (incomplete combustion) ..................................................................... .20-414
S- 8 Oil consumption is excessive (or exhaust gas is blue). ....................................................... .20-415
s- 9 Oil becomes contaminated quickly.. ....................................................................................... .20-416

g S-IO Fuel consumption is excessive.. .............................................................................................. .20-417
3 S-II Oil is in cooling water, or water spurts back, or water level goes down.. ........................ .20-418
Is
s-12 Oil pressure caution lamp lights up (drop in oil pressure) ................................................. .20-419
s-13 Oil level rises (water mixed with fuel) .................................................................................... 20-420
s-14 Water temperature becomes too high (overheating) ........................................................... .20-421
s-15 Abnormal noise is made .......................................................................................................... .20-422
S-16 Vibration is excessive ............................................................................................................... .20-423
20-40 1
0
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS
This troubleshooting chart is divided into three

sections: questions, check items, and troubleshoot-
ing. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspection with-
out using troubleshooting tools.
Next, troubleshooting tools or direct inspection
are used to check the high probability causes to
make final confirmation.
[Questions]
Sections @ + @ in the chart on the right corre-
spond to the items where answers can be ob-
tained from the user. The items in @ are items
that can be obtained from the user, depending
on the user’s level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under @ in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information @ that he has obtained from the
user and the results of @ that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
20-402
0
The basic method of using the troubleshooting chart

is as follows.
items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with 0, and of these, causes that have a high prob-
ability are marked with 0.
Check each of the [Questions] and [Check items] in
turn, taking note of the 0 or Q marks in the chart for
the horizontal lines of symptoms applicable to the
machine. The vertical column (Causes) that has the
highest number of applicable 0 or Q marks is the
most probable cause, so start troubleshooting for
that item to make final confirmation of the cause.
%I. For (Confirm recent repair history) in the

[Questions] Section, ask the user, and mark
the Cause column with n to use as reference
for locating the cause of the failure. How-
ever, do not use this when making calcula-
tions to narrow down the causes.
~2. Use the a in the Cause column as reference
for [Degree of use (Operated for long pe-
riod)] in the [Questions] section as reference.
As a rule, do not use it when calculating the
points for locating the cause, but it can be
included if necessary to determine the order
for troubleshooting.
20-403
0
. Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner1 is taken to be the cause of black exhaust gas. Three
symptoms have a causal relationship with this problem: [Exhaust gas gradually became black], [Power
gradually 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 5
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)
Gel Teral causes why exhaust gas is black.
. Insufficient intake of air.
. Improper condition of fuel injection.
. Excessive injection of fuel.
20-404
0
I I I I I
5 causes
Step 1
Clarify the relationship between the three
symptoms in the [Questions] and [Check items1
section and the 5 Cause items in the vertical
column.
Three symptoms
3-r
I
Step 2
Add up the total of 0 and 0 marked where the
horizontal lines for the three symptoms and the
vertical columns for the causes intersect.
(I 1 Clogged air cleaner element: 000
(2) Air leakage between turbocharger
and cyl. head: 00
(3) Clogged, seized injection nozzle: 0
(4) Defective contact of valve, valve seat: 0
(5) Worn piston ring, cylinder: 0
Step 3
The calculations in Step 2 show that the closest
relationship is with [Clogged air cleaner
element]. Follow this column down to the
troubleshooting area and carry out the
troubleshooting item marked 0. The Remedy is
given as [Clean], so carry out cleaning, and the
exhaust gas color should return to normal.
20-405
0
TROUBLESHOOTING S-l
S-l Starting performance is poor (starting always takes time)
Possible causes of the engine not starting though exhaust gas is

discharged.
. Electrical system is defective.
. Fuel supply is insufficient.
. Air intake is insufficient.
. Improper selection of fuel
(At ambient temperature of -10°C or below, use ASTEM D975
No. I)
Causes
li Battery charging rate
100% 90% 80% 76% 70%
20°C 1.28 1.26 1.24 1.23 1.22
0°C 1.29 1.27 1.25 1.24 1.23
-10°C 1.30 1.26 1.26 1.25 1.24
. A battery can be used if the specific gravity shows 70% or

higher charging rate as per the above table.
. In cold weather, 75% or higher charging rate is required.
* Confirm no abnormality display of electronic governor con-
troller system.
1 1) Even titheinjection pumpsleeve nutisloosened, littlefuel

comes out IIIIII I/IIIIII
2) Even if the fuel filter air bleeding plug is loosened, little fuel
00 8
comes out / t I I
Leakage from the fuel piping I I I loo
Engine hunting (rotation is irregular) I 00 I I Iso.
Compression pressure measurement found low pressure 0 01 I I I
Direct inspection of the air cleaner found clogging IO
Direct inspection of the fuel filter and ~1
trainer found clogging I a I I I.
Direct inspection of the feed pump strainer found clogging
Heater mount section is not heated
Voltage (26 - 30 VI rises between alternator terminals R and E E
No voltage (26 - 30 V) between alternator terminals R and E
Either specific gravity or voltage of the battery is low
Stop fuel injection to one cylinder at a time. If there is no
chanqe in enqine speed, that cvlinder is not workinq.
Checking delivery method found deviation in injection timing
When pushed, the control rack is heavy, or does not return
(Remove the blind cover at the rear of the pump. Plunger
control sleeve does not move)
Direct inspection of the fuel cap found clogging
Z Replacement of regulator only is not

Remedy
permissible.
20-406
0
TROUBLESHOOTING s-2
S-2 Engine does not start

@ Engine does not turn
General causes why engine does not turn. Causes
. Internal parts of engine seized. ///////
Ir If internal parts of the engine are seized,
carry out troubleshooting for “Engine
stops during operations”.
. Failure in power train.
. Defective electrical system.
Infirm recent reoair history I
“~~ Condition of horn when starting
I When starting switch is turned to Soon disengages again

START, pinion moves out, but
does not turn 0
I
When starting switch is turned to START, pinion does not
move out
When starting switch is turned to ON, there is no clicking sound
Battery terminal is loose
When battery is checked, battery electrolyte is found to be low
pecific gravity of electrolyte, voltage of battery is low

E
B
or the following conditions 1) - 5). turn the starting switch p
)FF, connect the cord, and carry out troubleshooting at ON m
-5
.;
1) When terminal B and terminal C of starting switch are 2
connected, engine starts 0
i
2) When terminal B and terminal C of starting motor are Lz
._
connected, engine starts
5
z
3) When terminal B and terminal C of safety relay are 1
connected, engine starts 9
e
4) When terminal of safety switch and terminal B of

2
starting motor are connected, engine starts
2
%
U
5) There is no 24V voltage between terminal M and
terminal E of battery relay
‘Vhen ring gear is inspected directly, tooth surface is found

o be chipped
Remedy -
20-407
0
TROUBLESHOOTING s-2
Engine runs but exhaust gas does not come out

(fuel is not being injected)
Confirm that no abnormality of governor con-

troller is displayed on the machine monitor
panel.
Possible causes of no exhaust gas coming out
though engine is running.
. Fuel is not supplied.
. Fuel supply is very low.
. Improper fuel is used. (particularly in win-
ter)
* Fuel selection standard
AMBIENT TEMPERATURE
KIND OF
FLUID -22 -& -YJ 32 50 68 86 104’1
-30 0 10 20 30 4o’c
Diesel fuel
* In winter, if Class 3 oil is not available, you

may use mixture of Class 2 diesel fuel and
kerosene at the rate of 1 : 1.
Confirm recent repair history
legree of use Operated for long period nn n
ixhaust gas suddenly (when starting again) stops coming out 000
‘ilten have not been replaced according to the operation manual 00

1’
rhere is leakage from fuel piping 0
Vlud is stucking to fuel tank cap 0
Uo fuel comes out when draining fuel filter G
Nhen the engine is cranked by the starter motor,

0v
1) Injection pump coupling does not rotate
2) Even though the fuel filter air bleeder plug is loosened,

fuel does not come out 0 00
3) Even though the injection pipe sleeve nut is loosened,

fuel does not spurt out 000
Nhen fuel is drained, rust and water come out 00
20-408
0
TROUBLESHOOTING s-2
@ Exhaust gas comes out but engine does not start

(fuel is being injected)
General causes why exhaust gas comes out but

engine does not stat-t.
. Lack of rotating force due to defective elec-
trical system.
. Insufficient supply of fuel.
. Improper selection of fuel.

Degree of use Operated for long period
Suddenly failed to start
When engine is cranked, abnormal noise is heard from

around head
Engine oil must be added more frequently

Non-specified fuel has been used
Replacement of filters has not been carried out according to
operation manual
Water is found when fuel is drained

Air cleaner cloaaina lame liahts LID
Pre-heat indicator lamp does not light up
Startina motor cranks enaine slowlv
Mud is stuck to fuel tank cap
When fuel lever is placed at FULL position, it does not

contact stopper
When engine is cranked with starting motor,

1) Little fuel comes out even when injection pump sleeve
nut is loosened
2) Little fuel comes out even when fuel filter air bleed plug
is loosened
There is leakaae from fuel pipina
When exhaust manifold is touched immediately after

starting engine, temperature of some cylinders is low
When fuel filter is drained, no fuel comes out
Remove head cover and check directly

When control rack is pushed, it is found to be heavy, or
does not return
When comoression oressure is measured, it is found to be low
When fuel filter, strainer are inspected directly, they are

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

be clogged
When air cleaner is inspecteddirectly,it is found to be clogged
Heater mount does not become warm
Either specific gravity of electrolyte or voltage of battery is low
When feed pump is operated, there is no response or pump

is heaw
Speed of some cylinders does not change when operating

on reduced cylinders
When fuel cap is inspected directly, it is found to be clogged
Remedy
20-409
0
TROUBLESHOOTING s-3
S-3 Engine does not pick up smoothly (follow-up is poor)
Ir Confirm that no abnormality of electric gov-

ernor controller is displayed.
General causes why engine does not pick up
smoothly.
. Use of improper fuel.
Degree of use 1Operated for long period n n n a n
Replacement of filters has not been carried out according to 0 0 0

operation manual
Non-specified fuel has been used 0000
Engine oil must be added more frequently I I I I I IQ1 I I I I

Dust indicator is red 101 1 I 1 1 1 I 1 I I
There is leakage from fuel piping
High idling speed under no load is normal, but speed

suddenly drops when load is applied
There is hunting from engine (rotation is irregular)

Blow-by gas is excessive
When air cleaner is inspected directly, it is found to be clogged

found to be clogged

be clogged

change in engine speed, that cylinder is not working.
When control rack is pushed, it is found to be heavy or does

not return
When comoression oressure is measured, it is found to be low
Turbocharger cannot be hand-rotated smoothly
When valve clearance is checked directly, it is found to be

outside standard value
1 When fuel cao is insoected directlv. it is found to be cloaaed 1 1 l 1 I 1 1 1 101 I 1

1 When feed pump is operated, operation is too light ortoo heavy
Remedy
20-410
0
TROUBLESHOOTING s-4
S-4 Engine stops during operation

* Confirm that fuel gauge on machine moni-
tor indicates certain amount of fuel. Causes
Possible causes of engine stoppage during op-
eration.
. Seizure of parts inside the engine.
. Fuel supply amount is insufficient.
. Overheating.
j, If the engine stops due to overheating,
carry out appropriate troubleshooting.
. Trouble in the power train.
t If the engine stops due to trouble in the
power train, carry out troubleshooting
of the body.
When turning the engine by

hand with a barring tool, etc. Moves by the amount of
backlash
%
When fuel is drained, rust and water come out 00
.-P
When oil is drained, metal chips come out 00 00
5
20-411
0
TROUBLESHOOTING s-5
S-5 Engine does not rotate smoothly (hunting)

Ir Confirm that no abnormality of electric gov-
ernor is displayed.
General causes why engine does not rotate
smoothly (hunting).
. Air in fuel system.
. Defective governor mechanism.
. Defective electrically controlled throttle
mechanism.
(electrically controlled throttle type)
* If hunting does not occur when rod con-
necting governor motor and fuel injec-
tion pump is disconnected, carry out
troubleshooting for electrical system.
Condition of hunting
Replacement of filters has not been carried out according to
1 When governor lever is moved it is found to be stiff I.1 I.1 I I I I I

When injection pump is tested, governor is found to be
improperly adjusted l
.-F
to be heavy, or
5 When control rack is pushed, it is found
does not return
2
4 When fuel cap is inspected directly, it is found to be clogged
20-412
0
TROUBLESHOOTING S-6
S-6 Engine lacks output (no power)

General causes why engine lacks output.
. Use of improper fuel.
(if non-specified fuel is used, output drops)
. Lack of output due to overheating.
* If there is overheating and insufficient
output, carry out troubleshooting for
overheating.
When air cleaner is inspected directly, it is found to be clogged l C

.9
Turbocharger cannot be hand-rotated smoothly 0 8
a:
u:
When compression pressure is measured, it is found to be low 0 0
‘F
found to be clogged

be clogged

change in engine speed, that cylinder is not working
._
When control rack is pushed, it is found to be heavy or does
0 E
not return E
20-413
0
TROUBLESHOOTING s-7
Exhaust gas is black (incomplete combustion)

Ger ieral causes why exhaust gas is black.
Insufficient intake of air.
Improper condition of fuel injection.
Excessive injection of fuel.

I I
I I g
a
Color of exhaust gas
II
Power was lost
r----.-.-
Gradually , ,.,,.A
Non-soecified fuel has been used I I I t
Interference sound heard around turbocharger

I I 1
Blow-by gas is excessive
I I IO I I
Engine pickup is poor and combustion is irregular 101 I 01 I 000 0
E
C
I I I 101 1 I I I I 101
Match marks on fuel injection pump are out of alignment 1 lo,1 I I I I I
%
al Seal on iniection oumo has come off I I I I I 161 I I I I
6 Clanging sound is heard from around cylinder head
I I I I I I Ia I I 1~
Exhaust noise is abnormal Inl I Inl I I lC?Il I I
Muffler is crushed
I I I I I I I 101 I I
Air leakage / loose clamp between turbocharger and cyl. head I I 1 I lo,1 I
Turbocharger cannot be hand-rotated smooth1
20-414
0
TROUBLESHOOTING S-8
S-8 Oil consumption is excessive (or exhaust gas is blue)
Sr Do not run the engine at idling for more

than 20 minutes continuously. (both low and
high idling)
General causes why oil consumption is exces-
sive.
. Abnormal combustion of oil.
. External leakage of oil.
. Wear of lubrication system.
.-6
5
2
I” IE nome
.’ oil becomes contaminated ouicklv lolalc
I Amount of blow-by gas

AbnOrmally exe
None
Area around engine is dirty with oil 0000
There is oil in engine cooling water Q
1 .g 1 When exhaust pipe is removed, inside is found to be dirty

I jF I with oil
0 0
5
air supply pipe interior is oil-contaminated
I i; I Turbocharger 0
I IOil level in PTO chamber rises I

0
1-1
1 10
1 1 Clamps for intake system are loose I I I I I I
1l 1l 1
I ’
When compression pressure is measured, it is found to be low
IIIIIIIIIIII
When intake manifold is removed, inside is found to be dirty
with oil
20-415
0
TROUBLESHOOTING s-9
S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated
quickly. Causes
. Intake of exhaust gas due to internal wear.
. Clogging of lubrication passage.
. Improper combustion.
. Use of improper oil.
. Operation under excessive load.
Amount of blow-by gas
When breather element is inspected directly, it is found to be clogged with
dirty oil, or hose is broken
When oil filter is inspected directly, it is found to be clogged
When oil cooler is inspected directly, it is found to be clogged
Cloaaed turbocharaer drain tube
Excessive Slav of turbocharaer shaft
When safety valve is directly inspected, spring is found to be catching or
broken
I
Remedy
20-416
0
TROUBLESHOOTING S-IO
S-IO Fuel consumption is excessive

General causes why fuel consumption is exces-
sive.
. Leakage of fuel. I Causes
I

. Excessive injection of fuel.
More than for
Condition of fuel consumption
When exhaust manifold is touched immediately after starting engine,
Injection pump test shows that injection amount is incorrect 1.1 1 1 1 1 [ r

I I I I I I I I
Stop fuel injection to one cylinder at a time. If there is no change in engine
0
speed, that cylinder is not working.
When control rack is pushed, it is found to be heavy or does not return 0
When check is made using deliven/ method, injection timing is found to be

a
incorrect
Remove head cover and check directly l

Remove feed pump and check directly
When engine speed is measured, low idling speed is found to be high

I
20-417
0
TROUBLESHOOTING S-l 1
S-l 1 Oil is in cooling water, or water spurts back, or water level goes
down
Ge mneral causes why oil is in cooling water.
. internal leakage in lubrication system.
. Internal leakage in cooling system.
Increase in oil level
Engine oil level has risen, oil is cloudy white 00
$ Excessive air bubbles inside radiator, spurts back 00

C
24 Hydraulic/torque converter/transmission oil cloudy white 0
8
5 When hydraulic/torque converter/transmission oil drained, water comes
out 0
P
‘Z
Pressure-tightness test of oil cooler shows there is leakage a 0
z Pressure-tightness test of cylinder head shows there is leakage 0

3
D Remove cylinder head and check directly a
a
C Remove oil pan and check directly 00
20-418
0
TROUBLESHOOTING s-12
S-12 Oil pressure caution lamp lights up (drop in oil pressure)

Possible causes of the oil pressure caution lamp
lighting up.
. Leakage, clogging, or wear of the lubricat-
ing system.
. Oil pressure control failure.
. Use of improper oil. (improper viscosity)
. Degradation of oil due to overheating.
* Confirm engine oil level is normal before
troubleshooting.
* Standard for engine oil selection
Causes
20-419
0
S-13 Oil level rises (water mixed with fuel)

+ If there is oil in the cooling water, carry out
troubleshooting for “Oil is in cooling wa-
Cause
ter”.
General causes why oil level rises.
l Water in oil.
. Fuel in oil. (diluted, and smells of diesel fuel)
Leave radiator cap open. When engine is run at idling, an
Fuel is added more frequently
Remove oil pan and check directly am
20-420
0
s-14 Water temperature becomes too high (overheating)

* If coolant level lamp on monitor panel is not
lighted.
* If coolant temperature checked by water
temp. gauge on machine monitor is normal,
refer to “Machine monitor troubleshooting
M-mode”.
General causes why water temperature becomes
too high.
. Lack of cooling air. (deformation, damage of
fan)
. Drop in heat dissipation efficiency.
. Defect in cooling circulation system.
* Cart-v out troubleshootina for chassis.
Engine oil level has risen, oil is cloudy white 0

Radiator shroud, inside of underguard are clogged with dirt or mud 0 0
When light bulb is held behind radiator, no light passesthrough 0
I Water isleaking becauseof cracksin hoseor looseclamos I I I I I I I I I I

1 Belt tension is found to be slack I I I I I lnl I I I I I
P
‘G
8 When a function test is carried out on the thermostat, it does
_c
not open even at the cracking temperature
H
LY
2
I=
20-42 1
0
S-15 Abnormal noise is made

Ir Judge if the noise is an internal noise or an
external noise.
General causes why abnormal noise is made.
. Abnormality due to defective parts.
. Abnormal combustion noise.
. Air sucked in from intake system.
Condition of abnormal noise
Color of exhaust gas

Black
Metal particles are found in oil filter
Blow-by gas is excessive lol I I I I I I I I I I

Interference sound heard around turbocharger I 101 I I I I I I I I I
Engine pickup is poor and combustion is irregular I I I 101 I I I I I I I
I I I HOI I I I I I I
Seal on injection pump has come off 0
Abnormal noise is loud when accelerating engine 00000 0
Clanging sound is heard from around cylinder head 00
Air leakage / loose clamp between turbocharger and cyl. head Q
Vibrating noise is heard from around muffler

I I I I I I I I I I I IOI
When compression pressure is measured, it is found to be low l
Turbocharger cannot be hand-rotated smoothly 0
Remove gear cover and check directly 0 0

0
P change in engine speed, that cylinder is not working.
g
5 When control rack is pushed, it is found to be heavy or does not return a
d Injection pump test shows that injection amount is incorrect a

D
2 Fan is deformed, or belt is loose l
L
0
outside standard value
Remove cylinder head cover and check directly 0
When muffler is removed, abnormal noise disappears 0
20-422
0
TROUBLESHOOTING S-16
S-16 Vibration is excessive

* If there is abnormal noise together with the
vibration, carry out troubleshooting for “Ab-
normal noise is made”.
General causes why vibration is excessive.
. Defective parts. (abnormal wear, breakage)
. Improper alignment.
. Abnormal combustion.
Remove oil pan and check directly l

F Remove side cover and check directly 0
.-
: Check directly for loose engine mounting bolts, broken cushion 0
_c
8 Check inside of output shaft (damper) directly 0
2
.I2
Remove front cover and check directly
z I I I I I.1 I
c Remove head cover and check directly I I.1

Injection pump test shows that injection amount is incorrect I I.1
20-423
0
TROUBLESHOOTING OF ELECTRICAL SYSTEM
(E MODE)
Points to remember when carrying out troubleshooting of HMT controller system .................... .20-503
Action taken by controller and condition of machine when abnormality occurs .......................... .20-504
Judgement table for HMT controller hydraulic and mechanical systems ...................................... .20-516
Electrical circuit diagram of HMT controller system.. ........................................................................ .20-518
Troubleshooting flow charts for each failure mode
E-101 [IO] Abnormality in HMT charge pressure is displayed ........................................................ .20-519
E-102 [II] Abnormality in HMT charge pressure sensor system is displayed .............................. .20-520
E-103 1121 Abnormality in travel speed selector switch system is displayed.. .............................. .20-521
E-104 1141 Abnormality in throttle potentiometer system ................................................................ .20-522
E-105 [I51 Abnormality in throttle potentiometer system is displayed .......................................... .20-523
E-106 [I61 Abnormality in FORWARD speed control potentiometer system is displayed.. ........ ..20-52 4
E-107 [I71 Abnormality in FORWARD speed control potentiometer system is displayed .......... ..20-52 5
E-108 f181 Abnormality in REVERSE speed control potentiometer system is displayed ............ ..20-52 6
E-109 1191 Abnormality in REVERSE speed control potentiometer system is displayed ............ ..20-52 7
E-110 [IA1 Abnormality in brake pedal potentiometer system is displayed .................................. .20-528
E-III [lc] Abnormality in power train oil temperature sensor system is displayed ................... .20-529
E-112 [Id] Abnormality in both directional lever potentiometer signal systems is displayed ... ..20-53 0
E-113 IIEI Abnormality in directional lever potentiometer [II system is displayed ...................... .20-530
E-114 [IF] Abnormality in directional lever potentiometer [II system is displayed ...................... .20-531
E-115 1201 Abnormality in brake pedal potentiometer system is displayed .................................. .20-532
E-116 1211 Abnormality in directional lever potentiometer [Ill system is displayed ..................... .20-533
E-117 [22] Abnormality in directional lever potentiometer [Ill system is displayed ..................... .20-534
8 E-118 [23] Abnormality in both steering lever potentiometer signal systems is displayed ...... ..20-53 5
z E-119 1241 Abnormality in steering lever potentiometer Ill system is displayed .......................... .20-535
z E-120 1251 Abnormality in steering lever potentiometer [II system is displayed .......................... .20-536
E-121 1261 Abnormality in steering lever potentiometer [III system is displayed ......................... .20-537
E-122 [271 Abnormality in steering lever potentiometer [Ill system is displayed ......................... .20-538
E-123 [28] Abnormality in both engine speed sensor systems is displayed ................................. .20-539
E-124 [291 Abnormality in engine speed sensor [II system is displayed ....................................... .20-539
E-125 [2A] Abnormality in engine speed sensor [Ill system is displayed ...................................... .20-540
E-126 f2cl Abnormality in HMT motor speed sensor system is displayed.. .................................. .20-541
E-127 [2d] Abnormality in HMT motor speed sensor system is displayed.. .................................. .20-542
E-128 1301 Disconnection in 1st clutch solenoid system is displayed ............................................ .20-543
E-129 1311 Short circuit in 1st clutch solenoid system is displayed.. .............................................. .20-544
E-130 [321 Disconnection in 2nd clutch solenoid system is displayed ........................................... ,20-545
E-131 1331 Short circuit in 2nd clutch solenoid system is displayed .............................................. .20-546
E-132 1341 Disconnection in 3rd clutch solenoid system is displayed ............................................ .20-547
E-133 [351 Short circuit in 3rd clutch solenoid system is displayed ............................................... .20-548
E-134 1381 Disconnection in brake solenoid system is displayed.. .................................................. .20-549
E-135 1391 Short circuit in brake solenoid system is displayed.. ..................................................... .20-550
E-136 [3A] Disconnection in R clutch solenoid system is displayed ............................................... .20-551
E-137 13~1 Short circuit in R clutch solenoid system is displayed .................................................. .20-552
E-138 f3dl Disconnection in F clutch solenoid system is displayed ............................................... .20-553
E-139 [3El Short circuit in F clutch solenoid system is displayed.. ................................................. .20-554
E-140 [401 Abnormality in operation of F spool switch is displayed .............................................. .20-555
E-141 [41] Abnormality in operation of F spool switch is displayed .............................................. .20-556
E-142 1421 Abnormality in operation of R spool switch is displayed.. ............................................ .20-557
E-143 1431 Abnormality in operation of R spool switch is displayed.. ............................................ .20-558
E-144 1441 Abnormality in operation of 1st spool switch is displayed ........................................... .20-559
E-145 [451 Abnormality in operation of 1st spool switch is displayed ........................................... .20-560
20-501
0
E-146 1461 Abnormality in operation of 2nd spool switch is displayed.. ........................................ -20-561
E-147 1471 Abnormality in operation of 2nd spool switch is displayed.. ........................................ .20-562
E-148 [481 Abnormality in operation of 3rd spool switch is displayed ........................................... 20-563
E-149 [491 Abnormality in operation of 3rd spool switch is displayed .......................................... .20-564
E-150 I4Fl Disconnection in HMT pump servo solenoid system is displayed.. ............................. .20-566
E-151 1501 Short circuit in HMT pump servo solenoid system is displayed .................................. .20-568
E-152 [511 Disconnection in HMT motor servo solenoid [A] system is displayed ........................ .20-570
E-153 [521 Short circuit in HMT motor servo solenoid [A] system is displayed ........................... .20-571
E-154 1531 Disconnection in HMT motor servo solenoid [Bl system is displayed ........................ .20-572
E-155 1541 Short circuit in HMT motor servo solenoid [B] system is displayed ........................... .20-573
E-156 I551 Disconnection in steering EPC solenoid system is displayed ....................................... .20-574
E-157 [561 Short circuit in steering EPC solenoid system is displayed .......................................... .20-576
E-158 1571 Drop in controller power source voltage is displayed ................................................... .20-578
E-159 1591 When parking brake switch [III is ON (closed), [II OFF (open) is displayed.. .............. .20-579
E-160 [5Al When parking brake switch [II is ON (closed), [III OFF (open) is displayed.. .............. .20-580
E-161 I5cl Excessive difference between directional potentiometer signal values
[II and [III is displayed ................................................................................................. .20-581
E-162 I5El Excessive difference between steering potentiometer signal values
[II and [III is displayed .................................................................................................. 20-581
E-163 1601 Abnormality in signal for engine speed sensor [II system is displayed.. .................... .20-582
E-164 [61] Abnormality in signal for engine speed sensor [Ill system is displayed.. ................... .20-583
E-165 1641 Disconnection in neutral safety relay output system is displayed ............................... .20-584
E-166 [651 Short circuit in neutral safety relay output system is displayed .................................. .20-585
E-167 1641 Disconnection in 2, 3, F, R clutch solenoid cut relay output system is displayed .... ..20-58 6
E-168 1651 Short circuit in 2, 3, F, R clutch solenoid cut relay output system is displayed..........20-58 7
E-169 [661 Disconnection in backup alarm relay drive system is displayed .................................. .20-588
E-170 1671 Short circuit in backup alarm relay drive system is displayed ..................................... .20-589
E-171 [681 Disconnection in 1st clutch solenoid cut relay system is displayed ............................ .20-590
E-172 I691 Short circuit in 1st clutch solenoid cut relay system is displayed ............................... .20-591
E-173 [6Al Misalignment in neutral position of directional lever potentiometer
[I] system is displayed ................................................................................................. .20-592
E-174 [SC] Misalignment in neutral position of directional lever potentiometer
[II] system is displayed ................................................................................................ .20-592
E-175 [6d] Misalignment in neutral position of steering lever potentiometer
[II system is displayed .................................................................................................. 20-593
E-176 [6El Misalignment in neutral position of steering lever potentiometer
[III system is displayed ................................................................................................. 20-593
E-177 [6Fl 1st fixed, 2nd start both impossible is displayed ............................................................ 20-593
E-178 1701 Abnormality in F spool switch system is displayed.. ..................................................... .20-594
E-179 1711 Abnormality in F spool switch system is displayed ....................................................... .20-594
E-180 1721 Abnormality in R spool switch system is displayed ...................................................... .20-595
E-181 [731 Abnormality in R spool switch system is displayed ...................................................... .20-595
E-182 1741 Abnormality in 1st spool switch system is displayed .................................................... .20-596
E-183 1761 Abnormality in 2nd spool switch system is displayed .................................................. .20-597
E-184 [78] Abnormality in 3rd spool switch system is displayed ................................................... .20-598
E-185 1791 Abnormality in 3rd spool switch system is displayed ................................................... .20-598
E-186 I8Al Abnormality in monitor panel alarm system is displayed ............................................ .20-599
E-187 [8dl S-NET communication error (abnormality between monitor panel and
HMT controller) is displayed . . . . . .. . . . . . .. . . .. . . . . . .. . . . . . . .. . . . . . . . . . .. . . .. . . . . . . . .. . . . . . .. . . .. . . . . . .. . .. . . .. .. . . . . 20-600
E-188 Backup alarm does not sound .. . . . . .. . . . . . . . . . .. . . . . . . .. . .. . . . . . .. . . . . . . .. . . .. . . . . .. . . . . . . . . . . . . .. . . . . . .. . . .. . . . . . .. . .. . . . . . .. . . . 20-601
E-189 Pin-puller cylinder does not work (machines with giant ripper only) .. . . . . . .. . . . . . . . . .. .. . . . . . .. .. . . . . . 20-602
E-190 Blade pitch does not work . . . . . . .. . . . . . . .. . .. . . . . . .. . . . . . . .. . .. . . . . . .. . . .. . . . . . . .. . . . . . .. . .. . . . . . . . .. . . . . . .. . . .. . . . . . .. . . .. . . . . .. . . . 20-603
E-191 Travel speed does not shift (1 2 1 mark does not light up on monitor panel
when button is pressed) (For Serial No.: 60001 - 60806) . . . . . . .. . . . . . . .. . . .. . . . . . .. . .. . . . . .. . . . . 20-604
20-502
0
TROUBLESHOOTING TROUBLESHOOTING OF HMT CONTROLLER SYSTEM

TROUBLESHOOTING OF HMT CONTROLLER SYSTEM
Points to remember if abnormality returns to normal by itself
In the following cases, there is a high probability that the same problem will occur again, so it is
desirable to follow up this problem carefully.
I) If any abnormality returns to normal by itself, or
2) If the connector is disconnected and the T-adapter is
inserted, or if the T-adapter is removed and the connector is returned to its original position
when carrying out troubleshooting of the failure, and the abnormality is no longer displayed.
3) After completing troubleshooting, always erase the abnormality code from memory. .pa
Abnormality code memory retention function

When displaying the abnormality code in memory and carrying out troubleshooting, note down
the content of the display, then erase the displayed code. After trying to re-enact the problem,
carry out troubleshooting according to the failure code that is displayed.
(There are cases where mistaken operation or abnormalities that occur when the connector is
disconnected are recorded by the memory retention function. Erasing the data in this way saves
any wasted work.)
20-503
0

Z “After machine stops” means stopping - the machine without turning the starting switch OFF. If the startina switch is turned OFF and is then turned ON aaain.
” . ooerate
I ~~~the machine
~~ until the- error
- - code
----- is
-- aenerated
Q---------
\b”c”l;d”,“lity Condition when normal Problem that appears on machine when the
Abnormal system Nature of abnormality Action by controller when abnormality is detected
(voltage, current, resistance) IS abnormality
1) Drop in charge pressure I) Voltage between CN2H1(6) (CRGP(2)) - GND I) Takes no particular action 1) When abnormality is Item 1
2) Disconnection in wiring harness between l When sensor is ON (engine running): Max. 1 V 2) Displays abnormality on both HMT controller Abnormal noise is generated from HMT pump
Abnormality in HMT charge CN2H1(6) - CRGP(2) . When sensor is OFF (engine stopped, starting and monitor panel, and sounds buzzer (when motor
10
pressure 3) Defective charge pressure sensor (stays open) switch ON): 20 - 30 V traveling: after 60 seconds) 2) When abnormality is Item 2
Abnormality is displayed and buzzer sounds
but there is no effect on the machine
1) Defective charge pressure sensor (stays closed) I) Displays abnormality on both HMT controller 1) Same as Item 2) above
2) Short circuit with chassis ground in wiring har- and monitor panel, and sounds buzzer
ness between CN2H1(6) - CRGP(2) or contact
Abnormality in HMT charge
11 with GND wire
pressure sensor system
1) Defective travel speed selector switch (switch I) Voltage between CN2Hl(l) (FNR(2)) - GND 1) Stops selection of travel speed using travel 1) It becomes impossible to change the travc
stays closed) Switch ON: Max. 1 V
l speed selector switch speed using the travel speed selector switch (a
2) Short circuit with chassis ground in wiring har- Switch OFF: 20 - 30 V
l 2) Displays abnormality on HMT controller only low speed)
Abnormality in travel speed
12 ness between CNPHl(1) - FNR(2) (buzzer does not sound) (Reference) When there is a disconnection in thl
selector switch system
circuit, no abnormality is displayed, but whel
the speed is switched to high speed, the [Hare
mark does not light up.
% When signal voltage is 4.68 V or above I) Voltage between CN2H2(7) (THRTL(2)) - I) Carries out control using the signal immediately I) The performance existing immediately befort
1) Defective throttle potentiometer CN2H2(15) (THRTL(1)) before abnormality occurred (full throttle if sig- the abnormality occurred is maintained until thl
2) Disconnection in wiring harness between @ At high idling: 3.45 - 3.5 V nal was full throttle) and maintains signal until machine is stopped.
Disconnection in throttle
14 CN2H1(15) - THRTL(1) @ At low idling (700 rpm): Max. 2.1 V machine stops (after the machine stops, it ac- 2) After the machine stops, it will not move unto
potentiometer system
3) Disconnection or contact between 5 V (24 V) wir- 2) Voltage between CN2H2( 14) (THRTL(2)) - cepts the signal as full throttle) the speed is set to full throttle.
ing harness and wiring harness between CN2H2(15) (THRTL(1)): 4.75 - 5.25 V 2) Displays abnormality on both HMT controller
CN2H1(7) - THRTL(2) and monitor panel, and sounds buzzer
% When signal voltage is 0.29 V or below

1) Defective throttle potentiometer
2) Short circuit with chassis ground in wiring har-
Short circuit in throttle
15 ness between CN2H1(7) - THRIL(2)
3) Disconnection or short circuit with chassis
ground in wiring harness between CN2H1(14) -
THRIL(1)
% When signal voltage is 4.68 V or above I) Voltage between CNOOI (I 1 (FMAX(3)) - I) Condition set at time when abnormality occurred I) The machine travels within the set travel speec
1) Defective FORWARD speed control potentiometer CN2H2(15) (FMAX(3)) is maintained until machine stops. range at the time when the abnormality occurrec
Disconnection in FORWARD 2) Disconnection in wiring harness between 2) Voltage between CN2H2(13) (FMAX(1)) - 2) After machine stops, travel speed signal is ac- until the machine stops.
16 speed control potentiometer CN2H2(15) - FMAX(2) CN2H2(15) (FMAX(2)): 4.75 - 5.25 V cepted as [full throttle]. 2) After the machine is stopped and then stattec
system 3) Disconnection or contact between 5 V (24 V) wir- 3) The abnormality is displayed on both the HMT again, it accelerates to the maximum speed.
ing harness and wiring harness between CNOOl(1) controller and monitor panel, and the buzzer 3) If the travel speed selector switch is operated
- FMAX(3) sounds. the machine travels at the fixed travel speed.
% For both error codes 16 and 17, if the travel
% When signal voltage is 0.29 V or below speed selector switch is operated, control is car-
1) Defective FORWARD speed control potentiometer ried out at the fixed travel speed, not at the
Short circuit in FORWARD 2) Short circuit with chassis ground in wiring har- command value from the lever.
17 speed control potentiometer ness between CNOOl(1) - FMAX(3)
system 3) Disconnection or short circuit with chassis ground
in wiring harness between CN2H2(13) - FMAX(1)
.% When signal voltage is 4.68 V or above I) Voltage between CNOOl(2) (RMAX(3)) - I) Condition set attime when abnormality occurred I) The machine travels within the set travel speec
1) Defective REVERSE speed control potentiometer CN2H2(15) (RMAX(1)) is maintained until machine stops. range at the time when the abnormality occurrec
Disconnection in REVERSE 2) Disconnection in wiring harness between 2) Voltage between CN2H2(13) (RMAX(2)) - 2) After machine stops, travel speed signal is ac- until the machine stops.
18 speed control potentiometer CN2H2(15) - RMAX(1) CN2H2(15) (RMAX(1)): 4.75 - 5.25 V cepted as [full throttle]. 2) After the machine is stopped and then starter
system 3) Disconnection or contact between 5 V (24 V) wir- 3) The abnormality is displayed on both the HMT again, it accelerates to the maximum speed.
ing harness and wiring harness between CNOOl(2) controller and monitor panel, and the buzzer 3) If the travel speed selector switch is operated
- RMAX(3) sounds. the machine travels at the fixed travel speed.
% For both error codes 18 and 19, if the travel
% When signal voltage is 0.29 V or below speed selector switch is operated, control is car-
1) Defective REVERSE speed control potentiometer ried out at the fixed travel speed, not at the
Short circuit in REVERSE speed 2) Short circuit with chassis ground in wiring har- command value from the lever.
19 ness between CNOOl(2) - RMAX(3)
control potentiometer system
3) Disconnection or short circuit with chassis
ground in wiring harness between CN2H2(13) -
RMAX(2)
20-504
0

% “After machine stops” means stopping the machine without turning the starting switch OFF. If the starting switch is turned OFF and is then turned ON again, operate the machine until the error code is generated
Abnc
xmality Condition when normal Problem that appears on machine when ther
C:ode I lvoltaae.
. - --u-r current.
--
resistance)
----I -----------I
IS abnormalitv
% When signal voltage is 468 V or above I) Voltage between CN2H2(3) (BKPT(2)) - 1) Takes no particular action I) Travels as normal
1) Defective brake pedal potentiometer CN2H2(15) (BKPT(3)) (Brake pedal not operated): 2) Displays abnormality on both HMT controller % In the HST, at stall (brake pedal fully depressed)
2) Disconnection in wiring harness between 2.6 - 2.7 V and monitor panel, and sounds buzzer the pump angle does not become l/2
Disconnection in brake
IA CN2H2(15) - BKPT(3) 2) Voltage between CN2H2(14) (BKPT(1)) -
3) Disconnection or contact between 5 V (24V) wir- CN2H2(15) (BKPT(3)): 4.75 - 5.25 V
ing harness and wiring harness between
CN2H2(3) - BKPT(2)
% When signal voltage is 0.29 V or below I) Resistance between CNl(10) (PLTP(1) - 1) If oil temperature is 15°C or above, machine 1) No change at all in the case of Item 1
1) Defective oil temperature sensor CN2H2(15) (PLTP(2)): does not carry out corresponding operation 2) In the case of Item 2, the shock when gear shift
2) Short circuit with chassis ground, disconnec- l Oil at normal temperature (20°C): Approx. 52 kQ 2) If oil temperature is 15°C or below, controller ing may be slightly greater
Short circuit in power train oil tion in wiring harness between CNl(10) - PLTP(1) Oil at 10°C: Approx. 80 kR
Ic l accepts oil as being at low temperature and
temperature sensor system
carries out control
3) Displays abnormality on HMT controller only
1) Disconnection in wiring harness between I) Voltage between CN2H2(1) (FNR(8)) - CN2H2(15) I) Uses signal value before abnormality occurred 1) The machine continues to travel as it is until it
CN2H2(15) - LEVER(2),(16) (FNR(14)) to carry out control until machine stops. is stopped
At neutral: 2.5 f 0.25 V 2) Displays abnormality on both HMT controller 2) After the machine is stopped, it will not start
Abnormality in both directional High idling FORWARD: 3.75 - 4.25 V and monitor panel, and sounds buzzer again
Id potentiometer signal systems High idling REVERSE: 0.75 - 1.25 V
2) Voltage between CN2H2(13) (FNR(9)) -
CN2H2(15) (FNR(14)): 4.75 - 5.25 V
% When signal voltage is 4.68 V or above I) Controls using signal voltage of potentiometer I) Travels as normal
I) Defective directional lever potentiometer [II [III
2) Disconnection in wiring harness between 2) Displays abnormality on both HMT controller
Disconnection in directional CN2H(15) - FNR(14) and monitor panel, and sounds buzzer
IE
potentiometer [II system 3) Disconnection or contact between 5 V (24 V) wir-
CN2H2(1) - FNR(8)

1) Defective directional lever potentiometer [II
Short circuit in directional ness between CN2HlIl) - FNR(8)
IF
potentiometer [II system 3) Disconnection or short circuit with chassis ground
in wiring harness between CN2H2(13) - FNR(9)
% When signal voltage is 0.29 V or below I) Voltage between CN2H2(3) (BKPT (2)) - I) Takes no particular action I) Travels as normal
1) Defective brake pedal potentiometer CN2H2(15) (BKPT(3)) (Brake pedal not operated): 2) Displays abnormality on both HMT controller % In the HST, at stall (brake pedal fully depressed),
2) Short circuit with chassis ground in wiring har- 2.6 - 2.7 V and monitor panel, and sounds buzzer the pump angle does not become l/2
Short circuit in brake pedal ness between CN2H2(3) - BKPT(2) 2) Voltage between CN2H2(14) (BKPT (I)) -
20
potentiometer system 3) Disconnection or short circuit with chassis ground CN2H2(15) (BKPT (3)): 4.75 - 5.25 V
in wiring harness between CN2H2(14) - BKPT(1)
% When signal voltage is 4.68 V or above 1) Voltage between CN2H2(5) (FNR(12)) - I) Controls using signal voltage of potentiometer 1) Travels as normal
1) Defective directional potentiometer [III CN2H2(15) (FNR(11)) [II
2) Disconnection in wiring harness between At neutral: 2.5 k 0.25 V 2) Displays abnormality on both HMT controller
Disconnection in directional CN2H(15) - FNR(11) High idling FORWARD: 3.75 - 4.25 V and monitor panel, and sounds buzzer
21 potentiometer [III system 3) Disconnection or contact between 5 V (24 V) wir- High idling REVERSE: 0.75 - 1.25 V
ing harness and wiring harness between 2) Voltage between CN2H2(14) (FNR(l3)) -
CN2H2(5) - FNR(12) CN2H2(15) (FNR(11)): 4.75 - 5.25 V
+Z When signal voltage is 0.29 V or below

1) Defective directional potentiometer [III
Short circuit in directional ness between CN2H2(5) - FNR(l2)
22 potentiometer [III system 3) Disconnection or short circuit with chassis ground

3%
“After machine stops” means stopping the machine without turning the starting switch OFF. If the starting switch is turned OFF and is then turned ON again, operate the machine until the error code is generated
,bnord”,““ty Condition when normal Problem that appears on machine when ther
1) Disconnection in wiring harness between 1) Voltage between CN2H2(2) (FNR(7)) - CN2H2(15) 1) Controls using signal value before abnormality 1) Machine continues to travel as it is until it is
CN2H2(15) - LEVER(16) (FNR(1)) occurred until machine stops (steering cannot stopped
At neutral: 2.5 2 0.25 V be used) 2) After the machine is stopped, it will not start
Abnormality in both steering
23 High idling FORWARD: 3.92 - 4.42 V 2) Displays abnormality on both HMT controller again
potentiometer signal systems
High idling REVERSE: 0.58 - 1.08 V and monitor panel, and sounds buzzer
2) Voltage between CN2H2(13) (FNR(6)) - CN2H2(15)
(FNR(1)): 4.75 - 5.25 V
% When signal voltage is 4.68 V or above 1) Controls using signal voltage of potentiometer Travels as normal
1) Defective steering lever potentiometer [II Ill1
Disconnection in steering lever CN2H(15) - FNR(1) and monitor panel, and sounds buzzer
24
potentiometer [II system 3) Disconnection or contact between 5 V (24 V) wir-
CN2H2(2) - FNR(7)

1) Defective steering lever potentiometer [II
Short circuit in steering ness between CN2H2(2) - FNR(7)
25 potentiometer [II system 3) Disconnection or short circuit with chassis ground
% When signal voltage is 4.68 V or above 1) Voltage between CN2H2(6) (FNR(4)) - CN2H2(15) 1) Controls using signal voltage of potentiometer Travels as normal
1) Defective steering lever potentiometer [Ill (FNR(5)) [II
2) Disconnection in wiring harness between At neutral: 2.5 + 0.25 V 2) Displays abnormality on both HMT controller
Disconnection in steering CN2H(15) - FNR(5) High idling FORWARD: 3.92 - 4.42 V and monitor panel, and sounds buzzer
26 potentiometer [Ill system 3) Disconnection or contact between 5 V (24 V) wir- High idling REVERSE: 0.58 - 1.08 V
ing harness and wiring harness between 2) Voltage between CN2H2(14) (FNFUIO)) -
CN2H2(6) - FNR(4) CN2H2(15) (FNR(5)): 4.75 - 5.25 V

1) Defective steering lever potentiometer [Ill
Short circuit in steering ness between CN2H2(6) - FNR(4)
27 potentiometer [III system 3) Disconnection or short circuit with chassis ground
1) Defective speed sensor or defective mounting 1) Resistance between CN009(CNOlO) (I) - (2) 1) Controls using signal value before abnormality 1) Continues to travel as it is until the machine i:
2) Disconnection in wiring harness between : 500 - 1,000 R occurred until machine stops. stopped
CN2H2(16) - CN009(CNOlO) (2) 2) Voltage between CN2H2(8) (CNOlO(1)) - 2) Displays abnormality on both HMT controller 2) After the machine is stopped, it will not star
Abnormality in both engine CN2H2(16) (CN010(2)), and monitor panel, and sounds buzzer again
28
speed sensor systems Voltage between CNOOl(17) (CN009(1)) -
CN2H2(16) (CN009(2)): 0.5 - 3.0 V (AC range)
1) Defective speed sensor [I] or defective mounting 1) Resistance between CN009(CNOlO) (male) (I) - (2): 1) Controls using signal from engine speed sensor Travels as normal
2) Short circuit with chassis ground or disconnec- 500 - 1,000 n [III
tion in wiring harness between CN2H2(8) - 2) Voltage between CN2H2(8) (CNOlO(1)) - 2) Displays abnormality on both HMT controller
Disconnection, short circuit in CNOlO(l), or contact with other power source CN2H2(16) (CNOlO(2)): 0.5 - 3.0 V (DC range) and monitor panel, and sounds buzzer
29
engine speed sensor [II system wiring harness 3) Voltage between CNOOl(17) (CN009(1)) -
3) Disconnection in wiring harness between CN2H2(16) (CN009(2)): 0.5 - 3.0 V (AC range)
CN2H2(16) - CNOlO(2)
1) Defective speed sensor [II] or defective mounting 1) Controls with signal from engine speed sensor
2) Short circuit with chassis ground or disconnec- [II
tion in wiring harness between CN2H2(17) - 2) Displays abnormality on both HMT controller
Disconnection, short circuit in CN009(1), or contact with other power source and monitor panel, and sounds buzzer
2A
engine speed sensor [III system wiring harness
3) Disconnection in wiring harness between
CN2H2(16) - CN009(2)
20-506
0

After machine stops” means stopping the machine without turning the starting switch OFF. If the starting switch is turned OFF and is then turned ON again, operate the machine until the error code is generated
;dm,alitV Condition when normal Problem that appears on machine when ther
% When number of A phase pulses is less than 1) Resistance between CNMREV(1) - (2): 2.5 - 7 s2 I) Controls so that machine travels at a fixed speed I) Travels at a fixed speed until the machine il
number of B phase pulses 2) Resistance between CNMREV(3) - (2): 2.5 - 7 Sz until it stops. stopped
I) Defective HMT speed sensor 2) Displays abnormality on both HMT controller 2) th;itthe machine is stopped, it can travel onI\
Abnormality in HMT motor 2) Disconnection, short circuit with chassis ground and monitor panel, and sounds buzzer
2c
speed sensor system in wiring harness between CNOOl(12) -
CNMREV(1)
% When number of B phase pulses is less than

number of A phase pulses
I) Defective HMT speed sensor
Abnormality in HMT moto 2) Disconnection, short circuit with chassis ground
2d in wiring harness between CNOOl(13) -
speed sensor system
CNMREV(3)
1) Defective 1st clutch solenoid (when internal re- 1) Resistance between lSOL(1) - (2): 5 - 20 R 1) When traveling in Ist, if abnormality is I), 2), 41, 1) When traveling in Ist, the machine stops
sistance is extremely high) or 5), operation of clutch solenoid is stopped 2) When traveling in any range other than Ist, the
2) Disconnection in wiring harness between 2) When traveling in any range other than Ist, con- machine continues to travel as it is until it is
Disconnection, short circuit dition is maintained until machine stops stopped
CNOOI (4) - 1 SOL(2)
30 with chassis ground in 1st 3) Short circuit with chassis ground in wiring har- 3) After machine stops, 1st clutch solenoid cut re- 3) After the machine is stopped, it can travel ir
clutch solenoid system lay cuts circuit 2nd when set to start in 2nd
ness between CNOOl(4) - lSOL(2)
4) Disconnection in wiring harness between lSOL(1) 4) Displays abnormality on both HMT controller
- cut relay (CN012) terminal (6) and monitor panel, and sounds buzzer
5) Defective 1st clutch solenoid (when internal re-

sistance is extremely low)
6) Contact between 24 V wiring harness and wir-
Short circuit in 1st clutch ing harness between lSOL(2) - CNOOl(4)
31
solenoid system
1) Defective 2nd clutch solenoid (when internal re- 1) Resistance between 2SOL(l) - (2): 5 - 20 Q 1) When traveling in 2nd, if abnormality is I), 2), I) When traveling in 2nd, the machine stops
sistance is extremely high) 41, or 5), operation of clutch solenoid is stopped 2) When traveling in any range other than 2nd, the
2) Disconnection in wiring harness between 2) When traveling in any range other than 2nd, machine continues to travel as it is until it is
Disconnection, short circuit
CNOOl(5) - 2SOL(2) condition is maintained until machine stops stopped
32 with chassis ground in 2nd
3) Short circuit with chassis ground in wiring har- 3) After machine stops, 2nd clutch solenoid cut 3) $ft;Ltthe machine is stopped, it can travel only
clutch solenoid system
ness between CNOOl(5) - 2SOL(2) relay cuts circuit
2SOL(l) - cut relay (CN013) terminal (6) and monitor panel, and sounds buzzer
5) Defective 2nd clutch solenoid (when internal re-

Short circuit in 2nd clutch so- ing harness between 2SOL(2) - CNOOl(5)
33
lenoid system
1) Defective 3rd clutch solenoid (when internal re- I) Resistance between 3SOL(l) - (2): 5 - 20 Q I) When traveling in 3rd, if abnormality is I), 21, 41, 1) When traveling in 3rd, the machine stops
sistance is extremely high) or 51, operation of the clutch solenoid is stopped 2) When traveling in any range other than 3rd, the
2) Disconnection in wiring harness between 2) If abnormality is 31, or when traveling in any machine continues to travel as it is until it is
CNOOl(6) - 3SOL(2) range other than 3rd, condition is maintained stopped
34 with chassis ground in 3rd
3) Short circuit with chassis ground in wiring har- until machine stops 3) $fi;Ltthe machine-is stopped, it can travel only
clutch solenoid system
ness between CNOOl(6) - 3SOL(2) 3) After machine stops, 3rd clutch solenoid cut
4) Disconnection in wiring harness between relay cuts circuit
3SOL(l) - cut relay (CN013) terminal (6) 4) Displays abnormality on both HMT controller
and monitor panel, and sounds buzzer
5) Defective 3rd clutch solenoid (when internal re-
Short circuit in 3rd clutch ing harness between 3SOL(2) - CNOOl(6)
35
solenoid system
20-507
0

% “After machine stops” means stopping the machine without turning the starting switch OFF. If the starting switch is turned OFF and is then turned ON again, operate the machine until the error code is generated
7\bm;dity Condition when normal Problem that appears on machine when ther
1) Defective brake solenoid (when internal resist- I) Resistance between BRAK(1) - (2): 30 - 80 s2 I) If abnormality is I), 2), or 4), operationof sole- 1) In case I), the machine stops
ante is extremely high) noid is stopped 2) In case 2), after the machine is stopped, it will
Disconnection, short circuit 2) Disconnection in wiring harness between 2) If abnormality is 3), condition is maintained un- not start again
38 with chassis ground in brake CNOOl(14) - BRAK(2) til machine stops
solenoid system 3) Short circuit with chassis ground in wiring har- 3) Displays abnormality on both HMT controller
ness between CNOOl(14) - BRAK(2) and monitor panel, and sounds buzzer
4) Disconnection in wiring harness between fuse 5
- BRAK(1)
I) Defective brake solenoid (when internal resist- 1) Output of brake solenoid is stopped I) Travels as normal
ante is extremely low) 2) Displays abnormality on both HMT controller 2) The machine cannot stop using the brake sole-
2) Contact between 24 V wiring harness and wir- and monitor panel, and sounds buzzer noid
Short circuit in brake solenoid ing harness between BRAK(2) - CNOOl(14) (If the brake pedal is depressed the machine
39
system will stop)
1) Defective R clutch solenoid (when internal re- I) Resistance between RSOL(1) - (2): 5 - 20 Q I) When traveling in R2 or R3, if abnormality is I), I) When traveling in R2 or R3, the machine stops
sistance is extremely high) 2), 41, 5) or 61, operation of clutch solenoid is 2) In case 2), after the machine is stopped, it can
2) Disconnection in wiring harness between stopped travel only in 1st
CNOOl(15) - RSOL(2) 2) If abnormality is 3) or when traveling in any
3A with chassis ground in R clutch
3) Short circuit with chassis ground in wiring har- other range, condition is maintained until ma-
solenoid system
ness between CNOOl(15) - RSOL(2) chine stops
4) Disconnection in wiring harness between 3) After machine stops, R clutch solenoid cut relay
RSOL(1) - cut relay (CN013) terminal (6) cuts circuit
4) Displays abnormality on both HMT controller
5) Defective R clutch solenoid (when internal re- and monitor panel, and sounds buzzer
Short circuit in R clutch ing harness between RSOL(2) - CNOOl(15)
3c
solenoid system
1) Defective F clutch solenoid (when internal re- I) Resistance between FSOL(1) - (2): 5 - 20 R 1) When traveling in F2 or F3, if abnormality is I), 1) When traveling in F2 or F3, the machine stops
sistance is extremely high) 2), 41, 5) or 61, operation of clutch solenoid is 2) In case 2), after the machine is stopped, it can
2) Disconnection in wiring harness between stopped travel only in 1st
CNOOl(19) - FSOL(2) 2) If abnormality is 31, or when traveling in any
3d with chassis ground in F clutch
3) Short circuit with chassis ground in wiring har- other range, condition is maintained until ma-
solenoid system
ness between CNOOl(19) - FSOL(2) chine stops
4) Disconnection in wiring harness between 3) After machine stops, F clutch solenoid cut relay
FSOL(1) - cut relay (CN013) terminal (6) cuts circuit
1) Defective F clutch solenoid (when internal re- and monitor panel, and sounds buzzer
Short circuit in F clutch ing harness between FSOL(2) - CN003(19)
3E
solenoid system
% When there is F clutch solenoid drive, the F I) Voltage between CN2H1(7) - GND I) Clutch solenoid condition is maintained until I) The machine continues to drive as it is until it
spool is not switched ON (closed) l When starting switch is ON: 20 - 30 V machine stops stops
I) Defective F spool switch * When in F2: Max. 1 V 2) After machine stops, clutch solenoid cut relay 2) $ft;;tthe machine is stopped, it can travel only
Abnormality in operation of 2) Disconnection in wiring harness between cuts solenoid circuit
40 F spool switch CN2H2(17) - FSW(1) 3) Displays abnormality on both HMT controller
% Display [401 is given when the operation (travel) and monitor panel, and sounds buzzer
is normal, and the F spool switch then gener-
ates an abnormality.
Display [411 is given if travel is restricted to 2nd
because of an abnormality, and the F spool 1) The machine continues to drive as it is until it
switch then generates an abnormality. stops
2) After the machine is stopped, it will not start
Abnormality in operation of again
41
F spool switch
20-508
0
L\CTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE

K“After machine stops” means stopping the machine without turning the starting switch OFF. If the starting switch is turned OFF and is then turned ON again, operate the machine until the error code is generated
Abn;;yality Condition when normal Problem that appears on machine when ther
(voltage, current, resistance) IS abnormalitv
% When there is R clutch‘solenoid drive, the R I) Voltage between CN2H1(8) - GND 1) Clutch solenoid condition is maintained until 1) The machine continues to drive as it is until il
I) Defective R spool switch l When in R2: Max. 1 V 2) After machine stops, clutch solenoid cut relay 2) :ktthe machine is stopped, it can travel only
Abnormality in operation of
42 2) Disconnection in wiring harness between cuts solenoid circuit
R spool switch
CN2H1(18) - RSW(1) 3) Displays abnormality on both HMT controller
% Display 1421 is given when the operation (travel) and monitor panel, and sounds buzzer
is normal, and the R spool switch then gener-
Display [431 is given if travel is restricted to 2nd
because of an abnormality, and the R spool I) The machine continues to drive as it is until ii
2) After the machine is stopped, it will not Stan
43 R spool switch
% When there is 1st clutch solenoid drive, the 1st I) Voltage between CN2Hlf9) - GND I) Clutch solenoid condition is maintained until 1) The machine continues to drive as it is until it
1) Defective 1st spool switch l When engine is started: Max. 1 V 2) After machine stops, clutch solenoid cut relay 2) After the machine is stopped, it can travel only
Abnormality in operation of 2) Disconnection in wiring harness between cuts solenoid circuit in 2nd when set to start in 2nd
44 1st spool switch CN2H1(9) - lSW(1) 3) Displays abnormality on both HMT controller
z Display 1441 is given when the operation (travel) and monitor panel, and sounds buzzer
is normal, and the 1st spool switch then gener-
Display [451 is given if travel is restricted to 1st
because of an abnormality, and the 1st spool I) The machine continues to drive as it is until it
45 1st spool switch
% When there is 2nd clutch solenoid drive, the I) Voltage between CNPHl(l0) - GND I) Clutch solenoid condition is maintained until 1) The machine continues to drive as it is until it
2nd spool is not switched ON (closed) l When starting switch is ON: 20 - 30 V machine stops stops
1) Defective 2nd spool switch l When engine is started: Max. 1 V 2) After machine stops, clutch solenoid cut relay 2) Amft;ltthe machine is stopped, it can travel only
Abnormality in operation of 2) Disconnection in wiring harness between cuts solenoid circuit
46 2nd spool switch CNZHl(l0) - 2SW(l) 3) Displays abnormality on both HMT controller
% Display [46] is given when the operation (travel) and monitor panel, and sounds buzzer
is normal, and the 2nd spool switch then gener-
Display [471 is given if travel is restricted to 1st
and 2nd because of an abnormality, and the I) The machine continues to drive as it is until it
2nd spool switch then generates an abnormal- stops
ity. 2) After the machine is stopped, it will not start
47
2nd spool switch
-
Z+ When there is 3rd clutch solenoid drive, the 3rd 1) Voltage between CNSHl(l1) - GND I) Clutch solenoid condition is maintained until 1) The machine continues to drive as it is until it
I) Defective 3rd spool switch l When switching to F3: Max. 1 V 2) After machine stops, clutch solenoid cut relay 2) Amft;Ltthe machine is stopped, it can travel only
Abnormality in operation of 2) Disconnection in wiring harness between
48 cuts solenoid circuit
3rd spool switch CNZHl(l1) - 3SW(l) 3) Displays abnormality on both HMT controller
I) The machine continues to drive as it is until it

stops
49 3rd spool switch

-X“After machine stoos” means stoooina the machine
II v~- ~~
without turnina _ the startina” switch
~~~ _~ __ OFF. _~_stat-tino
_ ~~ If the ---._...~ switch
_...__ is
.- turned
_-...-- _. and
OFF _ is then turned -
ON again, .
ooerate the machine until the error code is aenerated
Condition when normal Action by controller when abnormality Problem that appears on machine when the1
Abnormal system Nature of abnormality is detected
1) Defective HMT pump servo solenoid [Al or [Bl (Solenoid A) I) When [4Fl is displayed, solenoid cannot be ac- I) When traveling in Ist, the machine stops
2) Disconnection in wiring harness between 1) Resistance between CN003(1) (PUPA(2)) - tuated, so pump swash plate angle becomes 0 2) When traveling in 2nd or 3rd, the machine trav
CN003(1) - PUPA(2) (solenoid A) CN003(13) (PUPA(l)): 10 - 20 Q 2) With display [501, controller stops output of so- els at a fixed speed
Disconnection in HMT pump 3) Disconnection in wiring harness between (Solenoid B) lenoid, so pump swash plate angle becomes 0 3) When traveling it is impossible to shift betweer
4F servo solenoid system CN003(12) - PUPB(2) (solenoid B) 2) Resistance between CN003(12) (PUPB(2)) - in the same way FORWARD and REVERSE
4) Disconnection in wiring harness between CN003(13) (PUPB(1)): 10 - 20 Q 3) Clutch solenoid condition is maintained until 4) After the machine is stopped, it will not star
CN003(13) - PUPA(l) (PUPB(1)) machine stops, and if machine is stopped, clutch again
solenoid cut relay cuts solenoid circuit
1) Defective HMT pump servo solenoid [AI or [Bl and monitor panel, and sounds buzzer
ness between CN003(1) - PUPA(2) (solenoid A)
Short circuit in HMT pump , 3) Short circuit with chassis ground in wiring har-
50 servo solenoid system ness between CN003(12) - PUPB(2) (solenoid B)
ing harness between CN003(13) - PUPA(l)
(PUPB(l))
1) Defective HMT motor servo solenoid [AI (when (HMT motor solenoid A) I) With abnormality displays [511 and f531, sole- I) The machine travels at a fixed speed until i
internal resistance is extremely high) 1) Resistance between MRA(1) - (2): 10 - 20 R noid cannot be actuated, so motor swash plate stops
2) Disconnection in wiring harness between angle remains at maximum 2) When traveling it is impossible to shift betweer
Disconnection in HMT motor CN003(2) - MRA(1) 2) With abnormality displays (521 and 1541, con- FORWARD and REVERSE
51
servo solenoid [Al system 3) Disconnection in wiring harness between troller stops output of solenoid, so motor swash 3) After the machine is stopped, it can travel in Is
CN003(14) - MRA(2) plate angle remains at maximum in the same at under 1 km/h
way
3) Clutch solenoid condition is maintained until
machine stops, and if machine is stopped, clutch
1) Defective HMT motor servo solenoid IA] (when solenoid cut relay cuts solenoid circuit
internal resistance is extremely low) 4) After machine stops, output is sent only to 1st
2) Short circuit with chassis ground in wiring har- or 2nd clutch solenoids
Short circuit in HMT motor ness between CN003(2) - MRA(1) 5) Displays abnormality on both HMT controller
52 servo solenoid [Al system and monitor panel, and sounds buzzer
ing harness between CN003(14) - MRA(2)
ness between CN003(14) - MRA(2)
1) Defective HMT motor servo solenoid [Bl (when (HMT motor solenoid B)
internal resistance is extremely high) I) Resistance between MRB(1) - (2): 10 - 20 Q
2) Disconnection in wiring harness between
Disconnection in HMT motor CN003(16) - MRB(1)
53 servo solenoid [Bl system 3) Disconnection in wiring harness between
CN003(5) - MRB(2)
1) Defective HMT motor servo solenoid IBI (when

internal resistance is extremely low)
Short circuit in HMT motor ness between CN003(16) - MRB(1)
54
servo solenoid [Bl system 3) Contact between 24 V wiring harness and wir-
ing harness between CN003(5) - MRB(2)
ness between CN003(5) - MRB(2)
1) Defective steering EPC solenoid IA1 or [Bl (Solenoid A) I) When 1551 is displayed, solenoid is not actuated I) Machine continues to travel as it is until it is
2) Disconnection in wiring harness between I) Resistance between CN003(3) (STA(2)) - 2) When [561 is displayed, controller stops output stopped (the steering cannot be operated)
CN003(3) - STA(2) (solenoid A) CN003(4) (STA(l)) of solenoid 2) After the machine is stopped, it will not stan
Disconnection in steering EPC 3) Disconnection in wiring harness between (Solenoid B) 3) Clutch solenoid condition is maintained until again
55
solenoid system CN003(15) - SIB(P) (solenoid B) 2) Resistance between CN003(15) (STB(2)) - machine stops, and if machine is stopped, clutch
4) Disconnection in wiring harness between CN003(4) (STB(1)): 7 - 15 Q solenoid cut relay cuts solenoid circuit
CN003(4) - STA(1) (STB(1)) 4) After machine stops, there is no output to clutch
solenoid
1) Defective steering EPC solenoid [Al or [Bl and monitor panel, and sounds buzzer
ness between CN003(3) - STA(2) (solenoid A)
Short circuit in steering EPC 3) Short circuit with chassis ground in wiring har-
56
solenoid system ness between CN003(15) - STB(2) (solenoid B)
ing harness between CN003(4) - STA(1) (STB(1))
20-510
0

%“After machine stoos” means stoooing the machine without turning the starting switch OFF. If the starting switch is turned OFF and is then turned ON again, operate the machine until the error code is generated
bn;oryalib Condition when normal 4ction by controller when abnormality is detected Problem that appears on machine when ther
Abnormal system Nature of abnormality
1) Fuse 5 is blown ’ 1) Voltage between CN001(8),(6), CN003(16) - GND 1) All output stops I) The brake is applied and the machine canno
2) Defective contact, or disconnection in wiring har- 20 - 30 v travel
ness between CN001(8),(16), CN003(6) - fuse 5
Drop in controller power
57
source voltage
1) Defective parking brake switch [II 1) Voltage between CN2H1(2) (PSWP(1)) - GND 1) Does not show any particular response I) Travels as normal
2) Disconnection in wiring harness between l When switch is ON: Max. 1 V 2) Disolavs onlv abnormalitv on HMT controller % However,. if both occur at the same time, tht
CN2H1(2) - PSW2(1) l When switch is OFF: 20 - 30 V (buzzer does’not sound) engine WIII not start
59
Disconnection in parking brake 3) Disconnection in wiring harness between % However, if both occur at the same time, it actu-
switch [II system CN2H2(15) - PSW2(3) ates the neutral safety relay
% When parking brake switch 2 is ON (closed) and
switch 1 is OFF (open)
1) Defective parking brake switch [III 1) Voltage between CN2H1(4) (PSWl(1)) - GND
2) Disconnection in wiring harness between l When switch is ON: Max. 1 V
CNPHl(4) - PSWl(1) l When switch is OFF: 20 - 30 V
Disconnection in parking 3) Disconnection in wiring harness between
5A brake switch [Ill system CN2H2(15) - PSWl(3)
% When parking brake switch 1 is ON (closed) and
switch 2 is OFF (open)
% When sum of two potentiometer signal voltages 1) Between CN2H2(1) (FNR(8)) - CN2H2(15) (FNR(14)) 1) Clutch solenoid condition is maintained until I) Machine continues to travel as it is until it it
is not within 5 2 0.5 V 2) Between CN2H2(5) (FNR(l2)) - CN2H2(15) (FNR(11) machine stops, and if machine is stopped, clutch stopped
1) Misalignment in mount of directional lever Voltage: solenoid cut relay cuts solenoid circuit 2) After the machine is stopped, it will not star
Excessive difference between potentiometer 2) After machine stops, there is no output to clutch again
5c directional potentiometer signa 2) Defective directional lever potentiometer solenoid
valves [II and [Ill 3) Displays abnormality on both HMT controller
% When sum of two potentiometer signal voltages 1) Between CN2H2(2) (FNR(7)) - CN2H2(15) (FNR(1)) 1) Clutch solenoid condition is maintained until I) Machine continues to travel as it is until it i:
is not within 5 f 0.5 V 2) Between CN2H2(6) (FNR(4)) - CN2H2(15) (FNR(5)) machine stops, and if machine is stopped, clutch stopped
1) Misalignment in mount of steering lever Voltage: solenoid cut relay cuts solenoid circuit 2) After the machine is stopped, it will not star
Excessive difference between 2) After machine stops, there is no output to clutch again
potentiometer
5E steering potentiometer signal 2) Defective steering lever potentiometer solenoid
valves [II and [Ill 3) Displays abnormality on both HMT controller
ui
I) Defective soeed sensor [II 1) Resistance between CN009 (CNOlO)(male)(l) - (2) 1) Carries out control using signal from sensor with I) Travels as normal
2j Defective speed sensor ill mount : 500 - 1,000 R greater number of pulses
3) Defective contact of wiring harness between (When sensor [II is defective, controls with sig-
Abnormality in engine speed CN2H2(8) - CNOlO(1) nal from sensor [Ill: when sensor 1111is defec-
60 sensor [II signal % When number of pulses is less than sensor [Ill tive, controls with signal from sensor [II)
1) Defective speed sensor [Ill

2) Defective speed sensor [III mount
3) Defective contact of wiring harness between
Abnormality in engine speed CN2H2(17) - CN009(1)
61 sensor [III signal % When number of pulses is less than sensor [II

% “After machine stops” means stopping the machine without turning the starting switch OFF. If the starting switch is turned OFF and is then turned ON again,
_ operate
. the machine until the error code is generated
1\bnord”,“lity Nature of abnormality Condition when normal Problem that appears on machine when the
Abnormal system Action by controller when abnormality is detected
(1) Disconnection in neutral (1) Neutral safety relay system System (I] (engine stopped) System (1) System (I)
safety relay system 1) Defective neutral safety relay Between CN003(9) - GND: 1) When circuit is short circuiting with chassis In the case of I), the engine will not start
(2)Disconnection in 2, 3, F, R 2) Disconnection, short circuit with chassis l Joystick at neutral and parking lever at LOCK: ground, relay is not actuated In the case of 21, the engine will start if th
64 clutch solenoid cut relay ground, or short circuit in wiring harness be- 20 - 30 V 2) When there is disconnection in circuit, relay parking brake lever is released
system tween CN003(9) - relay (CN015) terminal (2) l JMys,ti;kVat neutral and parking lever at FREE: is not actuated System (2)
(2)2, 3, F, R clutch solenoid cut relay system System (2) I] The machine continues to drive as it is unt
I) Defective clutch solenoid cut relay System (2) (engine running) I) Clutch solenoid condition is maintained until it stops
2) Disconnection, short circuit with chassis Between CN003(9) - GND: 20 - 30 V machine stops, and after machine is stopped, 2) After the machine is stopped, it can travf
ground, or short circuit in wiring harness be- clutch solenoid is released only in 1st
(1)Short circuit in neutral tween CN003(9) - relay (CN012) terminal (2) 2) After machine stops, there is output only to
safety relay output system %XThis circuit is used for both the systems given 1st clutch solenoid
(2)Shor-t circuit in 2, 3, F, R above. l Displays abnormality on both HMT controller
clutch solenoid cut relay When engine speed is 0, relay (1) system is and monitor panel, and sounds buzzer
65
output system actuated; when engine is running, relay (2) sys-
tem is actuated.
I] Defective relay I] Voltage between CN003(10) - GND I] Alarm relay is not actuated I) Backup alarm does not sound
2) Disconnection in wiring harness between . Directional lever at N: 20 - 30 V
CN003(10) - CN014 terminal (2) l Directional lever at R: Max. 1 V
Disconnection in backup alarm 3) Disconnection, short circuit with chassis ground in 2) Voltage between CN244 - GND
66
relay drive system wiring harness between CN244 - CN014 terminal (3) . Directional lever at N: Max. 1 V
4) Disconnection in wiring harness between fuse 5, l Directional lever at R: 20 - 30 V
9 - relay terminal
% Relay is not actuated
I) Defective relay I) Alarm relay remains actuated I] Backup alarm continues to sound
2) Contact between 24V wiring harness and wiring
harness between CN003(10) - CN014 terminal (2)
Short circuit in backup alarm
67
relay drive system
I] Defective relay I) Voltage between CN003(1 I) - GND I) If abnormality occurs in 1st spool solenoid sys- I) The machine continues to drive as it is until i
2) Disconnection, short circuit with chassis ground lRelay not actuated: 20 - 30 V tern, stops
in wiring harness between CN003(11) - CN012 lRelay actuated: Max. 1 V actuation of solenoid cannot be stopped 2) After the machine is stopped, it can travel onI1
Disconnection in 1st clutch terminal (2) 2) Clutch solenoid condition is maintained until in 2nd when set to start in 2nd
68 solenoid cut relay system % Relay is not actuated machine stops, and after machine is stopped,
clutch solenoid is released
3) After machine stops, there is output only to F,
2nd clutch solenoid
1) Defective relay and monitor panel, and sounds buzzer
2) Contact between 24V wiring harness and wiring
harness between CN003(11) - CN012 terminal (2)
Short circuit in 1st clutch
69
solenoid cut relay system
% If potentiometer [II neutral signal voltage is not I] Voltage when potentiometer is at neutral: 2.5 f I] When potentiometer [I] is abnorma!, control is None in particular
2.5 * 0.5 V when starting switch is ON 0.5 v carried out using signal from potentrometer [II]:
1) Misalignment of potentiometer [I] when potentiometer [II] is abnormal, control is
Abnormality in neutral position
carried out using signal from potentiometer [I]
6A of directional lever
potentiometer [II
% If potentiometer [II] neutral signal voltage is not

2.5 & 0.5 V when starting switch is ON
Abnormality in neutral position I) Misalignment of potentiometer [II]
6C of directional lever
potentiometer [II]
20-512
0

% “After machine stops” means stoppino- the machine without turning the starting switch OFF. If the starting switch is turned OFF and is then turned ON again, operate the machine until the error code is generated
Nature of abnormality Condition when normal Action by controller when abnormality is detected Problem that appears on machine when ther
Abnormal system
% If potentiometer [I] neutral signal voltage is not 1) Voltage when potentiometer is at neutral: 2.5 2 I) When potentiometer [II is abnorma!, control is None in particular
2.5 k 0.5 V when starting switch is ON 0.5 v carried out using signal from potentrometer [Ill:
Abnormality in neutral position 1) Misalignment of potentiometer [II when potentiometer [III is abnormal, control is
6D of steering lever potentiometer carried out using signal from potentiometer [I]
[II 2) Displays abnormality on both HMT controller
% If potentiometer [Ill neutral signal voltage is not

2.5 2 0.5 V when starting switch is ON
Abnormality in neutral position 1) Misalignment of potentiometer [III
6E of steering lever potentiometer
[Ill
% Impossible to travel in either 1st clutch fixed or 1) Stops all output of clutch solenoids Machine does not start
2nd start % Displayed when machine cannot travel in either
(when abnormality occurs in both 1st clutch so- 1st or 2nd
Abnormality in both 1st fixed, lenoid system and 2nd clutch solenoid system) 2) Displays abnormality on both HMT controller
6F 2nd start and monitor panel, and sounds buzzer
x F spool solenoid is OFF but F spool switch is I) Clutch solenoid circuit is cut and brake solenoid I) The machine stops and will not start again
ON (closed) is switched ON
(if problem occurs when there is limit on travel 2) Displays abnormality on both HMT controller
Abnormality in operation of F speed) and monitor panel, and sounds buzzer
70 spool switch system
% F spool solenoid is OFF but F spool switch is I) 2, 3, F, R clutch solenoid cut relays are actuated 1) After the machine is stopped, it can travel onI1
ON (closed) and appropriate solenoid output is cut in 1st when set to start in 1st
2) After machine stops, there is output only to Ist,
Abnormality in operation of F 2nd clutch solenoid
71
spool switch system 3) Displays abnormality on both HMT controller
% R spool solenoid is OFF but R spool switch is I) Clutch solenoid circuit is cut and brake solenoid 1) The machine stops and will not start again
ON (closed) is switched ON
Abnormality in operation of R speed) and monitor panel, and sounds buzzer
72 spool switch system
% R spool solenoid is OFF but R spool switch is 1) 2, 3, F, R clutch solenoid cut relays are actuated I) After the machine is stopped, it can travel onl)
2) After machine stops, there is output only to 1st.
Abnormality in operation of R 2nd clutch solenoid
73 spool switch system 3) Displays abnormality on both HMT controller
+X 1st spool solenoid is OFF but 1st spool switch is I) 2, 3, F, R clutch solenoid cut relays are actuated I) After the machine is stopped, it can travel only
Abnormality in operation of 1st 2nd clutch solenoid
74 spool switch system 3) Displays abnormality on both HMT controller
20-513
0

\fter machine stops” means stopping the machine without turning the starting switch OFF. If the starting switch is turned OFF and is then turned ON again, operate the machine until the error code is generated
Abnormal system Nature of abnormality Condition when normal Problem that appears on machine when then
:!? (voltage, current, resistance) Action by controller when abnormality is detected
IS abnormality
z 2nd spool solenoid is OFF but 2nd spool switch 1) 1st clutch solenoid cut relay is actuated and 1) After the machine is stopped, it can travel only
is ON (closed) cuts output of 1st clutch solenoid in 2nd when set to start in 2nd
2) After machine stops, there is output only to F,
Abnormality in operation of
76 2nd clutch solenoid
2nd spool switch system
% 3rd spool solenoid is OFF but 3rd spool switch 1) Clutch solenoid circuit is cut and brake solenoid 1) The machine stops and will not start again
is ON (closed) is switched ON
Abnormality in operation of speed)
78 and monitor panel, and sounds buzzer
3rd spool switch system
% 3rd spool solenoid is OFF but 3rd spool switch 1) 2, 3, F, R clutch solenoid cut relays are actuated 1) After the machine is stopped, it can travel only
is ON (closed) and appropriate solenoid output is cut in 1st when set to start in 1st
Abnormality in operation of 2nd clutch solenoid
79 3rd spool switch system 3) Displays abnormality on both HMT controller
1) Defective monitor panel alarm 1) Voltage between P2(7) - GND ;1) When there is disconnection, alarm is not actu- Nothing in particular
2) Disconnection, short circuit with chassis ground l Starting switch ON: Max. 1 V ated
in wiring harness between fuse 3 - CN217(1) * 30 v 2) When there is short circuit at CN217 pin (2),
Abnormality in monitor Panel 3) Disconnection, short circuit with chassis ground alarm remains actuated
3A alarm system in wiring harness between P2(7) - CN217(2)
1) Disconnection, short circuit with chassis ground in 1) S-NET circuit is cut, so if abnormality occurs, Nothing in particular
wiring harness between P1(16), P2(10) - CN2Hl(ll) signal cannot be transmitted
S-NET communication error 2) Defective monitor panel (Even if abnormality is displayed on HMT con-
8d (abnormality between monitor 3) Disconnection, short circuit with chassis ground in troller, alarm does not sound)
panel and HMT controller) wiring harness between P1(16), P2(10) - CN2H2(11)
20-514
0
TROUBLESHOOTING JUDGEMENT TABLE FOR HMT CONTROLLER HYDRAULIC AND MECHANICAL SYSTEMS
JUDGEMENT TABLE FOR HMT CONTROLLER HYDRAULIC AND MECHANICAL SYSTEMS
% Check the HSS if the movement of

the work equipment is normal
Machine speed does not pick up when traveling FORWARD 00000000 000 H-3
Machine speed does not pick up when traveling in REVERSE 00000000 00 0 H-4
Travel speed does not change even when travel speed selector switch is pressed 0 E-191
z
r Acceleration is poor H-5
Machine lacks power (lacks drawbar pull) 0 H-6
Power train oil overheats H-II
Abnormal noise is generated from around HMT pump 0 H-12
Abnormal noise is generated from around HMT motor 0 H- 13
Does not turn to left

~ Machine does not turn H-7
Does not turn to right
Yl
1 Turning speed is slow or turning power is weak H-8
Machine does not stop turning even when steering lever is returned to neutral H-9
E
Troubleshooting code when abnormality display is given ,l01~02103104,l05106107108169110111 112113114115116117118119,l20121122123124125126127128129130131 132133134135136137138139140141 142143
20-5 15
0
TROUBLESHOOTING JUDGEMENT TABLE FOR HMT CONTROLLER HYDRAULIC AND MECHANICAL SYSTEMS
JUDGEMENT TABLE FOR HMT CONTROLLER HYDRAULIC AND MECHANICAL SYSTEMS
% Check the HSS if the movement of

the work equipment is normal
Machine lacks power (lacks drawbar pull) H-6

Power train oil overheats H-II
Abnormal noise is generated from around HMT pump H-12
Abnormal noise is generated from around HMT motor H-13
cn Machine does not turn

Does not turn to left 00 00 0
H-7
v)
Does not turn to right 0000 0
I Turning speed is slow or turning power is weak H-8
Machine does not stop turning even when steering lever is returned to neutral 0 0 00 H-9
E
Troubleshooting code when abnormality display is given 144145146147148149150151152153154155156157158159160161 162163164165166167166169170171172173174175176177178179180181 182183184185186187
20-5 16
0
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM OF HMT CONTROLLER SYSTEM
ELECTRICAL CIRCUIT DIAGRAM OF HMT CONTROLLER SYSTEM

-----_--------_-------
Serial No. : 60001 - 60271 /-cII”,,,, - 1
iDDO
20-5 17
8
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM OF HMT CONTROLLER SYSTEM
--
II/IIIII IIIII III I III III IIIIII/ II

IIIIIlII IIIII -IllI I III IIIIIlII I I II
L-
TKDO072I
20-518
@
E-101 [IO] Abnormality in HMT charge pressure is displayed

When there is a drop in the charge pressure or a disconnection in the wiring harness.
Always connect any disconnected connectors before going on to the next step.
If the starting switch was turned OFF momentarily after the
abnormality occurred, rotate the tracks under no load or drive
the machine for approx. 60 seconds and check if 1 E.ulIlOl is
displayed. (If it is not displayed, the system has been reset.) At
the same time as the abnormality occurs, the caution lamp on
Cause Remedy
1
the monitor panel will flash. (The buzzer will not sound.)
3 YES
Is [IO1 displayed
YES when everything
2 is returned to its
- original position?
Is resistance System has been reset -
YE between CPGP _ . Start engine. NO
(female) (1) and
(2) normal?
* Startingswitch Defective HMT charge

Replace
1 ON: Min. 1 MR NO pressure sensor
Is voltage between - Engine started:

CRGP (1) and (2) Max. 1 Q
as shown in - Disconnect
Table l? CRGP. Defective contact, or
YES Replace wiring
* Turn starting harness between CN2Hl
switch ON. 4 harness
(female) (6) - CN406 (I) -
*20-30V Is voltage between CRGP (female) (1)
CNZHI (6) and
N , CN003 (female) 5 YES
(21) normal? Is resistance Defective controller Replace
~ between CN003
* Turn starting - (female) (21) and - Defective contact, or
switch ON. NO CRGP (female) (2) disconnection in wiring
.20-30V normal? Replace wiring
- NO
* Turn starting (female) (21) - CN406
switch OFF. - CRGP (female) (2)
* Disconnect
CN003 and
CRGP.
Table 1 * Max. 1 R
% If the condition is as shown below, the sensor is normal.

Voltage between
Sensor CRGP (1) and (2)
When engine starting
pressure is normal Closed Max. 1 V
Starting switch Open 20 - 30 v
ON only

To monitor panel
CNZHI CN406
HMT controller (04020) (SWPIP) CRGP(X2)
a T_
CN003 HMT charge pressure sensor

(MIC21)
GND @j
TDD00168
,111
20-5 19
0
E-102 [II] Abnormality in HMT charge pressure sensor system is displayed

% If the charge pressure sensor is closed when the starting switch is ON.
* If the starting switch was turned OFF momentarily after the abnormality occurred, turn the starting
switch ON and check if [ ELI] [II] is displayed. (If it is not displayed, the system has been reset.)
Cause Remedy
Short circuit with chassis

ground in wiring harness
2 YES leplace wiring
between CN2Hl (female)
iarness
Is voltage between (6) - CN406 (1) - CRGP
YES CNPHI (male) (6) (female) (1)
and GND as
1 shown in Table I?
Defective controller leplace
Is resistance * Disconnect NO
between CRGP _ CN2Hl and
(male) (1) and (2) connect T-adapter to (male) only.
normal? * Turn starting switch ON.
*Diioyect 1
Defective HMT charge
ieplace
-Turn starting NO pressure sensor
switch OFF.
* Max. 1 R
Table 1
% If the condition is as shown below, the sensor is normal.
Voltage between
Sensor CRGP (I) and (2)
When engine starting
oressure is normal Closed Max. 1 V
Starting switch
Open 20 - 30 v
ON only
To monitor panel
CNPHI CN406
HMT controller (04020) (SWPIP) CRGP(X2)
3 T_
CN003 HMT charge pressure’sensor

(MIC21)
GND a QI
////
20-520
0
E-103 [I21 Abnormality in travel speed selector switch system is displayed

5% If the switch remains closed when the starting switch is ON.
switch ON and check if [E.u 1 [I21 is displayed after 100 seconds. (If it is not displayed, the system
has been reset.)
Defective speed selector

Replace
1 switch
Is voltage
between FNR
Short circuit with chassis I
(female) (2) and 2 YES Replace wiring
between CN2Hl (female) harness
GND normal? Is voltage - LEVER (12) - FNR
. Disconnect FNR _ between CN2Hl _ (female) (2)
and connect NO (male) (I) and
T-adapter to GND normal?
(female) only. * Disconnect NO
* Turn starting CNPHI and
switch OFF. connect
.20-30V T-adapter to
(male) only.
* Turn starting
switch ON.
g *20-30V
5
CNZHI LEVER FNR

Travel speed
(04020) (SWPIG) (SWPI 4)
I I I I I I selector switch
Travel speed
selector switch
CN2H2
(04016)
TOO00199
20-521
a
E-104 [I41 Abnormality in throttle potentiometer system is displayed

% When the signal voltage is 4.68 V or above.
switch ON and check if [E.u] [I41 is displayed. (If it is not displayed, the system has been reset.)
* Before carrying out troubleshooting, check that all the related
connectors are properly inserted. Remedy
jr Always connect any disconnected connectors before going on
to the next step.
I Power source wiring
harness in contact with
4 YES leplace wiring
wiring harness where
Is voltage formed rarness
voltage is formed
YES between CN2H2 (14)
- - (7) -chassis when - (see circuit diagram)
CN2H2, THRTL are
3 disconnected?
To A
Is resistance NO
. Disconnect
YES between CN2H.2 CN2H2 and
- (female) (7) and - connect T-adapter to
THRTL (female) (1) (female) only.
2 normal?
*Turn starting switch
Is resistance at ON. Defective contact, or
* Disconnect
YE THRTL (male) . When normal : 0 V disconnection in wiring
_ CNSH2and leplace wiring
end as shown in harness between CN2H2
THRTL. NO larness
Table I? (female) (7) - LEVER (4) -
* Turn starting
THRTL (female) (2)
Is resistance *Turn starting switch OFF.
between CN2H2 * Max. 1 D
switch OFF. Defective throttle leplace wiring
(female) (15) and * Disconnect NO potentiometer rarness
THRTL (female) (1)
THRTL.
normal?
*Turn starting
leplace wiring
switch OFF.
NO rarness
* Disconnect (female) (15) - LEVER (2) -
CN2H2 and THRTL (female) (I)
THRTL.
* Max. 1 D 5 YES
Defective HMT controller
Is [141 displayed
when everything
From A
is returned to its
original position?
System has been reset -
-Turn starting NO
switch ON.
Between (2) - (3) Between (7) - (14)
When measuring the item marked % from the CN2H2 (female) end, disconnect connectors BKPT, FNR.
(This is because the power source circuit is connected in parallel to the potentiometer of the above
connector.)

CNSMI LEVER
HMT controller (04016) (SWPIG) THRTL(X3)
c 3
(g -3
SIG GND a 3
Throttle
potentiometer
To other sensor
TDD00169
20-522
0
E-105 [I51 Abnormality in throttle potentiometer system is displayed

x When the signal voltage has dropped to 0.29 V or below.
Ir If the starting switch was turned OFF momentarily after the abnormality occurred, turn the starting
switch ON and check if 1E.u 1 1151 is displayed. (If it is not displayed, the system has been reset.)
Ir Always connect any disconnected connectors before going on to the next step.
Remedy
4 YES
Defective HMT controller leplace
3 YES Is 1151 displayed
when everything
Is resistance is returned to its
between CNZH2
original position?
(female) (14)and -
System has been reset
YES THRTL (female) (3). _ -Turn starting NO
and between
switch ON. Disconnection or short
2 CN2H2 (female) (7)
circuit with chassis
P and chassis as
Is resistance shown in Table 2? ~ ground in wiring harness leplace wiring
between CN2H2 p NO between CN2H2 (female) arness
YES (female) (7) and - * Turn starting (14) -LEVER (I)-THRTL
chassis as shown switch OFF. (female) (3)
1 I in Table 27 I . Disconnect
CN2H2 and Short circuit with chassis
* Turn starting
THRTL. ground in wiring harness
switch OFF. eplace wiring
between CN2H2 (female)
end as shown in - Disconnect NO
(7) - LEVER (4) - THRTL
arness
CN2H2 and
[female) (2)
THRTL.
* Turn starting
switch OFF.- I Defective throttle
eplace
E - Disconnect
THRTL.
NO Dotentiometer
;5
Table 1 Table 2
Between (2) - (3)
When measuring the item marked % from the CN2H2 (female) end, disconnect connectors BKPT, FNR.
connector.)

CNSMI LEVER
HMT controller (04016) (SWPIG) THRTL(X3)
c ,a
@ 3
SIG GND e:- -3

Throttle
potentiometer
v v
To othe;sensor
TDD00169
20-523
0
E-106 [I61 Abnormality in FORWARD speed control potentiometer system

is displayed
3% When the signal voltage is 4.68 V or above.
switch ON and check if [ E.u 1 [I61 is displayed. (If it is not displayed, the system has been reset.)
+ Before carrying out troubleshooting, check that all the related
Cause Remedy
connectors are properly inserted.
* Always connect any disconnected connectors before going on
to the next step. Power source wiring
teplace wiring
between CN2H2 rarness
voltage is formed
YE (female) (13) -
(see circuit diagram)
(female) (1) when
CN2H2, FMAX are ToA
* Connect T-adapter to
CNOOl (female) only.
* Turn starting switch
2 ON.
Is resistance at *When normal : 0 V Defective contact, or
YES FMAX (male) end disconnection in wiring
leplace wiring
as shown in harness between CNOOI
larness
1 Table l? (female) (1) - LEVER (6) -
FMAX (female) (2)
Is resistance * Turn starting switch OFF.
between CN2H2 Defective FORWARD
switch OFF. leplace wiring
(female) (15) and - speed control
* Disconnect NO larness
FMAX (female) (2) potentiometer
FMAX.
normal?
* Turn starting disconnection in wiring leplace wiring
switch OFF. harness between CN2H2
NO arness
* Disconnect (female) (15) -LEVER (16)
CN2H2 and - FMAX (female) (2)
FMAX.
. Max. 1 D 5 YES
A{SH
From
*Turn starting NO
switch ON.
Table 1
FMAX (male) CN2H2 (female) CNOOI (female) Resistance value
Between (1) - (2) z Between (13) - (15) - 4-6KQ
/Between (3)-(111 Between (13) - (I) 1 0.25 - 7 KQ 1

Between (3) - (2) Between (15) - (1) 0.25 - 7 KR
When measuring the item marked % from the CN2H2 (female) end, disconnect connectors RMAX, FNR.
connector.)
CN2H2 LEVER
HMT controller (04O’i6) (SWPIG) FMAX(X3)
Power source (5V) @ 43 -0

Speed control
GND 0 8 potentiometer(F)
@ = :
CNOOI RMAX(X3)
(MIC17) ,-
Speed control Speed control
potentiometer IF) 0 :
potentiometer(R)
Speed control ,k
potentiometer 03) 0
-11 -
+JI
To otcsensor TOD00170
20-524
E-107 [I71 Abnormality in FORWARD speed control potentiometer system

is displayed
3% When the signal voltage has dropped to 0.29 V or below.
sr If the starting switch was turned OFF momentarily after the abnormality occurred, turn the starting
switch ON and check if [E.u I [I71 is displayed. (If it is not displayed, the system has been reset.)
Cause Remedy
to the next step.
F=
when everything
is returned to its
original position?
(female) (13) and
and between
I switch ON. 1Disconnection or short
CN2H2 (female) (13)
and chassis as
Is resistance Replace wiring
shown in Table 2?
between CNOOl harness
YES (female) (1) and
r chassis as shown (female) (1)

1 1in Table 2? * Disconnect
Is resistance at
’ CNZHZ and Short circuit with chassis
* Turn starting
FMAX. ground in wiring harness
FMAX (male) end _ switch OFF. Replace wiring
as shown in between CNZHZ ((female) harness
* Disconnect NO
Table I? (1) - LEVER (6) - FMAX
CNOOl and
(female) (3)
FMAX.
* Turn starting
Defective FORWARD
switch OFF.
speed control
* Disconnect NO
potentiometer
FMAX.
Table 1 Table 2 ’
Resistance
value
Between CN2H2 (female) (13) -
FMAX (female) (1)
Max. 1 Sz
Between CNOOI (female) (I) -
FMAX (female) (3)
Between
(3) - (2) Between (15) - (I) 1 0.25 - 7 KQ 1 Between CN2H2 (female) (13) - chassis
Min. 1 MQ
Between CNOOI (female) (7) - chassis
connector.)
CN2H2 LEVER
HMT controller (04016) (SWPIG) FMAX(X3)
@ 0
Speed control
@ 0 potentiometer(F)
1
8; 0
CNOOI RMAX(X3)
(MIC17) #_
Speed control
potentiometer(F) 0 g
potentiometer(R)
Speed control 0
potentiometer (R) 0
- U
To otzsensor TOD00170
20-525
0
E-108 [I81 Abnormality in REVERSE speed control potentiometer system is

displayed
When the signal voltage is 4.68 V or above.
If the starting switch was turned OFF momentarily after the abnormality occurred, turn the starting
switch ON and check if [E.LJ 1 1181 is displayed. (If it is not displayed, the system has been reset.)
Before carrying out troubleshooting, check that all the related
connectors are properly inserted. Cause Remedy
Always connect any disconnected connectors before going on
to the next step. Power source wiring
qeplace wiring
larness
between CN2H2 voltage is formed (see
YI (13) - (15). CNOOl circuit diagram)
CN2H2, RMAX are

3 To A
Is resistance
. Connect
YES between CNOOI
- (female) (2) and T-adapter to
RMAX (female) (3) CN2H2 (female) only.
2 normal? * Turn starting switch
ON.
Is resistance at * Disconnect Defective contact, or
. When normal :0 V
YI RMAX (male) _ CNOOI and disconnection in wiring
ieplace wiring
end as shown in RMAX. harness between CNOOl
10 tamess
1 Table I? * Turn starting (female) (2) - LEVER (7) -
switch OFF. RMAX (female) (3)
-Turn starting
between CNZH2 * Max. 1 R
switch OFF. Defective REVERSE speed seplace wiring
(female) (15) and
* Disconnect NO control potentiometer lamtess
RMAX (female) (1)
RMAX.
-Turn starting disconnection in wiring
switch OFF. jeplace wiring
harness between CN2H2
* Disconnect JO lamess
(female) (15) - LEVER (16)
CN2H2 and - RMAX (female) (1)
RMAX.
* Max. 1 Q 5 YE!
Defective HMT controller teplace
From A
+Z.IZJJ

. Turn starting
Table 1 switch ON.
connector.)
CN2H2 LEVER
HMT controffer (04016) (SWPIG) FMAX(X3)
@
Speed control
8 potentiometer(F)
8;
CNOOI RMAX(X3)
(MIC17) ,-
potentiometer (F) 0 :
potentiometer(R)
Speed control 0
potentiometer(R) 0
To otzsensor TDD00170
20-526
0
E-109 [I91 Abnormality in REVERSE speed control potentiometer system is

displayed
When the signal voltage has dropped to 0.29 V or below.
switch ON and check if [E.u 1 [I91 is displayed. (If it is not displayed, the system has been reset.)
Before carrying out troubleshooting, check that all the related
connectors are properly inserted. Cause I Remedy
to the next step.
4 YEI
3 ’
when everything
Is resistance
is returned to its
between CNZH2
original position?
(female) (13) and
YES RMAX (female) (21,
and between
Disconnection or short
CN2H2 (female) (131
2 circuit with chassis
- and chassis as
Is resistance shown in Table 2? ground in wiring Replace wiring
YES between CNOOl NO harness between CN2H2 harness
(female) (2) and - * Turn starting (female) (13) - LEVER (14)
chassis as shown switch OFF. - RMAX (female) (2)
1 in Table 2? * Disconnect
‘c
Is resistance at * Turn starting
CN2H2 and Short circuit with chassis I
‘I RMAX. ground in wiring harness Rep,ace wiring
RMAX (male) switch OFF.
between CNOOI (female)
end as shown in * Disconnect harness
(2) - LEVER (7) - RMAX
Table I? CNOOl and
(female) (3)
* Turn starting RMAX.
switch OFF. Defective REVERSE speed
* Disconnect Replace
NO control potentiometer
RMAX.
Table 1 1-able 2
I I
CNOOI Resistance 1 Resistance 1
FMAX (male) (FeNz!-&
(female) value value
Between % Between Between CNOOI (female) (2) -
4-6KQ
(2) - (I) (13) - (15) -
Between
Between (13) - (2) 0.25 - 7 KS2
(2) - (3)
Between
Between (15) - (2) 0.25 - 7 KQ Between CNOOI (female) (2) - chassis
(1) - (3)
I3etween CN2lj2 (female) (13) - chassis
When measuring the item marked Z from the CN2H2 (female) end, disconnect connectors FMAX, FN!?.
connector.)
E-109 Related electrical circuit diagram
CN2H2 LEVER
HMT controller (04016) (SWPIG) FMAX(X3)
@
Speed control
8 potentiometer(F)
8 =
CNOOI RMAX(X3)
(MIC17) ,c-
potentiometer (F) 0 0 :
potentiometer(R)
Speed control 0
potentiometer U7) 0. .o
JJ
To otzsensor TDD00170
20-527
0
E-l 10 [IA] Abnormality in brake pedal potentiometer system is displayed

X When the signal voltage is 4.68 V or above.
Sr If the starting switch was turned OFF momentarily after the abnormality occurred, turn the starting
switch ON and check if [E.u] [IA] is displayed. (If it is not displayed, the system has been reset.)
connectors are properly inserted. Cause Remedy
to the next step.
I?ower source wiring
Ilarness in contact with
;
-, Xeplace wiring
larness
between CN2H2 (3).
voltage is formed
YI ,[see circuit diagram)
(14) - (15) when
CN2H2, BKPTare
To A
* Connect
1’
T-adapter to
(female) (3) and CN2H2 (female)
BKPT (female) (2)1 only.
*Turn starting
switch ON. IDefective contact, or
YE BKPT (male) end *When normal : 0 V ,disconnection in wiring
?eplace wiring
Iharness between CN2H2
*Turn starting rrl0 larness
ITable l? (female) (3) - LEVER (3) -
switch OFF. BKPT (female) (2)
* Turn starting
between CN2H2 * Max. 1 Q
switch OFF. Defective brake
(female) (15) and ?eplace wiring
* Disconnect BKPT. NO potentiometer
BKPT (female) (3) iarness
* Turn starting
switch OFF. qeplace wiring
. harness between CNZHZ
* Disconnect InlO Jarness
(female) (15) -LEVER (3) -
CNZHZ and
BKPT (female) (3)
BKPT.
* Max. 1 R 5 YE: ;
Defective HMT controller qeplace
FromAjZH

. Turnstarting NC1
Table 1 switch ON.
BKPT (female) CNZHZ(female) Resistance value

Between (1) - (3) %%
Between (14) - (15) 4-6KR
-Between101 Between(3)-(14) 1 , 0.25-7KS1 1
(Between (2) - (3) 1 Between (3) - (15) 1 0.25 - 7 KQ 1
When measuring the item marked % from the CN2H2 (female] end, disconnect connectors THRTL, FNR.
connector.]
E-l 10. Related electrical circuit diagram To other sensor

-
CN2H2 LEVER A A
HMT controller (04016) (SWPIG) BKPT(X3)
c 3
a 3
SIG GND
z-3
Brake potentiometer
TDD00171
20-528
0
E-l 11 [ICI Abnormality in power train oil temperature sensor system is

displayed
33 When the signal voltage has dropped to 0.29 V or below.
switch ON and check if [E.u I [ICI is displayed. (If it is not displayed, the system has been reset.)
Cause Remedy
F=
7 -1 Defective HMT controller Replace
Is IlCl displayed
2 YES when everything
I is returned to its
Is resistance
original position?
between CNOOl System has been reset -
YES (female) (10) and _ . Turn starting NO
CN2H2 (female) (15) switch ON.
_ 1 as shown in
Is resistance Table l?
ground in wiring harness Replace wiring
between PLTP - * Turn starting harness
NO between CM001 (female)
(male) (1) and (2) as
switch OFF. (10) and PLTP (female) (1)
shown in Table l?
. Disconnect
* Turn starting CNOOI and CN2H2.
Defective oil temneretrrre
Replace
sensor
. :%::,“,‘,:,LTP. No
._
I-
Table 1
z
Ambient temperature Resistance value
35°C Approx. 29 KQ
I I
20°C Approx. 52 KR
I I
10°C Approx. 80 KR
CNOOI Power train oil

HMT controller (MlC17) PLTP(X2) temperature sensor
Power train oil

temperature sensor
CN2H2
(04016)
GND
TDD00172
20-529
a
TROUBLESHOOTING E-II&E-113
E-112 [Id1 Abnormality in both directional lever potentiometer signal

systems is displsyed
% Carry out troubleshooting for the simultaneously displayed individual mode: [IEI, [IF], [211, P21.
E-113 [IE] Abnormality in directional lever potentiometer [I] system is

displayed
34 When the signal voltage is 4.68 V or above.
switch ON and check if [ E.u I [6Al “Neutral position abnormal” is displayed. (If it is not displayed,
the system has been reset.)
Remedy
,.-+J!zr leplace
YES Keep measurement
rl conditionsin Item 2.
normal? YES Defective directional lever

I leplace
potentiometer [II
bTurn starting 4
switch ON. Is voltage in Item
) Max. 4.42V _ 2 normal when _ Power source wiring
% At neutral: NO FNRis 5 YES harness in contact with ;eplace wiring
2.5 + 0.5 V disconnected? wiring harness where amess
1 p Is voltage formed
voltage is formed
. Same conditions _ between CN2H2
between CN2H2 as in Item 2. NO (female) (13), (1) Defective contact, or
(female) (15) and -chassis? disconnection in wiring
qeplace wiring
FNR (female) (14) - harness between CN2H2
* Disconnect tamess
CN2H2 and FNR,
No (female) (1) - LEVER (11) -
- Turn starting FNR (female) (8)
and connect
switch OFF. T-adapter to
* Max. 1 R CN2H2 (female).
* Disconnect * Turn startina I
CNZH2 and FNR.
qeplace wiring
tarness

To other sensor
CN2H2
(04016) (SWP14) Directional lever
meter
(II)
To othzensor TDD00173
20-530
0
E-l 14 [IF] Abnormality in directional lever potentiometer [II system is

displayed
switch ON and check if 1E.u 1 [6Al “Neutral position abnormal” is displayed. (If it is not displayed,
Before carrying out troubleshooting, check that all the related Cause Remedy
to the next step.
3 YES

Is voltage between * Turn starting NO
YE FNR (8) and (14) II switch ON.
Defective directional lever

Replace
potentiometer [II

between CN2H2 (female) harness
Il)-LEVER(ll)-FNR
between FNR (9) switch OFF. (female) (8)
and (14) normal? * Disconnect
CN2H2 and FNR.
switch ON.
f: disconnection in wiring Replace wiring
* 4.75 - 5.25 V
harness between CN2H2 harness
E
Ifemale) (13) - LEVER (14)
& - FNR (female) (9)
N
defective HMT controller Replace
L
* Turn starting L between CN2H2 _

NO (female) (13) and Short circuit with chassis
switch ON.
chassis normal? around in wiring harness
* 4.75 - 5.25 V Replace wiring
setween CN2H2 (female)
-Turn starting NO harness
:13) - LEVER (14) - FNR
switch OFF. :female) (9)
. Disconnect
CN2H2 and FNR.
* Min. 1 MR
Table 1
Lever I FNR I CN2H2 Voltage
Between (8) - (14) Between (8) - (14)
REVERSE Full
E-114. Related electrical circuit diagram To other sensor

-
Power source (5V)
Power source (5V)
I I I
To oth=ensor TDD00173
20-531
0
E-115 [20] Abnormality in brake pedal potentiometer system is

displayed
% When the signal voltage is 0.29 V or below.
switch ON and check if [E.u ] [20] is displayed. (If it is not displayed, the system has been reset.)
Remedy
4 YES
3 YES Is f201 displayed
when everything _
Is resistance
is returned to its
between CN2H2
original position?
(female) (14) - BKPT NO System has been reset -
YES (female) (1). and _ *Turn starting
between CN2H2 switch ON. Disconnection or short
(female) (14) -
2 circuit with chassis
chassis as shown in
Is resistance Table 2? ground in wiring harness Replace wiring
VES between CN2H2 - NO between CN2H2 (female) harness
(female) (3) and - *Turn starting (14) - LEVER (I) - BKPT
chassis as shown switch OFF. (female) (1)
Replace wiring
harness
*Turn starting
switch OFF.
* Disconnect BKPT. Replace
Table 1
BKPT (male)
21
CN2H2 (female) Resistance value CN2H2 (female) BKPT (female) Resistance value
Between (I) - (3) x Between (14) - (15) 4-6KQ
Between (2) - (1) Between (3) - (14) 0.25 - 7 K0
Between (2) - (3) Between (3) - (15) 0.25 - 7 KQ Between (3) - chassis
Min. 1 MQ
When measuring the item marked % from the CNH2 (female) end, disconnect connectors CN2H2, FNR.
connector.)
CN2H2 LEVER A A
HMT controller (04016) (SWPIG) BKPT(X3)
I
-3
a
SIG GND -3
Brake potentiometer
TDD00171
20-532
0
E-116 [21] Abnormality in directional lever potentiometer [III system is

displayed _
When the signal voltage is 4.68 V or above.

switch ON and check if [E.u ] [211 “Neutral position abnormal” is displayed. (If it is not displayed,
1
I-
Cause Remedy
3 YES
I7 Defective HMT controller Replace
Yl

*Turn starting NO
Is voltage
switch ON.
YE between CN2H2
(5) and (15)
YES Defective directional lever
normal? Replace
4 potentiometer [III
* Turn starting
Is voltage of Item
switch ON.
2 normal when Power source wiring
* Max. 4.42 V
h FNR is 5 YES harness in contact with Replace wiring
?ZAt neutral:
1 disconnected? wiring harness where harness
2.5 + 0.5 V _ Is voltage formed
voltage is formed
Is resistance *Same conditions _ between CN2H2
between CNZHZ as in Item 2. No (female) (14). (5) Defective contact, or
(female) (15) and -chassis? disconnection in wiring
FNR (female) (11) L Replace wiring
normal? 9 Disconnect NC harness
(female) (5) - LEVER (8) -
CN2H2 and FNR,
* Turn starting FNR (female) (12)
and connect
* Max. 1 Q CN2H2 (female).
* Disconnect *Turn starting
CN2H2 and FNR. switch ON. Defective contact, or
*When normal: 0 V disconnection in wiring
Replace wiring
IO (female) (15) - LEVER (2)
FNR (female) (1 I)

To other sensor
-
Power source (5V)
Power source (5V)
To othxensor
TOO00173
20-533
0
E-117 1221 Abnormality in directional lever potentiometer [II] system is

displayed
switch ON and check if [ E.u ] [6C] “Neutral position abnormal” is displayed. (If it is not displayed,
Before carrying out troubleshooting, check that all the related Remedy
to the next step.
3 YES
Is 1221 displayed
YI when everything
is returned to its
original position?
-Turn starting NO
YE FNR (12) and (13) switch ON.
4 YES Defective directional lever

Replace
Is resistance potentiometer [III
* Turn starting
switch ON. between CN2H2
F ) (female) (5) and Short circuit with chassis
1 chassis normal? ground in wiring harness Replace wiring
Is voltage *Turn starting NO (5) - LEVER (8) - FNR
between FNR switch OFF. (female) (12)
(13) and (II) * Disconnect
nnrmal?
CN2H2 and FNR.
+ Turn starting - Min. 1 MR
switch ON.
I Defective contact, or
-4.75 - 5.25 V YES Replace wiring
. harness between CN2H2
harness
5
Is voltage FNR (female) (13)
between CN2H2
NO (14) and (15) 6 YES
normal? P Defective HMT controller
( Is resistance
* Turn starting _ between CN2H2 _
switch ON.
chassis normal? ground in wiring harness
* 4.75 - 5.25 V Replace wiring
*Turn starting NO
(14) - LEVER (1) - FNR
switch OFF. (female) (13)
* Disconnect
CN2H2 and FNR.
* Min. 1 MR
Table 1
I Lever I FNR I CN2H2 Voltage
Neutral 2.5 f 0.5 V
FORWARD Full Between (12) - (11) Between (5) - (15) 3.92 - 4.42 V
REVERSE Full 0.59 - 1.08 V
E-l 17. Related electrical circuit diagram To othzensor

CN2H2
(04016) (SWP14) Directional lever
meter
(11)
20-534
0
TROUBLESHOOTING E-118,E-119
E-l 18 [23] Abnormality in both steering lever potentiometer signal systems

is displayed
% Carry out troubleshooting for the simultaneously displayed individual mode: P41, 1251, [261, [271.
E-119 [24] Abnormality in steering lever potentiometer [II system is

displayed
% When the signal voltage is 4.68 V or above.
* If the starting switch.was turned OFF momentarily after the abnormality occurred, turn the starting
switch ON and check if 1 E.u 1 [6dl “Neutral position abnormal” is displayed. (If it is not displayed,
cause Remedy
3 YES
Defective HMT controller Zeplace
- conditions in Item 2. -
Is I241 displayed?
2-p System has been reset -

* Turn starting NO
Is voltage
switch ON.
IES between CN2H2
(2) and (15)
YES Defective steering lever
normal? leplace
4 potentiometer [II
* Turn starting
Is voltage of Item
switch ON.
harness in contact with leplace wiring
wiring harness where iarness
2.5 + 0.25 V
voltage is formed
. Same conditions
between CN2H2 as in Item 2. Defective contact, or
(female) (15) and chassis? disconnection in wiring
leplace wiring
FNR (female) (1) harness between CN2H2
* Disconnect larness
CN2H2 and FNR,
and connect
* Max. 1 R CN2H2 (female).
* Disconnect * Turn starting
CN2H2 and FNR. switch ON. Defective contact, or
(eplace wiring
amess
- FNR (female) (I)

CN2H2 LEVER rA FNR
potentiometer (I)
Power source (5V)
To other sensor TDD00174
20-535
0
E-120 [25] Abnormality in steering lever potentiometer [II system is

displayed
% When the signal voltage has dropped to 0.29 V or below.
switch ON and check if [ E.u 1 [6dl “Neutral position abnormal” is displayed. (If it is not displayed,
* Before carrying out troubleshooting, check that all the related Cause Remedy
to the next step.
3 YES
Yf

* Turn starting NO
YI between FNR (7) switch ON.
and (1) as shown
4 YES Defective steering lever
potentiometer [II
* Turn starting
switch ON.
I\ Short circuit with chassis
between CN2H2 (female) larness
Is voltage * Turn starting NO (2) - LEVER (15) - FNR
between FNR (6) switch OFF. (female) (7)
and (I) normal? . Disconnect
CN2H2 and FNR.
switch ON.
disconnection in wiring qeplace wiring
.4.75 - 5.25 V YES
harness between CN2H2 Tarness
51
- FNR (female) (6)

ground in wiring harness ?eplace wiring
between CN2H2 (female) iarness
* Turn starting NO
(13) - LEVER (14) - FNR
* Disconnect
CN2H2 and FNR.
* Min. 1 MR
Table 1
Lever FNR CN2H2 Voltage
Neutral 2.5 2 0.25 V
Right Full Between (7) - (1) Between (2) - (15) 3.92 - 4.42 V
Left Full 0.59 - 1.08 V
E-120. Related electrical circuit diagram To other sensor

CN2H2 LEVER
HMT controller (04016) (SWP16) Steerina lever
Power source (5V)
20-536
0
E-121 [26] Abnormality in steering lever potentiometer [II] system is

displayed
S%When the signal voltage is 4.68 V or above.
switch ON and check if 1 E.u I [6El “Neutral position abnormal” is displayed. (If it is not displayed,
Cause Remedy
3 YES
II Defective HMT controller
Is 1261displayed?
2 Svstem has been reset -
*Turn starting NO
Is voltage
switch ON.
YI between CN2H2 _
(6) and (15)
YES Defective steering lever
normal? Replace
4 potentiometer [III
* Turn starting
Is voltage of Item
switch ON.
r
* Max. 4.42 V
NO FNRis 5 YEI harness in contact with Replace wiring
% At neutral:
disconnected? wiring harness where harness
2.5 + 0.5 V - Is voltage formed
f2 Is resistance . Same conditions _ between CN2H2 _
voltage is formed
2 between CNZHZ
(female) (15) and
as in Item 2. NO (female) (14). (6) Defective contact, or
z -chassis? disconnection in wiring Replace wiring
FNR (female) (5) harness between CN2H2
normal? * Disconnect N( harness
(female) (6) - LEVER (13).
CN2H2 and FNR,
and connect
. Max. 1 R CN2H2 (female).
* Disconnect . Turn starting
CN2H2 and FNR. switch ON.
Replace wiring
harness between CN2H2 harness
FNR (female) (5)
To other sensor
-
Power source (5V)
20-537
0
E-122 [27] Abnormality in steering lever potentiometer [III system is

displayed
switch ON and check if [ E.u I [271 “Neutral position abnormal” is displayed. (If it is not displayed,
Before carrying out troubleshooting, check that all the related Cause Remedy
to the next step.
3 YES

Is voltage between * Turn starting NO
YE FNR (4) and (10) _ switch ON.
as shown in
Table l? 4 YES Defective steering lever
Is resistance potentiometer Ill]
. Turn starting
switch ON. _ between CN2H2 _
1 chassis normal? ground in wiring harness
leplace wiring
*Turn starting NO iarness
(6) -LEVER (13) - FNR
between FNR switch OFF. (female) (4)
* Disconnect
CN2H2 and FNR.
*Turn starting * Min. 1 MR
switch ON.
. 4.75 - 5.25 V YES leplace wiring
iarness
FNR (female) (IO)
Defective HMT controller (eplace

leplace wiring
NO arness
* Turn starting (14) - LEVER (1) - FNR
+ Disconnect
CN2H2 and FNR.
* Min. 1 MR
Table 1
Lever FNR CN2H2 Voltage
Neutral 2.5 r 0.25 V
Right Full Between (4) - (5) Between (6) - (15) 3.92 - 4.42 V
Left Full 0.59 - 1.08 V

To other sensor
CN2H2 LEVER Ta FNR
Power source (5V)
20-538
0
E-123 [28] Abnormality in both engine speed sensor systems is

displayed
% Carry out troubleshooting for the simultaneously displayed individual mode: [291, [2Al.
E-124 [29] Abnormality in engine speed sensor [I] system is displayed

Ir If the starting switch was turned OFF momentarily after the abnormality occurred, start the engine
and check if 1E.u 1 1291 is displayed. (If it is not displayed, the system has been reset.)
* Check the sensor clearance. For details, see TESTING AND ADJUSTING.
Cause Remedy
4 YE5
is returned to its
original position?
YES between CN2H2
r-l (8) and (16)
2
H
Is resistance Defective engine speed
\ between CN2H2 sensor [II
Replace
* Measure with AC NO
(female) (8) and
range. Defective contact,
(16) normal?
* 0.5 - 3.0 v disconnection, or short
z * Turn starting circuit with chassis
Replace wiring
between CNOIO switch OFF. * ground in wiring harness
NO harness
(male) (I) and (2) . Disconnect between CN2H2 (female)
CN2H2. I;;, ;I$) - CNOIO (female)
-Turn starting
*500-1,OOOR , I
switch OFF. Defective engine speed
* Disconnect NO sensor [II
CNOIO.
* 500 - 1,000 R
CN2H2
HMT controller (04016) CNOlO(X2)
Engine speed
Speed sensor (II) (-) sensor (I)
Engine speed
sensor (II)
TDD00175
20-539
0
E-125 [2A] Abnormality in engine speed sensor [II] system is displayed

* If the starting switch was turned OFF momentarily after the abnormality occurred, start the engine
and check if 1EU I [2Al is displayed. (If it is not displayed, the system has been reset.)
* Check the sensor clearance. For details, see TESTING AND ADJUSTING.
Cause Remedy
is returned to its
original position?
YE IIs voltage
between CN2H2 u
1
* Start enaine
C~*-+a- Ir*= heen reset -
Replace
YE between CNZHZ
(female) (17) and range.
CN2H2 (161 normal? * 0.5 - 3.0 v
1 * Turn starting harness between CN2H2
switch OFF. (female) (16) - CN009
Is resistance I Replace wiring
* Disconnect (female) (2). or between harness
IO
CN2H2. CNOOI (female) (17) and
~500-1,000n CN009 (female) (1) or
short circuit with chassis
. Turn starting ground
switch OFF.
* Disconnect Defective engine speed
Replace
CNOlO. IO sensor Ill1
* 500 - 1,000 R
CN2H2
Engine speed
sensor (1)
CN009(X2)
Engine speed
sensor (II)
(MIC17) TDD00175
20-540
0
E-126 [2c] Abnormality in HMT motor speed sensor system is

displayed
% When the number of A phase pulses is lower than that of B phase pulses.
* If the starting switch was turned OFF momentarily after the abnormality occurred, rotate the tracks
freely or drive the machine and check if [ E.u 1 [2Cl is displayed. (If it is not displayed, the system
has been reset.)
CaUSe Remedy
3 YES
:;lEHT
Defective HMT motor
Replace
speedsensor
between CNOOl
YE
(female) (12) - (3). * 0 - 3.0 v
Isresistance
between MREV
(male) (1) - (2). (3)
- (2) as shown in
1 (13) - (3) as shown
in Table l?
* Turn starting
switch OFF.
- Disconnect
t
J
II
NO
* Measure with AC
range.
Defective contact or
harness between CNOOI
(female) (12) and MREV
(female) (3). or short
Replace wiring
harness

CNOOI.
ground
* Turn starting
Defective HMT motor
8 switch OFF. Replace
JO speedsensor
* Disconnect
x,
MREV.
z
Table 1
I MREV (male) CNOOI (female) 1Resistance value 1
1 Between (I) - (2) I Between (12) - (3) I 2.5 - 7 n I

I Between (3) - (2) I Between (13) - (3) I 2.5 - 7 Q
I
Between (1) - chassis Between (I) - chassis
Min. 1 MQ
Between each pin
CNOOI
HMT controller (MIC17)
GND MREV(X3) HMT motor

lb speedsensor
Motor speed sensor
A phase
A
B
Yc$;s;peed sensor
TDD00176
20-541
0
E-127 [2dl Abnormality in HMT motor speed sensor system is

displayed
x When the number of B phase pulses is lower than that of A phase pulses.
Ir If the starting switch was turned OFF momentarily after the abnormality occurred, rotate the tracks
freely or drive the machine and check if [ E.u I [2dl is displayed. (If it is not displayed, the system
has been reset.)
I Cause Remedy
leplace
YE
leplace
YE
(13) - (3) as shown
between MREV * Turn starting leplace wiring

(male) (1) - (2). (3) switch OFF. arness
- (2) as shown in * Disconnect
Table l? CNOOI.
. Turn starting I
I Defective HMT motor
switch OFF. eplace
NO speedsensor
* Disconnect
MREV.
Table 1
MREV (male) CNOOI (female) Resistance value
Between (1) - (2) Between (12) - (3) 2.5 - 7 R
Between (3) - (2) Between (13) - (3) 2.5 - 7 Q
Between (1) - chassis Between (12) -chassis

Min. 1 MQ
Between each pin
CNOOI
HMT controller (MIC17)
GND MREV(X3) HMT motor

speedsensor
Motor speed sensor 3
A phase A
3
B
3
TDD00176
20-542
0
E-128 [30] Disconnection in 1st clutch solenoid system is displayed

If there is any disconnection in the solenoid or wiring harness, the solenoid is not actuated.
If pin (2) of the solenoid is short circuiting with the ground, the solenoid will remain actuated.
If the starting switch was turned OFF momentarily after the abnormality occurred, start the engine
and check if [ E.u I [301 is displayed. (If it is not displayed, the system has been reset.)
Check that fuse 7 is normal.
Check that abnormal displays 1681 and [691 for the solenoid Remedy
cut relay system are not being displayed.
b YES1
Replace wiring
* Turn starting ground in wiring harness
NO harness
switch ON. between 1SOL (female)
*20-30V (2) and CNOOI (female) (4)
between 1SOL * Engine started:
(2) and chassis Max. 1 V Defective contact, or
YES Replace wiring
-Turn starting r; harness between relay
7arness
switch ON. fCN012) (6) - CNOll (i2) -
*20-30V ISOL (female) (1)
cut relay (CN012)
(6) and chassis YES
between ISOL Defective relay (CN012) Replace
(male) (I) and (2) ri
* Turn starting
* Turn starting .20-30V disconnection in wiring qeplace wiring
switch OFF. harness between fuse (7) Iarness
* Turn starting
. Disconnect ISOL. and relay (CN012) (3)
switch ON.
- Between (1) - (2): .20-30V
5-20R
Defective 1st clutch
* Between (1 j,(2) -
0 solenoid
chassis:
Min. 1 MD
1SOL(X2)
m-l
1st clutch solenoid / & \ 1 9 1st clutch solenoid
ClJt relay CN012
I \ I
CNOOI
t (MlC17)
I-
Fuse CN003
(MIC21) I
w
----Id 1st clutch solenoid cut relay

I
TDD00177
20-543
0
E-129 [31] Short circuit in 1st clutch solenoid system is displayed

and check if [ E.LJ] [31] is displayed. (If it is not displayed, the system has been reset.)
Cause Remedy
Contact of power source

wiring harness with
YES Replace wiring
3 i wiring harness between
harness
ISOL (female) (2) and
Is there voltage
YES between (female) CNOOl (4)
- (2) and chassis -
when ISOL is 3 YES
p Defective HMT controller Replace
1 disconnected? Is 1311 displayed
P when everything
Is resistance * Turn starting
between 1SOL NO is returned to its
switch ON.
(male) (I) - (2). and - original position?
* Disconnect ISOL. System has been reset -
between (1). (2) - NO
* When normal: 0 V * Start engine.
chassis normal?
*Turn starting
switch OFF. Defective 1st clutch
. Disconnect ISOL. Replace
NO solenoid
- Between (I) - (2):
5-20R
* Between (l), (2) -
chassis:
Min. 1 MQ
lSOL(X2)
3
1st clutch solenoid 1st clutch solenoid
cut relay CN012 ----a
CNOII
(SWPIP)
CNOOI
(MIC17)
a
g--$-J -3 1st clutch solenoid
3 \GND
CN003
(MIC21)
1st clutch solenoid cut relay
TDD00177
20-544
0
E-130 [32] Disconnection in 2nd clutch solenoid system is displayed

and check if 1E.u 1 [321 is displayed. (If it is not displayed, the system has been reset.)
Check that fuses 5 and 6 are normal.
Check that abnormal displays 1641 and [651 for the solenoid Cause Remedy
A YE:S
Defective HMT controller (eplace
YE between CNOOl
conditions in Item 2.
Is I321 displayed?
ENl3’
IDisconnection or short
-
,circuit with chassis

leplace wiring
Starting switch I ,ground in wiring harness
ON:20-30V NO arness
Ibetween 2SOL (female)
Is voltage
Engine started: 12) and CNOOl (female) (5)
YE between 2SOL
Max. 1 V
(2) and chassis IDefective contact, or
normal? ,disconnection in wiring
YES :eplace wiring
* Turn starting Iharness between relay
51 arness
switch ON. /lCN013) (6) -CNOll (IO) -
*20-30V ZSOL (female) (I)
T: ;
5 between 2SOL Defective relay (CN013) :eplace
(male) (1) and (2)
z
IDefective contact, or
switch OFF.
+ Disconnect 2SOL.
* Turn starting 3; harness between fuse (6)
-relay (CN013) (3)
arness
switch ON.
* Between (I) - (2):
.20-30V
5-20R
IDefective 2nd clutch
* Between (l),(2) - ;eplace
RIO solenoid
chassis:
Min. 1 MR
To other solenoid < T \

2,3, F, R solenoid 7 2nd clutch solenoid
cut relay CN013
CNOI 1
(SWPIS) I CNOOI
(MIC17)
HMT controller
Fuse 1 I
TDDQ0178
20-545
0
E-131 1331 Short circuit in 2nd clutch solenoid system is displayed

and check if [ E.ul 1331 is displayed. (If it is not displayed, the system has been reset.)
-k Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Cause Remedy

wiring harness with
YES leplace wiring
2 larness
2SOL (female) (2) and
Is there voltage
CNOOI (5)
YES between (female)
- (2) and chassis -
3 YES
when ZSOL is p Defective HMT controller leplace
when everything
Is resistance -Turn starting
NO is returned to its
between 2SOL switch ON. original position? -
hnale) (1) - (2). and - * Disconnect 2SOL. System has been reset
*When normal: 0 V * Start engine.
chassis normal?
*Turn starting
switch OFF. Defective 2nd clutch
leplace
- Disconnect 2SOL. ~0 solenoid
* Between (1) - (2):
5-20R
* Between (1). (2) -
chassis:
Min. 1 MR

2SOL(X2)
To other solenoid -
23, F, R solenoid l~~~---?$ 2nd clutch solenoid
cut relay CN013
I
CNOI 1
(SWPIP) CNOOI
(MIC17)
HMT controller
$J
$(J
d
Fuse
5
TDD00178
20-546
E-132 [34] Disconnection in 3rd clutch solenoid system is displayed

t If there is any disconnection in the solenoid or wiring harness, the solenoid is not actuated.
and check if [ E.ul [341 is displayed. (If it is not displayed, the system has been reset.)
* Check that fuses 5 and 6 are normal.
* Check that abnormal displays 1641 and [651 for the solenoid cut relay system are not being
displayed.
Cause Remedy
4 YE
3 Is [341 displayed?
.
Is voltage System has been reset -
Yf‘2 between CNOOl _ . Start engine. N
(6) and (7)
Replace wiring
* Starting switch ground in wiring harness
harness
ON:20-30V NO between 3SOL (female)
*When accelerating in Fi3: (2) and CNOOl (female) (6)
Max. 1 V
(2) and chassis % See TESTING AND Defective contact, or
r: . Turn starting
ADJUSTING. YES
harness between relay
qeplace wiring
5 switch ON.
5
(CN013) (6) - CNOI 1 (IO) -
?arness
s 1 *20-30V Is voltage between

cut relay (CN013) _
3SOL (female) (I)
h (6) and chassis 6 YE!

between 3SOL normal? Defective relay (CN013) qeplace
Is voltage
(male) (I) and (2) between relay
* Turn starting
switch ON. NO (CN013) (3) and Defective contact, or
= Turn starting *20-30V chassis normal? disconnection in wiring qeplace wiring
switch OFF. harness between fuse (6) larness
* Turn starting
+ Disconnect 3SOL. - relay (CN013) (3)
switch ON.
* Between (1) - (2):
*20-30V
5-2OC?
Defective 3rd clutch
* Between (l),(2) - qeplace
NO solenoid
chassis:
Min. 1 MQ

3SOL(X2)
2,3, F, R solenoid
cut relay
To Other“lenoid <_&Tb 3rd clutch solenoid
CN013
CNOOI
(MIC17) HMT controller
3rd clutch solenoid
2,3, F, R clutch solenoid

cut relay
TDD00179
20-547
0
E-133 [35] Short circuit in 3rd clutch solenoid system is displayed

If the starting switch was turned OFF momentarily after the abnormality occurred, accelerate to 3rd
and check if [E.“l [351 is displayed. (For details, see TESTING AND ADJUSTING, Measuring power
train oil pressure.)
(If it is not displayed, the system has been reset.)
wiring harness with

YES Replace wiring
2L wiring harness between
harness
3SOL (female) (2) and
Is there voltage
CNOOl (6)
YES between (female)
- (2) and chassis -
3 YES
when 3SOL is Defective HMT controller Replace
when everything
Is resistance * Turn starting
between 3SOL NO is returned to its
switch ON.
(male) (1)- (2).and - original position?
. Disconnect 3SOL. System has been reset -
between (l), (2) -
* When normal: 0 V * Accelerate to 3rd. NO
chassis normal?
I See TESTING
* Turn starting AND ADJUSTING.
switch OFF. Defective 3rd clutch
Replace
* Disconnect 3SOL. NO solenoid
* Between (1) - (2):
5-20R
* Between (I), (2) -
chassis:
Min. 1 MR
.E-133. Related electrical circuit diagram

3SOL(X2)
2,3, F, R solenoid To other solenoid ( 1 3

3rd clutch solenoid
cut relay CN013 I ----a
CNOOI
(MIC17) HMT controller
-3 3rd clutch solenoid

3 GND
CN003
(MIC21)
I 2,3, F, R clutch solenoid
cut relay
TDD00179
20-548
0
E-134 [38] Disconnection in brake solenoid system is displayed

* If there is any disconnection in the solenoid or wiring harness, the solenoid is not actuated.
switch ON and .pa check if 1E.u 1 I381 is displayed. (If it is not displayed, the system has been reset.)
* Check that fuse 5 is normal.
Remedy

YE
normal? circuit with chassis
I
* Start engine. ground in wiring harness 3eplace wiring
. Brake switch OFF: NO between CNOOI (female) iarness
20-30V (14) - BRAK (female) (2) -
(2) and chassis
* Brake switch ON: BRAKS (female) (2)
Max. 1 V Defective contact, or
Is resistance * Stat-t engine. disconnection in wiring
between BRAKS *20-30V qeplace wiring
(male) (I) and (2) 7arness
normal?
: gg? .“rve brake solenoid
*30-80R
CNOI 1
Fuse (SWPI 2) BRAK(X2) BRAKS(X2) Brake solenoid
&-c ($ 0
g -3
CNOOI
MC171 HMT controller
TDD00181
20-549
0
E-135 [39] Short circuit in brake solenoid system is displayed

+ If the starting switch was turned OFF momentarily after the abnormality occurred, start the engine,
release the safety lock, and check if [ E.u I [391 is displayed. (If it is not displayed, the system has
been reset.)
Remedy

wiring harness with
leplace wiring
arness
YE between (female)
3 YES
H
when BRAKS is Defective HMT controller (eplace
1 Is 1391 displayed
when everything
Is resistance
between BRAKS switch ON.
hale) (1) - (2). and
* Disconnect System has been reset -
BRAKS. * Start engine.
chassis normal?
Et *When normal: 0 V *Turn brake switch
. Turn starting ON.
switch OFF. I I
Defective brake solenoid leplace
* Disconnect NO
BRAKS.
. Between (1) - (2):
30-8022
* Between (1). (2) -
chassis:
Min. 1 MQ
CNOI 1
Fuse (SWPIS) BRAK(X2) BRAKS(X2) Brake solenoid
05% c-g (g 3
g $g
CNOOI
(MIC17) HMT controtfer
I
GND
Brake solenoid
TDD00181
20-550
0
E-136 [3A] Disconnection in R clutch solenoid system is displayed

and check if LE.,_,1 [3Al is displayed. (If it is not displayed, the system has been reset.)
Before carrying out troubleshooting, check that all the related connectors are properly inserted. .pa
Check that abnormal displays 1641 and 1651 for the solenoid Remedy
4 YES
Defective HMT controller Xeplace
Is [3Al displayed?
Is voltage I System has been reset -
YE : between CNOOI _ . Start engine. NO
(15) and (7) Disconnection or short
normal? circuit with chassis
ground in wiring harness qeplace wiring
2 * Starting switch
between RSOL (female) larness
ON:20-30V NO
(2) and CNOOl (female)
* When
YEiS between RSOL (15)
accelerating in
(2) and chassis R2: Max. 1 V Defective contact, or
YES 7eplace wiring
* Turn starting harness between relay
5 larness
switch ON. (CN013) (6) - CNOI 1 (IO) -
*20-30V Is voltage between RSOL (female) (I)
g . cut relay (CN013) _
5 between RSOL
N I (6) and chassis
normal?
6 YES
- Defective relay (CN013) ?eplace
z Is voltage
(male) (1) and (2) between relay
. Turn starting
switch ON. NO KN013) (3) and Defective contact, or
* Turn starting *20-30V chassis normal? disconnection in wiring 3eplace wiring
switch OFF. NO harness between fuse (6) ,rarness
* Turn starting
* Disconnect RSOL. switch ON.
- relay (CN013) (3)
* Between (I) - (2): .20-30V
5-209
Defective R clutch
* Between (l).(2) - NO Replace
solenoid
chassis:
Min. 1 MD
To other solenoid 1
2,3, F, R solenoid R clutch solenoid
cut relay CN013 II 2
CNOI 1
(SWP12)
-7 CNOOI
(MIC17) HMT controllc ?r
CN003
(MIC21)
I /
20-551
0
E-137 [3c] Short circuit in R clutch solenoid system is displayed

If the starting switch was turned OFF momentarily after the abnormality occurred, accelerate to
REVERSE 2nd and check if [ E.u ] [3C] is displayed. (For details, see TESTING AND ADJUSTING,
Measuring power train oil pressure.)
I Cause Remedy
Replace wiring
harness
YE IIs there voltage

between (female)
. (2) and chassis
II
-
3 YES
when RSOL is p Defective HMT controller Replace
1 disconnected? Is 13Cl displayed
when everything
* Turn starting
between RSOL NO is returned to its
switch ON.
(male) (1) - (2). and original position?
- Disconnect RSOL. System has been reset -
between (1). (2) -
*When normal: 0 V * Accelerate to ~2. NO
% See TESTING
* Turn starting AND ADJUSTING.
switch OFF. Defective R clutch
Replace
. Disconnect RSOL. JO
* Between (1) - (2):
5-20R
* Between (I), (2) -
chassis:
Min. 1 MR

RSOL(X2)
To other solenoid < T .s

2,3, F, R solenoid
R clutch solenoid
cut relay CN013 -a
g CNOII
@ (SWPIP)
CNOOI
-0 a 0 (MIC17) HMT controller
~----~$$ 0 GND
,7 -j-$ R clutch solenoid
Fuse CN003
5 (MIC21)
6
----B 2,3, F, R clutch solenoid cut relay
a
TDD00180
20-552
0
E-138 [3d] Disconnection in F clutch solenoid system is displayed

and check if [Eu I [3dl is displayed. (If it is not displayed, the system has been reset.)
Check that abnormal displays 1641 and 1651 for the solenoid Remedy
YES
- conditions in Item 3.
3 Is [3dl displayed?
c System has been reset -
YE between CN003 NO
* Starting switch s
ground in wiring harness (eplace wiring
ON:20-30V NO between FSOL (female) iarness
Is voltage (2) and CN003 (female)
* When
YE3 between FSOL (IS)
accelerating in
(2) and chassis Defective contact, or
F2: Max. 1 V
normal? disconnection in wiring
YES leplace wiring
*Turn starting I harness between relay
larness
switch ON. (CN013) (6) - CNOI 1 (IO) -
.20-30V Is voltage between FSOL (female) (1)
1
8 cut relay (CN013)
E between FSOL
hlo’ (6) and chassis ‘fES
Defective relay fCN013) leplace
;5 (male) (I) and (2)
*Turn starting
* Turn starting -2O-30V disconnection in wiring leplace wiring
c
switch OFF. NC harness between fuse (6) rarness
* Turn starting
* Disconnect FSOL. -relay (CN013) (3)
switch ON.
.20-30V
5-2OQ
Defective F clutch
. Between (l),(2) - ieplace
NO solenoid
chassis:
Min. 1 MQ
FSOL(X2)
I I I
2,3, F, R solenoid FA ( r$ F clutch solenoid
cut relav CN013
HMT controller
I
CN003
Fuse (MIC21)
TDDOO182
20-553
0
E-139 [3E] Short circuit in F clutch solenoid system is displayed

+ If the starting switch was turned OFF momentarily after the abnormality occurred, accelerate to
FORWARD 2nd and check if [E.” ] [3E] is displayed. (For details, see TESTING AND ADJUSTING,
Measuring power train oil pressure.)
t Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Cause Remedy

Wing harness with
YES leplace wiring
arness
FSOL (female) (2) and
CN003 (19)
il
when FSOL is
H 3 VFS
, 1, 1 Idisconnected?
Isresistance
between FSOL
(male) (1) - (2). and System has been reset -
between (1). (2) -
-When normal: 0 V . Accelerate to F2. NO
chassis normal?
% See TESTING
*Turn starting AND ADJUSTING.
switch OFF. I Defective F clutch
ieplace
* Disconnect FSOL. NO solenoid
5-20R
* Between (1). (2) -
chassis:
Min. 1 MD

FSOL(X2)
I I I
$)
2,3, F, R solenoid F clutch solenoid
cut relay CN013 ---a
g CNOI 1
(SWPl2) HMT controller
E
a .@ Pa F clutch solenoid
$) 2,3, F, R clutch solenoid cut relay

z
c- a GND
CN003
Fuse
(MIC21)
TDD00182
20-554
a
E-140 [40] Abnormality in operation of F spool switch is displayed

sx If the F spool switch is not turned ON when the output is sent to the F spool solenoid.
It Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Sr Always connect any disconnected connectors before going on to the next step.
Ir If the starting switch was turned OFF momentarily after the abnormality occurred, accelerate to F2
and check if [ELI] [401 is displayed. (For details, see TESTING AND ADJUSTING, Measuring power
% When interchanging the spool switch, always interchange the switch itself. Never interchange the
connector only. This will cause mistaken operation of the machine.
Cause Remedy
3 YES
Is 1401displayed?
2
Is voltage * Same conditions NO
YE between CNPHl _ as in Item 2.
(7) and chassis
normal? 4 YES
When F spool Defective F spool switch Replace
+ Accelerate to F2.
1 switch is
* Max. 1 V - interchanged with R -
% See TESTING NO spoolswitch,does
8 AND ADJUSTING. Defective operation of F
between FSW (I) display go out? Correct or
clutch solenoid valve or F
5 - NO replace
* Same conditions clutch spool
z as in Item 2. Defective contact, or
* Turn starting
5 YES disconnection in wiring
switch ON. Replace wiring
harness between CN2Hl
.20-30V Is voltage harness
(female) (7) and FSW
between CN2Hl _ (female) (I)
N’ (7) and chassis
normal?
Defective HMT controller Ieplace
*Turn starting NO
switch ON.
-2O-30V
CNZHI
HMT controller (04020) FSW(X1)
F spool switch
F switch
(B
TDDOOIg3
20-555
0
E-141 [41] Abnormality in operation of F spool switch is displayed

3~ If the F spool switch is not turned ON when the output is sent to the F clutch solenoid.
Ir If the starting switch was turned OFF momentarily after the abnormality occurred, start the ma-
chine in F2 and check if [E.u I 1411 is displayed. (If it is not displayed, the system has been reset.)
Cause Remedy
2 YES
Defective F spool switch Replace
When F spool
YES switch is
- mterchanged with R
spool switch, does Defective operation of F
1 display go out? Correct or
:lutch solenoid valve or F
Is voltage ~ NO replace
* Accelerate to F2. :lutch spool
between FSW _
(female) (I) and Defective contact, or
chassis normal? disconnection in wiring
3 YES Replace wiring
harness between CNPHl harness
* Start engine. Is voltage [female) (7) and FSW
*20-30V _ between CNZHI _ [female) (1)
NO (7) and chassis
normal?
* Start engine. NO
*20-30V
CNSHI
F spool switch
F switch (z-3
TDD00183
20-556
0
E-142 [42] Abnormality in operation of R spool switch is displayed

% If the R spool switch is not turned ON when the output is sent to the R spool solenoid.
* If the starting switch was turned OFF momentarily after the abnormality occurred, accelerate to R2
and check if [E.u] 1421 is displayed. (For details, see TESTING AND ADJUSTING, Measuring power
C&SC! Remedy
3 YES
-7
Yi

Is voltage * Accelerate to R2. NO
YI
I between CNPHl
(8) and chassis
normal?
* Accelerate to R2.
Defective R spool switch Replace
1 * Max. 1 V
% See TESTING h“Ow
1I
switch is
interchanged with F l-l
I Defective operation of R
8 between RSW AND ADJUSTING. Correct or
clutch solenoid valve or R
(female) (1) and replace
5 * Accelerate to R2. No clutch spool
chassis normal?
z Defective contact, or
* Start engine. disconnection in wiring
*20-30V 5 YES Replace wiring
harness between CNZHI harness
(female) (8) and RSW
between CNZHI (female) (1)
Ir (female) (8) and
chassis normal?
* Start engine. NO
-2O-30V
CNPHI
HMT controller (04020) RSW(X1) R spool switch
I \ I
R switch
h TDD00184
20-557
0
E-143 [43] Abnormality in operation of R spool switch is displayed

% If the R spool switch is not turned ON when the output is sent to the R clutch solenoid.
+ If the starting switch was turned OFF momentarily after the abnormality occurred, start the ma-
chine in R2 and check if [ELI] 1431 is displayed. (If it is not displayed, the system has been reset.)
z When interchanging the spool switch, always interchange the switch itself. Never interchange the
Cause Remedy
2 YES
Defective R spool switch Replace
When R spool
switch is
YE
. interchangedwith F -
spool switch, does Defective operation of R
clutch solenoid valve or R
P NO replace
* Accelerate to R2. :lutch spool
between RSW
(female) (1) and
chassis normal? 3 YES Replace wiring
harness between CN2Hl
harness
* Start engine. Is voltage (female) (8) and RSW
*20-3ov _ between CN2Hl _ [female) (1)
N I (8) and chassis
normal?
* Start engine. NO
.20-30V
CNZHI
HMT controller (04020) RSW(X1) R spool switch
R switch
g-3
TDD00184
20-558
0
E-144 [44] Abnormality in operation of 1st spool switch is displayed

If the 1st spool switch is not turned ON when the output is sent to the 1st spool solenoid.
and check if [ E.u I 1441 is displayed. (If it is not displayed, the system has been reset.)
When interchanging the spool switch, always interchange the switch itself. Never interchange the
Remedy
3 YES
17
conditions in Item 2
r
Is 1441displayed?
4-l
AI System has been reset -
Is voltage * Start engine. NO
YE between CNPHI _
(9) and chassis
normal? 4 YES
~ When 1st spool Defective 1st spool switch leplace
* Start engine. switch is
1 * Max. 1 V interchanged with
NO 3rd spool switch,
does display gc Defective operation of 1st
between ISW :orrect or
out? clutch solenoid valve or
(female) (I) and - NO eplace
1st clutch spool
chassis normal? * Start engine.
8 Defective contact, or
5 5 YES leplace wiring
*20-3ov harness between CN2Hl
z arness
Is voltage (female) (9) and ISW
between CNPHI _ (female) (I)
R (female) (9) and
chassis normal?
* Start engine. NO
*20-30V
CNPHI
HMT controller (04020) lSW(X1) 1st spool switch
1st switch @-zI

($!IJ
TDDO0185
20-559
0
E-145 1451 Abnormality in operation of 1st spool switch is displayed

.X If the 1st spool switch is not turned ON when the output is sent to the 1st clutch solenoid.
Jr Always connect any disconnected connectors before going on to the next step.
Cause Remedy
YE between CN2Hl
(9) and chassis YES
Defective 1st spool switch Replace
Start engine. interchanged with

N 3rd spool switch,
Max. 1 V
Defective operation of 1st
i Correct or
between 1SW clutch solenoid valve or
NO replace
(female) (I) and 1st clutch spool
-Start engine.
chassis normal? Defective contact, or
4 YES Replace wiring
*20-30V harness between CN2Hl
Is voltage harness
(female) (9) and 1SW
between CN2Hl (female) (I)
N :9) and chassis
normal?
- Start engine. NO
*20-30V
CN2Hl
HMT controller (04020)
1st spool switch
1st switch
($J)
TDD00185
20-560
0
E-146 [46] Abnormality in operation of 2nd spool switch is displayed

% If the 2nd spool switch is not turned ON when the output is sent to the 2nd spool solenoid.
and check if [ E.u 1 [461 is displayed. (If it is not displayed, the system has been reset.)
Cause Remedy
3 YES
YE
‘FHP

. Accelerate to F2 NO
IES between CN2Hl or R2.
(10) and chassis
Defective 2nd spool
Replace
* Start engine. switch
1 . Max. 1 V 1
N
Defective operation of
between 2SW Correct or
2nd clutch solenoid valve
(female) (1) and replace
3r 2nd clutch spool
chassis normal? * Accelerate to F or
8 Defective contact, or
R2.
* Start engine.
5 disconnection in wiring
*20-30V 5 YES Replace wiring
z harness between CN2Hl harness
Is voltage [female) (IO) and 2SW
i between CNPHI _ [female) (I)
NO (female) (IO) and
chassis normal?
. Start engine. NO
*20-30V
CNSHI
HMT controller (04020) SSW(X1)
1 2nd spool switch
\ 1 I I I
fi
2nd switch
77h- TDDOO186
20-561
0
E-147 [471 Abnormality in operation of 2nd spool switch is displayed

E If the 2nd spool switch is not turned ON when the output is sent to the 2nd clutch solenoid.
Cause Remedy
YES
L
Is voltage
YES_ between CNPHI
(10) and chassis 2 YES Defective 2nd spool
When 2nd spool Replace
normal? switch
switch is
* Start engine. _ interchanged with
1
* Max. 1 V NO 3rd spool switch,
Is voltage does display go Defective operation of
Correct or
between 2SW out? 2nd clutch solenoid valve
P NO replace
(female) (1) and or 2nd clutch spool
* Accelerate to F2
chassis normal? or R2. Defective contact, or
* Start engine. I 4 YES disconnection in wiring
harness between CNPHl
Replace wiring
*20-30V harness
Is voltage (female) (10) and 2SW
between CN2Hl (female) (I)
NO (IO) and chassis
normal?
. Start engine. NO
*20-30V
CNPH’l
HMT controller (04020)
2nd spool switch
2nd switch
TDtIO0186
20-562
0
E-148 1481 Abnormality in operation of 3rd spool switch is displayed

x If the 3rd spool switch is not turned ON when the output is sent to the 3rd spool solenoid.
sr Always connect any disconnected connectors before going on to the next step.
* If the starting switch was turned OFF momentarily after the abnormality occurred, accelerate to F3
or R3 and check if [E.ul [481 is displayed. (For details, see TESTING AND ADJUSTING, Measuring
power train oil pressure.)
CaUSe Remedy
YE
Defective 3rd spool switch leplace
Defective operation of 3rd

8 between 3SW :orrect or
clutch solenoid valve or
(female) (1) and aplace
5 3rd clutch spool
;; as in Item 3. Defective contact, or
*20-30V 5 YES eplace wiring
harness between CNPHl
arness
Is voltage [female) (11) and 3SW
between CN2Hl _ (female) (1)
h (female) (I 1) and
chassis normal?
Defective HMT controller eolace
. Start engine. NO
*20-30V
CN2Hi
HMT controller (04020) 3SW(Xl)
3rd spool switch
I \ I I / I
n
3rd switch
TDD00187
20-563
0
E-149 [49] Abnormality in operation of 3rd spool switch is displayed

% If the 3rd spool switch is not turned ON when the output is sent to the 3rd clutch solenoid.
z When interchanging the spool switch, always interchange the switch itself. Never interchange the
Cause Remedy
2 YES
Defective 3rd spool switch Replace
When 3rd spool
YE switch is
interchanged with R -
spool switch, does Defective operation of 3rd
clutch solenoid valve or
- NO replace
* Accelerate to F3 3rd clutch spool
between 3SW or R3.
(female) (I) and % See TESTING AND ADJUSTING. Defective contact, or
chassis normal? disconnection in wiring Replace wiring
3 YES
harness between CNZHI harness
*Start engine. Is voltage (female) (11) and 3SW
*20-30V between CN2Hl _ (female) (1)
h (11) and chassis
normal?
* Start engine. NO
.20-30V
CN2Hl
HMT controller (04020) 3SW(Xi) 3rd spool switch
3rd switch 3
d7 TDD00187
20-564
0
E-150 [4F] Disconnection in HMT pump servo solenoid system is displayed

Sr If the starting switch was turned OFF momentarily after the abnormality occurred, start the engine
and check if [E.u I [4F] is displayed. (If it is not displayed, the system has been reset.)
* Before carrying out troubleshooting, check that all the related 6 YES
to the next step.
YE
(female) (12) and
1 PUPB (female) (2)? 11
4 -Turn starting
switch OFF.
Is resistance * Disconnect
between PUPB CN003 and PUPB.
(male) (2) and (I) .X-Measure from
normal? CN003 (female)
* Turn starting end in the diode
switch OFF. range. (Note)
(female) (13) -
L-
YE PUPA, PUP6 * Disconnect PUPB.
(female) (1). and *IO-20n
between CN003 JO
(female) (13) -
chassis normal?
2
Is there continuity -Turn starting
YE between CN003 switch OFF.
(female) (1) and * Disconnect
CN003, PUPA, and PUPB.
. Between wiring harnesses: Max. 1 Q
1 *Turn starting . Between (13) -chassis: Min. 1 MD
switch OFF.
Is resistance
* Disconnect 8
between PUPA
(male) (2) and (I)
CN003 and
PUPA. IO x,
normal?
% Measure from is
. Turn starting CN003 (female)
switch OFF. end in the diode
* Disconnect range. (Note)
PUPA.
*IO-2oC?
Note: With a normal tester, switching to the diode range will give the display for the voltage of the
internal battery.
When checking wiring harnesses which include a diode, judge as follows.
If voltage does not change, there is no continuity
If voltage changes, there is continuity
20-566
0
Cause Remedy
* Defective diode
- Defective contact, or
harness between CN003 arness
(female) (12) - PUPB
(female) (2)
Defective HMT motor

leplace
servo solenoid [Bl
leplace wiring
(female) (13) -
larness
PUPB,PUPA (female) (1).
or short circuit with
chassis ground
* Defectivediode
* Defectivecontact, or
harness between CN003 arness
(female) (1) -PUPA
(female) (2)
Defective HMT motor leplace

servo solenoid [AI
To prolix switch
CN003
HMT controller (MIC21) PUPA(X2)
I I I
HMT pump solenoid (A) g 3 HMT pump
solenoid (A)
3
HMT pump solenoid (A) (+) @ 3 HMT pump

solenoid (B)
HMT pump solenoid (B) 6) @ 3
PUPB(X2)
CN004(M2) 2 1
c? TDD00188
20-567
0
E-151 [50] Short circuit in HMT pump servo solenoid system is displayed
and check if [ E.u 1 1501 is displayed. (If it is not displayed, the system has been reset.)
6 YES
Is [501 displayed
YES when everything
~ original position?
Is resistance
YESL between CN003 * Start engine. NO
(female) (12) and
chassis normal?
Is resistance
YES between PUPB
- (male) (2) - (1).
and between (2) - * Disconnect
chassis normal? CN003 and PUPB.
3
~
Is voltage formed switch OFF.
YE . between CN003 _ . Between (2) _ (1): NO
(female) (13) and lo-20R
chassis? * Between (2) -
chassis:
* Turn starting
switch ON. Min. 1 MQ
between CN003 * Disconnect PUPB.
* Disconnect
(female) (1) and CN003, PUPA, NO
I chassis normal? I and PUPB.
*Turn starting *When normal: 0 V
switch OFF. 8
* Disconnect
1 and between (2) - 1 CN003 and
chassis normal? PUPA.
switch OFF. I
- Between (2) - (1): NO
lo-20R
* Between (2) -
chassis:
Min. 1 MR
* Disconnect PUPA P-l
I I_
To prolix
-
switch
E-151. Related electrical circuit diagram A A
CN006IM2) @ (i)
CN003
HMT controller (MIC21) PUPA(X2)
HMT pump
solenoid (A)
HMT pump solenoid (A) (+) HMT pump

solenoid (B)
HMT pump solenoid (B) (-1
CN004(M2) 2 1
F?
TDDOO188
20-568
0
Cause Remedy

ci ~~~~~~~~&~~~, harness
Contact of 24V wiring

harness with wiring
Replace wiring
harness
(female) (13) -
PUPA,PUPB (female) (1)

between CN003 (female) harness
(I) and PUPA (female) (2)
20-569
0
E-152 [51] Disconnection in HMT motor servo solenoid [Al system is

displayed
and check if I ELI I 1511 is displayed. (If it is not displayed, the system has been reset.)
Remedy
Replace
YI
(female) (2) and harness between CNOg3
YES Replace wiring
(14) normal? (female) (14) and MRA
harness
(female) (2). or short
* Turn starting Is resistance
1 switch OFF. between CN003
ground
* Disconnect - (female) (2) and -
between MRA CN003. No MRA (female) (1)
(male) (1) and (2) .lO-2042 normal?
Replace wiring
* Turn starting harness between CN003
NO harness
switch OFF. (female) (2) and MRA
* Turn starting
- Disconnect (female) (I)
switch OFF.
CN003 and MRA.
* Disconnect MRA.
* Min. 1 42
*lo-2on Defective HMT motor
Replace
F servo solenoid IA]
CN003
HMT controller (MIC21) MRA(X2)
r I I I I
HMT motor solenoid (A) (+) E. 3 HMT motor
@ servo solenoid (A)
HMT motor solenoid (A) (-) 3
HMT motor solenoid (B) I+) @
HMT motor solenoid (B) (-) a MRB(X2)
3 HMT motor
servo solenoid (B)
a
TDD00189
20-570
0
E-153 [52] Short circuit in HMT motor servo solenoid [Al system is
displayed
and check if-[E.u 1 1521 is displayed. (If it is not displayed, the system has been reset.)
Cause Remedy
3 YES
YE
BHP
2 -
* Start engine. NO
YI between CN003
(female) (2) and
harness with wiring
leplace wiring
larness
1 . Turn starting (female) (14) and MRA
between MRA * Disconnect h
hale) (1) - (2). CN003.
ground in wiring harness leplace wiring
and between (1) - *IO-20R
*Turn starting NO between CN003 (female) larness
switch OFF. (2) and MRA (female) (1)
* Turn starting * Disconnect
switch OFF. CN003 and MRA.
8 * Disconnect MRA. * Min. 1 MD
Defective HMT motor
* Between (I) - (2): leplace
5 servo solenoid [Al
IO-20R NO
z * Between (1) -
chassis:
Min. 1 MD
CN003
HMT motor solenoid (A) (+)

HMT motor
servo solenoid (A)
HMT motor solenoid (A) 6)
HMT motor solenoid (B) (+)
HMT motor solenoid (B) (-)
HMT motor
servo solenoid (B)
TDD00189
20-571
0
E-154 1531 Disconnection in HMT motor servo solenoid [B] system is

displayed
+ If the starting switch was turned OFF momentarily after the abnormality occurred, start the engine
and check if [ E.u 1 1531 is displayed. (If it is not displayed, the system has been reset.)
Cause Remedy
3 YES
Defective HMT controller Xeplace
Is [531 displayed
YES when everything
is returned to its
original position? -
2-p System has been reset
* Start engine NO
Is resistance Defective contact or
IES . between CN003 _ disconnection in wiring
(female) (16) and harness between CN003
YES ieplace wiring
(5) normal? (female) (5) and MRB
4 larness
(female) (2), or short
. Turn starting Is resistance circuit with chassis
1 switch OFF. between CN003
ground
. Disconnect - (female) (16) and -
between MRB CN003. No MRB (female) (1)
(male) (1) and (2) *IO-20n normal?
leplace wiring
NO ,arness
-Turn starting switch OFF. (female) (16) and MRB
switch OFF. * Disconnect (female) (1)
* Disconnect MRB. CN003 and MRB.
.lO-2OQ * Min. 1 R
i Defective HMT motor
NO servo solenoid [B]
CN003
HMT motor solenoid (A) (+) 3 HMT motor

servo solenoid (A)
HMT motor solenoid (A) (-) a
HMT motor solenoid (B) (4

MRB(X2)
3 HMT motor
servo solenoid (B)
TOO00189
20-572
0
E-155 [54] Short circuit in HMT motor servo solenoid [B] system is
displayed
and check if [E.u 1 1541 is displayed. (If it is not displayed, the system has been reset.)
Cause Remedy
Defective HMT controller ieplace
I
YIES
harness with wiring
(5) normal? 4 YES ieplace wiring
1 P harness between CN003
rarness
1 * Turn starting Is resistance (female) (5) and MRB
switch OFF. _ between CN003 _ (female) (2)
between MRB * Disconnect NO (female) (16) and
CN003. chassis normal?
and between (1) - alO-2on
* Turn starting NO between CN003 (female) rarness
switch OFF. (16) and MRB (female) (1)
* Turn starting * Disconnect
switch OFF. CN003 and MRB.
8 * Disconnect MRB. * Min. 1 MD
Defective HMT motor
* Between (1) - (2): 1 leplace
2 servo solenoid IBI
IO-20R NO
z * Between (1) -
chassis:
Min. 1 MD
CN003
HMT motor solenoid (A) (+) 3 HMT motor

servo solenoid (A)
HMT motor solenoid (A) (-) G-3

I
HMT motor solenoid (B) (-)
MRB(X2)
3 HMT motor
servo solenoid (B)
3
TDD00189
20-573
0
E-156 [55] Disconnection in steering EPC solenoid system is displayed

Sr If the starting switch was turned OFF momentarily after the abnormality occurred, start the engine
and check if [E.u I [551 is displayed. (If it is not displayed, the system has been reset.)
6 YES
* Before carrying out troubleshooting, check that all the
related connectors are properly inserted.
* Always connect any disconnected connectors before go-
ing on to the next step.
YE
4 *Turn starting
switch OFF.
Is resistance 1 * Disconnect
YE
CN003 and STB.
1 Eizirkd 1 .X Measure from
CN003 (female)
Is resistance *Turn starting end in the diode
between CN003 switch OFF. range. (Note)
YE (female) (4) - STA, I - Disconnect STA.
ST6 (female) (2),
-7-15R
CN003 (female) (4)
2
* Turn starting
Is there continuity
switch OFF.
YEIS between CN003
. Disconnect
(female) (3) and
CN003, STA, and STB.
* Between wiring harnesses: Max. 1 R
1 * Turn starting . Between (4) -chassis: Min. 1 MR
switch OFF.
Is resistance
* Disconnect
between STA
CN003 and STA.
(male) (1) and (2) L
9%Measure from 140
z
1 CN003 (female)
z
* Turn starting end in the diode
switch OFF. range. (Note)
* Disconnect STA.
-7-1522 1
NO
Note: With a normal tester, switching to the diode range will give the display for the voltage of the
internal battery.
When checking wiring harnesses which include a diode, judge as follows.
If voltage does not change, there is no continuity
If voltage changes, there is continuity
20-574
0
Cause Remedy
. System has been reset -
* Defective diode
Replace wiring
harness
1 (female) (15) - CN406 (71
- STB (female) (I)
Defective steering EPC

solenoid [Bl
Replace wiring
(female) (4) - CN406
harness
(3),(S) - STA,STB (female)
(2). or short circuit with
chassis ground
* Defective diode, or
* defective contact, or
8 disconnection in wiring Replace wiring
X harness between CN003 harness
I-
(female) (3) - CN406 (4)
& - STA (female) (I)
1 LI;feet;;eering EPC
3eplace
E-156. Related electrical circuit diagram To prolix switch
CN007
(M2)
CN406
(SWPIZ)
CN003 sTA(x2) Steering EPC
solenoid (A)
iMT controller (MIC21) a
3
Steering EPC solenoid (A) (+) a _i .B c
Steering EPC solenoid (A) (-1 @ --I)

,
STB(X2) Steering EPC
solenoid (B)
a
Steering EPC solenoid (B) @$ a
CN007(M2) @ (1>
TDD00190
20-575
0
TROUBLESHOOTING F-157
E-157 1561 Short circuit in steering EPC solenoid system is displayed

and check if [E.ul [561 is displayed. (If it is not displayed, the system has been reset.)
* Always connect any disconnected connectors before going on to the next step. 6 VFS - .-_
Is [561 displayed
YES_ when everything
- original position?
Is resistance
* Start engine. NO
YES between CN003
(female) (15) and
4
_ chassis normal?
Is resistance
between STB * Turn starting
YE
. (male) (1) - (2), - switch OFF. NO
and between (1) - * Disconnect
chassis normal? CN003 and STB.
3 - Min. 1 MD
- Turn starting
switch OFF.
YE between CN003 + Between (1) - (2): No
(female) (4) and 7-15R
* Between (1) -
* Turn starting chassis:
switch ON. Min. 1 MD
+ Disconnect * Disconnect STB.
between CN003
(female) (3) and I CN003, STA, and IO
1 chassis normal? STB.
*When normal: 0 V
- Turn starting
switch OFF.
- Disconnect
and between f 1) - CN003 and STA. 8
IO
- Min. 1 MD
X
I-
* Turn starting &
switch OFF.
- Between (1) - (2): NO
7-150
- Between (I) -
chassis:
Min. 1 MD
* Disconnect STA.
To prolix switch
HMT controller
CN003
CN007
tM2)
(MIC21)
m II iNJO
(SWPIZ)
.a
Steering EPC solenoid (A) (+) a 3
Steering EPC solenoid (A) (-)
CN007(M2)
6+l
TDD00190
20-576
0
I Cause I Remedy
Replace wiring
harness
Replace
IContact of 24V wiring

harness with wiring
_,._“.,
Replace wiring
harness
(female) (4) - CN406 (3),
(6) - STA,STB (female) (2)

(3) - CN406 (4) - STA
(female) (1)
rteering EPC
20-577
0
E-158 [57] Drop in controller power source voltage is displayed

% When power source voltage has dropped to 17 V or below.
Cause I Remedy
1 YES harness between fuse 5 - Replace wiring
CNOI 1 (8) - CNOOI harness
Is voltage of (female) (8). (16) (CN003)
battery normal? (female) (6)
Charge or
Drop in battery voltage
.20-30V NO replace
CNOOI
(MIC17)
CNOI 1
(SWPIP) Fuse
CN003
(MIC21)
Power source EU4) (+

TDDOOlSl
20-578
0
E-159 1591 When parking brake switch [III is ON (closed), [I] OFF (open)
is displayed
switch ON and check if [ E.ul [591 is displayed. (If it is not displaved, the svstem has been reset.)
to the next step. Cause Remedy
3 YES

Is voltage between * Turn starting
switch ON.
chassis normal * Operate parking
when parking lever brake.
Defective mount of
4djust
* Turn starting parking brake switch [III
switch ON.
I\
Is voltagebetween Defective parking brake
Replace
switch [III
chassis as shown in * Check switch as
individual part.
* Turn starting * Disconnect PSW.
switch ON. harness between CNPHl
qeplace wiring
iarness
PSW2 (female) (1). or
pi_ short circuit with chassis
ground
Defective HMT controller xeplace

* Turn starting
switch ON.
* Connect
T-adapter to
CNPHI (male)
only.
Table 1
Parking brake l Between PSW2 (I) - chassis
l Between CNSHI (2) - chassis Between PSW2 (I) - (3)
switch (Resistance)
(Voltage)
Switch ON Max. 1 V Max. 1 Q
I
Switch OFF 20 - 30 v Min. 1 MQ
Related electrical circuit diagram

CN2Hl LEVER
(04020) LSWPIG) PsWl(X3) Switch (1)
1Parking brake \ d I
PSW2(X3) Switch (2)
JI J,
To%er sensor TDDOOlS?.
20-579
0
E-160 [5Al When parking brake switch [II is ON (closed), [II] OFF (open)
is displayed
switch ON and check if 1E.u I [5Al is displayed. (If it is not displayed, the system has been reset.)
to the next step. Remedy
1
3 YES
conditions in Item 2. -
Is [5Al displayed?
-
H
Is voltagebetween -Turn starting
PSWZ (1) and switch ON.
YE
chassis normal * Operate parking
when parking lever brake.
is operated? 4
-1,. 1
Defective mount of
parking brake switch [II Adjust
* Turn starting
switch ON.
‘Ok L$xc$; parking brake

Replace
chassis as shown in
* Turn starting
switch ON.
Replace wiring
harness
CN2Hl (male) (4)
and chassis as
shown in Table 1
when CN2Hl is
1 INil Defective HMT controller Replace
. Turn starting
switch ON.
* Connect
T-adapter to
CN2Hl (male)
only.
Table 1
Parking brake l Between PSW2 (I) - chassis
l Between CNPHI (4) - chassis Between PSWI (I) - (3)
switch (Resistance)
(Voltage)
Switch ON Max. 1 V Max. 1 Q
1 Switch OFF 1 20 - 30 v I Min. 1 MQ I

CN2Hl LEVER
(04020) (sWP16) PSWl(X3) Switch (I)
g \q
3
e -3 0
PSW2(X3) Switch (2)
@ 3
(04016) 3 Q
SIG GND 3 0
To%er sensor TDD00192
20-580
0
TROUBLESHOOTING E-161-E-162
E-161 [5C] Excessive difference between directional lever

potentiometer signal values [II and [III is displayed
W When the sum of the directional lever potentiometer [II and [III signals is not 5.0 + 0.5.
Cause Remedy
Defective mount of Replace lever

potentiometer [II and [III ass’y
E-162 [5El Excessive difference between steering lever potentiometer

8 signal values [II and [III is displayed
2 % When the sum of the directional lever potentiometers [II and [III signals is not 5.0 k 0.5.
z
I CaUSf! Remedy
Defective mount of Replace lever

potentiometers [II and [Ill ass’y
20-58 1
0
E-163 1601 Abnormality in signal for engine speed sensor [II system is
displayed
% When the number of pulses of speed sensor [II is lower than that of speed sensor [Ill.
and check if [ E.u 1 [601 is displayed. (If it is not displayed, the system has been reset.)
Ir Before carrying out troubleshooting, check that all the related connectors are properly inserted
Cause Remedy
2 YES Defective adjustment of

Adjust
speedsensor
speed sensor is
adjusted?
H
Is resistance wiring harness between Replace wiring
between CNOIO 3%See TESTING CN2H2 (female) (8) and harness
(male) (I) and (2) AND ADJUSTING. CNOIO (female) (1)
normal?
* Turn starting I Defective speed sensor [II Replace

switch OFF. NO
* Disconnect
CNOIO.
*500-1,000R
CN2H2
Speed sensor (I) (+)

Engine speed
sensor (1)
CN009(X2)
Engine speed
sensor (II)
(MIC17) TDD00175
20-582
0
E-164 [61] Abnormality in signal for engine speed sensor [III system is
displayed
When the number of pulses of speed sensor [II] is lower than that of speed sensor [I].
and check if [ELI] [61] is displayed. (If it is not displayed, the system has been reset.)
Remedy
2 YES Defective adjustment of

Adjust
speedsensor
Does display 90 out
Replace wiring
harness
*Turn starting I Defective speed sensor Ill1 Replace

switch OFF. NO
* Disconnect
CN009.
.500-1,OOOR
8
E
5; E-164. Related electrical circuit diagram
CN2H2
r \ I I I
Speed sensor (1) (+) Engine speed
eed sensor (II) (-1 sensor (I)
Engine speed
sensor (II)
L \ I
(MIC17) TDD00175
20-583
0
E-165 [64] Disconnection in neutral safety relay output system is

displayed
switch ON and check if [ELI I 1641 is displayed. (If it is not displayed, the system has been reset.)
* If relay terminal (2) is short circuiting with the ground: the relay remains actuated
. If before engine is started: Engine will not start
. If after engine is started: Power is not supplied to 2, 3, F, R clutch solenoids
* Check that there is no abnormality display for the parking brake system or directional lever
potentiometer system before starting troubleshooting.
% This mode is actuated when the engine speed is 0.
CENlSt? Remedy
3 YES
-II
-
YE
harness between CN003 iarness
switch ON. (female) (9) - CNOI 1 (9) -
*20-30V cut relay (015) (2)
Defective cut relay (015) leplace

chassis normal?
* Turn starting Short circuit with chassis

switch ON. ground in wiring harness
.20-30V leplace wiring
between CN003 (female) larness
(9) - CNOI 1 (9) -cut relay
(015) (2)
1chassis normal? 11
switch ON. NO harness between fuse 5 arness
*20-30V and cut relay (015) (I)

Neutral safetv relav
Fuse
0.L
4 To proximity switch
HMT controller CN003 CNOl ILSWP) Starting switch

terminal C
@
(2) 2, 3, F, R clutch cut relay
TDD00193
20-584
0
E-l66 1651Short circuit in neutral safety relay output system is displayed

Ir If the starting switch was turned OFF momentarily after the abnormality occurred, release the
parking brake lever, then turn the starting switch ON and check if [E.ul [651 is displayed. (If it is not
displayed, the system has been reset.)
% This mode is actuated when the engine speed is 0.
Cause Remedy
Defective cut relay (015) FIeplace

wiring harness with other
YES wiring harness between Fseplace wiring
L CN003 (female) (9) - I-rarness
CNOI 1 (9) -cut relay (015)
Is voltaae II
* Release parking (2)
brake lever. h
* Turn starting Defective HMT controller Fieplace
switch ON.
*Turn starting
switch ON.
* Disconnect original position? -
CN003 and relay - Same conditions NO
(015). as in Item 1.
. When normal: 0 V

Neutral safety relay
I
CN015
Fuse
w L To proximity ’ switch
HMT controller -CN003 CNOll(SWP) I-> Starting switch

terminal C
(2) 2,3, F, R clutch cut relay TDD00193
20-585
0
E-167 [641 Disconnection in 2, 3, F, R clutch solenoid cut relay output

system is displayed
switch ON and check if [EM 1 [641 is displayed. (If it is not displayed, the system has been reset.)
* If relay terminal (2) is short circuiting with the ground: the relay remains actuated
. If before engine is started: Engine will not start
. If after engine is started: Power is not supplied to 2, 3, F, R clutch solenoids
% This mode is actuated when the engine is running.
Cause Remedy
3 YES
2
~ Is [641 displayed?
Is voltage -
YE between CN003 _ *Turn starting NO
(9) and chassis switch ON. .pa
1 switch ON. NO (female) (9) - CNOII (9) -
harness
.20-3ov cut relay (013) (2)
5 YES
Defective cut relay (013) Replace
chassis normal?
YE
* Turn starting FH_ Short circuit with chassis
switch ON. 4
*20-30V between CN003 (female)
NO harness
* Turn starting (9) - CNOll (9) -cut relay
h (013) (I) and switch ON. (013) (2)
chassis normal?
* Turn starting disconnection in wiring Replace wiring
switch ON. NO harness between fuse 5 harness
* Disconnect relay and cut relay (013) (I)
(013).
* Between (1) -
chassis: 20 - 30 V

CN003(MIC21) CNOT3 cut relay
CNOI l(SWPl2)
Neutral safety relay
To each clutch solenoid _=

of 2,3, F, R
TDD00226
20-586
0
E-168 [65] Short circuit in 2, 3, F, R clutch solenoid cut relay output system
is displayed
sr If the starting switch was turned OFF momentarily after the abnormality occurred, see TESTING
AND ADJUSTING, accelerate to F2 - 3 or R2 - 3, then stop the machine and check if [ E.u I 1651 is
displayed. (If it is not displayed, the system has been reset.)
t Always connect any disconnected connectors before going on to the next step.
% This mode is actuated when the engine is running.
Cause Remedy
1
wirina harness with other
YES wiring harness between Replace wiring
2 CN003 (female) (9) - harness
I
Is voltage formed CNOI 1 (9) -cut relay (013)
YES between CN003 (2)
Replace
(013) terminal (I) -
* Check relay as
individual part :
Defective relay (013) Replace
S?s-a?~~~ssible No
8 to measure the resistance between
relay terminal (I) - (2) : 260 - 320 R
2
In this case, if the condition is
z normal, go to NO.

CN003(MIC21) CN013 cut relay
CNOI 1 (SWPIS)
R clutch solenoid
To each clutch solenoid

of2,3,F,R
20-587
0
E-169 [661 Disconnection in backup alarm relay drive system is displayed

and check if [ELI I 1661 is displayed. (If it is not displayed, the system has been reset.)
Sr Always connect any disconnected connectors before going on to the next step.
* If relay terminal (2) is short circuiting with the ground: the relay remains actuated and the backup
alarm continues to sound.
Cause Remedy
3 YES
I7
. Same condition~~Zj?HNo System has been reset -

YE
1Aoimal? Defective contact, or

harness between CN003 harness
as in Item 1. NO (female) (IO) - CNOll (4) -
relay (014) (21
between relay (2)
5 YES Defective backup alarm
Replace
relay (014)
*Turn starting Short circuit with chassis

*20-30V Replace wiring
between relay (1) NO (10) - CNOll (4) - relay
(014) (2)
* Turn starting disconnection in wiring Replace wiring
I
switch ON. NO harness between fuse 5 harness
*20-30V and relay (1)

Backup alarm
CN153
(SWPG)
I CN014
Backup alarm relay
-3
1
CNOI 1 CN003 HMT controller

(SWPIG) (MICZI)
TDD00194
20-588
0
E-170 1671 Short circuit in backup alarm relay drive system is displayed
If the starting switch was turned OFF momentarily after the abnormality occurred, start the engine,
set the directional lever to R, and check if [ELI] [671 is displayed. (If it is not displayed, the system
has been reset.)
CaUSe Remedy

wiring harness with
YES Replace wiring
wiring harness between harness
CN003 (female) (IO) -
CNOll (4) - relay (014) (2)
YE5
I
YES
1
Is resistance
between relay (014)
terminals (1)and (2)
normal? CN003 and relay * Start engine. NO
(014). * Set directional
* Turn starting *When normal: 0 V lever to R.
switch OFF. I
*260-320R
I Defective relay (014)
NO
Backup alarm
CN153
(SWPG) 6
Backup alarm relay CN014
I ,\ I Ihl I II CN244
Al I I
CNOI 1 CN003 HMT cant

(SWP16) (MIC21)
TDD00194
20-589
0
E-171 [68] Disconnection in 1st clutch solenoid cut relay system is

displayed
and check if [E.LJ 1 1681 is displayed. (If it is not displayed, the system has been reset.)
* If relay terminal (2) is short circuiting with the ground: the relay remains actuated and no power is
supplied to the 1st clutch solenoid.
Cause Remedy
YES
Is WI displayed?
between CN003 NO
(11) and chassis
disconnection in wiring 3eplace wiring
NO Iarness
switch ON. (female) (II)-CNOll (11)
*20-30V -relay (013) (2)
I YES Defective 1st clutch

I qeplace
Does display go solenoid cut relay
YES out when relay
* Turn starting Short circuit with chassis
4 (013) is
interchanged? ?eplace wiring
-2O-30V Is voltage between CN003 (female)
NO rarness
between relay * Same conditions Ill)-CNOII (II)-relay
N I (013) (1) and as in Item 3. 1013) (2)
chassis normal?
* Turn starting disconnection in wiring qeplace wiring
switch ON. NO harness between fuse 7 rarness
*20-30V snd relay (013) (I)
CN013
(g >To 1st clutch

CNOI 1 CN003
solenoid
@ (SWPI 2) (MIC21) HMT controller
1st solenoid
E
cut relay output
a 0
Fuse
I-
1 11
20-590
0
E-172 [691 Short circuit in 1st clutch solenoid cut relay system is displayed
t If the starting switch was turned OFF momentarily after the abnormality occurred, start the engine
and check if [ E.u] [691 is displayed. (If it is not displayed, the system has been reset.)
Cause Remedy

Niring harness with
wiring harness between Ieplace wiring
EN003 (female) (11) - larness
CNOll (I 1) - relay (013)
terminal (2)
3 YES
Defective HMT controller seplace
* Turn starting
between relay (013)

terminals (1)and (2) System has been reset
CN003 and relay * Start engine. NO
(013).
- Check relay as *When normal: 0 V
individual part.
*260-320R Iefective relay (013) seplace
IO
E?
5
z E-172. Related electrical circuit diagram
CN013
I I
a
a >To 1st clutch
CNOI 1 CN003
solenoid
a:- (SWP12) (MIC21) HMTcontroller
1st solenoid
a 0
cut relay output
a 0
TDD00195
20-59 1
0
E-173 [6Al Misalignment in neutral position of directional lever

potentiometer [I] system is displayed
% If the neutral signal of potentiometer [II is not 2.5 f 0.25 V when the starting switch is turned ON.
Remedy
1 YES -
Does display go
out when lever is
moved to neutral
position? Defective potentiometer Replace lever
NO 71 assembly
* Turn starting
switch ON.
E-174 [6c] Misalignment in neutral position of directional lever

potentiometer [II] system is displayed
% If the neutral signal of potentiometer [III is not 2.5 f 0.25 V when the starting switch is turned ON.
Cause Remedy
YES
out when lever is

moved to neutral
Defective potentiometer !place lever
NO [Ill sembly
- Turn starting
switch ON.
20-592
0
TROUBLESHOOTING E-175,E-176,E-177
E-175 [6d] Misalignment in neutral position of steering lever

potentiometer [I] system is displayed
% If the neutral signal of potentiometer [II is not 2.5 k 0.25 V when the starting switch is turned ON.
Cause I Remedy
1 YES
out when lever is

moved to neutral
Defective potentiometer Replace lever
NO [II assembly
* Turn starting
switch ON.
E-176 [6El Misalignment in neutral position of steering lever

8 potentiometer [II] system is displayed
5
E; Z If the neutral signal of potentiometer [III is not 2.5 f 0.25 V when the starting switch is turned ON.
CaUSe I Remedy
1 YES
Does display go
out when lever is
moved to neutral
position? Defective potentiometer Replace lever
NO [III assembly
-Turn starting
switch ON.
E-177 [6Fl 1st fixed, 2nd start both impossible is displayed

% Carry out troubleshooting for each simultaneously displayed individual mode.
20-593
0
E-178 [70] Abnormality in F spool switch system is displayed

If the F spool switch is ON when the system is OFF and nothing is being output to the F clutch
solenoid.
If the starting switch was turned OFF momentarily after the abnormality occurred, accelerate to F2
and check if [ELI] 1701 is displayed. (For details, see TESTING AND ADJUSTING, Measuring power
train oil pressure.) (If it is not displayed, the system has been reset.)
Cause Remedy
F spool remains pushed

YES
in -
(See H-l)
4 YES
1 Defective HMT controller leplace
Is [701 displayed
Is oil pressure YES when everything
formed at F 3 is returned to its
clutch? original position?
YES_ between CNZHI _ . Start engine. NC
- Start engine. (female) (7) and
f See STANDARD 2
_
Is resistance chassis normal? Short circuit with chassis
VALUE TABLE.
between FSW l Turn starting ground in wiring harness leplace wiring
_ (male) (1) and - switch OFF. NO between CN2Hl (female) larness
NO chassis normal (7) and FSW (female) (I)
l Disconnect
when switch is
interchanged? CN2Hl and FSW.
* Min. 1 MR
*Turn starting I Defective F spool switch leplace
switch OFF. NO
* Disconnect FSW. _-
- Min. 1 MD
E-179 [71] Abnormality in F spool switch system is displayed

% If the F spool switch is ON when the system is OFF and nothing is being output to the F clutch
solenoid.
% This is the same as flow display 1701, but read 1711 in place of 1701 in Troubleshooting Item 4.
CNSHI
F spool switch
F switch
($jJ
TDDOOt83
20-594
0
E-180 [721 Abnormality in R spool switch system is displayed

If the R spool switch is ON when the system is OFF and nothing is being output to the R clutch
solenoid.
If the starting switch was turned OFF momentarily after the abnormality occurred, accelerate to R2
and check if [E.ul 1721 is displayed. (For details, see TESTING AND ADJUSTING, Measuring power
train oil pressure.) (If it is not displayed, the system has been reset.)
Cause Remedy
R spool remains pushed

YES
in -
(See H-l)
/
4 YE!
1 Defective HMT controller leplace
Is f721 displayed
Is oil pressure YES when everything
formed at R 3 is returned to its
clutch? original position?
YES_ between CN2Hl _ * Start engine. N(
* Start engine. (female) (8) and
% See STANDARD
_2 chassis normal? Short circuit with chassis
VALUE TABLE.
Is resistance L ground in wiring harness leplace wiring
* Turn starting
_ between RSW - switch OFF. NO between CN2Hl (female) larness
NO (male) (1) and * Disconnect (8) and RSW (female) (I)
chassis normal? . CN2Hl and RSW.
* Turn starting . Min. 1 MR
switch OFF. Defective R spool switch leplace
- Disconnect RSW. NO
* Min. 1 MQ
E-181 1731 Abnormality in R spool switch system is displayed

% If the R spool switch is ON when the system is OFF and nothing is being output to the R clutch
solenoid.
% This is the same as flow display [721, but read [731 in place of [721 in Troubleshooting Item 4.
CNPHI
HMT controller (04020) RSW(X1)
R spool switch
R switch
1
(B
TDD00184
20-595
0
E-182 [74] Abnormality in 1st spool switch system is displayed

M If the 1st spool switch is ON when the system is OFF and nothing is being output to the 1st spool
solenoid.
and check if [E.u I [741 is displayed. (If it is not displayed, the system has been reset.)
Remedy
3 YES
Defective HMT controller ieplace
~~ System has been reset -

* Turn starting
NO between CNlHl (female) larness
switch OFF.
. Disconnect (9) and 1SW (female) (I)
between 1SW
CNZHI and ‘ISW.
*Min. 1 MR
4
* Turn starting YES
Is resistance Defective 1st spool switch leplace
switch OFF. between 1SW
* Disconnect 1SW. (male) (1) and
* Min. 1 MD NO chassis normal
when switch is 1st spool remains pushed
in -
4 interchanged? NO (See H-3, 4)
* Same conditions
as in Item 1.
CNPHI
HMT controller (04020) 1SW(X1) 1st spool switch
1st switch (iJ
TDD00185
20-596
0
E-183 [76] Abnormality in 2nd spool switch system is displayed

% If the 2nd spool switch is ON when the system is OFF and nothing is being output to the 2nd spool
solenoid.
+ If the starting switch was turned OFF momentarily after the abnormality occurred, start the engine
and check if 1E.LJI [761 is displayed. (If it is not displayed, the system has been reset.)
Cause Remedy
3 YES
Is [761 displayed
YES_ when everything
original position?
YES_ between CNPHl _ * Start engine. NO
(female) (10) and
chassis normal? Short circuit with chassis
_1 - Turn starting ground in wiring harness qeplace wiring
switch OFF. NO between CNlHl (female) iarness
Is resistance
* Disconnect 110) and 2SW (female) (1)
between 2SW
(male) (1) and CNPHl and 2SW.
chassis normal? - Min. 1 MD
* Turn starting 4 YES Defective 2nd spool

Is resistance Xeplace
switch OFF. switch
between 2SW
* Disconnect 2SW. _ (male) (1)and
- Min. 1 MR NO chassis normal
when switch is 2nd spool remains
interchanged? pushed in -
NO [See H-3, 4)
* Turn starting
switch OFF.
* Disconnect 2SW.
- Min. 1 MR
CNSHI
HMT controller (04020) 2SW(Xl)
2nd spool switch
I \ I I / I
2nd switch
77h- TDD00186
20-597
0
E-184 [781 Abnormality in 3rd spool switch system is displayed

If the 3rd spool switch is ON when the system is OFF and nothing is being output to the 3rd clutch
solenoid.
If the starting switch was turned OFF momentarily after the abnormality occurred, accelerate to F3
or R3 and check if [ELII 1781 is displayed. (For details, see TESTING AND ADJUSTING, Measuring
power train oil pressure.) (If it is not displayed, the system has been reset.)
Cause Remedy
3rd spool remains pushed
r/
YES -
in
(See H-l)
4 YES
1Is I781 disolaved 1
YE :S
formed at 3rd 3 is returned to its
I
, 1 original position?
YE
* Start engine.
% See STANDARD 2 Short circuit with chassis
I
VALUE TABLE.
Is resistance ground in wiring harness qeplace wiring
* Turn starting
between 3SW NIO between CNPHl (female) ,arness
switch OFF.
h ) (male) (1) and * Disconnect (11) and 3SW (female) (1)
I--lchassis normal? CN2Hl and 3SW.
* Turn starting * Min. 1 MD
switch OFF. )/ Defective 3rd spool switch qeplace
* Disconnect 3SW.
* Min. 1 Ma
E-185 [79] Abnormality in 3rd spool switch system is displayed

% If the 3rd spool switch is ON when the system is OFF and nothing is being output to the 3rd clutch
solenoid.
5% This is the same as flow display [78l;but read 1791 in place of 1781 in Troubleshooting Item 4.
CN2Hl
HMT controller (04020) 3rd spool switch
77?7 TDD00187
20-598
0
E-186 [8A] Abnormality in monitor panel alarm system is displayed

If there is any disconnection in the solenoid or wiring harness, the alarm is not actuated.
If pin (2) of the solenoid is short circuiting with the ground, the alarm will remain actuated.
switch ON and check if 1E.u 1 1871 is displayed. (If it is not displayed, the system has been reset.)
Check that fuse 3 is normal.
Cause
a) If alarm does not sound
YES
Defective monitor panel leplace
21
leplace wiring
rarness
(female) (2) and P2
*Turn startin (female) (7)
between CN217
(1) and chassis
* Turn starting
switch ON.
P L . . .. _. _. _.
I
. Turn starting
switch ON.
*20-30V
I I
NO
Defective monitor alarm
harness between fuse (3)
leplace
leplace wiring
*20-30V rarness
NO - CN215 (2) - CN217
(female) (1)
8
2 b) If alarm continues to sound
z
1 YES

between P2 (female) (7) tarness
* Turn starting NO
and CN217 (female) (2)
switch ON.
CN215
Fuse
(SWP8)
&I CN217(M2)
CNP2 2 Monitor alarm
I, )ci
I \ 1 I I
Monitor panel (04012) I 3
Alarm output g 3
TDD00196
20-599
0
E- 187 [8d] S-NET communication error (abnormality between monitor

panel and HMT controller) is displayed
1: If the starting switch was turned OFF momentarily after the abnormality occurred, turn the starting
switch ON and check if [E.u ] [8b] is displayed. (If it is not displayed, the system has been reset.)
Cause Remedy

Replace wiring
Is resistance between PI (female) (161,
between CNZHl harness
P2 (female) (IO) - SMI
n
(female) (11j - Pl
switch OFF. (female) l14)(15)
(female) (16). P2
(female) (10) * Disconnect’CNPH2, PI, P2,
normal? and SMI.
* Min. I MR
harness between CN2H2 Replace wiring
controller LED (female) (II) -CNOlI (7)- harness
NO
* Disconnect PI (female) (161, P2
CN2H2, PI, P2, (female) (IO)
* Turn starting and SMI.
switch ON. * Min. 1 MR
See E-158 -
NO
CNPl CN214 CNOII CN2H2

Monitor panel (04012) (SWPIG) (SWPIP) (04016) HMT controller
S-NET
I
CNP2
(04016)
S-NET @
TDD00161
20-600
0
E-188 Backup alarm does not sound

* Check that abnormal displays [661 and 1671 are not displayed on the HMT controller.
+ Check that fuse 9 is normal.
Cause Remedy
YES
Defective relay (014) leplace
2 I
1 Does condition II
Defective backup alarm leplace
harness between CN244 leplace wiring
* Same conditions (female) - CN233 (2) - larness
chassis normal? CN153 (1) relay (014)
as in Item 2.
terminal (3)
* Turn starting
.20-3on disconnection in wiring leplace wiring
IO harness between fuse 9 - larness
relay (014) terminal (5)
Backup alarm
CN153
Backup alarm relay (SWPG) 1
CN014
CNOII CN003 HMT controller

(SWP16) (MIC21)
TDD00194
20-60 1
0
E-189 Pin-puller cylinder does not work (machines with giant ripper only)
2 YES Defective operation of

Is resistance
solenoid valve (spool)
between CN246
YES (make)(1) - (2). and _
between (1). (2) -
chassis as shown in
1 Table I? Defective solenoid Replace
NO
Is voltage . Disconnect
between CN246 _ CN246. Disconnection or short
(I) and (2) *Turn starting circuit in wiring harness
YES Repair or
normal? switch OFF. 3 between CN263 (female)
replace
(2) - CN264 (4) - CN153
* Turn starting Is voltage (5) - CN246 (female) (I 1
switch ON. between CN263
*Turn pin-puller ~0- (2) and chassis 4 YES Defective pin-puller
switch ON. Replace
ground normal? switch
*20-30V Is voltage
*Turn starting _ between CN263 _
switch ON. NO (I) and chassis
*Turn pin-puller normal? Replace wiring
harness between fuse 8 - harness
switch ON. * Turn starting NO CN264 (3) - CN263 8
.20-30V switch ON. (female) (1) E
*20-30V
;;
Table 1
Between (I) - (2) 40 - 80 z1
Between (1 j,(2) - chassis Min. 1 MQ
CN264 CN153
CN263(X2) (SWPG) (SWPG) CN246(X2) Pin-puller
Switch solenoid valve
e:i @ ($- 3
g a 3
20-602
0
E-190 Blade pitch does not work

Cause Remedy
2 YES harness between SOL1 Replace wiring
(female) (2) - CN454 (2) - harness
Is resistance CN406 (10) -chassis
YE between SOL1 _ ground
(male) (I) and (2)
normal? Defective blade pitch
. Turn startina solenoid
1 switch OFF.-
Is voltage *Between (I) - (2):
between SOL1 40-8051
(1) and chassis . Between (1 j,(2) - chassis:
normal? I Min. 1 MR
- Disconnect SOLI. YES Replace wiring
-Turn starting _ harness between P2
3 (male) - CN451 (6) - harness
switch ON.
*Turn blade pitch CN406 (9) - CN454 (1) -
switch ON.
Is voltage .._._,(11
SOL1 (female) , .,
between P2 and -
*20-30V N YES
chassis normal? Defective switch Replace
- Is voltage
* Same conditions _ between PI and
as in Item 1. Defective contact, or
NO chassis normal?
* Disconnect P2 disconnection in wiring Replace wiring
and check at NO harness between fuse 8 harness
* Turn starting
switch end. and PI (female)
switch ON.
-2O-30V
- Disconnect Pl
and check at fuse
end.
CN451 CN406 CN454

Blade pitch (SWP8) o(2) Blade pitch
(SWPIZ)
solenoid valve
3
AA
3
TDD00198
20-603
E-191 Travel speed does not shift ([ f7

,lD;g,,
1 mark does not light up on
monitor panel when button is pressed) (For Serial No.: 60001 - 60806)
to the next step. Cause Remedy
a) Switch system
2 YES disconnection in wiring leplace wiring
harness between FNR iarness
Is resistance (female) (3) - LEVER (2) -
YE between FNR _ CN2H2 (female) (15)
(male) (2) and (3)
normal? Defective travel speed
leplace
1 * Turn starting NO selector switch
Is voltage switch OFF.

between FNR * Press button:
(female) (2) and I Max. 1 R
GND normal? . Disconnect FNR. Defective contact, or
. Connect 3 YES
harness between CN2Hl larness
T-adapter to Is voltage (female) (1) - LEVER (12) -
(male) only. between CN2Hl _ FNR (female) (2)
* Turn starting h (male) (I) and
switch ON. GND normal?
*20-30V Defective HMT controller leplace
* Connect NO
T-adapter to
(male) only.
* Turn starting
switch ON.
.20-30V
b) Monitor panel system
harness between CNPI (eplace wiring
(female) (9) - CN214 (7) - iarness
CNOll (3) - CN2H2
* Turn starting
Is---“_- (female) (12)
switch OFF.
be,..,=,
,n\ ^^A. * Disconnect CNPI
and CN2H2.
- Between wiring harnesses:
-Turn starting Max. 1 R
switch ON. + Between wiring harness-chassis:
Min. 1 MR
NO

CN2Hl LEVER FNR
(04020) Travel speed
(SWP16) (SWP14)
selector switch
D 3
switch
3 (($iJ
3
CN2H2
(04016)
CNOll CN214 CNPl
(SWPIZ) (SWPIG) (04016) Monitor panel
GND
Travel speed selector Travel speed

switch selector display
I I / I / I \
TDCO0219
20-604
0
TROUBLESHOOTING OF HYDRAULIC AND
MECHANICAL SYSTEM
(H MODE)
Table of failure modes and causes (HMT, HSS, and power train systems) . . . . . . . . . .._....................... 20-702
H-l. Machine does not move.. .......................................................................................................... .20-704

H-2. Machine does not start if engine is not at full throttle ......................................................... .20-706
H-3. Travel speed does not rise when traveling forward .............................................................. .20-708
H-4. Travel speed does not rise when traveling in reverse ........................................................... 20-710
H-5. Acceleration is poor ................................................................................................................... .20-712
H-6. Machine lacks power (lacks drawbar pull) .............................................................................. .20-713

H-7. Machine does not turn (turns in one direction only (left or right)) ..................................... .20-714
H-8. Travel speed is slow (machine does not turn) or turning power is weak .......................... .20-716
H-9. Machine does not stop turning when steering lever is returned to neutral ....................... .20-718
H-10. Brakes do not work ..................................................................................................................... 20-719
H-II. Power train oil overheats ........................................................................................................... 20-720
H-12. Abnormal noise from around HMT pump .............................................................................. .20-722
H-13. Abnormal noise from around HMT motor.. ............................................................................ .20-723

8 .20-724
H-101. All work equipment and turning speeds are slow or lack power ........................................
z
z H-102. Work equipment does not move and machine does not turn .............................................. 20-725
H-103. Blade RAISE speed is slow or lacks power.. ............................................................................ 20-726

H-104. Blade tilt speed is slow or lacks power.. .................................................................................. 20-726
H-105. Ripper RAISE speed slow or lacks power ............................................................................... .20-727
H-106. Ripper tilt speed slow or lacks power ..................................................................................... .20-727

H-107. Excessive hydraulic drift of blade lift.. ...................................................................................... 20-728
H-108. Excessive hydraulic drift of blade tilt.. ..................................................................................... .20-728
H-109. Excessive hydraulic drift of ripper ........................................................................................... .20-729

H-l 10. Pin-puller cylinder does not work ............................................................................................ .20-729
H-l 11. Blade pitch does not work ........................................................................................................ .20-730
H-l 12. Abnormal noise from around hydraulic, HSS pump ............................................................. .20-730
20-701
0
TROUBLESHOOTING TABLE OF FAILURE MODES AND CAUSES (HMT, HSS, AND POWER TRAIN SYSTEMS)
TABLE OF FAILURE MODES AND CAUSES (HMT, HSS, AND POWER TRAIN SYSTEMS)
Parts causing failure HMT pump
-
Transn- lission HSS Others
_ T
Modulating Sole1G Selector
Clutch T
5
x
5
P 3
5 J
j
u
a I
3
c
al c i
>
E F 3 - a:
c
)
9 c
; -
5 4I j
i c
: :
C): E i
.f ;
’ .-
m % j j
E i
I i:
.: 5
i
; I i E
Failure mode 2 i cI _
a .LL
-
Machine does not move 5
- ) c
- _
C H-l
H-2
Machine does not start if engine is not at full throttle
_ \
-
forward C 2 C H-3
Travel speed does not rise when traveling
- I
_
C C H-4
,
in reverse .pa 3
Travel speed does not rise when traveling
_ ,
- _
+ 1 Travel speed does not change when travel speed selector button is operated - 191
- _
2 Acceleration is poor 5
- C C H-5
1 Machine lacks power (lacks drawbar pull)

- I
\
/ 3
_ ;
_
C H-6
i-10
Brakes do not work
- -
.
C )C i-11
Power train oil overheats
- ,
_ _
HMT pump i-12

Abnormal noise from around
- -
4-13
Abnormal noise from around HMT motor
- -
Machine does not turn
Does not turn to left
- _ _
H-7
m
Does not turn to right
- -
does not turn) or turning power is weak H-8
m
I
Travel speed is slow (machine
- -
Machine does not stop turning when steering lever is returned to neutral H-9
_ - _
20-702
0
TROUBLESHOOTING TABLE OF FAILURE MODES AND CAUSES (WORK EQUIPMENT HYDRAULIC AND HSS SYSTEMS)
TABLE OF FAILURE MODES AND CAUSES (WORK EQUIPMENT HYDRAULIC AND HSS SYSTEMS)
Parts causing failure Work equipment oil pressure HSS Others
H draulic
H&i pump Control valve
%
s
-3
r=
0
Failure mode
All work equipment and turning speeds are slow or lack power 0 000000 00 00 0 H-10’
Work equipment does not move and machine does not turn 0 0 00 0 H-10:
Blade RAISE speed is slow or lacks power 0 0 0 0 0 H-10:
Blade tilt speed is slow or lacks power 0 0 0 0 0 H-101

E
i Ripper RAISE speed slow or lacks power 0 0 0 0 0 H-IO!
a
?z Ripper tilt speed slow or lacks power 0 0 0 0 0 H- 101
Excessive hydraulic drift of blade lift 0 0 H-10’

r
$ Excessive hydraulic drift of blade tilt 0 0 0 H- 101
Excessive hydraulic drift of ripper 0 0 0 H-IO!
Pin-puller cylinder does not work 00 H-III
Blade pitch does not work 00 H-II’
Abnormal noise from around hydraulic, HSS pump 00 0 H - 11:
Machine does not turn Does not turn to left 000 0

H-7
Does not turn to right 000 0
VI
V) Travel speed is slow (machine does not turn) or turning power is weak 000 00 00 00 000 H-8
I
Machine does not stop turning when steering lever is returned to neutral 0 00 H-9
20-703
a
TROUBLESHOOTING H-l
H-l. Machine does not move

When driving the machine, set the parking brake lever to the FREE position, release the brake
pedal, and set the directional lever to the FORWARD (or REVERSE) position and the FORWARD (or
REVERSE) speed control lever to any position other than low speed.
YES
51
t Is HMT turns i I
YES main (high
6
pressure) relief
Does condition
pressure normal?
become normal
FORWARD: PB port when HMT pump
4 REVERSE: PA port N; ;&I;;;;e,ief
Isadjustment of * Engine at high
valve is adjusted?
YE ; voltage of throttle idling.
potentiometer - - Min. 36.3 MPa FORWARD: PB port
normal? (370 kg/cm? REVERSE: PA port
z See TESTING - Engine at high
%: See TESTING AND ADJUSTING. idling.
AND ADJUSTING. * Min. 36.3 MPa
(370 kg/cm2)
YE Is 1st clutch
pressure normal?
1
t
- Joystick at
neutral
- Engine at high
idling.
* Min. 2.8 MPa
(29 kg/cm? I-
N 0 s
8 YES
parking brake lever - Joystrck at neutral Is transmission

YE
is at FREE position - Engine at high main relief
and joystick is at idling. No pressure normal?
* l.O? 0.1 MPa
(IO.8 + 1.0 kg/cm? * Joystick at neutral NO
- Jack up chassis. - Engine at high idling.
* Release brake
pedal.
- Engine at high
idling.
Is brake pressure * Min. 2.2 MPa
(22 kg/cm?
~~
parking brake lever
is at FREE position
and joystick is at N
* Release brake
pedal. at FORWARD full NO
- Engine at high and REVERSE full
idling. positions.
* 1.0 + 0.5 MPa % See STANDARD
(10 + 5 kg/cm?) VALUE TABLE.
* Measure voltage of
IlEl, [lFl, [211,1221.
IO (Stays at 0 MPa (0 kg/cm2j)
Ir For Step 2, it is also possible to check when traveling under the same conditions.
20-704
0
TROUBLESHOOTING H-l
I Cause Remedy
Replace
HMT pump main (high Adjust
pressure) relief valve
Replace
Adjust
Defective pressure
compensation relief valve
for Ist, 3rd clutch, or
Correct or
1st clutch selector valve
replace
spool, or 1st solenoid
valve, or defective 1st
I
clutch
Replace
Defective transmission
Adjust OI
main relief valve or power
replace
train pump
Defective parking switch Replace
Adjust
parking brake linkage
Replace
Adjust
20-705
0
TROUBLESHOOTING H-Z
H-2. Machine does not stat-t if engine is not at full throttle
‘9pik”t
9 of Adjust
* Note: The machine will not move if the decelerator pedal is being depressed. (It will not move if
the engine speed is less than 900 rpm.)
20-706
0
TROUBLESHOOTING H-3
H-3. Travel speed does not rise when traveling forward
‘ES
6 YES
YES Is 3rd clutch

pressure normal?
5
* Min. 2.8 MPa NO
YES Is FORWARD (29 kg/cm*)
1 - clutch pressure - * Jack up chassis.
normal? * Engine at high idling.
*When track is rotating
4
_ - Min. 2.8 MPa (29 freely in 3rd.
kg/cm’) See Note 2.
*Jack up chassis.
See Note 1. pressure normal? NO
* Engine at high
idling.
‘When track is rotating
I- freely in F2.
Does travel (29 kg/cm7
YE See Note 2.
speed become 1 - * Joystick at
km/h? neutral NO
* Engine at high
*Jack up chassis. idling. 8
2
* Engine at high 2
idling.
Is 1st clutch NO z
* Sorocket rotation
NO pressure normal?
speed? : 12 seclat
one turn
* Min. 2.8 MPa (Equivalent to travel
(29 kg/cm? speed of 1 km/h)
*Joystick at See Note 2.
neutral
* Engine at high 0
idling.
* With Step 3, it is also possible to check the travel speed when traveling on level ground for 20 m
under the same conditions. Calculate as 2o :rr,“,13’” km/h

>
Note 1: Jack up the chassis with the blade and ripper, run the engine at above mid-range speed, move
the joystick fully forward, set the Max. speed setter(FORWA!?D) to the FULL position (or drive
the machine under the same conditions), and check if the track moves.
Note 2: When driving the machine, set the parking brake lever to the FREE position, release the brake
pedal, and set the directional lever to the FORWARD position and the Max. speed setter
(FORWARD) to any position other than low speed.
AWhen carrying out Steps 3, 5, and 6, the machine is jacked up and the tracks will rotate freely, so
be extremely careful when carrying out the operation.
20-708
0
TROUBLESHOOTING H-3
Replace
Correct or
clutch
Defective Dressure
I cornpensaiion relief valve
for FORWARD, REVERSE Correct or
clutch or FORWARD replace
Correct or
replace
clutch
20-709
0
TROUBLESHOOTING H-4
H-4. Travel speed does not rise when traveling in reverse
6 YES
YE
It-
pressure normal?
* Engine at high idling.

Does brake *When track is rotating
d
dragging occur? 4- . Min. 2.8 MPa (29
kg/cm?
YES Is 2nd clutch * Jack up chassis.
See Note 1. pressure normal? * Engine at high
3 -
Does travel
YE
sspeed become 1 -
km/h? neutral NO
* Engine at high
*Jack up chassis. idling. B
. Engine at high 5
idling.
NO 5
s Sprocket rotation
I pressure normal?
speed? : 12 set/at
one turn
* Min. 2.8 MPa (Equivalent to travel
129 kg/cm? speed of 1 km/h)
*Joystick at See Note 2.
neutral
* Engine at high 0
idling.
* With Step 3, it is also possible to check the travel speed when traveling on level ground for 20 m
under the same conditions. Calculate as 2o :~~e~136 km/h

>
the joystick fully reverse, set the Max. speed setter (REVERSE) to the FULL position (or drive
Note 2: When driving the machine, set the parking brake lever to the FREE position, release the brake
pedal, and set the directional lever to the REVERSE position and the Max. speed setter
(REVERSE) to any position other than low speed.
AWhen carrying out Steps 3, 5, and 6, the machine is jacked up and the tracks will rotate freely, so
be extremely careful when carrying out the operation.
20-710
0
TROUBLESHOOTING H-4
Remedy
Excessive leakage from

HMT motor (defective Replace
HMT motor)
Defective 3rd clutch

selector valve spool or Correct or
3rd solenoid valve or 3rd replace
clutch
I
Defective pressure
compensation relief valve
for FORWARD, REVERSE Correct or
clutch or REVERSE replace
solenoid valve or
REVERSE clutch
Defective pressure
compensation relief valve Corred or
for 2nd clutch or 2nd
replace
solenoid valve or 2nd
I
clutch
20-711
TROUBLESHOOTING H-5
H-5. Acceleration is poor
Cause Remedy
YE: Defective HMT pump or

Zeplace
range speed and motor
YES
Defective HMT pump

charge pressure C servo or HMT motor leplace
1 WI;; buzzer
Is HMT main N( servo
(high pressure)
relief pressure * Engine speed:
* Engine at high NO
normal when
idling.
is at FREE position - Min. 36.3 MPa (370 kg/cm2)
I;
and joystick is at % See TESTING
When parking Defective parking switch leplace
AND ADJUSTING.
brake lever is at
YE FREE position, is
5 parking switch
separated from Defective adjustment of
n
rdjust
parking brake linkage
parkingbrake lever * Engine at high
is atFREEposition (directional lever) .X Contacts must
idling.
and joystick is at normal? be separated.
- 2.2 MPa
neutral?
(22 kg/cm? - Measure voltage Defective joystick
leplace
* Release brake at FORWARD full IO (directional lever)
peaar. and REVERSE full positions.
* Engine at high X See STANDARD VALUE TABLE. Defective adjustment of
idling. parking brake linkage or
- 1.0 f 0.5 MPa rdjust
NO (Stays at 0 MPa (0 kg/cmz)) defective adjustment of
(10 k 5 kg/cm? brake pedal linkage
* For Step 2, it is also possible to check when traveling under the same conditions.
Note 1: When PPC circuit is normal.
A When carrying out Step 4, the machine is jacked up and the tracks may rotate freely, so be
extremely careful when carrying out the operation.
20-712
0
TROUBLESHOOTING H-6
H-6. Machine lacks power (lacks drawbar pull)

* Check power train oil level before carrying out troubleshooting.
Cause Remedy
Brake dragging (See H-10 ) -
3 YES
YE~F/- To *
dragging occur?
Iefective transmission sepair or

See Note 1.
z-’ Jalve eplace
%% See TESTING NO
Is transmission AND ADJUSTING.
- main relief oil - * Engine at high idling.
No pressure normal? . Min 2.8 MPa (29 kg/cm2)
7 YES Iefective power train
* Joystick at - Isfree length of p
spring of main sump
neutral
relief valve
* Fd;y;;e at hrgh No nOrmal? Iefective main relief
. Does spool move /alve or defective spring,
* 3.2 + 0.3 MPa Xeplace or
smoothly? ~ defective spring, spool
(33 + 3 kg/cm? NO epair, clean
:atching, or clogging with
* Free length of
dirt
spring: 108 mm (small)
122 mm (large)
5 YEE Defect inside lepair or
Is engine speed :ransmission eplace
YES normal at
steering relief +
blade RAISE? Iefective engine
4 -
See ENGINE volume
Is HMT pump * Min. 1,750 rpm NC S-mode)
main (high -Engine at high
From A
pressure) relief - idling.
pressure normal? ~ Defective adjustment of
6 YEI
~ Does condition iMT pump main (high
FORWARD: PB port become normal aressure) relief valve
REVERSE: PA port when HMT pump
* Engine at high NO rnana6’r’~~e,ief -
Defective HMT pump
idling.
valve is adjusted? - nain (high pressure) leplace
* Min. 36.3 MPa NC .elief valve
(370 kg/cm? FORWARD: PB port
REVERSE: PA port
* Engine at high
idling.
- Min. 36.3 MPa
(370 kg/cm*)
the joystick fully forward, set the Max. speed setter (FORWARD) to the FULL position (or drive
&When carrying out Step 3, the machine is jacked up and the tracks will rotate freely, so be
20-713
0
TROUBLESHOOTING H-7
H-7. Machine does not turn (turns in one direction only (left or right))
Cause Remedy
2 YES Xl leakage from steering ieplace or

[PC piping orrect
Does steering
YES
spool move
1
smoothly?
Is steering EPC Iefective operation of ieplace or
solenoid valve steering spool orrect
output pressure
normal?
u-l
* Engine at high Defective steering EPC
leplace
idling. NO rolenoid valve
- Min. 3.5 MPa (36 kg/cm*)
* Output pressure in direction
of operation of steering lever.
20-714
0
TROUBLESHOOTING H-8
H-8. Travel speed is slow (machine does not turn) or turning power is
weak
* Check oil level in hydraulic tank before carrying out troubleshooting.
* When work equipment speed and power are normal.
YES
3
YE Is steering LS
relief pressure -
4 YES
normal?
Does steering
- Min. 30.9 MPa _ spool move
(315 kg/cm21 NO smoothly by
2
*Engine at high hand?
idling. NO
pressure (pump
delivery pressure)
normal?
YFS
mMin. 36.3 MPa
5
(370 kg/cm*)
Does steering relief
mEngine at high pressure (pump
idling. delivery pressure) YES
become normal -
when steering LS
6
relief valve is
adjusted? Does condition
~ become normal
* Min. 36.3 MPa - when steering LS - YES
(370 kg/cm? NO relief valve is 71
* Engine at high replaced?
solenoid valve idling.
output pressure * Min. 36.3 MPa
- Pressure delivery pressure)
(370 kg/cm’)
adjustment: One
* Engine at high when main relief
* Min. 3.5 MPa turn changes by
idling. valve is revlaced?
(36 kg/cm? 17.5 MPa
. Engine at high (179 kg/cm2).
* Min. 36.3 MPa
idling. (370 kg/cm?
* Operate steering * Engine at high
lever. idling.
NO
20-716
0
TROUBLESHOOTING H-8
I Cause Remedy
Correct or
replace
Defective HSS motor Replace
Correct or
steering control valve
replace
spool (see Note I)
Adjust
steering LS relief valve
Defective adjustment of Correct or

steering LS relief valve replace
Defective main relief

valve
Residual pressure of
work equipment LS
8 YES circuit (LS bypass valve Correct or
Is difference clogged with dirt or replace
between steering
defective operation of LS
relief pressure
check valve (steering))
(pump discharge
- pressure) and
* Defective operation of
steering LS
pressure 3.4 MPa steering control spool
(35 kg/cm’) or (catching)
Correct or
ahove? 2 * Defective operation of replace
~- NO unload spool
- Defective hydraulic, HSS
pump
Correct or
replace
Note 1: Check first that there is no clogging with dirt or deterioration of the spring, then check if the
spool can be moved smoothly by hand.
20-717
0
TROUBLESHOOTING H-9
H-9. Machine does not stop turning when steering lever is returned to
neutral
Cause Remedy
Defective steering EPC

1 YES solenoid valve or lack of Replace or
Does control steering EPC solenoid correct
valve steering valve output pressure
spool move
smoothly? Defective operation of Correct or
NO steering spool replace
20-718
0
TROUBLESHOOTING H-10
H-lO.Brakes do not work

Ir Check power train oil level before carrying out troubleshooting.
Cause Remedy
YFS
-v Year of brake disc, plate Ieplace
1
Is brake oil
pressure normal? 2 YES I:Iefective operation of Iepair or
t wake valve spool ,eplace
- Is adjustment of
% See Table 1. NC brake linkage -
normal?
I:defective adjustment of
idjust
NO tbrake linkage
I See TESTING
AND ADJUSTING.
Table 1 Unit : MPa (kg/cm*)

Brake oil
Conditions pressure
20-719
0
H-l 1. Power train oil overheats

Sr Check power train oil level before carrying out troubleshooting.
YES
I 1
5 YES
H
speed
steering rfzlief +
1
YES Is transmission
_
4
I_-
blade RAI!3E?
- Min. 1,75( ~rpm NO

Does brake - lubrication
pressure normal? * Engine at high
dragging occur?
idling.
3
* 0.2 5 0.05 MPa
% See Note 1. YES Is transmission (2.6 = 0.6 kg/cm? NO
- main relief oil - . Engine at high
pressure normal? idling.
2 YES
+ Is free length of
2 * Oil pressure: Min.
spring of main
2.9 MPa relief valve
Is power train oil (30 kg/cm’) Nc Norman?
- temperature - * Engine at high . Does spool move
NO sensor normal? idling. smoothly?
- NO
* Free length of
* Remove oil spring: 108 mm (small)
temperature 122 mm (large)
sensor.
* Check resistance NO
value.
(%4See Table 1)
Note 1: Jack up the chassis with the blade and riooer, run the Table 1
engine at above mid-range speed, set the Max. speed set-
ter to the FMAX or RMAX positions, then operate the joy-
stick to FORWARD or REVERSE (or drive the machine un-
der the same conditions), and check if the track moves.
I I
AWhen carrying out Step 1, the machine is jacked up and the
tracks may rotate freely, so be extremely careful when carrying 90°C Approx. 5 k.Q
out the operation.
I I
35°C Approx. 29 kQ
I I
20°C Approx. 52 l&2
I I
10°C Approx. 80 kQ
20-720
0
I Cause Remedy
Brake dragging (see H-10) -
Lubrication pump or
transmission clutch
Replace, adjust
slipping, or increase in
engine output
Defective coolant system

See ENGINE volume -
(S-mode)
Defective transmission
Replace
lubrication valve
Replace,
tighten
Repair or
replace, clean
Replace
20-72 1
0
H-12.Abnormal noise from around HMT pump
Cause Remedy
YES
Defective HMT pump leplace
1
Is HMT charge Defective seal

‘ighten, or
pressure normal? * Loose piping clamp eplace O-ring
* Damaged O-ring
*Jack up chassis. Is there oil
* Parking brake at - leakage in HMT - YES
Clogged HMT charge filter (eplace
FREE, brake NO charge circuit?
pedal released,
joystick at
FORWARD or
REVERSE. rdjust
HMT charge safety valve
* Engine at high become normal
idling. when HMT charge
* Min. 3.2 MPa
(33 kg/cm? To A
same as Step 1. S
charge valve relief valve
become normal idjust
(HMT servo, PPC charge
when charge valve
relief pressure pressure)
From A
(HMT servo, PPC Defective HMT charge
circuit charge safety valve or charge
pressure) is leplace
valve relief valve or HMT
charge relief valve
.X Same conditions
same as Step 1.
* For Step 1, it is also possible to check when traveling under the same conditions.
A When carrying out Step 1, the machine is jacked up and .pa the tracks will rotate freely,
so be
20-722
0
H-13.Abnormal noise from around HMT motor
l-
Cause Remedy
YES
Defective HMT motor
1
Is HMT charge Iefective seal

YES T ighten, or
pressure normal? *Loose piping clamp rtsplace O-ring
2 *Damaged O-ring
-Jack up chassis. Is there oil
* Parking brake at - leakage in HMT - YES
Zlogged HMT charge filterr Replace
FREE, brake NO charge circuit?
pedal released,
joystick at
FORWARD or 4 YES
4
REVERSE. r A djust
Does condition iMT charge safety valve
* Engine at high become normal
idling. when HMT charge u
L
NO
..-
. Min. 3.2 MPa safety valve is
(33 kg/cm? adjusted? r0 A
% Same conditions N”
same as Step 1. 5
:harge valve relief valve
become normal djust
when charge valve
HMT servo, PPC charge
xessure)
From A
(HMT servo, PPC 3efective HMT charge
safety valve or charge
leplace
valve relief valve or HMT
charge relief valve
Z Same conditions
same as Step 1.
For Step 1, it is also possible to check when traveling under the same conditions.
When carrying out Step 1, the machine is jacked up and the tracks will rotate freely, so be
i
20-723
0
H-101. All work equipment and turning speeds are slow or lack power
Cause Remedy
Defective hydraulic, HSS

leplace
become normal pump
when hydraulic,
Defective hydraulic, HSS :orrect or

pressure (pump pump drive portion eplace
YE pressure) and LS
pressure (steering), 2.0 f 0.5 MPa (20 + 5 kg/cm*)
and between blade - Engine at high idling.
tilt pressure (pump A VFS Defective main relief
discharge pressure) (eplace
valve
4
Does condition
become normal
when main relief
- Differential Noplve is replaced? 1 Defective operation of :orrect or
pressure: I
NO unload valve eplace
2.0 f 0.5 MPa - Differential
(20 + 5 kg/cm’) pressure:
- Engine at high 2.0 k 0.5 MPa (20 f 5 kg/cm?
idling. * Engine at high idling.
- Oil pressure:
Min. 3.5 MPa idjust
charge valve (HMT servo,
(36 kg/cm’)
PPC charge relief valve)
- Engine at high
idling. Does condition Internal leakage in PPC
become normal
valve or EPC valve in
when charge valve YES
circuit which became
is adjusted) I normal when portions A,
- Oil pressure: B, or C were blocked
Min. 3.5 MPa
(36 kg/cm? Defective charge pump leplace
- Engine at high
idling.
Defective charge valve

[HMT servo, PPC charge
- Engine at high NC relief valve)
idling.
% Install oil pressure gauge
directly to portion A or B.
20-724
0
H-102. Work equipment does not move and machine does not turn
+ Check oil level in hydraulic tank before carrying out troubleshooting.
Cause Remedy

1Does condd YES Replace
become normal pump
2’YEiS when hydraulic,
1 HSS pump
differences betweer assembly is
Defective hydraulic, HSS Correct or
replaced?
pressure (pump - NO pump drive portion replace
- Differential
YE pressure) and LS pressure:
pressure (steering), ’ 2.0 + 0.5 MPa (20 f 5 kg/cm?
and between blade * Engine at high idling.
tilt pressure (pump Defective main relief
discharge pressure) Replace
valve
1
* Differential
Defective operation of Correct or
pressure:
(basic pressure) NO unload valve replace
2.0 + 0.5 MPa - Differential
(20 + 5 kg/cm? pressure:
* Engine at high 2.0 k 0.5 MPa (20 + 5 kg/cm?
s: * Oil pressure:
idling. * Engine at high idling.
Min. 3.5 MPa
z (36 kg/cm*) 5 YES
Defective charge pump
z - Engine at high Is any foreign
idling. material found in
h strainer inside
charge valve? Defective charge valve
(HMT servo, PPC charge
NO
relief valve)
20-725
0
TROUBLESHOOTING H-103.104
H-103. Blade RAISE speed is slow or Cause Remedy

lacks power
* When the hydraulic drift of the blade is normal.
+ Defective operation of
Check oil level in hydraulic tank before car- 4 YE C:orrect or
blade lift control valve
rying out troubleshooting. rl eplace
spool
* Check if the blade has been modified.
Defective operation of lift
1 II . CZorrect or
pressure compensation
3 NO r8replace
. Oil pressure: valve
Is relief pressure 16.7 MPa
YE (pump delivery _ (170 kg/cm*)
pressure) at tilt * Engine at high idling.
stroke end normal?
5
-YES Defective adjustment of
* Oil pressure: Does tilt relief
pressure (pump work equipment LS relief f idjust
19.6 MPa valve
delivery pressure)
2 (200 kg/cm? - become normal -
. Engine at high NO when work
YES Is output idling. equipment LS relief Defective work equipmenl
pressure of PPC valve is adjusted? NO LS relief valve
: Fleplace
valve normal?
* Oil pressure:
il Min. 19.6 MPa
, 1 *Oil pressure:
(200 kg/cm?
* Engine at high idling.
* Pressure adjustment:
One turn changes by
Defective operation of C Iorrect or
NO PPC valve r eplace
I . Air in circuit EHeed air

NO
H-104. Blade tilt speed is slow or lacks I Cause Remedy

power
Sr When the hydraulic drift of the tilt is normal.
Ir Check oil level in hydraulic tank before car- ,, Y,-S Defective operation of
Correct or
. blade tilt control valve
rying out troubleshooting. replace
YES Is LS pressure at spool
* Check if the blade has been modified. - tilt stroke end -
nomal? Defective operation of tilt
Correct or
Nd pressure compensation
3 reolace
- * Oil pressure: valve
YES (pump delivery _ (170 kg/cm?
pressure) at tilt * Engine at high idling.
stroke end normal?
5
Does tilt relief
YES Defective adjustment of
* Oil pressure: - work equipment LS relief Adjust
pressure (pump
19.6 MPa valve
delivery pressure)
(200 kg/cm?
2 - become normal -
1 * Engine at high NO when work
YES Is output idling. equipment LS relief Defective work equipment
pressure of PPC valve is adjusted? No LS relief valve Replace
valve normal?
* Oil pressure:
Min. 19.6 MPa
1 rl * Oil pressure: (200 kg/cm?
Min. 3.5 MPa * Engine at high idling.
(36 kg/cm? * Pressure adjustment:
extended and
- Engine at high
One turnchanges by
idling.
smoothly? 15.1 MPa (154 kg/cm? Defective operation of
I Correct or
NO PPC valve replace
I
Air in circuit Bleed air
NO
20-726
0
TROUBLESHOOTING H-105.106
H-105. Ripper RAISE speed slow or Cause Remedy

lacks power.
When the hydraulic drift of the ripper is normal.
jefective operation of
Check oil level in hydraulic tank before car- 4 YE! Correct or
ipper lift control valve
replace
rying out troubleshooting. pool
Check if the ripper has been modified. ‘I
jefective operation of lift
Correct or
bressure compensation
N( replace
. Oil pressure: ,alve
YI (170 kg/cm’)
- Engine at high idling.
defective adjustment of
f Oil pressure: vork equipment LS relief Adjust
19.6 MPa ,alve
(200 kg/cm*)
* Engine at high F
idling. equipment LS relief L defective work equipmenl
YE
1valve is adjusted? 1 N( .S relief valve
-Oil pressure:
I I Min. 19.6 MPa
* Oil pressure:
1 Can cvlinder be
I extended and
retracted
1 smoothly? befective operation of Correct or
‘PC valve replace
NO
rir in circuit Bleed air

NO
H-106. Ripper tilt speed slow or lacks Cause

power.
* When the hydraulic drift of the tilt is normal.
* Check oil level in hydraulic tank before car- npper tilt control valve
Correct or
replace
rying out troubleshooting. spool
* Check if the ripper has been modified. ”
Defective operation of tilt
Correct or
pressure compensation
replace
valve
16.i MPa
YI (pump delivery ( 170 kg/cm?
- Engine at high idling.
stroke end normal?
5
* Oil pressure: work equipment LS relief
19.6 MPa valve
delivery pressure)
2 (200 kg/cm21 become normal
- Engine at high P
idling. equipment LS relief Defective work equipmen
LS relief valve
valve normal? *Oil pressure:
Min. 19.6 MPa
- Oil pressure: (200 kg/cm?
Min. 3.5 MPa * Engine at high idling.
Can cylinder be
(36 kg/cm?) - Pressure adjustment:
extended and
- Engine at high One turn changes by
retracted
idling.
‘5.’ MPa (154 kg/cm’). Defective operation of Correct or
ppc
smoothly?
I
NO
0 valve
’ Air in circuit
replace
Bleed air
20-727
0
TROUBLESHOOTING H-107,108
H-107. Excessive hydraulic drift of blade lift
Cause I Remedy
Excessive leakage inside

YES valve
Replace
- Internal leakage in blade
normal when blind lift valve
plug is fitted at
cylinder head end? Excessive leakage inside
cylinder Replace
* Stop engine. - Defective piston seal
- Downward
movement:
Max. 250mm/15 minutes
A- Fit blocks
block.
under the blade, disconnect the hose at the head end, fit a blind plug, then remove the
H-108. Excessive hydraulic drift of blade tilt
Cause Remedy

1 YES valve
- Internal leakage in blade Replace
Is leakage normal
tilt valve
when tilt cylinder
* Defective suction valve
is relieved at end
of stroke? Excessive leakage inside
cylinder Replace
* Max. 12 cc/min. NO
* Defective piston seal
* Extend tilt cylinder fully and
disconnect hose from head end.
- Run engine at full throttle and
relieve circuit at end where tilt
cylinder is extended.
20-728
0
TROUBLESHOOTING H-109.1 10
H-109. Excessive hydraulic drift of ripper
Cause Remedy

1 YES
valve, or defective suction
Is leakage normal valve
when cylinder is
relieved at end of
stroke? Excessive leakage inside
cylinder Replace
* Max. 11 cclmin. NO . Defective piston seal
* Extend ripper lift cylinder fully
and disconnect hose from
head end.
- Run engine at full throttle and
relieve circuit at end where
cylinder is extended.
8
5
& H-110. Pin-puller cylinder does not work
* When operation of pin-puller solenoid is normal (if it is abnormal, see E-2)
* When power train oil pressure is normal.
Cause Remedy
1 YES Defective pin-puller Repair or

Is output cylinder replace
pressure of pin-
puller solenoid
valve normal? Defective pin-puller
Replace
solenoid valve
% See TESTING NO
AND ADJUSTING.
20-729
0
TROUBLESHOOTING H-111,112
H-l 11. Blade pitch does not work
I Cause Remedy
1 YES Defective blade pitch Correct or

Is output cylinder replace
pressure of blade
pitch solenoid
valve normal? Defective blade pitch
% See TESTING NO solenoid valve
AND ADJUSTING.
H-112. Abnormal noise from around hydraulic, HSS pump

* Check oil level in hydraulic tank before carrying out troubleshooting.
Remedy
YES
FDefective seal
* Loose piping clamp Tighten
2 * Damaged O-ring
Is air being
YES sucked in by
YES
pump suction Clogged strainer Clean
circuit?
1
Replace
pump
Is correct oil
when hydraulic Check again
oil is drained? Operate for a short time
[according to
and watch for any change
change in
in symptoms
symptoms)
Improper oil Replace
20-730
0
TROUBLESHOOTING OF
MACHINE MONITOR SYSTEM
(M MODE)
Electrical circuit diagram for machine monitor related parts . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . .. . . . . 20-802
M-l. Monitor panel display does not appear when starting switch is turned ON.. ..................... .20-803
M-2. When starting switch is turned ON, monitor panel lamps all light up but do not go out .... ..20-80 3
M-3. Abnormality in preheating ( @I 1.............................................................................................
.20-804
a) Preheating monitor lamp does not light up ....................................................................... .20-804
b) Preheating monitor lamp is lighted up continuously.. ...................................................... .20-804
M-4. Caution item lights up or flashes .............................................................................................. .20-806
a) (m 1 (Battery charge) lights up or flashes ...................................................................... .20-806
b) When starting switch is turned ON and engine is started, (&)
(Engine oil pressure) lights up or flashes ................................................................. .20-807
c) ( a-’ ) (Coolant temperature) flashes ................................................................................. .20-808
d) ( +f$#j1 U’ower train oil temperature) flashes ..................................................................... .20-809

e) ( $JI 1 (Hydraulic oil temperature) flashes.. ....................................................................... .20-810
M-5. Abnormality in buzzer.. ............................................................................................................... .20-811
8 a) Caution item flashes but buzzer does not sound.. ............................................................. .20-811
z
z b) Monitor display is normal but buzzer sounds.. .................................................................. .20-811
M-6. Abnormality in warning lamp .................................................................................................... .20-812
a) Caution item flashes but lamp does not flash ................................................................... .20-812
b) Monitor display is normal but lamp lights up ................................................................... .20-812
M-7. Abnormality in gauge ................................................................................................................. .20-813
a) Abnormality in engine coolant temperature gauge.. ......................................................... .20-813
b) Abnormality in power train oil temperature gauge.. ......................................................... .20-814
c) Abnormality in fuel level gauge.. ......................................................................................... .20-815
M-8. Service meter does not move after engine is started ............................................................ .20-816
M-9. Monitor panel lighting does not light up (front lamp is normal). ......................................... .20-817
M-10. Lamp does not light up .............................................................................................................. .20-818
a) Front lamp ............................................................................................................................... 20-818
b) Rear lamp (ripper lamp) ........................................................................................................ .20-819
M-l 1. Automatic preheating is not carried out when glow switch is set to AUTO ....................... .20-820
M-12. Wiper does not work .................................................................................................................. .20-822
M-13. Washer fluid is not sprayed out ................................................................................................ .20-826
M-14. Air conditioner has no effect ..................................................................................................... .20-828
a) Air does not blow out ........................................................................................................... .20-828
b) There is no cooling effect ..................................................................................................... .20-832
M-15. Overrun alarm continues to sound ........................................................................................... .20-836
20-801
0
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR RELATED PARTS
ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR RELATED PARTS

Serial No. : 60001 - 60271
CN-243 Rearlamp
-
Hornswitch CN-262(X2) CN-264(SWP6)
I:N-.
0.85LY
0.85GM
Headlamp CN-203(M) 1.25R

1.25RW
A
1.25G
0.85~
Alternator
0.85P 0.85~
6’
0.85L 0.85GR
0’
1.
3’
0.85YG
o.asw 0.
2’
0. 0.
1’
=
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR RELATED PARTS
Startino switch
CN-201 IX21 (
0 B5B 0 858
1: 25WI 1: 25wr
Frontlain0 imer
(right1
h
1. 0.85YG
i 5*.-
24V
GND
Chaise
Stutiac rlittk ltrrainal Cl
Preheating signal
Lamp switch
w
I
0 85W
Engine oi I mwre
0’8% _
EleCtr ical
intake
II I I
air he
HMT control
CN-01 I ISWPIZI
Power train
temoerature sensor
TKD00722
20-802-l
@
TROUBLESHOOTING M-l,M-2
M-l. Monitor panel display does not appear when starting switch is
turned ON
When the battery and battery relay are normal.
When fuse 3 is normal.
(If fuse 3 is blown, check for a short circuit with the chassis ground in the wiring harness between
CNPl(1) - CN215(2) -fuse 3.)
Cause I Remedy
2 YES
1
III
YES Does problem
1 appear again?
Is voltage -
between CNPl - NO I
* Turn starting
(female) (1) and .__
swrrch ON.
(2) normal? Defective contact or
II disconnection in wiring
*20-30V I Sepair or
harness between fuse 3 -
* Turn starting NO veplace
CN215 (2) - CNPI (female]
switch ON. (1)
* Disconnect CNPl and
connect T-adapter to
female.
8
2
z
M-2. When starting switch is turned ON, monitor panel lamps all light
up but do not go out
Cause Remedy
Defective monitor leplace
M-l, M-2. Related electrical circuit diagram
CNPI CN215
Monitor panel (04016) (SWP8)

Fuse
Battery
- -
TDD00202
20-803
a
TROUBLESHOOTING M-3
M-3. Abnormality in preheating @I

* When the battery and battery relay are normal.
* When fuse 10 is normal.
electrical intake air heater - CNlOl(2) - CN214(13) - starting switch terminal RI, terminal B -
CN214(12) - fuse, or between battery relay BR - CN214(11) - CN212(2), CN213(4).)
Cause Remedy
1 YES -
Go to M-3 a), b)
Does problem in
M-3 a) orb)
appear again? Carry out troubleshooting
for defective bimetal
* Disconnect NO timer, glow switch
CN212 and CN213.
* Turn starting
switch ON.
a) Preheating monitor lamp does not light up

Cause Remedy
YES
Defective monitor panel
1 Disconnection in wiring
Is voltage harness between CNPl
3 YES Repair or
between CNPl (female) (6) - CN214 (9) -
Is voltage replace
CNlOl (1) -electrical
(female) (6) and
YES between CNlOl intake air heater relay
chassis normal?
(1) and chassis
2
*4-3ov - normal? Defective electrical intake
Is voltage Replace
*Turn starting NO air heater relay
between CNlOl *4-3ov
switch to
NO (2) and chassis *Turn starting
PREHEAT. Defective contact or
normal? switch to
PREHEAT. disconnection in wiring
*16-30V harness between starting Repair or
. Turn starting switch terminal RI - replace
NO
switch to electrical intake air heater
PREHEAT. relay-chassis
b) Preheating monitor lamp is lighted up continuously

Cause Remedy
Contact of +24V with

CNPl (female) (6) - CN214
(9) - CNlOl (1) -electrical ~;+pp$eor
intake air heater relay or
Is voltage starting switch Rl - CN214
between CNPl (13) - CNlOl (2) -electrical
(6) and chassis intake air heater relay
normal?
- Defective monitor panel Replace
.4-3ov NO
*Turn starting
switch ON.
20-804
0
TROUBLESHOOTING M-3
M-3. a), b) Related electrical circuit diagram
Electrical intake
air heater
Monitor CNP, CN214 CNlOl

panel (SWPIG) (SWPlL)
(04016)
Preheating
signal
B> oA
t3
Electrical
intake
u
air heater
relay
Startina switch
C Starting
motor
Fuse CN105(L2)
Bimetal timer
f Battery
-I CN212v
Glow switch I I
20-805
0
TROUBLESHOOTING M-4
M-4. Caution item lights up or flashes

a) rl- + (Battery charge) lights up or flashes

@ If it lights up
Remedy
.x-A 2
t/s/
I
Defective monitor panel
I disconnection in wirino
Replace
harness between CNPi

Is voltage
(female) (4) -CN214 (IO) -
between CNPI
CNIOI (6) -alternator
1(4) and chassis
YES terminal Ft. or short circuit Repair or
ground normal?
with chassis ground reolace
alO-3ov 3 between same wiring
. Start engine. Is voltage between harness and wiring
alternator terminal harness between CN103
NO R and chassis (2) -starting motor
Is engine oil
ground normal? terminal R - battery relay
pressure caution
I
lamp also lighted
up?
* Start engine. connected to alternator terminal R.

Replace
Fs:o,tage bemeen4i .;h”..“l..i Defective monitor panel
4 CNPl (5) and

NO chassis ground
when cranking?
. lo-3ov
* Turn starting
NO
harness between CNPl (5)
and startina switch
terminal C-
Repair or
switch ON.
I
0 If it flashes
a) Carry out troubleshooting from items in a) marked %.
20-806
0
TROUBLESHOOTING M-4
b) When starting switch is turned ON and engine is started, (Engine oil pressure) lights up or
flashes
* Check that engine oil pressure is the standard

Cause Remedy
pressure before carrying out troubleshooting.
@ If it lights up
1 YES Start troubleshooting

from M-4 a) X A
Is charge lamp
also lighted up?
Start troubleshooting -
NO from M-4 a) % B
* Start engine.
@ If it flashes
Cause Remedy
Check that
contact, insertion
of terminal is
YES Defective engine oil
normal, check
1 pressure sensor system
sensor according
Does display go out to table below,
when wiring Contact of chassis ground replace
harness terminal of - with wiring harness
engine oil pressure 2 YES between CNPl (female) Repair or
sensor is removed? (8) - CN214 (8) - CNIOI replace
~ Is there continuity
. Remove engine between CNPI (5) -engine oil pressure
8 oil pressure NO (female) (8) and sensor
5 sensor terminal. chassis ground?
* Start engine. Defective monitor panel Replace
G * Turn starting NO
switch OFF.
* Remove engine
oil pressure
sensor terminal
and CNPI.

Battery relay
Engine oil
Alternator terminal R
Starting motor V.3
Engine oil pressure
If the condition is as show

below, the sensor is normal.
terminal C
TDD00205
20-807
a
TROUBLESHOOTING M-4
c) 01
- (Coolant temperature) flashes
Cause Remedy
Check sensor
Defective coolant (see
YES
2 I temperature sensor STANDARD
system VALUE TABLE),
replace
YE
3 YES
1 disconnected? Defective monitor panel Replace
1 * Disconnect ‘,I- Short circuit with chassis

CN402. ground in wiring harness
Is indicator of normal?
* Start engine. between CNPP (female) Repair or
coolant temperature
* Run at half NO (1) - CN214 (3) - CNlOl replace
gauge above border * Min. 2.5 V
throttle or above. * Start engine. (3) - CN402 (1) -coolant
- Run at half temperature sensor
- Start engine.
throttle or above.
- Run at half
* Disconnect CN402.
throttle or above.
L
NW
M-4. c) Related electrical circuit diagram
CNPP CN214 CNIOI Coolant

Monitor panel (04012) (SWPIG) (SWPIP) CN402(X2) temperature
sensor
3
1
TDcQo206
20-808
0
TROUBLESHOOTING M-4
d) @l(I’ ower train oil temperature) flashes
Cause I Remedy
Check sensor
Defective power train (see
temperature sensor STANDARD
system VALUE TABLE),
replace
YE
YES
disconnected?
* Disconnect
CN453. h jF-zI%J
harness between CNP2
* Start engine.
(female) (2) - CN214 (2) - Repair or
temperature gauge . Run at half
CN451 (2) - CN453 (l),(2) replace
below border of red throttle or above. NO
CN453. - power train temperature
* Start engine. sensor, or between CN453
* Start engine. * Run at half (female) (2) - chassis
* Run at half throttle or above. ground
throttle or above. . Min. 2.5 V
NO
M-4. d) Related electrical circuit diagram
CNP2 CN214 CN451

(SWPIG) (SWP8) Power train oil
Monitor panel
(04012) CN453(X2) temperature sensor
temperature
TDD00220
20-809
0
TROUBLESHOOTING M-4
-LI
e) Hl (Hydraulic oil temperature) flashes
Cause Remedy
YEi.S Defective contact or

jl
1 harness between CN452 Ieplace wiring
I Is resistance (female) (1) - CN153 (3) - iarness
I
between between . Turn starting CN215 (5) - CNP2 (female)
CN452 knale) (1) switch OFF. (5)
and chassis * Disconnect
normal?
CN452, CNPP.
*Turn starting - Max. 1 R
Defective hydraulic oil
switch OFF. (eplace
temperature sensor
* Disconnect r10
CN452.
* Oil temperature
120” C or below
(sensor ON): Max. IQ
M-4. e) Related electrical circuit diagram
CNPP CN215 CN153

Hydraulic oil
(04012) (SWP8) (SWPG) CN452(Xl)
temperature sensor
temperature
20-810
0
TROUBLESHOOTING M-5
M-5. Abnormality in buzzer

* Of the Caution items, the buzzer does not sound if there is an abnormality in the battery charge.
a) Caution item flashes but buzzer does not sound
Cause Remedy
1 YES
Does buzzer sound Defective monitor panel Replace
when CNP2 Defective contact or
(female) (7) is
connected to
harness between fuse 3 - Pepair or
chassis ground?
CN215 (2) - CN217
replace
. Connect CNP2 No (female) (I), or between
(female) (7) to CN217 (female) (2) - CNPP
chassis ground. (female) (7)
*Turn starting
switch ON.
b) Monitor display is normal but buzzer sounds
Cause Remedy
1 YES
Does buzzer stop
when CNP2 is - Short circuit with chassis
removed? ground in wiring harness
Repair or
I between CNPP (female)
replace
+ Remove CNP2. No (7) and CN217 (female)
*Turn starting (2), or defective buzzer
switch ON.
CN215
TDD00207
20-811
a
TROUBLESHOOTING M-6
M-6. Abnormality in warning lamp

a) Caution item flashes but lamp does not flash

* Check the lamp visually to check that the bulb is not blown. (If it is blown, replace the lamp.)
Cause Remedy
Defective monitor panel ieplace
b1 Monitor display is normal but lamp lights up
Cause Remedy
20-8 12
0
TROUBLESHOOTING M-7
M-7. Abnormality in gauge

a) Abnormality in engine coolant temperature gauge

. Abnormally low temperature is given for engine coolant temperature.
Remedy
1 Check sensor
When short Defective coolant (see
YES
connector is temperature sensor STANDARD
connected to system VALUE TABLE),
CN402, does gauge
replace
indicator move to Defective contact or
end of high disconnection in wiring
temperature range, harness between CN402
(female) (1) -CNlOl (3) - Repair or
CN214 (3) - CNPP (female) replace
(1). or between CN402
. Connect short (female) (2) -chassis
connector to
CN402 (female).
. Turn starting
switch ON.
M-7. a) Related electrical circuit diagram
CNPP CN214 CNIOI

Coolant temperature
Monitor panel (04012) (SWPIG) (SWPIZ) CN402IX2) sensor
a, 3
Coolant temperature
Connector
sensor
If the condition is as shown below, it is normal.

Ambient temperature When normal
I 35°C Approx. 29 kd
I I
20°C
I
Approx. 52 kQ
I I
10°C Approx. 80 kSI
20-813
0
TROUBLESHOOTING M-7
b) Abnormality in power train oil temperature gauge

. Abnormally low temperature is given for power train oil temperature.
Cause Remedy
:heck sensor
Defective power train see
temperature sensor ;TANDARD
connected to
system ‘ALUE TABLE),
CN453, does gauge
eplace
indicator move to Defective contact or
end of high
temwrature ranoe. H
lepair or
(female) (1) - CN451 (2) -
eplace
CN214 (2) - CNP2 (female1
L
(2), or between CN453 (2)
* Connect short
-chassis ground
connector to
CN453.
* Turn starting
switch ON.
M-7. b) Related electrical circuit diagram
CNP2 CN214 CN451

Power train oil
Monitor panel (04012) (SWPIG) (SWP8) CN453(X2) temperature sensor
Power train oil
a:- 3
temperature
GND -3
+fE+-- Connector
Powertrain oi,
temperature sensor
If the condition is as shown below, it is normal.

Ambient temperature When normal
I 35°C
I
I
Approx. 29 kQ
I
I
20°C Approx. 52 kQ
I I
10°C I Approx. 80 kQ I
TROUBLESHOOTING M-7
c) Abnormality in fuel level gauge

0 Fuel level gauge always shows FULL
I Cause Remedy
Check sensor
(see
Defective fuel level sensor
STANDARD
system
Does fuel gauge VALUE TABLE),
YES go below EMPTY replace
1 mark when CN423
- is removed?
Does fuel gauge P , between CN423 (female) Repair or
go below EMPTY * Disconnect NO (1) - CN422 (1) - CN153 replace
mark when CNP2 CN423. (2) - CN214 (1) - CNP2
is removed? . Turn starting switch ON. (female) (3)
* Wait for approx. 1 minute.
* Remove CNP2.
*Turn starting NO
switch ON.
. Wait for approx.
1 minute.
@ Fuel level gauge always shows EMPTY or below
Cause Remedy
Check sensor
(see
Defective fuel level sensor
STANDARD
Does fuel gauge system
VALUE TABLE),
go above FULL replace
YES mark when short
connector is
1 connected to
- CN423? (female) (I) -CN422 (1) -
Repair or
Does fuel gaugego ~ c CN153 (2) - CN214 (I)-
* Connect short NO replace
above F mark when CNP2 (female) (3). or
CNPP pins (3) - (4) connector to CN423. between CN423 (female)
are short circuited? . Turn starting switch ON. (2) - CN422 (2) -chassis
+ Wait for approx. 1 minute. ground
* Short circuit CNP2
pins (3). (4). Defective monitor panel Replace
* Turn starting NO
switch ON.
*Wait for approx. 1 minute.
M-7. c) Related electrical circuit diagram
CNPP CN214 CN153 CN422 CN423

Monitor panel (04012) (SWPI 6) (SWPG) (X2) (X2) Fuel level sensor
Fuel level
I
Bottom
level sensor
TDD00210
20-815.
0
TROUBLESHOOTING M-8
M-8. Service meter does not move after engine is started

Cause Remedy
1 YES
-
See M-4 a)
Does charge
abnormality
display flash?
* Start engine. NO
20-816
0
TROUBLESHOOTING M-9
M-9. Monitor panel lighting does not light up (front lamp is normal)
Check the lamp visually to check that the bulb is not blown. (If it is blown, replace the lamp.)
When fuse 4 is normal.
fuse - CN215(4) - CN216(3), or between CN216(2) - CN215(3) - CNlOl(7) - CN201(1) - CN203 (204) - light.)
Cause Remedy
1 YES
Is voltage
between CNPl
(7) and chassis Defective contact or
ground normal? disconnection in wiring
Repair or
harness between CNPI
NO replace
*20-30V (female) (7) and CN216
* Turn starting (female) (2)
switch ON.
. Turn front lamp
switch ON.
M-9. Related electrical circuit diagram
CNPI
0” Monitor panel (04016)
z
Work lamp switch 7
z
CNIOI CN215 CN216 Lamp
Lamp CN201 (X2) (SWPIS) (SWP8) switch
CN203
Battery relay Batten/

Fuse
TDW0212
20-817
0
TROUBLESHOOTING M-10
M-10. Lamp does not light up

Ir When the battery is normal.
Sr Check that fuse 4 is normal before carrying out troubleshooting.
a) Front lamp
Cause Remedy
Defective lamp (lamp

which does not light up) Repair or
or defective connection of replace
wiring harness
Repair or
replace
* Turn starting
YE switch ON. Replace
(3) and chassis *20-30V
* Turn front lamp
*20-30V switch ON.
I disconnection in wiring
Repair or
JO replace
switch ON. (female) (3) - CN215 (4) -
fuse 4
*Turn starting
switch ON + OFF. I
NO
IDefective battery relay Replace
M-10. a) Related electrical circuit diagram

CNPI
Monitor panel (04016)
CNIOI CN215 CN216 Lamp

Lamp CN201 (X2) (SWPIP) (SWPS) (KES4)
,q 3
3 3
Battery relay Battery

Fuse
cl+ IbAll IQ
TDD00212
20-818
0
b) Rear lamp (ripper lamp)
I Cause Remedy
Defective lamp (lamp

Repair or
or defective connection 01f replace
chassis normal? disconnection in wiring
I. harness between CN224 Repair or
Is voltage *20-30V
_ replace
YES between CN211 * Turn starting KN245 (1)) - CN153 (4) -
(2) and chassis switch ON. CN215 (I)-CN211
2 normal? *Turn rear lamp
I
Is voltage * Turn starting switch ON.
YE between CN211 Defective rear lamp
- switch ON. I Replace
(3) and chassis NO switch
*20-30V
normal?
*Turn rear lamp
.20-3ov switch ON.
disconnection in wiring Repair or
battery relay when * Turn starting harness between CN211
starting switch is NO replace
switch ON. (female) (3) - CN215 (2) -
B
-Turn starting
5 switch ON --f OFF. Reblace
jrive battery relay
z
M-10. b) Related electrical circuit diagram
CN153 CN215 CN216

Rear lamp CN223(Xl) (SWPG) (SWP8)
1 @ 3
CN224(Ml) -3
r:;‘-= ) -(Fuse
Ripper lamp CN245IXl) I
TDD00213
20-819
0
TROUBLESHOOTING M-II
M-l 1. Automatic preheating is not carried out when glow switch is set
to AUTO
Sr When the battery is normal.
* When fuse 10 is normal.
YES
I
.I’
YE
4
Is voltage
YEiS between CN212
(2) and chassis I individual part. NO
Note 1) 3 normal? * Turn starting switch OFF.
- Disconnect CN212.
L-l
Is there continuity 20-30V
i between starting Turn starting
switch terminal B switch ON.
Note 1) 2 and BR?
*Turn starting
switch ON.
* Leave terminal B NC1
Note 1) removed.
I ISsound heard from 1 1 * Put1-j Pole of 1
switch ON ; OFF.
NO
20-820
0
TROUBLESHOOTING M-II
Cause Remedy
8 YES
Defective heater relay Replace
Is voltage
YES between CNIOI
(2) and chassis Defective contact or
7 disconnection in wiring
p normal? Repair or
Is there continuity - ~ harness between CN213
between CN213 NO replace
*20-30V (female) (2) - CN214 (13) -
YE (male) (2) and (3) _ * Turn starting CNIOI (female) (2)
when glow switch ON.
6 switch is at AUTO
*Turn glow switch
position?
to AUTO.
chassis normal in * Check glow
switch as Defective glow switch Replace
NO
conditions given individual part.
‘Turn starting switch OFF. Defective contact or
*20-30V . Disconnect CN213. disconnection in wiring
Repair or
IO replace
switch ON. (female) (3) - CN212
-When ambient temperature [female) (I)
is -5 ’ C or below.
Defective bimetal timer
harness between starting Repair or
switch terminal BR - replace
EN214 (11) - CN212
Ifemale) (2)
Defective starting switch Replace
larness between starting Repair or
switch terminal B - CN214 replace
:12)-fuse lo-CN105 (I)
-battery relay terminal B
defective battery relay
Related electrical circuit diagram

Blower switch
Air conditioner I
relay
CN391
(KES4)
Air conditioner
compressor
CN351lXl) (SWPIZ)
TDMO216
20-821
0
M-12. Wiper does not work

* When the battery is normal.
Ir Check that each wiper fuse is normal before carrying out troubleshooting.
YES
Does wiper move

YES when wiper switch
is interchanged with
4 other wiper switch?
Does washer work * Turn starting

YES normally at place - switch ON.
where wiper does NO
* Turn wiper
not work?
switch ON.
-Turn starting % When other wiper switches are normal.
3 switch ON.
NO
I -Turn washer
‘ES r-
r
Do other wipers switch ON.
move? % When the washer is normal. z
- Turn starting
switch ON. NO
*Turn wiper
and BR?
switch ON.
Vote 1) % When other wipers are normal.
Is sound heard fror * Turn starting
battery relay when switch ON. JO
starting switch is - Leave terminal B
turned OFF? removed.
I
* Turn starting
NO
switch ON + OFF.
Note I) If the lamp (front lamp, rear lamp) or horn circuits are normal, it is also possible to carry out
troubleshooting by checking if the lamps light up normally or if the horn sounds normally.
Note 2) This troubleshooting flow chart uses the left wiper as an example. When checking the other
wipers, the connector No. corresponding to CNII at the cab end is as given in the table below.
Wiper position Left Front Right Rear
Connector No. CNII CN12 CN13 CN14
20-822
0
Cause Remedy
Note 2) 6 YES
Is 7 YES
1I Defective wiper motor Replace
l-
wiper arm
normal?
between terminals
unale) (2) - (3)of Defective wiper arm Replace
NO
Note 2)
motor (front wiper:
(5) - (2). rear wiper: Repair or
harness between CNI 1 (4
NO replace
-connector (2) directly in
. Min. 10 R iront of wiper motor
* Turn starting Ifront wiper: (5))
switch OFF.
Defective wiper switch
Vote 2)
*Defective contact or
harness between cab replace
end CN 11 (3) - cab end
fuse
Repair or
larness between battery
replace
.elay M - cab end fuse
30x terminal B
Defective starting switch Replace
Defective battery relay
20-823
0
Wiring harness for washer tor
a-z----J
Left wiDer switch I
Rear wiper motor
CN-11
Front wiDer switch I I-

\ Chassis ground
CN-9 Front wiper motor
CN-12
Right wiper switch
Rear wiper switch

I I I I I 1
CN-14
TDDO0214
20-824
0
M-13. Washer fluid is not sprayed out

* When the battery is normal.
sr Check that each wiper fuse is normal before carrying out troubleshooting.
1 L‘ES
Is washer motor I
5
turning (does
d
motor make Does wiper move
turning noise)? 1 YES at place where
washer fluid does
- Turn starting not come out?
switch ON.
*Turn washer * Turn starting
switch ON. i
switch (wiper
*Turn wiper I\JO
switch) ON.
move normally? switch ON.
Note I) 3 % When wiper is
- Turn starting normal.
Is there continuity
YES between starting switch ON. I
switch terminal B -Turn washer I
and BR? switch ON. NO
Note 1) 2
% When other
Is sound heard from - Turn starting washers are normal.
battery relay when switch ON.
I starting switch is - Leave terminal B
turned OFF?
JO
removed.
-Turn starting
switch ON -+ OFF.
NO
Note I) If the lamp (front lamp, rear lamp) or horn circuits are normal, it is also possible to carry out
troubleshooting by checking if the lamps light up normally or if the horn sounds normally.

For left washer Cab end CNI 1
For right washer Cab end CN13
For front washer Cab end CN12
For rear washer Cab end CN14
Washer CN... Fuse box
M
CN...
For left washer CN362
For right washer CN363
For front washer CN361
For rear washer CN364
Wiper switch TDD00215
20-826
0
Cause Remedy
Lack of water, clogged

Repair or
- nozzle, or defective water
replace
piping
8 YES
Defective washer motor
YES Is washer motor
- connected to
7
p ground?
Is voltage normal Repair or
p Defective ground
YES between CN26 NO replace
6 - (cab end) -
p Does condition chassis? Note 2)
become normal Defective contact or
*20-30V Repair or
when washer disconnection in wiring
* Turn starting NO replace
- switch is harness between cab end
interchanged with switch ON. CN360 - cab end CNI 1
other washer switch . Turn washer
(wiper switch)? switch ON. Defective washer switch
Replace
* Turn starting NO (wiper switch)
switch ON.
* Turn washer switch ON. Note 2)
X When other switches are normal. Defective contact or
harness between cab end replace
CNll (2),(3) -cab end
fuse
Repair or
replace
21 Defective starting switch Replace
71 Defective battery relay
Note 2) This troubleshooting flow chart uses the left washer as an example. When checking the other
washers, the connector No. corresponding to CNI 1 at the cab end is as given in the table below.
Washer position Left Front Right Rear
Connector No. CNII CN12 CN13 CN14
20-827
0
M-14. Air conditioner has no effect

-k When the battery and battery relay are normal.
Ir Check that fuse FB2 No. 3 is normal before carrying out troubleshooting.
j, Always connect any disconnected connectors before going on to the next step.
a) Air does not blow out
YES
5
Is continuity
YES between CN395
(4) (female) and
4 chassis normal?
Is continuity lMax. 1 R
YES_ betwaan blower _ . Turn starting
switch terminals as switch OFF. NO
3 shown in Table l?
Is voltage *Turn starting

YES between CN395 _ switch OFF.
(3) and chassis NO
- Disconnect
2 normal? CN395.
Is resistance *20-30V
YES between CN391 _ *Turn starting
(male) (1) and (3) switch ON. NO
1 normal?
Is voltage .240+4IJD
between CN391 _ *Turn starting
(1) and chassis switch OFF. NO zz
ground normal? * Disconnect
5
CN391.
.20-30V 5;
-Turn starting
switch ON. NO

Blower switch
Blower motor
TDO00216
20-828
0
Cause Remedy
YES
r~-_,
YE between CN391
(4) and chassis
I;
Defective air conditioner
Is voltage Replace
NO relay
between CN391 -Turn starting
(2) and chassis switch ON.
ground normal? * Blower switch:
Other than OFF Defective contact or
*20-30V disconnection in wiring Repair or
1
* Turn starting harness between fuse 8 - replace
NO
switch ON. CN391 (l),(2)
harness between CN395 replace
(3) and chassis ground
Defective blower switch
13) and CN395 (3)

relay
harness between fuse 8 - replace
CN215 (8) - CN391 (l),(2)
Table 1
hPosition1 1 1 1 1
\I
erminal
B ILWILYI L
20-829
0
12 YES
YE :S
pHp
* Max. 1 !A NO
*Turn starting
switch OFF.
IO
* Disconnect
Is resistance CN394 and CN395.
. Max. 1 R
YES between CN394
- . Turn starting
(male) (2) - (I) or NO
switch OFF.
9 (2) - (3) normal?
* Disconnect
. Between (2) - (3): CN394.
YES Does blower _ 32 0.3R
motor rotate? - Between (2) - (I): NO
a 1 to.1 a
*Turn starting switch OFF.
Is voltage * Turn starting s:
* Disconnect CN394.
A_ between CN392 _ switch ON.
(1) and chassis 5
* Blower switch: NO
normal? Other than OFF z
*20-30V
*Turn starting
switch ON. NO
. Blower switch:
Other than OFF
20-830
0
Cause Remedy
Go to Item b)
Defective blower resistor Replace
Defective.blower motor Replace
20-831
0
b) There is no cooling effect
YES
5
Is continuity
YES_ between CN397 (2) _
(female) and CN398
(female) (3) normal?
4
pzG- * Max. 1 R
YES between CN397 * Turn starting
switch OFF. NO
1 frr;e$3) and (2) -
* Max. 1 R
YE * Turn air
between CN397
conditioner
(1) and CN395 (3)
switch ON.
2 * Disconnect
* Max. 1 ~2 CN397.
Yl between CN397 * Turn starting
(male) (3) and (1) switch OFF.
- Max. 1 R
between CN397 * Turn air
(3) and chassis conditioner
switch ON.
* Disconnect
*20-30V
CN397.
-Turn starting
switch ON.
20-832
0
Cause I Remedy
7 YES GotoBon - -
Is continuity next page
YES between CN398
r (1) and CN395 (3) Defective contact or
6
~ normal? disconnection in wiring Repair or
Is resistance harness between CN398 replace
. Max. 1 R NO
between magnet (1) and CN395 (3)
relay (3) and (1) *Turn starting
normal? switch OFF.
*240*40R
Defective magnet relay Replace
* Turn starting NO
switch OFF.
(2) CN398 (3)

Replace
switch
(1) and CN395 (3)

Replace
switch
harness between fuse 8 - replace
CN215 (8) - CN397 (3)
20-833
0
12 YES
Is voltage
YES between CN351
(I) and chassis
normal?
11 NO
- .20-30V
Is voltage -Turn dual
YES between CN393 _ pressure switch
(4) and chassis ON.
normal? . Turn thermostat
10 switch ON.
- .20-30V
z See Note 1).
Is voltage 9Turn dual
YE between CN393 _ pressure switch
(1) and chassis ON. NO
normal? -Turn thermostat
9 switch ON.
.20-30V
I See Note I).
*Turn starting
YE iS between switch ON.
II
CN391
(4) and chassis * Blower switch: NO
Other than OFF
*Turn air
.20-30V conditioner
*Turn starting switch ON.
between CN398 switch ON.
B (2) and chassis . Blower switch: ~0
Other than OFF
*Turn air
*20-30V
conditioner
* Turn starting
switch ON.
switch ON.
N0
Note 1) ON-OFF selection voltage of dual pressure switch

Refrigerant circuit pressure:
OFF (when rising) at 2.6 MPa (27 kg/cm?

High pressure side
ON (when going down) at 2.1 MPa (21 kg/cm*)
OFF (when going down) at 0.21 MPa (2.1 kg/cm*)

Low pressure side
ON (when rising) at 0.24 MPa (2.35 kg/cm*)
. ON-OFF selection temperature of thermostat switch

Evaporator discharge pressure:
OFF (when going down) at 1°C or below
ON (when rising) at 4.5”C or above
20-834
8
I Cause Remedy
( F&$iiv;s;r conditioner lepair or

eplace
lepair or
eplace
(4) - CN215 (7) - CNlOl
(9) - CN351 (I)
Defective dual pressure

leplace
’ switch
lepair or
eplace
Defective magnet relay leplace
disconnection in wiring Sepair or
harness between fuse 8 - eplace
CN215 (8) - CN398 (2)
20-835
0
M-15. Overrun alarm continues to sound

Serial No. : 60001 - 60271
% Note: If there is a disconnection (defective contact) in the wiring harness between the HMT
controller - relay - monitor panel, the warning will not sound even if there is overrun.
Cause Remedy
YES Iefective overrun alarm

.elay
2 YES
Does condition Defective HMT controller Replace
Is resistance
become normal
between CN003
when relay is Short circuit with chassis
(female) (1 I) and -
replaced? ground in wiring harness
chassis normal? Replace wiring
between CN003 (female)
. Turn starting NO harness
* Turn starting (11) -CNll (5) -relay
switch ON.
switch OFF. (016) terminal (2)
* Disconnect
Nk CN003, relay (016).
. Min 1 MR
3 YES
Is resistance
between CNPl
(female) (II) and Short circuit with chassis
chassis normal? ground in wiring harness
Replace wiring
between CNPl (female)
NO harness
*Turn starting (11) -CN214 (6) -relay
switch OFF. (016) terminal (3)
. Disconnect
CNPl, relay (016).
* Min 1 MD
Overrun alarm relay
Fuse
CNOI 1 CN214
(SWPI 2) (SWPIG)
TDD00217
20-836
@
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL .................. .30- 3 RADIATOR, OIL COOLER, GUARD

PRECAUTIONS WHEN CARRYING OUT Removal ............................................... .30- 54
OPERATION ........................................... .30- 5 Installation.. .......................................... .30- 56
SPECIAL TOOL LIST ..................................... 30- 7 FAN DRIVE
SPECIAL TOOL SKETCH .............................. 30-16 Removal ............................................... .30- 57
STARTING MOTOR Installation.. .......................................... .30- 59
Removal and Installation ..................... .30-26 HYDRAULIC COOLER
ALTERNATOR Removal and Installation ................... .30- 60
Removal and Installation ..................... .30-27 ENGINE
ENGINE OIL COOLER CORE Removal ................................................ 30- 61
Removal and Installation ..................... .30-28 Installation.. .......................................... .30- 63
FUEL INJECTION PUMP DAMPER
z? Removal .................................................. 30-29 Removal ............................................... .30- 64
E Installation ............................................. .30-30 Installation.. .......................................... .30- 65
;; WATER PUMP Disassembly.. ....................................... .30- 66
Removal and Installation ..................... .30-31 Assembly .............................................. 30- 69
TURBOCHARGER POWER TRAIN UNIT
Removal and Installation ..................... .30-32 Removal ................................................ 30- 73
NOZZLE HOLDER Installation.. .......................................... .30- 78
Removal and Installation ..................... .30-33 Separation.. .......................................... .30- 79
ENGINE FRONT SEAL Connection ........................................... .30- 84
Removal and Installation ..................... .30-34 PTO
ENGINE REAR SEAL Disassembly.. ....................................... .30- 86
Removal ................................................. .30-35 Assembly ............................................. .30- 90
Installation ............................................. .30-36 HMT
CYLINDER HEAD Disassembly.. ....................................... .30- 95
Removal ................................................. .30-38 Assembly ............................................. .30-109
Installation ............................................. .30-42 HSS CASE
THERMOSTAT Disassembly.. ........................................ 30-I 26
Removal and Installation ..................... .30-44 Assembly ............................................. .30-135
AIR CONDITIONER COMPRESSOR POWER TRAIN, LUBRICATION PUMP
Removal ................................................. .30-45 Removal ................................................ 30-148
Installation ............................................. .30-46 Installation ............................................ 30-I 49
AIR CONDITIONER CONDENSER SCAVENGING, CHARGE PUMP
Removal ................................................. .30-47 Removal and Installation .................. ..30-15 0
Installation .............................................. 30-48 HMT PUMP
FUEL TANK Removal ............................................... .30-151
Removal ................................................. .30-49 Installation ........................................... .30-152
Installation ............................................. .30-50 Disassembly ...................................... 30-I 52-l
RADIATOR Assembly ........................................... 30-I 52-7
Removal ................................................. .30-51
Installation ............................................. .30-53
30-l
0
HMT MOTOR TRACK SHOE
Removal ............................................... .30-153 Checking before removal ................... .30-223
Installation ........................................... .30-155 Removal (normal) ............................... .30-223
Disassembly.. .................................. .30-l 55- 1 Removal (when there is abnorma-
Assembly ........................................ .30-155-10 lity inside track frame) ............. ..30-223- 1
PPC, EPC, HMT CHARGE VALVE Installation ........................................ .30-223-2
Removal and Installation ................... .30-156 Overall disassembly.. .......................... .30-224
Disassembly.. ....................................... .30-l 57 Overall assembly.. ............................... .30-229
Assembly ............................................. .30-158 PRESS-FITTING JIG DIMENSION
HMT CONTROL VALVE TABLE FOR LINK PRESS .................... .30-243
Removal ............................................... .30-159 ONE LINK
Installation ........................................... .30-161 Disassembly.. ....................................... .30-244
Disassembly and Assembly.. ............. .30-162 Assembly ............................................. .30-246
HSS MOTOR MASTER LINK
Removal and Installation ................... .30-163 Disassembly.. ....................................... .30-248
Disassembly .................................... ..30-163- 1 Assembly ............................................. .30-250
Assembly ......................................... ..30-163- 5 PIVOT SHAFT
STEERING EPC VALVE Removal and Installation ................... .30-253
Removal and Installation ................... .30-164 EQUALIZER BAR
BRAKE VALVE Removal ............................................... .30-254
Removal and Installation ................... .30-165 Installation ............................................ 30-255
Disassembly.. ....................................... .30-l 66 EQUALIZER BAR SIDE BUSHING
Assembly ............................................. .30-l 67 Removal and Installation ................... .30-256
FINAL DRIVE SEGMENT TEETH
Removal ............................................... .30-168 Removal and Installation ................... .30-257
Installation ........................................... .30-170 HYDRAULIC TANK
Disassembly.. ....................................... .30-171 Removal and Installation ................... .30-258 2
Assembly ............................................. .30-176 HYDRAULIC, HSS PUMP W
TRACK FRAME Removal and Installation ................... .30-259 z
Removal ............................................... .30-182 Disassembly .................................... ..30-259- 1
Installation ........................................... .30-184 Assembly .......................................... .30-259-7
IDLER MAIN CONTROL VALVE
Removal ............................................... .30-185 Removal ............................................... .30-260
Installation ........................................... .30-186 Installation ........................................... .30-262
Disassembly.. ....................................... .30-187 Disassembly.. ....................................... .30-263
Assembly ............................................. .30-l 89 Assembly ............................................. .30-267
RECOIL SPRING HMT OIL COOLER BYPASS VALVE
Removal and Installation ................... .30-192 Removal and Installation ................... .30-272
Disassembly.. ....................................... .3b-193 Disassembly and Assembly ................ 30-273
Assembly ............................................. .30-198 BLADE PPC VALVE
TRACK ROLLER Removal ............................................... .30-274
Removal ............................................... .30-199 Installation ........................................... .30-275
Installation ........................................... .30-200 RIPPER PPC VALVE
Disassembly.. ....................................... .30-201 Removal ............................................... .30-276
Assembly ............................................. .30-204 Installation ........................................... .30-277
BOGIE PPC VALVE
Removal ............................................... .30-207 Disassembly and Assembly.. ............. .30-278
Installation ........................................... .30-209 BLADE PPC VALVE
Disassembly.. ....................................... .30-210 Disassembly and Assembly.. .......... .30-279-l
Assembly ............................................. .30-213 BLADE LIFT CYLINDER
CARRIER ROLLER Removal and Installation ................... .30-280
Removal and Installation ................... .30-217 BLADE TILT CYLINDER
Disassembly.. ....................................... .30-218 Removal and Installation ................... .30-281
Assembly ............................................. .30-220
30-2
8
RIPPER LIFT CYLINDER
Removal and Installation ................... .30-282
RIPPER TILT CYLINDER
Removal and Installation .................... 30-283
HYDRAULIC CYLINDER
Disassembly.. ....................................... .30-284
Assembly ............................................. .30-287
BLADE
Removal ............................................... .30-291
Installation ........................................... .30-292
Disassembly.. ....................................... .30-293
Assembly ............................................. .30-295
MULTI-SHANK RIPPER
Disassembly.. ....................................... .30-297
Assembly ............................................. .30-299
ROPS GUARD
OPERATOR CAB
HOOD
FLOOR FRAME
Removal ............................................... .30-304
Installation ........................................... .30-309
DASHBOARD
Removal ............................................... .30-311
g Installation ........................................... .30-312
5 MONITOR
z Removal and Installation ................... .30-313
GOVERNOR MOTOR
JOYSTICK
ENGINE THRO-lTLE CONTROLLER
HMT CONTROLLER
30-2-l
@
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
METHOD OF USING MANUAL

1. When removing or installing unit assemblies
@ When removing or installing a unit assembly, the order of work and techniques used are given
for the removal operation; the order of work for the installation operation is not given.
@ Any special techniques applying only to the installation procedure are marked jl, 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 OQOQASSEMBLY . . . . . . . .. . . Title of operation

A . . . . . .. . . . . . .. .. . . . . . . . . .. . . . . .. . . . . . . . . . .. . . . . . . .. . . . . . .. . . . . . . Precautions related to safety when carrying out the operation
1. xxxx (I) . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . .. . . . . . .. . . . . Step in operation
* . . . . . . . . .. . . . . . .. . . . . . . . .. . . . . . . . . .. . . . . . .. . . . . . . .. . . . . . . . .. Technique or important point to remember when
removing x x x x (I).
2. n n a A(2) . . . . . . . . . .. . . . . . .. . . . . . .. . . . . . . . .. . . . . . . .. . . m ..........Indicates that a technique is listed for use
during installation
3. 0 0 0 0 assembly (3)
.(. .............................................................See Lubricant and Coolant Table
INSTALLATION OF OOoOASSEMBLY...Title of operation

l Carry out installation in the reverse order to removal.
m . .. . . . . . .. . . . . . . . . .. . . . . . .. . . . . . .. . . . . . . .. . . . . . . . .. . . . . . .. . . . . .Technique used during installation
* . . .. . . . . . . . .. . . . . . . .. . . . . . .. .. . . . . . . . .. . . . .. . .. . . .. . .. . . . . . . Technique or important point to remember when
installing (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 PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to
follow these precautions when carrying out the operation.
3. Listing of special tools

@ For details of the description, part number, and quantity of any tools (Al, etc.) that appear
in the operation procedure, see the SPECIAL TOOLS LIST given in this manual.
@ Special tools marked * in the table cannot be supplied.
@ Special tools with part number 790T-000-0000 in the table are prohibited for supply.
@ Special tools marked 0 in the sketch column are tools introduced in this manual in
sketches for special tools.
However, note that Komatsu cannot accept any responsibility for special tools manufactured
according to the sketch.
30-3
@
4. General tightenin! I torque table (when using torque wrench)

* In the case of metri : nut and bolts for which there is no special instruction, tighten to the torque
given in the table b !lOW.
Thread diameter Width across flats

SAD00481 SAD00482
mm mm kgm Nm
6 10 1.35kO.15 13.221.4
8 13 3.2kO.3 31.4k2.9
10 17 6.7kO.6 65.7a6.8
12 19 11.5al.O 11229.8
14 22 18.01-2.0 177119
16 24 28.5i3 279k29
18 27 3924 383a39
20 30 5626 549k58
22 32 76+8 745k78
24 36 94.5klO 927298
27 41 135k15 1320+140
30 46 175+20 1720+190
33 50 225k25 221O-c240
36 55 28Oe30 275Ok290
39 60 335235 328Ok340 g
,Sealing surface 5
b
5. Table of tightening torques for flared nuts
* In the case of flared nuts for which there is no special
instruction, tighten to the torque given in the table
below.
Thread diameter Width across flats Tightening torque
mm mm kgm Nm
14 19 2.5kO.5 24.554.9
18 24 5kl 49219.6
22 27 8k.1 78.5219.6
24 32 1423 137.3k29.4
30 36 18+3 176.5k29.4
33 41 2025 196.1+49
36 46 2525 245.2+49
42 55 3Ok5 294.2249
6. Table of tightening torques for split flange bolts

Ir In the case of split flange bolts for which there is no special instruction, tighten to the torque given
in the table below.
Thread diameter Width across flats Tightening torque
mm mm kgm Nm
14 14 6.750.7 65.7k6.8
18 17 11.5+1 11229.8
22 22 28.5&3 279+29
30-4
0
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the
general precautions given below when carrying out the operation.]
1. Precautions 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 neces-
sary places before removal to prevent any mistake when assembling.
. To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors. Do not pull the wires.
. Fit wires and hoses with tags to show their installation position to prevent any mistake when
installing.
Check the number 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 uniformly in
turn.
. Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt
from entering after removal.
* Precautions when handling piping during disassembly
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
I) Hoses and tubes using sleeve nuts
Nominal number Plug Sleeve nut (elbow end) Use the two items below as a set
02 07376-50210 07221-20210(Nut), 07222-00210(Plug)
03 07376-50315 07221-20315(Nut), 07222-00312(Plug)
04 07376-50422 07221-20422(Nut), 07222-00414(Plug)
05 07376-50522 07221_20522(Nut), 07222-00515(Plug)
06 07376-50628 07221-20628(Nut), 07222-00616(Plug)
10 07376-51034 07221-21034(Nut), 07222-01018(Plug)
12 07376-51234 07221-21234(Nut), 07222-01219(Plug)
2) Split flange type hoses and tubes
Nominal number Flange (hose end) Sleeve head (tube end) Split flange
04 07379-00400 07378-I 0400 0737 I-30400
05 07379-00500 07378-I 0500 0737 I-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
27 ~~~49-02734 1 22.5 1 34
30-5
0
2. Precautions when carrying out installation work

Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
Install the hoses without twisting or interference.
Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
Bend the cotter 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 w/th gasket sealant, clean the surface and remove all oil and grease, check that there
is no dirt or damage, then coat uniformly with gasket sealant.
Clean all parts, and correct any damage, dents, burrs, or rust.
Coat rotating parts and sliding parts with engine oil.
When press fitting parts, coat the surface with anti-friction compound (LM-P).
After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then
connect securely.
When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and
align the direction of the hook.
When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one
side.
When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and
other hydraulic equipment removed for repair, always bleed the air as follows:
1. Start the engine and run at low idling.
2. Operate the work equipment control lever to operate the hydraulic cylinder 4 - 5 times,
stopping 100 mm from the end of its stroke. s:
3. Next, operate the hydraulic cylinder 3 -4 times to the end of its stroke. 5
4. After doing this, run the engine at normal speed. z
Ir When using the machine for the first time after repair or long storage, follow the same
procedure.
3. Precautions when completing the operation

. If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run
the engine to circulate the water through the system. Then check the water level again.
. If the hydraulic equipment has been removed and installed again, add engine oil to the specified
level. Run the engine to circulate the oil through the system. Then check the oil level again.
. If the hydraulic equipment has been removed for repair, always bleed the air from the system after
reassembling the parts. For details, see TESTING AND ADJUSTING, Bleeding air.
. Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
30-6
0
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

rro Remarks
Nature of work ;ymbol Part No. Part Name ;sg?
l Removal, installation of
nozzle holder assembly
* Removal, installation of
A 795-570-I 100 Remover assembly 1 Removal of nozzle holder
cylinder head assembly I I
I I i
I I I
l Removal, installation of
cylinder head assembly Wrench Tightening of cylinder
I3 790-331-1110 (angle tightening method) ’
l Removal, installation of head, flywheel bolts
engine rear seal I 1 I
1 791-612-1100 Installer assembly 1
l-l . 790-201-2220 - Plate 10
Disassembly, assembly Press fitting of damper

of damper assembly
Disassembly, assembly of
HMT assembly
791-622-1110 1 Bracket III I
I I ,
01010-31685 Bolt Removal, installation of

1 1
clutch brake assembly
8 01017-31620 Bolt 1
5
z Disassembly, assembly oF
2
790-302-I 500 Wrench kit 1 Removal, installation of
round nut for holding
HSS case assembly l 09003-09200 Wrench 1 pinion shaft bearing
1 790-302-I 500 Supanar kit 1

5
l-l l 09003-08290 l Wrench 1
I I I I I I
Checking operation of
799-301-I 600 Leak tester 1 clutch piston
Removal, installation of
final drive assembly
2 01010-52080 Bolt 2
3 01643-32060 Washer 2
1 790-101-2310 Block 1
2 790-I 01-2550 Leg 2
3 790-101-2730 Adapter 2
4 790-101-2360 Plate 2
Disassembly, assembly Removal of sprocket hub
of final drive assembly , 5 790-I 01-2560 Nut 2
6 01643-32060 Washer 2
7 791-650-I 130 Bracket 10
8 790-101-2102 Puller (30 ton) 1
9 790-101-1002 Pump 1
Installation of floating
791-580-1510 1
_L 2 Installer seal
30-7
0
P-5
Nature of work Symbol Part No. Part Name .* Remarks
02
Press fitting of sprocket

hub bearing
Disassembly, assembly
of final drive assembly
Removal of planetary
of idler assembly
7 790-101-2102 Puller (30 ton) 1
8 790-101-1102 Pump 1
J
Installation of idler
2 796-670-I 020 Installer 1 floating seal
3 791-601-1000 Oil pump Filling idler with oil

I
1 791T-630-1600 Installer assembly 1
l-l l 79 I-685-8501 l Compressor 1
1-2 l 791T-630-1150 l Spacer 10

1-3 l 791T-630-1160 l Spacer 1 0 Disassembly, assembly of
1 . recoil spring assembly
2 791-635-3160 Extension 1
of recoil spring assembl,
3 04530-01222 Eyebolt 1
4 790-101-1600 Cvlinder (70 ton) 1
5 790-101-1102 Pump 1
2 790-445-4210 Push tool Press fitting of recoil.
1 sprmg cylrnder bushmg
30-8
0
Nature of work symbol Part No. Part Name

rro Remarks
gg
Press fitting of recoil

spring case yoke
of recoil spring assembl)
Removal of recoil spring
1 1 790-101-2680 1 Adapter
121 I
2 1 790-101-2550 Leg 121 I
3 790-101-2510 Block 1
4 790-101-2570 Washer 4
Disassembly, assembly 790-101-2560 Press fitting of track
5 Nut 2
of track roller assembly roller seal guide
6 790-201-2730 Spacer IO
7 1 791T-630-1340 ( Spacer I1 loI

8 / 790-101-2102 1 Puller 294.2 kN 131 ton1 1 I I I
9 1 790-101-1102 1 Pump
III I
assembly part no.:

791-630-1500
Removal, press fitting of
of bogie assembly
l 791-630-1430
9 l 791-630-1520 l Nut 2
10 l 791-630-1530 l Extension 1
11 l 791-630-1510 l Shaft 2
30-9
6%
Nature of work
T
Symbol Part No. Part Name
r5
52
v,
Remarks
11 - 791-630-1540 l Adapter 1 - Remover, installer

assembly part no.:
12 l 791-630-1560 l Adapter 1
791-630-1500
13 l 04530-I 2030 l Eyebolt 1 Removal, press fitting of
1
14 l 04530-I 1018 l Eyebolt 2 pin assembly
15 l 01643-31032 l Washer 4
16 . 791T-630-1440 l Spacer 1
2 790-101-4300 Cylinder 1471 kN {I50 ton} 1 Removal, press fitting of

3 790-101-1102 Pump 1 pin assembly
11 1
I
l 791-685-9510 1 . Frame
I
Ill
I I
I l Remover, installer
assembly part no.:
2 l 79 I-685-9520 l Frame 1
791-630-1500
3 l 791-685-9530 l Rod 1
4 l 79 I-685-9540 l Rod 1
5 l 791-685-9550 l Nut 3
4
6 l 791-685-9560 l Bolt 4
7 l 791-630-1510 l Shaft 2
8 l 79 1-630-I 520 l Nut 2
9 l 791-630-1530 i Extension 1
Disassembly, assembly Removal of shaft
of bogie assembly K 10 l 791-630-1550 l Adapter 1
Ill ( l 791-630-1560 1 Adapter

l
Ill I
1151 l 791-630-1440 I l Spacer III I

I 16 1 l 791-630-1450 I l Spacer III I
5 I 790-101-4300 / Cvlinder 1471 kN 1150 ton) I 1I I
6 790-101-1102 Pump 1
1 l 791-685-9510 l Frame 1 . Remover, installer

2 l 791-685-9520 l Frame 1 assembly part no.:
791-630-1500
3 l 791-685-9530 l Rod 1
4 1 l 791-685-9540 j l Rod III I

5 l 791-685-9550 l Nut 3
Assembly of shaft
6 l 79 I-685-9560 . Bolt 4
71 l 791-685-9620 I l Extension III I

8 I l 791-630-1510 I l Shaft 121 I
9 1 l 791-630-1520 I . Nut 121 I
10 l 791-630-1530 l Extension 1
11 . 791-630-1540 l Adapter 1
30-10
8
rZ
Nature of work I;ym bol Part No. Part Name Remarks
791-630-1500
Disassembly, assembly Assembly of shaft

of bogie assembly
Disassembly, assembly 01
carrier roller assembly
2
5 Overall disassembly,
z
assembly of track
shoe assembly
Disassembly, assembly Disassembly of a single
of a single link in field

rz
Nature of work Symbol Part No. Part Name .+ 5 Remarks
us
1 791-675-9570 1 Adapter III I
01010-51030 Bolt 1
3 04530-I 2030 Eyebolt 1
790-101-1102 Pump III I
790-101-4300 1 Cylinder 1471 kN {15Oton)/ 1 1 I

791-685-9540 Rod 1
4
791-685-9550 Nut 1
791-685-9510 Frame 1
r-- 791-685-9520 Frame III I

791-685-9530 Rod 4
Disassembly of a single
791-685-9550 Nut 1 link
791-675-5530 Pusher III I

791-675-9570 I Adapter III I
of a single link in field
I 01010-51030 / Bolt III I
1 790-101-4300 1 Cylinder1471 kNI150tonII 1 1 1

790-101-1102 Pump 1
6
790-101-4200 Puller 294.2 kN {30 ton} 1
791-675-5542 Adapter 1
791-675-5571 Adapter 1
7
790-101-1102 Pump 1
I 790-101-4300 I Cylinder 1471 kN ~l~ton~~ I 1 I

8 791-675-5580 Guide 1
791-685-9510 Frame 1
Assembly of a single
791-685-9520 Frame 1
link
791-685-9530 Rod 1
9 I 791-685-9540 1Rod
01010-51030 Bolt III I
30-12
@
rS
Nature of work Symbol Part No. Part Name Remarks
52
Disassembly, assembly Assembly of a single

of a single link in field link
g
5
z
790-101-1102 Pump 1
13
790-101-4200 Puller 294.2 kN I30 ton} 1
30-l 3
8
rS
Nature of work Symbol Part No. Part Name 52
Remarks
of master link
I I I I I
1 t 791T-650-2100 Installer assembly 1
l-l l 791T-650-2110 Sleeve 10
l-2 l 791T-650-2120 Plate 10

Press fitting of pivot
l-3 ’ 790-201-3310 Bolt 1
shaft ring
Removal, installation of
1 l-4 l 790-101-2510 Block 1
pivot shaft assembly
II-51 l 790-101-2570 1 Washer III I
‘I-6 . 01580-01613 Nut 1
2 790-105-2300 Puller 196 kN {20 ton) 1
Pump 1
’ Press fitting of pivot
3 790-101-1102 shaft ring
1 I or 791T-650-2010 I Remover assembly III I

I-II l 791T-650-2130 I . Sleeve I1 lol
i-21 l 791-181-1010 j l Adapter Ill I

l-3 791-50224140 l Screw 1
1
l
equalizer bar center pin

l-4 l 790-101-2540 l Washer 1
l-5 l 791-112-1180 l Nut 1
2 790-101-4000 Puller 490.3 kN (50 ton} 1
Removal, installation 0 3 790-101-1102 Pump 1

equalizer bar assembly
1 $i 791T-650-2200 Remover&installer assembly 1
II-11791-827-1510
l l Sleeve 11 lol
1-21 l 791T-650-2210 I - Sleeve I I lol
l-3 l 790-438-I 110 l Screw 1
eaualizer bar side
I 3 I 790-101-1102 I Pump
30-14
@
>G
S$
790-502-1003 Cylinder repair stand 1

1 For reducing labor
790-101-1102 Pump 1
2 790-I 02-3802 Multi-wrench 1 Removal and assembly

- of round head
1 1 790-720-1000 ( Expander
I
Ill
I I
I Expansion
I
of piston ring
I
796-720-I 670 Ring 1

Blade lift
07281-01279 Clamp 1
Disassembly, assembly - I
Fo;KrF fitting coil
of hydraulic cylinder 790-201-I 702 Push tool kit 1
assembly
l 790-201-1821 l Push tool 1 Blade lift
Ripper lift
l 790-201-1831 l Push tool 1 Ripper tilt
4
l 790-201-1841 l Push tool 1 Blade tilt
l 790-101-5021 l Clip 1
l 01010-50816 l Bolt 1
790-201-1500 l Push tool kit 1 For press fitting dust seal
l 790-201-I 630 l Plate 1 Blade lift

I I I I
Ripper lift
790-201-1640 Plate 1
l l
Ripper tilt
5 I I
l 790-201-1650 l Plate 1 Blade tilt
* 790-101-5021 l Grip 1
l 01010-50816 l Bolt 1
799-703-I 200 Service tool kit 1
Charging with freon gas S I 799-703-1100 I Vacuum DUtTlD III I
799-703-I 400 Gas leak tester 1
790-501-5000 Unit repair stand 1 For Japan
assembly 790-501-5200 Unit repair stand 1 For overseas

Disassembly,
1
of HMT pump Bracket 1
790-901-2110
I 792-901-1343 I Plate II lol

790-101-1102 Bolt 1
I-
0101 E2060 Bolt 1
Removal, installation 110 Washer 10

796-465-l
of HMT pump cylinder 2
01643-33080 Washer 1
block spring
I 01643-32060 I Washer I21 I
01580-02016 Nut 1
30-15
0
>s
Nature of work
T Symbol Part No. Part Name Remarks
Setting neutral
position of HMT pump
servo piston
Press-fitting of HMT
pump oil seal
of HMT motor
Securing HMT motor

shaft
of HMT motor
cylinder block
Press fitting of HMT

motor bearmg
Press fitting of HMT

motor sub bearing
Press fitting ‘of HMT

motor oil seal
of hydraulic, HSS
pump
Removal, installation
of hydraulic, HSS
pump cylinder block
01643-32060 Washer 1
spring
01580-02016 Nut 1
30-M-l
0
T
z-6
23
Removal, installation
of hydraulic, HSS
pump servo piston rod
Positioning hydraulic,
HSS pump servo
piston swash plate
angle
Press fitting of
hydraulic, HSS pump
oil seal
of HSS motor
r-
z Removal, installation
of HSS motor cylinder
block spring
Press fitting of HSS motor

main bearing inner race
Press fitting of HSS motor
sub bearing inner race
Securing HSS motor
shaft
Press fitting of HSS
motor oil seal
30-15-2
0
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL SKETCH
SPECIAL TOOL SKETCH

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these
sketches.
Cl-l-l Plate
co.5
-
co.5
DDDO!l850
HEAT TREATMENT MATER!AL
co.5
c 0.5
L
790-201-2220 A
Cl-l-2 Spacer
PART NAME
STKMIGA may also be used for the material in this sketch. 790-201-2750 A
F2-1 Plate
!
-
8
h T
\
Cl0
I
,I Cl0 L
2-22 DRILLS / 24 67.5 DDWOBU
t
I
HEAT TREATMENT MATERIAL
I??--/-
.._ SS4WP
/
I PAFiT NAME
PLATE I
QTY
791T-627-1340 A
Gl-7 Bracket
-f
SEE DEG
02 TUBE STKMlW 1 2.52 0177.8 x f10 PART NAME Q-I-Y
BRACKET 1
01 PLATE ss4lP 7 3.67 f19
WM. PART NAME MATERIAL QTYf%T r REMAFKES 791-650-1130 A
30-l 7
0
G3-5 Plate
circumference
27 DRILL
G3-6 Sleeve
30-l 8
0
G4-1 Spacer
co.5 co.5
co.5 co.5
SPACER 1
791T-627-1380 A
Hl-1 Plate
2-14 DRILLS DDW0858
-6
I-
32
v 791T-630-1230 n
11-I-2 Spacer
DDCOO859
791T-630-1150 A
11-l-3 Spacer
DDCO3860
CI Cl HEAT TREATMENT
12z3xm3w
500 PART NAME
30-20
0
14-6 Spacer
co.5 co.5
co.5
1225M)14Ol (HnC3-361 s43c
PART NAME QlY
SPACER 1
v (W)
Jl Plate
2-14 DRILLS /
DDW0862

... SS4ooP
PART NAME QTY
PLATE 1
l-4
32
791T-630-1290 A
30-21
0
J2-6 Spacer
co.5 ., co.5
+<
100
< > DDDOU263
HEAT TREATMENT MATERWL
122m14ca S43C
I
PART NAME al-f
SPACER 1
52-7 Spacer
1
D a
DDNX64
,
1223001900 STKMlSA
Cl Cl
PART NAME Q-w
SPACER 1
485~0.2
< >
791T-630-1340 A
30-22
0
L3 Spacer
\I
0
7
I\
-- F
a
D a
V
791T-630-1350 A
Pl-l-l Sleeve
80
465.5kO.2
1
I
HEAT TREATMENT h4ATERlAl
___ SEE DWG
02 TUBE STKM164 1 PART NAME al-v

17.7 01Soxt10
SLEEVE 1
01 PLATE S4WP 1 2.7 m
SYM. PART NAME MATERIAL Ql-%SET

MASS
tksj REMAFKES 791T-650-2110 A
30-23
0
PI-l-2 Plate
DDDOX67
Cll I
Cl
22
--I-k 791T-650-2120
01-1-l Sleeve
Cl
DDWO853
HEAT TREATMENT MATERLAL

._. SEE DWG
PAFtT NAME al-f

TUBE STKMXW 1 5.64 01X,x37
SLEEVE 1
PLATE SS4OOP 1 0.99 t12
PART NAME MATER!AL QrffSET ;$S REhJARKES 791T-650-2130 A
30-24
0
QZ-l-l Sleeve
---___-
““l-x-cm%
HEAT TREATMENT MATEFOAL
i .__ SEE DEG

I I I QP/
TUBE STKMlW 1 PART NAME
02 2.07 0152.4 xl22
SLEEVE 1
01 PLATE S4coP 1 2.99 a2
SYM. PART NAME MATERIAL QWSET y REMARKES 791-827-1510 A
02-l-2 Sleeve
DDiXB370
SEE DEG
PART NAME QTY

02 TUBE STKMlW 1 1.55 012oxt5
SLEEVE 1
01 PLATE SS4WP 1 1.51 f19
SYM. PART NAME MATER!AL QWSET zSS REMARKES 791T-650-2210 n
30-25
0
T-l, U-l, V-l, W-l Plate
i 200 260 -' UNIT: mm
130 295
I /
1. -
w
IL3 I IL91 >, 7-22L
/I -
/_ 88.4 1 88.4 DAD01261
2-18DRILLS
670
L
720
1 790-901- 1343 n
T-2, U-3, V2, W-2 Washer
1
UNIT: mm
c1.5
I
I
‘4
P
3
HEAT TREATMENT
1225001400
DAD01262
MATERIAL
s43c
0-w
I PART NAME
PLATE I 1
v 1 796-465- 1110 A
30-25-l
0
T-4, V-5 Spacer
UNIT : mm
A
1
“! -!
0 0 - - - - -. -
+/ +I
R B
B. a
co.5 co.5
J
J
co.5 co.5
DAD01263

1225001400 s43c
I PART NAME
SPACER I
QP/
1
1 790-201-274oA
W-5 Sleeve
UNIT : mm
DAD01431
HEATTREATMENT MATERIAL
SEE DWG
I
I PART NAME
PLATE I
QlY
1
/ 791T-650-2210 A
30-25-2
0
DISASSEMBLY AND ASSEMBLY STARTING MOTOR
REMOVAL OF STARTING
MOTOR ASSEMBLY
g,-.Disconnect the cable from the negative (-) ter- ----cc ‘\ 8
_.
minal of the battery. II I \\ /Jr /==A// \\-
1. Open engine right side cover (top) and remove
cover (bottom).
2. Disconnect 3 starting motor wires (I) and 1 wir-

ing connector (2).
3. Remove 3 bolts, then remove starting motor as-

sembly (3). ----.- DEWOWl
INSTALLATION OF STARTING
MOTOR ASSEMBLY
l Carry out installation in the reverse order to
removal.
30-26
0
DISASSEMBLY AND ASSEMBLY ALTERNATOR
REMOVAL OF ALTERNATOR
ASSEMBLY
ADisconnect the cable from the negative (-1 ter-
minal of the battery.
1. Open engine right side cover (top) and remove

cover (bottom).
2. Disconnect alternator wiring (1) and (2).
3. Loosen locknut (31, then turn adjustment nut (4)

to loosen tension of V-belt (5).
I // DEDOWX
4. Remove bolts (6) and (7), then remove alterna-

tor assembly (8) together with belt cover. m
Ir Remove the V-belt from the pulley when re-
moving the alternator assembly.
INSTALLATION OF
ALTERNATOR ASSEMBLY
. Carry out installation in the reverse order to
removal.
g
2 m
z
* After installing the alternator, adjust the belt
tension. For details, see TESTING AND AD-
JUSTING, TESTING AND ADJUSTING AL-
TERNATOR BELT TENSION.
30-27
0
DISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER CORE
REMOVAL OF ENGINE OIL

COOLER CORE ASSEMBLY
Ir Drain coolant.
1. Remove wiring clamp (1).
2. Remove muffler water drain tube (2).
3. Remove adiabatic plate (3).
4. Disconnect turbocharger lubrication tube (4) at

turbocharger end, then move it towards rear.
DEwooo5
5. Disconnect connector (5).
6. Remove oil cooler assembly (6).
7. Remove core assembly (8) from cover (7).
INSTALLATION OF ENGINE OIL

COOLER CORE ASSEMBLY
removal.
l Refilling with watei

Add water through water filler to the specified
level.
* Run the engine to circulate the water through
the system. Then check the water level
again.
30-28
0
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
REMOVAL OF FUEL INJECTION

PUMP ASSEMBLY
1. Close valve of fuel supply piping.
2. Rotate crankshaft in normal direction and align

match mark of fuel injection pump.
* This makes it easier to check the compres-
sion top dead center position of the No. 1
cylinder when installing the fuel injection
pump.
3. Open engine left side cover (top) and remove _

- i -‘5 -‘I
cover (bottom). CLD02.170
4. Disconnect fuel control rod (I), and fuel hoses

(21, (3L (41, and (5). m
5. Remove boost compensator tube (19).

. Boost compensator tube is installed at serial
No. 60272 and up.
6. Disconnect fuel hose (6) and tube (7).
7. Remove coupling cover (8).
8. Remove lubrication tubes (9) and (IO).
- IO- -\
9- DEDKCO9
9. Disconnect 6 delivery tubes (II).

DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
10. Loosen tightening bolt (12) at drive shaft end,

and remove 4 pump mounting bolts (13).
11 Remove fuel injection pump assembly (14) to-

gether with coupling. m
- 13 i3 -
DELXOO12
INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY
removal.
* Adjust the linkage. For details, see TEST-

ING AND ADJUSTING, ADJUSTING FUEL
CONTROL LINKAGE.
w Sleeve nut: 23.5 f 1.0 Nm

12.4 f 0.1 kgm1
* Install the fuel injection pump as follows.

I) After installing pump assembly, align
damper (I,J) marks (15) and pointer (16)
correctly.
2) Loosen bolt of coupling (18) to align match
mark (17) of injection pump.
30-30
8
DISASSEMBLY AND ASSEMBLY WATER PUMP
REMOVAL OF WATER PUMP

ASSEMBLY
1. Drain coolant.
2. Using an adjustable wrench, push tension pul-

ley (2) of fan belt (I), and remove fan belt.
3. Loosen locknut (3), then loosen adjustment nut

(41, and remove V-belt (5). m
4. Remove connectors (6) and (7).
5. Remove pulley (8).
6. Remove water pump assembly (9).
INSTALLATION OF WATER
PUMP ASSEMBLY
removal.
(I
* After installing the V-belt, adjust the belt ten-
sion. For details, see TESTING AND AD-
JUSTING, TESTING AND ADJUSTING AL-
TERNATOR BELT TENSION.
. Refilling with water

Add water through water filler to the speci-
fied level.
* Run the engine to circulate the water
through the system. Then check the
water level again.
DISASSEMBLY AND ASSEMBLY TURBOCHARGER
REMOVAL OF
TURBOCHARGER ASSEMBLY
1. Remove hood assembly.
For details, see REMOVAL OF HOOD ASSEM-
BLY.
2. Remove adiabatic covers (2) and (3).
3. Disconnect tube (4) and hose (5), then lift off air
cleaner assembly (6).
&I kg Air cleaner assembly : 35 kg

DBW0025
4. Disconnect lubrication hose (7) and drain tube

(8). m
5. Remove turbocharger assembly (9). m
INSTALLATION OF
TURBOCHARGER ASSEMBLY
removal.
w Hose mounting bolt: 66.2 + 7.4 Nm

(6.75 z 0.75 kgm)
(12(
w Turbocharger mounting bolt :
49.0 t 9.8 Nm (5 I 1 kgm)
30-32
0
DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER
REMOVAL OF NOZZLE
HOLDER ASSEMBLY
BLY.
2. Remove cylinder head cover (I). m

* For No. 4 and 5 cylinders, remove the air
cleaner assembly and air supply connector.
3. Disconnect delivery tube (2). m
4. Loosen locknut (31, and remove connector (4).

a
5. Remove holder (5). m
6. Usina tool A, remove nozzle holder assembly

(6).
INSTALLATION OF NOZZLE
HOLDER ASSEMBLY
8
X removal.
DEW0414
Cylinder head cover mounting bolt :

24.5 +. 4.9 Nm (2.5 f 0.5 kgm)
Delivery tube sleeve nut :

23.5 f 0.98 Nm (2.4 + 0.1 kgm)
Connector : 31.9 + 2.5 Nm

(3.25 f: 0.25 kgm)
Locknut : 39.2 2 4.9 Nm (4.0 + 0.5 kgm)
6
Holder mounting bolt : 66.2 + 7.4 Nm DWCW15
(6.75 + 0.75 kgm)
m. ____
* When assembling the nozzle holder, clean
L
the nozzle holder mount and check that there
is no dirt or dust inside the sleeve before
assembling.
Tighten the mounting bolts uniformly in turn
to prevent excessive tightening on one side. 6
DBWO416
30-33
0
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
REMOVAL OF ENGINE FRONT

SEAL
1. Remove radiator, oil cooler, and guard assem-
bly.
For details, see REMOVAL OF RADIATOR, OIL
COOLER, GUARD ASSEMBLY.
2. Remove crankshaft pulley (I). m
3. Remove front seal (2).
DEW0023
INSTALLATION OF ENGINE
FRONT SEAL
removal.
m
* Use a pin (round cylinder) to align the posi-
tion of the crankshaft and crankshaft pulley.
DEDXG24
& Lip of oil seal : Grease (G2-LI)

Ir Press fit the front seal to a position 13 +i mm
from the end face of the front cover.
30-34
0
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
REMOVAL OF ENGINE REAR

SEAL
1. Remove damper assembly.
For details, see REMOVAL OF DAMPER ASSEM-
BLY.
2. Remove 1 mounting bolt of flywheel (I), and

install guide bolt 0.
3. Using eyebolts 0, sling flywheel (I), then re-

move remaining mounting bolts. m
4. Pull flywheel (I) out and lift off.
A The flywheel
may fall out
pilot portion is shallow,
suddenly, so be careful
and it
not to
get your fingers caught.
l&lkg Flywheel : 60 kg
5. Remove rear seal (2). m

* Measure the dimension from the end face of
the housing.
30-35
0
REAR SEAL
removal.
6 Coat the thread and seat of the bolt corn

pletely with SAE30CD engine oil.
* Tighten the flywheel mounting bolts in the

order given in the diagram on the right.
w Flywheel mounting bolt : DAD09419
1st step : Tighten to 117.7 + 4.9 Nm

(12 +. 0.5 kgm)
2nd step : I) When using tool B
Using an angle tightening
wrench, tighten bolt 90”+3r.
2) When not using tool B
Make marks on bolt and fly-
wheel with a felt pen, then
tighten bolt 90°+3r.
I DBCCCO44
Make marks on
DAD01249
* After tightening, make one punch mark on the

Make mark with punch
bolt head to indicate the number of times it has
been tightened.
If any bolt already has five punch marks, do not
reuse it. Replace it with a new bolt.
30-36
0
* After installing the flywheel, use dial gauge

0 to measure the face runout and radial
runout.
. Face runout: Max. 0.3 mm
. Radial runout: Max. 0.3 mm
m
Ir When installing the rear seal, check the wear
groove of the seal contact portion of the
crankshaft. If necessary, move the seal to-
wards the flywheel to the end face of the
housing when assembling.
30-37
0
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
REMOVAL OF CYLINDER HEAD

ASSEMBLY
Serial No. : 60001 - 60271
& Disconnect the cable from the negative (-) ter-

1. Drain coolant.
2. Close fuel supply valve.

BLY.
4. Remove engine side covers (left, right).
6. Disconnect tube (4) and hose (5), and lift off air
& kg Air cleaner assembly : 35 kg
7. Remove tube (71, then lift off muffler assembly

(8).
Muffler assembly : 45 kg
8. Remove bracket (9).
9. Disconnect turbocharger lubrication hose (IO)

and return tube (II). m
DBDW328
30-38
@
10. Lift off turbocharger and exhaust manifold as-

sembly (12). m
&I kg Turbocharger, exhaust manifold assem-

bly : 50 kg
11. Remove aeration tube (13). m
12. Disconnect hose (14) and tube (151, and remove

corrosion resistor (16) and fuel filter (17) together
with bracket. m
* The ground connection of the electrical in-
take air heater is tightened with the same
bolt.
13. Remove engine oil filter (18).

14. Disconnect dust indicator hose (19).
15. Disconnect 4 heater relay wires (20).
* Make marks when disconnecting.
17. Remove oil tube (22) and oil filler (23).

18. Remove clamp bolts of air conditioner hose (241,
wiring (251, level gauge (261, fuel hose (271, and
corrosion hose (28). m
* The bolts are used also for tightening the
intake manifold, so check the length and
position of installation of the bolts.
CYLINDER HEAD
19. Remove intake connector (29).
20. Remove delivery tube clamp (30).
21. Remove clamp of PTO level gauge (31).
22. Remove intake manifold assembly (32).
23. Remove spill tube (33).
24. Remove delivery tube (34).
25. Remove turbocharger lubrication hose (1OJ.m

* No. 3 cylinder head only
26. Remove head cover. m
27. Remove rocker arm assembly (35). m

* Loosen the locknut and turn the adjustment
screw back 2 - 3 turns.
28. Remove crosshead (36).
29. Remove push rod (37).
30-40
0
30. Loosen locknut (38).
31. Remove connector (39).

39,
32. Remove holder (40).

38’
33. Using tool A, remove nozzle holder assembly

(41).
DBW1246
34. Remove housing (42).
35. Remove cylinder head assembly (43). m
&I kg Cylinder head assembly : 30 kg (each)

INSTALLATION OF CYLINDER
HEAD ASSEMBLY
Serial No. : 60001 - 60271
0 Carry out installation in the reverse order to

removal.
m
w Mounting bolt : 66.2 = 7.4 Nm
i6.75 t. 0.75 kgml
m
Ir Tighten the bolts in the order @ - @ as
shown in the diagram on the right, then
tighten in the order @ - @. DBDXO41
w Exhaust manifold mounting bolt :
1st step : 29.4 = 4.9 Nm
I3.0 + 0.5 kgm1
2nd step : 66.2 f 7.4 Nm
I6.75 2 0.75 kgm1
m
m Joint bolt : 11.28 + 1.47 Nm
Il.15 + 0.15 kgml
0
* Install the hoses without twisting or interfer-
ence.
w Joint bolt : 29.4 + 4.9 Nm
13.0 + 0.5 kgm1
m DAD00042
* Tighten the bolts in the order of @ - @ as
shown in the diagram on the right.
w Intake manifold mounting bolt :
1st step : 29.4 f; 4.9 Nm
{3.0 t 0.5 kgm1 * Adjust the valve clearance.
2nd step : 66.2 + 7.4 Nm For details, see TESTING AND ADJUST-
16.75 + 0.75 kgml ING, ADJUSTING VALVE CLEARANCE.
m m Rocker arm assembly : 98.1 + 4.9 Nm
w Intake connector mounting bolt : {IO + 0.5 kgm}
49.0 + 9.8 Nm I5 2 1 kgm} w Locknut : 48.1 2 2.9 Nm
m I4.9 + 0.3 kgml
w Joint bolt : 8.8 + 0.98 Nm m
jO.9 t. 0.1 kgml Ir Adjust the crosshead as follows.
m 1) Loosen locknut, then turn adjustment
w Delivery tube sleeve nut : screw back.
23.5 +. 0.98 Nm I2.4 + 0.1 kgm1 2) Press top of crosshead lightly and
m tighten adjustment screw.
w Head cover mounting bolt : 3) When adjustment screw contacts
24.5 + 9.8 Nm {2.5 f 1.0 kgml valve stem, screw in a further 20”.
m Tighten locknut to hold in position.
* Clean the mounting bolt oil holes before in- & Locknut : 58.8 f 5.9 Nm
stalling. I6.0 2 0.6 kgml
* Check that the ball of the adjustment screw m
is fitted properly into the socket of the push w Locknut : 39.2 z 4.9 Nm
rod. I4.0 + 0.5 kgm}
w
w Connector : 31.9 t 2.5 Nm
i3.25 2 0.25 kgm}
m
m Holder mounting bolt : 66.2 = 7.4 Nm
I6.75 f 0.75 kgm}
* Check that there is no dirt or dust on the

cylinder head mounting surface or inside the
cylinder.
* When installing the gasket, check that the
grommet does not come out.
* Coat the bolt thread and seat face completely
with molybdenum disulphide (LM-PI.
* Tighten the cylinder head mounting bolts in
the order given in the diagram.
& Cylinder head mounting bolt :
Anti-friction compound (LM-PI
m Cylinder head mounting bolt :
1st step : Tighten to 147 + 9.8 Nm

{I5 + 1 kgm1
2nd step : Tighten to 215.6 -c 4.9 Nm
(22 -e 0.5 kgm1
3rd step : 1) When using tool B
. Using an angle tightening
wrench, tighten bolt 90°+3r.
2) When not using tool B Make marks on
. Make marks on bolt and fly-
tighten bolt 90”.
L
*Tighten bolt @) to 66.2 2 7.4 Nm 16.75 f 0.75 kgm1
one time.
Ir After tightening, make one punch mark on
the bolt head to indicate the number of times
it has been tightened.
If any bolt already has five punch marks,
l
do not reuse it. Replace it with a new

bolt.
. Refilling with water Make mark with punch
. Add water through water filler to the speci-
fied level.
again.
REMOVAL OF CYLINDER HEAD

ASSEMBLY

1. Drain coolant.
2. Close fuel supply valve.

For details, see REMOVAL DBW0025
OF HOOD ASSEM-
BLY.
4. Remove engine side covers (left, right).
6. Disconnect tube (4) and hose (51, and lift off air
Air cleaner assembly : 35 kg
7. Remove tube (7), then lift off muffler assembly

(8).
C+lkg Muffler assembly : 45 kg
9. Disconnect turbocharger lubrication hose (IO)

and return tube (II). a
30-43-2
0
10. Lift off turbocharger and exhaust manifold as-

sembly (12). m
&I kg Turbocharger, exhaust manifold assem-

bly : 50 kg
11. Remove aeration tube (13). m
12. Disconnect hose (14) and tube (151, and remove

corrosion resistor (16) and fuel filter (17) together
with bracket. a
* The ground connection of the electrical in-
take air heater is tightened with the same
bolt.
13. Remove engine oil filter (18).

14. Disconnect dust indicator hose (19).
15. Disconnect 4 heater relay wires (20).
* Make marks when disconnecting.
DBW0031 DBMXM32
17. Remove oil tube (221, oil filler (23), and boost
compensator tube (44).
18. Remove clamp bolts of air conditioner hose (241,
wiring (251, level gauge (261, fuel hose (271, and
corrosion hose (28). m
* The bolts are used also for tightening the
intake manifold, so check the length and
position of installation of the bolts.
30-43-3
@
19. Remove aftercooler piping (45), (46).
45 46
CLD02172 CLD02173
20. Remove intake connector (29). m
21. Remove delivery tube clamp (30).
22. Remove clamp of PTO level gauge (31).
23. Remove intake manifold and aftercooler assem-

bly (32). m
24. Remove spill tube (33).
25. Remove delivery tube (34). m
26. Remove turbocharger lubrication hose (1Oj.m

j, No. 3 cylinder head only
27. Remove head cover.
28. Remove rocker arm assembly (35). m

* Loosen the locknut and turn the adjustment
screw back 2 - 3 turns.
29. Remove crosshead (36).
30. Remove push rod (37).
31. Loosen locknut (38).
32. Remove connector (39).
33. Remove holder (40).
34. Using tool A, remove nozzle holder assembly

(41).
35. Remove housing (42).
30-43-5
8
36. Remove cylinder
Cylinder
head assembly
head assembly
(43). m
: 30 kg (each)
r
30-43-6
@
INSTALLATION OF CYLINDER
HEAD ASSEMBLY

removal.
m
-w Mounting bolt : 66.2 + 7.4 Nm
16.75 z 0.75 kgm1
m
* Tighten the bolts in the order @ - @ as
shown in the diagram on the right, then
tighten in the order @ - @. DBDW341
w Exhaust manifold mounting bolt :

1st step : 29.4 I 4.9 Nm
13.0 + 0.5 kgm}
2nd step : 66.2 = 7.4 Nm
(6.75 + 0.75 kgm1
m
m Joint bolt : 29.4 2 4.9 Nm
Il.15 + 0.15 kgm)
m
ence.
w Joint bolt : 29.4 + 4.9 Nm
13.0 + 0.5 kgm1
m DADXM7
li Tighten the bolts in the order of @ - @ as

w Intake manifold mounting bolt Ir Adjust the valve clearance.
1st step : 29.4 + 4.9 Nm For details, see TESTING AND ADJUST-
I3.0 +. 0.5 kgm} ING, ADJUSTING VALVE CLEARANCE.
2nd step : 66.2 f 7.4 Nm w Rocker arm assembly : 98 2 4.9 Nm
16.75 f 0.75 kgm1 {IO 2 0.5 kgm1
m_ w Locknut : 48.0 2 2.9 Nm
m Intake connector mounting bolt : 14.9 2 0.3 kgm1
49.0 z 9.8 Nm I5 d 1 kgm1 m
m * Adjust the crosshead as follows.
w Joint bolt : 8.8 + 1.0 Nm 1) Loosen locknut, then turn adjustment
IO.9 r 0.1 kgm1 screw back.
m 2) Press top of crosshead lightly and
m Delivery tube sleeve nut : tighten adjustment screw.
23.5 f 1.0 Nm j2.4 2 0.1 kgm} 3) When adjustment screw contacts
ET- I., , valve stem, screw in a further 20”.
w Head cover mounting bolt : 4) Tighten locknut to hold in position.
24.5 2 9.8 Nm I2.5 = 1.0 kgm} w Locknut : 58.8 2 5.9 Nm
I6.0 + 0.6 kgm}
* Clean the mounting bolt oil holes before in- m
stalling. w Locknut : 39.2 = 4.9 Nm
Ir Check that the ball of the adjustment screw I4.0 = 0.5 kgm}
is fitted properly into the socket of the push
rod.
30-43-7
@
w Connector : 31.9 2 2.5 Nm

I3.25 e 0.25 kgm}
w Holder mounting bolt : 66.2 2 7.4 Nm

I6.75 + 0.75 kgm}
Check that there is no dirt or dust on the

cylinder head mounting surface or inside the
cylinder.
When installing the gasket, check that the
grommet does not come out.
Coat the bolt thread and seat face completely
with molybdenum disulphide (LM-P).
Tighten the cylinder head mounting bolts in
the order given in the diagram.
& Cylinder head mounting bolt :
w Cylinder head mounting bolt :
1st step : Tighten to 147 2 9.8 Nm

(15 z 1 kgm1
2nd step : Tighten to 215.6 f 4.9 Nm
(22 +. 0.5 kgm1
3rd step : 1) When using tool B
. Using an angle tightening
wrench, tighten bolt 90°+3y.
2) When not using tool B Make marks on
. Make marks on bolt and fly- 6any e+;

tighten bolt 90”.
Tighten bolt Q) to 66.2 + 7.4 Nm 16.75 +. 0.75 kgm1

one time.
After tightening, make one punch mark on
the bolt head to indicate the number of times
it has been tightened. DACCCG45
l If any bolt already has five punch marks,
do not reuse it. Replace it with a new
bolt.
. Refilling with water Make mark with punch
. Add water through water filler to the speci-
fied level.
Ir Run the engine to circulate the water through
again.
30-43-8
@
DISASSEMBLY AND ASSEMBLY THERMOSTAT
REMOVAL OF THERMOSTAT
ASSEMBLY
1. Drain coolant.
2. Remove alternator assembly.

For details, see REMOVAL OF ALTERNATOR AS-
SEMBLY.
3. Disconnect radiator inlet hose (I).
4. Disconnect bypass tube (2).
5. Remove cover (3).
6. Remove 2 thermostats (4).
INSTALLATION OF
THERMOSTAT ASSEMBLY
removal.
level.
DBCOO422
again.
30-44
0
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
REMOVAL OF AIR
ASSEMBLY
1. Open engine left side cover (top) and remove
cover (bottom).
2. Remove wiring connector (1).
3. Disconnect hoses (2) and (3). m

* Loosen the sleeve nut slightly, and release
the air conditioner gas (R134a) completely
before disconnecting the hose.
* Fit blind plugs to prevent dirt or water from
entering the hoses.
4. Loosen 4 mounting bolts (4).
5. Remove V-belt cover (5).
6. Loosen adjustment bolt (6) and remove.
7. Remove mounting bolts (4), remove V-belt (7)

from pulley, then remove compressor assembly
(8). m
30-45
0
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
INSTALLATION OF AIR
ASSEMBLY
removal.
m
* Install the hoses without twisting or intetfer-
ence.
* Install the air conditioner circuit hoses care-
fully to prevent dirt, dust, or water from get-
ting inside the hoses.
* Check that there are O-rings at the piping O-ring
connection of the air conditioner hoses be-
DED01219
fore installing.
Coat the O-rings thoroughly with compres-
sor oil (Showa Shell Suniso 4G or 5G).
N Tighten the air conditioner gas piping to
the following tightening torques.
Thread size Tig;;;i;kgg;;pue Remarks
m
* After installing the V-belt, adjust the belt ten-
sion. For details, see TESTING AND AD-
JUSTING, TESTING AND ADJUSTING AIR
CONDITIONER COMPRESSOR BELT TEN-
SION.
l Charging with air conditioner gas

Using tool S, charge the air conditioner circuit
with air conditioner gas (R134a).
30-46
0
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER CONDENSER
REMOVAL OF AIR
CONDITIONER CONDENSER
ASSEMBLY
1. Drain coolant.

BLY.
3. Disconnect air conditioner hose (1). a

entering the hoses.
4. Disconnect radiator inlet hose (21, move it to-

wards engine. a
5. Disconnect aeration hose (3), and remove hose

clamp bracket (4). 113
6. Disconnect sub-tank hose (5), and move it to-

wards sub-tank end.
7. Remove sub-tank (6).

g
5 8. Remove air conditioner condenser assembly (7).
z
30-47
0
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER CONDENSER
INSTALLATION OF AIR
CONDITIONER CONDENSER
ASSEMBLY
removal.
a
ence.
ting inside the hoses. O-kg
* Check that there are O-rings at the piping
connection of the air conditioner hoses be- DED01219
fore installing.
w Tighten the air conditioner gas piping to
Tightening torque Remarks

Thread size
(Nm Mm))
w Radiator inlet hose clamp:

882.6 z 49.0 Ncm
(90 = 5 kgcm)
m
w Aeration hose clamp: 333.4 2 49.0 Ncm
(34 = 5 kgcm)
level.
again.
Using tool S, charge the air conditioner cir-
cuit with air conditioner gas (R134a).
30-48
0
DISASSEMBLY AND ASSEMBLY FUEL TANK
REMOVAL OF FUEL TANK

ASSEMBLY
ADisconnect the cable from the negative (-) ter-
Disconnect rear lamp connector (I) (CN243).
Remove cover (2).
Disconnect intermediate connector (3) (CN245).
Remove bracket (4).

I I
DEDOO871 DEW0872
5. Close fuel supply valve and disconnect fuel sup-

ply hose (5).
6. Remove fuel drain hose clamp.
7. Disconnect connector (6) (CN422) for fuel level

sensor.
9. Disconnect fuel return hose (8).

FUEL TANK
10. Remove cover (9), then remove right mounting

bolts.
11. Remove left mounting bolts.
12. Lift off fuel tank assembly (IO).
elkg Fuel tank assembly : Approx.

(full tank)
660 kg
‘DECO0878
INSTALLATION OF FUEL TANK

ASSEMBLY
removal.
30-50
0
DISASSEMBLY AND ASSEMBLY RADIATOR
REMOVAL OF RADIATOR
ASSEMBLY
ALower the work equipment completely to the
ground.
Release the remaining pressure in the circuit.
For details, see TESTING AND ADJUSTING, RE-
LEASING REMAINING PRESSURE IN HYDRAU-
LIC CIRCUIT. Then loosen the oil filler cap slowly
to release the pressure inside the hydraulic tank.

BLY.
2. Drain coolant.
3. Lift opposite side of hinge and gradually open

underguard under engine.
4. Disconnect 2 power train oil cooler hoses (1).
5. Disconnect 2 radiator hoses (2).
zz 6. Disconnect clamp (3) for hydraulic cooler hose

z from radiator.
z
7. Open radiator grill (4).
8. Remove radiator top cover (5) and left and right

6
side plates.
9
9. Disconnect hydraulic cooler hose (6) and remove
clamp.
10. Loosen locknuts on locknuts on hydraulic cooler

assembly swing bolts (7), and screw bolts into
both top and bottom swing holes (condition a).
11. Remove 8 bracket mounting bolts (81, and open

hydraulic cooler assembly (9) to front.
12. Disconnect radiator inlet hose (IO). m
13. Disconnect aeration hose (11). m
14. Disconnect sub-tank hose (12).
15. Disconnect head lamp connector (13) (CN2011,

then remove 6 clamps and move wiring towards
head lamp.
16. Remove left and right hood mount brackets (14).
17. Remove seal (15).
18. Remove bottom mount bracket (16).
20. Remove top mount bolt (18).
17 16
rIBaX)
21. Lift off radiator assembly (19).

* Be extremely careful not to damage the seal
or radiator core when removing the radia-
tor.
&I kg Radiator assembly : 310 kg
30-52
0
INSTALLATION OF RADIATOR
ASSEMBLY
removal.
m
Sr After installing the hydraulic cooler assem-
bly, remove bolts (7) from both top and bot-
tom swing holes, then fix them at the origi-
nal positions with the locknuts (condition b).
m Radiator inlet hose clamp : a b

882.6 = 49.0 INcm (90 = 5 kgcm)
m
w Aeration hose clamp : 333.4 = 49.0 Ncm
(34 = 5 kgcm)

level.
again.
3 Refilling with oil (hydraulic tank, power train

3 . case)
z Add engine oil through oil filler to the specified
level.
* Run the engine to circulate the oil through
the system. Then check the oil level again.
30-53
0
DISASSEMBLY AND ASSEMBLY RADIATOR, OIL COOLER, GUARD
REMOVAL OF RADIATOR, OIL

COOLER, GUARD ASSEMBLY
1. Drain coolant.
2. Disconnect blade lift cylinder assembly from

blade, then secure to guard.
For details, see REMOVAL OF BLADE ASSEM-
BLY.
3. Lift engine undercover at opposit end of hinge

and open engine undercover gradually.
4. Disconnect 2 blade lift cylinder hoses (I).
5. Disconnect 2 hydraulic cooler hoses (2).
6. Disconnect 2 power train oil cooler hoses (3).
7. Disconnect 2 radiator hoses (4).
8. Remove hood assembly (5).

BLY.
9. Remove left and right covers (6).
10. Remove left and right side covers (7). DEW0429
11. Remove radiator top cover (8).
12. Disconnect radiator inlet hose (9). m

* Disconnect at the radiator end and move
towards the engine.
13. Disconnect aeration hose (IO). m
* Disconnect at the radiator end, then remove
2 clamps and move towards the engine.
14. Disconnect air conditioner hose (11). a
entering the hoses.
15. Disconnect head lamp wiring connector (12)
(CN201).
30-54
0
16. Remove fan guard (13).
17. Push tension pulley (141, loosen belt tension,

and remove fan belt (15).
18. Remove head lamp (16).
DEW0434
19. Sling radiator, oil cooler, guard assembly (171,

remove lock plate, then remove 4 pins (181, and
lift off radiator, oil cooler, guard assembly (17).
* Be extremely careful not to damage the wir-
ing and hoses when removing.
&?Ikg Radiator, oil cooler, guard assembly :

2,050 kg
30-55
0
INSTALLATION OF RADIATOR,
OIL COOLER, GUARD
ASSEMBLY
removal.
w Radiator inlet hose clamp :

882.6 f 49.10 Ncm (90 r. 5 kgcm)
w Aeration hose clamp : 333.4 + 49.0 Ncm

(34 +. 5 kgcm)
m
ence.
fore installing.
DED01219

Thread size
(Nm (kgm))
11 19.6 - 24.5 (2 0 - 2 5) Discharge

level.
again.
. Refilling with oil (hydraulic tank, power train

case)
Add engine oil through oil filler to the specified
level.
. Charging with air conditioner gas

30-56
0
DISASSEMBLY AND ASSEMBLY FAN DRIVE
REMOVAL OF FAN DRIVE

ASSEMBLY
1. Drain coolant.

BLY.
3. Remove radiator top cover and left and right

side plates.
4. Disconnect radiator inlet hose (I) and move it

towards engine end. a
5. Disconnect aeration hose (2) and remove hose

clamp bracket (3). m
6. Disconnect sub-tank hose (5) and move it to-

wards sub-tank end.
7. Disconnect air conditioner hose (5). m

the air- conditioner gas (R134a) completely
+ Fit blind plugs to prevent dirt or water from
entering the hoses.
8. Remove condenser, guard, and sub-tank assem-

bly (6).
I+ kg Condenser, guard, sub-tank assembly :

25 kg
9. Using an adjustable wrench, push tension pul-

ley (8) of fan belt (7), and remove fan belt (7).
10. Remove fan guard as 3 parts in order (9), (IO),

(II).
DISASSEMBLY AND ASSEMBLY FAN DRIVE
11. Disconnect head lamp connector (12) (CN201),

then remove 2 clamps and move wiring towards
radiator.
12. Remove left and right hood mount brackets (13).
DEW0896
14. Using eyebolts 0, sling fan drive and guard

assembly (151, then remove mounting bolts, and
remove assembly.
&I kg Fan drive, guard assembly : 150 kg
15. Remove guard (17) from fan drive assembly (16).
16
17
DECCO696
30-58
0
DISASSEMBLY AND ASSEMBLY FAN DRIVEFAN DRIVE
INSTALLATION OF FAN DRIVE

ASSEMBLY
removal.
w Radiator inlet hose clamp :

882.6 2 49.0 Ncm (90 r 5 kgcm)
m Aeration hose clamp : 333.4 = 49.0 Ncm

(34 2 5 kgcm)
m
ence.
fore installing.
m Tighten the air conditioner gas piping to
g the following tightening torques.
X DED01219
I-
& Thread size Tightening torqueRemarks

Wm (kgm))

level.
again.
. Charging with air conditioner gas

30-59
0
DISASSEMBLY AND ASSEMBLY HYDRAULIC COOLER
REMOVAL OF HYDRAULIC
COOLER ASSEMBLY
a Lower the work equipment completely to the
ground. Release the remaining pressure in the
circuit. For details, see TESTING AND ADJUST-
ING, RELEASING REMAINING PRESSURE IN
HYDRAULIC CIRCUIT.
Then loosen the oil filler cap slowly to release
the pressure inside the hydraulic tank.
1. Open radiator grill (1).
3. Disconnect hoses (3) and (41, and clamp (5).
4. Loosen locknuts on hydraulic cooler assembly

swing bolts (61, and screw bolts into both top
and bottom swing holes (condition a).
5. Remove 8 bracket mounting bolts (7)
6. Open hydraulic cooler assembly (81 to front.
7. List off hydraulic cooler assembly (8).
& kg Hydraulic cooler assembly : 110 kg
INSTALLATION OF HYDRAULIC
COOLER ASSEMBLY
removal.
. Refilling with oil (hydraulic tank)

level.
30-60
0
DISASSEMBLY AND ASSEMBLY ENGINE
REMOVAL OF ENGINE
ASSEMBLY
a. Drsconnect the cable from the negative (-1 ter-
* Close the supply valve of the fuel tank.
1. Remove radiator, oil cooler, guard assembly.

For details, see REMOVAL OF RADIATOR, OIL
COOLER, GUARD ASSEMBLY.
2. Disconnect starting motor wiring (1).
3. Disconnect engine speed sensor connectors (2)

(CN009, CNOIO).
4. Disconnect wiring connector (3) (CNIOI).
5. Disconnect 2 air conditioner hoses (4). m

* Loosen the sleeve nut slightly, and re-
lease the air conditioner gas (R134a)
completely before disconnecting the
hose.
* Fit blind plugs to prevent dirt or water
from entering the hoses.
* Disconnect at the air conditioner end, then
remove all the clamps from the floor
frame and move towards the engine.
6. Disconnect 2 heater hoses (5).

* Disconnect at the air conditioner end,
then move towards the engine.
30-6 1
7. Disconnect fuel supply hose (6).
8. Disconnect fuel return hose (7).
9. Disconnect fuel control rod (8).
10. Disconnect ground wiring (9).
7 ‘6 DEDOO440
11. Disconnect universal joint (IO) at damper

end.
12. Remove front mount bolts (II) and rear 11 12

mount bolts (12). m
DDDDWAZ
13. Move engine assembly (13) towards front of

machine, and lift off gradually.
* Be careful not to damage the wiring or
hoses when removing the engine assem-
bly.
el kg Engine assembly : 1,750 kg
30-62
0
ASSEMBLY
I
removal.
m
ence.
ting inside the hoses. O-ring
connection of the air conditioner hoses be- DED01219
fore installing.
sor oil (Shell Suniso 4G or 5G).
m Tighten the air conditioner gas piping to
Thread size Tightening torque Remarks

N-n (kg-n))
w Engine mount bolt: 931.6 + 98.1 Nm

(95 + 10 kgm)
30-63
0
DISASSEMBLY AND ASSEMBLY DAMPER
REMOVAL OF DAMPER
ASSEMBLY
1. Drain oil from damper chamber.
- : Damper chamber : 1.5 t
2. Remove floor frame assembly.

For details, see REMOVAL OF FLOOR FRAME
ASSEMBLY.
3. Lift off HMT pump assembly.

For details, see REMOVAL OF HMT PUMP AS-
SEMBLY.
4. Disconnect or remove piping and hoses installed

to power train and lubrication pump.
FOR DETAILS, SEE REMOVAL OF POWER TRAIN,
LUBRICATION PUMP ASSEMBLY.
5. Disconnect breather hose (I) and remove dip-

stick tube (2) together with hose.
6. Lift off universal joint assembly (31, then remove

coupling (4) at torque converter end. m
--_\k-yll I4 DBD00453
7. Remove mounting bolts of damper cover assem-

bly (51, then install (2) guide bolts @ on opposite
sides, and use forcing screws @ to pull damper
cover (6) out to position where it is possible to
install lifting tool. m
8. Lift off damper cover assembly (6). m
& kg Damper cover assembly : 117 kg
30-64
0
9. Removal of Damper
I) Remove 2 mounting bolts of damper (7), then
set guide bolts (3) in position. m
2) Remove remaining mounting bolts, then use
forcing screws (4) to pull out. m
3) Pull out to position where it is possible to
install eyebolts 0, set lifting tool to damper
(7), then remove.
INSTALLATION OF DAMPER
ASSEMBLY
removal.
m
6 Universal joint mounting bolt :
Thread tightener (LT-2)
m Universal joint mounting bolt :
110.8 f 12.7 Nm (11.3 = 1.3 kgm)
m
m Damper cover Mounting bolt :
110.8 + 12.7 Nm (11.3 f 1.3 kgm)
a
* When installing the damper cover assem-
bly, remove all oil and grease from the shaft
spline, coat with dry lubricant A, leave for 2
or 3 minutes, then coat with lithium-based
molybdenum disulphide extreme pressure
grease B, and assemble.
Dry type molyb- SUMICO LUB:

A denum disulphide ROCOL DRY SPRAY
lubricant or equivalent
* KYODO YUSHI:
MORILEX NO. 2
Lithium lubricant l SHOWA SHELL:
B grease with molyb- RETINAX AM
denum disulphide * NIPPON OIL:
MORITEX NO. 2
or equivalent
m Damper Mounting bolt : 110.8 2 12.7 Nm

(11.3 + 1.3 kgm)
. Refilling with oil
%# Damper chamber : 1.5 fi (SAE30CD)
m Plug : 152.0 + 24.5 Nm (15.5 f 2.5 kgm)
30-65
0
AND ASSEMBLY DAMPER
DISASSEMBLY
DISASSEMBLY DAMPER ASSEMBLY
DDE01208
Disassembly of damper cover assembly (I)

4
1. Coupling
Remove bolt (3) from cover (2), then remove
holder (4) and coupling (5). 3
5
2
30-66
0
2. Shaft
I) Set damper cover assembly (I) to block 0,
then tap from output end with a plastic ham-
mer, and pull out shaft (6).
Ir Remove shaft (6) together with oil seal
(8) and inner race (7-I) of bearing (7).
‘8 DDW1203
2) Remove collar (7-2) and O-ring of bearing

:I from shaft (61, then remove inner race (7-
6 7-1 7-2
I /
3. Bearing, oil seal

I) Remove oil seal (9) from cover (2), then re-
move inner race (7-3) of bearing (7).
I DDDO1211
2) Remove outer races (7-4) and (7-5) of bear-

ing (7) from cover (2).
7-5 DDW1212
30-67
Disassembly of damper assembly (IO)

4. Remove bolt (II), then remove flange (12). 12 11
5. Remove outer body (13), inner body (14), and

cushion (15).
6. Pull out plug (17) from flange (16).

* Only when replacing the plug.
16 15 17 14 13
DDCQ1213
30-68
0
ASSEMBLY OF DAMPER ASSEMBLY
2
1
17 16 15 1’4
Assembly of damper assembly (IO)

1. Align bolt holes of flange (16) and outer body
14
(13) with cylinder 0, then assemble inner body
(14).
& Mating surface of flange, outer body :
Gasket sealant (LG-4)
6 Inside surface of outer body :
Grease (G2-LI) ‘13
6 Cushion contact surface of inner body :
Grease (G2-LI)
DDE01214
30-69
0
2. Assemble cushion (15).

Ir Coat the whole surface of the cushion with
grease (G2-LI).
* After assembling the cushion, fill 30% of the
clearance (16 places) between the inner body
and outer body with grease.
Cushion
3. Assemble flange (12) and tighten with bolt (11).

m Mounting bolt : 66.2 z 7.4 Nm
(6.75 + 0.75 kgm)
I DDDO1216
4. Filling with grease

I) Fill inner body @with 800 g of grease listed
below.
& : Grease
I Grease I Brand name I

I 1 KYODO
l YUSHI: I
Lithium lubricant MORILEX NO. 2
grease with lSHOWA SHELL:
molybdenum RETINAX AM
disulphide l NIPPON OIL:
MORITEX NO. 2
or equivalent DDW1217
Assembly of damper cover assembly (II

5. Using push tool 0, press fit outer races (7-4)
and (7-5) of bearing (7) to cover (2) with press.
30-70
0
6. Press fit inner race (7-l) of bearing (7) to shaft

(6) with tools Cl and C2.
7. Assemble collar (7-2) and O-ring to shaft (6).

6 7-l 7-2
O-ring
DEW1210
8. Set cover (2) to shaft (61, and using tools Cl and

C2, press fit bearing inner race (7-3).
9. Install oil seals (8) and (9) to cover assembly (2).

& Oil seal press-fitting surface :
& Lip of oil seal : Grease (G2-LII
Sr Coat the oil seal surface thinly with gasket
sealant and wipe off any sealant that is
squeezed out.
30-71
0
10. Coupling
Assemble coupling (5) and holder (4), and tighten 4
bolt (3).
m Mounting bolt : 277.5 2 32.4 Nm
(28.3 e 3.3 kgm) 3
2 5
30-72
0
DISASSEMBLY AND ASSEMBLY POWER TRAIN UNIT
REMOVAL OF POWER TRAIN

UNIT ASSEMBLY
1. Drain oil
- : Hydraulic tank : Approx. 97 i?
- : Power train case : Approx. 60 4?

ASSEMBLY.
3. Lift opposite side of hinge and gradually open

underguard under power train unit to ground
surface.
4. Disconnect 2 fuel return hoses (I) from fuel tank

(2).
5. Disconnect fuel level sensor connector (CN422)

(3) at bottom of fuel tank.
6. Close fuel supply valve and disconnect fuel sup-

ply hose (4).
8
3
s
7. Remove fuel drain hose clamp, then remove fuel

tank assembly (2).
&I kg Fuel tank assembly (when full) : 660 kg
8. Remove connecting pin at injection pump end

of fuel control rod (51, then remove control rod
(5).
9. Disconnect engine speed sensor connectors (6)

(CN009, CNOIO).
10. Remove suspension rod (7).
11. Remove top cover of centralized pressure detec-

tion port, then remove bracket (8) for central-
ized pressure detection from frame.
12. Remove power train oil filler pipe (9).
13. Disconnect dipstick tube (IO) for power train from

case, and move it towards right side of chassis.
14. Disconnect hose (11) between power train filter

and HMT control valve at pipe end (power train
unit end).
15. Disconnect hose (12) between power train cooler

and HMT control valve at pipe end (power train
unit end).
30-74
0
16. Remove hose (13) between hydraulic cooler by-

pass valve and hydraulic tank, and hose (drain
hose) (14) between HMT motor and hydraulic
tank together with clamp brackets.
17. Disconnect 2 hoses (15) between hydraulic cooler

bypass valve and hydraulic cooler at relief valve
end.
18. Disconnect 2 hoses (16) between HSS, hydraulic

pump LS valve and steering, main control valve
at LS valve end.
19. Disconnect HMT servo charge hose (17) at HMT

pump end.
Disconnect 2 HSS motor hoses.(18) at valve end,

and put on top of power train unit.
21. Disconnect hose (19) between HSS, hydraulic

pump and steering, main control valve at pump
end.
22. Remove hydraulic suction tubes (20) and (21).
23. Disconnect hose (22) between charge pump and

charge filter at charge filter end.
24. Disconnect hose (23) between charge valve and

HMT pump at charge valve end.
25. Disconnect pin puller hose (24) at pin puller valve

end.
26. Disconnect hose (25) between power train pump

and power train filter at pump end.
27. Disconnect hose (26) (left side of power train

Mew from bottom
unit) between power train cooler and lubrica-
tion valve at lubrication valve end.
28. Raise universal joint (27) from top with rope,

then lower and remove. a
29. Remove final drive shaft cover (28), then use

bolt @I to pull out drive shaft (29) to a point
where spline at steering case end comes out.
Ir If the shaft does not come out, move the
sprocket (push up the shoe grouser from
the ground surface with a jack) to adjust to a
position where the shaft comes out, then
pull out the shaft.
30-76
0
30. Remove mount caps (30) at both ends of steer-

ing case together with cover. a
31. Loosen coupling clamp (311, and move (open)

seal (32) slightly to outside. m
32. Remove front mount bolt (33).
33. Lift off power train unit assembly (34). B

* Check that the wiring and piping has all been
removed, then lift off the power train unit
assembly.
Power train unit assembly : 2,800 kg
DBECO542
INSTALLATION OF POWER
TRAIN UNIT ASSEMBLY
removal.
w Universal joint mounting bolt :

110.3 t 12.3 Nm (11.25 = 1.25 kgm)
m Mount cap mounting bolt :

277.0 + 31.9 Nm (28.25 + 3.25 kgm)
Clamp the protruding portion of the cou-

pling seal, then assemble the clamp thread
so that it is parallel to the cap mount seat
surface.
m Front mount mounting bolt :

926.7 + 103.0 Nm (94.5 2 10.5 kgm)
Sr When assembling the power train assem-

bly, be extremely careful not to damage seal
(32).
. Refilling with oil (Hydraulic tank. power train

case.)
level.
Q Hydraulic tank : Approx. 97 f?
G Power train case : Approx. 60 !J
30-78
0
SEPARATION OF POWER
TRAIN UNIT ASSEMBLY
1. Remove wiring harness (I).
2. Disconnect brake rod (21, parking brake cable

(one unit with bracket) (31, and pressure detec-
tion tube (4). a
3. Remove bracket (5) for clutch switch wiring har-

ness. m
I DBW0545
4. Remove 13 top and side hoses (6).

s 6
5. Remove 2 hoses (71, 2 tubes (81, and 1 tube (9)

at front.
* When tubes (8) and (9) are removed, the oil
in the piping and inside the case will leak
out. Prepare a pan to collect oil.
6. Remove 3 top tubes (IO).
7. Remove HMT pump assembly (II), and power

train and lubrication pump assembly (12).
30-80
0
8. Remove scavenging pump, charge pump assem-

bly (13).
9. Remove HSS motor assembly (30).
10. Remove HMT motor speed sensor (141, then use

forcing screws @ to remove cover (15).
11. Remove snap ring (161, then remove shaft (17).

* Remove the spring from the tip of the shaft.
30-81
0
12. Remove mount bracket (18), then remove HMT

motor assembly (19). m
13. Remove brake valve assembly (20).
14. Remove filter assembly (21). m
15. Remove modulating valve (22). m

* Mounting bolts: 3 hexagonal bolts
16. Remove bracket (231, then remove HMT control

valve assembly (24). m
* The 2 bolts marked are used to secure the
top body and bottom body, so they do not
need to be removed.
30-82
0
17. Remove HSS and hydraulic pump assembly (25).
18. Remove front mount (26).
19. Remove HMT oil cooler bypass valve assembly

27
(27).
20. Disconnect HSS assembly (28) from HMT as-

sembly (29). mfi1
30-83
0
CONNECTION OF POWER TRAIN UNIT ASSEMBLY

. Carry out connection in the reverse order to
disconnection.
a
Sr See the diagram for the color bands on the
detection tubes and be careful not to make
any mistake when installing the pressure
detection tubes.
None (brake pressure)

Whiie (1st clutch pressure)
Black (2nd clutch pressure)
Blue (3rd clutch pressure Black&d 1
Yellow (F clutch pressu (lubrication pressure)
White/black (R clutch pressure)’ / Black (2nd clutch pres! rel ’\ yone ‘rake presure)
Red (pilot pressure) White (1st clutch r-=--\ RI, ,P ,-&A ,.I, *A. n*OCCImm\
Black/red (lubrication pressure)
* Install the bracket wiring harness connec-

tors as shown in the diagram
30-84
0
After installing the HMT motor assembly,

install the mount bracket to the HMT motor,
then measure the clearance between the
transmission and bracket. Insert shims of a
thickness equivalent to the clearance, then
install the mount bracket.
. There are 3 types of shims:
0.2 mm, 0.3 mm, 0.5 mm
(Reference) Standard shim thickness: 3 mm
w Mount bracket mounting bolt :
277.0 f 31.9 Nm (28.25 z 3.25 kgm)
m Filter assembly mounting bolt :

49.0 + 4.9 Nm (5.0 = 0.5 kgm)
w Modulating valve mounting bolt :

49.0 + 4.9 Nm (5.0 + 0.5 kgm)
m Valve mounting bolt : 49.0 z 4.9 Nm

(5.0 2 0.5 kgm)
* The positions for the clamps for the sole-
noid valve wiring harness bracket are as
R SOL (green), \ St SOL(gray)

m HSS connecting bolt : 110.3 t 12.3 Nm
(11.25 f 1.25 kgm)
3rd SOL
(yellow) 6
30-85
0
t When the elbows have been removed during

disassembling of the power train unit, re-install
each elbow in the direction shown in the figure.
Overview of the power train unit
a/
30-85-l
0
- Front side
Front side
I /q
Front side
Front side
-L.---f
Upper side
A B C
Front side Front side

-
Upper side
Upper side
(View from rear side)

E F G
Upper side Front side Front side

- - Front side
Front side
Upper side
J K L M
Front side -
Front side
- k
/ /
N 0 P 0
DAD02452
30-85-2
0
DISASSEMBLY AND ASSEMBLY PTO
DISASSEMBLY OF PTO
ASSEMBLY
1 HMT pump mount Input portion
1. Lubrication tube
Remove lubrication tube (I).
2. Power train, lubrication pump drive gear, cover

assembly
I) Using forcing screws 0, remove gear and
cover assembly (2). m
2) Disassemble gear and cover assembly as fol-

lows.
i) Remove cover (3) from gear and bearing
assembly (4).
ii) Remove lubrication guide plate (5) from

cover (3).
..I
DEW0961
iii) Remove bearing (6) from gear (7). 6

6 6
7’ DEL-X963 DDDX9E4
30-86
0
3) Remove lubrication guide plate (5) from case.
3. HMT pump drive gear, cover assembly

I) Using forcing screws 0, remove gear and
cover assembly (8).
2) Disassemble gear and cover assembly as fol-

lows.
i) Remove cover (9) from gear and bearing
assembly (IO).
DEDoos67 DDCKS3
ii) Remove bearing (11) from gear (12).
DEW0969 DDDO0370
30-87
0
Input gear, bearing assembly

1) Remove snap ring (13), then remove spacer
(14).
DDDCO971
2) Using puller 0, remove input gear and bear-

ing assembly (15).
DDDO’J972
3) Remove bearing (16) (inner race) from input

gear (17). 16 17
DDWa974
5. Bearing (input portion)

18
Remove bearing (18) from case.
30-88
0
6. Scavenging pump, charge pump drive gear

Remove snap ring (19) (small), then remove gear
(20).
DEDGOS76
7. Bearing (at scavenging pump, charge pump

drive portion)
Remove snap ring (21) (large), turn over case,
then remove bearing (22).
8. Idler gear
1) Remove holder (23).
28
2) Turn over case, use forcing screws @ to pull
up shaft (24), then remove idler gear (25)
and bearing (26) together. 27
* The gear will drop, so spread cloth or
thick paper below the parts.
24
3) Pull out shaft (24) further and remove bear-

ing (27) (inner race).
4) Remove bearings (26) and (27) (outer race),

and snap ring (28) from idler gear (25).
30-89
0
ASSEMBLY OF PTO
ASSEMBLY
Ir Clean all parts, and check for dirt or damage
before assembling.
* Drop engine oil on the rotating parts of the bear-
ing and rotate several times.
* Check that the snap ring is fitted securely in the
groove.
24
-;_
1. Idler gear
(Example of symbols)
Ir Match the production numbers and symbols
[Bl [Al
of the bearing and spacer, and use them in \ /
sets.
DAD01122
1) Fit snap ring (28) to idler gear (251, then

press fit outer race (27).
28 DAD01486
2) Using 3 guide bolts 0, insert shaft (24) to 6

position drawn in diagram.
Ir If shaft (24) is inserted fully, it will be
impossible to install idler gear (25).
& O-ring: Grease (G2-LI)
DAD01437
30-90
0
3) Install bearing (26) to shaft (24)

28
4) Install spacer (28).
DAD01488 DACO1483
5) Install idler gear (25).

6) Fit bearing (26), then tighten holder (23) with
bolt and press fit to shaft.
& Mounting bolt:
w Holder mounting bolt :
277.0 d 31.9 Nm (28.25 = 3.25 kgm)
7) Secure shaft (24) with bolts.
XC& Shaft O-ring portion: Grease (G2-LI)
6 Mounting bolt:
w Mounting bolt: 110.3 2 12.3 Nm DAD01492 II DAD01491
(I 1.25 I 1.25 kgm)
2. Bearing (scavenging pump, charge pump drive

portion)
Press fit bearing (22), turn over case, then install
snap ring (21) (large).
DEW0979 DDCOG378
3. Scavenging pump, charge pump drive gear

1) Hold bearing (22) from opposite side and
install gear (20).
2) Install snap ring (19) (small).

4. Bearing (input portion)

Install bearing (18) to case.
I DECO3975
5. input gear, bearing assembly

1) Press fit bearing (16) (inner race) to input
gear (17).
16
2) Support bearing (18) (already installed to Push

case), and press fit input gear and bearing S
assembly (15) from opposite side.
+
support DADtO
3) Fit spacer (14) and install snap ring (13).
I DDDOG971
30-92
0
6. HMT pump drive gear, cover assembly

1) Assemble gear and cover assembly as fol- Press t
lows.
i) Press fit bearing (11) to gear (12).
ii) Install gear and bearing assembly (IO)
to cover (9).
2) Install gear and cover assembly (8) to case.

8
6 Cover O-ring portion : Grease KGS-LI)
m Mounting bolt : 110.3 d 12.3 Nm
(11.25 f 1.25 kgm)
7. Power train, lubrication pump drive gear, cover Press fit 6 6

assembly
+
I) Assemble gear and cover assembly as fol-
lows.
DiSASSEMBLY AND ASSEMBLY PTO
ii) install lubrication guide plate (5-I) to

cover (3).
+ Align the direction when installing
so that the protruding portion enters
the groove.
iii) Install gear and bearing assembly (4) to

cover (3).
'5-1
3 DELXOS62 DAwo995
2) Install lubrication guide plate (5-2) to case.

* Align the direction when installing so that
the protruding portion enters the groove.
3) Install gear and cover assembly (2) to case.

6 Cover O-ring portion : Grease (G2-LI)
w Mounting bolt : 110.3 f 12.3 Nm
(11.25 f 1.25 kgm)
5-2 DACYSSS
8. Lubrication tube
Install lubrication tube (1).
w Joint bolt: 39.2 c 4.9 Nm
(4.0 + 0.5 kgm1 nt
30-94
0
DISASSEMBLY AND ASSEMBLY HMT
DISASSEMBLY OF HMT
ASSEMBLY
+ After removing the discs and plates, keep them
in a flat place to prevent bending or deforma-
tion.
1. PTO assembly
1) Remove cover (I), then remove strainer as-
sembly (2).
2) Remove lubrication tube (4).

3) Remove coupling (6).
4) Cover
i) Using forcing screws, remove cover (7).
ii) Remove oil seal (8) from cover (7).
5) Remove snap ring (9).
DLCOO563
6) Lift off PTO assembly (IO).
’ DLW0571
2. Control valve seat

Remove control valve seat (11).
3. Sleeves
Using eyebolts 0, remove 5 sleeves (12).
* Only one is long.
12
I DLCCCUZ DLCCC573
4. Transfer
1) Set
assembly
HMT assembly with transfer at top. 1
2) Lift off transfer assembly (13).
* The outer race of the bearing at the tip of
the HMT intermediate shaft will come out.
I ‘I DLDN574
. Disassembly of transfer assembly

I) Remove lubrication tubes (14) and (15).

3) Knock out from shaft end to remove trans-
mission output shaft assembly (17).
I J
30-96
0
4) Press outside circumference of ring (18) at

several places to compress it, then remove 18
ring gear (19) from output shaft (20).
5) Remove snap ring (211, then using forcing

DLC00577
7!ll
19
DKD00578
screws 0, remove gear and ring gear as-

sembly (22).
* The inner race of the ball bearing will
come out.
D-579
6) Remove ring gear (24) from housing (25).

Ir For details of the removal procedure, see
Step 4-4).
7) Remove housing (25) from gear (26).
* See Step 4-4).
8) Remove bearing (271, snap ring (281, and
bearing (27) from gear (26).
9) Using forcing screws 0, remove gear cage

(31) from rear case (23).
DKDW581
10) Idler gear

i) Using forcing screws 0, pull out shaft
(35).
ii) Remove gear assembly (36) from case
(23).
36 DLCWJ583
iii) Remove bearing (38) and snap ring (39)

from gear (37).
iv) Remove outer race (40) from gear (37).
40 37
DLDW585
1
11) HMT motor output gear assembly
i) Using forcing screws 0, remove cover
(41).
ii) Using gear puller @, pull out bearing
(43).
iii) Remove snap ring (441, then knock shaft

(42) out to end where snap ring was re-
moved.
44 42
DKDCO583
30-98
0
iv) Remove HMT motor output gear (45)

from rear case (23).
VI Remove bearing (46) from HMT motor
output shaft (42).
5. Transmission case
1) Remove block (1101, then using eyebolts,
remove sleeve (111).
2) Lift off transmission case (47).
Ir Remove the mounting bolts from the
PTO case end.
DBD01492 DLDo1254
6. Transmission intermediate shaft bearing

Using gear puller 0, remove bearing (48).
7. No. 6 carrier assembly

I) Remove snap ring (49).
DL!XN593
2) Lift off No. 6 carrier assembly (50).

* The bearing will come out on the 57 59 54 56
inside of the No. 5 carrier sun gear.
3) Disassembly of No. 6 carrier assembly
i) Remove ring (54).
ii) Pull out shaft (55), and remove thrust
washer (56), gear (571, bearing (58),
and ball (59).
58 55
DLW0594 DKIXX595
30-99
0
iii) Retract ring (52) to carrier side, then re-

move No. 5 carrier ring gear (51).
iv) Remove bearing (60) and sleeve (61)
from carrier (53).

I) Lift off No. 5 carrier assembly (62).
* The outer race of the bearing fitted in
the No. 6 housing will come out.
. Removal of inside planetary gear assembly
i) Knock roll pin (63) into shaft (64).
1 DLlXO597
ii) Pull out shaft (641, and remove gear (651,

thrust washer (661, and bearing (67).
* Remove roll pin (63) from shaft (64).
. Disassemble the outside planetary gear in
the same way.
iii) Compress ring (68) to sun gear side, then

remove sun gear (69).
30-100
0
9. Transmission intermediate shaft

(71).
2) Using eyebolts 0, lift off transmission inter-

mediate shaft (72).
Ir The outer race of the bearing will come
out.
DLCiOEOl
10. No. 5 sun gear

2) Remove ring (75), then remove snap ring
0’6).
3) Remove No. 5 sun gear (77).
11. Tie bolt

Remove tie bolt (78). 78
12. No. 5 housing

Using eyebolts @, lift off No. 5 housing (79).
13. No. 5 (1st) clutch disc, plate, spring

Remove springs (81) and (82), discs (84), and
plate (85).
* Discs: 2, Plate: 1
DLDX607
14. Spacer
Remove spacer (85).
15. No. 5 (1st) clutch hub

Remove hub (86).
16. No. 4 housing

I) Remove 28 mounting bolts (88).
DLD00608 DLDOO6G9
I
2) Using eyebolts @I, raise No. 4 housing (891,
then remove together with No. 5 (1st) clutch
piston (90).
17. No. 4 (3rd) clutch piston

Remove piston (91).
18. Guide pin

Remove guide pin (92). 95.
19. No. 4 (3rd) clutch discs, plates, springs

Remove springs (93) and (941, discs (95). and
plates (96).
* Discs: 3, Plates: 2
‘93
DLCW612

1) Using eyebolts 0, remove carrier assembly
(98).
2) Pull out shaft (991, then remove thrust washer
(IOO), bearing (lOI), gear (1021, and ball (103).
101 100 102
DLDW613 DKCCQ614
30-102
0
21. No. 4 sun gear

Remove No. 4 sun gear (97).
22. No. 4 carrier ring gear, No. 3 sun gear assembly

1) Remove No. 4 ring gear and No. 3 sun gear
assembly (104).
2) Remove snap ring (log), then remove bear-
ing (105) from sun gear (106).
3) Compress ring (108), and remove No. 4 car-
rier ring gear (107) from sun gear (106).
* For details of the removal procedure, see
Step 4-4). DLDOC615 DKECC616
23. Spacer
Remove spacer (I IO).
24. No. 4 (3rd) clutch inside ring gear

Remove ring gear (III).
25. No. 3 housing

Using eyebolts 0, remove No. 3 housing (112).
DLDO3517

1) Remove No. 3 carrier assembly (113).
* The inner race of the bearing will come
out.
2) Remove ring (114), and pull out shaft (115),
then remove thrust washer (1161, bearing
(1171, gear (1181, and ball (119).
3) Remove snap ring (1201, then remove bear-
ing (121).
115 11611E
DLCC0319 DKLXC620
27. No. 3 (2nd) clutch assembly

I) Ring gear (123) and washer (124).
2) Remove hub (125).
125 DKDCG621
3) Remove guide pin (130).

4) Remove springs (126) and (1271, discs (128),
and plates (129).
12:
DKDIX622
6) No. 3 (2nd) clutch housing’ I

i) Remove snap ring (131).
ii) Using eyebolts 0, remove housing (132) ((: 132
together with piston (133).
* Be careful not to make scratches when
levering from the No. 3 housing end.
I DLDX623 1 133 DLCCC624
28. Washer
Remove washer (138).
138
29. No. 2 housing assembly
1) Using eyebolts @I, remove No. 2 housing
assembly (139).
2) Remove hexagon socket head bolt (1401, then I

remove retainer (141). 1 142 141 I
3) Remove snap ring (1421, then remove bear-
ing (143) from retainer (141).
I DLDOG527 1 I DLDW628
1
30-104
0
30. No. 2 (F) clutch piston

Remove piston (144).
31 No. 2 (F) clutch springs, disc, plate

Remove springs (145) and (1461, disc (1481, and
plate (147).
146 147 DLDCCGO
32. Washer
Remove washer (149).
33. No. 2 carrier ring gear

Remove ring gear (150).
34. No. 1 housing

Using eyebolts 0, remove No. 1 housing (151).
DLBJC631 DLCW332
35. No. 1 (RI clutch piston 152

Remove piston (152).
DLiXC633
30-l 05
0
36. Guide pin

Remove guide pin (157).
37. No. 1 (RI clutch springs, disc, plate

Remove springs (153) and (1541, disc (156), and
plate (I 55).
154 ;55 DLDOO634

I) Remove No. 2 carrier assembly (158).
i) Compress ring and remove No. 1 carrier
ring gear (159).
ii) Remove ring (160).
iii) Pull out shaft (1611, and remove thrust

washer (1621, bearing (163), gear (164),
and ball (165).
163
DLDDW37
iv) Remove snap ring (166), then remove

bearing (167).
VI Remove bearing (168).
DLDOCCiB
30-106
0
39. input shaft

Remove snap ring (169), and disconnect input
shaft (170) from carrier.
* The input shaft will drop under its own
weight when the snap ring is removed.
40. No. 2 sun gear

Remove No. 2 sun gear (171).
41. Bearing, collar assembly

1) Remove bearing (172) and spacer (173) as a
set. I DLCOW41
2) Remove bearing (172) from collar.
42. No. 1 sun gear

1) Raise front cage assembly (175) and remove
input shaft (170).
2) Remove sun gear (176).
DLDOEG! DL-
43. Front cover

Remove cover (179), then remove bearing (180). 182
44. Collar
1) Remove snap ring (182) from front cage.
I DLDLW4.3 )
2) Remove cage (183) and ball (184) from front

cage (181).

1) Using forcing screws 0, remove No. 1 car-
rier assembly (185) from front cage (181).
181
DLlXW45 DLEXE47
2) Disassembly of No. 1 carrier

i) Remove snap ring (186), then remove
cage (187).
ii) Compress ring, and remove No. 1 (R)
clutch ring gear (188).
iii) Pull out shaft (191), and remove thrust

washer (192), bearing (193), gear (194),
and ball (195).
IQ2 DL!XC&S
46. No. 1 housing bearing

Remove bearing (196) from front cage (181). 181
DKDOOW
30-l 08
0
ASSEMBLY OF HMT
ASSEMBLY
* Clean all parts, and check for dirt or damage.
* Apply drops of engine oil to the rotating portion
of the bearing, then rotate several times.
* Coat the sliding surfaces of all parts with engine
oil before installing.
* Assemble the piston seal rings with the side
receiving the pressure facing the housing, coat
with grease (G2-LI) and install uniformly, taking
care that they do not move to one side.
* Fix the rotation seal ring in position with grease
DKDCU551
(G2-LI) and be extremely careful not to get it
caught when assembling.
* Check that the snap ring is fitted securely in the
groove.
* Align the plates and housings with the match
marks made during disassembly, and install.

1) Assembly of No. 1 carrier assembly
i) Assemble bearing (193) to gear (194),
then put thrust washers (192) in contact
on both sides, and set to carrier (189).
ii) Fit ball (195) and install shaft (191).
iii) Assemble cage (1871, and install snap

ring (186).
iv) Set No. 1 (R) clutch ring gear (188) to
No. 1 carrier (189).
v) Fit ring (190) to carrier end, then com-
press and install ring gear (188) to car-
rier.
DKCOC654
2) Fit seal ring to front cage (181), and set No.

1 carrier assembly (189) in position.
3) Press fit bearing (196) fitted with snap ring
(197) push tool @.
DKWa655
2. Cage
1) Install seal ring to cage (183). 182
2) Assemble ball (184) to front cage (181).
3) Install cage (183).
4) Install snap ring (182).
181
DLDOE46 DLDCO645
3. Front cover
I) Install bearing (180) to cover (179).
2) Install cover (179) to front cage (181).
DLEOO656 DLCO1256
4. Input shaft I I
1) Install snap ring (178) and seal ring to input
shaft (170).
2) Stand input shaft (170) upright, use eyebolts
@to raise cage. No. 1 carrier assembly (177),
and install input shaft.
5. No. 1 sun gear

Install sun gear (176).
6. Spacer assembly
I) Install bearing (172) to spacer (173).
172
30-110
0
2) Install spacer assembly (174). I 1
7. No. 2 sun gear

Fit No. 2 sun gear (171) and install snap ring
(169).
I I

I) Assembly of No. 2 carrier assembly
i) Press fit bearing (167) for input shaft,
and install snap ring (166).
ii) Install bearing (168) for transmission in-
termediate shaft to carrier.
iii) Assemble bearing (163) to gear (164),

ISI ,164
then put thrust washers (162) in contact
on both sides, and set to carrier.
iv) Fit ball (165) and install shaft (161).
* For details of the assembly condi-
tion, see the diagram in Step 1-1).
163
DLDJC637
v) Install ring (160).

vi) Set No. 1 carrier ring gear (159) to No. 2
carrier.
vii) Fit ring to carrier end, then compress
and install ring gear (159).
2) Install No. 2 carrier assembly (158) to No. 1 i
carrier.
Ir Press fit to the outer race of the bearing
between the No. 1 and No. 2 sun gears.
DLDoo636 DLiXOE35
30-111
0
9. Guide pin
install guide pin (157).
10. No. 1 (R) clutch discs, plates, springs

Install discs (156), plates (155), and springs (154)
and (153).
* Free length of spring (153) : 56.8 mm
11. No. 1 (RI clutch piston

Fit seal ring and install piston (152). 152
* Check that the spring is fitted securely in the
groove.

1) Install seal ring.
2) Using eyebolts 0, install No. 1 housing (151).
13. No. 2 carrier ring gear

Install ring gear (150).
14. Washer
Install washer (149).
DLDOOG?l
15. No. 2 (F) clutch discs, plates, springs

Install discs (1481, plates (1471, and springs (146)
and (145).
Ir Discs: 3, Plates: 2
145
//q 0000~ * \I
146 147 DLWX30
30-112
0
16. No. 2 (F) clutch piston

Fit seal ring and install piston (144).
Ir Check that the spring is fitted securely in the
groove.

1) Using push tool, press fit bearing (143) to
retainer (141), then install snap ring (142).
2) Install retainer (141) to No. 2 carrier, and

tighten bolts (140).
& Mounting bolt : Thread tightener (LT-2)
m Mounting bolt : 66.2 2 7.4 Nm
(6.75 z 0.75 kgm)
3) Install seal ring to No. 2 carrier.
4) Using eyebolts @, install No. 2 housing as-
sembly (139).
18. Washer
Install washer (138).
19. No. 3 (2nd) clutch assembly

I) No. 3 (2nd) clutch housing
i) Assemble ball (136) to housing (137),
then install sleeve (135).
ii) Install snap ring (134).
iii) Fit seal ring and install piston (133).

iv) Using eyebolts @I, install No. 3 clutch

housing (132).
* Press fit to the inner race of the bear-
ing of No. 2 housing.
v) Install snap ring (131).
DLDCC623
2) Fit seal ring and install hub (125).
I 125
3) Install guide pin (130).

4) Install discs (128), plates (1291, and springs
130
(127) and (126).
* Discs: 5, Plates: 4 128 l2? I
* Free length of spring (126) : 84 mm
DKDCC667
5) Install washer (124).

6) Install ring gear (123).
6 Mounting bolt : 123 124
m Mounting bolt : 156.9 d 19.6 Nm
(16 2 2 kgm)
DK-
30-114
0
20. No. 3 housing

I) Assemble sleeve (122) to housing (112).
Ir Install with the slit of sleeve facing the
No. 2 housing (input shaft end).
Ir Sleeve: 18 PCS. (the same as the number
of tie bolts).
2) Using eyebolts 0, install No. 3 housing (I 12).
Ir If the housing is not in tight contact,
tighten with temporary bolts to bring it
into tight contact.

Using push tool, press fit bearing (121) to
carrier, then install snap ring (120).
Assemble bearing (117) to gear (1181, then
put thrust washers (116) in contact on both
sides, and set to carrier.
Fit ball (119) and push shaft (1151, then in-
stall ring (114).
Install snap ring (120).
Install No. 3 carrier assembly (113).
* Be careful not to get your fingers caught.
DKCCCSZO I DLW0619
22. NO. 4 (3rd) clutch ring gear

Install ring gear (111).
23. Spacer
Install spacer (110).
DLCX617
24. No. 4 carrier ring gear, No. 3 sun gear assembly

I) Using push tool, press fit bearing (105) to
sun gear, then install snap ring (109).
2) Set No. 4 carrier ring gear (107) to sun gear
(106).
3) Fit ring (108) to sun gear, then compress
and install ring gear (107).
4) Install No. 4 carrier ring gear and No. 3 sun
gear (104).
DKW0616 DLW0670

I) Assemble bearing (101) to gear (1021, then
put thrust washers (100) in contact on both 98
2) Fit ball (103) and install shaft (99).
3) Using eyebolts, install carrier assembly (98).
DKDOD614 DLCCW.71
26. NO. 4 sun gear

Install No. 4 sun gear (97).
27. Guide pin

install guide pin (92).
g5\
28. No. 4 (3rd) clutch discs, plates, springs
Install discs (95), plates (96), and springs (94)
and (93).
29. No. 4 (3rd) clutch piston

Fit seal ring and install piston (91).
I DLtOJ611
30-m
0
HMT
30. No. 4 housing

1) Fit seal ring and install No. 5 (1st) clutch
piston (90) to No. 4 housing.
2) Using eyebolts @, install No. 4 housing (89).
3) Tighten mounting bolts (88).
a Mounting bolt :
w Mounting bolt : 66.2 + 7.4 Nm
(6.75 + 0.75 kgm)
Dm10 II
31. No. 5 (1st) clutch hub

hub gear (86).
2) Install No. 5 (1st) clutch hub (86).
32. Spacer
Install spacer (85).
33. No. 5 (1st) clutch discs, plate, springs

Install discs (841, plate (83), and springs (82) and
(81).
j, Discs: 2, Plate: 1
34. No. 5 housing

housing (79).
2) Using eyebolts @, install No. 5 housing (79).
DLCCO674
35. Tie bolt

Tighten tie bolt (78).
Tie bolt : Thread tightener (LT-2)
w Tie bolt : 166.7 + 9.8 Nm
(17 = 1 kgm)
36. Clutch piston operation check

Using tool D, check operation and stroke of pis-
ton.
. Piston stroke (when assembling as new
parts)
..
DLCOOS76
37. No. 5 carrier sun gear

1) Install sun gear (77).
2) Install snap ring (76), and assemble ring (75).
38. Transmission intermediate shaft 72

intermediate shaft (72).
2) Fit seal ring to tip of shaft and install inter-
mediate shaft (72).
* The outer race is press fitted to the inner
race of the bearing for the No. 3 carrier sun
gear and the No. 5 carrier sun gear.
30-118
0
3) Assemble spacer (71) and install snap ring

(70).
6

I) Assembly of No. 5 carrier assembly
i) Set NO. 6 carrier sun gear (69) to carrier,
then compress ring (68) to sun gear end,
and install sun gear (69).
DW’ II DLDO1253
ii) Assemble bearing (67) to gear (65), then 64

iii) Align hole of roll pin, then install shaft

(64), and knock in roll pin (63).
2) Raise No. 5 carrier assembly (62) and install. 2
DLDOO598 DLLXX597

I) Assembly of No. 6 carrier assemblv 57 59 54 56
i) Using push tool, press fit sleeve (61) and
bearing (60) to carrier.
ii) Assemble bearing (58) to gear (57), then
iii) Fit ball (59) and install shaft (55).
iv) Install ring (54).
v) Set No. 5 carrier ring gear (51) to

carrier (53), compress ring (52) to
carrier (53) end, and install ring gear
(51).
2) Raise No. 6 carrier assembly (50) and install.

* The outer race of the bearing installed
to the carrier is press fitted to the inside
of the No. 6 carrier sun gear.
3) Install snap ring (49) to intermediate shaft.
DLDC0594
41. Transmission intermediate shaft bearing

Using push tool, press fit bearing (48) to inter-
mediate shaft.
DLDCC631
42. Transmission case

1) Raise transmission case (47) horizontally and
install.
2) Using eyebolts, install sleeve (III).
3) install block (110).
DLD01254 DBD01492
30-120
0
DISASSEMBLY AND ASSEMBLY .H M T
43. Transfer assembly

l Assembly of transfer assembly
1) HMT motor output gear assembly
i) Using push tool, press fit bearing (46) to
HMT motor output shaft (42).
ii) Assemble HMT motor output gear (45)
to case (23).
1
iii) Align output shaft (42) with gear and set

in position, then press fit to case (23).
43 42 44
* The outer race of the bearing is press
fitted.
iv) Install snap ring (44).
v) Using push tool, press fit bearing (43) to

shaft (42).
vi) Fit O-ring and install cover (41).
2) Idler gear
i) Install snap ring (39).
ii) Using push tool, press fit outer race (40)
to gear (37).
iii) Assemble gear to bearing (38) and set in
case (23).
Ir There are 2 sets of inner race and
outer race for bearing (38). Snap ring
(39) and inner race spacer (38-I) are
manufactured as a set and are
marked with the same production
number, so during replacement,
match the production numbers when
assembling.
* In addition to the production num-
bers, the end faces of both the inner
race and outer race of bearing (38)
are marked with [Al and [Bl, so align
[AI with [Al and [Bl with [Bl when
assembling.
CVD0253(
30-121
a
iv) Procedure for selecting thickness of shim

(33).
1) Without assembling shim, press fit
shaft (35) completely to bearing (38).
2) Tighten 2 mounting bolts on diago-
nally opposite sides.
m Mounting bolt : 176.5 +. 19.6 Nm
{I9 + 2 kgm}
3) Loosen both mounting bolts (tight-
ened in step 2)) completely.
4) Measure clearance a between case
(23) and flange of shaft (35) at 2
places on diagonally opposite sides
with thickness gauge.
5) Select shim thickness so that it is di-
mension of clearance a + (0 - 0.05
mm).
l There are 3 types of shims: 0.05, 0.1,
0.3 mm
l Assemble the same type and number
of shims on the left and right.
v) Insert shims at clearance a on both sides,
then tighten 4 mounting bolts.
& Mounting bolt :
m Mounting bolt : 176.5 z 19.6 Nm CVDO2531
{I8 + 2 kgm1
3) Gear cage
gear cage (31).
ii) Install snap ring (32).
iii) Install gear cage (31) to rear case (23).
& Mounting bolt :
{I 1.25 f 1.25 kgm1
4) Gear assembly
ii) Install snap ring (28). 27 28
iii) Press fit bearing (27).
30- 122
a
5) Set housing (25) to gear assembly (26), fit

ring (30) to gear assembly, then compress
and install housing (25).
6) Set housing (24) to housing (25), fit snap
ring (29) into the groove on housing (24),
then compress and install housing (24).
7) Raise gear and ring gear assembly (22) and

install to rear case (23).
Ir The inner race of the bearing installed to
the gear is press fitted to the gear cage.
9) Transmission output shaft assembly

i) Set No. 6 carrier ring gear (19) to output
shaft (20).
ii) Fit ring to output shaft (20), then com-
press and install ring gear (19).
iii) Fit seal ring, then raise output shaft as-
sembly (17), and install to gear cage.
* Press fit to the inner race of the gear
cage bearing.
DUXK)ST DLW06-33
iv) Turn over output shaft assembly and in-

stall snap ring (16).
30-123
0
IO) Install lubrication tubes (15) and (14).
11) Fit O-ring, then raise transfer assembly (13)

and install to transmission case.
* Press fitted to the outer race of the bear-
ing at the tip of the transmission
mediate shaft.
inter-
1”
* Coat both sides of washers to be used
for 3 long bolts (underhead length : 155
mm) with gasket sealant.
. Both sides of washer (3 PCS.) :
Gasket sealant (LG-I or LG-5)
44. Sleeves
1) Raise HMT assembly and set facing to side.
2) Fit O-ring, then using eyebolts @I, install 5
sleeves (12).
* Only one is long.
45. Control valve seat

Fit O-ring and install control valve seat (II).
i2
DLW0573
46. PTO assembly

1) Fit O-ring, then raise PTO assembly (IO) and
install.
30-124
0
3) Cover
i) Using push tool, press fit oil seal (8) to
cover (7).
DUXC570
ii) Fit O-ring and install cover (7).

4) Install coupling (6).
5) Fit seal washer and install lubrication tube
(4).
6) Assemble strainer assembly (2) and install

cover (I).
30-125
0
DISASSEMBLY AND ASSEMBLY HSS CASE
DISASSEMBLY OF HSS CASE

ASSEMBLY
1. Brake, carrier assembly
1) Angie the HSS case assembly approx. 15”
so that tool El is perpendicular to ground
surface.
2) Remove mounting bolts, then using tool El,
remove brake, carrier assembly (I).
Ir Do not remove the hexagon socket head
bolt.
* Remove the brake and carrier assembly
on the other side in the same way.
. Disassembly of brake, carrier assembly

1) Remove flange (2) and plate (3).
2) Loosen hexagon socket head bolts uniformly,

then using eyebolts 0, remove brake case
(5).
* The case is being pushed by the brake
spring, so loosen it slowly and uniformly.
* The outside bearing will come out to-
gether with the cover.
3) Remove spacer (61, brake spring (7), piston

(81, and cylinder (9).
30-126
0
4) Remove brake drum (12) together with disc

and plate.
DKWlWl
5) Remove plate (13), disc (15), spring (’16), and

plate (14) from brake drum.
6) Remove mounting bolts, then remove car-

rier assembly (19) from hub (18).
7‘1 Remove gear assembly (20) from hub as-
sembly (18).
DLW1003 DLDUW4
8) Remove ring (211, then remove ring gear

(22) from gear (108). 23
9) Remove snap ring (231, and pull out shaft
(24).
24
DLDOlCC5 DLDOlCnX
30-127
0
IO) Remove planetary gear (251, bearing (26),

thrust washer (27), shaft (241, and ball (28).
11) Remove snap ring (31), then remove stop-

per (32) from hub (18).
DKCM1008
2. Bevel pinion assembly

I) Using guide bolts @ and forcing screws 0,
remove bevel pinion assembly (33) and shim
(34).
* Check the number and thickness of the
shims, and keep in a safe place.
2) Disassembly of bevel pinion assembly

i) Hold with press to prevent pinion from
moving, then use tool E2 to remove
locknut (39).
ii) Using push tool 0, remove bevel pinion

(40) from cage (41).
DLWlOlO DKlmo11
30-128
0
iii) Remove bearing (42).

iv) Remove outer races (43) and (107) from
cage (41). 42
/
41
DLDOlOl3
v) Remove bearing (109) from bevel pinion

(40).
DLD01014
3. Sun gear
Remove sun gear (45).
* Remove the sun gear on the opposite side
in the same way.
4. Gear
(48).
DLDOlOl5
2) Using gear puller 8, remove gear (49).

* Only inner race (50) of bearing (55) will re-

main.
* Remove the gear on the opposite side in the
same way.
DKDO1018
5. Valve seat
I) Pull out 2 brake circuit tubes (51) and 3 lu-
brication tubes (52), then remove.
2) Remove valve seat (53).
.s.
I DKDO1019
J
6. Lubrication tubes, dipstick tube, suction tube

I) Remove lubrication tubes (52) and (56).
2) Remove lubrication tubes (57) and (58).

3) Remove dipstick tube (59) and suction tube
(60).
DLW1022
30-130
0
7. Motor output gear

I) Remove flange (61) from case (62).
2) Remove flange and gear assembly (63). 63
61.___
DKDO1023
3) Remove gear assembly (65) from flange (64).
64
65
&
:;
4) Remove inner race (67) and bearing (68) from

gear (66).
5) Remove bearing (69) from flange (61).
69
61
~
66 DKCO1025 DKDN026
8. Right carrier drive gear

1) Remove bolt (701, then remove plate (71)
and gear (72).
’ //,I
DLD01027 DLC01028
2) Knock out shaft (73) with a plastic hammer

to remove.
3) Remove inner race (75) from bearing (74).

4) Remove bearing (74).
DLhJ3l
9. Intermediate gear
1) Remove shaft mounting bolt.
2) Using shock hammer @, pull out shaft (76),
then remove gear (77) and bearing (78).
10. Bevel gear shaft, bevel gear assembly

1) Remove left retainer mounting bolts (85).
2) Remove right retainer mounting bolts (86).
3) Using eyebolts (=(I, lift off bevel gear shaft
and bevel gear assembly (87).
shims at the left cage, and keep in a safe
place.
DLW1033 DLW1034
30-132
0
4) Disassembly of bevel gear shaft, bevel gear

assembly
i) Using puller 0, remove inner race (91)
from right shaft (92).
* Remove inner race (91) from the left shaft
in the same way.
AJ
DLWlG35 DKDO1036
ii) Remove right retainer (89) from shaft

(92).
DLDOlO37
iii) Remove hexagon socket head bolt (95),

then remove plate (93) and shim (94).
iv) Using tool E3, remove nut (96).

v) Using puller 0, pull out left retainer (97)

from shaft (92).
vi) Remove bearing (98) from retainer (97).
I
' DLW1040 DLW1041
vii) Remove nut (991, then remove bevel gear

(100) from shaft (92).
viii)Remove bearing (101) from right retainer

(89).
30-134
0
ASSEMBLY OF HSS CASE

ASSEMBLY
. Precautions when assembling \
Ir Apply drops of engine oil to the rotating portion
of the bearing, then rotate several times.
* Coat the sliding surfaces of all parts with engine
* Assemble the piston seal rings with the side
receiving the pressure facing the housing, coat
with grease (G2-LI) and install uniformly, taking
care that they do not move to one side.
+ Fix the rotation seal ring in position with grease I DLD01044
(G2-LI) and be extremely careful not to get it

caught when assembling.
t Check that the snap ring is fitted securely in the
groove.
1. Bevel gear shaft, bevel gear assembly

I) Assembly of bevel gear shaft, bevel gear
assem blv
i) Using push tool, press fit bearings (101)
and (74) to right retainer (89).
DIoxJ1045
ii) Shrink fit inner race (106) to shaft (92).

* Shrink-fitting temperature:
100°C for approx. 30 minutes
, DKW1047
iii) Set bevel gear (100) to shaft (921, and

tighten nut (99).
m Nut : 245.2 2 29.4 Nm
(25 2 3 kgm)
iv) Install seal ring.
I DLW1042
v) Assemble outer race (1031, bearing (1041,

spacer (1051, bearing (104) and outer race
(103) to left retainer (97) in order.
vi) Fit plate (931, then temporarily tighten
with several hexagon socket head bolts.
DKDO1048
vii) Support bevel gear with block 0, then

using push tool @, press fit retainer as-
sembly (102) to shaft.
I I
I
DKDO1049
I
viii)Secure shaft, then using tool E3, tighten

nut (96).
& Nut : Thread tightener (LT-2)
m Nut : 818.8 z 83.4 Nm
(83.5 2 8.5 kgm)
* Remove the hexagon socket head
bolts at the portion where the tool
contacts the bolts.
DLh)10!50
ix) Adjusting shim

Tighten 4 bolts lightly, measure dimen-
,o.
sion @ and dimension @ to calculate
_@
dimension @, then decide thickness of 0
shim @.
Shim thickness @ = 95---
(0 - 0) - (0.1 to 0.2 mm)
x) Assemble selected shim (941, then
tighten bolts (95).
DKDO1051
30-136
0
xi) Install right retainer (89) to shaft (92).

92
89
L-J DLw1037
xii) Shrink fit inner race (91) to shaft (92).

* Shrink-fitting temperature: 100°C for
approx. 20 minutes
DLWlG52
2) Install left retainer (88) and guide bolt @.

3) Using eyebolts @, raise right retainer, then
align guide bolt with bolt hole, and install
bevel gear shaft assembly (90) to case.
DLDO105.3 DLDO1054
4) Assemble shim to left retainer, then tighten

mounting bolts (85) and (86) of left and right
retainers.
* There are three types of shims: 0.1, 0.2,
0.5 mm
* The mounting bolts of the left retainer
are loosened when adjusting the back-
lash and tooth contact, but tighten them
fully here in order to check the starting
torque of the bevel gear shaft.
30- 137
0
5) Push tip of teeth of bevel gear (100) with

push-pull scale 0, and measure starting
torque of bevel gear shaft.
* Starting torque: Max. 3.0 Nm (0.31 kgm)
(At tip of bevel gear teeth:
Max. 19.6 N (2.0 kg))
I DLD31056
2. Intermediate gear
‘I) Assemble snap ring (83) and spacer (84) to
gear (771, then using push tool, press fit outer
race (82).
2) Assemble lower bearing (781, spacer (811,
and upper bearing (78).
78 77
I DKD3105?
3) Assemble gear assembly (79) to case (80),

then align bolt hole and install shaft (76).
* Align the bolt holes of the plate when
installing the shaft.
DLCO1058 DLCO1059
3. Right carrier drive gear

case.
2) Using push tool, press fit inner race (75) to
shaft (73).
* Press fit to a point approx. 27 mm from
shaft surface.
* Install to one side only.
DLWlOGO
30-138
0
3) Align shaft (73) with bearing and install.
4) Using push tool, install inner race (75) to

between shaft and bearing.
li Hold the shaft from the opposite side.
5) Fit gear (72) and plate (71), then tighten bolt

(70).
w Mounting bolt : 110.3 2 12.3 Nm
(11.25 = 1.25 kgm)
DLDO1027 DLKi102i
4. Lubrication tubes, dipstick tube, suction tube

1) Install suction tube (60) and dipstick tube
(59).
2) Install lubrication tube (57),(58).
QEEI Joint bolt: 8.8 L $9 Nm
(0.9 + 0.1 kgm)
DLW1022 1 DLW1021
3) Install lubrication tube (56).

m Joint bolt: 39.2 = 5.0 Nm
(4 2 0.51 kgm)
5. Bevel pinion assembly

I) Assemble bevel pinion as follows.
i) Using push tool, press fit bearing (109)
to bevel pinion (40).
DLWlOl4
ii) Using push tool, press fit outer races

(43) and (107) to cage (41).
iii) Put bevel pinion (40) on press stand, and
set cage (41) in position.
iv) Press fit bearing (42) to cage (41) with

press.
VI Hold in press so that pinion does not
move, then use tool E2 and tighten
locknut (39).
6 Locknut: Thread tightener (LT-2)
w Locknut : 779.6 f 83.4 Nm
(79.5 f 8.5 kgm)
* Rotate the cage when tightening.
* After tightening the nut, check that
the bevel pinion rotates smoothly.
,
’ DLDOlOS7 DLWlC68
30-140
0
2) Using guide bolt 0, assemble shim (34) and

install bevel pinion assembly (33).
* There are three types of shim:
0.1, 0.2, 0.5 mm
6. Adjusting tooth contact, backlash

1) Adjusting backlash
Put the probe of dial gauge @ at right an-
gles in contact with the tip of the bevel gear
teeth. Hold the bevel pinion in position, and
read the measurement when the bevel gear
is moved forward and backward.
* Standard value for backlash :
0.25 - 0.33 mm
* Measure at least three points on oppo-
site sides.
. If the result of the inspection shows that
the correct backlash is not being ob-
tained, adjust as follows.
* Adjust the shim thickness at the left cage.
. If backlash is too small Front
Loosen mounting bolt of cage and re- t

move shim.
0Amo157
. If backlash is too large

Loosen mounting bolt of cage and add Front
shim. t
BC
i
DAco3158
1
30-141
0
2) Adjusting tooth contact

Testing
i) Coat the tooth face of the bevel pinion lightly
with red lead (miniurn). Rotate the bevel
gear forward and backward and inspect the
pattern left on the teeth.
ii) Tooth contact should be checked as follows
(from tip of teeth of bevel pinion).
a) Center of tooth contact: 20 - 40 % of
tooth width (from small end) _..----
Small end
b) Width of tooth contact: 30 - 50 % of tooth
width DBD00159
I
c) Center of tooth contact: 35 - 65 % of
tooth height (from root of tooth)
d) Width of tooth contact: 60 - 80 % of tooth
height
In addition, there should be no strong con-
tact at the addendum or dedendum (tip or
root of the gear teeth) or at the big and
small ends.
* If the gears are adjusted to this pattern,
the tooth contact will be correct when
load is applied.
I \ DBiXXWiC
Adjustment
If the result of the inspection shows that the
correct tooth contact is not being obtained, ad-
just again as follows.
i) If bevel pinion is too far from center line of
bevel gear.
Contact is at the small end of the convex
tooth face of the bevel gear and at the big
end of the concave tooth face.
. Correct the tooth contact as follows.
Adjust the thickness of the shims at the bevel
pinion to move the bevel pinion in direction
A.
Move the bevel gear in direction B, then
check the tooth contact pattern and back-
lash again.
ii) If bevel pinion is too close to center line of
bevel gear.
Contact is at the big end of the convex tooth
face of the bevel gear and the small end of
the concave tooth face.
. Correct the tooth contact as follows. BC
Adjust the thickness of the shims at the bevel
pinion to move the bevel pinion in direction
B. d
Move the bevel gear in direction A, then
check the tooth contact pattern and back-
lash again. I- L,,
30-142
0
7. Motor output gear

6
flange (61).
2) Using push tool, press fit inner race (67) and
bearing (68) to gear (66).
61
DKC01026 66 DKDO1025
3) Install gear assembly (65) to flange (64).
DKD01024
4) Install flange and gear assembly (63) to case

(62).
5) Install flange (61).
61
KDO1023
8. Valve seat
1) Install lubrication tube (52).
52
2) Align with lubrication tube (52) (installed in

Step 8-l)), then install valve seat (53).
3) install brake circuit tube (51) and lubrication 52
tube (52).
:
51
‘51
DKW1019
9. Gear
1) Install inner bearing (551, snap ring (541, and
outer bearing (55) to gear (49).
2) Align gear (49) with bearing of bevel gear
shaft and install.
DLW1072
3) Using push tool, press fit inner race (50).

II II DKD01074
10. Sun gear

I) Install thrust washer (46) to sun gear (45).
2) Install sun gear (45).
457 DKCQ107: I I DLD01015
30-144
0
11. Brake, carrier assembly

Ir Assemble both sets in the same way. 32
. Assembly of brake, carrier assembly
I) Assemble stopper (32) to hub (18). then in-
2) Install bushing (38).
3) Using push tool, press fit inner race (37).
I DKEO1075
4) Carrier assemblv
i) Assemble bearing (26) to gear (251, then
ii) Fit ball (28) and install shaft (24).
iii) Remove snap ring (23).
iv) Install sleeve (36) to carrier (35).
24 35 36
DKC01076
v) Install bushings (29) and (30) to gear

(108).
vi) Set gear (108) to ring gear (221, then fit
ring (21) and install ring gear to gear.
DLDolCO5
vii) Install gear assembly (20) to hub (18).

viii)lnstall carrier assembly (19) to hub (18). 20
18
m Mounting bolt : 110.3 = 12.3 Nm
(11.25 = 1.25 kgm)
9
18
I DLDO1004 DLWlW3
30-l 45
0
5) Set brake drum (12) to hub assembly (18).

6) Install discs (15), plates (14) and (13);and
spring (16). 13 18
* Discs: 5, Plate (14): 4, Plate (13): 1
DKD01079
7) Hub
hub (9).
DKDO1080
ii) Fit seal ring and install hub (9).

9) Install piston (8) and spring (7).
Ir Install so that the outside circumference
of the spring opens.
IO) Brake cover assembly

brake cover (IO).
ii) Install guide bolt @ to hub (9).
30- 146
0
iii) Using eyebolts 0, align bolt hole with

hub and brake drum, then install brake
cover assembly (5).
Sr Tighten the mounting bolts tempo-
rarily.
* The force of the spring is applied, so
tighten the hexagon socket head
bolts uniformly.
iv) Using push tool, press fit inner race (4).

v) Install plate (3) and flange (2).
w Flange: 66.19 + 7.35 Nm
(6.75 + 0.75 kgm)
vi) Fully tighten bolts temporarily tightened
in Step iii).
,
w Mounting bolt: 110.32 z 12.26 Nm
(11.25 d 1.25 kgm)
r DKWlOS3
II DLW1255
. Installation of brake, carrier assembly

1) Angle steering case assembly approx. 15”
so that tool El is perpendicular to ground
surface.
2) Using tool El, install brake, carrier assembly
(I).
w Mounting bolt: 110.32 t 12.26 Nm
(11.25 t 1.25 kgm)
* Assemble the brake, carrier assembly on
the opposite side in the same way.
DLDC0997
Sr When cover (109) of the rear surface on

HSS case (107) has been removed, in-
stall new gasket (108).
& Gasket (apply to both surfaces):
DAD02453
DISASSEMBLY AND ASSEMBLY POWER TRAIN, LUBRICATION PUMP
REMOVAL OF POWER TRAIN,

LUBRICATION PUMP
ASSEMBLY
1. Remove floor frame cover.
2. Disconnect fuel control rods (I) and (2). a
3. Disconnect brake rod (3). m
DBDOO594
4. Disconnect throttle potentiometer connector (4)

(CN-THRTL).
5. Disconnect brake potentiometer connector (5)

(CN-BRAK).
6. Remove floor plate (6).
7. Disconnect intermediate connector (7) (CN406),

and remove from bracket.
8. Disconnect connectors (8) (CN-PLTP) and (9)

(CN453) for power train oil temperature sensor,
and remove from bracket.
9. Disconnect inlet tube (IO).
10. Disconnect outlet tubes (II) and (12).
11. Sling power train, lubrication pump assembly

(131, then remove mounting bolts and lift off.
&I kg Power train, lubrication pump assembly :

30 kg
30-l 48
0
DISASSEMBLY AND ASSEMBLY POWER TRAIN, LUBRICATION PUMP
INSTALLATION OF POWER
TRAIN, LUBRICATION PUMP
ASSEMBLY
removal.
pd-
j, After connecting the rod, adjust the fuel con-
trol linkage.
For details, see TESTING AND ADJUSTING,
ADJUSTING FUEL CONTROL LINKAGE.
m
Ir Tighten the locknut of the rod securely.
w Locknut: 46.6 z 12.3 Nm (4.75 2 1.25 kgm)
Ir After connecting the rod, adjust the brake

pedal linkage.
ADJUSTING BRAKE PEDAL LINKAGE.
30- 149
0
DISASSEMBLY AND ASSEMBLY SCAVENGING, CHARGE PUMP
REMOVAL OF SCAVENGING,
CHARGE PUMP ASSEMBLY
1. Drain oil from hydraulic tank.
- : Hydraulic tank : 97 .r?
3. Disconnect hose (I 1.
* Carry out the operation from the engine room
end.
4. Lift opposite side of hinge and gradually open DEW0699

underguard under power train unit to ground
surface.
5. Disconnect tubes (2) and (3).

2
7’
i
6. Sling scavenging, charge pump assembly (4)

with rope from floor frame end and remove.
& kg Scavenging, charge pump assembly :

30 kg
INSTALLATION OF
SCAVENGING, CHARGE PUMP
ASSEMBLY

removal.
level.
30- 150
0
DISASSEMBLY AND ASSEMBLY HMT PUMP
REMOVAL OF HMT PUMP

ASSEMBLY
A Disconnect the cable from the negative
(-) ter-
sr Make match marks or fit tags to the hoses and

pipes to prevent any mistake in the position
when installing.
2. Disconnect fuel control rods (I) and (2). m
4. Disconnect throttle potentiometer connector (4)

(CN-THRTL).

(CN-BRAK).
6. Remove floor plate (6).
. . Disconnect intermediate connector (7) (CN406).
8. Disconnect connectors (8) (CN-PLTP) and (9)

(CN453) for power train oil temperature sensor.
9. Disconnect connectors (IO) (CN-PUPA) and (11)

-(CN-PUPB) for pump servo.
10. Disconnect connectors (12) (CN009, CNOIO)

for engine speed sensor.
* Move the wiring assembly to the left.
11. Disconnect drain hoses (13) and (14).
12. Disconnect pilot hoses (15) and (16).
13. Disconnect main hoses (17) and (18).
14. Disconnect charge tube (19).
15. Disconnect cooler hose (20).
16. Sling HMT pump assembly (211, then remove

mounting bolts, and lift off HMT pump assem-
bly (21).
&I kg HMT pump assembly : 110 kg
INSTALLATION OF HMT PUMP

ASSEMBLY
removal.
m
* After connecting the rod, adjust the fuel con-
trol linkage.
* After connecting the rod, bleed the air from
the HMT pump.
BLEEDING AIR FROM HMT PUMP.
m
* Tighten the locknut of the rod securely.
m Locknut: 46.6 2 12.3 Nm
(4.75 +. 1.25 kgm)
* After connecting the rod, adjust the brake
pedal linkage.

level.
Ir Run the engine to circulate the oil through
30-152
0
DISASSEMBLY OF HMT PUMP

ASSEMBLY
1. Set pump assembly (I) to tool Tl.
2. Servo valve assembly

1) Remove servo valve assembly (2) from pump
assembly (1).
* Loosen and remove the bolts marked *X

in turn on opposite sides.
* Be extremely careful not to bend the arm
when removing.
% DAD01266
2) Remove O-ring (3) and filter (4).
3. End cap assembly

I) Remove relief valve assembly (5).
* Loosen relief valve (8) first.
DBDO1267 i-h ’ DBD01268
2) Turn over tool Tl 90”, then remove end cap

assembly (6).
* When removing the end cap assembly, ,Tl
be careful not to drop the valve plate.
\ 1 DBD01270
30-152-l
0
. Disassembly of end cap assembly

I) Remove valve plate (7) from end cap (6).
2) Remove relief valve (8).
3) Remove bearing (9) and dowel pin (IO).
4) Remove 3 O-rings.
7
DBD01271 DBD01272
4. Cylinder block, piston assembly

Remove cylinder block and piston assembly (11)
from pump case (12).
* The cylinder block, piston assembly, and re-
tainer guide may come off separately, so be
careful not to drop them.
. Disassembly of cylinder block, piston assem-

bly
I) Pull out piston assembly (14) from cylinder
block (131, then remove retainer guide (15).
* When the piston assembly is removed 16
from the cylinder block, preload pin (16)
may fall out, so be careful. 13-
DAD01274
. Disassembly of piston assembly

Pull out piston (18) from retainer shoe (17). 18
17 DAD01275
30-152-2
0
. Disassembly of cylinder block

1) Set tool T2 to cylinder block (131, secure bolt 13
of tool T2 with wrench, and tighten nut to T2 22 I 21
compress spring (191, then remove snap ring
(20).
2) Loosen nut of tool T2 slowly and release
tension of spring (19), then remove tool T2.
3) Remove spacer (21), spring (191, and spacer
(22) from cylinder block (13).
* Check the assembly direction of spacer
(21).
DAD01295
I
5. Rocker cam
Remove rocker cam (24) and slider (25) from
shaft (23).
6. Servo piston
28
1) Loosen locknut (26) for adjusting stroke of
servo piston.
2) Remove cap assembly (27) from pump case
(28).
3) Remove servo piston (29).
26 2Ei
DBD01278 DBD01279
. Disassembly of cap assembly

Remove locknut (261, then remove cap
(30), retainer (311, spring (32), and rod
(33).
DBD01280
30- 152-3
0
7. Shaft, cradle assembly

1) Remove 6 bolts (341, then remove shaft and
cradle assembly (35).
2) Remove O-ring (36) and dowel pin (37).
DBD01281 DBD01282
. Disassembly of shaft, cradle assembly

1) Remove cradle (38) from shaft (23).
2) Remove snap ring (391, then remove washer 23
(40).
DBD01283 DBD01284
3) Using push tool 0, remove bearing (41) from

shaft (23).
* Bearing (41) will divide into the inner
race and bearing, so be careful not to to
lose either part.
t Check the assembly direction of the bear-
ing.
DBD01285
8. Oil seal
42
1) Remove snap ring (42) from pump case (28),
then remove spacer (43). +-===T?
_lG -
2) Remove oil seal (44).
/\
DBD01286
Q 0
(
DBD01287
30-152-4
0
9. If above disassembly operation is not needed,

and only oil seal is replaced, replace oil seal as
follows.
I) Remove snap ring (42) and spacer (43).
2) Using bar @ (hit end face with hammer), hit
through to core of oil seal (44), then twist to
remove.
* Hit at a point midway between the in-
side and outside circumference of the
oil seal, and twist at two places on op-
posite sides (A and B in diagram) to re-
move.
* Be careful not to damage the case press-
fitting surface and sliding surface of the
shaft and the oil seal.
30-152-5
0
ASSEMBLY OF HMT PUMP

ASSEMBLY
* Clean all parts, remove all burrs, and check for

dirt or damage.
* Coat the rotating and sliding surfaces of all parts
with engine oil (EOIO-CD) before installing.
* Always check the following parts before assem-
bling.
i) Check contact of cradle and rocker cam (for
details, see PROCEDURE FOR CHECKING
CONTACT).
ii) Check contact between cylinder block and
valve plate (for details, see PROCEDURE FOR
CHECKING CONTACT).

. Assembly of shaft and cradle assembly
1) Assemble inner race to shaft (23), then using
push tool 0, press fit bearing (41).
& Press-fitting surface of bearing:
Grease (G2-LI)
* When press fitting the bearing, push the
end face of the bearing inner race with
push tool 0.
DBD01289
2) Assemble washer (40), and install snap ring

(39).
* Method of selecting lock washer (40).
i) After press fitting bearing (41) to shaft
(23), assemble washer (40).
ii) Measure clearance a between end face
of assembled washer (40) and snap ring
groove.
* Clearance a: 1.8 - 2.0 mm
iii) If clearance a is not within above stand-
ard value, select washer from table be-
low and assemble. DBD01290
w
Snap ring groove 1
40
41
7 23
DAD01291
30- 152-7
0
3) Press fit cradle (38) to shaft (23) with

hydraulic press.
4) Set pump case (28) to tool Tl.
5) Assemble dowel pin (37) and O-ring (36)
to bottom surface of inside of pump case.
DBD01292 DBD01282
6) Set shaft and cradle assembly (35) to pump

case, and tighten mounting bolts (34).
m Mounting bolt: 110.3 z 12.3 Nm
(11.25 = 1.25 kgm)
DBD01293
2. Servo piston
Assemble servo piston (29) to pump case (28).
* Be careful of the left and right directions of
the servo piston.
3. Rocker cam
Fit slider (25) to rocker cam (241, then set to
servo piston and shaft assembly (23).
01277
30-152-8
0
4. Cap assembly
I) Assembly of cap assembly
Fit O-ring, retainer (311, and spring (32) to
rod (331, then screw into cap (30), and install
locknut (26).
2) Install O-ring to cap assembly.
I DBD0128C
3) Adjusting stroke of servo piston

i) Align groove for servo valve arm of servo
piston and dowel pin, then install tool
T3.
ii) Assemble until retainer of cap assembly
(27) contacts servo piston (29).
* Installed load: 29.4 - 49.0 N
(3 - 5 kg)
iii) In condition in Step ii), measure with
feeler gauge @ and turn rod (33) to ad-
just so that clearance at portion S is 0 -
0.1 mm. DBDO129;
iv) Tighten mounting bolts of cap assembly

(27).
w Mounting bolt: 66.2 L 7.4 Nm
(6.75 = 0.75 kgm)
v) Secure rod (33) so that it does not turn,
then tighten locknut (26).
m Locknut: 294.2 2 29.4 Nm
(30 = 3 kgm)
vi) Remove tool T3.

. Assembly of cylinder block
I) Assemble spacer (22), spring (19), and spacer
(21) to cylinder block (13).
* Assemble with the tapered portion on
I 27 3i 29
DAD01299
the inside of spacer (22) facing down.

2) Set tool T2 to cylinder block (13).
3) Secure bolt of tool T2 with wrench, tighten 13
nut to compress spring (191, then install snap T2 22 / 21
ring (20).
* Check that the snap ring is fitted securely
in the groove.
4) Remove tool T2.
DAD01295
30-152-9
0
. Assembly of piston assembly

5) Measure thickness b of each piston shoe.
* Standard value of thickness b:
5.8 + 0.015 mm r--IF--
t DAD01300
6) Assemble piston (18) to retainer shoe (17).
I 17 DAD01275 5
7
0
7) Assemble 3 preload pins (16) to cylinder

block (13).
* To prevent preload pins (16) from com-
ing out, coat the pins with grease (G2-
LI). 16
8) Assemble retainer guide (15) to cylinder
block (131, then assemble piston assembly
(14).
DAD01274
9) Turn over tool Tl 90”, and install cylinder

block and piston assembly (IO) to pump case
(11).
* Before installing the cylinder block and
piston assembly, assemble the width
across flats of the rocker cam securely
to the cradle.
30-152-10
0
5. End cap assembly

1) Assembly of end cap assembly
i) Using push tool 0, press fit bearing (9)
to end cap (6).
ii) Install dowel pin (IO) to end cap.
DBD01301
2) install valve plate (7) to end cap (6).

* Fit relief valve (8) temporarily. 8
\
* When assembling the valve plate, check
that there is no interference with bear-
ing (9) and dowel pin (IO).
* Do not hit the valve plate or apply any
impact when assembling. (There is dan-
ger that this will damage the sliding sur-
face or cause distortion.)
3) Install 3 O-rings.
7
DBD01272 DBD01271
4) Fit dowel pin to pump case and install end I
cap assembly (6).

* Be careful not to drop the valve plate.
Tl
* Be careful that the O-ring does not come
out or get caught.
* Be careful that there is no rising and
that the pin does not fall out.
w Mounting bolt: 384.9 + 41.7 Nm
(39.25 = 4.25 kgm)
DBD01270
5) Install relief valve (5).

w Relief valve: 225.5 + 9.8 Nm
(23 2 1 kgm)
6) Tighten relief valve (8).
w Relief valve: 53.9 = 4.9 Nm
(5.5 + 0.5 kgm)

I) Fit filter (4) to pump assembly and install O-
ring (3).
30-152-11
0
2) Install servo valve assembly (2) to pump as-

sembly (I).
m Servo valve: 30.9 2 3.4 Nm
(3.15 + 0.35 kgm)
1265
7. Oil seal
1) Turn tool Tl 90” clockwise, then using tool
T4, install oil seal (44) to pump case (28).
& Lip of oil seal:
Lithium grease (GS-LI-S)
in the groove.
DAD01371 DBD01286
8. Measuring rotating torque

Install bolt (Ml0 x 1.5, length below head 13
mm) to shaft (23), set torque wrench @ in posi-
tion, then rotate shaft at a constant speed (3 - 5
set/l turn) and measure rotating torque.
* Check that the shaft rotates smoothly when
measuring the rotating torque.
* Variation range: Max. 5.9 Nm (0.6 kgm)
* Rotating torque: 25.5 +. 7.8 Nm
(2.6 f 0.8 kgm)
30-152-12
0
CHECKING CONTACT BETWEEN CYLINDER

BLOCK AND VALVE PLATE, ROCKER CAM AND
CRADLE, VALVE PLATE AND END CAP
Cylil
plate
1. Checking contact between cylinder block and
valve plate
* This check is unnecessary if both the cylin-
der block and valve plate are replacement
parts (new parts).
* This check applies if one of the parts is a
replacement part or a restored part.
1) Make a centering tool @ for the cylinder
U u DAD01304
block and valve plate.
* The tool can be made from plastic,
bakelite or any other soft material.
2) Remove all oil and grease from the parts to
be checked.
* Do not wipe with a cloth.
3) Set the tool in position, then paint the cylin-
der block with inspection paint.
* Coat thinly with paint.
4) Push the valve plate with a force of 39 - 49
N (4 - 5 kg) against the cylinder block, turn
the valve plate 90”, then turn it back to the
original position. Repeat this process 2 or 3
times.
5) Remove the valve plate, transfer the contact
surface to a tape, and check the contact sur-
face.
* Check that the contact of the spherical
surface of the valve plate and cylinder Cylinder block Valve plate
block fulfills the conditions in the dia-

gram on the right and covers the whole
circumference without any break.
* The standard for the contact surface at
seal portion a is as shown in the table
below.
(Seal portion)
Range more then 60% contact

DAD01305
Land portion
* Check that the relationship of the con- I Outside seal
tact is as given below.

Inside seal > Outside seal z= Land
* For details of the operation, see the Shop
Manual GUIDANCE FOR REUSABLE
PARTS (SEBG4240).
Valve plate Cylinder block

DAD01306
30-152-13
0
2. Checking contact of rocker cam and cradle

* This check is unnecessary if both the rocker
cam and cradle are replacement parts (new
parts).
be checked.
2) Set the tool in position, and paint the cradle
with inspection paint.
3) Put the rocker cam on top, push with a force
of 39 - 49 N (4 - 5 kg], and move it between
the maximum swash plate angle and the
position where it contacts the stopper. Re-
peat this process 2 or 3 times.
4) Remove the rocker cam, transfer the contact
face.
* Check that the contact between the cy-
lindrical surface of the cradle and the
cylindrical surface of its rocker cam is a
seat contact.
* The standard for the contact surface is
as given below.
Rocker cam
Contact
Min. 90% 50 - 90% Max. 50%
surface
* It is not permitted to have contact only

at the outside and no contact at the
L67mml
center. Cradle
[Reference] If the contact is not within the stand- DE001307
ard value, and lapping is carried

out, it must always be carried out
for both parts together.
* Parts with any scratches or damage must
not be used.
30-152-14
0
3. Checking contact between valve plate and end

cap
* This check is unnecessary if both the valve Valve plate
End cap
plate and end cap are replacement parts (new
parts). /
* If the contact is defective, use a surface plate The contact of
surface must
and correct by lapping. cover at least
1) Remove all oil and grease from the parts to 80% without
any variation
be checked. ‘i
* Do not wipe with a cloth. DAD01308
2) Paint the end cap with inspection paint.

N (4 - 5 kg) against the end cap, turn the
valve plate 90”, then turn it back to the origi-
nal position. Repeat this process 2 or 3 times.
face.
* The contact of the mating surface of the
valve plate and end cap must cover at
least 80% without any variation.

Manual GUIDANCE FOR REUSABLE PARTS
(SEBG4240).
30-152-15
0
DISASSEMBLY AND ASSEMBLY HMT MOTOR
REMOVAL OF HMT MOTOR

ASSEMBLY
* After disconnecting the pipes and hoses, fit blind
plugs to prevent dirt or dust from entering.
* Make match marks or fit tags to the hoses and
when installing.

ASSEMBLY.
2. Disconnect fuel return hose (I) from fuel tank

(2).
3. Disconnect connector (3) (CN422) for fuel level

sensor at bottom of fuel tank.
4. Close fuel supply valve, and disconnect fuel sup-

ply hose (4).
Remove fuel drain hose clamp, and lift off fuel

tank assembly (2).
&?Ikg Fuel tank assembly : Approx. 660 kg

(when full)
6. Disconnect connectors (5) KIN-MRA) and (6) (CN-

MRB) for motor servo.
7. Disconnect connector (7) (CN452) for hydraulic

oil temperature sensor, and remove pump case
clamp.
8. Disconnect drain hose (81, then remove clamp,

and move towards HSS case.
9. Disconnect charge hose (9), then remove clamp,

and move towards engine.
IO. Disconnect transmission lubrication pressure

detection tube (IO) and brake pressure detec-
tion tube (II).
11. Remove bracket (12) for centralized pressure

sensor, then remove clamp and move bracket
and tube towards right.
DAD30707
12. Disconnect cooler hose (13).
13. Disconnect drain hose (14) and remove clamp.
14. Disconnect drain hoses (151, (16), and (17).
15. Disconnect main hoses (18) and (19).
30- 154
0
16. Disconnect parking brake cable (20), then re-

move mounting bolts of bracket (211, and re-
move cable (20) together with bracket (21).
17. Disconnect connector (22) (CN-MREV) for motor

speed sensor.
18. Remove motor speed sensor (23).

* Remove the spring at the tip of the shaft.
20. Remove snap ring (25), then remove shaft (26).
21. Remove mounting bolts of mount bracket (27) a

motor end, and loosen mounting bolts at trans-
mission end. m
8
3 22. Sling HMT motor assembly (281, then remove DBW0711 DBCGO712
z mounting bolts, and lift off HMT motor assem-

bly (28).
+I ks HMT motor assembly : 180 kg
INSTALLATION OF HMT
MOTOR ASSEMBLY
DEW0713
removal.
m Mounting bolt of mount bracket:

277.0 + 31.9 Nm
(28.25 2 3.25 kgm)

level.
MOTOR ASSEMBLY
* The procedure for disassembling the front and
rear motors is basically the same, so only the
procedure for disassembling the front motor is
given here. In cases where there is a difference
in the procedure for the front and rear motors,
the procedure for the rear motor is given sepa-
rately.
1. Motor assembly
Set motor assembly (I) to tool Ul.

I) Remove servo valve assembly (2).
I
DBDOl
* Loosen and remove the mounting bolts

marked % in turn on opposite sides.
* Be extremely careful not to bend the arm
when removing.
g
DAD01266
30- 155-1
0
2) Remove O-ring (3) and filter (4).
DBD01312
I
3. Servo piston cap

1) Rotate tool Ul 90” and face servo piston
caps to left and right.
2) Remove servo piston cap (5) on your left.
JJI
DBD01314
3) Servo piston cap (6) on your right is under

tension from a spring, so remove it as fol-
lows.
i) Remove 2 mounting bolts on opposite
sides, then set bolts @ and nuts @ in
position and remove remaining mount-
ing bolts.
ii) Loosen nuts @ uniformly, and remove

servo piston cap (6) and spring (7).
DBD01316
4. Rear motor assembly

1) Remove snap ring (8). then remove cap (9).
2) Using tool U2, secure shaft of rear motor.
8, DBD01319
3) Lift off rear motor assembly (IO).

* The valve plate may be stuck to the rear
motor, so be careful not to drop it.
5. Valve plate
1) Rotate tool Ul 90”, and set end cap facing
up.
2) Remove valve plate (11) for rear motor from
end cap.
* When using the valve plate again, keep
in a safe place and be careful not to
scratch or damage the cylinder block
contact surface.
322
30- 155-3
0
3) Remove sub bearing outer race (12) and

spacer (13).
6. Coupling
Remove coupling (141, dowel pin (151, and O-
ring (16).
‘1324
-
7. End cap assembly

I) Remove end cap assembly (17).
* The valve plate for the front motor may
be stuck to the rear surface, so be care-
ful not to drop it.
* Be careful not to let the front motor bear-
ing outer race and spacer fall from the
rear surface.
2) Loosen shuttle valve (28).
DBD01325
3) Remove valve plate (18) for front motor from

back face of end cap.
4) Remove O-ring (19).
DBD01326
30- 155-4
0
5) Remove dowel pin (20).

6) Remove sub bearing outer race (21) and
spacer (22) for front motor.
DBD01327 DBD01328
. Disassembly of end cap assembly

I) Remove charge relief valve (23).
23
DBD01329
2) Loosen plug (24) of shuttle valve slowly and

remove.
3) Remove outer spring (25), inner spring (261,
spring retainer (271, and shuttle valve (28).
27
25
DAD0
8. Sub bearing
I) When end cap is removed, if valve plate
remains at cylinder block end, remove valve
plate.
2) Using bearing puller 0, remove sub bearing
(29) from shaft.
* Use protective sheet @ and be careful
not to damage the cylinder block.
* Be careful not to let the claws of the
puller come off.
DBD01331
30-155-5
0
9. Ring
Remove ring (30).
DBD01332
IO. Cylinder block, piston assembly

I) Rotate tool Ul 90”, and set opening of mo-
tor case facing to side.
2) Remove cylinder block and piston assembly
(31) from shaft.
* The cylinder block assembly and piston
assembly may come off separately, so
be careful not to drop them.
. Disassembly of cylinder block and piston as-

sembly
Pull out piston assembly (33) from cylinder
block assembly (32), and remove retainer
guide (34) and pin (35). -35
DAD01335

Pull out piston (37) from shoe retainer (36).
36
DAD01336
30-155-6
0
. Disassembly of cylinder block assembly

I) Set tool U3 to cylinder block assembly. 40
2) Secure bolt of tool U3 with wrench, then U3 42 I 41
tighten nut to compress spring (38), and re-
move snap ring (39).
3) Loosen nut of tool U3 slowly and release
tension of spring (381, then remove tool U3.
4) Remove spacer (411, spring (38), and spacer
N;t
38 v
39
DAD01338
11. Rocker cam

1) Remove rocker cam (43).
* Move the servo piston to the center to
make it easier to separate the mating of
the slider and servo piston.
2) Remove slider from rocker cam.
DBW133S
12. Servo piston

1) Remove servo piston (45) from front case
(44).
2) Remove spacer (46) from servo piston.
* There is a spacer only at the left side as
seen from the rear (the side where the
spring is installed).

1) Remove shaft and cradle assembly (47).
30-155-7
0
2) Remove shaft (49) and main bearing outer race

(50) from cradle (48).
DBD01342
3) Using push tool 0, remove bearing (51) from

shaft (49).
DAD01343
14. Oil seal

1) Remove snap ring (52) and spacer (53) from
front case (44).
DBD01344
2) Knock out and remove oil seal (54) from

inside case.
DBD01345
30-155-8
0
. If disassembly operation in Steps 1 - 14

above is not needed, and only oil seal is
replaced, replace oil seal as follows.
1) Remove snap ring (52) and spacer (53) from
front case (44).
through to core of oil seal (54), then twist to
remove.
posite sides (A and B in diagram) to re- 46
move.
* When removing, be careful not to dam-
age the sliding surface of the oil seal
and the shaft, and the press-fitting sur-
face of the case.
Disassembly of rear motor assembly

* The-procedure for disassembly differs from
the front motor only in the following places.
For all other places, follow the PROCEDURE
FOR THE FRONT MOTOR.

DBD01346
Set rear motor assembly (IO) to tool Ul.
16. Sub bearing

Same operation as in Step 8.
17. Ring

19. Rocker cam

20. Servo piston


30-155-9
0
ASSEMBLY OF HMT MOTOR

ASSEMBLY
* The procedure for assembling the front and rear
motors is basically the same, so only the proce-
dure for assembling the front motor is given
here. In cases where there is a difference in the
procedure for the front and rear motors, the
procedure for the rear motor is given separately.
Precautions when assembling

1) Clean and dry all parts thoroughly before
assembling.
2) Be careful not to damage any parts or to let
dirt or dust get in.
3) Handle all parts carefully and do not hit them
against other objects or drop them, or sub-
ject them to any shock.
4) Keep the front and rear parts separate and
be careful not to mix them.
5) Replace the O-rings and oil seals with new
parts.
6) Coat the sliding surfaces with engine oil
(EOIO-CD) before assembling.
Use a torque wrench and tighten all parts to
the specified torque.
Always check the following parts before assem-

bling.
l Check contact between cylinder block and
CHECKING CONTACT).
parts (new parts).
l Check contact of rocker cam and cradle (for
CONTACT).
parts).
l Check contact between valve plate and end
cap (for details, see PROCEDURE FOR
CHECKING CONTACT).
* This check is unnecessary if both the valve
parts).
1. Front case
Set front case (44) to tool Ul.
30-155-10
0

1) Using tool U4, press fit main bearing (51) to
shaft (49).
* Put tool U4 in contact with the end face
of the inner race of the main bearing,
and press fit until the flange of the shaft
press-fitting portion is in tight contact.
* Press-fitting load: 3.55 - 10.15 kN
(362 - 1036 kg)
6 Press-fitting surface of bearing:
Lubricating oil (EOIO-CD)
2) Install pin and stopper to cradle (48).

3) After inserting shaft (49) in cradle (481, in- 48
stall main bearing outer race (50).
‘50
DBD01342
4) Rotate tool Ul 90”, and set opening of mo-

tor case facing up.
7
5) Assemble O-ring and pin to front case, and
install shaft and cradle assembly (47).
* Be careful not to drop the main bearing
outer race when installing.
w Mounting bolt: 110.3 2 12.3 Nm
(I 1.25 f 1.25 kgm)
DBD01341
6) Using tool U2, secure shaft and cradle

sembly.
DBD01354
30-155-11
0
3. Servo piston
1) Assemble spacer (46) to servo piston (45).
2) Install servo piston (45) to front case (44).
* Install a spacer only at the left side as
seen from the rear.
4. Rocker cam
I) Move servo piston to center of motor case
so that slider mounting groove is at center.
2) Assemble slider to rocker cam (431, and in-
stall to cradle.
* Be careful not to damage the cradle slid-
ing surface and piston shoe sliding sur-
face of the rocker cam.
* Fit the slider securely in the mounting
groove of the servo piston.
8 * Move the servo piston and check that
5 the rocker cam moves smoothly and DBD01339
z does not come off from the cradle.

. Assembly of cylinder block assembly
1) Assemble spacer (421, spring (38), and spacer
2) Set tool U3 to cylinder block assembly.
3) Secure bolt of tool U3 with wrench, then
tighten nut to compress spring (381, and in-
in the groove.
4) Remove tool U3. 39
DAD01338
30-155-12
0
. Assembly of piston assembly I I

1) Measure thickness b of each piston shoe.
* Standard value of thickness b:
5.8 f 0.015 mm
b
DAD01300
2) Assemble piston (37) to shoe retainer (36).
36
DAD01336
l Assembly of cylinder block, piston assem- r

bly
1) Assemble pin (35) to cylinder block assem-
bly (32).
* Coat the pin with grease (G2-LI) prevent 35
it from falling out.
32
2) Install retainer guide (34) to cylinder block
assembly (32), then install piston assembly
(33).
* Align the cylinder block and the spline
of the retainer guide.
DAD01335
. Installation of cylinder block, piston assem-

bly
1) Rotate tool Ul SO”, and set opening of mo-
tor case facing to side.
2) Install cylinder block and piston assembly
(31) to shaft.
DBD01334
30-155-13
0
6. Sub bearing
I) Install ring (30) and sub bearing (29) to shaft.
* Install the ring so that the plane surface
contacts the bearing.
2) Using tool U5 and puller @, press fit sub
bearing (29).
* Put tool U5 in contact with the end face
at the bottom of the shaft, and support
with jack 0.
* When press fitting the bearing, push the
end face of the sub bearing inner race
with tool U5 and press fit until it is in
tight contact with the flange, ring, and
inner race of the shaft.
* Press-fitting load: 4.03 - 13.93 KN
(411 - 1421 kg)
a Press-fitting surface of bearing:
Lubricating oil (EOIO-CD)
7. Adjusting end play of shaft

Install sub bearing outer race (21) to shaft, then
measure dimension C to end face of front case
Unit: mm
Dimension C 1.11 - 1.2 1.01 - 1.1 0.91 - 1.0 0.81 - 0.9
(441, and select spacer from table below.

8. End cap assembly
. Assembly of end cap assembly
I) Assemble shuttle valve (281, spring retainer 27
(27), inner spring (261, and outer spring (25) 25
to end cap, and install plug (24).
* Remove all oil and grease from the plug 26/c’oO /
and plug hole, and dry completely.
/@
* When coating with adhesive, coat with 24
DAD01330
two drops (approx. 0.04 g) at a point 2 -
3 mm from the tip of the thread of the
plug.
* After tightening the plug, do not apply
pressure for 2 hours.
* Tighten the plug to the specified torque
after installing the end cap assembly to
the motor case.
& Plug: Thread tightener
(Loctite No. 638)
w Plug: 362.8 t 39.2 Nm (37 = 4 kgm)
2) Install charge relief valve (23) to end cap.

* Tighten to the specified torque after in-
stalling the end cap assembly to the
motor case.
w Charge relief valve: 53.9 + 4.9 Nm
(5.5 + 0.5 kgm)
DBD01329
. Installation of end cap assembly

1) Install sub bearing outer race (21) and spacer
(22) selected in Step 7 to end cap assembly.
2) Install dowel pin (20).
DBD01327 DBD01328
3) Install O-ring (19).

4) Align with dowel pin, and install valve plate
(18) to end cap assembly.
* Check that there is no interference with
the bearing and pin.
impact when assembling.
DBD01326
5) Install end cap assembly (17) to front case.

* Install with the surface with the casting
letter facing the front case.
* Be careful not to damage the sliding sur-
face between the cylinder block and the
valve plate.
* Be careful not that the O-ring does not
come out of position.
w Mounting bolt: 384.7 2 41.7 Nm
(39.25 i: 4.25 kgm)
6) Tighten shuttle valve (28).
m Shuttle valve: 362.6 2 39.2 Nm
(37 + 4 kgm)
30-155-M
0
9. Inspecting of end play

I) Remove tool U2.
2) Install dial gauge @to front case, move shaft
(49) in axial direction, and measure end play.
* End play: 0.05 - 0.25 mm
3) If end play is not within standard value, se-
lect spacer (22) again and replace so that
end play is within standard value.
(See Step 7.)
10. Measuring rotating torque of front motor as-

sembly
Install bolt (Ml0 x 1.5, length below head:13
mm) to drive shaft (49), set torque wrench @ in
position, then rotate shaft at a constant speed (3
- 5 set/l turn) and measure rotating torque.
* Rotating torque: Max. 29.4 Nm (3 kgm)
Assembly of rear motor assemblv

* The procedure for assembly differs from the
front motor only in the following places. For
all other places, follow the PROCEDURE FOR
THE FRONT MOTOR.
1) Rear case
Set rear case (55) to tool Ul.
2) Shaft, cradle assembly
3) Servo piston
4) Rocker cam 11361

5) Cylinder block, piston assembly
6) Sub bearing
7) Adjusting end play of shaft
30-155-16
0

I) Install dowel pin (15) and O-ring (16) to end
cap.
2) Install coupling (14) to shaft.
1324
3) Secure shaft of rear motor assembly with

tool u2.
DBD01363
4) Install rear motor assembly (IO).

Be careful not to damage the sliding sur-
face between the cylinder block and the
valve plate.
Be careful not that the O-ring does not
Align the spline of the shaft and the cou-
pling and install.
(39.25 + 4.25 kgm)
DBD01320
12. Checking end play of rear motor shaft

I) Install dial gauge @to rear case, move shaft
(56) in axial direction, and measure end play.
* Install bolt (Ml0 x 1.5) to tap hole in
shaft, and use a bar to move in the axial
direction.
* End play: 0.05 - 0.25 mm
2) If end play is not within standard value, se-
lect spacer and replace so that end play is
within standard value. (See Step 7.)
DBD01364
30-155-17
0
13. Measuring rotating torque of motor assembly

Install bolt (Ml0 x 1.5, length below head:13
mm) to drive shaft (491, set torque wrench @ in
* Rotating torque: Max. 58.8 Nm (6 kgm)
14. Cap
Install cap (9) and snap ring (81 to rear case.
* Check that the snap ring is fitted securely in
the groove.
DBD01317
15. Oil seal

1) Using tool U6, press fit oil seal (54) to front
case (44).
* Install the oil seal so that the metal sur-
face is facing the inside.
* Press the fit oil seal until the flange sur-
face of tool U6 contacts the end face of
the front case.
& Lip of oil seal: Grease (GS-LI-S)
U DAD01366
2) Install spacer (53) and snap ring (52).
I I DBD01367
30-155-18
0
16. Adjusting maximum swash plate angle

Adjust so that the dimension d between end
face of rod (57) and flange surface of servo pis-
ton cap (58) is 64.3 2 0.1 mm, then tighten
locknut (59).
m Locknut: 294.0 r 29.4 Nm (30 + 3 kgm)
DBD01368
17. Servo piston cap

I) Rotate tool Ul 90”, and face servo piston
mounts to left and right.
2) Install servo piston cap (5) on your left.
* Check that there is no spacer at the tip
of the servo piston.
DBD01314
3) Install spring (7) and servo piston cap (6) on

your right as follows.
* Check that there is a spacer at the tip of
the servo piston.
DBDOlJlE
i) Set bolts @ and nuts @ on diametrically

opposite sides.
ii) Tighten nuts @ uniformly, and install
servo piston cap (6).
(6.75 f 0.75 kgm)
30-155-19
0

I) Install O-ring (3) and filter (4).
DBD01312
2) Install servo valve assembly (2).

* Fit the arm of the servo valve assembly
securely in the mounting groove of the
servo piston.
* Check that there are no burrs, flashes, or
dirt at the mating surface.
* Be extremely careful that the O-ring and fil-
ter do not fall out when installing.
* Tighten the mounting bolts gradually in turn
on opposite sides.
(3.15 2 0.35 kgm)
30-155-20
0
CHECKING CONTACT BETWEEN ROCKER CAM

AND CRADLE, VALVE PLATE AND END CAP

parts).
be checked.
2) Paint the cradle with inspection paint.
3) Put the rocker cam on top and push with a
force of 39 - 49 N (4 - 5 kg), and move it
between the maximum swash plate angle
and the position where it contacts the stop-
per. Repeat this process 2 or 3 times.
face.
* The standard for the contact surface is

as given below. Rocker cam
i) Contact within central portion (36 - 55
mm) must be at least 90%.
ii) Contact in range between central por-
tion (36 - 55 mm) and 67 mm must be
50 - 90%.
iii) Contact of area outside 67 mm width
(outside) must be less than 50%.
(It is not permitted to have contact only
at the outside and no contact at the Cradle
center.) OBD01369
[Reference] If the contact is not within the

standard value, and lapping is
carried out, it must always be
carried out for both parts to-
gether.
* Parts with any scratches or damage must
not be used again.
30-155-21
0

cap
* This check is unnecessary if both the valve End cap
parts).
surface must
any variation
be checked.

face.
* The contact of the plane surface of the
PARTS (SEBG4240).
30- 155-22
0
DISASSEMBLY AND ASSEMBLY PPC, EPC, HMT CHARGE VALVE
REMOVAL OF PPC, EPC, HMT

CHARGE VALVE ASSEMBLY
Make match marks or fit tags to the hoses and
when installing.
1. Drain oil.
Remove drain plug at bottom of charge filter
and drain oil from filter.
2. Remove right side cover.
3. Disconnect PPC hoses (1) and (2).
4. Disconnect accumulator hose (3).
5. Disconnect PPC hose (4) and remove hose clamp.
6. Remove clamp (5).
7. Disconnect tube (6).
6. Remove charge filter assembly (7).
9. Disconnect PPC hoses (8) and (9).
10. Disconnect drain hose (IO).
11. Disconnect tube (11).
12. Remove PPC, EPC, HMT charge valve assembly
(12).
INSTALLATION OF PPC, EPC,

HMT CHARGE VALVE
ASSEMBLY
removal.

level.
30-l 56
0
DISASSEMBLY AND ASSEMBLY PPC, EPC. HMT CHARGE VALVE
DISASSEMBLY OF PPC, EPC, HMT CHARGE VALVE

ASSEMBLY
1. Remove plug (I), then remove springs (3) and

(4) from valve body (2).
2. Remove plug (51, then remove spool assembly
(6).
3. Remove valve (81, spring (9), valve (IO), and
shim (1 I) from spool (7).
4. Remove plug (121, then remove spring (13).
5. Remove plug (141, then remove spool assembly
(15).
6. Remove valve (171, spring (181, and valve (19)
from spool (16).
7. Remove plug (201, then remove spring (21) and
valve (22).
8. Remove plug (23).
30- 157
0
DISASSEMBLY AND ASSEMBLY PPC, EPC, HMT CHARGE VALVE
ASSEMBLY OF PPC, EPC, HMT CHARGE VALVE ASSEMBLY
!i DKW1197
* Clean all parts, and check for dirt or dam- 8. Assemble springs (4) and (31, and tighten
age. Coat the sliding surfaces of all parts plug (I).
with engine oil before installing. w Plug : 68.6 + 9.8 Nm 17 2 1 kgm)
1. Tighten plug (23).
2. Assemble valve (22) and spring (21) to valve
body (21, and tighten plug (20).
3. Assemble valve (191, spring (181, and valve
(17) to spool (16).
4. Assemble spool assembly (15) to valve body
(21, and tighten plug (14).
m Plug : 63.7 t 14.7 Nm (6.5 f 1.5 kgm)
5. Assemble spring (13) and tighten plug (12).
m Plug : 68.6 f 9.8 Nm (7 = 1 kgm)
6. Assemble valve (IO), spring (91, valve (S),
and shim (II) to spool (7).
shims, then assemble.
Shim thickness: 0.5 mm
No. of shims: 4
7. Assemble spool assembly (6) to valve body
(2) and tighten plug (5).
m Plug : 68.6 + 9.8 Nm (7 + 1 kgm1
30- 158
0
DISASSEMBLY AND ASSEMBLY HMT CONTROL VALVE
REMOVAL OF HMT CONTROL

VALVE ASSEMBLY
ASSEMBLY.
2. Remove brake rod (I).
3. Disconnect 2 HSS motor hoses (2) at HSS motor

end, then move towards front of chassis.
4. Remove tube (lubrication tube, tube between

valve and power train cooler, and tube between
power train filter and valve) (3).
Disconnect clutch switch wiring harness con-

nectors (4) (5 places) and clutch solenoid wiring
harness connectors (5) (5 places). m
6. Remove filter (6).

7. Remove modulating valve (7). m

Sr It is installed at an angle, and may slip to-
wards the frame, so be extremely careful
when removing it.
Sr Mounting bolts: 3 hexagonal bolts .pa
* Be extremely careful not to let dirt or dust
enter the valve seat when removing.
8. Lift off HMT control valve (8). a

Ir The 2 bolts marked 4 are used to secure the
top body and bottom body, so they do not
need to be removed. DLW1088
* The 3 bolts marked % cannot be completely
removed, so lift up and leave in a raised
condition.
* Be extremely careful not to let dirt or dust
enter the valve seat when removing.
&I kg HMT control valve: 45 kg
DKWlCE3
Layout of clutch switch wiring harness connector
I Brake solenoid\
Layoul : of clutch solenoid valve connector
/ DAD30565
30-160
0
INSTALLATION OF HMT
CONTROL VALVE ASSEMBLY
removal.
m
Ir The layout of the clutch switch wiring har-
ness connector and clutch solenoid valve
connector is as shown in the diagram on the
right.
w Filter assembly mounting bolt :

49.0 +: 4.9 Nm (5 + 0.5 kgm)
w Modulating valve mounting bolt :

49.0 2 4.9 Nm (5 e 0.5 kgm)
w HMT control valve mounting bolt :

49.0 e 4.9 Nm (5 t 0.5 kgm)
30-l 61
0
DISASSEMBLY OF HMT ASSEMBLY OF HMT

CONTROL VALVE CONTROL VALVE
ASSEMBLY ASSEMBLY
1. Disassembly of pressure compensating re- + Clean all parts, and check for dirt or dam-
lief valve age. Coat the sliding surfaces of all parts
I) Remove cover (I), then remove guide with engine oil before installing.
(2) and spring (3).
2) Remove plug (81, then remove fuel in- 1. Assembly of clutch selector valve, gear
jection valve (51, piston (6), and shim (4). shift solenoid valve, pilot reducing valve,
power train oil cooler relief valve
2. Disassembly of main relief valve i) Assemble valve (23) and 2 valves (311,
I) Remove cover (181, then remove shim spring (241, and 2 springs (301, and in-
(171, guide (161, and springs (15) and (14). stall valve body (25) to valve body (33).
2) Remove cover (91, then remove piston 2) Assemble valve (381, shim (39), and
(IO), spring (II), piston (12) and valve spring (40), and install cover (41).
(13). 3) Assemble valves (481, (461, and (451,
spring (47), shim (441, spring (431, and
3. Disassembly of clutch selector valve, guide (42), and install cover (19).
gear shift solenoid valve, pilot reducing 4) Install valve (32) and (22), spring (21),
valve, power train oil cooler relief valve and R detection (selector) switch, and
1) Remove solenoid valve (26). 2nd detection (selector) switch (20).
2) Remove F detection (selector) switch (271, * Be careful to install the detection (se-
1st detection (selector) switch (281, and lector) switches correctly in their
3rd detection (selector) switch (29). original position.
3) Remove R detection (selector) switch and 5) Install F detection (selector) switch (27),
2nd detection (selector) switch (201, then 1st detection (selector) switch (28), and
remove spring (21) and valves (22) and 3rd detection (selector) switch (29). g
X
(32). Ir Be careful to install the detection (se- b
4) Remove cover (19), then remove guide lector) switches correctly in their z
(421, spring (431, shim (441, valves (451, original position.
(46), and (481, and spring (47). 6) Install solenoid valve (26).
5) Remove cover (411, then remove spring
(401, shim (39), and valve (38). 2. Assembly of main relief valve
6) Remove valve body (25) from valve body 1) Assemble valve (131, piston (121, spring
(331, then remove spring (24) and 2 (II), and piston (IO), then install cover
springs (301, valve (231, and 2 valves (31). (9).
* Stoppers (37) and (491, and pins (341, 2) Assemble springs (14) and (151, guide
(351, and (36) do not need to be removed. (16), and shim (17), then install cover
(18).
3. Assembly of pressure compensating re-

lief valve
1) Insert shim (4) in valve (5), assemble pis-
ton (61, then install plug (8).
2) Check that there is shim (4) inside valve
(51, then assemble spring (3) and guide
(21, and install cover (I).
30-162
0
AND ASSEMBLY HOT CONTROL VALVE
DISASSEMBLY
7 8
\ \
\
10
1
DDE01193
30-l 62-1
0
DISASSEMBLY AND ASSEMBLY HSS MOTOR
REMOVAL OF HSS MOTOR

ASSEMBLY
1. Remove fuel tank assembly.
For details, see REMOVAL OF FUEL TANK AS-
SEMBLY.
2. Disconnect main hoses (I) and (2).
3. Disconnect drain hose (3).
4. Sling HSS motor assembly (41, then remove

mounting bolts, and lift off HSS motor assem-
bly (4).
C?lkg HSS motor assembly : 65 kg
INSTALLATION OF HSS
MOTOR ASSEMBLY
removal.
level.
30-163
0
DISASSEMBLY OF HSS
MOTOR ASSEMBLY
1. End cover assembly
1) Set motor assembly (I 1 to tool WI.
* After setting motor assembly (I) to tool
WI, loosen relief valve (2), plug (II), and
the mounting bolts of left and right cov-
ers (7).
I \ \ DBDO1433
2) Remove end cover assembly (3).

* The valve plate may be stuck to the end
cap, so be careful not to drop it.
3) Disassemblv of end cover assemblv
i) Remove sub bearing outer race (4), ,
spacer (51, and dowel pin (6) from end
cover assembly (3).
DBD01434 DBD01435
ii) Remove relief valve assembly (2).

iii) Remove plate (71, then remove O-ring,
spring (81, retainer (9), and spool (IO).
iv) Remove plug (II), then remove O-ring,
spring (121, and valve (13).
8- Y
DAD01436
30-163-l
0

1) Remove valve plate (15).
* Check the mounting direction of valve
plate (15).
DBD01437
3) Turn over tool WI 90”, then remove cylinder

block and piston assembly, and plate (16)
from motor case (17).
* Tap the end face of the shaft of the cyl-
inder block and piston assembly with a
plastic hammer to knock it out and re-
move it.
4) Disassembly of cylinder block, piston assem-

bly
i) Using bearing puller 0, pull out sub
bearing (18).
* To prevent scratches or damage to
the valve plate contact surface, set
protective sheet @ between the valve
plate contact surface of the cylinder
block and the bearing puller, then
pull out bearing (18).
DBDOl 1440
ii) Remove cylinder block (19) from piston

and shaft assembly (20).
* When removing cylinder block (19),
preload pin (21) may fall out, so be
careful not to lose it.
DBD01441
30- 163-2
0
5) Disassembly of piston, shaft assembly

i) Remove guide retainer (22) from piston
and shaft assembly (20).
ii) Remove piston assembly (24) from shaft
(23).
DBD01442 DBD01443
iii) Pull out piston (26) from shoe retainer

(25). 26
i5 DAD01444
iv) Remove plate (27) from shaft (23).
27
DBD01445
J
VI Using push tool 0, push main bearing

inner race (28) with a press and remove
from shaft (23).
DBD01446
30-163-3
0
6) Disassembly of cylinder block

i) Set tool W2 to cylinder block. 19
ii) Secure bolt of tool W2 with wrench,
tighten nut to compress spring (32), then
remove snap ring (30).
iii) Loosen nut of tool W2 slowly and re-
lease tension of spring (32), then remove
tool w2.
50
DAD01448
iv) Remove spacer (31) and spring (32) from

cylinder block (19).
DBD01449
3. Oil seal, main bearing outer race

1) Remove snap ring (34) from motor case (17).
2) Remove spacer (35).
DBD01450 DBD01451

4) Remove main bearing outer race (37) from
motor case (17). 36
5) Remove dowel pin (29) from motor case.
DBD0145: 2 DAD01453
30- 163-4
0
ASSEMBLY OF HSS MOTOR

ASSEMBLY
dirt or damage.
* Using chromium oxide compound, remove all
the lapping particles from the lapped areas.
1. Main bearing outer race

1) Install dowel pin (29) to motor case (17).
2) Using push tool 0, press fit main bearing
DAD01 454
outer race (37) to motor case (17).

1) Cylinder block assembly
i) Assemble spacer (31), spring (32), and
spacer (31) to cylinder block (19).
DEW1
ii) Set tool W2 to cylinder block.
DBD01456
iii) Secure bolt of tool W2 with wrench,

tighten nut to compress spring (321, then
install snap ring (30).
* Check that the snap ring is fitted se-
curely in the groove.
iv) Remove tool W2.
30
DAD01448
30-163-5
0
v) Assemble 3 preload pins (21) to cylinder

block (19).
* To prevent preload pins (21) from
coming out, coat the pins with grease
(G2-LI).
vi) Assemble guide retainer (22) to cylinder
block (19).
19’
DAD01457
2) Piston assembly
i) Measure each piston shoe thickness.
* Standard value of thickness a:
5.8 f 0.015 mm
I
DAD01458
ii) Assemble piston (26) to shoe retainer

(25). 26
$
25 DAD01444
iii) Assemble piston assembly (24) to cylin-

der block (19). 24
3. Shaft
I) Using tool W3, press fit bearing (28) to shaft
(23).
* Press fit until the end face is in tight 23
contact with the shaft.
DBD01460 DBD01462
30-163-6
0
2) Set motor case (17) to tool WI, and install

shaft (23).
DBD01494
4. Cylinder block, piston, bearing, end cover

1) Assemble plate (27) to motor case (17).
Turn over tool WI 90”, and assemble cylin-

der block and piston assembly (16) to motor
case (17).
Turn over tool Wl 90”, then using tool W4,

press fit sub bearing (18).
* Support the end face of the bottom of
the shaft with a jack and press fit the
sub bearing.
DAD01 467
30-163-7
0
4) Assembly of end cover

i) Assemble spool (IO) to end cover, then
fit retainer (9), spring (8), and O-ring, and
install left and right covers (7).
w Mounting bolt: 110.3 = 12.3 Nm
(11.25 I 1.25 kgm)
ii) Fit valve (13) and spring (12) to end
cover, and tighten plug (11) temporarily.
* Remove all oil and grease from the
plug and female thread, and dry com-
pletely.
& 2 - 3 mm from tip of plug:
Gasket sealant (Loctite 638/648)
w Plug: 323.6 - 421.7 Nm
(33 - 43 kgm)
* Tighten the plug to the specified
torque after installing the end cover
assembly to the motor case.
ti O
g--Q G-y1
0
8y S
DAD01436
iii) Fit relief valve assembly (2) and tighten

temporarily.
* Tighten the relief valve assembly to
the specified torque after installing
the end cover assembly to the motor
case.
DBDO1468
5. Adjusting end cover

. Adjust the end cover as follows.
I) Assemble spacer (5) and outer race (4) to
end cover (3).
* Assemble the same spacer (5) that was
removed during disassembly.
30- 163-8
0
2) Install end cover assembly (3) to motor case

(17).
m Mounting bolt: 277.0 + 31.9 Nm
(28.25 + 3.25 kgm)
3) Turn over tool WI 180”, and set bolt @ and

dial gauge @ to shaft.
4) Using lever 8, move shaft in axial direction,
and measure movement (end play) of shaft
in axial direction.
* End play: 0.05 - 0.25 mm
DBD01472
5) If end play is not within standard value, ad-

just again as follows.
i) Remove end cover (3) from motor case
(17).
ii) Remove sub bearing outer race (4) and

spacer (5) from end cover (3).
5
DBD01469
30-163-9
0
iii) Assemble inner race and outer race (4)

of sub bearing to shaft, then measure I 17 4 b
dimension b from end face of motor case
(17) to end face of outer race, and calcu-
late spacer dimension c from the follow-
ing formula.
c= 12.95-b
iv) Select spacer (5) from table below ac-
cording to the result of Step iii).
Unit: mm
Dimen- 1.65 1.75 1.85 1.95 2.05 2.15 2.25
sion c - 1.74 - 1.84 - 1.94 - 2.04 - 2.14 -2.24 - 2.34
DAD01474
Spacer 708-8H 708-8H 708-8H 708-8H 708-8H 708-8H 708-8H
Part No. -32220 -32230 -32240 -32250 -32260 -32270 -32280
VI Assemble outer race (4) and selected

spacer (5) to end cover (31, and install to
motor case (17).
(27.5 + 2.5 kgm)
3
DBD01469
vi) Turn over tool WI 180”, and set bolt @

and dial gauge @ to shaft.
vii) Using lever 8, move shaft in axial direc-
tion, and measure movement (end play)
of shaft in axial direction.
* End play: 0.05 - 0.25 mm
vii) After completing measurement, turn over
tool WI 180” and remove end cover (3).
1472
6. Valve plate, dowel pin

I) Install dowel pin (14) to motor case (17).
2) Install dowel pin (6) to end cover assembly
(3).
DBD01476
30-163-10
0
3) Install valve plate (15) to end cover assem-

bly.
* Check that there is no interference with
the bearing and pin.
impact when assembling.
I DBDO1477
4) Using tool W5, secure shaft, cylinder block

and piston assembly, then turn over tool WI
90”.
5) Install end cover assembly (3) to motor case
(17).
* Be extremely careful that the O-ring does
not come out or get caught.
(28.25 + 3.25 kgm)
DBD01479
6) Tighten main relief valve assembly (2) to

specified torque.
w Main relief valve: 279.3 + 24.5 Nm
(28.5 z 2.5 kgm)
7) Tighten left and right plugs (11).
w Plug: 372.7 + 29.4 Nm (38 = 3 kgm)
DBD014Sl I
7. Oil seal
1) Turn tool WI 90” clockwise, then using tool Lip portion
W6, install oil seal (36) to motor case (17).
& Lip of oil seal:
Lithium Grease (GtLI-S)
0
Apply one drop of oil
on four places of
circumference with a
finger tip and spread
equally to entire
circumference of oil
lip
DAD01482 DAD01483
30-163-11
0

in the groove.
I 35 DBDO1484 1
8. Measuring rotating torque

install bolt (Ml0 x 1.5, length below head:13
mm) to drive shaft (23), set torque wrench 0 in
* Rotating torque: 17.7 - 34.3 Nm
(1.8 - 3.5 kgm)
30-163-12
0
DISASSEMBLY AND ASSEMBLY STEERING EPC VALVE
REMOVAL OF STEERING EPC

VALVE ASSEMBLY
1. Remove right floor cover.
2. Disconnect connectors (1) (CN-STA, CN-STB) and

remove clamp. 6
3. Disconnect hoses (2), (3), (4), and (5).

Ir Make match marks or fit tags to the hoses
and pipes to prevent any mistakes in the
position when installing.
4. Remove steering EPC valve assembly (6).
INSTALLATION OF STEERING
EPC VALVE ASSEMBLY
removal.
30-164
0
DISASSEMBLY AND ASSEMBLY BRAKE VALVE
REMOVAL OF BRAKE VALVE

ASSEMBLY
1. Remove fuel tank assembly.

For details, see REMOVAL OF FUEL TANK AS-
SEMBLY.
2. Disconnect connector (I) (CN-BRAK).
3. Disconnect brake rod (2). a
4. Loosen locknut of parking brake cable (3) and

disconnect cable (3). a
* Measure installation dimension a of the ca-
ble before disconnecting the cable.
5. Disconnect hose (4).
6. Remove brake valve assembly (5).
INSTALLATION OF BRAKE
VALVE ASSEMBLY
removal.
a
* After installing the cotter pin, bend the cot-
ter pin securely at least 30” on one side (to-
tal for both sides: min. SO’).
a
Ir Tighten the locknut securely, then install the
cotter pin and bend it securely.
Ir After connecting the cable, adjust the park-

ing brake lever linkage.
ADJUSTING PARKING BRAKE LEVER LINK-
AGE.
30-165
0
DISASSEMBLY AND ASSEMBLY BRAKE VALUE
DISASSEMBLY OF BRAKE ASSEMBLY OF BRAKE

VALVE ASSEMBLY VALVE ASSEMBLY
1. Remove solenoid valve (I). Clean all parts, and check for dirt or dam-
2. Remove lever and cover assembly (28). age. Coat the sliding surfaces of all parts
3. Remove check valve assembly (31) from with engine oil before installing.
body (6).
4. Remove plug (33), then remove spring (32) 1. Install shaft (bolt) (7), guide (8), spring (9),
and spool (30). guide (II), and nuts (14) and (15) as one
5. Remove plug (2), then remove spring (31, unit to body (6).
piston (4), and valve (5). 2. Assemble spring (IO), and guides (12) and
6. Remove cover (291, remove guides (13) and (13), then install cover (17).
(12), and spring (IO), then remove shaft (bolt) 3. Assemble valve (51, piston (4), and spring
(7), guide (81, spring (9), guide (1 I), and nuts (3), then install plug (2).
(14) and (15) as one unit. 4. Assemble spool (30) and spring (321, then
7. Disassembly of lever case (26) install plug (33).
1) Remove levers (18) and (23). 5. install cover (29).
* Be careful not to lose keys (17) and 6. Install check valve assembly (31) to body
(24). (6).
2) Remove lever assemblies (16) and (26). 7. install lever and cover assembly (16).
3) Remove seals (19) and (22) from case 8. Install solenoid valve (I).
(25), then remove bearings (201, (211, and 9. Assembly of lever case assembly (26)
(27). 1) Install bearings (20), (21), and (271, and
oil seals (19) and (22) to case (25).
2) Install lever assemblies (16) and (261,
then install levers (18) and (23).
* Install key (17) and (24) securely to
levers (18) and (23).
3) Install lever case (28) to valve body (6)
with cover (29) between case and body.
30- 166
0
DISASSEMBLY AND ASSEMBLY BRAKE VALUE
30-167
0
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
REMOVAL OF FINAL DRIVE

ASSEMBLY
1. Remove track shoe assembly.
For details, see REMOVAL OF TRACK SHOE AS-
SEMBLY.
2. Remove 8 mounting bolts (2) on inside of final

drive assembly (1). a
3. Jacking up chassis
Using hydraulic jack (686 kN (70 ton))
I
Al)
and ripper of machine, jack up chassis
and set stands @ under steering case on
l-i-7-H
I i
I
I
left and right.

2) Set stands @ on left and right under
main frame at front of chassis.
* After setting stands @ and 0, set the
hydraulic jack and ripper again to act as
extra support.
DLW0175
4. Lift off guard (3).
Guard : 45 kg
30-168
0
5. Remove 2 segment teeth (4).
6. Remove drive shaft cover (5).
8
5 DBDCO727
z
7. Pull out drive shaft (6).
* Use a forcing screw to pull out the drive
shaft to a point where the spline comes out.
* If the shaft does not come out, move the
sprocket backward and forward to adjust to
a position where the shaft comes out, then
pull out the shaft.
8. Align place where segment teeth were removed

with track frame.
9. Remove mounting bolts on top of final drive

assembly, then install tool F2. a
DBDW729
30- 169
0
IO. Using tool Fl, sling final drive assembly (I), and
remove remaining bolts.
A To prevent the final drive from flying out,
slightly loosen one mounting bolt each on
both sides of the final drive, then loosen
while pulling out the final drive assembly,
and remove.
11. Lift off final drive assembly (I).
E?lkg Final drive assembly : 1,500 kg

DBCOO730
INSTALLATION OF FINAL
DRIVE ASSEMBLY
removal.
IIfiIlf
& Final drive mounting bolt :
m Final drive mounting bolt :
1323.8 + 147.1 Nm (135 t 15 kgm)
& Guard mountingbolt :

m Guard mounting bolt :
745.3 f 83.4 Nm (76 2 8.5 kgm)
& Segment teeth mounting bolt :

w Segment teeth mounting bolt :
1176.7 2 98.1 Nm (120 t 10 kgm)
30- 170
0
DISASSEMBLY OF FINAL
DRIVE ASSEMBLY
1. Carrier assembly
I) Remove cover.
2) Remove mounting bolts, then using eyebolts
0, remove carrier assembly (1).
DEW1142
3) Remove lock plate (2).
4) Using tool G4, pull out shaft (3).

* Remove all three shafts.
DKW1144
5) Remove gear assembly (4).

* When removing the gear assembly, push
the gears which are not being removed
against the outside wall, then remove
the gear which is to be removed.
DKw1145
30- 171
0
6) Remove bearing (6) from gear (5).

7) Remove outer race (7) from gear (5).
6 7
2. Shaft
Using eyebolts 0, remove shaft (9).
3. Holder
Remove holder (IO).
I DEW1147 I I DEW1148
4. Ring gear, hub assembly

1) Using wire, remove ring gear and hub as-
sembly (II).
2) Remove 6 plates (12), then remove ring gear
(14) from hub (13).
5. Sprocket, hub assembly

1) Fit eyebolts, pull out sprocket and hub as-
sembly (15) with tool Gl and remove.
DLCO1152
30-172
0
+r Bearing (19) will come out at the same

time.
- Gl
DKDO1151
2) Remove floating seal (16).

t If the floating seal to be used again, be
careful not to damage the seal surface, 16 18
and keep it in a safe-place.
3) Remove outer race (18).
6. Cover assembly
I) Screw in forcing screws 0, and pull out
cover assembly (21) from case (221, then use
eyebolts @ to remove.
2) Remove floating seal (16).

Ir If the floating seal to be used again, be
careful not to damage the seal surface,
and keep it in a safe place.
3) Using bolts 0, knock out spacer (20) and
bearing (19) from cover.
DKDOll55
30-173
0
7. Gear
Remove mounting bolts (21). pull out with forc-
ing screws @, then using eyebolts 0, remove
gear (24) from hub (25).
* Turn the gear at an angle and remove it.
DED01156 DEE41157
8. Hub
I) Using eyebolts 8, remove hub (25).
2) Using puller @, remove inner race (26) from
hub (25).
26
DED01158 DUB1159
9. Guide plate
Remove guide plate (37).
10. Pinion assembly

1) Using forcing screws @, remove cage (27).
30- 174
0
2) Remove pinion assembly (29).
3) Remove bearing (31) from pinion (30).
3-i $1
DLDOllE3
4) Remove outer race (32) and oil seal (33) from

cage (28).
32 28
34
5) Remove outer race (34) from case.
0 0
’ 0
w 0
0
33 b
DLDO1164 ( DLDO1165 1
30-I 75
0
ASSEMBLY OF FINAL DRIVE

ASSEMBLY
* Coat the sliding surfaces of all parts and the
rotating parts of the bearings with engine oil
before installing.
1. Pinion assembly
1) Using push tool 0, install oil seal (33) to
cage (28).
DKD01166
2) Using push tool, install outer race (32) to

cage (28). 32 28
3) Using push tool, press fit oil seal (36) to

case (35).
!!!iiGP
35 36
DLDO1167
4) Using push tool, press fit outer race (34) to

case (35). 30

pinion (30).
35 DLBJ1169
6) Install pinion assembly (29) to case.
7) Assemble shim, and install cage (28).

* Be careful not to damage the oil seal.
DLD01171 DLDO?172
30-176
0
+ Select the shim thickness as follows.

i) Install pinion to cage without assembling
O-ring.
ii) Tighten 4 mounting bolts to specified
tightening torque.
m Mounting bolt : 9.8 Nm (I kgm)
iii) Using a clearance gauge, measure clear-
ance a between cage and case at 2 places
around circumference, then calculate
average value.
iv) Select shim of measured average value
+ (0.05 - 0.1 mm). DKD01173
Ir There are four types of shim: 0.15,
0.5, 0.6, 0.7 mm
2. Guide plate
-r 26 26
Install guide plate (37).
3. Hub
1) Using push tool, press fit inner race (26) to
hub (25).
25
::I DKDo1175
2) Using eyebolts 8, install hub (25).
4. Gear
I) Using eyebolts 0, install gear (24) to hub
(25).
* Turn the gear at an angle and insert it.
DEW1156 DEW1 176
2) Tighten mounting bolts (21).

m Mounting bolt : 277.0 + 31.9 Nm
(28.25 t 3.25 kgm) 8
5. Cover assembly
I) Using push tool, press fit bearing (8) to cover
(38).
DECO1156 DKWll77
30- 177
0

3) Using tool G3, press fit bearing (19) to case
(38).
4) Using tool G2, install floating seal (16).
* Remove all oil and grease from the O-
(
ring and O-ring contact surface, then dry
before installing.
* After installing the floating seal, check
that the angle of the seal is less than 1 I
mm.
16
DKCOl178 DLD01179
5) Using eyebolts 0, install cover assembly (21)

to case (221, and tighten mounting bolts.
& Mounting bolt :
(56 2 6 kgm)
/22
DEW1190
6. Sprocket, hub assembly

1) Install outer race (18) to hub (13).
2) Using tool G2, install floating seal (16).
* Remove all oil and grease from the O-
ring and O-ring contact surface, then dry 18
before installing.
* After installing the floating seal, check
that the angle of the seal is less than 1
mm.
3) Check that there is no dirt or dust on sliding
surface of floating seal, then coat thinly with
engine oil. 13 DKW1181 DLDO1182
4) Using eyebolts 0, set sprocket and hub as-

sembly (15) to cover.
30-178
0
5) Using tool G3, rotate sprocket and hub as-

sembly, and press fit bearing (19).
Ir Press fit within a range where no preload
is applied.
DKW11&1
7. Ring gear, hub assembly

1) Assemble ring gear (14) to hub (13), and
tighten plate (12).
6 Mounting bolt :
m Mounting bolt : 66.2 = 7.4 Nm
(6.75 = 0.75 kgm)
2) Using wire, install ring gear and hub assem-
bly (11).
DEM)1159
8. Holder
I) Assemble shim and tighten holder (IO).
& Mounting bolt :
m Mounting bolt : 549.1 z 58.8 Nm
(56 f 6 kgm)
2) Select shim thickness as follows.
i) Tighten 4 bolts to specified torque, then
settle all parts.
& Mounting bolt :
m Mounting bolts : 549.1 = 58.8 Nm DECO1148 DEW1185
(56 = 6 kgm)
ii) Remove bolts, then turn sprocket hub
and check that bearing rotates smoothly.
* At position of carrier assembly
mounting bolts: 216 - 265 N
(22 - 27 kg)
...
III) Tighten 4 bolts to 34.3 Nm (3.5 kgm),
measure clearance b between holder and
hub at 4 places around circumference,
calculate average value, then select shim
thickness.
Shim thickness = Average clearance b +
(0 - 0.1 mm)
iv) Finally adjust so that clearance a between DKDO1186 DECO1187 1
holder and hub is 0.05 - 0.1 mm.
10. Shaft
Using eyebolts 0, install shaft (9).
11. Carrier assembly

I) Using push tool, press fit outer race (7) to
gear.
* Make match marks on the outer race and
bearing.
2) Assemble bearing 6) to gear (5).
7 7
.c111 6 -6
I I
DKD01189 DKDOl190
3) Set gear assembly (4) to carrier, then align

shaft hole and inner race hole of bearing.
* insert the gear assembly through the
hole in the center of the carrier, push
against the outside wall, then set the gear
assemblies in the mounting position af-
ter inserting all three gear assemblies.
DKCO1145
4) Expand-fit shaft (3) to install.

* Cool in dry ice for approx. 30 minutes.
* When the shaft warms up it will be im-
possible to push it in by hand, so align
the notched portion with the hole in the
plate and push in quickly.
5) Tighten lock plate (2).
& Mounting bolt :
w Mounting bolt : 109.3 t 12.3 Nm
(11.15 f 1.25 kgm)
DEW1192
30-180
0
6) Using eyebolts 0, install carrier assembly

(I).
6 Mounting bolt :
(56 f 6 kgm)
7) Install center cover.
I I ’ -’ /// mm142
30-181
0
DISASSEMBLY AND ASSEMBLY TRACK FRAME
REMOVAL OF TRACK FRAME

ASSEMBLY
SEMBLY.
2. Jacking up chassis
AlI Using hydraulic jack (686 kN (70 ton))
and ripper of machine, jack up chassis
and set stands @ under steering case on
left and right.
2) Set stands @ on left and right under
main frame at front of chassis. DLW0175
3) Set blocks under front of raised track
frame to ensure safety during operation.
* After setting stand @ and 0, set the
hydraulic jack and ripper again to act
as extra support.
DLlXN176
3. Disconnection of equalizer bar 1
I) Sling track frame assembly, and remove

cover (I) of equalizer bar, then remove pin
cover (2) and spacer (3).
'1
2) Remove equalizer bar side pin (4) together

with collars (5) and (6).
3 56 4
DKCQO178
30-182
0
4. Disconnection of track frame assembly

. Left track frame assembly
Remove cover (7), then remove spacer (8).
DLW0179 DLKO180
. Right track frame assembly

1) Remove cover (91, and disconnect block
(IO).
I DLDOOlll ( DLDW192
2) Disconnect hose (11) from block (IO), IF

then remove spacer (12). I
3) Remove seal (13), then remove washer
(14) and washer (15). m
L
i
I DLDCO183
5. Lift off track frame assembly (16).
A kg Track frame assembly : 3,960 kg
16 DL!XQ195
30-183
0
INSTALLATION OF TRACK
FRAME ASSEMBLY
removal. Maker’s 12
t Assemble seal (13) as follows.

1) Keep seal in direction @ in relation to
pivot shaft.
lSet with the maker’s mark on the
outside.
2) Turn seal by hand from condition @ in
direction of arrow to position @. DLW018E
. Set with the maker’s mark on the
inside.
3) Coat surface @ of washer (15) with oil
(EO-30).
4) Keep the seal in condition @I, and as-
semble between washer (14) and washer
(15).
* Be careful not to let seal (13) extend outside
surface @.
. Refilling with oil
%# Pivot chamber oil : Approx. 8.2 .k!(EO-30) DLD00187
* The oil level in the pivot chamber will be 25

mm from the end face of the shaft.
30-184
0
DISASSEMBLY AND ASSEMBLY IDLER
REMOVAL OF IDLER
ASSEMBLY
For details, see REMOVAL OF TRACK SHOE
ASSEMBLY.
g To prevent danger, never stand in front of
the idler assembly.
2. Remove side covers (1).
* Remove one each on the inside and outside.
3. Loosen support mounting bolts, remove shim,

then remove supports (2). a
* Remove one each on the inside and outside.
4. Loosen guide tension bolt (3).

* Loosen two each on the inside and outside.
5. Remove idler guide mounting bolts (4).
DKWOWJ
6. Raise idler assembly (51, then lift out to front

and remove.
&I kg Idler assembly: 341 kg
7. Remove spring seat (61, then remove tension 6

spring (7).
* The above parts are assembled between the
support and track frame.
DLWO191
30-185
0
INSTALLATION OF IDLER
ASSEMBLY
removal.
* Set the idler assembly at the center of the

track frame, then adjust clearance a between
the track frame and guide plate with shims.
l Standard clearance a : 0.5 - 1.0 mm
l Standard shim thickness : 6 mm
30- 186
0
DISASSEMBLY OF IDLER
ASSEMBLY
1. Remove oil drain plug and drain oil.
& Idler : Approx. 530 - 590 cc
2. Set idler assembly (I) on block 0.
3. support
I) Remove nut (21, and pull out bolt (3).
2) Remove support (4).
DDD00193
4. Retainer
Remove mounting bolts, then using forcing
screws 0, remove retainer (5).
DDDW194
5. Shaft
1) Turn over idler assembly.
2) Remove nut (6) and bolt (71, then remove
support (8).
I DDCCO195
3) Using forcing screws 0, remove retainer (9).

4) Lift off shaft (IO).
DDLWlSS
30-187
0
6. Disassembly of support
Remove floating seals (II) from supports (4) $3
1
11
and (8). 12 59
7. Disassembly of retainer
Remove floating seals (12) from retainers (5)
and (9). J&L
DEW197 DEW0198
8. Bushing
Remove bushing (13) from idler (I).
DEW0199
30-188
0
ASSEMBLY OF IDLER
ASSEMBLY
1. Bushing
Set tool HI to idler (I), and press fit bushing
(13).
Ir When press fitting the bushing, use a plastic
hammer to align the center, then press fit
with a puller.
Ir Press fit the bushing so that the dimension
from the end face of the idler to the top face
of the bushing is 15 + 1 mm. I 13 DEDfYJZW
2. Assembly of retainer
Using tool H2, assemble floating seals (12) to
retainers (5) and (9).
* See Fig. @ for the protrusion of the seal.
* After inserting, check that the angle of the
seal is less than 1 mm.
* When assembling the seal, wash the area
marked by the bold line in Fig. @ (the O-
ring and O-ring contact surface), remove all
oil and grease, then dry completely.
8
5
z
3. Assembly of support
Using tool H2, assemble floating seals (II) to -@-- -@-
supports (8) and (4).
P
* See Fig. @ for the protrusion of the seal.
* After inserting, check that the angle of the 5-7mm
* When assembling the seal, wash the area
marked by the bold line in Fig. @ (the O- TJ
ring and O-ring contact surface), remove all
oil and grease, then dry completely.
DEW203
30-l 89
0
4. Shaft, retainer
I). Set idler @ on block (1).
2). Install retainer (9).
3). Raise idler (I) and turn over, then set on
block 0.
4). Raise shaft (IO) and assemble to idler.

* When assembling, be careful not to dam-
age the retainer mount floating seal at
the bottom.
5) Install retainer (5).
5. supports
1) Assemble support (4) to shaft, then fit bolt
(3) and tighten nut (2).
* Before assembling the support, coat the
floating seal mating surface thinly with
engine oil.
DDWOM7
2) Turn over idler (I), assemble support (8) to

shaft, then fit bolt (7) and tighten nut (6).
* Before assembling the support, coat the
floating seal mating surface thinly with
engine oil.
I DDWD195
30-190
0
6. Refilling with oil

Using tool H3, add oil to specified level and
-) To vacuum
tighten plug.
@ Idler : Approx. 530 - 590 cc (G0140B)

m Plug : 205.9 + 49.0 Nm (21 + 5 kgm) 8 t=,- To oil pump
* If oil has been added with tool H3, always

angle approx. IO” as shown in the diagram
on the right, and check that the oil level is at
the bottom face of the oil filler port. c
DDW0203
30-l 91
0
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
REMOVAL OF RECOIL SPRING

ASSEMBLY
1. Remove idler assembly.
For details, see REMOVAL OF IDLER ASSEM-
BLY.
2. Remove cover (1) from track frame.
\ r DLDOD210
3. Remove lock plate (21, then remove pin (3).
4. Lift off recoil spring assembly (4).

3
R 2
0
0
i
DLD00211
Recoil spring assembly : 425 kg
DLDO0212
INSTALLATION OF RECOIL
SPRING ASSEMBLY
removal.
30-192
0
DISASSEMBLY OF RECOIL
SPRING ASSEMBLY
1. Disconnection of cover assembly
* Remove cover assembly (2) from recoil
spring case assembly (I) as follows.
I) Set recoil spring assembly (I) on block 0.
* When doing this, check that there is no
damage to the weld of recoil spring case
(I).
DEW0213
2) Loosen mounting bolts (24) of cover (2)

gradually in turn on diagonally opposite
sides.
A To prevent danger, never stand in front
of the cover assembly or behind the re-
coil spring case assembly.
\
24
CLD01049
A The recoil spring

case is applying
inside the recoil spring
a pushing force of 294
kN (30 tons) on the yoke, so be careful
not to loosen the mounting bolts sud-
denly. Loosen the mounting bolts gradu-
ally until clearance a between the flange
of the recoil spring case and idler yoke
assembly is 10 - 13 mm.
3) When the bolts are loosened, the torque will

suddenly drop. Check that the spring is not
applying any pushing force on the mount- 1 f- CLD01050
ing bolts, then remove all bolts.
* If the torque increases (the pushing force
of the spring is applied) during the loos-
ening operation, stop the loosening op-
eration and disassemble as follows.
A 3)If thedescribed
torque does not drop during Steps 2) and
above, and the torque when the
18
bolts are loosened remains large, there is prob-

ably damage to recoil spring set bolt (181, or
nut (16) at the tip of the shaft has fallen off, so
there is danger that the yoke assembly may fly
off to the front. For this reason, disassemble as
follows.
II 16
CLDO1051
30- 193
0
A recoil
When disconnecting the cover assembly and
spring case assembly, do not stand in
front of the yoke assembly or behind the recoil
spring case assembly until safety has been con-
firmed and the recoil spring assembly has been
removed.
i) Prepare the following parts.

Bolt @ (x4): 791-730-1130
Nut @ (x4): 01580-12016
Washer @ (x4): 01643-32060 (use again)
CLD01052
ii) Remove 4 bolts marked *X, then install bolts

0, nuts 0, and washers @ listed in Step i).
+ Check that dimension L is less than 300
mm.
* Screw in bolts @) until they contact the
bottom of the yoke thread.
iii) Remove remaining 8 bolts (those not marked
%).
iv) Hold bolts @with a wrench to prevent them

from turning, then loosen 2 nuts @simulta-
neously on opposite sides.
* Be careful not to let the load bear on
only one bolt.
VI When recoil spring is fully extended and

torque has completely dropped in loosening
direction of nut 0, remove bolt 0.
* When clearance b is approx. 180 mm,
the spring is fully extended.
b
CLD01054
4) Sling cover assembly (21, then remove

mounting bolts, and lift off cover assembly.
Ir The oil inside the spring chamber will
flow out, so set a container under the
cover to catch the oil.
- : Spring chamber : Approx. 12 e
DEWa
30-194
0
2. Recoil spring assembly

Raise recoil spring assembly (3) and remove
from case.
DEW0215
3. Disconnection of yoke
1) Remove mounting bolts of yoke (41, then
remove spacer (5).
2) Using tool 14, disconnect yoke (4) from case.

._
IA
Disconnection pressure for yoke: h
Approx. 147 kN (15 ton) i4j5 1 ’

Before disconnecting the yoke, make
match marks on the yoke and case.
’ I
L-J ‘4 DEW0217
4. Disassembly of cover assembly

1) Remove cylinder rod (22) from cover assem-
bly (2).
2) Remove bracket, then remove lubricator (6).
DEW0218
30-195
0
3) Remove piston (7) from cylinder rod (22).

* Using an air gun, blow in compressed air 22
through the lubricator mounting hole to I
remove the piston.
-
JYQ
,>
-A ;
DEW0219
4) Remove snap ring (8) from piston (7), then

remove U-packing (9) and wear ring (IO). 7
10
I DEDOO220
5) Remove cover (12) from cover (II), then re-

move oil seal (13).
6) Remove bushing (14) from cover (II).
5. Disassembly of recoil spring assembly

1) Set recoil spring assembly (3) in tool Il.
A The spring is under high installed load,
so be careful to set it correctly to tool II.
* Installed load of spring:
285.8 kN (29,160 kg}
30-196
@
2) Apply hydraulic pressure slowly to compress

spring, then remove lock plate (15) and re-
move nut (16).
16 .I5
3) Release hydraulic pressure gradually and re-
lieve tension of spring.
4) Remove set bolt (181, rear pilot (191, shaft

(20),and pilot (21) from spring (17). 18
30-197
0
ASSEMBLY OF RECOIL SPRING

ASSEMBLY
1. Assembly of recoil spring assembly
I 18
\
I) Assemble pilot (211, shaft (20), rear pilot (19),

and set bolt (18) to spring (171, then set in
tool II.
A The spring is under high installed load,
so be careful to set all parts correctly.
2) Apply hydraulic pressure gradually to com-

press spring, and set so that installed length
@ of spring is standard value. When doing
this, check clearance @ between shaft (20)
and rear pilot (19).
* Installed load of spring:
285.8 kN (29,160 kg)
* Installed length 0: 945 mm
* Clearance @: 60 mm
3) Fit nut (161, then install lock plate (15).

Sr When securing nut (16), make a clear- DEDcm25
ance of 0 - 1 mm between lock plate (15)

and nut (161, then bring lock plate (15)
and bolt (18) into tight contact.
* Purpose of making clearance
i) If the nut is screwed in a small amount
and nut (16) protrudes beyond bolt (181,
Bring into
lock plate (15) may bend and lock bolt
(23) may fall off.
ii) If the nut is screwed in too far, the load
of the spring will always be applied to
the set bolt, and the set bolt will break.
4) Gradually release hydraulic pressure to com-
pletely relieve tension of spring, then remove
recoil assembly (3) from tool Il. DLD02921
30-198
0
2. Assemblv of cvlinder assembly

1) Using tool i2, press fit bushing (14) to cover
(II).
. Bushing press-fitting force :
19.6 - 29.4 kN (2 - 3 tons)
ll-
2) Assemble oil seal (13) to cover (II), install

cover (12) and O-ring.
DEcao221
3) Assemble wear ring (IO) and U-packing (9)

to piston (71, then install snap ring (8). 7
8
4) Assemble piston (7) to cylinder rod (5) from
U-packing end.
To prevent air from remaining inside the
9
cylinder when carrying out the opera-
tion in Step 4) above, fill with grease as
10
follows, and assemble piston (7).
i) Fill inside of cylinder with approx. 65 cc
of grease.
ii) Set with drain hole in cylinder rod (22) DEW0220
facing up, then fit lubricator (61, and
loosen.
iii) Push in until piston (7) contacts stopper
face of cylinder rod, and push out all air 22
and remaining grease. 7
\ I
I DErm219
30-198-l
0
iv) Tighten lubricator (6), then install bracket.

w Lubricator : 49.0 i: 2.5 Nm 6 22 2
(5 2 0.25 kgm}
5) Assemble cylinder rod (22) to cover assem-

bly (2).
DECCO218
3. Press fitting yoke

1) Align match marks on yoke and case (made
before disconnecting) and assemble.
2) Using tool 13 and spacer (5), press fit yoke
(4) to case.
+ Do not coat press-fitting surface @ with
Molycoat.
. Press-fitting force: 245.2 kN 125 ton1
I CVD02532
3) Fit spacer (5) and tighten mounting bolts.

6 Mounting bolt : Thread tightener (LT-2)
A II\/ I I \ DEDoo216
4. Raise spring assembly (3) and assemble to case.

Ir Before assembling, coat surface @ of spring
assembly (3) with grease.
& Spring assembly surface @ : Grease
(G2-LI)
CKD01056
30- 198-2
a
5. Raise cover assembly (2) and install to case as-

sembly (1).
/crzL, Mounting bolt : Thread tightener (LT-2)
w Mounting bolt : 549.11588 Nm (5626 kgm)

Add oil to spring chamber.
Q Spring chamber : 12 e (SAE30CD)
CKD01030
30-198-3
0
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
REMOVAL OF TRACK ROLLER

ASSEMBLY
1. Loosen track shoe tension.
SEMBLY.
2. Remove 7 mounting bolts of guard (I), and drop

on top of shoe. m
. Remove guard (I) only for the track roller
assembly at the rear.
3. Remove 4 mounting bolts of track roller assem-

bly (2), and disconnect from bogie (3). a
4. Using work equipment, raise chassis and lift off

guard (I). m
elkg Guard : 45 kg
DBCCO732
5. Pull out track roller assembly (2) to outside from

top of shoe link.
elkg Track roller assembly
0: Single flange: 97 kg
@: Double flange: 109 kg
. Mounting position of track roller assembly
0: Single flange type

@: Double flange type
DAD@3734
30- 199
0
ROLLER ASSEMBLY
removal.
6 Guard mounting bolt :

w Guard mounting bolt : 745.3 2 83.4 Nm
(76 t 8.5 kgm)
6 Track roller mounting bolt :

m Track roller mounting bolt :
745.3 f 83.4 Nm
(76 2 8.5 kgm)
m
* install the track roller assembly as follows.
1) install guard (I) temporarily.
2) Lower chassis to a position where track roller
assembly mounting bolts can be assembled,
then install mounting bolts.
3) Tighten guard mounting bolts.
30-200
0
D SASSEMBLY OF TRACK
R 3LLER ASSEMBLY
1. Remove plug and drain oil.
- : Track roller : Approx. 390 - 450 cc
2. Remove mounting bolts of retainer (2) of track

roller (1).
3. Turn over track roller, and set cylinder @ or

block so that there is enough space to remove
shaft from bottom.
4. Remove 2 mounting bolts of retainer (31, then

set tool 52 in position and pull out shaft (4) from J2
bottom.
5. Remove seal guide (51, then remove mounting

bolts of retainer (3).
6. Using forcing screws 0, remove retainer (3).
7. Raise roller (61, and pull out from shaft assem-

bly (7).
8. Set shaft assembly (7) to cylinder 0.
9. Using tool 52, remove retainer (2) and seal guide

(8) from shaft (7).
10. Remove floating seals (9) from seal guides (5)

and (8).
11. Remove floating seals (IO) from retainers (2)

and (3), then remove O-ring. 23
30-202
0
TRACK ROLLER
23 1
O-ring
DEW0240
12. Remove 2 coil bushings (11) from roller (6).
11
DEm41
30-203
0
ASSEMBLY OF TRACK ROLLER

ASSEMBLY
Jl
Ir Clean all parts, and check for dirt or damage.
1. Set roller (6) in press, then use tool Jl to press
fit 2 bushings (II).
When press fitting the bushing, use a plastic
hammer to align the center, then press fit
with a press.
Press fit the bushing so that the dimension
from the end face of the roller to the top
face of the bushing is 17 f 1 mm.
2. Using tool 53, assemble floating seals (IO) to

retainers (3) and (2).
* After inserting, check that the angle of the
* ‘See Fig. @ for the protrusion of the seal.
J3
2,
DED00243
- Fig. @ -
3. Using tool 53, assemble floating seals (9) to seal

guides (8) and (5).
After inserting, check that the angle of the
See Fig. @ for the protrusion of the seal.
83
30-204
0
4. Set roller (6) to cylinder 0, and assemble shaft

(7) to roller.
5. After installing retainer (31, turn over with shaft

assembled to roller and set on block 0.
6. Install retainer (21, assemble seal guide (8) to

shaft, then using tool 52, press fit seal guide (8).
J2
+ Press fit the seal guide so that dimension a
from the end face of the shaft to the top
surface of the seal guide is 48.5 + 0.2 mm.
* Turn over the track roller assembly and press
fit seal guide (5) in the same way as above. 85
* Before assembling, coat the mating surface
of the floating seals at the seal guide end
and retainer end thinly with engine oil.
Mcc-3251
30-205
0
7. Using tool J4, apply standard pressure to roller

oil filler port, and check for leakage of air from
seal.
* Standard pressure : 0.1 MPa (I kg/cm21
* Method of checking : Hold standard pres-
sure for 10 seconds. Gauge indicator must
not go down.
8. Using tool J4, fill track roller assembly with oil.
@ Track roller oil : 390 - 450 cc (G0140B)

DDWJ252
9. After filling with oil, check that the oil is at speci-

fied level, then tighten plug.
* Checking oil level: Angle track roller approx.
IO” and check that oil level is up to bottom
face of oil filler.
w Plug : 205.9 + 49.0 Nm (21 2 5 kgm) IO"
DDE00253
30-206
DISASSEMBLY AND ASSEMBLY BOGIE
REMOVAL OF BOGIE
ASSEMBLY
1. Loosen track shoe tension.
SEMBLY.
2. Remove 7 mounting bolts of guard (I), and drop

on top of shoe. a
3. Sling guard (I), then use work equipment to

jack up chassis, and remove guard (I).
j&lkg Guard : 45 kg
4. Lower chassis, then remove mounting bolts of

bogie guard (2). 112(
. Bogie guard mounting bolt : 2 each on in-
side and outside of track frame
‘2
DBCOO735
5. Use work equipment to jack up chassis, then

use clearance a between bogie assemblies to
remove bogie guard (2).
DBCW737
6. Using tool KIO, secure inner bogie (3) and outer

bogie (4).
‘KIO
7. Set steel plate @ between bogie assembly and

shoe link, then lower chassis and remove mount-
ing bolts of bogie assembly (5). m
* After removing the bogie assembly, set block
@ between the bogie assemblies to prevent
it from moving.
8. Using work equipment, jack up chassis, fit rope

around bogie assembly (51, then slide on steel
plate 0 and pull to outside. m
Bogie assembly : 410 kg
30-208
0
INSTALLATION OF BOGIE
ASSEMBLY
removal.
& Guard mounting bolt :

w Guard mounting bolt :
745.3 1 83.4 Nm(76 = 8.5 kgm)
6 Bogie mounting bolt :

Thread tightener (LT-21
w Bogie mounting bolt :
2108.3 + 245.2 Nm(215 + 25 kgm)
m
. Procedure for setting bogie assembly on link
1) Set steel plate @ on top of link as shown in
Fig.
2) Fit wire @ to bogie bracket (6) of track frame
on opposite side.
3) Fit wire @I to 2 track rollers of bogie assem-
bly to be installed, then use lever block @ to
8 pull up to top of link.
5 4) Set bogie assembly in mounting position, D-41
z then secure with block so that it does not

move.
5) Using work equipment, gradually lower chas-
sis to position where bogie mounting bolts
can be assembled, then install mounting
bolts.
6) Lower chassis completely, then tighten bo-
gie mounting bolts.
7) Raise chassis, then remove steel plate and
install bogie guard (2).
DAD00742
30-209
0
DISASSEMBLY OF BOGIE
ASSEMBLY
* Fixture tool KIO (used when removing the bogie
assembly) is also used for the disassembly op-
eration, so leave it installed.
1. Track roller assembly

Turn over bogie assembly, and lift off 2 track
roller assemblies (1). a
* When removing the track roller, check the
mounting positions of the @ single flange
and @ double flange.
2. Pulling out pin assembly

I) Set bogie assembly (2) to tool Kl.
* When removing the pin assembly from
the bogie assembly, the pin assembly
must be removed in the correct direc-
tion, so check casting mark @ (INSERT -
I)) on the inside of the outer bogie, and
set the bogie assembly correctly in the
direction for removal.
I / DLW0744
2) Using tool Kl, pull out pin assembly (3) from
bogie assembly (2).
Ir Removal pressure for pin assembly :
Approx. 800.2 kN (81.6 ton)
K1-6 Kl-1 Kl-7 Kl-10 2 Kl-15 Kl-3 Kl-14 Kl-13 Kl-5
Kl-II 3 Kl-4 Kl-16 Kl-2

DKhXn45
30-210
0
3. Pulling out shaft

1) Set pin assembly (3) to tool K4.
2) Push in shaft (4) with tool K4, remove collar
(5), then remove spacer (6) and floating seal
(7).
Ir Dimension for pushing in shaft (4):
78.2 mm
* Pressure for pushing in shaft (4):
58.8-103.9 kN (6-10.6 ton)
DKW0746
3) Turn over pin assembly (3) while still assembled to tool K4-14,
then set to tool K4 again.
4
DKW0747
4) Push in shaft (4) with tool K4, then remove collar (8).
Ir Dimension for pushing in shaft (4):
156.4 mm
* Pressure for pushing in shaft (4):
58.8 - 103.9 kN (6 - 10.6 ton)
30-211
5) Remove pin assembly (3) from tool K4, and

pull out spacer (91, ring (IO), spacer (II),
9 10 11 12 13 14
ring (12), spacer (131, and ring (I 41 from shaft
(4).
I 1
DLEQO748
4. Disassembly of ring
1) Remove floating seals (15) and (16) from 15,19 IO,14 16 17 12 18
ring (IO).
2) Remove floating seals (17) and (18) from
ring (12).
3) Remove floating seal (19) from ring (14).
I DlDCQ749
5. Disassembly of collar
Remove floating seals (20) from collars (5) and
(8).
6. Disconnection of bogie
Remove tool KIO, and disconnect inner bogie
(21) and outer bogie (22).
DLDOJ751
30-212
0
ASSEMBLY OF BOGIE
ASSEMBLY
1. Securing bogie
Assemble outer bogie (22) and inner bogie (211,
and secure with tool KIO.
* After securing with tool KlO, check that the
center of the pin assembly hole is showing.
2. Shaft, collar
1) Set collar (8) to tool K7-11, and assemble
bushing (12) to shaft (4) temporarily, as-
semble to tool K7-15, set in position, then
press fit. DLlXQ751
* When press fitting the shaft, center the

shaft with the collar, then press fit.
* Press-fitting force for collar:
58.8-98.1 Kn (6-10 ton)
li Press-fitting dimension: 78 mm
6 Collar press-fitting surface of shaft:
* After press fitting, there must be no
stepped difference at the end face of the
collar and shaft.
2) Remove shaft from tool K7-15, then remove 8

bushing (12).
3) Using tool Kll, assemble floating seal (20)

to collar (8).
When assembling the floating seal, re-
move all oil and grease from the O-ring
and O-ring contact surface.
The angle of the floating seal must be
less than 1 mm.
Protrusion @ of the seal must be within
5- 7 mm.
DKDO0754
K7-15 12 4 8 K7-11 DKCO3755
30-2 13
0
3. Assembly of ring, collar

1) Using tool Kll, install floating seals (191, Kll. Kll
(18), (171, (16), and (15) to rings (141, (121, 17 --I
and (IO).
When assembling the floating seals, re-
move all oil and grease from the O-ring 12’
and O-ring contact surface.
The floating seal must be tilted less than
1 mm.
Protrusion @ of the seal must be within
5-7 mm. 18 19
DLW0756 DLDCQ757
2) Using tool Kll, assemble floating seal (7) to

collar (5). I Kll 7
* The precautions are the same as the
items marked * for Step I) above.
I Dl!xoEa
4. Assembly of pin assembly

Ir When assembling the floating seals for each
bushing and collar, coat the seal mating
surface thinly with oil (EO-30).
1) Install spacer (6) to shaft (41, then assemble
ring (14).
2) Install spacer (131, then assemble ring (12).
3) Install spacer (1 I), then assemble ring (IO).
30-214
a
5) Set pin assembly (3) to tool K7, press fit

collar (5).
* Press-fitting force for collar:
58.8 - 98.1 Kn (6 - IO ton)
Ir Press-fitting dimension: 78 mm
& Collar press-fitting surface of shaft:
Anti-friction compound (LM-P)
+ Stepped difference at the end face of the
collar and shaft after press fitting:
0-2mm
5. Press fitting pin assembly

I) The bogie and pin assembly must be press
fitted in the correct direction, so check the
press-fitting direction and set tool Kl in po-
sition.
i) On the inside of the outer bogie @, there
is an [INSERT+] casting mark and ar-
row, so set the bogie with the letters
and arrow facing the hydraulic cylinder
end of tool Kl.
ii) The pin assembly with the distinguish-
ing mark machined on the outside cir-
cumference of the bushing has the larger
diameter, so press fit the bushing that
has no distinguishing mark first.
30-215
0
3
I 2 K1-8 DKDW761
2) Press fit pin assembly (2) to bogie assem-

bly.
& Outside circumference of pin assem
bly: Anti-friction compound (LM-P)
* Press fit with the [UPI mark on the tip of
the pin at the top.
* Press-fitting force for pin:
Approx. 800.2 kN (81.6 ton)
6. Track roller assembly

Install 2 track roller assemblies (I).
* Check the installation position of the @ sin-
gle flange and @ double flange, then install.
6 Mounting bolt : Thread tightener (LT-2)
m Mounting bolt :
745.3283.4 Nm (76~8.5 kgm)

After assembling, add oil to bogie assembly.
Q Bogie assembly : 210-230 cc (G0140B)
30-2 16
0
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER
REMOVAL OF CARRIER
ROLLER ASSEMBLY
1. Remove top cover of track frame, loosen lubri-
cator (I), then loosen track shoe tension.
A The recoil spring cylinder is under high in-
ternal pressure, so never loosen lubricator
(I) more than one turn.
* If the track tension is not relieved when the
lubricator is loosened, move the machine
backwards and forwards.
2. Using hydraulic jack 0, raise track shoe.
3. Remove mounting bolts (2).
4. Pass rope @ through hole in link, wrap around

carrier roller (31, and tighten rope. Gradually
loosen rope to pull out carrier roller (3) from
support and remove it. m
&I kg Carrier roller : 45 kg
z
z
INSTALLATION OF CARRIER
ROLLER ASSEMBLY
removal.
m
* When installing the carrier roller to the sup-
port, leave a clearance as shown in the dia-
gram.
a Support mounting bolt :
l Adjust the tension of the track shoe assembly. _ 1 Clearance:1.2mm

For details, see TESTING AND ADJUSTING, AD-
JUSTING TENSION OF TRACK SHOE ASSEM-
BLY.
DISASSEMBLY OF CARRIER
ROLLER ASSEMBLY
1. Remove plug and drain oil.
* Rotate the shaft when draining the oil.
- : Carrier roller : Approx. 0.7 t
2. Set carrier roller assembly (1) on block @).
3. Remove mounting bolts, then remove cover (2).
4. Remove ring (3).
5. Using tool Ll, remove nut (4).
6. Using puller 0, remove press-fitting portion of

seal guide, then using eyebolts, remove bearing
(5) and roller (6) as one unit.
7. Remove outer race (7) from roller.
8. Using Puller 0, remove seal guide (8) and bear-

ing (9) as one unit.
9. Remove floating seal (IO) from seal guide (8).
8 IO
DEW0266
30-218
0
IO. Using push tool 0, remove seal guide (11).

r-----l7
11. Remove floating seal (12) from seal guide (II).
DEW0264 DELI03266
30-2 19
0
ASSEMBLY OF CARRIER
ROLLER ASSEMBLY
Ir Clean all parts, and check for dirt or damage.
1. Using push tool 0, press fit bearing (9).
2. Using push tool @, press fit outer race (7).
3. Set roller (6) and bearing (5) to shaft.

5 0 0
4. Using push tool 0, press fit bearing (5) to shaft.
ii!%
* Rotate the roller when press fitting the bear-
ing, and press fit to a position where the
rotation of the roller becomes slightly
heavier.
F?
DELm269 DEW0270 z.5
I &
0
5. Using tool Ll, tighten nut (4) to 58.8 Nm (6

kgm).
* After tightening the nut, if the nut hole and
shaft hole are not aligned, turn the nut in
the direction of loosening to align.
6. Install ring (3).
DEW0260 DEW0259
7. Fit O-ring, then fit cover (2) and tighten with

mounting bolts.
* Temporarily tighten the oil filler plug.
30-220
0
L MD00271
8. Turn over roller (61, and add oil between shaft

and roller.
Q Oil : 570 - 680 cc (G0140B)
9. Using tool L2, install floating seal (IO) to seal

guide (8).
F
10. Fit O-ring, then align with dowel pin, and install IO
seal guide (8).
DECO3273
11. Using tool L2, install floating seal (12) to seal

guide (1 I).
MLXQ76
12. Using tool L3, press fit seal guide (II).

* Press fit the seal guide until dimension a
from the end face of the shaft to the top
surface of the seal guide is 131.95 f 0.2 mm.
30-221
0
13. Using tool L4, apply standard pressure to roller

oil filler port, and check for leakage of air from
seal.
* Standard pressure : 0.1 MPa (I kg/cm*)
* Method of checking : Hold standard pres-
sure for IO seconds. Gauge indicator must
not go down.
14. After checking for air leakage, check again that

level of oil added in Step 8 is at specified level.
* Method of checking oil level
Remove the oil filler plug and tilt the carrier
roller assembly to an angle of approx. IO” to
check the oil level.
15. Tighten oil filler plug.

w Plug : 205.9 t 49.0 Nm (21 2 5 kgm)
I DDWOZ79
30-222
0
DISASSEMBLY AND ASSEMBLY TRACK SHOE
CHECKING BEFORE REMOVAL

OF TRACK SHOE ASSEMBLY
AIn some cases, it may be extremely dangerous
to remove the track shoe assembly. To prevent
danger, carry out the following checks before
removing the track shoe assembly.
l Checks before starting
I) Loosen the lubricator at the adjustment cyl-
inder, release the grease, then move the
machine backward and forward a short dis-
tance, and check that the track tension is
relieved. If the track tension is not relieved
and the track shoe assembly remains tense,
there may be an abnormality inside the track
frame (the recoil spring case is broken, the
recoil spring set bolt is broken, or the nut at
the end of the shaft has fallen off).
a Never loosen the lubricator more than
one turn.
2) Check that there is no interference between
the track frame and the guide shown in the
diagram. If there is any interference (when
progress of link pitch elongation is extreme),
there are cases where it is impossible to
know if there is any abnormality inside the
8 track frame.
X Track frame
i-
s
REMOVAL OF TRACK SHOE
ASSEMBLY (NORMAL)
* If CHECKING BEFORE REMOVAL OF TRACK
SHOE ASSEMBLY shows that there is no abnor-
mality, do as follows.
1. Remove blade assembly.

BLY.
2. Loosen lubricator (I) and loosen track shoe ten-
DUXlO.254
sion. m
A The recoil spring cylinder is under high internal
pressure, so never loosen lubricator (I) more
than one turn.
If the track tension is not relieved, move the
machine backwards and forwards.
3. Using block 0, adjust position so that master
link is perpendicular.
4. Remove mounting bolts, then remove
track shoe (2).
a
5. Disconnect master link (31, guide end of track

link with a crane, move machine slowly in re-
verse, and lay out track shoe assembly.
REMOVAL OF TRACK SHOE ASSEMBLY

(WHEN THERE IS ABNORMALITY
INSIDE TRACK FRAME)
* When CHECKING BEFORE REMOVAL OF TRACK

SHOE ASSEMBLY shows any abnormality, do
as follows.
A If there is any abnormality inside the track frame,

there is danger that the track shoe assembly
may spring back when it is removed or that the
idler may spring out when the track shoe as-
sembly is removed. This may lead to serious
injury, so remove the track shoe assembly as
follows.
a If there is any interference or abnormal catching
around the idler assembly, examine carefully
and remove the problem before starting.
1. Remove blade assembly.
BLY.
2. Loosen lubricator (I) of adjustment cylinder, then
move machine backwards and forwards to re-
lease grease. a
A Never loosen the lubricator more than one

turn.
Ir Check that all the grease has been removed.
DLD00254
30-223-l
0
3. Drive slowly forward to put track shoe at idler

end in contact with large block @ or a wall (if
another large bulldozer of the same capacity as
the machine being repaired is available, put in A 5
contact with the blade). Stop machine when
recoil spring bends and slack is formed in track
shoe assembly, then apply brake. When doing
this, set so that master link is between idler and
front carrier roller. For safety reasons, fit a le-
ver block between carrier roller support and link.
4. Remove idler guide (2).
AAlways remove the idler guide without fail
at this point.
If the track shoe is opened without remov-
ing idler guide (21, it will move to the front
when it opens, and idler guide (2) will be
pushed against the track frame. If the idler
guide is removed in this condition, the idler
yoke assembly will fly out to the front.
5. Remove shoe (41, then disconnect master link
(5). m
ABe extremely careful to ensure safety when
disconnecting the track shoe.
6. Move machine towards rear slowly, and lay out
8 track shoe assembly.
5
z
SHOE ASSEMBLY
removal.
w
j, Track shoe tension : 20 - 30 mm
lff21
w Master link mounting bolt :
1st step 441.3k49.0 Nm (4525 kgm)
2nd step 120 +2;
* When winding on the track, use a bar and

make sure that the link does not come off
the sprocket.
When winding on the track, make sure that
the track tension does not become loose.
* Check that there is no dirt or dust on the
mating surface or thread of the master link.
* Tighten the track shoe bolts in the order @ -
0. DKDO0282
30-223-Z
@
OVERALL DISASSEMBLY OF
TRACK SHOE
* This section describes only the procedure for
the lubricated track.
1. Shoe (master link portion)

Set the track assembly on a flat floor with the
shoe facing up, then remove the shoe bolt at
the master link, and remove the shoe.
+ Do not use an impact wrench when loosen-
ing the master link bolt.
2. Disassembly into l/4 parts
Because of the weight of the track assembly, if DLDC0283
the l/2 assembly is too large and there are prob-

lems with disassembly and assembly work, di-
vide into l/4 assemblies.
3. Shoe (regular link portion)
Raise the track assembly and set it on the floor
with the shoe facing up, then use a shoe bolt
impact wrench to remove the shoes.
* When moving the track assembly, be careful
not to damage the master link portion.
Sr If a gas cutter has to be used to remove the
shoe nut, to prevent deterioration of the seal
due to the heat, keep the temperature of the
seal portion below 8O”C, and take action to
prevent welding spatter from entering the DLW0284
gap between the links.

4. Draining oil
Before disassembling the link assembly, drain
the oil from inside the pin and take precautions
Chamfer
so that the link press does not become dirty
with oil.
A
Ir Before disassembling, if it is judged that it is
necessary to rebuild the track as a dry type
track, the following work need not be car-
ried out.
1) Set the link assembly on a flat floor with the
large plug side facing up, then chamfer the
burrs on the end face of the pin with a
grinder. DLD02923
Ir If the track is disassembled with burrs

still at the end face of the pin, the pin
press-fitting hole of the link will be
scratched, and this will cause leakage
from the pin press-fitting portion after
rebuilding.
2) Using a drill (al0 mm), make a hole in the
large plug, then remove the large plug.
* If any dirt or deteriorated oil is stuck to
the pin hole, drill through with a longer
drill to remove it. When doing this, be
careful not to damage the oil hole.
I DLCC0286
30-224
0
3) After removing the large plug, use a baby

grinder (angle of grinder tip: 45” - 60”), and
chamfer the pin hole so that the plug is not
damaged when the plug is knocked in.
4) Turn over the link assembly so that the small
plug side is facing up, remove the burrs at
the end face of the pin with a grinder, then
use tool M5 to knock the small plug to the
inside.
* If the small plug hole is blocked with
burrs, grind with a grinder until the hole
can be seen completely. DLDCO287
5) Using a drill (al0 mm), chamfer the small

plug hole.
6) Blow with compressed air to remove the
metal particles when draining the oil inside
the pin or removing the burrs, then wash
the link assembly with high-pressure water
or steam.
DLDO3288
5. Disassembly of link
I) Set the link assembly on a link press, then
hit with a hammer so that the bushing and
jaw are in tight contact.
Ir If the link tread and outside diameter of
the bushing are worn, adjust the height
of the shoe or guide plate, and center
the disassembly jig with the pin and
bushing center to prevent damage to the
link hole when disassembling.
Jr If the centering is not carried out prop- \
Left dikassemblu disassembly jig
erly, the link hole may be damaged, the DLD02924
pin may break, or the bushing may crack
during disassembly.
2) Operate the left cylinder and remove the left
link and pin and bushing press-fitting por-
tion at the same time.
Ir Check the removal force of the pin and
bushing, and use this value as reference
to judge if it is possible to obtain the
necessary pin and bushing press-fitting
force when turning and reassembling.
* Do not push the disassembly jig inside
more than is necessary as the spacer
may break.
30-225
3) Return the left cylinder, then operate the right

cylinder and remove the right link and pin
and bushing press-fitting portion at the same
time.
4) Return the right cylinder, remove the left
and right links, pins, bushings, and spacers,
then feed the following set for one link as-
sembly into the jaw.
* To decide if the seal can be used again,
carry out inspection when the seal is still
installed to the link, so do not remove
the seal from the link.
* If oil is remaining, this can be used as a
1 DLD00291
guideline for reuse of the seal, so mark

such links or seals.
* If the end face of the bushing and seal
surface are damaged, it will cause oil
leakage, so be extremely careful when
handling.
6. Inspection
Check the following items to determine if the
part can be reused as a lubricated track or as a
grease-filled track. Carry out a comprehensive
check to determine if the link assembly can be
I DLD00292
rebuilt as a lubricated track or as a grease-filled

track.
When making judgments about reuse of
parts, see “Guidance for Reusable Parts, Un-
dercarriage, Lubricated Track”.
Check the pins, bushings, links, and spacers
visually for damage, and carry out a color
check or use a flaw detector to check parts
that are suspected of being damaged. Any
part that is cracked must not be used again,
so scrap it.
Check the external appearance of the seal
and the end face of the bushing visually to
determine if they can be used again.
If only the bushing is replaced with a new
part, the worn or damaged part of the seal
lip will contact the end face of the bushing
directly, so it may not be able to carry out
its sealing function. For this reason, always
replace the seal
together with the bushing, or rebuild as a
grease-filled track.
30-226
0
3) Using calipers, measure spacer thickness a

and overall length b of the sliding portion of
the bushing and spacer. Check if it is possi-
ble to obtain the specified seal mounting
dimension when reassembling.
* If the amount of wear of the spacer and
bushing is greater than the specified
amount, the assembly precision of the
seal portion cannot be guaranteed, so
replace with new parts, or rebuild as a
grease-filled track.
I DLW0293
4) Using a micrometer, cylinder gauge, and

calipers, measure the outside diameter of
the pin and the inside diameter of the bush-
ing at the worn portion, and judge if the
parts can be used again.
* If the amount of wear is greater than the
specified amount, there will be play dur-
ing travel, and it will also cause oil leak-
age, so replace with new parts or re-
build as a grease-filled track.
* For details of the dimensions when mak-
ing judgment, see MAINTENANCE
I DLCCE94
STANDARDS.
5) Using a micrometer and cylinder gauge,

measure the outside diameter of the pin and
bushing press-fitting portion, and the inside
diameter of the pin and bushing press-fit-
ting portion of the link to determine if the
permitted interference can be obtained.
However, when rebuilding as a lubricated
track, check that the standard interference
for the pin and link can be obtained.
* If the permitted interference can not be
obtained, replace with new parts or re-
place with an oversize part.
* For details of the dimensions when mak-
ing judgment, see MAINTENANCE
STANDARDS.
DLDWB6
* Precautions for storage

1) To prevent rust of the counterbore portion
of the link, leave the seal installed to the link
and be careful not to damage the seal lip
during storage.
2) Coat the pin and bushing press-fitting por-
tion, shoe mating surface, and master link
mating surface of the link with rust preven-
tion oil to prevent rust.
3) Coat the whole circumference of the pins,
bushings, and spacers with rust prevention
oil to prevent rust, and be particularly care-
ful not to damage the end face of the bush-
1i DLDCW97
ing during storage.
30-228
0
OVERALL ASSEMBLY
1. When rebuilding as lubricated track
1. Preparatory work
I) Washing seal assembly
. Machines fitted with F3 type seals
Remove the seal assembly from the link,
then separate into the seal ring and load
ring, and clean the parts.
* The seal ring and load ring deteriorate
easily when brought into contact with
DLDS3299
cleaning agent (trichlene, etc.), so wash
the parts quickly. After cleaning, wipe
the parts with a clean cloth to remove
all the cleaning agent.
. Machines fitted with W7 type seals
For seals that are to be reused, leave the
seal installed to the link, and do not wash it.
When reusing the pin, chamfer the corner of

the end face smooth with a grinder. Use a
grinder to remove any protruding parts stuck
to the press-fitting portion.
* If the corner of the end face has become
sharp due to wear, there will be scuffing
at the press-fitting portion and this will
cause oil leakage.
3) Make a mark on the end face at the small

plug end to show the direction of the side
Make mark to indicate
hole (hole in the radial direction) in the pin
direction of hole
when assembling.
* When reusing the pin, assemble in the
same direction as when the part is new
(side hole on the link tread side).
4) If the link, pin, bushing, or spacer are dirty,

wash them. Remove any protruding parts
stuck to the link and bushing with a grinder.
* These parts easily rust, so wash them
immediately before assembly.
* Use tool M3 to wash the pin hole.
Ir Do not polish or carry out any other treat-
ment of the end face of the bushing as
this will cause oil leakage.
5) Use tool M4 to knock the large plug into the
pin.
i) Insert the plug into the guide hole
through the plug insertion window.
ii) Push the bar by hand and insert the plug
as far as possible.
iii) Push the plug with the bar and push the
guide itself against the pin.
iv) Knock in the bar with a hammer.
Dimension a to knock in from end
face of pin: 6 t 2 mm
If there is no more place to chamfer
at the pin hole because of wear, use
a baby grinder (angle of grinder tip:
45” - SOY to carry out chamfering.
Coat the outside circumference of the
plug with GO90 and knock in the DLW0303
smaller diameter part first.
6) Installation of seal assembly
. Machines fitted with F3 type seal
Clean the link counterbore, then use tool M6 Remove all oil and \ \I
grease from portions
to push the seal in fully to the bottom.
marked
* If there is oil stuck to the link counterbore
Direction
and seal assembly, the seal will rotate and
of insertion
its sealing performance will drop, so do not I
coat with oil. In addition, be careful not to
let oil get into the counterbore portion of
the seal when pushing in.
. Machines fitted with W7 type seal
6
When reusing the link and replacing the seal
with a new part, clean the link counterbore, I DLEWXJ4
then push the seal in fully to the bottom.

* If there is oil stuck to the link counterbore
and seal assembly, the seal will rotate and
its sealing performance will drop, so do not Remove all oil and
grease from portions
coat with oil. In addition, be careful not to marked by bold line
let oil get into the counterbore portion of
the seal when pushing in.
30-230
0
7) In order to keep the protrusion of the pin

and bushing constant and the installation
dimensions of the seal within the specified
value during assembly, adjust the press-fit-
ting jig dimensions of the link press.
* For details of the standard dimensions,
see PRESS-FITTING JIG DIMENSION
TABLE FOR LINK PRESS.
* To leave a small space for the pin when
assembling, ensure that the dimension
(dimension a’) is greater than dimension
a at the pin pushing portion of the left DLD00306
press-fitting jig.
When assembling in order 0 press fit
ting left link, @ press fitting right link,
provide the extra space for the pin on
the right press-fitting jig.
* If the end face of the pin (portion P) or
the side face of the link (portions 0, RI
are worn, add the amount of wear to the
standard dimension when adjusting the
dimension of the press-fitting jig so that
the amount of protrusion of the left and
right pin and bushing is uniform.
DLW0307
8) Adjust the relief pressure of the link press to

make sure that the pushing force of the press
does not exceed the specified value.
t If the pushing force is too strong, exces-
sive force will be brought to bear on the
spacer, and it will be pushed against the
bushing. This will cause the spacer to
break or will cause abnormal wear be-
tween the spacer and bushing end face.
* If the interference at the press-fitting
portion is different from when the part
is new, as when reusing a pin or bush- DLW0306
ing, measure several of the press-fitting

portions, and use the table below to de-
termine the set pushing force according
to the average interference.
* Pushing force for pin, bushing: 785 kN
(80 ton)
Pushing force L. 1.8 x average press-fit-
ting force
(Adjust the relief pressure of the link
press and set the pushing force.)
30-231
0
2. Assembly of link
1) Use a clean brush to coat the area between
the pin and bushing with oil (G0901, set in
position, then set in front of the jaw of the
link press.
* When reusing (turning) the bushing, set
the worn surface on the outside circum-
ference of the bushing facing the shoe
mounting surface of the link (facing up
on the link press).
2) Set the left and right bushing end master

link with the shoe mounting surface facing
up, then press fit to the bushing.
* When doing this, use the pin end master
link as a support.
* Press-fitting force for bushing:
49 - 196 kN (5 - 20 ton)
DLW0310
3) Using a shoe bolt hole pitch gauge, press fit

until the distance between the shoe bolt
holes of the left and right link is the speci-
fied value.
Ir Use compressed air to remove all metal
particles from burrs caused by press fit-
ting the bushing.
DLDoo311
4) Turn over the master link, and check that

the left and right master links have been
press fitted in parallel.
30-232
0
5) Measure the amount of protrusion of the

left and right bushings with a depth gauge.
* Adjust the press-fitting jig for the link
press so that the protrusion of the left
and right bushings is uniform.
6) Feed the master link portion, then set the

pin and bushing in position.
* When reusing the pin, assemble so that
the side hole is on the link tread side in
the same way as when the part is new.
If the parts are not assembled facing the
specified direction, the strength may
drop, so mark the direction of the side
hole clearly on the end face to prevent
any mistake during assembly.
* Align the large plugs so that they are on
the left side facing the link press when OLD02925
assembling.
7) To prevent oil from leaking out from scuff

marks on the pin press-fitting portion, coat
the pin press-fitting hole in the link and the
outside diameter of the pin press-fitting por-
tion with gasket sealant (198-32-19890).
Coat whole circumference/ /
DLD02926
8) Set the right link in position and install the

spacer to the pin.
Ir Check that there is no dirt or dust stuck
to the seal surface and bushing end face,
then use a clean cloth or brush to coat
with oil (G090).
Ir Wipe the spacer with a clean cloth, then
install it.
DLD00315
30-233
0
9) Using the right jig as the receiving end and

the left jig as the pushing end, press fit the
pin and bushing at the same time.
+ The seal may come off the link due to
the play when press fitting, so press fit
smoothly. If the seal comes off the link,
stop the press-fitting operation and fit
the seal correctly on the link, then start
the press-fitting operation again.
* Press-fitting force for pin, bushing:
245 - 490 kN (25 - 50 ton)
DLD0031E
IO) Using a fine adjustment spacer, press fit so Fine a djust,yent

SDacel \ \ I /
that the end face of the pin is in tight con-
tact with the bottom of the receiving jig.
J, Adjust the depth of the hole in the re-
ceiving jig so that the protrusion of the
left and right pins is uniform.
11) Set the left link in position and install the r

spacer to the pin.
* Coat with oil in the same way as when
installing the right link.
I DLD00318
I
12) Using the left jig as the receiving end and
the right jig as the pushing end, press fit the
left link.
When press fitting, be careful that the
left and right seal and spacer do not
Provide enough space on the left jig so
that the end face of the pin does not
contact the bottom of the jig.
Press-fitting force for link:
245 - 490 kN (25 - 50 ton)
30-234
0
13) Press fit the link, spacer, and bushing so SmaI I

that they are each in tight contact. at en
* It is impossible to check from outside if
they are in tight contact, so control the
hydraulic force of the link press and set
the relief pressure to a constant value.
Then apply hydraulic force and push in c
until this pressure is reached.
For details of the setting for the relief
pressure, see “Preparatory work”.
+ Check that adjacent links swivel freely in
relation to each other. DLL302928
14) After assembling each link, use a dial gauge
and pinch bar to measure the end play from
the link previously assembled, to check that
the link is assembled within the specified
value.
If the end play does not come within 0 -
0.13 mm even when applying the push-
ing force until the relief valve is actu-
ated, raise the relief pressure setting
gradually to adjust.
Adjust the relief pressure setting care-
fully and be sure not to raise the push-
ing force of the link press higher than
necessary.
15) Using a shoe bolt hole pitch gauge, check
that the distance between the shoe bolt holes
is within the standard value.
If the distance between the shoe bolt
holes is greater than the specified value,
disassemble and check for any abnor-
mality, then press fit again.
If the distance between the shoe bolt
holes is smaller than the specified value,
and the shoe cannot be installed, the
wear of the spacer or bushing end face
is probably greater than the repair limit,
so disassemble and replace with a new
part.
If the end play is too large, the sealing
performance will drop, so set the end
play to a small value.
16) After assembling each link, use tool M7 to
remove the air from inside the pin, and check
the sealing performance.
-k Hold the space inside the pin at a vacuum
of 650 - 700 mmHg for 5 seconds and
check that there is no change in pres-
sure.
If the pressure changes, disassemble and
check the seal for any abnormality, then
assemble again.
DLRW323
17) Assemble the pin end master link as the

final link.
* Check that the left and right master links
are press fitted in parallel.
3. Filling with oil

After completion of assembly of the link assem-
bly, add oil through the pin hole.
1) Using tool M7, remove the air inside the pin
from the small plug hole, set to a vacuum of
650 - 700 mmHg, then fill with oil (G090)
until the pressure is 0.2 - 0.3 MPa (2 - 3 kg/
cm2).
* In cold or extremely cold areas, instead
of G090, fill with Komatsu genuine oil
(150-09-19270) which has excellent low-
temperature qualities. I DLDKI324
* Be careful not to raise the oil pressure
too high as this will have an adverse
effect on the seal.
* To determine the oil amount, set the
L
small plug end at the top (stand the link Oil level
assembly on its side), leave for 30 min- +
utes, then fill with oil so that depth L of
the space at the pin hole is within the
specified value below. GO9
Dimension L: 35 - 65 mm
-Pin
.- -Large ~1~9
J
DLD0292S
2) After completion of filling with oil, use tool

M5 to knock in the small plug to the speci-
fied position.
+ Coat the outside circumference of the
small plug with G090.
* The depth to knock in the plug is as fol-
lows.
Depth from end face: 7.5 c 1 mm
30-236

Set the link assembly on the bed, then use a
shoe bolt impact wrench and torque wrench to
install the shoe.
m Shoe bolt (regular link):
Initial torque: 588.4 f 58.8 Nm
(60 e 6 kgm)
Tightening angle: 120” + IO”
5. Connecting to make l/2 assembly

Set two completely assembled portions of track
on a flat surface in a straight line with the shoes
facing up. Pull master link (I) at the pin end to
master link (2) at the bushing end, and set at the
mating surfaces. Then put shoe (3) on top, check
that shoe bolt (4) goes in easily by hand, and
connect the two parts with the master bolt.
!
& Shoe bolt: Anti-friction compound (LM-P)
w Shoe bolt (regular link):
Initial torque: 588.4 f 58.8 Nm
(60 L 6 kgm)
Ir When tightening, tighten in the order @ - 0.
* Do not use an impact wrench for the master

link.
DLD00298
2. When rebuilding as grease-filled track

Load ring
1. Preparatory work
I) Washing seal assembly
. Machines fitted with F3 type seals
Remove the seal assembly from the link,
then separate into the seal ring and load
ring, and clean the parts.
* The seal ring and load ring deteriorate
easily when brought into contact with
cleaning agent, so wash the parts quickly.
After cleaning, wipe the parts with a DLDW299
clean cloth to remove all the cleaning

agent.
. Machines fitted with W7 type seals

For seals that are to be reused, leave the
seal installed to the link, and do not wash it.
2) When reusing the pin, chamfer the corner of

the end face smooth with a grinder so that
press fitting can be carried out smoothly.
DLCQCBCCJ
3) Make a mark on the end face at the small

plug end to show the direction of the side
hole (hole in the radial direction) in the pin Make mark to indicate
when assembling.
* When reusing the pin, assemble in the
same direction as when the part is new
(side hole on the link tread side).
DLDOSUl
30-238
0
4) Use tools M4 and M5 to knock the large

plug and small plug into the pin.
i) Insert the plug into the guide hole
through the plug insertion window.
(Coat the plug with oil.)
ii) Push the bar by hand and insert the plug
as far as possible.
iii) Push the plug with the bar and push the
guide itself against the pin.
iv) Knock in the bar with a hammer.
* Dimension a to knock in from end
face of pin:
Small pin: 7.5 * 1 mm
Large pin: 6 = 2 mm
* If the plug was not removed from
the pin during disassembly, it can be
used again as it is.
Remove a II oil and Dreeee
5) Clean any part where outside diameter of from the
the pin, front face of the spacer, or end face Direction
or inside diameter of the bushing are dirty. to push in
6) Coat the outside diameter of the pin and the C 1

front face of the spacer with grease.
Installation of seal assembly
Machines fitted with F3 type seal
Clean the link counterbore, then use tool M6 6
to push the seal in fully to the bottom. DLD02931
* If there is grease stuck to the link
counterbore and seal assembly, the seal
will rotate and its sealing performance
will drop, so do not coat with grease.
. Remove all oil and greeee
Machines fitted with W7 type seal from the shaded area
When reusing the link and replacing the seal
with a new part, clean the link counterbore,
then push the seal in fully to the bottom.
Ir If there is grease stuck to the link
counterbore and seal assembly, the seal
will rotate and its sealing performance
will drop, so do not coat with grease.
8) In order to keep the protrusion of the pin
and bushing constant and the installation DLD02932
I
dimensions of the seal within the specified
value during assembly, adjust the press-fit-
ting jig dimensions of the link press.
* For details of the standard dimensions,
see PRESS-FITTING JIG DIMENSION
TABLE FOR LINK PRESS.
* If the end face of the pin (portion P) or
the side face of the link (portions 0, R)
are worn, add the amount of wear to the
standard dimension when adjusting the
dimension of the press-fitting jig so that
the amount of protrusion of the left
and right pin and bushing is uniform.
u
C DLD00306
30-239
0
2. Assembly of link
I) Coat the area between the pin and bushing
with lithium grease (G2-LI), set in position,
then set in front of the jaw of the link press.
* When reusing (turning) the bushing, set
the worn surface on the outside circum-
ference of the bushing facing the shoe
mounting surface of the link (facing up
on the link press).
2) Set the left and right bushing end master

link with the shoe mounting surface facing
up, then press fit to the bushing.
* When doing this, use the pin end master
link as a support.
Ir Press-fitting force for bushing:
49 - 196 kN I5 - 20 ton)
3) Using a shoe bolt hole pitch gauge, press fit

until the distance between the shoe bolt
holes of the left and right link is the speci-
fied value.
* Use compressed air to remove all metal
particles from burrs caused by press fit-
ting the bushing.
4) Turn over the master link, and check that

the left and right master links have been
press fitted in parallel.
5) Measure the amount of protrusion of the

left and right bushings with a depth gauge.
* Adjust the press-fitting jig for the link
press so that the protrusion of the left
and right bushings is uniform.
30-240
0
6) Feed the master link portion, then set the

pin and bushing in position.
* When reusing the pin, assemble so that
the side hole is on the link tread side in
the same way as when the part is new.
If the parts are not assembled facing the
specified direction, the strength may
drop, so mark the direction of the side
hole clearly on the end face to prevent
any mistake during assembly.
* If the outside diameter of the pin is worn,
assemble so that the face that is not worn
is on the pulling side. However, in this
case also assemble so that the side hole
faces the tread surface of the link.
7) Set the left and right links in position, then
operate the left and right pushing jigs to
press fit the pin and bushing at the same
time.
Ir The seal may come off the link due to
the play when press fitting, so press fit
smoothly. If the seal comes off the link,
stop the press-fitting operation and fit
the seal correctly on the link, then start
the press-fitting operation again.
Ir Pushing force for pin, bushing: 785 kN
DLD00330
(80 ton)
Pushing force = 1.8 x average press-fit-
ting force
(Adjust the relief pressure of the link
press and set the pushing force.)
8) Using a shoe bolt hole pitch gauge, meas-
ure the distance between the shoe bolt holes
and stop press fitting when it is within the
standard value.
9) Assemble the pin end master link as the
final link.
* Check that the left and right master links
are press fitted in parallel.
DLDC0311

Set the link assembly on the bed, then use a
shoe bolt impact wrench and torque wrench to
install the shoe.
w Shoe bolt (regular link):
Initial torque: 588.4 +. 58.8 Nm
(60 + 6 kgm)
Tightening angle: 120” = IO”
Connecting to make l/2 assembly

facing up. Pull master link (1) at the pin end to
master link (2) at the bushing end, and set at the
mating surfaces. Then put shoe (3) on top, check
that shoe bolt (4) goes in easily by hand, and
connect the two parts with the master bolt.
& Shoe bolt: Anti-friction compound U-M-PI
w Shoe bolt (master link):
Initial torque: 588.4 + 58.8 Nm
(60 + 6 kgm)
DLlBm27
Tightening angle: 180” z IO”
Ir When tightening, tighten in the order @ - 0.
* Do not use an impact wrench for the master

link.
DLDOO298
30-242
0
DISASSEMBLY AND ASSEMBLY PRESS-FITI-ING JIG DIMENSION TABLE FOR LINK PRESS
PRESS-FITTING JIG DIMENSION

TABLE FOR LINK PRESS
DLD00331
Unit: mm
Jig dimension
a b C
5.7 3.25 50.6
30-243
0
DISASSEMBLY AND ASSEMBLY ONE LINK
FIELD DISASSEMBLY OF ONE

LINK
* This section describes only the procedure for
using the tools. For details of the procedure for
disassembly or assembly, see OVERALL DISAS-
SEMBLY (or ASSEMBLY) OF TRACK SHOE.
1. Using two bolts (21, install tool Nl (adapter,

guide, bolt) to link (I).
Nl
* It is also possible to use two track bolts for
bolt (2).
DE00032
2. Assemble tool N2 (pump, cylinder 150t) and tool

N3 (frame, rod, adapter, bolt x 1, eyebolt), then
raise the assembly and set on the track.
3. Insert the rod of tool N4 from the cylinder end,

and install with two nuts.
Pass the rod through the hole in link (I) to in-
stall.
4. Set tool N5 (adapter, guide, pusher) in position,

then apply hydraulic pressure and remove pin
(3).
When the cylinder reaches the end of its stroke,
insert tool N5 (extension) between the adapter
and guide, and repeat the operation.
‘i_!fgz3&-~ ’
DLD02935
30-244
0
5. Set tool N6 (294 kN (30t) puller) and spacer @ to

the center of the roller tread of the link to be
disassembled, then apply hydraulic pressure to
the puller, open the link 5 - 6 mm, and discon-
nect the link.
DED00336
30-245
0
FIELD ASSEMBLY OF ONE

LINK
Press (for remover)
1. Assemble the link sub-assembly.
I) Set tool N7 to the end face of the link, then
press fit bushing (1).
* Press-fitting force for bushing:
49 - 196 kN (5 - 20 ton)
DLD02936
2) Set tool N7 to the end face of the link (pin

Rress (or remover)
end), and press fit bushing [I).
4
* Set with the side hole in the pin facing
the link tread.
* Press-fitting force for pin: 196 - 294 kN
(20 - 30 ton)
N7
DLD02937
2. Set link sub-assembly (3) on the link to be con-

nected.
3. Set link (4) on the opposite side, and support

with tool N8 (guide). N8
4’
em DED00340
30-246
0
4. Set tools N9 and NIO in the same way as for

NIO
the operation to remove the pin, then use tool
N9 (adapter, extension, guide, adapter, bolt) for
press fitting the pin, and tool NIO (extension,
guide, adapter, bolt) for press fitting the bush-
ing, and press fit in turn.
Ir Press-fitting force for pin: 196 - 294 kN CYI inder
(20 - 30 ton)
Jr Press-fitting force for bushing: 98 - 196 kN
(IO - 20 ton)
5. Use tool N13 (294 kN (30t) puller) in the same

way as when disassembling, and push open link
(5) at the bushing end.
N13
DEW0342
6. Set link (6) at the pin end to link (5) at the bush-
ing end, connect with tool Nil (guide), then
remove tool N13 (puller).
DEW0343
7. Set tool N5 at pin (7) end, then use tool N12

(adapter, bolt, guide) to press fit pin (7).
& Pin press-fitting hole in link:
Gasket sealant (198-32-19890)
* Set with the side hole in the pin facing the
link tread.
Sr Press-fitting force for pin: 392 - 588 kN
(40 - 60 ton)
DLD02939
30-247
0
DISASSEMBLY AND ASSEMBLY MASTER LINK
DISASSEMBLY OF MASTER
LINK
1. Removal of track assembly
Remove the track assembly from the track frame.
For details, see REMOVAL OF TRACK SHOE
ASSEMBLY.
2. Separation of track
Disconnect all master link portions, and divide
into four parts.
3. Removal of master link

. Master pin type
1) Gas-cutting of regular link
Gas cut the portion marked WV, and re-
move a.
Special tool to use: Gas cutter
Bushing <
‘\I <
OLD02940
2) Removal of regular link

Push pin (I) in the direction of the arrow
with a press, remove from link (21, then re-
move pin (I) and link (3) at the same time
from bushing (4).
. Master link type

1) Gas cutting, removal of master link at bush-
ing end
Gas cut the portion marked WV, remove @ ,
then move master links (5) and (6) up or
down to remove them. Push pins (8) and (9)
press fitted to regular link (7) with a press in
the direction of the arrows to remove them.
. Special tool to use: 1. Gas cutter
2. Tool 01
30-248
0
2) Removal of master link at pin end

Gas cut the portion marked WV, remove a,
push pin (IO) with a press in the direction of
the arrow and remove from link (II), then
remove pin (IO) and link (12) at the same
time from bushing (13).
. Special tool to use: 1. Gas cutter
2. Tool 02
30-249
0
ASSEMBLY OF MASTER LINK

1. Assembly of link at bushing end
I) Using a press, press fit master link (I) at the
bushing end to bushing (2).
* When press fitting the left and right mas-
ter links, be extremely careful to keep
them parallel.
* Be careful not to scratch or damage the
mating surface of the master link and
the end face of the bushing. D2
DEW0249
Unit: mm
Ll 1 169eO.7
L2 219.8 k 0.7
2. Installation of link at bushing end

1) Push open the central part of the link tread
with tool 02 as shown in the diagram. (Open
0
=I 5mm
zzl
approx. 10 mm at the tip of the link.) 0
02
0 5mm
0 =I
2) Set spacer (3) and seal assembly (4) at the

counterbore of the link at the connection.
30-250
0
3) Align the pin hole and bushing hole, and

connect with guide pin 0.
I
DLD02942
1
4) Remove tool 02, press fit pin (5) with tool
01, and install master link (I) at the bushing
end.
& Pin press-fitting hole in link:
Gasket sealant (198-32-19890)
* Set with the side hole in the pin facing
the link tread.
I
.:
Press fit
DLD02943
5) Install the shoe to the link at the connection.
6) After knocking in large plug (6) with tool

M4, fill with oil using tool M7, then knock in
small plug (7) with tool M5.
* When press fitting the left and right mas-
ter links, be extremely careful to keep
the left and right links parallel. (Bushing
end and pin end)
* Be careful not to scratch or damage the
mating surface of the master link and
the end face of the bushing. 6 DBDWJ354
* End play at connection (play in thrust
direction of links on both sides of pin):
0 - 0.13 mm
Sr Be extremely careful not to get mud or
dust on the tap hole mating face of the
master link, bushing end face, spacer, or
seal.
30-251
0
3. Assembly of link at pin end

1) Set spacer (3) and seal assembly (4) in the
counterbore of the master link. Link
a
Ex
Bushing
DLD0294 I
2) Pass pin (9) through bushing (81, set pin

master link (IO) from the left and right, then
press fit with tool 01.
3) After knocking in large plug (II) with tool

M4, fill with oil using tool M7, then knock in
small plug (12) with tool M5.
4. Connecting master link portion

facing up. Pull master link (13) at the pin end to
master link (14) at the bushing end, and set at
the mating surfaces. Then put the shoe on top,
and check that the shoe bolt goes in easily by
hand.
& Shoe bolt: Anti-friction compound (LM-P)
w Shoe bolt (master link):
Initial torque: 588.4 d 58.8 Nm
(60 f 6 kgm) 14 DBDOO35.5
30-252
0
DISASSEMBLY AND ASSEMBLY PIVOT SHAFT
REMOVAL OF PIVOT SHAFT

ASSEMBLY
1. Remove track frame assembly.
For details, see REMOVAL OF TRACK FRAME
ASSEMBLY.
2. Remove seal (I), then remove ring (2). m
3. Sling pivot shaft assembly (3), then remove
mounting bolts, and using forcing screws 0,
raise pivot shaft assembly (3) and pull out.
m
&I kg Pivot shaft assembly : 116 kg

I
INSTALLATION OF PIVOT
SHAFT ASSEMBLY
g
removal.
5
I
z
a
* Assemble the seal as follows. (See diagram
on right)
I) Turn over seal so that embossed letters Embossed
on seal are on inside. letter
Ring Seal
2) With seal turned over, insert seal on
shaft. \
+ When inserting the seal, be careful not to - (2) Insert

scratch or damage the surface. o+Q
=\
-&5&
* Use tool PI to press fit ring (2).
Pivot shaft (1) Turn
. Press-fitting force : 8.8 - 22.6 kN
(0.9 - 2.3 ton)
m DLDW359
& Pivot shaft mounting bolt :
w Pivot shaft mounting bolt :
926.7 f 103.0 Nm (94.5 + 10.5 kgm)
DISASSEMBLY AND ASSEMBLY EQUALIZER BAR
REMOVAL OF EQUALIZER BAR

ASSEMBLY
1. Remove side pin top cover (1).
2. Set jack (490 kN(50 ton)) under radiator, jack up,

then raise work equipment and set stand @ in
position.
* Set at a height where the center pin will
come out.
3. Remove equalizer bar side pin cover (21, then

pull out outside bushing (3) and side pin (4),
and remove inside bushing (5). m I GEcoo762
* Operate the jack to carry out fine adjust-

ment of the height, and when the pin is at a
point where it moves easily, tap the pin to
remove it.
4. Sling equalizer bar assembly (61 with crane and

chain block.
5. Remove lock plate (71, then using tool Ql, pull

out center pin (8). m
a When operating the hydraulic system, do
not stand under or in front of the puller.
Stand as far as away as possible when oper-
ating it.
0 DLDOO176
6. Operate chain block and crane, and remove

equalizer bar assembly (6).
&I kg Equalizer bar assembly : 229 kg
A Do not lower the chassis after removing the

equalizer bar assembly.
235 4
30-254
0
DISASSEMBLY AND ASSEMBLY EQUALIZER BAR
INSTALLATION OF EQUALIZER
BAR ASSEMBLY
l Carry out
removal.
installation in the reverse order to
I \
\
\
\
Inside cover : Fill with grease (G2-LI)
Between equalizer bar side pin portion
and bushing : Fill with grease (G2-LI)
Connecting portion of pin and bushing :

Coat with grease (G2-LI) 8 Ql
Frame boss portion :
Coat with anti-friction compound (LM-PI
Between bushing and bushing :
Fill with grease (G2-LI)
DEW0766
DEW0767
30-255
0
DISASSEMBLY AND ASSEMBLY EQUALIZER BAR SIDE BUSHING
REMOVAL OF EQUALIZER BAR

SIDE BUSHING
1. Remove equalizer bar assembly.
For details, see REMOVAL OF EQUALIZER BAR
ASSEMBLY.
2. Remove seal (1).
3. Remove ring (2).
4. Remove spherical bushing (3).
INSTALLATION OF EQUALIZER
BAR SIDE BUSHING
1. Install ring (2) to one side.
2. Press fit spherical bushing (3) with press.

* Press-fitting force : 15.7 kN (1.6 ton)
3. Install ring (2) on opposite side.
4. Install seal (I).

DEWO770
a Between bushing and seal :
Fill with grease (G2-LII
5. Install equalizer bar assembly.

For details, see INSTALLATION OF EQUALIZER
BAR ASSEMBLY.
30-256
0
DISASSEMBLY AND ASSEMBLY SEGMENT TEETH
REMOVAL OF SEGMENT
TEETH
I
1. Stop machine at position where it is easy to
remove teeth (between shoe and track frame).
2. Remove mounting bolts, then remove teet
INSTALLATION OF SEGMENT
TEETH I

removal.
& Thread of teeth mounting bolt:

w Teeth mounting nut : 1176.8 z 98.1 Nm
(120 2 10 kgm)
30-257
0
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
REMOVAL OF HYDRAULIC
TANK ASSEMBLY
a Lower the work equipment completely to the
HYDRAULIC CIRCUIT. Then loosen the oil filler
cap slowly to release the pressure inside the
hydraulic tank.
1. Drain oil from hydraulic tank.
- : Hydraulic tank : 97 f? DAD01094

3. Disconnect drain hoses (I) and (2).
5. Disconnect drain hose (4) at filter end.
6. Disconnect filter tube (5) at filter end.
7. Remove filter (6).
8. Disconnect filter tube (5) from tank and move it
towards main valve.
9. Disconnect suction tube (7).
10. Lift off hydraulic tank assembly (8).
I+ kg Hydraulic tank : 120 kg

DBDO1095
A 4
INSTALLATION OF HYDRAULIC
TANK ASSEMBLY
Carry out installation in the reverse order to
removal.
Refilling with oil (hydraulic tank)

level.
Bleeding air
Bleed the air from the piping.
BLEEDING AIR FROM HYDRAULIC CYLINDER.
30-258
0
DISASSEMBLY AND ASSEMBLY HYDRAULIC, HSS PUMP
REMOVAL OF HYDRAULIC,
HSS PUMP ASSEMBLY
ASSEMBLY.
2. Remove HMT control valve assembly.

For details, see REMOVAL OF HMT CONTROL
VALVE ASSEMBLY.
3. Loosen mounting bolts of block (I).
4. Disconnect outlet hose (21, then remove block

(I).
5. Disconnect pilot hoses (3) and (4).
6. Disconnect suction tube (5).
7. Remove clamp for clutch pressure detection

tube.
8. Using eyebolts (I), sling pump assembly (61,

then remove mounting bolts and lift off hydrau-
lit and HSS pump assembly.
8
X
I-
z kg
Id3 Hydraulic, HSS pump assembly : 120 kg
INSTALLATION OF
HYDRAULIC, HSS PUMP
ASSEMBLY
removal.

level.
30-259
8
DISASSEMBLY OF HYDRAULIC,
HSS PUMP ASSEMBLY
1. Set pump assembly (I) to tool VI.
2. Valve assembly, cover

I) Remove valve (2) and plate (3) from pump
assembly (I).
2) Disassembly of valve assembly
. Variable throttle valve

i) Loosen nut (4) and remove plug (5).
ii) Remove spring (6) and seat (7), and pull
out spool (9).
iii) Remove plug (81.
iv) Remove nut (4) and O-ring from plug
(5).
. LS valve
i) Loosen nut (IO) and remove plug (II).
ii) Remove seat (121, spring (131, and seat
(14).
iii) Remove plug (151, and pull out spool
(16).
iv) Remove backup ring (17) and O-ring from
plug (II).
3. Cover
I) Remove 6 bolts.
2) Remove cover (60).
DBD01376
4. Impeller, washer
1) Remove nut (181, then remove spacer (19).
2) Remove impeller (20).
DBD01378
DBD01377
30-259-l
0
3) Remove key (61), then remove washer (21).

* Be careful not to lose the key.
DBD01379
5. End cap assembly

1) Remove nut (221, washer (23), and screw
(24).
2) Remove 7 bolts (25).
3) Remove end cap assembly (26).
* The valve plate may be stuck to the end
cap, so be careful not to drop it.
4) Remove valve plate (27).
DBD01380 DBD01381
I I I I
. Disassembly of end cap

1) Remove dowel pin (27) from end cap.
26
* When removing bearing (28), use 2 push
holes a as shown in the diagram on the
right, and push out with a hydraulic
press.
28’
DAD01 382
6. Valve plate, dowel pin

I) Remove valve plate (29).
383
30-259-2

Turn over tool VI 90”, and remove cylinder block
and piston assembly (30) from pump case (31).
* Cylinder block (32) and piston assembly (33)
may come off separately, so be careful not
to drop them.
. Disassembly of cylinder block, piston assem-

bly
1) Pull out piston assembly (33) from cylinder
block (321, and remove retainer guide (34).
* When removing the piston assembly
32
from the cylinder block, preload pin (35)
may fall out, so be careful.
DAD01385
I

Pull out piston (37) from shoe retainer (36).
1
36
. Disassembly of cylinder block

32
1) Set tool V2 to cylinder block, secure bolt of
tool V2 with wrench, tighten nut to com-
press spring (381, then remove snap ring
(39).
2) Loosen nut of tool V2 slowly and release
tension of spring (38), then remove tool V2.
3) Remove spacer (401, spring (38), and spacer
* Check the assembly direction of spacer N;t 38 \/
(41). 39
DAD01388
30-259-3
0
8. Servo piston assembly

I) Remove plug (42), then remove spring (43).
2) Using bolt (6 mm), remove stopper (44).
3) Set tool V3 in position, and assemble spacer

@ to bottom of rod (45).
4) Raise rocker cam (47) slightly, move to side
and loosen piston (46) so that width across
flats of rocker cam comes off from width
across flats of cradle.
DBD01392
5) Remove piston (46), then remove rod (45).

* Check the mounting direction of rod (45).
DBD01393
30-259-4
9. Shaft, cradle assemblv r
I) Remove rocker cam (47).

2) Remove 6 bolts (48), then remove shaft and
cradle assembly (49).
DBD01394 DBD0139t
. Disassembly of shaft, cradle assembly

1) Remove cradle (51) from shaft (50).
2) Remove snap ring (521, then remove washer 5
(53).
DBD01396 DBD01397
3) Using push tool 0, pull out bearing (54)

from shaft (50).
* Bearing (54) divides into the inner race
and the bearing, so be careful not to
lose either part.
* Check the assembly direction of the bear-
ing.
DBD01398
. . I
10. Disassembly ot pump case

I) Loosen nut of swash plate adjustment screw
(55), then remove screw (55).
* Before loosening the nut, measure the
dimension between the end face of the
case and the end of the screw.
DBD01399
30-259-5
0
2) Remove snap ring (56) from pump case (31),

then remove spacer (57).
DBD01400
DBD01401
11. If above disassembly operation is not needed,

and only oil seal is replaced, replace oil seal as
follows.
I) Remove snap ring (56) and spacer (57) from
pump case (31).
through to core of oil seal (581, then twist to
remove.
posite sides (A and B in diagram) to re-
move.
* Be careful not to damage the case press-
fitting surface and sliding surface of the
shaft and the oil seal.
30-259-6
0
ASSEMBLY OF HYDRAULIC,
HSS PUMP ASSEMBLY
dirt or damage.
* Using chromium oxide compound, remove all
the lapping particles from the lapped areas.
. Always check the following parts before assem-
blino.
* Check contact of cradle and rocker cam (for
CONTACT).
* Check contact between cylinder block and
CHECKING CONTACT).

. Assembly of shaft-and cradle assembly
1) Assemble spacer to shaft (50), then use push
tool @ to press fit bearing (54).
& Press-fitting surface of bearing:
Grease (G2-LI)
* When press fitting the bearing, put push
tool @ in contact with the end face of
the bearing inner race.
DAD01403
2) Assemble washer (53), and install snap ring
(52).
* Method of selecting lock washer (53)
i) After press fitting bearing (54) to shaft Snap ring groove
(501, assemble washer (53) (removed
during disassembly). r a
ii) Measure clearance a between end face 53/T “1 ’

of assembled washer (53) and snap ring
groove.
* Clearance a: 1.8 - 2.0 mm
iii) If clearance a is not within above stand-
ard value, select washer from table be-
low and assemble.
50
DAD01404
Washer Part No. Washer Thickness (mm)
708-17-12750 3.0
708-17-12760 3.1
708-17-12770 3.2
30-259-7
0
3) Using hydraulic press, press fit cradle (51)

to shaft (50).
4) Fit dowel pin and O-ring to bottom surface
of inside of pump case (311, then install shaft
and cradle assembly (49).
m Mounting bolt: 110.3 2 12.3 Nm
(11.25 d 1.25 kgm)
DBD01405 DBD0140Z
2. Rocker cam
Assemble rocker cam (47) to shaft and cradle
assembly (49).
3. Servo piston assembly
1) Assemble spherical portion of rod (45) to
rocker cam (47).
* When assembling the rod, assemble with
the spring seat surface facing down.
47
DBDO1407 DBD01408
2) Fit piston (461, set tool V3 in position, and

tighten piston (46).
* Before tightening piston (46), raise rocker
cam (47) slightly, and move to the side
so that the width across flats of the rocker
cam comes out from the width across
flats of the cradle.
(This is to prevent damage to the rocker
cam and cradle when tightening the pis-
ton.)
& Piston: Gasket sealant (Loctite 648)
(48.75 2 3.75 kgm)
I Apply three drops of loctite
1 DAD01411
30-259-8
0
3) Positioning minimum swash plate angle

i) Set tool V4 to pump case (31).
ii) Check that length b from end cap mount-
ing surface of pump case to rod (45) is
115.1 + 0.05 mm.
iii) Tighten screw (55) until it contacts pis-
ton (461, then tighten locknut.
m Screw: 6.4 r. 1.5 Nm
(0.65 f 0.15 kgm)
m Locknut: 255.0 f 29.4 Nm
(26 = 3 kgm)
* After tightening, check that the end DO1413
face of the locknut and screw (55) is

not protruding from the flange sur-
face. (To prevent interference with
the chassis.)
* When doing this, check that the
Locknut
rocker cam enters the width across
flats of the cradle securely and moves
smoothly.
Flan& surface 55 46
DAD01414
4) Assemble spring (43) and install plug (42).

QKJ Plug: 152.0 2 24.5 Nm
(15.5 +. 2.5 kgm)
5) Assemble backup ring and O-ring to stopper

(44), and install to case.
\
DBD01415
30-259-9
0

. 32
Assembly of cylinder block
1) Assemble spacer (411, spring (38), and spacer
* Assemble with the tapered portion on
the inside of spacer (41) facing down.
2) Set tool V2 to cylinder block (32).
3) Hold bolt of tool V2 with wrench, tighten
nut to compress spring (38), then install snap
ring (39).
in the groove. DAD01388
4) Remove tool V2.
. Assembly of piston assembly

Assemble piston (37) to retainer shoe (36).
5) Assemble 3 preload pins (35) to cylinder
block (32).
* To prevent preload pins (35) from com-
ing out, coat the pins with grease (G2-
LI).
6) Assemble retainer guide (34) to cylinder
block (32), then install piston assembly (33)
to make cylinder block and piston assembly
(30). 36
DAD01336
DAD01385
7) Install cylinder block and piston assembly

(30) to pump case (31).
* Before assembling the cylinder block and
piston assembly, assemble the width
across flats of the rocker cam to the cra-
dle securely.
30-259-10
0
5. End cap assembly

1) Assembly of end cap assembly
i) Using push tool @, press fit bearing (28)
28
to end cap (26).
ii) Install dowel pin (27) to end cap.
28
DAD01420 DBD01381
iii) Install valve plate (29) to end cap (26).

26
* Check that there is no interference
with the bearing and pin.
* Do not hit the valve plate or apply
any impact when assembling.
iv) Install O-ring (63) to end cap.
63 DElDO1421
2) Assemble dowel pin to pump case, then in-

stall end cap assembly (26).
w Mounting bolt: 384.9 f 41.7 Nm
(39.25 f 4.25 kgm)
I I $ DBD01422
6. Positioning maximum swash plate angle

1) Install nut (22), washer (23), and screw (24)
to end cap (26).
24
w Nut: 235.4 z 9.8 Nm (24 t 1 kgm)
* After completion of assembly of the hydrau-
lic and HSS pump, carry out a bench test to
check the performance. Adjust the amount
that screw (24) is tightened to adjust the
maximum swash plate angle.
2
23
0 0
DBD01423
30-259-11
0
7. Impeller, cover
I) Adjust clearance between impeller and end
cap.
i) With the shaft pushed down fully in the
diagram, measure dimension c from the
end face of the shaft to the end face of
the shaft washer mount seat face and
dimension d from the end face of the
shaft to the .end face of the case as
shown in the diagram.
ii) Calculate the washer thickness in the way
shown below, select washer (21) from
the table below, and assemble.
* c-d=e
Washer thickness = e + 0.4 -0.6 mm
(or measure e directly)
* In this way a clearance of 0.4 - 0.6 mm
can be made at e.
Washer Part No. Washer Thickness (mm)
708-IE-11650 2.7
708-IE-11660 3.0
708-IE-11670 3.3
708-IE-11680 3.6
2) Assemble key (61) to shaft, then assemble

impeller (20).
* After installing the impeller, check that
the key is assembled securely to the shaft
and impeller.
3) Install spacer (19) and tighten nut (18).
& Nut: Gasket sealant (Loctite 648)
m Nut: 176.5 f 19.6 Nm (18 = 2 kgm)
8. Cover
Fit O-ring to cover (601, then install to end
cap.
& Mating surface of end cover:
Gasket sealant
(LG-7 or LG-5 (Loctite 572/575))
@3 Mounting bolt: 110.3 2 9.8 Nm
(11.25 2 1.00 kgm)
DBD01376
30-259-12
0
9. Valve assembly
1) Assembly of valve assembly (2)
. LS valve
i) Assemble spool (16) to body, then fit O-
ring to plug (15) and install.
m Plug: 39.2 = 4.9 Nm
(4.0 + 0.5 kgm)
ii) Fit O-ring and backup ring (17) to plug
(1 I), assemble seat (12), spring (13), and
seat (14), tighten to body, then install
nut (IO). DAD01375
m Nut: 147.1 = 29.4 Nm (15 t 3 kgm)
. Variable throttle valve

i) Assemble spool (9) to body, then fit O-
ring to plug (8) and install.
* Spool (9) cannot be assembled from
plug (8) end.
w Plug: 39.2 z 4.9 Nm
(4.0 t 0.5 kgm)
ii) Fit O-ring to plug (5), assemble spring
(6) and seat (7). tighten to body, then
install nut (4).
B Nut: 147.1 + 29.4 Nm (15 t 3 kgm)
2) After completion of assembly, carry out a

bench test on valve assembly (2) as an indi-
vidual part, and adjust and check the per-
formance of the valve assembly.
3) Fit O-ring to plate (3), then install to pump
assembly (1).
(6.75 +. 0.75 kgm)
4) Install valve assembly (2) to pump assembly
(1).
w Mounting bolt: 66.2 L 7.4 Nm
(6.75 + 0.75 kgm)
30-259-13
0
10. installing oil seal

I) Check that there are no burrs or flashes at
the corners of the shaft.
2) Using tool V5, install oil seal (58) to pump
case (31).
I
3) Fit spacer (57), then install snap ring (56).
56
DAD01426 DBD01427
Measuring rotating torque of pump assembly

Install bolt (Ml0 x 1.5, length below head: 13
mm) to shaft (501, set torque wrench @ in posi-
tion, then rotate shaft at a constant speed (3 - 5
set/l turn) and measure rotating torque.
* Rotating torque: Max. 24.5 8 Nm (2.5 kgm)
If above disassembly operation is not needed,

and only oil seal is replaced, install oil seal as
follows.
I) Using tool V5, press fit oil seal (58).
* Check that there are no burrs or flashes
at the corners of the shaft.
2) Assemble spacer (571, then install snap ring
(56). 56
DAD01 426 DBD01427
30-259- 14
0
CHECKING CONTACT BETWEEN CYLINDER

BLOCK AND VALVE PLATE, ROCKER CAM AND
CRADLE, VALVE PLATE AND END CAP
1. Checking contact between cylinder block and

valve elate
parts (new parts).
1) Make a centering tool @ for the cylinder
block and valve plate. u DAD01429
* The tool can be made from plastic,

bakelite or any other soft material.
be checked.
3) Set the tool in position, then paint the cylin-
der block with inspection paint.
N (4 - 5 kg) against the cylinder block, turn
the valve plate 90”, then turn it back to the
original position. Repeat this process 2 or 3
times.
face.
* The standard for the contact surface at Land portion
seal portion a is as shown in the table Outside seal
below. I / Inside seal
* Check that the relationship of .the con-

I Valve plate Cylinder block
tact is as given below. I DAD01430
Inside seal > Outside seal > Land

PARTS (SEBG4240).
30-259-M
0

parts).
be checked.
2) Set the tool in position, and paint the cradle
with inspection paint.
3) Put the rocker cam on top, push with a force
of 39 - 49 N (4 - 5 kg), and move it between
the maximum swash plate angle and the
position where it contacts the stopper. Re-
peat this process 2 or 3 times.
face.
* Check that the contact between the cy-
lindrical surface of the cradle and the
cylindrical surface of its rocker cam is a
seat contact.
It The standard for the contact surface is
as given below.
Position
b C d Rocker cam
Measure-
ment Center
range portion Center Outside width
36 - 50 portion greater than
-67mm 67 mm
mm
Contact
Min. 90% 50 - 90% Max. 50%
surface
* It is not permitted to have contact only

at the outside and no contact at the _.
center. Cradle
DBD01307
[Reference] If the contact is not within the stand-
ard value, and lapping is carried out,
it must always be carried out for
both parts together.
t Parts with any scratches or damage must
not be used again.
30-259-16
0

cap
* This check is unnecessary if both the valve Valve plate
End cap
parts). /

surface must
any variation
be checked. ‘5

face.
* The contact of the mating surface of the

Manual GUIDANCE FOR REUSABLE PARTS
(SEBG4240).
30-259-17
0
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
REMOVAL OF MAIN CONTROL

VALVE ASSEMBLY
HYDRAULIC CIRCUIT. Then loosen the oil filler
cap slowly to release the pressure inside the
hydraulic tank.
* After disconnecting the pipes and hoses, fit blind
plugs to prevent dirt or dust from entering.
* Make match marks or fit tags to the hoses and
when installing.

2. Disconnect PPC hoses (I). m
* Disconnect 6 hoses on the left and 5 hoses
on the right, then remove the clamp at the
top of the control valve and move to the
rear.
3. Remove drain hose (2).
4. Remove accumulator (3).
5. Remove charge filter (4).
6. Disconnect ripper tilt cylinder tube (5).
7. Disconnect ripper lift cylinder tube (6).
8. Disconnect blade lift cylinder tube (7).
9. Disconnect blade tilt cylinder hose (8).
DAD33777
30-260
0
10. Disconnect HSS motor hose (9).
DAD00778
11. Disconnect drain hose (IO).
12. Disconnect pump hose (11).
13. Disconnect pilot hose (12).
14. Disconnect pilot hose (13).
15. Lift off hydraulic and steering valve assembly

(14).
Hydraulic, steering valve assembly :

140 kg
30-26 1
0
INSTALLATION OF MAIN
CONTROL VALVE ASSEMBLY
removal.
a
Sr The positions for connecting the PPC hoses
are distinguished by color bands at the quick
coupler, so check the colors when installing.
DED01248
. Bleeding air
B5 A5
Bleed the air from the blade and ripper cylin-
ders. B4 A4
BLEEDING AIR FROM HYDRAULIC CYLINDER. B3 A3
B2 A2
Add engine oil through oil filler to the specified Bl Al
level.
DA!33781
30-262
0
AIN CONTROL
DISASSEMBLY OF M
VALVE ASSEMBLY
21
1
\_ 23
2s \
DDD01196
30-263
0
Ir This section uses the 5-spool assembly as an

example for the disassembly procedure.
1. Remove bolt (I), and disconnect bodies (2) and
(3) from body (4).
2. Disassembly of ripper (tilt, lift) or scraper (ejec-
tor, apron, bowl) valve spool
1) Remove case (5) from bodies (2) and (3).
2) Remove case (61, pull out to point where
portion @ of spool assembly (7) comes out,
then hold portion @ with wrench (width
across flats: 14 mm), and loosen bolt (8).
* If it is possible to carry out work without DDWlZOl
scratching or bending the spool, remove

spool assembly (7) and carry out disassem-
bly work.
3) Pull out spool assembly (7) from bodies (2)
and (3).
4) Remove bolt (81, then remove washer (9),
spacer (IO), retainer (II), spring (121, and
retainer (13) from spool (14).
5) Remove plug (151, then remove spring (16)
and valve (17).
6) Remove plugs (18) and (201, then remove
check valve (19).
7) Remove check valve (21) and suction valve
(22).
8) Remove plug (231, then remove retainer (24).
3. Disassembly of blade lift valve spool

1) Remove case (25) from body (41, then re-
move spring (26) and retainer (27).
2) Remove case (28), pull out to point where
* If it is possible to carry out work without
bly work.
3) Pull out spool assembly (29) from body (4). DDDO1202
4) Remove bolt (301, then remove washer (311,

spacer (321, retainer (331, spring (341, and
5) Remove plug (371, spring (381, and valve (39)
from spool (36).
30-264
4. Disassemblv of blade tilt valve spool

1) Remove case (40) from body-(4).
then hold portion 0 with wrench (width
jr If it is possible to carry out work without
bly work.
3) Pull out spool assembly (42) from body (4).
4) Remove bolt (43), then remove washer (44), DDD012G3 1
retainer (45), spring (46), and retainer (47).
5) Remove plug (48), and pull out spring (50)
and valve (51) from spool (49).
5. Disassembly of steering valve spool

1) Remove case (40) from body (4).
* If it is possible to carry out work without
8 spool assembly (53) and carry out disassem-
5 bly work.
1 DclDo1201
;; 3) Pull out spool assembly (53) from body (4).

4) Remove bolt (54), then remove washer (55),
spacer (56), retainer (57), spring (58), and
6. Disassembly of unload spool, pressure compen-

sation spool
1) Remove plug (61), then remove spring (62)
and retainer (63).
2) Remove plug (64), then remove piston (65)
and spool (66).
and spool (69).
and valve (72).
and spool (75).
6) Remove plug (76).
30265
0
7. Plugs, valves
1) Remove plugs (77), (78), and (79).
2) Remove check valve (80a), (8Oc), LS check
valve (80b) and plugs (81) and (82).
3) Remove suction valve (83), relief valve (84),
suction and safety valve (85), and valve (86).
30-266
0
ASSEMBLY OF MAIN CONTROL

VALVE ASSEMBLY
Of-P 25
30-267
0

Coat the sliding surfaces of all parts with engine
1. Plugs, valves
1) Fit O-rings to valve (861, suction and safety
valve (851, relief valve (84), and suction valve
(83), then install.
w Valve (86) : 127.5 2 19.6 Nm
{I3 2 2 kgm}
m Suction & safety valve (85) :
186.3 2 9.8 Nm {I9 f 1 kgm}
w Relief valve (84) : 69.6 2 9.8 Nm
I7 t: 1 kgml
w Suction valve (83) :
186.3 + 9.8 Nm {I9 + 1 kgm}
2) Fit O-rings to plugs (82) and (811, and check
valve (80).
Ir When assembling LS check valve (80b),
screw in sleeve (90) to specified height a
(19 + 0.75 mm). Then fix the position of
the punch mark on the end face of the
sleeve to the direction shown in the dia-
gram on the right, and tighten with nut
(91).
w Plug (82) : 23.5 + 3.9 Nm
12.4 + 0.4 kgm}
w Plug (81) : 23.5 2 3.9 Nm
I2.4 + 0.4 kgml
w check valve (80) : 23.5 2 3.9 Nm
I2.4 = 0.4 kgm}
w LS check valve (80b) :
68.6 +. 9.8 Nm I7 + 1 kgml
3) Fit O-rings to plugs (79), (781, and (77).
m Valve (79) : 139.7 = 22.1 Nm
114.25 z 2.25 kgml
w Valve (78) : 127.5 + 19.6 Nm
I13 = 2 kgm}
(Punch mark)
w Valve (77) : 186.3 = 9.8 Nm
{I9 + 1 kgml cvoo2533
2. Assembly of unload spool, pressure compensa-

tion spool
1) Fit O-ring to plug (76) and install.
w Plug (76) : 107.9 +. 14.7 Nm
{II + 1.5 kgml
30268
0
2) Assemble spool (75) and spring (74) to body,

then fit O-ring and ring to plug (73) and in-
stall.
w Plug (73) : 321.1 + 46.6 Nm
(32.75 f 4.75 kgml
3) Assemble spring (71) and valve (72) to plug
(701, then fit O-ring and install.
w Plug (70) : 149.5 2 22.1 Nm
115.5 +. 2.5 kgml
4) Assemble spool (69) and spring (681, then fit
O-ring and ring to plug (67) and install.
w Plug (67) : 321.1 = 46.6 Nm
j32.75 = 4.75 kgm1
5) Assemble piston (65) to spool (66), assem-
ble in body, then fit O-ring and ring to plug
(64) and install.
w Plug (64) : 107.9 2 14.7 Nm
{II z 1.5 kgml
6) Assemble retainer (63) and spring (62), then
fit O-ring to plug (61) and install.
w Plug (61) : 419.2 = 46.6 Nm
I42.75 + 4.75 kgml
8 3. Assembly of steering valve spool

5 1) Assemble retainer (591, spring (581, retainer
z (571, and spacer (56) to spool (601, then fit
washer (55) to bolt (54) and temporarily as-
semble.
2) Push spool assembly (42) into body to a
point where wrench fits spool portion 0,
hold spool in position with wrench, then
tighten bolt (54).
w Bolt (54) : 66.2 2 7.4 Nm
16.75 = 0.75 kgml
3) Push spool assembly (53) into body, fit O-
ring to case (521, then install.
m Case mounting bolt : 30.9 t 3.4 Nm
(3.15 = 0.35 kgml
4) Fit O-rings to case (401, then assemble to DDW1201
body.
w Case mounting bolt : 30.9 I 3.4 Nm
13.15 +. 0.35 kgml
30-269
a
4. Assemblv of blade tilt valve spool

I) Assemble valve (51) and spring (50) to spool
(49), then temporarily tighten plug (48).
2) Assemble retainer (471, spring (461, and re-
tainer (45) to spool, then fit washer (44) to
bolt (43) and temporarily assemble.
point where wrench fits spool portion 0,
tighten plug (48) and bolt (43), and push
into body.
w Plug (48) : 66.2 + 7.4 Nm
16.75 2 0.75 kgm}
m Bolt (43) : 66.2 z 7.4 Nm
i6.75 z 0.75 kgm}
4) Fit O-rings to cases (41) and (40), then as-
semble to body.
w Case mounting bolt : 30.9 2 3.4 Nm
13.15 = 0.35 kgml
5. Assembly of blade lift valve spool

1) Assemble valve (39) and spring (38) to spool
(361, then install plug (37).
2) Assemble retainer (351, spring (34), retainer
(331, and spacer (32) to spool (361, then fit
semble.
point where wrench fits spool portion @,
tighten bolt (30).
w Bolt (30) : 66.2 t. 7.4 Nm
I6.75 f 0.75 kgm1
4) Assemble spool assembly (29) to body (41,
then install case (28).
w Case mounting bolt : 30.9 + 3.4 Nm
13.15 + 0.35 kgm1
5) Assemble retainer (27) and spring (26) from
opposite side, then fit O-ring to case (25) DDDOlZM
and install to body.
w Case mounting bolt : 30.9 + 3.4 Nm
13.15 +. 0.35 kgm}
30-270
0
6. Assembly of ripper (tilt, lift) or scraper (ejector,

apron, bowl) valve spool
I) Fit O-ring and ring to valve (151, assemble
spring (16) and valve (171, then assemble to
bodies (3) and (2).
w Valve (15) : 152.0 + 24.5 Nm
(15.5 + 2.5 kgm1
2) Assemble retainer (241, then fit O-ring and
ring to plug (23) and install to body.
w Plug (23) : 321.1 + 46.6 Nm
(32.75 + 4.75 kgm1
3) Install suction valve (22) and check valve
(21).
w Suction valve (22) : 68.6 z 9.8 Nm
(7 + 1 kgm1
m Check valve (21) : 68.6 t. 9.8 Nm
I7 t 1 kgm)
4) Install plugs (20) and (181, and check valve
(19).
w Plug (20) : 11.3 + 1.5 Nm
(1.15 = 0.15 kgm}
w Plug (18) : 34.3 + 4.9 Nm
(3.5 f: 0.5 kgm}
m Check valve (19) : 23.5 + 3.9 Nm
8 (2.4 + 0.4 kgm}
5 5) Assemble retainer (131, spring (12), retainer
z (1 I), and spacer (IO) to spool (14), then fit
6)
semble.
Push spool assembly (7) into body to a point
where wrench fits spool portion 0, hold
spool in position with wrench, then tighten
bolt (8).
r-
1 I
m Bolt (8) : 66.2 + 7.4 Nm

16.7 + 0.75 kgm1
7) Assemble spool assembly to bodies (2) and
(31, and install cases (6) and (5). I
w Case mounting bolt : 30.9 2 3.4 Nm
(3.15 z 0.35 kgm}
DLnm201
7. Assemble
I
bodies (2) and (3) to body (4), and
tighten mounting bolts (I).
w Mounting bolt : 166.7 2 9.8 Nm
(17 +. 1 kgm}
j, Assemble the O-ring at the body mating sur-
face securely.
30-271
a
DISASSEMBLY AND ASSEMBLY HMT OIL COOLER BYPASS VALVE
REMOVAL OF HMT OIL

COOLER BYPASS VALVE
ASSEMBLY
a Disconnect the cable from the negative (-) ter-

2. Disconnect fuel control rods (I) and (2). a
PmDisconnect throttle potentiometer connector (4)
(CN-THRTL).
(CN-BRAK).
6. Remove floor plate (6). DBCCO&!34
7. Disconnect charge hoses (7) and (8).

9. Disconnect cooler hoses (IO) and (II).
IO. Remove HMT oil cooler bypass valve assembly
(12).
INSTALLATION OF HMT OIL

COOLER BYPASS VALVE
ASSEMBLY
removal.
After connecting the rod, adjust the fuel con-

trol linkage.
Tighten the locknut of the rod securely.

m Locknut: 46.6 + 12.3 Nm
(4.75 f 1.25 kgm)
* After connecting the rod, adjust the brake
pedal linkage.
30-272
0
DISASSEMBLY AND ASSEMBLY HMT OIL COOLER BYPASS VALVE
DISASSEMBLY, ASSEMBLY OF HMT OIL COOLER

BYPASS VALVE ASSEMBLY
DDW1200
Disassembly Assembly
1. Remove plug (I), then remove shim (2) from * Clean all parts, and check for dirt or dam-
plug (I). age. Coat the sliding surfaces of all parts
2. Remove spring (3) and spool (4) from body (5). with engine oil before installing.
3. Remove plug (6). 1. Tighten plug (6).
2. Assemble spool (4) and spring (3) to body
(5).
3. Assemble shim (2) to plug (I), and tighten
plug (3).
shims, then assemble.
Shim thickness: 0.5 mm
No. of shims: 2
30-273
0
DISASSEMBLY AND ASSEMBLY BLADE PPC VALVE
REMOVAL OF BLADE PPC

VALVE ASSEMBLY
Serial No. : 60001 - 60271
A Fully lower work equipment to the ground. Re-

lease the remaining pressure in the circuit. For
details, see TESTING AND ADJUSTING, RELEAS-
ING REMAINING PRESSURE IN HYDRAULIC CIR-
CUIT. Then loosen the oil filler cap slowly to
release the pressure inside the hydraulic tank.
1. Remove operator’ seat, remove 1 cover on in-

side right, then remove side cover on right side
of chassis.
& kg Operator’s seat : 50 kg
2. Remove cover (I).

* Disconnect the horn switch connector
(CN262) at the same time.
4. Loosen lock bolt of lever (3), and pull out lever

(3) together with boot.
_A
DBEWJ783 DBCOO7&1
7. Disconnect PPC hose (6).
8. Remove blade PPC valve assembly (7).
30-274
8
INSTALLATION OF BLADE PPC

VALVE ASSEMBLY
Serial No. : 60001 - 60271

removal.
m@-qmj
* The connection position for the pump hose,
drain hose, and PPC hose are distinguished
by color bands at the caulking portion for
pi (View of valve from above)

Port Band color Port Band color Port Band color DADD3788
P None PI Green P3 Black

T Blue P2 Yellow P4 None
the hoses, so check the colors when con-

necting.
Set the PPC valve in the mounting direction

shown in the diagram on the right when
installing.
(The diagram on the right shows the PPC
valve as seen from the top of the panel.)

level.
30-275
8
REMOVAL OF BLADE PPC

VALVE ASSEMBLY
a Fully lower work equipment to the ground. Re-


of chassis.
&I kg Operator’s seat : 50 kg

KN262) at the same time.
4. Loosen lock bolt of lever (31, and pull out lever

5. Disconnect pump hose (4). m
6. Disconnect drain hose (5). m
7. Disconnect PPC hose (6). a
DBD007ES
8. Remove blade PPC valve assembly (7). m
I CLD0217t
30-275-l
@
INSTALLATION OF BLADE PPC

VALVE ASSEMBLY

removal.
fi/~(z-
(View of valve from above)

Port Band color Port Band color Port Band color DAwo788
P None PI Green P3 Black

T Blue P2 Yellow P4 None

necting.
m
Ir Set the PPC valve in the mounting direction
installing.
2 valve as seen from the top of the panel.)
5
z . Refilling with oil (hydraulic tank)
level.
30-275-2
0
DISASSEMBLY AND ASSEMBLY RIPPER PPC VALVE
REMOVAL OF RIPPER PPC

VALVE ASSEMBLY
Serial No. : 60001 - 60271


of chassis.
t+ kg Operator’s seat : 50 kg

3. Loosen lock bolt of lever (2), and pull out lever

4. Disconnect relay connector (3) (CNSX2).
DBDOO790
8. Remove ripper PPC valve assembly (7). m
30-276
@
INSTALLATION OF RIPPER PPC

VALVE ASSEMBLY I
Serial No. : 60001 - 60271

removal.

necting. DAM0793
Port Band color Port Band color Port Band color

P None PI White P3 Black
T Blue P2 Brown P4 None
1141
* Set the PPC valve in the mounting direction
installing.

8
E
level.
z
30-277
8
REMOVAL OF RIPPER PPC

VALVE ASSEMBLY


of chassis.
& kg Operator’s seat : 50 kg

3. Loosen lock bolt of lever (2). and pull out lever

CLD02177
7. Remove ripper PPC valve assembly (7). m
- / CLD02178
30-277-l
@
INSTALLATION OF RIPPER PPC

VALVE ASSEMBLY
Serial No. : 60272 and up P P3

removal.
pqm2jll
Ir The connection position for the pump hose,
the hoses, so check the colors when con- ’ (View of valve from above)
necting. / P4 om793
Port Band color Port Band color Port Band color

P None PI White P3 Black
T Blue P2 Brown P4 None
pJ
* Set the PPC valve in the mounting direction
installing.

level.
30-277-2
8
DISASSEMBLY AND ASSEMBLY PPC VALVE
DISASSEMBLY OF PPC VALVE

ASSEMBLY
Serial No. : 60001 - 60271
1. Remove nut (I), then remove disc (2) and boot

(3).
2. Remove joint (41, then remove plate (5).
3. Remove seal (6) and collar (7).
4. Pull out piston (81, then remove retainer (9),

springs (IO) and (II), and shim (12).
* Spring (IO) consists of a set of 2 springs
each with different installed loads, so check
the mounting position (hydraulic port) and
fit tags to prevent any mistake when install-
ing.
5. Pull out valve (13) from body (14).
PI---
8
DECW794
30-278
@
DISASSEMBLY AND ASSEMBLY PPC VALVE
ASSEMBLY OF PPC VALVE

ASSEMBLY
Serial No. : 60001 - 6027 1
1. Assemble valve (13) to body (14).
2. Assemble shim (12) and spring (11) to valve

(13).
* Assemble spring (11) so that the end face with
the small seat coil diameter (inside diameter) is
at shim (12) end.
3. Assemble spring (IO), retainer (9), and piston

(8).
j, Springs with a different number of coils are
used for spring (10) for each hydraulic port
below, so check carefully when installing.
Port position Number of coils for spring

PI, P2 9
P3, P4 10.5
Sr The position of each port is stamped on the

bottom of the valve body.
& Piston: Grease (G2-LI)
* When assembling piston (8), coat the out-
side surface of the piston and the inside sur-
face of the body hole with grease.
Fit O-ring to collar (7), then assemble to body

(14) and install seal (6).
5. Install plate (5).

Il.4 f 0.2 kgml
6. Install joint (4).

6 Sliding portion of joint : Grease (G2-LII
& Joint : Thread tightener (LT-2)
m Joint : 44.1 + 4.9 Nm 14.5 2 0.5 kgml
* Keep strictly to the tightening torque for the
joint.
7. Assemble boot (3) and disc (2), and tighten with

nut (1).
w Nut : 11.3 2 14.7 Nm III.5 +. 1.5 kgm}
* After assembling the disc, adjust the height
of the disc.
For details, see TESTING AND ADJUSTING, AD-
JUSTING PPC VALVE.
30-279
@
DISASSEMBLY OF BLADE PPC

VALVE ASSEMBLY
1. Remove nut (I), then remove disc (2) and boot

(3).
2. Remove joint (4), then remove plate (5).
3. Remove seal (6) and collar (7).
4. Remove body (8).
5. Remove plate (9).
6. Remove orifice (IO).
7. Remove blade tilt valve.
1) Remove pistons (11) and (121, retainer (13),
springs (14) and (151, and shim (16).
* Check the mounting position (hydraulic
port) of spring (14), mark with tags, and
keep in a safe place.
2) Pull out valve (17) from body (18).
8. Remove blade LOWER valve.
1) Remove piston (IS), spacer (201, spring (21),
IO_
collar (22), ball (23), retainer (241, shim (251,
piston (26), retainer (271, springs (28) and
(291, and shim (30).
port) of spring (281, mark with tags, and
9. Remove blade RAISE valve.
I) Remove piston (321, spring (331, piston (34),
retainer (35), springs (36) and (37), and shim
(38).
port) of spring (361, mark with tags, and
30-279-l
8
ASSEMBLY OF BLADE PPC

VALVE ASSEMBLY
1. Install blade RAISE valve.

1) Assemble valve (39) to body (18).
2) Assemble shim (38) and spring (37) to valve
(39).
* When installing spring (371, install with
the small end face of the seat coil sur-
face (inside diameter) on the side of shim
(38).
3) Assemble spring (361, retainer (351, piston
(34), spring (331, and piston (32).
* When assembling piston (341, coat the
outside circumference of the piston and
the inside circumference of the body
hole with grease (G2-LI).
inside circumference of the body hole
with grease grease (G2-LI).
2. Install blade LOWER valve.
(31).
(30).
3) Assemble spring (281, retainer (271, piston
(361, shim (25), retainer (241, ball (231, collar
(22), spring (21), spacer (201, and piston (19).
the inside circumference of the body
hole with grease (G2-LI).
3. Install blade tilt valve.
CEDO
(17).
(16).
30-279-2
8
3) Assemble spring (14), retainer (13). and pis-

tons (12) and (II).
* When assembling piston (12), coat the
the inside circumference of the body hole
with grease (G2-LI).
* When assembling piston (II), coat the
4. Install orifice (IO).
w Orifice : 11.8 + 14.7 Nm Il.2 + 1.5 kgm1
5. Fit O-ring and install plate (9).
6. Fit O-ring and install body (8).
7. Fit O-ring to collar (7) and assemble to body (81,
then install seal (6).
8. Install plate (5).
Il.2 + 1.5 kgm1
9. Install joint (4).
j, When installing the joint, coat the female
thread of body (8) with thread tightener (LT-
2).
w Joint : 44.1 f 4.9 Nm (3.5 + 0.5 kgm}
* Coat the sliding portion of the joint with
grease (G2-LI).
10. Assemble boot (3) and disc (21, then tighten
with nut (I).
* Coat the contact surface portion of disk (2)
and pistons (321, (191, and (11) with grease
(G2-LI).
w Nut : 112.7 f 14.7 Nm
ill.5 f 1.5 kgm1
* After installing the disc, adjust the height of
the disc.
Adjusting PPC valve.
30-279-3
@
DISASSEMBLY AND ASSEMBLY BLADE LIFT CYLINDER
REMOVAL OF BLADE LIFT

CYLINDER ASSEMBLY
A ground
Lower the work
and stop
equipment
the engine.
completely to the
1. Sling head end of lift cylinder assembly, then

remove cap (I). m
Sr Check the number and thickness of the
AStart the engine and retract piston rod fully,
then tie the piston rod with wire to prevent
it from coming out.
2. Sling lift cylinder assembly, then disconnect hose

(2).
ARelease the remaining pressure inside the
hvdraulic circuit. For details, see TESTING
AND ADJUSTING, RELEASING REMAINING
PRESSURE INSIDE HYDRAULIC CIRCUIT.
Ir Fit blind plugs to prevent dirt or dust from
entering the piping.
3. Remove cap (3) and lift off cylinder assembly

(4). 112/
& kg Blade lift cylinder assembly : 170 kg.
INSTALLATION OF BLADE LIFT

CYLINDER ASSEMBLY
removal.
* Standard shim thickness : 4 mm
& Yoke : Grease (G2-LI)
. Bleeding air
Bleed the air from the cylinder.
For details, see TESTING AND ADJUSTING.

level.
30-280
8
DISASSEMBLY AND ASSEMBLY BLADE TILT CYLINDER
REMOVAL OF BLADE TILT

CYLINDER ASSEMBLY
ground and stop the engine.
1. Remove cylinder protection cover (I) and hose

protection cover (2).
2. Sling tilt cylinder assembly, remove bolt (I 1, then
disconnect cap (3) and remove shim. m
A Start the engine and retract piston rod fully,
then tie the piston rod with wire to prevent DE1301111
it from coming out.
3. Disconnect 2 hoses (4).

ARelease the remaining pressure inside the
hydraulic circuit. For details, see TESTING
It Fit blind plugs to prevent dirt or dust from
4. Remove lock bolt, then pull out pin (5) and lift
off cylinder assembly (6). m
* Be careful not to damage the hose at the
8 bottom end when lifting off.
2
z &I kg Blade tilt cylinder assembly : 190 kg.
INSTALLATION OF BLADE TiLT

CYLINDER ASSEMBLY
removal.
m
(12(
& Yoke : Grease (G2-LI)
. Bleeding air

level.
30-281
0
DISASSEMBLY AND ASSEMBLY RIPPER LlFT CYLINDER
REMOVAL OF RIPPER LIFT

CYLINDER ASSEMBLY
1. Sling lift cylinder assembly (I), then remove lock
plate and pull out pin (2) at head end. a
A Start the engine and retract the piston rod fully.
A several
Stop the engine
times to
and operate the control lever
release the pressure inside the
piping. Then loosen the oil filler cap slowly to

li Fit blind plugs to prevent dirt or dust from
3. Remove lock plate, pull out pin (4) at bottom

end and lift off cylinder assembly (I). m
& ks Ripper lift cylinder assembly : 120 kg
* One pin (4) is supporting the bottom end of

the lift and tilt cylinders, so pull out the pin
only far enough to remove the lift cylinder
INSTALLATION OF RIPPER LIFT

CYLINDER ASSEMBLY
removal.
m
6 Pin : Grease (G2-LI)
m
& Pin : Grease (G2-LI)
. Bleeding air
For details, see TESTING AND ADJUSTING
. Refilling with oil (fydraulic tank)

level.
30-282
0
DISASSEMBLY AND ASSEMBLY RIPPER TILT CYLINDER
REMOVAL OF RIPPER TlLT

CYLINDER ASSEMBLY
1. Sling tilt cylinder assembly (I), then remove lock
plate and pull out pin (2) at head end. m
g Start the engine and retract the piston rod fully.
AStop the engine and operate the control lever

several times to release the pressure inside the
piping. Then loosen the oil filler cap slowly to

* Fit blind plugs to prevent dirt or dust from
3. Remove lock plate and pull out pin (4). (12
&I kg Ripper tilt cylinder assembly : 130 kg.
* One pin (4) is supporting the bottom end

of the lift and tilt cylinders, so when remov-
ing the tilt cylinder assembly, put a block @
under lift cylinder (5) to prevent the lift cyl-
inder from falling, or pull out the pin gradu-
g ally and set a temporary pin in the bottom
z end of the lift cylinder.
&
INSTALLATION OF .RlPPER TILT

CYLINDER ASSEMBLY
removal.
& Pin : Grease (G2-LI)

m
6 Pin : Grease (G2-LI)
. Bleeding air

Add engine oil to circulate the oil through the
system. Then check the oil level again.
30-283
0
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
DISASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
(BLADE LIFT, BLADE TILT, RIPPER LIFT, RIPPER
TILT CYLINDER)
1. Tube
Remove tube.
2. Quick drop valve (blade lift cylinder only)

Remove block (I), and pull out spring (2), spacer
(31, valves (4) and (51, and collar (6).
3. Piston rod assembly

. Blade lift cylinder
1) Set cylinder assembly (7) on tool RI.
2) Using hydraulic pump or power wrench, dis-
connect head assembly (8) with tool R2.
3) Pull out piston rod assembly (9).
* Place a container under the cylinder to
catch the oil.
. Blade tilt, ripper lift, ripper tilt cylinder

1) Remove mounting bolts, and disconnect
head assembly (IO).
2) Pull out piston rod assembly (II).

* Place a container under the cylinder to
catch the oil.
4. Piston assembly
I) Remove mounting bolts, then remove spacer 16
(12), and pull out valve (13).
2) Pull out piston assembly (14).
3) Remove backup ring (15) and O-ring (16).
4) Remove retainer (17).
i7
DBCW3M
30-284
0
5) Disassembly of piston assembly

i) Remove wear ring (18).
ii) Remove piston ring (19).
Sr Do not remove seat (20) and valve (21)
from the piston.
18
18 DBDCO365

1) Remove mounting bolts, then remove spacer
(22).
2) Pull out piston assembly (23).
3) Remove backup ring (24) and O-ring (25).
\
23
24
4) Disassembly of piston assembly

i) Remove wear ring (26).
ii) Remove piston ring (27).
27
DBNG375
5. Head assembly
I) Remove head assembly (8) or (IO).
Blade lift
Blade tilt
Ripper lift
Rippertilt
30-285
0
2) Disassembly of head assembly

32 33 34 31 28 30 29
i) Remove O-ring (28). (Blade lift cylinder
only)
ii) Remove O-ring (29) and backup ring (30). Blade lift
iii) Remove packing (31).

iv) Remove snap ring (32), then remove dust
seal (33).
v) Remove bushing (34). 32 33 34 31 30 29
Blade tilt
Ripper lift
Ripper tilt
30-286
0
ASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
Coat the sliding surfaces of all parts with engine
oil, and be careful not to scratch or damage the
rod packing, dust seal, or O-ring when install-
ing.
32 33 34 31 30 29
DLD02944
1. Head assembly
1) Assembly of head assembly R4
i) Using tool R4, press fit bushing (34).
34 34
DBW0369 DEW0370
ii) Using tool R5, assemble dust seal (33),

and secure with snap ring (32).
iii) Assemble packing (31).
r R5 R5
33
Di3DOO371 DBLX0372
iv) Assemble backup ring (30) and O-ring

(29).
* Do not try to force the backup ring 32
into position. Warm it in warm wa- /
ter (50 - 60%) before fitting it.
v) Assemble O-ring (28). (Blade lift cylinder
only)
29
DBCCQ373 DBW0374
2) Assemble head assembly (8) or (IO) to pis-

ton rod.
Blade lift
Blade tilt
Ripper lift
Ripper tilt
DLD02945
2. Piston assembly
. Blade lift cylinder 33-2 19
1) Assembly of piston assembly
Es
i) Using tool R3-1, expand piston ring (19). R3-1
Sr Set the piston ring on tool R3-1 and
,I9
Q
0
turn the handle 8 - 10 times to ex-
pand the ring.
ii) Remove piston ring (19) from tool R3-1,
and install to piston.
iii) Using tool R3-2, compress piston ring
(19).
iv) Assemble wear ring (18). DBW0377
2) Install retainer (17).

3) Fit O-ring (16) and install backup ring (15).
* Do not try to force the backup ring into
position. Warm it in warm water (50 - 18
60°C) before fitting it.
* Coat the O-ring and backup ring with 18
grease, and secure so that the backup
ring does not open.
4) Install piston assembly (14).
5) Assemble valve (13) to spacer (12), then fit ti
spacer and tighten with mounting bolts.
& Mounting bolt :
w Mounting bolt : 110.3 f 12.3 Nm b
(11.25 = 1.25 kgm)
16
1‘7
DBW0378
30-288
0
. Blade tilt, ripper lift, ripper tilt cvlinder

1) Using tool R3, assemble piston ring (27), 26
then assemble wear ring (26) in same way 27
as in Step 2-I) -i) - iv) above.
DBDLM375
2) Assemble O-ring (251, backup ring (24), and

piston assembly (23) in same way as in Step
2-3) - 4) above.
3) Secure with spacer (22) and tighten with
mounting bolts.
& Mounting bolt :
m Mounting bolt : 110.3 z 12.3 Nm 24
(11.25 f 1.25 kgm)
DBDW3E6
3. Piston rod assembly

1) Set cylinder (7) to tool RI.
2) Assemble
der.
piston rod assembly (9) to cylin- RR289 7
6 Seal portion : Grease (G2-LI)

* Push the piston rod in to the end of its
stroke.
3) Using tool R2, tighten head assembly (8).
m Head assembly : 980.7 + 98.1 Nm
(100 +: 10 kgm)

I) Assemble piston rod assembly (11) to cylin-
der (7).
& Seal portion : Grease (G2-LI)
* Push the piston rod in to the end of its
stroke.
2) Tighten head assembly (IO) with mounting

bolts.
& Mounting bolt :
Unit: Nm (kgm)
Blade tilt 343.2 + 34.3 (35 2 3.5)
Ripper lift 245.2 + 24.5 (25 r 2.5)
Rioter tilt 245.2 + 24.5 (25 + 2.5)
4. Quick drop valve (blade lift cylinder only)

Assemble collar (61, valves (5) and (4), spacer
(31, and spring (2), then fit O-ring and install
block (1).
5. Tube
Fit O-ring and install tube.
30-290
0
DISASSEMBLY AND ASSEMBLY BLADE
REMOVAL OF BLADE
ASSEMBLY
4k Lower the work equipment completely to the
ground at a flat place, then set blocks @ se-
curely under the left and right straight frame.
I DLCO3381
1. Remove cap (1) of lift cylinder. a

2. Sling lift cylinder assembly (2), start engine,

retract piston rod fully, then fit cylinder clamp
and secure to radiator guard.
* Tie the piston rod with wire to prevent it
from coming out.
Disconnect the cylinder from the blade
on the opposite side in the same way.
a’ Release the remaining pressure inside the
hydraulic circuit. For details, see TESTING
Then loosen the oil filler cap slowly to re-
lease the pressure inside the hydraulic tank.
3. Remove left and right covers (3).
4. Disconnect hose (4).

* Fit blind plugs to prevent dirt or dust from
5. Remove left and right trunnion caps (5). m
6. Remove plate assembly (6). a

* Start the engine, drive the machine slowly
in reverse, and disconnect the blade assem-
bly from the trunnion.
INSTALLATION OF BLADE
ASSEMBLY
removal.
m
Ir Adjust with shims so that clearance a at the
cap mating surface is the dimension given
below. Check also that it rotates smoothly.
* Standard clearance a : 0.2 - 0.5 mm
. Standard shim thickness : 4 mm
+ After installing the blade, adjust the blade
tilt. DLW0386

ADJUSTING SEMI U-TILTDOZER.
w Trunnion cap mounting bolt :

730.5 2 98.1 Nm (74.5 2 10 kgm)
* Adjust with blocks 0 so that height b and

width c of the left and right straight frames
is the dimension below.
. Height b at trunnion : Approx. 633.5 mm
. Frame width c : Approx. 2,940 mm
DLDW3.37
level.
Ilr Run the engine to circulate the oil through
30-292
0
DISASSEMBLY OF BLADE
ASSEMBLY
APut blocks @ and hydraulic jack @ under left
and right straight frame and blade, and set se-
curely so that the blade is stable.
1. Remove right frame cover (I), and disconnect

tilt cylinder hose (2).
I DEDKi3W
2. Sling tilt cylinder assembly (31, and remove lock

plate, then remove pin (4).
3. Remove mounting bolts, disconnect cap (51, then
lift off tilt cylinder assembly (3).
* There are shims at the cap portion, so check
the number and thickness of the shims, and
A kg Tilt cylinder assembly : 190 kg
4. Set block @ under right center brace (6), and

remove mounting bolts of cap (7) at center frame
end.
5. Sling right straight frame (8) and disconnect right

center brace (6).
6. Remove lock plate, then remove pin (9), and lift
off right straight frame (8).
kg
LE?l Straight frame : 900 kg
DECCGS3
7. Remove left frame cover (IO).

8. Sling tilt brace (II), remove lock plate, then
remove pin (12).
9. Remove mounting bolts, disconnect cap (13),
then lift off tilt brace (11).
kg
EL?l Tilt brace : 100 kg
IO. Disconnect left center brace (14) and remove
left straight frame (15) in same way as in Steps DEW0594
4 - 6 above.
11. Sling center brace (141, remove mounting bolts,

disconnect cap (16), then lift off left and right
center braces (14) and (6).
L&lkg Center brace : 95 kg
14 6
DEW0395
12. Raise blade (171, then tip blade over.
A kg Blade : 2,900 kg
30-294
0
ASSEMBLY OF BLADE
ASSEMBLY
* Check the number and thickness of the shims
removed from each place during disassembly,
then assemble them again in the same position.
Ir When carrying out shim adjustment, see TEST-
ING AND ADJUSTING, ADJUSTING SEMI U-
TILTDOZER.
1. Raise blade (17), and insert block and hydraulic
jack under blade, and set securely so that the
blade is stable.
& kg Blade : 2,900 kg
2. Raise center brace (141, assemble shim, and

tighten mounting bolts of cap (16).
* Set a block under the center brace to match
the height of the straight frame.
elkg Center brace : 95 kg
14 6
DEW0395
3. Raise right center frame (81, then install pin (9)

and secure with lock plate.
&?Ikg Straight frame : 900 kg

4. Sling right center frame (8), then set spherical
portion of right center brace (6) to right center
frame (8).
5. Assemble shim to cap (7) of right center brace

(61, and tighten mounting bolts.
Ir Standard shim thickness : 4 mm
30-295
0
6. Sling tilt cylinder assembly (3), assemble shim

to cap (5), then tighten mounting bolts.
&I kg Tilt cylinder assembly : 190 kg

7. Install pin (41, and secure with lock plate.
8. Connect tilt cylinder hose (2).
9. Install right frame cover (I).
DEW0390
10. Install left straight frame (15) and connect left

center brace (14) in same way as in Steps 3 - 5
above.
11. Sling tilt brace, assemble shim to cap (131, and
tighten mounting bolts.
Ir Standard shim thickness : 4 mm
el kg Tilt brace : 100 kg

12. Install pin (121, and secure with lock plate.
13. Install left frame cover.
14. Greasing
After completion of assembly, grease the points
in the diagram on the right thoroughly.
6 Parts of work equipment: Grease (G2-LI)
30-296
0
DISASSEMBLY AND ASSEMBLY MULTI-SHANK RIPPER
DISASSEMBLY OF MULTI-
SHANK RIPPER ASSEMBLY
* After disconnecting the pipes and hoses, cover
with blind plugs to prevent dirt or dust from
entering.
1. Start engine and set ripper to maximum height
and maximum tilt in.
2. Sling shank (I), remove lock pin, then remove
mounting pin (2), and lower shank (I) slowly to
remove.
elkg Shank : 270 kg
3. Set stand @ under beam and block @ under

arm, then lower ripper assembly.
4. Sling lift cylinder assembly (31, remove lock plate,

then remove pin (4) at rod end.
Ir Start the engine, retract the piston rod fully,
then lower on top of the arm.
5. Sling tilt cylinder assembly (51, remove lock plate,

then remove pin (6) at rod end.
* Start the engine, retract the piston rod fully,
then lower on top of the arm.
* The pin is used when removing the beam,
so leave the pin temporarily installed to the
beam.
a Release the remaining pressure in the circuit.
For details, see TESTING AND ADJUSTING, RE-
LEASING REMAINING PRESSURE IN HYDRAU-
LIC CIRCUIT. Then loosen the oil filler cap slowly
to release the pressure inside the hydraulic tank. DLD30401
30-297
0
6. Disconnect lift cylinder hose (7) and tilt cylinder

8 8
hose (8) and move towards fuel tank end.
7. Sling lift cylinder assembly (3), remove lock plate
and pull out pin (9), then lift off lift cylinder
assembly (3).
* The pin is the same for the lift cylinder and
tilt cylinder, so pull it out to a position where
the lift cylinder can be removed.
* The mounting bolt for the lock plate of the
pin on the right is also used to tighten the
rear lamp, so remove the rear lamp at the
same time.
& Lift cylinder assembly : 130 kg

8. Sl6g tilt cylinder assembly (5), remove pin (91,
then remove tilt cylinder assembly (5).
r+lkg Tilt cylinder assembly : 130 kg
9. Sling beam (IO), remove lock plate, then remove

left and right pins (II), and lift off beam (IO).
& kg Beam : 1,200 kg
IO. Sling arm (121, remove lock plate, then remove

left and right pins (131, and lift off arm (12).
& kg Arm : 470 kg
30-298
0
ASSEMBLY OF MULTI-SHANK
RIPPER ASSEMBLY
1. Raise arm (12), install left and right pins (131,
then secure with lock plate.
&I kg Arm : 470kg

* Set block @ under the arm.
2. Raise beam (IO), install left and right pins (II),

then secure with lock plate.
&I kg Beam : 1,200 kg

j, Set stand @ under the beam.
3. Raise tilt cylinder assembly (51, then install pin

(9).
* The same pin is used for the tilt cylinder and
lift cylinder, so push it in to a position where
the tilt cylinder can be installed.
& kg Tilt cylinder assembly : 130 kg

* After installing, lower the rod end on top of
the arm.
4. Raise lift cylinder assembly (31, then install pin
(9).
* The mounting bolt for the lock plate of the
pin on the right is also used to tighten the
rear lamp, so install the rear lamp at the
same time.
E?lkg Lift cylinder assembly : 130 kg

Sr After installing, lower the rod end on top of
the arm.
5. Connect tilt cylinder hose (8) and lift cylinder
hose (7).
30-299
0
6. Sling tilt cylinder assembly (5), start engine, ex-

tend piston rod, align pin holes, then install pin
(6) and secure with lock plate.
7. Sling lift cylinder assembly (31, start engine, ex-

tend piston rod, align pin holes, then install pin
(4) and secure with lock plate.
8. Start engine and set ripper to maximum lift and

maximum tilt in.
9. Pass wire from shank mounting hole in beam,
raise shank (I), and install, then install pin (2)
and secure with lock pin.
A kg Shank : 130 kg
10. Greasing
After completion of assembly, grease points in
1
diagram on right thoroughly.
& Pin : Grease (G2-LI) DLCW338

level.
30-300
0
DISASSEMBLY AND ASSEMBLY ROPS GUARD
REMOVAL OF ROPS GUARD

1. Sling ROPS guard (I) and remove 12 mounting
bolts (2). !Tc-iJ
2. Lift off ROPS guard (I).
&I kg Rops guard : 700 kg
INSTALLATION OF ROPS
GUARD
removal.
m
-w ROPS guard mounting bolt :
926.7 z 103.0 Nm (94.5 f 10.5 kgm)
30-301
0
DISASSEMBLY AND ASSEMBLY OPERATOR CAB
REMOVAL OF OPERATOR CAB

ASSEMBLY
1. Remove ROPS guard.
For details, see REMOVAL OF ROPS GUARD.
2. Open left side cover.
3. Disconnect connectors (I) (CN3661, (2) (CN-

CABI), and (3) (CN-CAB2).
4. Disconnect 4 washer hoses (4). a DEW1132
5. Remove step (5), then remove cover (6).
6. Remove garnishes (71, (81, and (9).
7. Remove 19 mounting bolts, then lift off opera-

tor cab assembly (IO).
&I kg Operator cab assembly : 290 kg
-I .
II/ I’ ’ DEW1133
INSTALLATION OF OPERATOR
CAB ASSEMBLY
removal.
Ir Match the color bands and connect the
I DEW1135
30-302
0
DISASSEMBLY AND ASSEMBLY HOOD
REMOVAL OF HOOD
ASSEMBLY
1. Remove exhaust pipe (I).
2. Remove partition (21, then remove rubber

seal.
3. Loosen clamp (3) and disconnect connector

(4) from hood end.
4. Lift off hood assembly (5).
elkg Hood assembly : SO kg
INSTALLATION OF HOOD
ASSEMBLY
removal.
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
REMOVAL OF FLOOR FRAME

ASSEMBLY
1. Remove operator cab assembly.
For details, see REMOVAL OF OPERATOR CAB
ASSEMBLY.
2. Remove left side cover and right side cover of

operator’s compartment.
3. Lift off operator’s seat (1).

Sr Bolts with width across flats of 5/S inch (KES
parts) are used as the mounting bolts for
the seat belt.
l+l kg Operator‘s seat : 50 kg
4. Remove 4 left and right side covers of opera-

tor’s seat.
cry
5. Remove left armrest (2) and right armrest (3).
* Disconnect connector CN-SX5 (left armrest)
and CN262 (right armrest).
.
-_---__ ,
DLW0819
6. Disconnect washer wiring harness connectors

(4) (CN361, CN362, CN363, CN364). 5
7. Disconnect 4 washer hoses (5).
8. Disconnect intermediate connectors (9) (CN104)

and (IO) (CN105) between battery relay and floor.
9. Disconnect floor frame ground connection (II).
10. Disconnect intermediate connectors (12) (CN-

LEVER), (13) (CNOII), (14) (CN4511, and (15) DLDKE20
(CN153).
11. Remove HMT controller (16). m
I 16 DLWX21
30-304
0
12. Disconnect connector CN-FMAX for FORWARD

max. speed setter, then remove HMT controller
mounting plate (base) (17). m
13. Disconnect 4 PPC hoses (181, 4 PPC hoses (19),

2 PPC hoses (20), and 1 PPC hose (21). m
* Disconnect PPC hoses (18) and (19) at the
steering and main control valve end, PPC
hose (20) at the hydraulic tank end, and PPC
hose (21) at the PPC safety block valve end.
* Remove the hose clamps.
14. Remove 1 triangular step cover each on left and

right (side of dashboard).
15. Disconnect wiring connector (22) (CNIOI).

16. Disconnect 2 air conditioner hoses (23). m

Loosen the sleeve nut slightly, and release
Disconnect at the air conditioner end, then
remove all the clamps from the floor frame
and move towards the engine.
Fit blind plugs to prevent dirt or water from
entering the hoses.
Be careful not to drop or damage the O-ring.
17. Disconnect 2 heater hoses (24).

* Disconnect at the air conditioner end, then
move towards the engine.
18. Remove air conditioner air filter (25) and cover

(26).
19. Remove intermediate connectors (27) (CN214)

and (28) (CN215) between monitor panel and
floor from clamp. m
* These parts will hit the frame when the floor
frame assembly is raised, so remove them
at this point.
20. Remove operator side cover and floor plate

(small), and disconnect brake rod (291, fuel con-
trol rod (301, and parking brake control cable
30-306
0
21. Disconnect throttle potentiometer

connector (32)
(CN-THRTL) and brake potentiometer connector
(33) (CN-BRAK).
\ 32’ DLDWSi9
22. Disconnect power train oil temperature sensor

connectors (34) (CN-PLTP) and (35) (CN4531, and
intermediate connector (36) (CN406).
* These connectors (CN-PLPT, CN453, CN406)
are under the floor plate and cannot be seen
from above.
. Power train oil temperature sensor connec-
tors (34) (CN-PLTP) is not installed at serial
No. 60272 and up.
23. Remove left and right covers of front mount

bolts (371, then remove 4 front mount bolts each
on left and right.
DLLXJE31
24. Remove 4 rear mount bolts (38) each on left and 38

right.
25. Lift off floor frame assembly (39). m
A kg Floor frame assembly : 410 kg

* When lifting off, the frame will interfere
slightly with the seat portion of the suspen-
sion cylinder top flange, so raise at a slight
angle to avoid any interference.
30-308
0
INSTALLATION OF FLOOR
FRAME ASSEMBLY
removal.
After completion of the installation of the

floor frame, check the error codes on the
HMT controller.
Do not forget to install the HMT controller

ground connection (CN008) and the control- DED01248
ler wiring harness clamp.
The positions for connecting the PPC hoses

are distinguished by color bands at the quick B5
coupler, so check the colors when installing.
B4 A4
Port 1 Band color 1 Port 1 Band color B3 d A3

B5 1 Brown I A5 I White B2 A2
B4 None A4 Black
Bl Al
B3 Black A3 None
B2 Yellow A2 Green
DACW781
Install the hoses without twisting or inter-

ference.
Install the air conditioner circuit hoses care-
fully to prevent dirt, dust, or water from
getting inside the hoses.
fore installing.
sor oil (Shell Suniso 4G or 5G). O-ring
the following tightening torques. DED01219
Thread size Tightening torque

Remarks
(Nm (kgm))
16 x 1.5 11.8 - 14.7 (1.2 - 1.5) Liquid
22 x 1.5 19.6 - 24.5 (2.0 - 2.5) Discharge
24 x 1.5 29.4 - 34.3 (3.0 - 3.5) Suction
30-309
0
m
Ir In the same way as when lifting off, the frame
will interfere slightly with the seat of the
suspension cylinder top flange, so raise at a
slight angle to avoid the interference when
setting in position.
m
* Adjust the brake pedal linkage.
For details, see ADJUSTING BRAKE PEDAL
LINKAGE.
* Adjust the fuel control linkage.
For details, see ADJUSTING FUEL CONTROL
LINKAGE.
* Adjust the parking brake lever linkage.
For details, see ADJUSTING PARKING
BRAKE LEVER LINKAGE.
m
* Set the direction of installation of the sus-
pension cylinder in the correct direction
when installing the floor frame.
l Set seat portion of flange on top of sus-
pension cylinder as follows.
Set LEFT side facing FRONT
Set RIGHT side facing REAR
Then install floor frame assembly.
30-310
0
DISASSEMBLY AND ASSEMBLY DASHBOARD
REMOVAL OF DASHBOARD
ASSEMBLY
j, Close the heater hose valve at the engine end.
1. Remove operator cab assembly.
For details, see REMOVAL OF OPERATOR CAB
ASSEMBLY.
2. Disconnect connectors (I) (CN214) and (2)

(CN215).
3. Remove 5 mounting bolts and disconnect air

conditioner air connector (3).
4. Disconnect connector (4) KNIOI).
5. Disconnect air conditioner hose (5). m

sr Fit blind plugs to prevent dirt or water from
entering the oses.

0
z 7. Disconnect heater hose (7).

z
9. Open cover (9), remove cleaner cover (IO) and

cleaner element, then remove cover (9).
10. Remove covers (11) and (121, and install 2

eyebolts.
11. Lift off dashboard assembly (13).
r&lkg Dashboard assembly : 85 kg

DISASSEMBLY AND ASSEMBLY DASHBOARD
INSTALLATION OF
DASHBOARD ASSEMBLY
removal.
Install the hoses without twisting or interfer-

ence.
Install the air. conditioner circuit hoses care-
Check that there are O-rings at the piping
fore installing.
Q~EI Tighten the air conditioner gas piping to

Thread size
(Nm (kgm))
ji 19.6 - 24.5 (2.0 - 2.5) Discharge
DEW1141

OIring
I DED01219
30-312
0
DISASSEMBLY AND ASSEMBLY MONITOR
REMOVAL OF MONITOR
ASSEMBLY
Ak Disconnect the cable from the negative (-) ter-
1. Remove mounting bolts and open monitor as-

sembly (I).
2. Disconnect connectors (2) ICN-PI and CN-P2), and

remove monitor assembly (I).
18
INSTALLATION OF MONITOR
ASSEMBLY
removal.
30-3T3
0
DISASSEMBLY AND ASSEMBLY GOVERNOR MOTOR
REMOVAL OF GOVERNOR
MOTOR ASSEMBLY
& Drsconnect the cable from the negative (-) ter-
1. Disconnect fuel rod (I).
2. Loosen nut (2) and remove spring (3).
3. Disconnect wiring connectors (4) and (5), and

clamp (6).
4. Remove governor motor assembly (7). a
INSTALLATION OF GOVERNOR
MOTOR ASSEMBLY
removal.
+ After installing the governor motor assem-

bly, check the engine speed and the engine
stop function.
30-314
0
JOYSTICK
REMOVAL OF JOYSTICK
ASSEMBLY
4k Disconnect the cable from the negative (9 ter-
1. Remove handle (I).
2. Remove knob (2) of max. speed setter.

* Disconnect the fuel control dial connector
(CN-SX5) at the same time.
5. Remove slider (5).
6. Disconnect connector (CN-FMAX), then remove

FORWARD max. speed setter (6).
7. Disconnect connector (7) (CN-FNR).
8. Remove joystick assembly (8).
INSTALLATION OF JOYSTICK
ASSEMBLY
removal.
DISASSEMBLY AND ASSEMBLY ENGINE THROlTLE CONTROLLER
REMOVAL OF ENGINE
THROTTLE CONTROLLER
ASSEMBLY
A’ Disconnect the cable from the negative (-1 ter-
I. Disconnect wiring clamps (I), (2), and (3), and

connector (4).
3. Disconnect wiring connector (6).
4. Remove 3 mounting bolts, then remove engine

throttle controller assembly (7).
DEW0409
THROTTLE CONTROLLER
ASSEMBLY
removal.
30-316
0
DISASSEMBLY AND ASSEMBLY HMT CONTROLLER
REMOVAL OF HMT
CONTROLLER ASSEMBLY
1. Remove 2 connectors (1) from holder.
--I
2 DEW0410
3. Disconnect wiring connectors (31, (41, (5), and

(6).
5 4 3 DEW0411
4. Remove 4 mounting bolts, then remove HMT

controllen assembly (7).
INSTALLATION OF HMT
CONTROLLER ASSEMBLY
removal.
30-317
0
40 MAINTENANCE STANDARD
Engine mount.. .............................................. 40- 2

Power train unit mount ................................ 40- 3
Damper, universal joint ................................ 40- 4
PTO ................................................................ 40- 6
HMT ............................................................... 40- 9
HMT control valve ) ...................................... 40-13
Bevel gear shaft, HSS, brake ....................... 40-16
Brake valve .................................................... 40-20
Scavenging, PPC charge pump ................... 40-21
Power train, lubrication pump ..................... 40-22
PPC, EPC, HMT charge valve ....................... 40-24
Oil cooler bypass valve ................................ 40-26
Final drive ...................................................... 40-28
Main frame.. .................................................. 40-30
Track frame ................................................... 40-32
Recoil spring ................................................. 40-33
Track roller bogie .......................................... 40-34
Idler.. .............................................................. 40-36
Track roller .................................................... 40-38
Carrier roller .................................................. 40-40
Track shoe (dry track) ................................... 40-42
Track shoe (sealed and lubricated track). .... 40-44
Suspension .................................................... 40-46
Hydraulic, HSS pump ................................... 40-48
EPC solenoid valve ....................................... 40-49
PPC valve.. ..................................................... 40-50
Main control valve ........................................ 40-51
HSS motor .................................................. .40-57-5
Work equipment cylinder.. ........................... 40-58
Quick drop valve ............................................ 40-62
Cylinder stay ................................................. 40-63
Work equipment ........................................... 40-64
40-l
@
MAINTENANCE STANDARD ENGINE MOUNT
ENGINE MOUNT
926.7+102.9Nm
(94.5t10.5kgm)
tD=
926.7+102.9Nm
(94.5210.5kgm)
A-A B-B SAD00410
Unit: mm
I I
No. Check item I Criteria Remedy
-
Standard Clearance
clearance between bracket clearance limit
1 and cushion
Standard size
Free height of mount
2
rubber 90
40-2
MAINTENANCE STANDARD POWER TRAIN UNIT MOUNT
POWER TRAIN UNIT MOUNT
-926.7+102.9Nm A~
(94.5?10.5kgm) _
A-A
B-B
/
4
SKD00425
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance

size Hole clearance limit
Interference between Shaft
’ steering case and bushing
+0.096 +0.046 -0.096 -
204 Max. 0
+0.050 0 - 0.004
Clearance between -
2 bracket 6. -0.1 +0.046 -0.100 0.4
and cushion -0.3 0 0.346 Replace
Standard size* Repair limit

3 Free height of front mount _
rubber 90 88
Free height of rear mount

43 41
4 rubber
40-3
MAINTENANCE STANDARD DAMPER, UNIVERSAL JOINT
DAMPER, UNIVERSAL JOINT
a=
276.85231.85Nm
(28.25+3.25kam)
110.0~12.ONm
(11.2*1.2kgm)
66.15?7.35Nm
(6.75*0.75kgm)
SDD00412
Unit: mm

Clearance between size Shaft Hole clearance limit
I flywheel housing
and cover -
511.18 -0.022 +0.070 0.022 0.2
-0.092 0 0.162
2 Clearance between 466.72 -0.02d 0.020 - 0.2 Replace

flywheel and damper -0.083 0.146
Standard size Tolerance Repair limit

Outer circumference
3 of coupling oil seal
contact surface 90 0 89.8
-0.087
40-4
MAINTENANCE STANDARD PTO
PTO
m 110.3?12.2Nm
(11.25~1.25kgm) m 39.2?4.9Nm
(4.0e0.5kgm)
/n k--C
A-A
B-B
SKD00426
40-6
MAINTENANCE STANDARD PTO
c-c ‘4 D-D 3
SKD00427
Unit: mm
Standard size Tolerance Repair limit Repair

Outer diameter of input hard chrome
I coupling oil seal contact 0 plating
surface 100 99.8
-0.054 or replace
Standard clearance Clearance limit

Backlash between PTO
2 drive gear and PTO idler
gear 0.204 - 0.516 0.204 - 0.516
Backlash between PTO idler

3 gear and power train/HSS 0.204 - 0.516 0.204 - 0.516
pump drive gear
Replace
Backlash between PTO idler
4 gear and HMT pump drive 0.204 - 0.516 0.204 - 0.516
gear
Backlash between PTO drive
5 gear and scavenging pump 0.204 - 0.516 0.204 - 0.516
drive gear
40-7
MAINTENANCE STANDARD HMT
HMT (l/2)
m 39.2+4.9Nm *
(4.0+0.5kgm)
m 176.5t19.6Nm
(18.0+2.0kgm)
, m 110.0+12.ONm
(11.2-cl.2kgm)
\ m 110.0~12 ONm
A (11.2=1.2kgm)
110.0~12.ONm
(11.2-cl.2kgm)
\
m 1;6.5*19.6Nm m 110.0~12.ONm
(18.0*2.0kgm) (11.2?1.2kgm)
SKD00428
40-9
HMT (2/2)
m llO.Ot12.ONm
(11.2+1.2kgm)
16a P 16b
m 176.5*19.6Nm m 166.7?9.8Nm
(18.0+2.0kgm) (17.O~l.Okgm)
11 12 13 14 15
\ \ I
18
\
176.55 :19.6Nm
(18.0+2.0kgm)
B-B
8 7 1 2 10 9 3 4 5
A-A
40-10
Unit: mm
No.
1 No. 1 clutch spring (x12)
3 No. 3 clutch spring (x6)
5
-
Thickness of clutch disc

7
(No. 1, 2, 4, 5 clutches)
11
-
12
13
Overall assembled thickness

14
15
16
16b. Thickness
Backlash between sun

17
0.13 - 0.36
18 0.14 - 0.38 0.14 - 0.38
19
drive gear and idler gear
Backlash between transfer

20 idler and driven 0.20 - 0.50 0.20 - 0.50
gear gear
40-11
MAINTENANCE STANDARD HMT CONTROL VALVE
HMT CONTROL VALVE (l/2)
m 49.024.9Nm m 49.0k4.9Nm
(5.0-cO.5kgm) (5.0?0.5kgm)
1.66t0.98Nm
(0.17+0.lkgm)
(5.0z0.5kgm)
-49.&4.9Nm m ;9.0+4.9Nm -\30.8z3.4Nm

(5.0k0.5kgm) (5.0+0.5kgmI (3.15?0.35kgm)
6 30.8+3.4Nm
(3.15+0.35kgm)
SDD00430
40-l 3
HMT CONTROL VALVE (2/2)
11 19 3 2 8
21 13 14 5 15 22
SDD00431 Unit: mm
No Check item Criteria Remedy

Clearance between clutch size clearance limit
Shaft Hole
1 selector valve and valve
body -
22 -0.035 +0.013 0.035 0.078
-0.045 0 0.058 Replace
Clearance between pilot
2 reducing valve and valve 22 -0.035 +0.013 0.035 - 0.078
body -0.045 0 0.058
40-l 4
Unit: mm

Clearance between oil size Shaft Hole _ clearance limit
3 cooler relief valve and
valve body -
22 -0.035 +0.013 0.035 0.078
-0.045 0 0.058
Clearance between pressure

4 compensation relief valve -0.035 +0.013 0.035 -
25 0.078
and valve body -0.045 0 0.058
5 Clearance between main 32 -0.035 +0.016 0.035 -

relief valve and valve body 0.081
-0.045 0 0.061
Clearance between
-
6 modulating valve and 14 -0.035 +O.Oll 0.035 0.076
valve body -0.045 0 0.056
Clutch selector valve spri
Main relief valve spring
5.5 (changes 0.082

MAINTENANCE STANDARD BEVEL GEAR SHAFT, HSS, BRAKE
BEVEL GEAR SHAFT, HSS, BRAKE (l/2)
m 110.0+12.ONm m 110.0t12.ONm m 818.3283.3Nm m 245.0t29.ONm m 110.0t12.ONm

(11.2-cl.2kgm) SDD00432
(11.2+1.2kgm) (83.528.5kgm) (25.0+3.0kgm) (11.2*1.2kgm)
40-16
Unit: mm
Standard size Repair limit

Brake plate thickness 2.9 2.6 Replace
1
Tolerance Repair limit
Correct
Brake plate distortion
Max. 0.15 0.3 or replace

Brake disc thickness Replace
4.5 4.2
Tolerance Repair limit

Correct
Brake disc distortion
Max. 0.25 0.4 or replace

Overall assembled
3 thickness of brake
plates and discs 34.1 31.4

4 Backlash between brake
disc and brake inner drum
0.4 - 0.7 1.0
5 Backlash between sun gear

0.17 - 0.52 0.60 Replace
and planet pinion
6 Backlash
pinion andbetween planet
ring gear 0.19 - 0.55 0.70

size Shaft Hole clearance limit
Seal ring contact surface
7 at brake piston small-
-
diameter portion 220 -0.100
-0.172 +0.072
0 0.1000.244 -
40-17
BEVEL GEAR SHAFT, HSS, BRAKE (2/a
m 779.1?83.3Nm
(79.5+8.5kgm)
~.O=lZ.ONm
2r1.2kgm)
& 110.0+12.ONm
(11.2e1.2kgm)
SDD00433
40-18
MAINTENANCE STANDARD BEVEL GEAR SHAFT, HSS. BRAKE
Unit: mm

, Backlash between gear A
and pinion 0.19 - 0.62 0.70
2 Backlash between gears A

0.18 - 0.58 0.70
and C Replace
3 Backlash between gears D

0.19 - 0.61 0.80
and E
4 Backlash between gears A

0.20 - 0.67 0.80
and B
5 Backlash between bevel Adjust or

0.25 - 0.33 0.50
gear and pinion replace
40-19
MAINTENANCE STANDARD BRAKE VALVE
BRAKE VALVE
-1 ml I
(7.0kl.Okgm)
SKD00434
Unit: mm
-
No Check item
-
Clearance between brake

valve and body
Clearance between brake
Clearance between parking
Brake modulating spring
40 36.5 40.5 N 38.8 38.2 N

(4.13 kg) (3.9 kg)
Brake valve return spring 52.5 33 176.0 N 51 166.6 N

(17.96 kg) (17.0 kg)
Parking brake valve return 29.6 N 28.0 N

6 spring 70.5 37 68.4
(3.02 kg) (2.86 kg)
40-20
MAINTENANCE STANDARD SCAVENGING, PPC CHARGE PUMP
SCAVENGING, PPC CHARGE PUMP

112 + 104
4 -2 1 3 2 3 1
I- 112
I
104 \ 1
QEa A6~14.7Nrn
(16.5t1.5kgm)
SDD00438
Unit: mm
No. Check item

-
1 Side clearance
ear shaft outer diameter
3 Pin driving depth
4 Spline shaft rotation torque 6.9 - 11.8Nm (0.7 - 1.2 kgm)
1
Delivery
-
temperature: 45 - 50°C 112 (3
0.29
kg,cm21
MPa 230 e/min 210 e/min -
2,200 rpm
104 (45
4.35kg,cm21
MPa 215 .@/min 195 f/min
-
40-21
MAINTENANCE STANDARD POWER TRAIN, LUBRICATION PUMP
POWER TRAIN, LUBRICATION PUMP

SAL (3) 100 + 80
277.0k32.ONm
(28.5+3.0kgm) (28.5+3.0kgm)
SYD00435
Unit: mm
Type Standard clearance Clearance limit
Side clearance SAL (3) 100 0.13 - 0.18 0.19

1
SAL (3) 80 0.10 - 0.15 0.19
Clearance between plain

2 aear shaft
bearing outer
inner diameterand
diameter 1-1 0.60 - 0.149 1 0.20 1
Type Standard size Tolerance

- Replace
3 Pin driving depth SAL (3) 100 0
14
SAL (3) 80 -0.5
4 Spline shaft rotation torque 13.7 - 23.5Nm (1.4 - 2.4 kgm)
Delivery Standard Delivery

Type Speed
pressure delivery limit
_
Delivery
temperature: 45 - 50°C 1SAL (3) 100 (30
2.9kg,cm2j
MPa 241 Urnin 221 Urnin -
2,500 rpm
SAL (3) 80 (30
2.9kg,cm21
MPa 192 Umin 176 Urnin
-
40-22
MAINTENANCE STANDARD PPC, EPC, HMT CHARGE VALVE
PPC, EPC, HMT CHARGE VALVE
5 9
A-A \
s/ 7
8 3 4
2’ I
B-B c-c
SAD00436
40-24
MAINTENANCE STANDARD PPC, EPC, HMT CHARGE VALVE
Unit: mm
8 No. Check item Criteria Remedy

X

Clearance between charge
’ valve and valve body
-0.035 +0.013 0.035 -
28 0.08
-0.045 0 0.058
2 Clearance between charge

1 15 1 1;:;;; j +;“I8 1 “.“‘,9,,, 1 0.06 /
valve and piston
Clearance between filter

-
3 gss valve and valve 28 -0.035 +0.013 0.035 0.08
-0.045 0 0.058
Clearance between filter

4
bypass valve and piston
1 15 1 $8;; 1 +;“I8 1 “.“‘,9,,, / 0.06 1
5 Clearance between check 1 ,8 1 rL;Ji 1 +;.027 1 0.01,“.,, 1 o_, 1 Replace

valve and valve body
6 Charge valve spring (large) ~~
90.2 N 85.3 N
7 Charge valve spring (small) 92.4 74 90
(9.2 kg) (8.7 kg)
8 Filter bypass valve spring 70.3 61 110.7 N 68 104.9 N

(11.3 kg) (IO.7 kg)
9 Check valve spring 26.1 23.5 3.2 N 25 2.9 N

(0.33 kg) (0.3 kg)
40-25
MAINTENANCE STANDARD OIL COOLER BYPASS VALVE
OIL COOLER BYPASS VALVE
A-A
SAD00437
Unit: mm
No. Check item I Criteria Remedy

size Hole clearance limit
Clearance between oil Shaft
1 cooler bypass valve and
valve body -0.035 +0.013 0.035 -
22 0.08
-0.045 0 0.058
Standard size Repair limit Replace
Free Installed Installed Free Installed

length length load length load
2 Spring
156.8 N 149.0 N
52 46 50
(16 kg) (15.2 kg)
40-26
MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
6 51 84
11-1 I I
-926.1z102.9Nm
(94.5k10.5kgm)
-276.85t31.85Nm
(28.25a3.25kgm)
4 151.9=24.5Nm
(15.5e2.5kgm)
m 548.8258.8Nm m 1176.8+98.1 Nm m 548.8e58.8Nm m 151.9k24.5Nm

(56.0?6.0kgm) (120.0~10.0kgm) (56.0*6.0kgm) (15.5+2.5kgm)
SDD00421
40-28
MAINTENANCE STANDARD FINAL DRIVE
Unit: mm
pinion and No. 1 gear 0.28 - 0.93
8 0.26 - 0.87
2
Z

7 Clearance between pinion
shaft and carrier
-
58 -0.010 -0.009 0.006 0.1
-0.003 -0.039 0.049
8 Clearance of No. 1 pinion

0 - 0.1 (standard shim thickness: 2) Adjust
bearing in axial direction
Standard size Tolerance Repair limit

g Wear of dia. of sprocket
tooth tip *2
1,002 962
,. Wear of dia. of sprocket

909.4 kO.6 895.0
tooth root
Rebuild
or replace
11 Wear of width of sprocket
tooth tip 83 75
12 Wear of width of sprocket

103 95
tooth root
40-29
MAINTENANCE STANDARD MAIN FRAME
MAIN FRAME
6
;’
A-A B-B
D-D
c-c 7
SKD00441
40-30
MAINTENANCE STANDARD MAIN FRAME
Unit: mm

Clearance between HSS size Shaft Hole clearance limit
1 case and main frame
-
250 -0.015 +0.046 0.015 0.2
-0.061 0 0.107
Clearance between main
2 frame and radiator guard 95 +0.054 +0.154 0.070 - 1.5 Replace
bushing 0 +0.124 0.154
Clearance between main
-
3 frame and radiator guard 95 +0.054 +0.154 0.070 1.5
bushing 0 +0.124 0.154
Clearance between
-
4 equalizer bar center pin 85 -0.120 +0.207 0.240 1.5
and bushing -0.174 +0.120 0.381
Press-fitting force for
5 radiator guard mount 73.5 - 122.6 KN (7.5 - 12.5 ton)
bushing
6 radiator guard mount 73.5 - 122.6 KN (7.5 - 12.5 ton) -
bushing
7 equalizer bar center pin 63.7 - 132.4 KN (6.5 - 13.5 ton)
40-31
MAINTENANCE STANDARD TRACK FRAME
TRACK FRAME
m 745583Nm
(76.0+8.5kgm)
m 745283Nm m 745&83Nm m 745+83Nm

(76.028.5kgm) (76.0t8.5kgm) (76.0=8.5kgm)
A-A
SKD00442
Unit: mm

-
Check item Repair limit
Correct
1 Deformation of track frame Curvature 7 (over length of 3000)
Twisting or replace
3 (over length of 300)
Dents (pipe portion) 12

Clearance between idler
Adjust
and guide 0.5 - 1.0 3
40-32
MAINTENANCE STANDARD RECOIL SPRING
RECOIL SPRING
SKD00443
Unit: mm
Free Installed Installed Free Installed

1 Recoil spring length length load length load
298.7 KN 283.7 KN
1,125 937 1,091
(30,456 kg) (28,930 kg)
Standard Tolerance Standard Clearance Replace
Clearance between inner size Shaft Hole clearance limit

2 cylinder and outer cylinder
bushing 0 +0.277 0.062 -
130 0.7
-0.063 +0.062 0.340
Clearance between inner
3 cylinder and protrusion of +0.039 +0.130 0.061 -
75 1.0
adjustment cylinder +0.009 +O.lOO 0.121
Press-fitting force for outer
4 cylinder bushing (outer 19.6 - 29.4 KN (2 - 3 ton)
cylinder side)
Press-fitting force for idler

5 yoke 245 KN (25 ton)
I
40-33
MAINTENANCE STANDARD TRACK ROLLER BOGIE
TRACK ROLLER BOGIE

-206+49Nm
9 5 10 5 11 65 5 9
QEi2108t245~177 QGEl745+83~m A-A SKD00444
(215225kgm) (76.0?8.5kgm) Unit: mm

Clearance between size Shaft Hole clearance limit
1 cartridge pin and bushing
-0.165 +0.189 0.294 -
80 0.8
-0.195 +0.129 0.384
2 Clearance between collar +0.203 +0.083 -0.183 -

133 Replace
and outer bogie +0.183 +0.020 -0.100 -

and outer bogie 135
+0.183 +0.020 -0.100 -

and inner bogie 134
+0.183 +0.020 -0.100 -
5 Clearance of collar 1.5
6 Press-fitting force for 0.98 - 18.6 KN (0.1 - 1.9 ton)

bushing
7 Press-fitting force for 2.94 - 5.88 KN (0.3 - 0.6 ton)

washer

0.98 - 3.92 KN (0.1 - 0.4 ton)
8 washer
g Press-fitting force for

58.8 - 103.9 KN (6.0 - 10.6 ton)
collar I
88.3 - 202 KN (9.0 - 20.6 tOnI
lo outer bogie

198 - 436 KN (20.2 - 44.5 ton)
11 inner bogie

94 - 206 KN (9.6 - 21.0 ton)
I2 outer bogie I
40-34
MAINTENANCE STANDARD IDLER
IDLER
8’
SAD00445
40-36
MAINTENANCE STANDARD IDLER
B
X
I-
& Unit: mm

Outer diameter of idler
’ protrusion 792 -
2 Outer diameter of idler

750 725
tread
Rebuild
3 Width of idler protrusion 123 106
I or replace
4 Idler tread width 58.5 67
5 Overall idler width 240 -
6 Shaft flange width 216

I -
7 Clearance between shaft Replace
I
an Id bushing bushing
-
140 -0.350 +0.270 0.310 1.5
-0.413 -0.040 0.683

8 Play in axial direction
Replace
or shaft 0.47 - 0.83 1.5
40-37
MAINTENANCE STANDARD TRACK ROLLER
TRACK ROLLER
\ \
/
12 11 14
9
m
201k44Nm
(20.5?4.5kgm)
-_--_-_i_c-_
1
-1
5
-L-L
SAD00446
40-38
MAINTENANCE STANDARD TRACK ROLLER
Unit: mm

, Outer diameter of flange
(outside flange) 285 -
2 Cuter diameter of flange -

275
(rnsrde flange)
3 Outer diameter of track

250 210
roller tread
4 Overall track roller width 295 -
5 Width of tack roller tread Rebuild

(single flange) 61 70
or replace
6 Width of track roller tread

(double flange) 61 80
7 Flange width
(single flange) 25 16
8 Flange width
(outside of double flange) 25 16
g flange width
22 12
(rnsrde of double flange)
10 Shaft flange width I 246.0 I 245.5 I

Clearance between shaft Replace
11 and bushing bushing
-0.350 +0.260 0.360 -
125 1.5
-0.413 +O.OlO 0.673
Standard Tolerance _ Standard Interference

size Shaft Hole interference limit
Interference between shaft
12
and seal guide
+0.046 -0.150 0.150 -
65 0.10
0 -0.200 0.246 Replace

Play in shaft axial
13
direction 0.49 - 0.86 1.5
Press-fitting force for seal -

14 39.2 - 68.6 KN (4 - 7 ton) (Reference value)
guide
40-39
MAINTENANCE STANDARD CARRIER ROLLER
CARRIER ROLLER
206=49Nm
(21*5kgm)
SAD00447
Unit: mm
Standard size Repairable limit
1 Outside diameter of flange

220 -
2 Outer carrier roller tread

190 171 Rebuild
diameter
or replace
3 Flange width 21 14
4 Carrier roller tread width 63 72

Adjust nut
6 Play in shaft axial direction or replace
0.10 - 0.13 0.2
bearing
40-40
MAINTENANCE STANDARD TRACK SHOE
TRACK SHOE
DRY TYPE
* P portion shows the link of bushing press fitting end.
40-42
a
- Unit: mm

-
1 Link pitch 231.85 (Heavy-duty areas)
228.85
233.85 (Standard areas)
Reverse or
When turned
Standard size replace
Normal load impact load
2 Bushing outside diameter
81 75.0 77.0

3 Link height Repair or
144 128 replace
I I
Thickness of link metal
4 45.5
(bushing press-fitting portion)
5 219.8
6 Shoe bolt pitch 76.2
7 25.4
8 -
x,
z 8 Inside width 122.8
-
Overall width Repair or

9 Link 61.4
replace
-
10 Tread width 54.3

-
11 Protrusion of pin 4.5
Protrusion of regular
12 10.4
bushing
-
13 Overall length of pin 294

Adjust or
replace
14 Overall length of bushing 202.2
-
15 Thickness of bushing metal 15.8

-
16 Thickness of spacer -
17 Bushing 88.2 - 313.6 kN 19 - 32 ton1

I
-
Press-fitting
18 Regular pin 205.8 - 568.4 kN (21 - 58 ton}
force
%
19 Master pin 107.8 - 274.4 kN {II - 28 ton1
- i
% : Dry type track link
40-43
a
Unit: mm
Nc Check item Criteria Remedy
Tightening torque Additional tightening

N-n Ikgm}) I angle (deg.) I
a. Regular link
2f Shoe bolt
b. Master link
No. of shoes (each side) 41 -
Standard Tolerance _ Standard

size Shaft Hole interference
Interference between
21
bushing and link
+0.404 +0.074 0.230 -
77.0
+0.304 0 0.404
Interference between +0.584 +0.062 0.272 -

22 regular pin and link 48.5
+0.434 0 0.584
Clearance between
2: regular pin and bushing
-
Standard Tolerance Standard
% size interference
Interference between Shaft Hole
24
master pin and link
+0.330 +0.062 0.238 -
48.5
-0.300 I 0 0.330

5%
size Shaft Hole clearance
Clearance between
2E
master pin and bushing
-0.550 +0.280 0.670 -
49
-0.650 +0.120 0.930
% : Dry type track link
40-44
a
LUBRICATED TYPE
21 22 6 5 II 24 16
17 I8 2 23 7 I! 25 I5
* P portion shows the link of bushing press fitting end.

Unit: mm

1 Link pitch 231.85 (Heavy-duty areas)
228.85
233.85 (Standard areas)
Reverse or
When turned
Standard size replace
Normal load Impact load
2 Bushing outside diameter
81 72.5 75.0

Link height Repair or
3
144 128 replace
Thickness of link metal

4 (bushing press-fitting portion) 45.5
-
5 219.8
Replace
6 Shoe bolt pitch I 169
7 76.2
8 -
5 8 Inside width 122.8
Z
-
Overall width Repair or

9 Link 61.4
replace
10 Trea width 54.3
11 Protrusion of pin 4.5
Protrusion of regular
12 3.25
bushing
13 Overall length of pin 291.6

- Adjust or
replace
14 Overall length of bushing 187.9
15 Thickness of bushing metal 15.8

-
16 Thickness of spacer 11.1

-
17 Bushing 49-196kN{5-20tonI
Press-fitting
18 Regular pin 196 - 294 kN I20 - 30 ton1
force
3%
19 Master pin -
E : Dty type track link
40-45-2
a
MAINTENANCE STANDARD TRACK StlOE
Unit: mm
NO Check item Criteria

1 Remedy
Tightening torque Additional tightening

(Nm {kgm}) angle (deg.)
a. Regular link
588.4 + 58.8 I60 2 6) 120 f 10
20 Shoe bolt Retighten
Tightening torque Additional tightening Lower limit torque
(Nm {kgml) angle (deg.) (Nm {kgm})
b. Master link
588.4 * 58.8 160 5 61 180 + IO 882.6 1901
No. of shoes (each side) 41

I
size Shaft Hole interference
Interference between
21 bushing and link
+0.404 +0.074 0.230 -
77.0
+0.304 0 0.404
Interference between +0.484 -0.038 0.372 -

22 regular pin and link 48.5
I +0.434 -0.100 0.584
-
size Shaft Hole clearance
Clearance between
23 regular pin and bushing
+0.484 +0.664 0.230 - Adjust or
48.5
+0.334 +0.164 0.830 replace

-24 size interference
Interference between Shaft Hole
24 master pin and link
I - I - I - I -
% size clearance
Clearance between Shaft Hole
25, master pin and bushing
- - - -
- I I I I i
.X :I It-y type track link
40-45-3
- 0
SINGLE SHOE
SED01627
Unit: mm

Height
80 30
Repair by
Thickness 17 build-up
welding or
replace
Length of base 33
Length of tip 15
I I
I I
40-45-4
a
MAINTENANCE STANDARD SUSPENSION
SUSPENSION
m 549*59Nm m 549+59Nm
(56=6kgm) (56+6kgm)
5 4 8
A-A B-B
SKDJ0450
40-46
MAINTENANCE STANDARD SUSPENSION
m 927+103Nm 927=103Nm 2 7
{94.5*10.5kgm) /” 1 (9\5+10.5kgm)
i” \
C-C (Left side) C-C (Right side)
SKD00451
Unit: mm
Clearance between side pin

5 and spherical surface of 82 -0.1 +0.3 0.2 - 0.6i 1.0
bushing -0.3 +O.l
Press-fitting force for pivot

1.96 - 38.2 KN (0.2 - 3.9 ton)
6 shaft bushing (inner)
Press-fitting force for pivot -

0.98 - 33.3 KN (0.1 - 3.4 ton)
7 shaft bushing (outer) I
8 Press-fitting force for side
pin bushing 43.1 - 213.8 KN (4.4 - 21.8 ton)
40-47
MAINTENANCE STANDARD
HYDRAULIC, HSS PUMP
HYDRAULIC, HSS PUMP
m 66.2=7.4Nm
(6.75?0.75kgm)
\
Y SDD00471
40-48
MAINTENANCE STANDARD EPC SOLENOID VALVE
EPC SOLENOID VALVE
m 11.3-cl.5Nm
(1.15~0.15kgm)
u m 98+20Nm
(It0.2kgm)
SDD00472
Unit: mm
Check item

Replace
Free length installed Installed Free Installed EPC valve
I Return spring x OD length load length load assembly
if damaged
3.14 N - or deformed
9.0 x 11.4 7.9
IO.32 kg} -
40-49
@
MAINTENANCE STANDARD PPC VALUE
PPC VALVE
For blade , and ripper Serial No.: 60001 - 60279
For ripper Serial No.: 60280 and up
112.8~14.7Nm
(11.5t1.5kgm)
,m 13.2k1.5Nm
(1.35+0.15kgm)
44.1k4.9Nm
(4.5+0.5kgm)
m 39.224.9Nm
(4=0.5kgm)
‘m 8.5+2.5Nm
(0.85*0.25kgm)
SYD00454
Unit: mm
Free length Installed installed Free Installed

, Centering spring x OD length load length load
(for P3, P4)
71.39 N 56.9 N
50.05 x 15.5 34 spiing
i7.28 kg1 - 15.8 kg}
if damaged
or deformed
2 Centering spring 55.9 N 45.1 N
50.35 x 15.5 34
(for PI, P2) j5.7 kg1 - 14.6 kg}
16.7 N 17.7 N
3 Metering spring 26.53 x 8.15 24.9 {I.7 kg1 - Il.4 kg}
40-50
8
MAINTENANCE STANDARD PPC VALVE
For blade Serial No.: 60280 and up
44.lt4.9Nm ,w13.2*1.47Nm
(4.5t0.5kgm) (1.35+0.15kgm)
14.4=1.9Nm
(1.47?0.2kgm) w 13.221.47Nm
(1.35=0.15kgm)
w 6.37&2.45Nm
(0.65a0.25kgm)
\
SKD00595
40-50-2
8
MAINTENANCE STANDARD PPC VALUE
Unit: mm

- I I
Free length Installed Installed Free Installed

~Z;t;,i;g spring x OD length load length load
1
71.4 N 57.1 N
33.8 x 15.5 31.9
i7.28 kg1 - 15.82 kg1
Metering spring 16.7 N 13.7 N

2 (for P3, P4) 27.23 x 8.14 24.9
Il.7 kg} - II.4 kg} Replace
spring
62.8 N 50.0 N if damaged
3 ;Z;t;;;i;g spring 50.35 x 15.5 31.9
{6.4 kg} - j5.1 kg} or deformed
Eentering spring 80.81 N 64.63 N

4 :for PI, P2) 50.05 x 15.5 31.9
(8.24 kg1 - 16.59 kg}
Metering spring 16.7 N 13.7 N

5 Ifor PI, P2) 26.53 x 8.15 24.9
{I.7 kg} - Il.4 kg1
Detent spring 159.36 N 127.5 N

6 :for P4) 20.39 x 19.5 13.1
(16.25 kg} - {I3 kg)
Detent spring 38.44 N 30.79 N

7 :for P3) 45.36 x 7.5 26
l3.92 kg1 - {3.14 kg}
40-50-3
@
MAINTENANCE STANDARD MAIN CONTROL VALVE
MAIN CONTROL VALVE

Serial No. 60001 - 60279
* Precautions when tightening portions

marked *X. _%
To ensure that the 3 bolts are tight- 186.3+9.8Nm
ened evenly, tighten the bolts in three
steps as follows.
1st pass: 58.8 +. 9.8 Nm 16 + 1 kgml
pass: 137.3 f 9.8 Nm {I4 + 1 kgm)
pass: 186.3 + 9.8 Nm {I9 +. 1 kgm)
c2-
31.4=2.9Nm
/(3.2+0.3kgm)
l--K
CX
SAD00473
(6.75k0.75kgm)
A-A
Q=
139.7k22.1Nm
(14.25=2.25kgm)
m
152.0e24.5Nm 321.2+46.6Nm
(15.5k2.5kgm) (32.75a4.75kgm)
c2=
107.9e14.7Nm
(1 lt1.5kgm)
1 419.2k46.6Nm
(42.75?4.75kgm)
B-B 6
SAD00474
40-52
a=
68.6+9.8Nm
186.3k9.8Nm
(7kl kgm)
186.3?9.8Nm 4
1 ’ 127.5+19.6Nm
9 (13+2kgm)
D-D
m
34.3+4.9Nm
(3.5=0.5kgm)
SAD00475
8
5 Unit: mm
z
(for blade LIFT only)
9 Suction safety valve spring 0.88 N 0.72 N

20 x 7 14
(0.09 kg) - (0.073 kg)
68.6*9.8Nm
(7klkgm)
Q=
68.6=9.8Nm
(72:Ikgm)
\
23.5=3.9Nm
(2.420.4kgm)
K-K
Q-
186.3=9.8Nm
186.3=9.8Nm \ (19klkgm)
(19-clkgm)
E-E
62=
66.227.4Nm
(6.75?0.75kgm)
w
F-F
SAD00476
40-54
m
186.3=9.8Nm
(19klkgm)
2<5*3.9Nm
(2.4+0.4kgm)
m
68.6e9.8Nm
68.6t9.8Nm
H-H
J-J
SAD00477
Unit: mm

1 Suction valve spring x OD length load length load
/
27.9 x 31 18.8 6.27 N 5.0 N
IO.64 kg} - IO.51 kg1 Replace
spring
2 Check valve spring inner 22 x 5.3 17 1.9 N 1.57 N if damaged
spool IO.2 kg) - iO.16 kg} or deformed
3 Check valve spring inner x 0.29 N - 0.19 N

spool 9.4 4.6 8.5 iO.03 kg} iO.02 kg}
4 Suction valve spring 1 / $;;kNgl / -

129.8 x 8.95 16.5 / $;kNg) /
40-55
8
Serial No. 60280 and up

* Precautions when tightening portions
marked *X.
To ensure that the 3 bolts are tight-
ened evenly, tighten the bolts in three
steps as follows.
1st pass: 58.8 f 9.8 Nm 16 f 1 kgm)
2nd pass: 137.3 + 9.8 Nm I14 f 1 kgm} D x
3rd pass: 186.3 + 9.8 Nm (19 + 1 kgm) ,86.3i9.8Nm
31.4*2.9Nm
(3.2*0.3kPm)
P-A / I--
lX
m
23.5*3.9Nm
(2.4*0.4km)
SAD01500
B
139.7k22.1Nm
(14.25k2.25kgm)
a=
152.0+24.5Nm 321.2e46.6Nm
(15.5t2.5kgm) (32.75k4.75kgm)
-
107.9+14.7Nm
(1 l+l.Skgm)
419.2k46.6Nm
(42.75=4.75kgm)
SAD00474
40-57-l
@a
q@g a=
127.5+19.6Nm
186.3+9.8Nm
(13=2kgm)
(19elkgm)
\ \
186.3+9.8Nm
(19+lkgm)
127.5k19.6Nm
(13k2kgm)
D-D
34.3t4.9Nm
(3.5t0.5kgm)
SAD00475
8
5 Unit: mm
(for blade LIFT only)
4 Load check valve spring 20.8 x 10.2 13.5 12.7 N

Il.3 kg1 - Il.0 kg} if damaged
or deformed
5 Pressure compensation 70 x 26.5 62.5 197 N - 157.8 N
valve spring I20.1 kg} 116.1 kg}
6 Unload spring 94.8 x 30 67 258.7 N - 206.8 N

126.4 kg} f21.1 kg}
7 Back valve spring 99.5 x 14.9 96 71.5 N 56.84 N

pressure
(7.3 kg} - f5.8 kg1
8 Suction safety valve spring 16 x 16 12 6.66 N 5.3 N

iO.68 kg} - IO.54 kg1
9 Suction safety valve spring x 7 14 0.88 N 0.706 N

20
IO.09 kg1 - (0.073 kg}
40-57-2
@
A-A
f 9.8Nm
186.3
186.3
+ 9.8Nm I km)
(19*tIcam)
c-c
2
m 66.2*7.4Nm
(6.75*0.75kom)
\
I
D-D SAD01501
40-57-3
@
Es=
23.5*3.9Nm
(2.4*0.4km)
E-E
m68.6*9.8Nm cz=
(7*lksm) 68.6*9.8Nm
F-F
G-G
SAD01502
Unit: mm

1 Suction valve spring x OD length load length load
6.37 N 5.1 N
64.9 x 12.5 56
IO.65 kg} - IO.52 kg} Replace
spring
2 Check valve spring inner 22 x 5.3 17 1.96 N 1.57 N if damaged
spool (0.2 kg) - IO.16 kg] or deformed
3 Check valve spring inner 9.4 x 4.6 8.5 0.29 N 0.20 N

spool (0.03 kg1 - IO.02 kg1
4.4 N
4 Suction valve spring 46.8 x 7.5 40.6 5.49 kg}
IO.56 N - IO.45 kg1
MAINTENANCE STANDARD HSS MOTOR
HSS MOTOR
m
227k32Nm
(28.25=3.25kgm)
m
54k5Nm
110.3+12.3Nm (5.520.5kgm)
(11.25?1.25kgm)
m
373549Nm
(38?5kgm)
A-A
/
Es=
279+25Nm
(28.5+2.5kgm)
SAD00478
Unit: mm

1 Spool return spring x OD length load length load Replace
spring
241.2 N 193.2N if damaged
43.4 x 35 41.0
i24.6 kg1 - l19.7 kg1 or deformed
3.04 N 2.45 N
Check valve spring 62.5 x 20 39.0
IO.31 kg} - lo.25 kg}
40-57-5
@
MAINTENANCE STANDARD WORK EQUIPMENT CYLINDER
WORK EQUIPMENT CYLINDER

. BLADE LIFT CYLINDER
981+98Nm 110.3+12.3Nm
(lOO*lOkgm) (11.25?1.25kgm)
. BLADE TILT CYLINDER
343t34.3Nm 110.3?12.3Nm
(35?3.5kgm) (11.25e1.25kgm)
. PIN PULLER CYLINDER
4 1 6
m
441+44Nm
(45.0+4.5kgm)
40-58
8
2 Unit: mm
z - 1
Tole xi once T Standard Clearance

Shaft Hole clearance limit
-0.030 +0.271
Clearance -0.104 +0.075
1 between piston
rod and bushing -0.036 +0.270
-0.123 +0.061
Pin -0.065 +0.133

puller 3o -0.117 +0.007
Clearance between
2 piston rod spherical Blade 65 -0.200 +0.030 0.200 - 1.0
surface and blade LIFT -0.300 0 0.330
ball portion Replace
I
Clearance between
Blade 85 -0.120 +0.054 0.120 -
3 0.5
;;Fhd;rg Tn,p;rJk,hah Lll=T -0.207 0 0.261
Blade -0.200 +0.300

TILT 115
Clearance between -0.300 0
4 piston rod spherical
surface and cap Pin -0.100 +I .300
puller 2g -0.200 +I .200
Clearance between
Blade -0.300 +0.174
5
;~~r&!f~~d~~~h”hng TILT ” -0.500 +O.lOO
Clearance between
Pin -1.1
6 cylinder bottom sup- puller 26 20.1
port shaft and boss -1.2
40-59
. RIPPER LIFT CYLINDER
cc@=
245+24.5Nm
D=
110.3=12.3Nm
(25=2.5kgm) (11.25e1.25kgm) SAD00463
. RiPPER TILT CYLINDER
m
245k24.5Nm
Es=
110.3+12.3Nm
(2522.5kgm) (11.25?1.25kgm)
SAD00464
40-60
Unit: mm

Clearance between
-
1 piston rod and Ripper 80 -0.030 +0.271 0.091 0.675
bushing LIFT -0.104 +0.061 0.375
Clearance between Ripper

LIFT 85
-0.036
-0.090 +0.207
+0.120 0.1560.297
- 1.0 Replace
2 piston rod support

shaft and bushing Ripper -0.036 +0.207 0.156 -
TILT 85 -0.090 +0.120 0.297 1.0
-
Clearance between LIFT
Ripper 85 -0.036 +0.207 0.156 1.0
-0.090 +0.120 0.297
3 cylinder bottom
support shaft and
bushing Ripper 85 -0.036 +0.207 0.156 - 1.0
TILT -0.090 +0.120 0.297
40-61
MAINTENANCE STANDARD QUICK DROP VALVE
QUICK DROP VALVE
SED00465
Unit: mm

, Clearance between spool
and valve body
-
38.0 -0.011 +O.OlO 0.011 0.03
-0.016 0 0.026
I I I I I I
I
1 Standard size Repair limit Replace
Free Installed installed Free Installed

2 Valve spring length length load length load
136.3 N 122.6N
75.2 55.9 67.7
(13.9 kg) (12.5 kg)
40-62
MAINTENANCE STANDARD CYLINDER STAY
CYLINDER STAY
SAD00466
Z
Unit: mm
I
Check item Criteria Remedy

Clearance between cylinder
’ yoke and bushing
125 -0.172 +0.063 0.172 - 0.5 Replace
-0.235 0 0.298
2 Clearance between cylinder 100 -0.170 +0.054 0.170 -

yoke and bushing 0.5
-0.224 0 0.278
40-63
MAINTENANCE STANDARD WORK EQUIPMENT
WORK EQUIPMENT
SEMI U-DOZER
3 9 6 10 14
A-A c-c
7 8 5
4 1
D-D E-E F-F G-G
SW300467
40-64
Unit: mm
Criteria
,. Clearance between blade -0.3 +0.3

60 0.3 - 0.8 3
bracket pin and bracket -0.5 0
Clearance between center Adjust shims

11 brace spherical surface 115 -0.2 +0.3 0.2 - 0.6 1
and -0.3 0 or replace
cap
,2 Clearance between center -0.3 +0.3

85 0.6 - 0.8 2
lrnk pin and center link -0.5 0
13 Clearance between center -0.3 +O.l 2

85 -0.5 -0.1 0.2 - 0.6
link pin and blade bracket
Replace
14 Clearance between center +0.3
196 0 0.3 - 0.6 2
lrnk and blade bracket -0.1 +0.5
l5 Clearance between trunnion -0.5 +0.5 8

160 0.5 - 1.5
and cap spherical surface -1.0 0
40-65
U-DOZER
3 9 6 10
k
A-A
7 8 5
1
D-D F-F G-G
SED00468
40-66
Unit: mm

, Clearance between brace
and pin
-0.3 +0.5
60 0.6 - 1.0 2 Replace
-0.5 +0.3
2 Cjearance between brace 60 -0.3 +0.5 0.6 - 1.0 2

pm and bracket -0.5 +0.3
3 Clearance between brace -0.2 +0.3

spherical surface and cap 115 -0.3 0
Clearance between center

4 brace spherical surface 115 -0.2 +o _
and cao -0.3 0
5 Clearance between joint 120 -0.2 +0.5 0.5 - 1.2 2

and blade bracket -0.7 +0.3
6 Clearance between joint 120 -0.2 +0.5 0.5 - 1.2 2

and frame -0.7 +0.3
7 Cjearance between
pin and joint frame 60 -0.3
-0.5 +0.3
0 0.3 - 0.8 3
Replace
Clearance between frame +0.3
60 0 0.3 - 0.8 3
’ pin and frame 3::
9 Clearance
bracket pinbetween
and jointblade 60 -0.3 +0.3 0.3 - 0.8 3
-0.5 0
1o Clearance between blade

bracket pin and bracket / 60 / 2:; / +;‘3 1 0.3 - 0.8 / 3 j
Clearance between center -0.2 +0.3 1 Adjust shims

11 brace spherical surface
115 0.2 - 0.6 or replace
and -0.3 0
cap
12 Clearance 85 -0.3 +0.3 0.6 - 0.8 2

lrnk pin andbetween center
center link -0.5 0
13 Clearance
lrnk pin andbetween center
blade bracket 85 -0.3 +O.l 0.2 - 0.6 2
-0.5 -0.1
Replace
Clearance between center 0 +0.3
I4 link and blade bracket 196 -
-0.1 +0.5 0.3 0.6 2 I
and spherical surface 160 0.5 - 1.5

cap
15 Clearance between trunnion -1.0
-0.5 0
+0.5 8 I
40-67
MAINTENANCE STANDARD WaRK EQUIPMENT
CUTTING EDGE, END BIT
m 1495+162Nm
(152.5216.5kgm)
_--_---------- --_--
t
m----
11
__----------------
I
~1495+162Nm
(152.5216.5kgm)
SD000469
Unit: mm
Check item Criteria Remedy

1 Height of outside of end bit
415 300
Replace
2 Width of end bit 662 500
3 Height of inside of end bit 330 260
4 Height of cutting edge 330 260 (215 to turning) Turn

or replace
40-68
STANDARD WORK EQUIPMENT
MAINTENANCE
MULTI-SHANK RIPPER
GIANT RIPPER
A-A B-B
40-70
Unit: mm
Tolerance Standard Clearance

Shaft Hole clearance limit
Clearance between arm
1
mounting pin and mounting
bracket -0.036 +0.207 0.156 -
1.5
-0.090 +0.120 0.297 I
Clearance between arm -0.036 +0.520 0.348 -

110 1.5
mounting pin and bushing -0.090 +0.312 0.610 I
-0.036 +0.207 0.156 - 1.5

-0.090 +0.120 0.297
-0.036 +0.520 0.348 -

1.5
-0.090 +0.312 0.610 Replace
+0.300 +0.300
-0.300 -0.300 1.4 - 2.6 10.0
+0.300 +O.lOO
6 -0.300 -0.100 4.6 - 5.4 151.0
i
I
Wear of point
335 225
-
8 Wear of protector 115 90
40-71
Komatsu America international Company
440 North Fairwav Drive I 1
Vernon Hills, IL 66061-8112 U.S.A.
Attn: Technical Publications PROPOSAL FOR MANUAL REVlslON
Fax No. (847) 970-4186
FOR INTERNAL USE ONLY -- No. PMR
2 NAME OF COMPANY: LOCATION:
: PHONE NO:
:
S DEPARTMENT: DATE:
E
R NAME:
MANUAL NAME:
MANUAL NO:
MACHINE MODEL:
S/N IF APPLICABLE:
PAGE NO:
PROBLEM:
Attach photo or sketch.

If more space is needed, use another sheet.
1 FOR INTERNAL USE ONLY

CORRECTIVE ACTION:
PFMRl 081696

(SM) D155ax 3

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SEBM005207

SERIAL NUMBERS D155AX=3 - 60001 mdw

December 1997 Coovriaht 1997 Komatsu America Intemational Comoanv 00-l

01 GENERAL . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . ..~..................................... 01-I

‘IO STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..*............. 10-I

20 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-I

30 DISASSEMBLY AND ASSEMBLY . . . . . . ..m...................*.......... 30-I

40 MAINTENANCE STANDARD . . . . . . . ..n..................................... 40-I

be newly added Add

Pages having no marks are not revised atthistime.

LIST OF REVISED PAGES

Revision Revision Revision Revision Revision

0 oo- 1 IO- 8 IO-49 IO- 94 IO-136

IO-183 IO-234 20- 5 @ 20-144 @ 0 20-316 0

20-525 @ 20-583 @ 20-807 0 30-25-I 30- 74 @

30-129 @ 30-155-17 @ 30-194 @ 30-246 @ 30-279-3

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to

2. When carrying out any operation, always PREPARATIONS FOR WORK

16. When removing components, be careful not

18. As a general rule, do not use gasoline to

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL

VOLUMES REVISED EDITION MARK

Adjusting) Places to be coated with ad-

. If a part cannot be smoothly removed from

3) Do not sling a heavy load with one rope

A Slinging with one rope may cause

Wire ropes 4) Do not sling a heavy load with ropes form-

20 43.1 4.4 hanging angle. On the other hand, two

* The allowable load value is estimated to

bers, plastics and woods.

l Features: Resistance to water, oil

l Used as sealant for various threads, pipe

l Features: Silicon based, resistance to heat,

l Features: Silicon based, quick hardening

Three bond l Used as heat-resisting sealant for repairing

l Used as lubricant for sliding portion (to pre-

SYG2-4OOLl l General purpose type

l Used for normal temperature, light load

1Mf!$Er/ SYG2-400M 1 (r{r ISelows type1

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUES OF BOLTS AND NUTS

Thread diameter Width

6 10 13.2f 1.4 1.35kO.15

Thread diameter Width

TIGHTENING TORQUE OF HOSE NUTS

Thread diameter Width across flat Tightening torque

TIGHTENING TORQUE OF SPLIT FLANGE BOLTS

10 14 65.7+ 6.8 6.7f0.7

TIGHTENING TORQUE OF O-RING BOSS CONNECTOR

Thread diameter Width across flat Tightening torque

TIGHTENING TORQUE OF O-RING BOSS CONNECTOR

Thread diameter Width across flat Tighteni 4 J torque

TIGHTENING TORQUES OF FLARE NUT

Thread diameter Width across flat Tightening torque

TIGHTENING TORQUE FOR 102 SERIES ENGINE (BOLT AND NUTS)

Thread diameter Tightening torque

TIGHTENING TORQUE FOR 102 SERIES ENGINE (EYE JOINTS)

Thread diameter Tightening torque

TIGHTENING TORQUE FOR 102 SERIES ENGINE (TAPERED SCREWS)