00-2

CONTENTS

01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1

10 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

20 TESTING AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1

30 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 30-1

40 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1

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00-3 Î

PRODUCT PUBLICATIONS INFORMATION

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

SPECIAL PUBLICATIONS SUCH AS SERVICE TOOL, AIR CONDITIONING, AND TURBOCHARGER SHOPMANUALS ARE ALSO AVAILABLE AS WELL AS SELECTED OPERATION & MAINTENANCE AND SHOP MANUALSIN FOREIGN LANGUAGES.

THE PUBLICATIONS LISTED BELOW ARE AVAILABLE FOR THIS PARTICULAR MACHINE(S).

DESCRIPTION FORM NUMBER

PARTS BOOK - PAPER:

Engine and Chassis BEPB002100

PARTS BOOK - MICROFICHE:

Engine and Chassis BEPM002100

OPERATION & MAINTENANCE MANUAL:

Engine and Chassis CEAM001300

SHOP MANUAL:

Chassis CEBM001101Engine: SEBM010002

SAFETY MANUAL WLT70-1

PARTS AND SERVICE PUBLICATIONS CAN ONLY BE ACQUIRED BY AUTHORIZED KOMATSU DISTRIBUTORS,USING THE KOMATSU AMERICA INTERNATIONAL COMPANY PARTS INFORMATION PROCESSING SYSTEM(PIPS).

IF THE PIPS SYSTEM IS NOT AVAILABLE AT THE DISTRIBUTOR LOCATION, THEN THE FOLLOWINGREQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS CAN BE USED. FORM KDC91DIS SHOWN ON THE REVERSE SIDE OF THIS PAGE.

00-4

PURCHASE ORDER NO.

ORDER DATE

REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS

COMPLETE FORM

AND RETURN TO << Komatsu America International Company440 North Fairway DriveVernon Hills, IL 60061-8112 U.S.A.Attn: Technical PublicationsFax No. (847) 970-4186Tel No. (847) 970-5887

COMPANY NAME

ATTN.

STREET ADDRESS

CITY, STATE, ZIP CODE

COUNTRY

SHIP TO <<

TYPE or PRINTONLY <<

PHONE NO. FAX NO. SHIPPING METHOD DISTR/BRANCH CODE

IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND MACHINESERIAL NUMBER MUST BE SHOWN.

QTY. PUBLICATION FORM NO. P-Paper MODEL NUMBER SERIAL NUMBER PARTS BOOK

M-Microfiche

PUBLICATIONDESCRIPTION

KDC91D 081696 CURRENT PRICES WILL BE CHARGED

SAFETY SAFETY NOTICE

00-5

SAFETY

SAFETY NOTICE

IMPORTANT SAFETY NOTICE

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

To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. Thecautions accompanying these symbols should always be followed carefully. If any dangerous situation arisesor may possibly arise, first consider safety, and take the necessary actions to deal with the situation.

GENERAL PRECAUTIONS clean and make sure that there is no dirt or oil on the

Mistakes in operation are extremely dangerous. Read the Never smoke while working.OPERATION & MAINTENANCE MANUAL carefullyBEFORE operating the machine. PREPARATIONS FOR WORK

1. Before carrying out any greasing or repairs, read all 7. Before adding oil or making repairs, park thethe precautions given on the decals which are fixed to machine on hard, level ground, and block thethe machine. wheels or tracks to prevent the machine from

2. When carrying out any operation, always wear safetyshoes and helmet. Do not wear loose work clothes, 8. Before starting work, lower blade, ripper, bucket oror clothes with buttons missing. any other work equipment to the ground. If this is

not possible, insert the safety pin or use blocks to ! Always wear safety glasses when hitting parts

with a hammer.

! Always wear safety glasses when grinding partswith a grinder, etc.

3. If welding repairs are needed, always have a trained,experienced welder carry out the work. Whencarrying out welding work, always wear weldinggloves, apron, glasses, cap and other clothes suitedfor welding work.

4. When carrying out any operation with two or moreworkers, always agree on the operating procedurebefore starting. Always inform your fellow workersbefore starting any step of the operation. Beforestarting work, hang UNDER REPAIR signs on thecontrols in the operator's compartment.

5. Keep all tools in good condition and learn the correctway to use them.

6. Decide a place in the repair workshop to keep toolsand removed parts. Always keep the tools and partsin their correct places. Always keep the work area

floor. Smoke only in the areas provided for smoking.

moving.

prevent the work equipment from falling. Inaddition, be sure to lock all the control levers andhang warning signs on them.

9. When disassembling or assembling, support themachine with blocks, jacks or stands beforestarting work.

10. Remove all mud and oil from the steps or otherplaces used to get on and off the machine. Alwaysuse the handrails, ladders or steps when getting onor off the machine. Never jump on or off themachine. If it is impossible to use the handrails,ladders or steps, use a stand to provide safefooting.

PRECAUTIONS DURING WORK

11. When removing the oil filler cap, drain plug orhydraulic pressure measuring plugs, loosen themslowly to prevent the oil from spurting out. Beforedisconnecting or removing components of the oil,

SAFETY SAFETY NOTICE

00-6

water or air circuits, first remove the pressure completely 18. As a general rule, do not use gasoline to washfrom the circuit. parts. In particular, use only the minimum of

12. The water and oil in the circuits are hot when theengine is stopped, so be careful not to get burned. 19. Be sure to assemble all parts again in their originalWait for the oil and water to cool before carrying out places. Replace any damaged part with new parts.any work on the oil or water circuits.

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

14. When raising heavy components, use a hoist orcrane. Check that the wire rope, chains and hooksare free from damage. Always use lifting equipmentwhich has ample capacity. Install the liftingequipment at the correct places. Use a hoist or craneand operate slowly to prevent the component fromhitting any other part. Do not work with any part stillraised by the hoist or crane.

15. When removing covers which are under internalpressure or under pressure from a spring, alwaysleave two bolts in position on opposite sides. Slowlyrelease the pressure, then slowly loosen the bolts toremove.

16. When removing components, be careful not to breakor damage the wiring, Damaged wiring may causeelectrical fires.

17. When removing piping, stop the fuel or oil fromspilling out. If any fuel or oil drips on to the floor, wipeit up immediately. Fuel or oil on the floor can causeyou to slip, or can even start fires.

gasoline when washing electrical parts.

! When installing hoses and wires, be sure thatthey will not be damaged by contact with otherparts when the machine is being operated.

20. When installing high pressure hoses, make surethat they are not twisted. Damaged tubes aredangerous, so be extremely careful when installingtubes for high pressure circuits. Also check thatconnecting parts are correctly installed.

21. When assembling or installing parts, always usethe specified tightening torques. When installingprotective parts such as guards, or parts whichvibrate violently or rotate at high speed, beparticularly careful to check that they are installedcorrectly.

22. When aligning two holes, never insert your fingersor hand. Be careful not to get your fingers caughtin a hole.

23. When measuring hydraulic pressure, check thatthe measuring tool is correctly assembled beforetaking any measurements.

24. Take care when removing or installing the tracks oftrack-type machines. When removing the track, thetrack separates suddenly, so never let anyonestand at either end of the track.

FOREWARD GENERAL

00-7

FOREWARD

GENERAL

This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurateunderstanding of the product and by showing him the correct way to perform repairs and make judgements. Make sureyou understand the contents of this manual and use it to full effect at every opportunity.

This shop manual mainly contains the necessary technical information for operations performed in a service workshop.For ease of understanding, the manual is divided into the following sections. These sections are further divided into eachmain group of components.

GENERAL

This section lists the general machine dimensions, performance specifications, component weights, and fuel,coolant and lubricant specification charts.

STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an understandingof 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 bemade at completion of the checks and repairs. Troubleshooting charts correlating "Problems" to "Causes" arealso included in this section.

DISASSEMBLY AND ASSEMBLY

This section explains the order to be followed when removing, installing, disassembling or assembling eachcomponent, 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 advancenotice. Contact your distributor for the latest information.

FOREWARD HOW TO READ THE SHOP MANUAL

00-8

HOW TO READ THE SHOP MANUAL

VOLUMES REVISED EDITION MARK

Shop manuals are issued as a guide to carrying outrepairs. They are divided as follows:Chassis volume: Issued for every machine modelEngine volume: Issued for each engine seriesElectrical volume: Each issued as one to cover all

modelsAttachment volume: Each issued as one to cover all

models

These various volumes are designed to avoid duplicationof information. Therefore to deal with all repairs for anymodel, it is necessary that chassis, engine electrical andattachment be available.

DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be sentto your distributors. Get the most up-to-date informationbefore you start any work.

FILING METHOD

1. See the page number on the bottom of the page. Filethe pages in correct order.

2. Following examples show how to read the pagenumber:

Example 1 (Chassis volume):

10 - 3

Item number (10. Structure andFunction)

Consecutive page number for each item

Example 2 (Engine volume):Refer to the pertinent engine manual.

3. Additional pages: Additional pages are indicated by ahyphen (-) and numbered after the page number. Fileas in the example.

Example:10-4 10-4-1

A Added pages10-4-2

10-5

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

REVISIONS

Revised pages are shown at the LIST OF REVISEDPAGES between the title page and SAFETY page.

SYMBOLS

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

Symbol Item Remarks

SafetySpecial safety precautions arenecessary when performing thework.

Caution

Special technical precautions orother precautions for preservingstandards are necessary whenperforming the work.

Weight

Weight of parts or systems.Caution necessary when selectinghoisting wire or when workingposture is important, etc.

Tighteningtorque

Places that require specialattention for tightening torqueduring assembly.

CoatPlaces to be coated with adhesivesand lubricants etc.

Oil, waterPlaces where oil, water or fuelmust be added, and the capacity.

DrainPlaces where oil or water must bedrained, and quantity to bedrained.

FOREWARD HOISTING INSTRUCTIONS

00-9

HOISTING INSTRUCTIONS

HOISTING

Heavy parts (25 kg or more) must be lifted witha hoist etc. In the DISASSEMBLY AND

ASSEMBLY section, every part weighing 25 kg ormore is indicated clearly with the symbol

! If a part cannot be smoothly removed from themachine by hoisting, the following checks should bemade:

1) Check for removal of all bolts fastening thepart to the relative parts.

2) Check for existence of another part causinginterface with the part to be removed.

WIRE ROPES1) Use adequate ropes depending on the weight of

parts to be hoisted, referring to the table below:

Wire ropes(Standard "Z" or "S" twist ropes without galvanizing

Rope diameter (mm) Allowable load (tons)

10.0 1.011.2 1.412.5 1.614.0 2.216.0 2.818.0 3.620.0 4.422.4 5.630.0 10.040.0 18.050.0 28.060.0 40.0

The allowable load value is estimated to be 1/6 or1/7 of the breaking strength of the rope used.

2) Sling wire ropes from the middle portion of thehook. Slinging near the edge of the hook maycause the rope to slip off the hook duringhoisting, and a serious accident can result.Hooks have maximum strength at the middleportion.

3) Do not sling a heavy load with one rope alone, butsling with two or more ropes symmetrically woundon to the load.

Slinging with one rope may cause turning ofthe load during hoisting, untwisting of the rope,

or slipping of the rope from its original windingposition on the load, which can result in a dangerousaccident.

4) Do not sling a heavy load with ropes forming a widehanging angle from the hook. When hoisting a loadwith two or more ropes, the force subjected to eachrope will increase with the hanging angles. Thetable below shows the variation of allowable load(kg) when hoisting is made with two ropes, each ofwhich is allowed to sling up to 1000 kg vertically, atvarious hanging angles. When two ropes sling aload vertically, up to 2000 kg of total weight can besuspended. This weight becomes 1000 kg whentwo ropes make a 120E hanging angle. On theother hand, two ropes are subject to an excessiveforce as large as 4000 kg if they sling a 2000 kgload at a lifting angle of 150E.

FOREWARD COATING MATERIALS

00-10

COATING MATERIALS

The recommended coating materials prescribed in the shop manuals are listed below.

Category Code Part No. Qty Container Main applications,features

Adhesive

LT-1A 790-129-9030 150 g Tube! Used to prevent rubber gaskets, rubber cushions and cork plugs from

coming out

LT-1B 790-129-9050 20 g (x2) Used for plastics (except polyethylene, polypropylene,Plastic

container

! Used in places requiring an immediately effective, strong adhesive.

tetrafluoroethylene, and vinyl chloride), rubber, metal and non-metal.

LT-2 09940-00030 50 gPlastic ! Features: Resistance to heat, chemicals

container ! Used for anti-loosening and sealant purposes for bolts and plugs.

LT-3 of adhesive and Hard agt Can ! Used as adhesive or sealant for metal, glass or plastic.790-129-9060 Set Adh 1 kg

hardening agent 500 kg

LT-4 790-129-9040 250 g ! Used as sealant for machined holes.Plastic

container

Loctite ! Features: Resistance to heat, chemicals648-50 ! Used at joint portions subject to high temperature.

79A-129-9110 50 cc ---

Gasket sealant

LG-1 790-129-9010 200 g Tube! Used as adhesive or sealant for gaskets and packing of power train

case, etc.

LG-3 790-129-9070 1 kg Can locations; used to prevent seizure.

! Features: Resistance to heat! Used as sealant for flange surfaces and bolts at high temperature

! Used as sealant for heat resistant gasket for at high temperaturelocations such as engine pre-combustion chamber, exhaust pipe.

LG-4 790-129-9020 200 g Tube ! Also possible to use as sealant for flanges with large clearance.

! Features: Resistance towater, oil! Used as sealant for flange surface, thread.

! Used as sealant for mating surfaces of final drive case, transmissioncase.

LG-5 790-129-9080 1 kgPlastic ! Used as sealant for various threads, pipe joints, flanges.

container ! Used as sealant for tapered plugs, elbows, nipples of hydraulic piping.

LG-6 09940-00011 250 g Tube ! Used as sealant for flange surface, thread.! Features: Silicon based, resistant to heat, cold.

! Used as sealant for oil pan, final drive case, etc.

LG-7 09920-00150 150 g Tube ! Used as sealant for flywheel housing, intake manifold, oil pan,! Features: Silicon based, quick hardening type.

thermostat housing, etc.

Rust preven-tionlubricant

--- 09940-00051 60 g Can ! Used as lubricant for sliding parts (to prevent squeaking).

Molybdenumdisulfide lubricant

--- 09940-00040 200 g Tube shrink fitting.! Used to prevent seizure or scuffing of the thread when press fitting or

! Used as lubricant for linkage, bearings, etc.

Lithium grease G2-L1 SYG-400Ll-A Various Various ! General purpose type

SYG-350LlSYG-400Ll

SYG-160LlSYGA-160CNLl

Calcium grease G2-CA SYG2-400CA-A Various Various

SSG2-400CASYG2-350CA

SYG2-160CASYGA-16CNCA

! Used for normal temperature, light load bearing at places in contact withwater or steam.

Molybdenum 400 gdisulfide grease (10/case)

--- SYG2-400M Bellows type ! Used for places with heavy load.

FOREWARD STANDARD TORQUE REQUIREMENTS

00-11

STANDARD TORQUE REQUIREMENTS

STANDARD TORQUE REQUIREMENTS OF BOLTS AND NUTS

The following charts give the standard torques values of bolts and nuts. Exceptions are given in sections ofDISASSEMBLY AND ASSEMBLY.

1 kgm = 9.806 Nm

Thread diameter of bolt Width across flat

mm mm kgm Nm

6 10 1.35 ±0.15 13.2 ±1.4

8 13 3.20 ±0.3 31.4 ±2.9

10 17 6.70 ±0.7 65.7 ±6.8

12 19 11.5 ±1.0 112 ±9.8

14 22 18 ±2.0 177 ±19

16 24 28.5 ±3 279 ±29

18 27 39 ±4 383 ±39

20 30 56 ±6 549 ±58

22 32 76 ±8 745 ±78

24 36 94.5 ±10 927 ±98

27 41 135 ±15 1320 ±140

30 46 175 ±20 1720 ±190

33 50 225 ±25 2210 ±240

36 55 280 ±30 2750 ±290

39 60 335 ±35 3280 ±340

This torque table does not apply to the bolts with which nylon packing or other non-ferrous metal washers are tobe used, or which require torquing to otherwise specified values.

FOREWARD STANDARD TORQUE REQUIREMENTS

00-12

TORQUE REQUIREMENTS OF SPLIT FLANGE BOLTS

Use these torques values for split flange bolts.

Thread diameter of bolt Width across flat torque requirement values

mm mm kgm Nm

10 14 6.70 ±0.7 65.7 ±6.8

12 17 11.5 ±1.0 112 ±9.8

16 22 28.5 ±3 279 ±29

TORQUE REQUIREMENTS FOR FLAIRED NUTS

Use these torque values for flaired part of nut.

Thread diameter of bolt Width across flat torque requirement values

mm mm kgm Nm

14 19 2.5 ±0.5 24.5 ±4.9

18 24 5 ±2 49 ±19.6

22 27 8 ±2 78.5 ±19.6

24 32 14 ±3 137.3 ±29.4

30 36 18 ±3 176.5 ±29.4

33 41 20 ±5 196.1 ±49

36 46 25 ±5 245.2 ±49

42 55 30 ±5 294.2 ±49

FOREWARD ELECTRIC WIRE CODE

00-13

ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire codetable will help you understand WIRING DIAGRAMS.Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.

CLASSIFICATION BY THICKNESS

Nominal Cable Current ratingnumber O.D. (mm) (A)

Copper wire

Applicable circuitNumber of Dia. Of strand Cross sec-strands (mm) tion (mm²)

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.

2 26 0.32 2.09 3.1 20 Lighting, signal etc.

5 65 0.32 5.23 4.6 37 Charging and signal

15 84 0.45 13.36 7.0 59 Starting (Glow plug)

40 85 0.80 42.73 11.4 135 Starting

60 127 0.80 63.84 13.6 178 Starting

100 217 0.80 109.1 17.6 230 Starting

CLASSIFICATION BY COLOR AND CODE

Priority Circuits Charging Ground Starting Lighting Signal OtherClassification Instruments

1 PrimaryCode W B B R Y G L

Color White Black Black Red Yellow Green Blue

2

Auxiliary4

Code WR --- BW RW YR GW LW

Color White/Red --- Black/White Red/White Yellow/Red Blue/WhiteGreen/White

3Code WB --- BY RB YB GR LR

Color --- Blue/RedWhite/Black Red/Black Yellow/Black Green/RedBlack/Yellow

Code WL --- BR RY YG GY LY

Color --- Black/RedWhite/Blue Red/Yellow Blue/YellowYellow/Green Green/Yellow

5Code WG --- --- RG YL GB LB

Color --- --- Yellow/Blue Blue/BlackWhite/Green Green/BlackRed/Green

6Code --- --- --- RL YW GL ---

Color --- --- --- Red/Blue ---Yellow/White Green/Blue

FOREWARD CONVERSION TABLES

00-14

CONVERSION TABLES

METHOD OF USING THE CONVERSION TABLEThe Conversion Table in this section is provided to enable simple conversion of figures. For details of the methodof using the Conversion Table, see the example given below.

EXAMPLE ! Method of using the Conversion Table to convert from millimeters to inches. 1. Convert 55 mm into inches.

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

(2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down from.

(3) Take the point where the two lines cross as . This point gives the value when converting frommillimeters to inches. Therefore, 55 millimeters = 2.165 inches.

2. Convert 550 mm into inches.(1) The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to

convert it to 55 mm.(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one

place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

Millimeters to Inches 1 mm = 0.03937 in

mm 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 2.244 2.283 2.323

60 2.362 2.402 2.441 2.480 2.520 2.559 2.638 2.677 2.717

70 2.756 2.795 2.835 2.874 2.913 2.953 3.032 3.071 3.110

80 3.150 3.189 3.228 3.268 3.307 3.346 3.425 3.465 3.504

90 3.543 3.583 3.622 3.661 3.701 3.740 3.819 3.858 3.898

2.2052.598

2.992

3.386

3.780

FOREWARD CONVERSION TABLES

00-15

Millimeters to Inches1 mm = 0.03937 in

mm 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 Pound1 kg = 2.2046 lb

kg 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

90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26

FOREWARD CONVERSION TABLES

00-16

Liter to U.S. Gallon1R = 0.2642 U.S. Gal

R 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. Gallon1R = 0.21997 U.K. Gal

R 0 1 2 3 4 5 6 7 8 9

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 7.699 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

FOREWARD CONVERSION TABLES

00-17

kgm to ft. lb1 kgm = 7.233 ft. lb

kgm 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

FOREWARD CONVERSION TABLES

00-18

kg/cm² to lb/in²1kg/cm² = 14.2233 lb/in²

kg/cm² 0 1 2 3 4 5 6 7 8 9

0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2

20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5

30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7

40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9

50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2

60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4

70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124

80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266

90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408

100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550

110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693

120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835

130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977

140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119

150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262

160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404

170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546

180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688

190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830

200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973

210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115

220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257

230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399

240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542

FOREWARD CONVERSION TABLES

00-19

TemperatureFahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vise versais to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit orCentigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheittemperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheitdegrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.

1EC = 33.8EF

EC EF EC EF EC EF EC EF

-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 48 118.4 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 89 192.226.1 -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 68 154.4 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

FOREWARD MEMORANDA

00-20

01-1 Î

01 GENERAL

SPECIFICATION DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . 01- 2

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01- 3

WEIGHT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01- 6

FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . 01- 7 Î

ENGINE OIL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 01- 8

DIESEL FUEL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 01- 9

COOLANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 01-10

GENERAL SPECIFICATION DRAWINGS

01-2

SPECIFICATION DRAWINGS

WA180-3

GENERAL SPECIFICATIONS

01-3

SPECIFICATIONS

Model: WA180-3 Size TireSerial Number: A80001 and up

17.5-25 -12PR, L2

WEIGHT (Includes full fuel tank,and optional counterweigh)

Operating weight 8750 kgDistribution front axle 3460 kgDistribution rear axle 5290 kg

PERFORMANCE

Bucket capacity (piled) 1.7 m³Rated load 2720 kg

Travel speed

FORWARD

1st 7.2 km/h

2nd 12.0 km/h

3rd 22.0 km/h

4th 34.5 km/h

REVERSE

1st 7.7 km/h

2nd 12.6 km/h

3rd 22.9 km/h

4th 35.0 km/h

Grade ability 25 deg

Minimum Outside of chassis 5385 mmturningradius Center of outside 4650 mm

wheel

DIMENSIONS

Overall length 6415 mm

Overall width (chassis) 2260 mm

Bucket width (with bolt on cutting 2440 mmedge))

Overall height (top of cab) 3095 mm

Overall height (bucket raised) 4695 mm

Wheelbase 2700 mm

Tread 1820 mm

Minimum ground clearance 425 mm

Height of bucket hinge pin 3540 mm

Dumping clearance (tip of cutting 2715 (2775) mmedge)

GENERAL SPECIFICATIONS

01-4

Dumping reach (tip of cutting edge) 985 (960) mm

Bucket dump angle 45 deg

Bucket tilt (SAE carrying position) 46 deg

Digging depth (10E dump angle) 290 mm

ENGINE

Model S6D102E-1 diesel engine

Type Direct injection (Aspiration, Turbo charged)

Number of cylinders - bore x stroke 6 - 102 mm x 120 mm

Piston displacement 5.88 R (359 in³)

Gross power @ 2400 rpm 82 kWMaximum torque @ 1600 RPM 426 NCm (314 lbf ft)

High idle 2600 rpmLow idle 850 rpm

Starting motor 24V, 4.5 kW

Alternator 24V, 50A

Battery 12V, 110Ah x 2

POWER TRAIN

Torque converter 3-element, 1-stage, single-phase (Komatsu TCA30-6Z)

Transmission Spur gear, constant-mesh multiple-disc,hydraulic actuated, modulation type

Reduction gear Spiral bevel gear

Differential Straight bevel gear, torque proportioning

Final drive Planetary gear, single reduction

AXLE, WHEEL, AND TIRE

Drive type Front/rear wheel drive

Front axle Fixed frame, semi-floating

Rear axle Center pin support type, semi-floating type

Standard tire 17.5-25 x 12 pr (L2)

Wheel rim 25 x 13.00

Front tire inflation pressure 294 kPa (3.0 kg/cm²)

Rear tire inflation pressure 294 kPa (3.0 kg/cm²)

GENERAL SPECIFICATIONS

01-5

BRAKES

Main brakes Front/rear wheel independent wet-type sealed disc brakeswith hydraulic booster

Parking brake Thrust shaft (transmission shaft) braking, wet-type disc brake,mechanical type

STEERING SYSTEM

Type Articulated type

Structure Fully hydraulic power steering

HYDRAULIC SYSTEM

Hydraulic pump type Gear pumpDelivery 144 R/min.

Control valves:Set pressure for work equipment Spool type 20.59 MPA (210 kg/cm²)Set pressure for steering Spool type 18.64 MPa (190 kg/cm²)

Cylinders: Reciprocating pistonBoom - qty. - bore x stroke 2 - 110 x 618Bucket - qty. - bore x stroke 1 - 120 x 423Steering - qty. - bore x stroke 2 - 60 x 340

WORK EQUIPMENT

Linkage type Single link (Z-bar linkage)

Bucket edge type Flat edge with bolt on cutting edge

GENERAL WEIGHT TABLE

01-6

WEIGHT TABLE

Machine model WA180-3 Machine model WA180-3

Serial No. Serial No.A80001 and A80001 andup up

kg kg

Engine (with air cleaner & muffler) 540 Main control valve 21

Radiator 80 Boom lift cylinder (each) 62

Torque converter 35 Bucket cylinder 56

Transmission with torque converter 480 Engine hood with side panel 127

Center drive shaft 11 Front frame 726

Front drive shaft 12 Rear frame 612

Rear drive shaft 6 Bucket link 17

Front axle 387 Bellcrank 125

Rear axle 393 Boom lift arm including bushings 520

Axle pivot 69 Bucket with bolt on cutting edge 710

Wheel (each) 71 Counterweight 1210

Tire (each) 106 Fuel tank 80

Orbit-roll valve 8 Battery (each) 30

Priority valve 6 Floor, cab assembly 1060

Steering cylinder (each) 14 Cab (ROPS) 500

Hydraulic tank 53 Operator’s seat 40

Equipment / Steering pump 10

Brake booster 11

GENERAL FUEL, COOLANT AND LUBRICANTS

01-7 Î

FUEL, COOLANT AND LUBRICANTSPROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS

Reservoir Kind offluid

Ambient Temperature Capacity-22 -4 14 32 50 68 86 104EF-30 -20 -10 0 10 20 30 40EC Specified Refill

Engine oil pan 5.8 US gal 5.1 US gal

Engine oil

SAE 5W-3022 R 19.5 R

4.8 UK gal 4.3 UK galSAE 10W-30

SAE 15W-40

Brake 0.26 US gal 0.26 US gal1 R 1 R

0.22 UK gal 0.22 UK galSAE 5W

Transmissioncase

28 R 23.5 R7.4 US gal 6.2 US gal6.6 UK gal 5.2 UK gal

SAE 10W

Hydraulicsystem

80 R 41 R21.1 US gal 10.8 US gal17.6 UK gal 9.0 UK gal

SAE 10W

Axle 14 R 14 R(front & rear) Axle oil 3.7 US gal 3.7 US gal(each) 3.1 UK gal 3.1 UK gal

See Note 1

Pins Grease - -NLGI No. 2

Fuel tank Diesel fuel 44.9 US gal170 R

37.4 UK gal-ASTM D975 No. 2

ŠŠ

Cooling system Coolant 10.1 US gal 9.2 US galSee 20.3 Coolant specification on page 3-1338.5R 35 R

8.5 UK gal 7.7 UK gal

ŠŠ ASTM D975 No. 1Other equipment will be necessary, when operating the machine at temperatures below -20EC (-4EF),therefore consultyour distributor for your needs.

Note 1: For axle oil, use only the recommended oil as follows.SHELL: DONAX TT or TDCALTEX: RPM TRACTOR HYDRAULIC FLUIDCHEVRON: TRACTOR HYDRAULIC FLUIDTEXACO: TDH OILMOBIL: MOBIL 424

It is permissible to substitute engine oil SAE 30 API classification CD for axle oil. Although an increased in brake noisemay occur, the durability of the axle is not be affected.

GENERAL FUEL, COOLANT AND LUBRICANTS

01-8 Î

ENGINE OIL SPECIFICATIONS

Normal operation NOTE: limited use of low viscosity oils, such as

Oil performance recommendations are as follows: and providing sufficient oil flow at ambient

The use of a quality engine lubricating oil combined However, continuous use of low viscositywith appropriate oil and filter change intervals are oil can decrease engine life due to wear.critical factors in maintaining engine performance anddurability. Single graded oils may be used if multi-graded oil is

SAE 15W-40 multi-viscosity oil meeting the American temperature shown in the table.Petroleum Institute (API) performance classificationof CE/SG is recommended. Special break-in lubricating oils are not

NOTE: CC/CD or CD/SF oils may be used in areas same type of oil during the break-in as specified forwhere CE oil is not yet available but the oil normal operation.change interval must be reduced to one half theinterval given in the maintenance schedule Additional information regarding lubricating oil

A sulfated ash limit of 1.0 mass percent is suggested "E.M.A. Lubricating Oils Data Book For Heavy Dutyfor optimum valve and piston deposit and oil Automotive and Industrial Engines". The data bookconsumption control. the sulfated ash must not may be ordered from the Engine Manufacturersexceed 1.85 mass percent. The sulfated ash limit of Association, 401 North Michigan Ave., Chicago, Il1.85 mass percent has been placed on all engine U.S.A. 60611. The telephone number is (312) 644-lubricating oils recommended for use in the engine. 6610.Higher ash oils can cause valve and/or pistondamage and lead to excessive oil consumption. Arctic Operation

The API service symbol displays the appropriate oil If an engine is operated in ambient temperaturescategories; the lower half may contain words to consistently below -23EC (-10EF) and there are nodescribe oil energy conserving features. The center provisions to keep the engine warm when it is not insection identifies the SAE oil viscosity grade. operation, use a synthetic API performance

Oil viscosity recommendations are as follows: low temperature properties such as SAE 5W-20 or

The use of a multi-graded lubricating oil has beenfound to improve oil consumption control and The oil supplier must be responsible for meeting theimprove engine cranking in cold temperatures while performance service specifications.maintaining lubrication at high operatingtemperatures. IMPORTANT:

While SAE 15W-40 multi-viscosity oil is extended oil change intervals. Extended oil changerecommended for most operating climates, refer to intervals can decrease engine life due to factors suchthe previous chart for oil viscosity recommendations as; corrosion, deposits and wear.for extreme climates.

10W-30 may be used for easier starting

temperatures below -5EC (23EF).

not available. But be sure to use oil that matches the

recommended for a new or rebuilt engine. Use the

availability throughout the world is available in the

classification CE or CF-4 engine oil with adequate

5W-30.

The use of a synthetic base oil does not justify

GENERAL DIESEL FUEL SPECIFICATIONS

01-9

DIESEL FUEL SPECIFICATIONS

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

Due to the precise tolerances of diesel injectionsystems, it is extremely important that the fuel be

kept clean and free of dirt or water. Dirt or water in thesystem can cause severe damage to both the injectionpump and nozzles.

For normal service above -12EC (+10EF), the use ofASTM Grade No. 2-D diesel fuel with a minimum Cetanenumber of 40 is recommended. The use of No. 2-D dieselfuel will result in optimum engine performance undermost operating conditions. Fuels with Cetane numbershigher than 40 may be needed in high altitudes orextremely low ambient temperatures to prevent misfires

and excessive smoke.

At operating temperatures below -12EC (+10EF), useASTM Grade No. 1-D diesel fuel. The use of lighter fuelscan reduce fuel economy.

Where a winterized blend of Grade No. 2-D and No. 1-Dfuels is available, it may be substituted for Grade No. 1-Dfuel. However, it is the supplier's responsibility to providethe fuel for the anticipated ambient temperature.

Use a low sulfur content fuel having a cloud point that isat least 10 degrees below the lowest expected fueltemperature. Cloud point is the temperature at whichcrystals begin to form in the fuel. The viscosity of the fuelmust be kept above 1.3 cSt to provide adequate fuelsystem lubrication.

GENERAL COOLANT SPECIFICATIONS

01-10

COOLANT SPECIFICATIONS

GENERAL ANTIFREEZE

Selection and maintenance of the engine coolant is In climates where the temperature is above -37EC (-important to long engine life. The following information 34EF), use a coolant mixture that contains 50 percentprovides recommendations for selecting the engine antifreeze. Antifreeze is essential in any climate. Itcoolant and maintaining the coolant inhibitors. broadens the operating temperature range by lowering

Heavy duty diesel engines require a balanced coolant Do not use more than 50 percent antifreeze in themixture of water, antifreeze, and supplemental coolant mixture unless additional freeze protection is required.additives. Supplemental coolant additive Never use more than 68 percent antifreeze under anyrecommendations are included in the section entitled condition.Inhibitors Conditioners. The coolant mixture must bedrained and replaced at the specified service interval An antifreeze concentration greater than 68% willshown in the OPERATION & MAINTENANCE MANUAL, adversely affect freeze protection and heat transfer rates.or every two years of operation, whichever comes first. Antifreeze concentrations between 68 and 100% actually

WATER concentration and should not be used due to reduced

Use water which has a low mineral content. Water usedin conjunction with antifreeze, coolant filters and inhibited Low silicate ethylene glycol antifreeze is recommended.water must meet the following standards: The antifreeze should contain no more than 0.1%

Total Hardness - Not to exceed 170 parts per million recommended to avoid the formation of silica-gel (hydro-(10 grains/gallon maximum) to prevent scale gel). This gel formation can occur when the coolingdeposits. Water containing dissolved magnesium and system contains an over concentration of high silicatecalcium (the usual reason for water hardness) above antifreeze and/or supplemental coolant additive. DO NOTthe specified amount will cause scale deposits to use methanol or alcohol as an antifreeze because of itsdevelop in the engine. low boiling point.

Chlorides - Not to exceed 40 parts per million (2.5 Antifreeze may retain its freeze protection for more thangrains/gallon maximum) to prevent corrosion. one season but coolant conditioners must be added to

Sulfites - Not to exceed 100 parts per million (5.8grains/gallon maximum) to prevent corrosion. Antifreeze formulated with methoxy propanol, or

Dissolved Solids - Not to exceed 340 parts permillion (20 grains/gallon maximum) to minimize Do not mix types of antifreeze solutions. Mixedsludge deposits, scale deposits, corrosion or a solutions make it impossible to determine thecombination of these. protection against freezing. Antifreeze containing sealer

If any of the above requirements cannot be met, use Sealer or anti-leak additives will cause plugging problemsdistilled, de-ionized, or de-mineralized water. To in the cooling system.determine if local water supplies meet these standards,water samples can be tested by water treatment Check the solution periodically and at normal operatinglaboratories. Softened water that is prepared using temperature, to be sure the cooling system has sufficientcommon salt (sodium chloride) contains excessive protection against freezing.amounts of chlorides and should not be used.

Never use water alone in the cooling system antifreeze solution required for various temperatures.because corrosion will occur.

the coolant freezing point and by raising its boiling point.

have a higher freezing point than a 68% antifreeze

heat transfer rates.

anhydrous alkali metasilicate. Low silicate antifreeze is

maintain corrosion protection.

propylene glycol, is not recommended for this system.

or anti-leak additives should NOT be used in this system.

The following table shows the approximate percentage of

GENERAL COOLANT SPECIFICATIONS

01-11

Approximate Freezing Point Specific Gravity at 16EC (60EF)Percentage of Antifreeze Concentration by Volume

0EC (+32EF) 0 1.000 -7EC (+20EF) 15 1.025-12EC (+10EF) 25 1.040-18EC (0EF) 33 1.053-23EC (-10EF) 40 1.062-29EC (-20EF) 45 1.070-34EC (-30EF) 48 1.074-40EC (-40EF) 53 1.080-46EC (-50EF) 56 1.083-51EC (-60EF) 59 1.088-57EC (-70EF) 62 1.092-62EC (-80EF) 65 1.095-68EC (-90EF) 67 1.097-69EC (-92EF) 68 1.098

In tropical climates where antifreeze availability may be Maintenance of Cooling System Inhibitorslimited, use a corrosion inhibitor DCA4, to protect theengine cooling system. Keeping the engine coolant properly inhibited will keep

INHIBITORS/CONDITIONERS corrosion.

1. All cooling system inhibitors, including those in New machines are delivered with antifreeze protection.antifreeze solutions, become depleted through Service at regular scheduled intervals specified in thenormal operation. If the inhibitors in antifreeze are OPERATION & MAINTENANCE MANUAL with a serviceallowed to become depleted, the antifreeze becomes DCA4 filter.corrosive and attacks and coats the metallic surfacesof the cooling system which reduces heat transfer. Each time the coolant is drained and replaced, theCooling system conditioners which contain these coolant must be recharged with DCA4. New coolant caninhibitors must be added to maintain corrosion be correctly charged with supplemental coolant additivesprotection. by using DCA4 filters or DCA4 concentrate listed in the

2. Soluble oil is not recommended for use in this engineas its use will reduce heat transfer. If coolant is added between drain intervals, additional

3. There are no miracle additives that will increase heattransfer or prevent overheating. Conditioned water is Coolant Testing for Conditioner Concentrationstill the best coolant.

4. DCA4 is recommended to inhibit corrosion in the recommended, the conditioner concentration should becooling system for the following reasons: satisfactory. The DCA4 concentration must not fall below

! Improved compatibility with high silicate US gal) of coolant. The only accurate method for testingantifreezes to minimize hydro-gel formation if chemical concentrations in coolant with mixed chemicalover concentration occurs. compounds is a laboratory analysis. For this reason, the

! Provides engine protection in the following areas: OPERATION & MAINTENANCE MANUAL.- Solder corrosion/bloom- Copper corrosion/erosion/stress cracking Inadequate concentration of the coolant additive- Oil fouling- Cylinder liner cavitation corrosion- Aluminum cavitation corrosion- Seal and gasket degradation

the engine and radiator free of rust, scale deposits and

table entitled, DCA4 Unit Guide.

DCA4 will be required.

When the cooling system is maintained as

1.0 unit per 3.8 R (1 US gal) or exceed 2 units per 3.8 R (1

coolant inhibitor should be maintained as shown in the

GENERAL COOLANT SPECIFICATIONS

01-12

can result in major corrosive damage to cooling system following table. The coolant mixture must be drained andcomponents. Over concentration can cause formation of replaced as defined under General.gel that can cause restriction, plugging of passages andoverheating. The amount of replacement inhibitor is determined by the

Replenishing Coolant Conditioner capacity. Refer to the DCA4 Unit Guide for the selection

Install a precharge DCA4 filter when the coolant ischanged or a significant (more than 50%) coolant loss If coolant is added between drain intervals, additionaloccurs. Install a service DCA4 filter as specified in the DCA4 will be required. Check the coolant DCA4OPERATION & MAINTENANCE MANUAL When concentration level anytime make-up coolant is added toantifreeze is added, add coolant conditioner equal to 1.0 the system. The DCA4 concentration must not fall belowunit per 3.8 R (1 US gal) of antifreeze. 0.13 units per liter or exceed 0.5 units per liter (0.5 units

Mixing of DCA4 and other supplemental coolant additivesis not recommended because there is currently no test kit DCA4 Unit Guideavailable to measure concentration levels with mixedchemical solutions.

DCA4 Unit Maintenance Guide

Use supplemental coolant additives (corrosion inhibitors)to protect the engine cooling system from corrosion.Antifreeze alone does not provide enough corrosionprotection for a heavy duty diesel engine. Supplementalcorrosion protection must be supplied through periodicadditions of supplemental coolant additives to the coolant.

To protect against corrosion, a new coolant charge mustbe brought up to 0.26 DCA4 unit per liter (one unit perU.S. gal) of coolant (initial charge). Maintain the correctDCA4 concentration by changing the service coolant filterat each engine oil and filter change interval.

Each time the coolant is drained and replaced, thecoolant must be recharged with supplemental coolantadditives. Use the appropriate DCA4 spin-on filter listed in

length of the service interval and the cooling system

of the correct filter to replenish the DCA4.

per U.S. gallon or exceed 2 units per U.S. gallon).

Fleetguard Part No. DCA4 Units

DCA4 Coolant FilterWF-2070 2WF-2071 4WF-2072 6WF-2073 8WF-2074 12WF-2075 15WF-2076 23WF-2077 0

DCA4 LiquidDCA60L 4 (1 Pint)DCA80L 1760 (55 USgal)

DCA4 PowderDCA95 20

DCA4 Precharge and Service Filters

System CapacityPrecharge Filter Service Filter(See NOTE 1) (See NOTE 3)

Liters US Gallons

19 to 26 5 to 7 WF-2072 WF-2070

26 to 38 7 to 10 WF-2073 WF-2071

38 to 57 10 to 15 WF-2074 WF-207157 to 76 15 to 20 WF-2075 WF-2071

76 to 114 20 to 30 WF-2076 WF-2072114 to 190 30 to 50 (See NOTE 2) WF-2073

GENERAL COOLANT SPECIFICATIONS

01-13

NOTE 1 - After draining and replacing coolant, always required to precharge the cooling system. Four bottles ofprecharge the cooling system to maintain the powder, part number DCA95, will provide a sufficientDCA4 concentration between 1.0 and 2.0 units amount of DCA4 units (80) to precharge the exampleper 3.8 R (1 US gal). cooling system.

When performing service which requires draining ! Install the appropriate service filter at the nextthe cooling system, discard the coolant. Reusing and subsequent maintenance intervals.

coolant can introduce contaminates or over concentratedchemicals, resulting in premature failure of cooling NOTE 3 - Change the coolant filter at every engine oilsystem components. and filter change interval to protect the cooling

! Install appropriate service filter listed in the abovetable based on cooling system capacity.

Example: 95 gal (360 R) cooling system R (1 US gal) of coolant in the system. Less than 0.5 unitcapacity per 3.8 R (1 US gal) indicates an under-concentrated

-15 Units (1) WF-2075 Filter coolant solution. More than 2.0 units per 3.8 R (1 USgal) 80 Units indicates an over-concentrated coolant solution.

! The answer represents the additional units To check the DCA4 concentration level, use the Fleet-

system.

Maintain a nominal concentration of 1.0 DCA4 unit per 3.8

guard coolant test kit, CC2626. Instructions are includedwith the test kit.

DCA4 Unit Concentration Guide

Number of Solution A Drops toCause Color Change Coolant Condition Action Required

0 to 10 DropsExtremely under-concentrated - less Initially charge the system to a minimumthan 0.4 DCA4 units per 3.8 R (1 US gal) of 1.0 DCA4 unit per 3.8 R (1 US gal)

11 to 16 Drops DCA4 unit per 3.8 R (1 US gal) minimumMarginally under-concentrated - 0.45 to0.8 DCA4 units per 3.8 R (1 US gal)

Add DCA4 liquid units to maintain 1.0

or change the DCA4 coolant filter

17 to 25 Drops NONEAcceptable - 0.85 to 1.3 DCA4 units per3.8 R (1 US gal)

26 to 35 Drops NONEHighly acceptable - 1.35 to 2.0 DCA4units per 3.8 R (1 US gal)

36 to 55 Drops Review maintenance practiceMarginally over-concentrated - 2.1 to 3.3DCA4 units per 3.8 R (1 US gal)

Over 55 Drops Extremely over-concentrated

Drain 50% of the coolant and replacewith water antifreeze mixture. Retest thesystem for correct DCA4 unitconcentration.

GENERAL COOLANT SPECIFICATIONS

01-14

The following may be purchased from your Komatsu International Company distributor.

Cooling system test kit

The Fleetguard® Coolant Test Kit is used to check the coolantconcentration of coolant additives in the cooling system.

Part Number: CC-2626

1. Test strip bottles2. Solution #1 bottle3. Small plastic container4. Large plastic cup5. Syringe

10-1 Î

10 STRUCTURE AND FUNCTION

POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3POWER TRAIN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 10-4TORQUE CONVERTER, TRANSMISSION PIPING . . . 10-6TRANSMISSION HYDRAULIC SYSTEM DIAGRAM . . . 10-8TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM . . . 10-9TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . 10-10TORQUE CONVERTER OIL FILTER . . . . . . . . . . . . . 10-12

TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15

REVERSE CLUTCH . . . . . . . . . . . . . . . . . . . 10-15FORWARD, 2ND CLUTCH . . . . . . . . . . . . . . 10-163RD, 4TH CLUTCH . . . . . . . . . . . . . . . . . . . . 10-16

FORWARD 1ST . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18FORWARD 2ND . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19FORWARD 3RD . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20FORWARD 4TH . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21REVERSE 1ST . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22

TRANSMISSION CONTROL VALVE . . . . . . . . . . . . . . 10-23UPPER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24LOWER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25TRANSMISSION SOLENOID VALVE . . . . . . . . . . 10-26TORQUE CONVERTER OUTLET PORT VALVE 10-27PILOT REDUCING VALVE . . . . . . . . . . . . . . . . . . 10-28TRANSMISSION SOLENOID VALVE . . . . . . . . . . 10-29PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . 10-30MAIN REGULATOR VALVE . . . . . . . . . . . . . . . . . 10-31QUICK RETURN VALVE . . . . . . . . . . . . . . . . . . . . 10-32MODULATION FILL VALVE . . . . . . . . . . . . . . . . . 10-36DIRECTIONAL SELECTOR SPOOL . . . . . . . . . . 10-38EMERGENCY MANUAL SPOOL . . . . . . . . . . . . . 10-39OPERATION OF FORWARD 1ST . . . . . . . . . . . . 10-40ACCUMULATOR VALVE . . . . . . . . . . . . . . . . . . . 10-42

TRANSMISSION CONTROL . . . . . . . . . . . . . . . . . . . . 10-44DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46

FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46FRONT DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . 10-47REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-48REAR DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . 10-49TORQUE PROPORTIONING DIFFERENTIAL . . 10-51

FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52AXLE MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-54CENTER HINGE PIN . . . . . . . . . . . . . . . . . . . . . . . . . . 10-56STEERING PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-57STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-59

CUSHION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62

STEERING VALVE (ORBIT-ROLL) . . . . . . . . . . . . . . . . . 10-64OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-66

1. Steering wheel at neutral. . . . . . . . . . . . . . . 10-662. Steering wheel turned (turning to left) . . . . . 10-68

CONNECTION between hand pump and sleeve . . . 10-70

BRAKE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-72BRAKE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-73BRAKE BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-74BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-78PARKING BRAKE CONTROL . . . . . . . . . . . . . . . . . . . 10-80PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-81HYDRAULIC PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-82WORK EQUIP. HYDRAULIC SYSTEM DIAGRAM . . . 10-84WORK EQUIP. HYDRAULIC CIRCUIT DIAGRAM . . . 10-85

HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-86OIL FILTER BYPASS VALVE . . . . . . . . . . . . . . . . . . 10-87BREATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-88

MAIN CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . 10-902-SPOOL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-903-SPOOL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-92RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-94SAFETY VALVE (WITH SUCTION) . . . . . . . . . . . . . 10-95SUCTION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-96Boom and bucket spool at NEUTRAL position . . . . . 10-97Boom spool at RAISE position . . . . . . . . . . . . . . . . . 10-98Boom spool at LOWER position . . . . . . . . . . . . . . . . 10-99Boom spool at FLOAT position . . . . . . . . . . . . . . . . 10-100Bucket spool at TILT BACK position . . . . . . . . . . . . 10-101Bucket spool at DUMP position . . . . . . . . . . . . . . . . 10-102

WORK EQUIPMENT LEVER LINKAGE . . . . . . . . . . . . 10-103WORK EQUIPMENT LINKAGE . . . . . . . . . . . . . . . . . 10-104BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-106

BUCKET POSITIONER AND BOOM KICK-OUT . . . . . 10-107BUCKET POSITIONER . . . . . . . . . . . . . . . . . . . . . . 10-108BOOM KICK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . 10-108

PROXIMITY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-109OPERATION OF THE PROXIMITY SWITCH . . . . 10-110

Bucket TILT BACK switch . . . . . . . . . . . . . . . . 10-110Boom RAISE switch . . . . . . . . . . . . . . . . . . . . . 10-110

ACTION OF THE PROXIMITY SWITCH . . . . . . . . 10-110

ROPS CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-111

STRUCTURE AND FUNCTION TABLE OF CONTENTS

10-2 Î

AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . 10-112 ÎAIR CONDITIONER AND HEATER PIPING . . 10-112 ÎELECTRIC CIRCUIT DIAGRAM . . . . . . . . . . . 10-113 Î

E.C.S.S. (ELECTRONIC CONTROLLED SUSPENSIONSYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-114E.C.S.S. HYDRAULIC, ELECTRICAL CIRCUIT DIAGRAM

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-115OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-116

ELECTRICAL WIRING ILLUSTRATION . . . . . . . . . . 10-119ELECTRICAL WIRING DIAGRAM (1/2) . . . . . . . . . . . 10-120CENTRAL PANEL (CLUSTER GAUGE) . . . . . . . . . . 10-122

SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-123ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . 10-123BRAKE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . 10-123

ENGINE STARTING CIRCUIT . . . . . . . . . . . . . . . . . . 10-122ENGINE STOP CIRCUIT . . . . . . . . . . . . . . . . . . . . . . 10-125

AUTOMATIC PREHEATING CIRCUIT . . . . . . . . . . . . 10-126QUICK HEATING SYSTEM (Q.H.S.) . . . . . . . . . 10-126Q.H.S. CONTROLLER . . . . . . . . . . . . . . . . . . . . 10-128HEATER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . 10-128RIBBON HEATER . . . . . . . . . . . . . . . . . . . . . . . . 10-129Q.H.S. WATER TEMPERATURE SENSOR . . . 10-129

ELECTRICAL TRANSMISSION CONTROL . . . . . . . 10-130COMBINATION SWITCH . . . . . . . . . . . . . . . . . . . . . . 10-131TRANSMISSION CUT-OFF FUNCTION . . . . . . . . . . 10-132PARKING BRAKE FUNCTION . . . . . . . . . . . . . . . . . . 10-134

KICK-DOWN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . 10-135KICK-DOWN SWITCH . . . . . . . . . . . . . . . . . . . . 10-135KICK DOWN ELECTRIC CIRCUIT DIAGRAM . . 10-136KICK-DOWN SWITCH OPERATED . . . . . . . . . . 10-137KICK-DOWN SWITCH ACTUATION - CANCELED (1) . . . . . . . . . . . . . . . . . . . . . . . . . 10-138KICK-DOWN SWITCH ACTUATION - CANCELED (2) . . . . . . . . . . . . . . . . . . . . . . . . . 10-139KICK-DOWN SWITCH ACTUATION - CANCELED (3) . . . . . . . . . . . . . . . . . . . . . . . . . 10-140

POWER TRAIN STRUCTURE AND FUNCTION

10-3

POWER TRAIN

Outline! The motive force from engine (3) passes through ! The motive force from the output shaft of the

the engine flywheel and is transmitted to torque transmission passes through center drive shaft (6),converter (2), which is connected to the input shaft front drive shaft (5) and rear drive shaft (7), and isof transmission (1). then transmitted to front axle (4) and rear axle (8)

! The transmission has six hydraulically actuatedclutches, and these provide four speed ranges forboth FORWARD and REVERSE. The transmissionspeed ranges are selected manually.

to drive the wheels.

STRUCTURE AND FUNCTION POWER TRAIN SYSTEM

10-4

POWER TRAIN SYSTEM

POWER TRAIN SYSTEM STRUCTURE AND FUNCTION

10-5

1. Engine the flywheel and is transmitted to torque converter 2. Torque converter (2). 3. Steering pump The torque converter uses oil as a medium. It 4. Hydraulic pump converts the transmitted torque in accordance with 5. Torque converter charging pump the change in the load, and transmits the motive 6. Transmission force to the input shaft of the transmission. In 7. Parking brake addition, the motive force of the engine passes 8. Center drive shaft through the pump drive gear of the torque 9. Flange bearing converter, and is transmitted to hydraulic, steering10. Front drive shaft pump (4), (3) and torque converter charging pump11. Front axle (5) to drive each pump.12. Front differential ! Transmission (6) operates the directional spool and13. Front brake speed spool of the transmission valve through the14. Front final drive solenoid valves, and actuates the six hydraulically15. Front tire actuated clutches to select one of the four16. Rear drive shaft FORWARD or REVERSE speeds. The17. Rear axle transmission speed range is selected manually.18. Rear differential ! The output shaft of transmission (6) transmits the19. Rear brake power to the front and rear axles. At the front, the20. Rear final drive power is transmitted to front axle (11) through21. Rear tire center drive shaft (8), flange bearing (9), and front

Outline! The motive force from engine (1) passes through

drive shaft (10). At the rear, the power istransmitted to rear axle (17) through rear driveshaft (16).

! The motive force transmitted to front axle (11) andrear axle (17) has its speed reduced by the bevelgear and pinion gear of differentials (12) and (18),and is then transmitted to the sun gear shaftthrough the differential mechanism.

! The motive force of the sun gear is reduced furtherby the planetary mechanism and is transmitted tothe wheels through the axle shaft.

STRUCTURE AND FUNCTION TORQUE CONVERTER, TRANSMISSION PIPING

10-6

TORQUE CONVERTER, TRANSMISSION PIPING

1. Transmission Outline2. Oil filter ! The oil from the torque converter charging pump3. Torque converter passes through the oil filter and flows to the brake4. Torque converter charging pump booster. From the brake booster, it flows to the5. Radiator main regulator valve and is divided into three lines:6. Oil cooler the torque converter circuit, clutch circuit, and

solenoid pilot circuit.! The oil flowing to the torque converter circuit enters

the torque converter. The oil pressure is adjustedby the torque converter outlet port valve, the oil iscooled by the oil cooler, lubricates the transmissionand returns to the transmission case.

MEMORANDA STRUCTURE AND FUNCTION

MEMORANDA

STRUCTURE AND FUNCTION TRANSMISSION HYDRAULIC SYSTEM DIAGRAM

10-8

TRANSMISSION HYDRAULIC SYSTEM DIAGRAM

(Engine low idling, directional lever at Neutral, Speed lever at 2nd)

TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM STRUCTURE AND FUNCTION

10-9

TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM

(Engine stopped)

1. Transmission case 11. Transmission lubrication 21. Accumulator valve 2. Strainer 12. Pilot reducing valve 22. FORWARD clutch 3. Torque converter charging pump 13. Pilot oil filter 23. REVERSE clutch 4. Oil filter 14. Quick return valve 24. 4th clutch 5. Priority valve 15. Modulation fill valve 25. 3rd clutch 6. Main regulator valve 16. Accumulator 26. 2nd clutch 7. Torque converter 17. Solenoid valve 27. 1st clutch 8. Torque converter outlet valve 18. Speed spool 28. Brake booster 9. PTO lubrication 19. Directional spool10. Oil cooler 20. Emergency manual spool

STRUCTURE AND FUNCTION TORQUE CONVERTER

TORQUE CONVERTER

1. 6. PTO gear (drive)2. Turbine Housing (transmission case) Model: TCA30-6A

Stator 8. Type: 3-element, 1-stage, 1-phaseDrive case Stall torque ratio: 2.84Pump

TORQUE CONVERTER

10-11

Path of motive forceThe torque converter is installed between the engine

The e(4) from flywheel.

c )are each securethe rotation of the engine. The motive force of pump

uses oil as a medium to rotate turbine (2) antransmit to transmission input shaft(11).The otive force of drive case (4) is used as the

e Ogear (drive) (6).

! The oil supplied from the torque converter charging en l

passage of stator shaft (8), and flows to pump (5).il is given centrifugal force by pump (5), enters

turbine (2), and transmits the energy of the oil to thebine. t

sh (11), so the motive force is transmitted to thtransmission input shaft.The oil from turbine (2) is sent to stator (3), and

the pump again. However, part of the oil isent rom the stator through outlet port B to the

STRUCTURE AND FUNCTION TORQUE CONVERTER OIL FILTER

10-12

TORQUE CONVERTER OIL FILTER

1. Relief valve2 Element3. Center bolt4. Drain plug

SpecificationsFilter mesh size: 10 micronsFiltering area: 8900 cm²Relief pressure: 0.34 MPa (3.5 kg/cm²)

Operation! The oil from the torque converter charging pump enters filter

inlet port A. It is filtered from the outside of element (2) to theinside, and flows to outlet port B.

! If element (2) becomes clogged with dirt, or the oil temperatureis low and the pressure rises at inlet port A, the oil from inletport A opens relief valve (1) and flows directly to outlet port Bin order to prevent damage to the pump or element (2).

STRUCTURE AND FUNCTION

10-13

1. Transmission control valve Transmission 7.2. Oil filter Parking brake lever 8.3. Accumulator valve 4th gear (Teeth 33) 9.

STRUCTURE AND FUNCTION TRANSMISSION

10-14

10. Torque converter charging 15. 3rd, 4th shaft 21. 2nd clutchpump 16. Rear coupling 22. FORWARD, 2nd shaft

11. Input shaft 17. Output shaft 23. REVERSE, 1st shaft12. Torque converter 18. Front coupling 24. 1st clutch13. FORWARD clutch 19. Parking brake 25. REVERSE clutch14. 4th clutch 20. 3rd clutch 26. Input gear (Teeth 34)

STRUCTURE AND FUNCTION

10-15

! The motive forctransmission input shaft and enters the transmission.

! e forward or reverseclutches and the foand transmits the motive force from the input shaft to the output

CLUTCHREVERSE 1ST CLUTCH

7. REVERSE cutch disc (x9) a. REVERSE clutch oil port 8. REVERSE gear (Teeth 45) b. 1st clutch oil port 9. REVERSE, 1st shaft c. Lubricating oil port10. REVERSE ring gear (Teeth: 59)

5. 1st clutch disc (x5)6. REVERSE clutch plate (x10)

STRUCTURE AND FUNCTION TRANSMISSION

10-16

FORWARD, 2ND CLUTCH

1. Spacer 7. FORWARD gear (teeth: 47) a. FORWARD clutch oil port2. Thrust washer 8. FORWARD 2nd shaft b. 2nd clutch oil port3. 2nd clutch plate (x6) 9. FORWARD ring gear (teeth: 58) c. Lubricating oil port4. 2nd clutch disc (x5) 10. 2nd ring gear (Teeth: 58)5. FORWARD clutch plate (x10) 11. 2nd gear (Teeth: 27, 49)6. FORWARD clutch disc (9)

3RD, 4TH CLUTCH

1. Spacer 7. 4th gear (Teeth: 51) a. 4th clutch oil port2. Thrust washer 8. 3rd, 4th shaft b. 3rd clutch oil port3. 3rd clutch plate (x6) 9. 4th ring gear (Teeth: 59) c. Lubricating oil port4. 3rd clutch disc (x5) 10. 3rd ring gear (Teeth: 59)5. 4th clutch plate (x6) 11. 3rd gear (Teeth: 40, 52)6. 4th clutch disc (x5)

TRANSMISSION STRUCTURE AND FUNCTION

10-17

Operation of clutch

When operated! The oil sent from the transmission valve passes through the oil

passage inside shaft (1), and goes to the rear face of piston (6)to actuate the piston.

! When piston (6) is actuated, separator plate (2) is pressedagainst clutch disc (3) and forms shaft (1) and clutch gear (4)into one unit to transmit the motive force.

! Oil is drained from oil drain hole (5) at this time, but this does notaffect clutch operation since less oil is drained than supplied.

When not actuated! If the oil from the transmission valve is shut off, the pressure of

the oil acting on the rear face of piston (6) drops.! The piston is returned to its original position by wave spring (7),

so shaft (1) and clutch gear (4) are separated.! When the clutch is disengaged, the oil at the rear face of the

piston is drained by centrifugal force through oil drain hole (5),preventing the clutch from remaining partially engaged.

TRANSMISSION

10-18

Operation! the D ! driven gear (31) forms one unit with 2nd gear

(13) and 1st (32), so the power of 1st driven gear (31) passeoil pressure from the transmission valve. thr 2nd gear (32), is transmitted to 3rd gearThe power from the torque converter is transmitted and output gear (34), and is then transmitted

input shaft (11) and input gear (26) t to output shaft (17).FORWAR gear (28). FORWARD clutch (13) iengaged, so the power is transmitted to REVERSE,

Note: Inp gear (26) is always meshed with1st clutch (24) is engaged, so the rotation of VERSE gear (27) and FORWARD geaREVERSE, r (28).

TRANSMISSION STRUCTURE AND FUNCTION

10-19

FORWARD 2ND

Operation! In the case of FORWARD 2nd gear, FORWARD ! The power is transmitted from 3rd gear (33) and

clutch (13) and 2nd clutch (21) are connected by the output gear (34) to output shaft (17).oil pressure from the transmission valve.

! The power from the torque converter is transmitted Note: Input gear (26) is always meshed withfrom input shaft (11) and input gear (26) to REVERSE gear (27) and FORWARD gearFORWARD gear (28). FORWARD clutch (13) is (28).engaged, so the power is transmitted to FORWARD,2nd cylinder gear (35).

! 2nd clutch (21) is engaged, so the rotation ofFORWARD, 2nd cylinder gear (35) rotates 2nd gear(32) and is transmitted to 3rd gear (33).

STRUCTURE AND FUNCTION TRANSMISSION

10-20

FORWARD 3RD

Operation! In the case of FORWARD 3rd gear, ! 3rd clutch (20) is engaged, so the power of

FORWARD clutch (13) and 3rd clutch (20) are 3rd, 4th cylinder gear (36) is transmitted to 3rdconnected by the oil pressure from the gear (33). The power is then transmittedtransmission valve. through output gear (34) to output shaft (17).

! The power from the torque converter is transmittedfrom input shaft (11) and input gear (26) toFORWARD gear (28). FORWARD clutch (13) isengaged, so the power is transmitted to 3rd, 4thcylinder gear (36).

Note: Input gear (26) is always meshed withREVERSE gear (27) and FORWARD gear(28).

TRANSMISSION STRUCTURE AND FUNCTION

10-21

FORWARD 4TH

Operation! In the case of FORWARD 4th gear, FORWARD ! The power of 4th gear (40) is transmitted to 4th

clutch (13) and 4th clutch (14) are connected by the gear (41), which forms one unit with 3rd gear (33),oil pressure from the transmission valve. so the power passes through 3rd gear (33), is

! The power from the torque converter is transmitted transmitted to output gear (34) and output shaftfrom input shaft (11) and input gear (26) to (17).FORWARD gear (28). FORWARD clutch (13) isengaged, so the power is transmitted to 3rd, 4thcylinder gear (36). Note: Input gear (26) is always meshed with

! 4th clutch (14) is engaged, so the power of 3rd, 4th REVERSE gear (27) and FORWARD gearcylinder gear (36) is transmitted to 4th gear (37). (28).The power is then transmitted to 4th gear (38), 4thshaft (39), and 4th gear (40).

STRUCTURE AND FUNCTION TRANSMISSION

10-22

REVERSE 1ST

Operation! In the case of REVERSE 1st gear, REVERSE clutch ! 1st clutch (24) is engaged, so the power of

(25) and 1st clutch (24) are connected by the oil REVERSE, 1st cylinder gear (29) passes throughpressure from the transmission valve. 1st gear (30) and is transmitted to 1st driven gear

! The power from the torque converter is transmitted (31).from input shaft (11) and input gear (26) to ! 1st driven gear (31) forms one unit with 2nd gearREVERSE gear (27). REVERSE clutch (25) is (32), so the power of 1st driven gear (31) passesengaged, so the power is transmitted to REVERSE, through 2nd gear (32), is transmitted to 3rd gear1st cylinder gear (29). (33) and output gear (34), and is then transmitted

to output shaft (17).

TRANSMISSION CONTROL VALVE STRUCTURE AND FUNCTION

10-23

TRANSMISSION CONTROL VALVE

1. Lower valve a. Pilot oil pressure measurement port2. Upper valve b. To oil cooler3. Emergency manual spool c. From pump4. Solenoid valve port d. Pump oil pressure measurement port

e. Clutch oil pressure measurement port

STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE

10-24

UPPER VALVE

1. Upper valve body 9. Check valve2. Main regulator valve 10. Lower valve body3. Pilot reducing valve 11. Torque converter outlet valve4. Priority valve 12. FORWARD and REVERSE spool5. Modulation fill valve pressure adjusting screw 13. HIGH and LOW spool6. Modulation fill valve 14. Speed range spool7. Accumulator 15. Solenoid valve8. Quick return valve 16. Emergency manual spool

TRANSMISSION CONTROL VALVE STRUCTURE AND FUNCTION

10-25

LOWER VALVE

Outline! The oil from the pump passes through the torque They act to raise the clutch oil pressure smoothly,

converter oil filter, enters the transmission valve, and thereby reducing the shock when shifting gear.is divided into the pilot circuit and the clutch During traveling, the clutch pressure is kept theactuation circuit. same.

! The priority valve gives priority to the oil sent to the ! The pressure of the oil which flows to the circuit ispilot circuit, so the pilot pressure is always kept the adjusted by the pilot reducing valve. During gearsame. shifting, the oil flows in accordance with ON-OFF

! The pressure of the oil flowing to the clutch position of the solenoid valves and actuates theactuation circuit is adjusted by the modulation fill FORWARD, REVERSE and speed spools.valve and actuates the clutch. The oil which is ! By switching the FORWARD, REVERSE, andrelieved is sent to the torque converter. speed spools, the oil regulated by the modulation

! The quick return and modulation fill valve are fill valve is sent to the selected clutch to obtain theinterconnected during gear shifting. necessary gear combination.

STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE

10-26

TRANSMISSION SOLENOID VALVE

1. Connector2. Valve body3. 1st, 4th solenoid valve4. 3rd solenoid valve5. REVERSE solenoid valve6. FORWARD solenoid valve7. Emergency manual spool8. Lock plate

STRUCTURE! The transmission solenoid valve is installed to the

transmission together with the transmission valve.When the directional lever or speed control lever areoperated, the solenoid valve is actuated and movesthe spool inside the transmission valve.

TRANSMISSION CONTROL VALVE STRUCTURE AND FUNCTION

10-27

TORQUE CONVERTER OUTLET PORT VALVE

Function! The torque converter outlet port valve is installed in the outlet

line of the torque converter and adjusts the maximum pressureof the torque converter.

Operation! The oil at port a passes through the orifice in spool (1) and flows

to port c.

! When the pressure at port a rises, the pressure at port c alsorises. This overcomes the tension of spring (2) and movesspool (1) to the left in the direction of the arrow to allow oil toflow from port a to port b.

! If the pressure at port a becomes even higher, spool (1) ismoved further to the left in the direction of the arrow, and the oilflows from port a to port b and drain port d. (Cold relief)

STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE

10-28

PILOT REDUCING VALVE

Function! The pilot reducing valve controls the pressure used to actuate

the directional selector spool, H-L selector spool, range selectorspool.

Operation! The oil from the pump enters port a, passes through port b of

pilot reducing spool (1), enters spool (2) in the lower valve, andfills the pilot circuit.The oil at port b passes through the orifice (3)and flows to portc.

! When the pressure in the pilot circuit rises, the pressure at portc also rises. This overcomes the tension of spring (4) andmoves pilot reducing spool (1) to the right in the direction of thearrow.For this reason, port a at port b are shut off, so the pressure atport c is maintained.

TRANSMISSION CONTROL VALVE STRUCTURE AND FUNCTION

10-29

TRANSMISSION SOLENOID VALVE

Function! There are four solenoid valves installed to the transmission

control valve. When the gear shift lever in the operator'scompartment is operated, the solenoid valves are switchedON/OFF, and the oil is drained to actuate the gear shift spool.

Operation1. Solenoid valve OFF

The oil from pilot reducing valve (3) flows to ports a and b ofgear shift spools (1) and (2). The oil at ports a and b is stoppedby solenoids (4) and (5), and gear shift spools (1) and (2) moveto the right in the direction of the arrow. As a result, the oil fromthe pump flows to the 2nd clutch.

2. Solenoid valve ONWhen the gear shift lever is operated, the drain port of solenoidvalves (4) and (5) opens.The oil at ports a and b of gear shift spools (1) and (2) flowsfrom ports c and d to the drain circuit. Therefore, ports a and bbecome the low pressure circuit, and the gear shift spool ismoved to the left in the direction of the arrow by the tension ofspring (6).As a result, the oil at port e flows to the 4th clutch and theclutch is switched.

STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE

10-30

PRIORITY VALVE

Function! The priority valve gives priority to sending oil to the pilot circuit of

the lower valve. When the pressure in the circuit goes abovethe set pressure, it acts as a main relief valve to protect thecircuit.

Operation! The oil from the pump is divided into two lines. One oil flow

enters port a, passes around priority valve (2), goes through pilotreducing valve (1), and flows to the pilot circuit of the lowervalve. The other oil flow goes to priority valve (2).

! The oil flowing to priority valve (2) passes through orifice (3) andflows to port b.As a result, it pushes priority valve(2) to the left in the directionof the arrow against the force of spring (4), and flows to port c.

! When the pressure at port b goes above the set pressure,priority valve (2) is pushed further to the left in the direction ofthe arrow, and the oil is drained from port d to protect thecircuit. (The main relief function)

TRANSMISSION CONTROL VALVE STRUCTURE AND FUNCTION

10-31

MAIN REGULATOR VALVE

Function! The main regulator valve controls the flow of oil to the clutch

circuit, and sends any excess oil to the torque converter circuit.

Operation! The oil from the pump enters port a of priority valve (1), and

then passes from port c through modulation fill valve (3) andmain orifice (2), and flows to the clutch circuit.

! The oil passing through orifice (4) and entering port b moves thespool to the left in the direction of the arrow against the force ofspring (5), so the oil passes through port c and flows to thetorque converter circuit.

STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE

10-32

QUICK RETURN VALVE

Function! The pressure of the transmission clutch is raised smoothly by

the modulating action. This reduces any shock when shiftinggear and prevents the generation of peak torque and the powertrain. Therefore, it reduces operator fatigue and ensures acomfortable ride for the operator. At the same time, it alsoincreases the durability of the power train.

Operation

1. After starting engine, clutch fully engaged (clutch pressureat point A) (FORWARD 1st)

TRANSMISSION CONTROL VALVE STRUCTURE AND FUNCTION

10-33

2. When shifting from FORWARD to REVERSE(clutch pressure at point B)

! When the directional lever is moved from and the oil at port b flows to port a. At the sameFORWARD to REVERSE, FORWARD solenoid (1) time, quick return valve (6) is moved to the left incloses, REVERSE solenoid (2) opens, and the direction of the arrow by the pressure of thedirectional spool (3) moves to the right in the accumulator, and the oil from accumulator (8) isdirection of the arrow. FORWARD clutch (4) is suddenly drained from port c.connected to the drain circuit and the oil is drained. ! Accumulator (8) is returned fully to the left by the

! At the same time, the oil from the pump flows to force of spring (9).REVERSE clutch (5), but while the oil is filling the i To reduce the shock when shifting gear, theclutch, the clutch pressure is low. As a result, the oil pressure in the clutch circuit must be completelypressure at port a of quick return valve (6) also lowered and accumulator (8) must move fully todrops, so check valve (7) opens the left.

STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE

10-34

3. Clutch pressure starting to rise (clutchpressure at point C)

! The oil from the pump fills the REVERSE clutch andthe pressure in the clutch circuit starts to rise. As aresult, the pressure at port a rises, so quick returnvalve (6) is moved to the right in the direction of thearrow, and closes drain port c.

TRANSMISSION CONTROL VALVE STRUCTURE AND FUNCTION

10-35

4. Start of accumulator action, clutch completelyengaged (clutch pressure at point D)

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

STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE

10-36

MODULATION FILL VALVE

Function! The modulation fill valve adjusts the pressure and controls the

amount of oil flowing to the accumulator while allowing theclutch pressure to rise.

Operation1. Clutch completely engaged (point a)

2. Shifting from FORWARD to REVERSE! The oil inside the accumulator is drained by the quick return

valve, and accumulator piston (1) moves to the left. Whenthis happens, the pressure in chamber c and Chamber ddrops, and spring (2) moves modulation fill valve (3) to theright to open port a.

TRANSMISSION CONTROL VALVE STRUCTURE AND FUNCTION

10-37

3. Clutch pressure starting to rise (point c point d)! When the oil from the pump fills the clutch piston, the

pressure in the clutch circuit starts to rise. When thishappens, the drain circuit of the quick return valve is closed.

! When the drain circuit of the quick return valve closes, theoil passing through port a enters chamber d and pressureP2 in chamber d starts to rise. When the relationshipbetween P1 and P2 becomes P2 > P1 + P3 (tension ofspring (2)), the fill valve moves to the left, shuts off port a,and prevents the clutch pressure from rising suddenly.

! At the same time as the oil from port a flows to thedirectional spool, the relationship is P2 > P1, so oil alsopasses through the orifice in the quick return valve andflows into chamber c. P1 rises and P2 also rises at thesame time. This process is repeated while maintaining therelationship P2 = P1 + P3 (tension of spring (2)), and theclutch pressure rises.

! The oil from the torque converter outlet port circuit formsthe pilot pressure to the modulation fill valve and flows toport e. The pressure at port e changes according to theengine speed. The relationship is P2 = P1 + P3 + P4(changes according to engine speed), so if pressure P4changes, pressure P2 also changes by the same amount.Therefore, pressure P2 rises at the same time by the sameamount that pressure P4 changes, so it is possible to createoil pressure characteristics that matches the engine speed.

STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE

10-38

DIRECTIONAL SELECTOR SPOOL

Operation

1. When at neutral! Solenoid valves (4) and (5) are OFF and the drain port is

closed. The oil from the pilot circuit passes through the oilhole in the emergency manual spool and fills ports a and bof the directional spool.In this condition, P1 + spring force (1) = P2 + spring force(2), so the balance is maintained. Therefore, the oil at portc does not go to the FORWARD or REVERSE clutch.

2. When at FORWARD! When the directional lever is placed at the FORWARD

position, solenoid valve (4) is switched ON and drain port dopens. The oil which is filling port a is drained, so P1 +spring force (1) < P2 + spring force (2). When thishappens, the directional spool moves to the left, and the oilat port c flows to port e and is supplied to the FORWARDclutch.

TRANSMISSION CONTROL VALVE STRUCTURE AND FUNCTION

10-39

EMERGENCY MANUAL SPOOL

Function! If there should be any failure in the electrical circuit and the

directional solenoid valve does not work, this spool can beoperated manually to engage the FORWARD or REVERSEclutch.

Operation

1. Emergency manual spool at neutral ! The oil from the upper valve (pilot reducing valve) passes

around emergency manual spool (1), and is blocked bysolenoid valves (2) and (3).

! When the operating condition is normal, the emergencymanual spool is at the neutral position.

2. Emergency manual spool actuated (FORWARD)! When emergency manual spool (1) is pushed in, port a and

the drain port are connected, so the oil in chamber b isdrained. As a result, directional spool (4) moves to the leftin the direction of the arrow, and the oil flows to theFORWARD clutch to engage the clutch.

STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE

10-40

OPERATION OF FORWARD 1ST

TRANSMISSION CONTROL VALVE STRUCTURE AND FUNCTION

10-41

! The oil from pump (1) passes through priority valve (2) and isdivided to the pilot circuit and clutch actuation circuit.

! When the gear shift lever is operated to FORWARD 1st,FORWARD solenoid (3) and gear shift solenoid (6) areactuated. The oil filling ports a and b is drained and directionalspool (7) and gear shift spool (9) move to the left.

! When directional spool (7) moves, the oil flows from clutchpressure port c to port d, and engages the FORWARD clutch.

! Gear shift solenoid (5) is closed, and H-L spool (8) is pushedfully to the right, so the oil flows from clutch pressure port e toport f, passes through spool (9) and engages the 1st clutch.

! When the oil completely fills the clutch cylinder, the action ofaccumulator (10) and quick return valve (11) raises the oilpressure gradually, and when it reaches the set pressure, theFORWARD and 1st clutches are completely engaged.

STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE

10-42

ACCUMULATOR VALVE

1. Piston (for 2nd clutch) Outline 2. Piston (for 1st clutch) ! The accumulator valve is installed in the FORWARD, 3. Body 1st, 2nd clutch circuit. When the transmission shifts 4. Piston (for FORWARD clutch) gear, the accumulator valve slowly reduces the oil 5. Spring (for FORWARD clutch) pressure to the clutch that was first engaged in order to 6. Stopper (for FORWARD clutch) prevent loss of torque and to reduce the transmission 7. Cover shock when shifting gear. It temporarily stores the 8. Spacer (for FORWARD clutch) clutch oil pressure in order to allow gear shifting to be 9. Spacer (for 1st clutch) carried out smoothly without any time lag. (To make it10. Spacer (for 2nd clutch) possible to reduce the oil pressure to the clutch slowly,11. Stopper (for 1st clutch) there are throttles installed in the directional spool, H-L12. Spring (for 1st clutch) spool and range spool of the transmission control13. topper (for 2nd clutch) valve.)14. Spring (for 2nd clutch)

TRANSMISSION CONTROL VALVE STRUCTURE AND FUNCTION

10-43

Operation

1. Shifting down when digging (kick-down F2 öö Fl)When the transmission is in F2, oil pressure is stored in the 2ndclutch accumulator.When the kick-down is operated, the Fl clutch is engaged, butthe oil pressure in the accumulator is maintained for the 2ndclutch until the torque is transmitted to the 1st clutch. In thisway, it is possible to shift gear smoothly without losing thetorque.

2. Moving out after digging (Fl öö R2)When the transmission is in Fl, oil pressure is stored in theaccumulator for the FORWARD clutch and 1st clutch.When shifting to R2 after completing digging operations, the R2clutch is engaged, but the oil pressure for the FORWARDClutch and 1st clutch is maintained in the accumulator. Thismakes it possible to reduce the loss of torque due to thereaction force to the product being handled, and to move backsmoothly without shock.

STRUCTURE AND FUNCTION TRANSMISSION CONTROL

10-44

TRANSMISSION CONTROL

1. Directional lever Outline2. Gear shift lever ! With the transmission control, an electrical signal is3. Gear shift lever stopper sent to the transmission solenoid valves when the4. Turn indicator, lamp, dimmer switch directional and gear shift levers are operated. This

opens or closes the solenoid valves and moves thespool inside the transmission valve.

DRAIVE SHAFT STRUCTURE AND FUNCTION

10-45

DRIVE SHAFT

1. Front drive shaft ! The drive shaft has the following purpose in2. Flange bearing addition to simply transmitting the power. The drive3. Center drive shaft shaft has a universal joint and sliding joint to enable4. Rear drive shaft it to respond to changes in the angle and length.

Outline force when the machine is articulated and to! The motive force from the engine passes through protect the components from damage from shock

the torque converter and the transmission. Some of when the machine is being operated or shock fromit is transmitted from rear drive shaft (4) to the rear the road surface when the machine is traveling.axle, while the rest goes from center drive shaft (3)through flange bearing (2) and front drive shaft (1)to the front axle.

This enables the drive shaft to transmit the motive

STRUCTURE AND FUNCTION AXLE

10-46

AXLEFRONT AXLE

AXLE STRUCTURE AND FUNCTION

10-47

FRONT DIFFERENTIAL

1. Side gear (No. of teeth: 12)2. Pinion gear (No. of teeth: 9)3. Shaft4. Bevel gear (No. of teeth: 47)5. Sun gear shaft6. Bevel pinion (No. of teeth: 13)

STRUCTURE AND FUNCTION AXLE

10-48

REAR AXLE

1. Oil supply port2. Differential3. Differential housing4. Wet-type single-disc brake5. Final drive6. Axle housing7. Axle shaft8. Drain plug9. Level plug

AXLE STRUCTURE AND FUNCTION

10-49

REAR DIFFERENTIAL

1. Side gear (No. of teeth: 12)2. Pinion gear (No. of teeth: 9)3. Shaft4. Bevel gear (No. of teeth: 47)5. Sun gear shaft6. Bevel pinion (No. of teeth: 13)

STRUCTURE AND FUNCTION AXLE

10-50

Outline! The motive force from the engine is transmitted to the front and

rear axles via the torque converter, the transmission and thepropeller shaft.

! In the axle, the motive force is transmitted from pinion gear (1)to bevel gear (5), shifted 90E and reduced, and transmitted tosun gear shaft (2) via differential (4).

! The motive force of the sun gear is further reduced by planetarygear-type final drive, and transmitted to the axle shaft andwheel.

When moving straight forward! When moving straight forward, the speed of rotation of the left

and right wheels is equal, so pinion gear (4) in the differentialassembly does not rotate, and the motive force of carrier (6) istransmitted equally to the left and right sun gear shafts (2) viathe pinion gear (4) and side gear (3).

When slewing! When slewing, the speed of rotation of the left and right wheels

is unequal, so pinion gear (4) and side gear (3) in thedifferential assembly rotate according to the difference in the leftand right rotation speeds, and the motive force of carrier (6) istransmitted to the sun gear shafts (2).

AXLE STRUCTURE AND FUNCTION

10-51

TORQUE PROPORTIONING DIFFERENTIAL

Function! Because of the nature of their work, 4-wheel drive loaders have

to work in places where the road surface is bad. In such places,if the tires slip, the ability to work as a loader is reduced, andalso the life of the tire is reduced. The torque proportioningdifferential is installed to overcome this problem.

! In structure it resembles the differential of an automobile, butdifferential pinion gear (4) has an odd number of teeth.Because of the difference in the resistance from the roadsurface, the position of meshing of pinion gear (4) and side gear(3) changes, and this changes the traction of the left and righttires.

OperationWhen traveling straight (equal resistance from road surface toleft and right tires)! If the resistance from the road surface to the left and right

wheels is the same, the distance between pinion gear (4) andmeshing point "a" of left side gear (7) is the same as thedistance between pinion gear (4) and meshing point "b" of rightside gear (3).

! Therefore the left side traction TL and the right side traction TRare balanced.

When traveling on soft ground (resistance from road surface toleft and right tires is different)! On soft ground, if the tire on one side slips, the side gear of the

tire on the side which has least resistance from the road surfacetries to rotate forward. Because of this rotation, the meshing ofpinion gear (4) and side gear changes.

! If left side gear (7) rotates slightly forward, the distance betweenthe pinion gear and the meshing point "a" of the left side gearbecomes longer than the distance between the pinion gear andthe meshing port "b" of the right side gear. The position isbalanced as follows.a x TL = b x TRThe ratio between the distances to "a" and "b" can change to 1: 1.38.

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

STRUCTURE AND FUNCTION AXLE

10-52

FINAL DRIVE

1. Sun gear shaft (Teeth 15) Outline2. Ring gear (Teeth 69) ! As the final function the final drive operates to3. Planetary gear (Teeth 26) reduce the rotative speed of the motive force from4. Planetary carrier the engine and increases the driving force.5. Axle shaft ! Ring gear (2) is press-fitted in the axle housing and

fixed in place by a pin.! The motive force transmitted from the differential to

the sun gear shaft (1) is reduced using a planetarygear mechanism, increasing the driving force. Theincreased driving force is transmitted to the tires viaplanetary carrier (4) and axle shaft (5).

MEMORANDA STRUCTURE AND FUNCTION

10-53

MEMORANDA

STRUCTURE AND FUNCTION AXLE MOUNT

10-54

AXLE MOUNT

AXLE MOUNT STRUCTURE AND FUNCTION

10-55

1. Front axle FRONT AXLE2. Front frame ! Front axle (1) receives the force directly during3. Rear frame operations, so it is connected directly to front frame4. Rear axle (2) by tension bolt (5).5. Tension bolt6. Pivot REAR AXLE

! The rear axle (4) has a structure which allows thecenter of the rear axle to float, so that all tires canbe in contact with the ground when traveling oversoft ground.

STRUCTURE AND FUNCTION CENTER HINGE PIN

10-56

CENTER HINGE PIN

1. Front frame Outline2. Rear frame ! The front frame (1) and rear frame (2) are3. Upper hinge pin connected through a bearing by the center hinge4. Lower hinge pin pin (3), (4). The steering cylinders are connected

to the left and right front and rear frames, so whenthe cylinders are operated, the frame bends at themiddle to give the desired angle, that is the desiredturning radius.

STEERING PIPING STRUCTURE AND FUNCTION

10-57

STEERING PIPING

1. Main control valve2. Steering valve (orbit-roll)3. Hydraulic tank4. Priority valve5. Hydraulic pump6. Steering pump7. Cushion valve8. Steering cylinder

STRUCTURE AND FUNCTION STEERING COLUMN

10-58

STEERING COLUMN

1. Steering wheel2. Steering column3. Steering valve (orbit-roll)

PRIORITY VALVE STRUCTURE AND FUNCTION

10-59

PRIORITY VALVE

Outline 1. Plug! The priority valve is in the circuit between the 2. Valve body

steering pump and the steering valve. It acts to 3. Spooldivide the flow of oil from the steering pump and 4. Return springsend it to the steering valve or oil cooler circuit. It 5. Plugalso sets the oil pressure in the circuit from the 6. Relief valve bodypriority valve to the steering valve to 18.6 MPa (190 7. Spring seatkg/cm²) to protect the circuit. 8. Valve spring

9. Poppet10. Seat11. ScreenA. To steering valveB. To main control valveC. From steering valveD. DrainE. From pump

STRUCTURE AND FUNCTION PRIORITY VALVE

10-60

Operation

1. Steering wheel at neutralWhen the engine is stopped, spool. (3) are pushed fully to theleft by the tension of spring (4). In this condition, the circuitsbetween ports M and N are fully open, while the circuits betweenports M and Q are fully closed.If the engine is started and the steering pump start to turn, theoil from the pump goes from port M to port N, and then entersport A of the steering valve.The oil entering port A is throttled by orifice a, so the pressure inthe circuit rises.When this happens, the oil passing through orifices m in spool(3) enters port P. It then compresses spring (4), and movesspool (3) to the right in the direction of the arrow. This stabilizesthe condition so that the circuits between ports M and Q arealmost fully open and the circuits between ports M and N arealmost fully closed. Therefore, the oil from the steering pumpalmost all flows to the work equipment circuit.

2. Steering wheel turned to leftWhen the steering wheel is turned to the left, an angle variationis generated between the spool and sleeve of the steering valve,and the oil flow is switched. (For details, see STEERINGVALVE.)The oil from the pump flows from port M to port N, and entersport A. The degree of opening of the sleeve (port A) and spool(port B) of the steering pump creates a difference between thepressure up to port A and the pressure beyond port B. Some ofthe oil from port B flows to the Girotor E, and then goes to thefront right cylinder. The remaining oil passes through orifice b,flows to port J, and then enters port R. When this happens,spool (3) stabilizes at a position where the differential pressurebetween the circuit up to port A and circuit beyond port B(pressure of port P - pressure of port R) and the load of spring(4) are balanced. It adjusts the degree of opening from port Mto ports N and Q, and distributes the flow to both circuits. Theratio of this distributed flow is determined by the degree ofopening of port A and port B, in other words, the angle variationbetween the sleeve and spool of the steering valve. This degreeof opening is adjusted by the amount the steering wheel isturned.

PRIORITY VALVE STRUCTURE AND FUNCTION

10-61

3. Steering cylinder at end of strokeIf the operator tries to turn the steering wheel further when thesteering cylinder has reached the end of its stroke, the circuitfrom port M through port N to port S is kept open and thepressure rises.When this pressure rises above 18.6 MPa (190 kg/cm²), reliefvalve (10) opens and the oil is relieved to the hydraulic tank.Because of this flow of oil, a differential pressure is created onboth sides of orifice r. Therefore, the balance is lost between theload of spring (4), and the pressure up to port A and thepressure beyond port B. As a result, the pressure up to port Abecomes relatively higher.For this reason, the pressure at port P moves spool (3) evenfurther to the right from the condition in Item 2. It stabilizes thecondition at a position where the circuits between ports M and Nare almost fully closed, and the circuits between ports M and Qalmost fully open.

STRUCTURE AND FUNCTION CUSHION VALVE

10-62

CUSHION VALVE

1. Valve seat 6. Plug 11. Poppet2. Valve body 7. Spring3. Spring 8. Spool4. Poppet 9. Plug L. Steering cylinder5. Orifice 10. Spring R. Steering cylinder

Outline orifice (5) and goes to the pressure chamber of plug! When There is a reaction to the sudden rise in the (6). When it becomes greater than the pressure at port

pressure of the steering cylinder, the cushion valve L and force of spring (7), it pushes spool (8) fully to theacts to prevent shock by relieving the momentary left. This shuts off the flow of high pressure oil fromhigh pressure oil to another line. port R through poppet (4) to port L. This temporary

Function flow of oil has a cushion effect. The valve is not! If high pressure oil suddenly enters from port R, the actuated any further, so there is no effect on the

high pressure oil compresses spring (3), and pushes steering, and the steering operates as normal.open poppet (4). It then passes through the center ! When the pressure rises slowly and there is nogroove of spool (8), goes through poppet (11) of port need for any cushion effect, spool; (8) closes moreL, and Flows to port L. quickly than poppet (4) opens so there is no

! At that time, the high pressure oil passes through unnecessary cushion action.

MEMORANDA STRUCTURE AND FUNCTION

10-63

MEMORANDA

STRUCTURE AND FUNCTION STEERING VALVE

10-64

STEERING VALVE (ORBIT-ROLL)

STEERING VALVE STRUCTURE AND FUNCTION

10-65

Outline! The steering valve is connected directly to the shaft of the

steering wheel. It switches the flow of oil from the steering pumpto the left and right steering cylinders to determine the directionof travel of the machine.

! The steering valve, broadly speaking, consists of the followingcomponents: rotary type spool (3) and sleeve (5), which havethe function of selecting the direction, and the Girotor set (acombination of rotor (8) and stator (9), which acts as a hydraulicmotor during normal steering operations, and as a hand pump(in fact, the operating force of the steering wheel is too high, soit cannot be operated) when the steering pump or engine havefailed and the supply of oil has stopped.

Structure! Spool (3) is directly connected to the drive shaft of the steering

wheel, and is connected to sleeve (5) by center pin (4) (it doesnot contact the spool when the steering wheel is at neutral) andcentering spring (12).

! The top of drive shaft (6) is meshed with center pin (4), andforms one unit with sleeve (5), while the bottom of the drive shaftis meshed with the spline of rotor (8) of the Girotor.

! There are four ports in valve body (2), and they are connectedto the pump circuit, tank circuit, and the circuits at the head endand bottom end of the steering cylinders. The pump port andtank port are connected by the check valve inside the body. Ifthe pump or engine fail, the oil can be sucked in directly fromthe tank by this check valve.

STRUCTURE AND FUNCTION STEERING VALVE

10-66

OPERATION1. Steering wheel at neutral.

STEERING VALVE STRUCTURE AND FUNCTION

10-67

! When the steering wheel is at neutral, centering spring (12)makes spool (3) and sleeve (5) stop at a position where centerpin (4) is at the center of the oblong hole in spool (3).At this point, pump port A of the sleeve and ports E, F, and G tothe steering cylinder and Girotor, and vertical grooves B, C, andD of the spool are shut off.However, orifice a of pump port A is connected to orifice d(connected to drain port H) of the spool.Orifice b of port J from the priority valve is connected to verticalgroove B of the spool.In addition, port K of the sleeve is connected to drain port L ofthe spool and vertical groove B.

! By shutting off and connecting these ports and grooves, the oilfrom the pump passes from port A through orifices a and d, andis drained to the hydraulic tank.In addition, the oil which forms the pilot pressure of the priorityvalve passes from port J through orifice b, then through verticalgroove B and port K, and is returned to the hydraulic tank fromport L.

STRUCTURE AND FUNCTION STEERING VALVE

10-68

2. Steering wheel turned (turning to left)

STEERING VALVE STRUCTURE AND FUNCTION

10-69

! When the steering wheel is turned to the left, spool flows from port G to the head end of the right(3), which is connected by the spline of the steering cylinder.shaft, also turns to the left. The spool and sleeve The oil entering vertical groove B passes through(5) are interconnected by centering spring (12), so orifice b and flows to port J. From port J, itthe spool compresses the centering spring. becomes the pilot pressure of the priority valve.Therefore, a difference in the angle of rotation The oil from the head end of the left cylinder enters(angle variation) is generated between the spool and vertical groove D from port F and is drained to thesleeve equal to the amount that the centering spring hydraulic tank.is compressed.When this happens, first, port A and vertical groove 3. Steering wheel stoppedB are connected. Then vertical groove B and port When the operation of the steering wheel isE to the Girotor, and port E from the Girotor to stopped, the difference in rotation between thevertical groove C are connected. Finally, vertical spool and sleeve is returned to the neutralgroove C and port G to the head end of the right condition by the reaction of centering spring (12).cylinder are connected.In addition, vertical groove B is kept connected toorifice b of port J to the priority valve, but port K ofthe sleeve gradually closes the connection ofvertical groove B and port L.Port F from the head end of the left cylinder isconnected to vertical groove D (connected to drainport H) at the same time as port A and verticalgroove B are connected.

! By shutting off and connecting the above ports andgrooves, the oil from the pump enters verticalgroove B from port A, then flows to port E to theGirotor, and turns the Girotor. The oil dischargedfrom the Girotor enters vertical groove C from portE, and

STRUCTURE AND FUNCTION STEERING VALVE

10-70

CONNECTION BETWEEN HAND PUMP AND SLEEVE

! The diagrams above show the connections with the sleeve portsused to connect the suction and discharge ports of the Girotor.

! If the steering wheel has been turned to the right, ports a, c, e,g, i and k are connected by the vertical grooves in the spool tothe pump side. At the same time, ports b, d, f, h, j, and I areconnected to the head end of the left steering cylinder in thesame way. In the condition in Fig. 1, ports 1, 2, and 3 are thedischarge ports of the Girotor set. They are connected to portsl, b, and d, so the oil is sent to the cylinder.Ports 5, 6, and 7 are connected and the oil flows in from thepump.If the steering wheel is turned 90E, the condition changes to thecondition shown in Fig. 2. In this case, ports 1, 2, and 3 are thesuction ports, and are connected to ports i, k, and c. Ports 5, 6,and 7 are the discharge ports, and are connected to ports d, f,and h.

STEERING VALVE STRUCTURE AND FUNCTION

10-71

! In this way, the ports acting as the discharge ports of the Girotorare connected to the ports going to the steering cylinder, whilethe ports acting as the suction ports are connected to the pumpcircuit.

! Adjustment of discharge according to amount steering wheel isturned.For each 1/7 turn of the steering wheel, the inside teeth of theGirotor advance one tooth, and the oil from the pump isdischarged in an amount that matches this movement.Therefore, the amount of oil discharged is directly proportionalto the amount the steering wheel is turned.

Role of centering spring

! Centering spring (12) consists of four X-shaped leaf springs andtwo flat leaf springs. It is assembled between spool (3) andsleeve (5) as shown in the diagram on the right. When thesteering wheel is turned, the spool compresses the spring, anda difference (angle variation) is generated in the turning angleof the spool and sleeve.

! Centering spring (12) consists of four X-Shaped leaf springs andtwo flat leaf springs. It is assembled between spool (3) andsleeve (5) as shown in the diagram on the right. When thesteering wheel is turned, the spool compresses the spring, anda difference (angle variation) is generated in the turning angleof the spool and sleeve.As a result, the port of the spool and sleeve is connected and oilis sent to the cylinder.However, when the rotation of the steering wheel is stopped, therotation of the Girotor also stops, so no more oil is sent to thecylinder, and the oil pressure rises.To prevent this, when the turning of the steering wheel isstopped, the action of the centering spring only allows it to turnby an amount equal to the difference in angle of rotation (anglevariation) of the sleeve and spool, so the steering wheel returnsto the NEUTRAL position.

STRUCTURE AND FUNCTION BRAKE PIPING

10-72

BRAKE PIPING

Outline 1. Front axle! Brake booster (7) consists of a hydraulically actuated boosting 2. Right brake pedal

mechanism. It is designed to reduce the operating force of the 3. Left brake pedalpedal, and to ensure a powerful braking force. 4. Rear axle

! When the brake pedal is depressed, the oil sent from the pump 6. Rear brakeshuts off the transmission circuit inside the valve and actuates 7. Brake boosterthe piston to apply the front and rear brakes. 8. Transmission cut-off switch

! A relief valve is installed in the circuit to protect the circuit fromdamage if any abnormal pressure should be generated in the oilsent from the pump.

5. Brake oil tank

9. Front brake

BRAKE CONTROL STRUCTURE AND FUNCTION

10-73

BRAKE CONTROL

STRUCTURE AND FUNCTION BRAKE BOOSTER

10-74

BRAKE BOOSTER

Outline 1. Dust cover! The brake booster is a boosting system to increase the braking 2. Spool

force. It increases the pressure in the master cylinder in 3. Relief valveproportion to the operating force by using the oil pressure 4. Cylinder coverdelivered from the oil pump. 5. Power piston

6. Return spring (for power piston) 7. Return spring (for connector) 8. Connector 9. Reaction spring10. Reaction piston11. Secondary piston12. Primary piston

BRAKE BOOSTER STRUCTURE AND FUNCTION

10-75

Operation

Brake OFF! When the push rod connected to the brake pedal is returned,

spool (2), connector (8), and power piston (5) are returnedtowards cylinder cover (4) by return springs (6) and (7).Therefore, primary piston assembly (12) and secondary pistonassembly (11) of the master cylinder are each in their respectiveneutral positions. The respective pressures in the chambers Eand F (the chambers connected to the discharge port) passthrough the relief port and are released to atmospheric pressurechambers C and D in the reservoir.The oil from the pump flows from port A to port B and then flowsinto the transmission circuit.In addition, the oil in the master cylinder is connected to the frontand rear axles.

Hydraulic pressure starting to rise! When the brake pedal is depressed, the push rod connected to

the pedal compresses reaction spring (9) and moves spool (2)forward. Connector (8) is pushed towards the power piston byreturn spring (7), so the passage between power piston (5) andspool (2) is restricted. A difference in pressure is generatedbetween the front and rear walls of the power piston, so thepower piston moves forward, pushes connector (8), andactuates secondary piston assembly (11) of the master cylinder.

STRUCTURE AND FUNCTION BRAKE BOOSTER

10-76

Hydraulic force rising! When secondary piston (11) moves forward and primary cup

(13) closes relief port (14), pressure is generated in chamber E.Reaction piston (10) (piston with small diameter) built intosecondary piston (11) moves to the rear and is in continuouscontact with the tip of spool (2). The pressure generated in themaster cylinder and bearing on the area of reaction piston (10)passes through push rod (16) and is transmitted to the pedal asthe operating force.

! The pressure generated at chamber E of secondary piston (11)of the master cylinder is also generated at the same time inchamber F of primary piston (12).

! In addition, when the brake pedal is depressed, power piston (5)moves to the right, and the pressure of the oil in chamber E andchamber F rises, so the braking force of the front brake and rearbrake is also increased.

Relief valve! When the brake is being operated, if the pressure inside the

power cylinder (port A) goes above the specified level, reliefvalve (3) is actuated. The oil is relieved to the transmissioncircuit to prevent abnormal pressure in the brake system.

! If there should be any failure in the hydraulic pump sending oilto the power cylinder, the operating force of the pedal istransmitted through spool (2) and connector (8), so the piston inthe master cylinder can be actuated. However, when thishappens, the operating force of the brake pedal is heavier thanusual.

BRAKE BOOSTER STRUCTURE AND FUNCTION

10-77

Brake actuated (oil leaking from front brake)! The brake oil tanks from independent systems, so if there is any

leakage of oil in either the front or rear brake systems, only oneof the brakes (front or rear) will be applied.This increases the safety and ensures that the machine canalways be stopped.

Brake pedal released! When the pedal is released, spool (2) is returned by reaction

spring (9), so the passage between spool (2) and power piston(5) is restricted. It is released to the same conditions as whennot actuated (brake OFF), and the difference in pressurebetween front and rear chambers of power piston (5) isremoved, so the power piston and connector (8) are acturnedby return springs (6) and (7). Following this, the pistons of themaster cylinders are also returned to the neutral position by theirrespective return springs. The relief ports are connected to thereservoir, and the pressure returns to atmospheric pressure.

STRUCTURE AND FUNCTION BRAKE

10-78

BRAKE

1. Differential housing 4. Disc 7. Axle housing2. Piston 5. Outer ring 8. Sun gear shaft3. Inner ring 6. Bearing carrier

Function! The brake is a wet-type, single disc brake. It consists Inner ring (3) is installed to the notched part of bearing

of piston (2), inner ring (3), disc (4), and outer ring (5). carrier (6). Outer ring (5) is secured to axle housing (7)

! The brake cylinder consists of differential housing (1)and bearing carrier (6). Piston (2) is assembled inside ! Disc (4) has a lining stuck on both faces. It isthe brake cylinder. assembled between inner ring (3) and outer ring (5). It

by pin.

is connected by the spline of the sun gear shaft.

BRAKE STRUCTURE AND FUNCTION

10-79

OperationBrake applied! When the brake pedal is depressed, the rod of the master

cylinder is pushed. Oil pressure P is generated, and this acts onthe piston inside the brake cylinder to slide piston (6) slightly.Therefore, the rotation of disc (4), which is between inner ring(3) and outer ring (5), is stopped, and the brakes. are applied tostop the machine.

Brake released! When the oil pressure is released, piston (6) moves back slightly

because of the return force of piston O-ring (9). A gap iscreated between inner ring (3) and outer ring (5), so disc (4) isfree.Grooves are cut in a lattice pattern on the lining stuck to disc (4).When the disc is rotating, oil flows in these grooves to cool thelining.

STRUCTURE AND FUNCTION PARKING BRAKE CONTROL

10-80

PARKING BRAKE CONTROL

Outline 1. Parking brake pedal! When parking brake pedal (1) is depressed, control cable (3) 2. Parking brake release lever

pulls brake lever (4) up and actuates the multiple disc brake 3. Control cableinstalled to the output shaft of the transmission. 4. Parking brake lever

! To release the parking brake, pull parking brake release lever(2).

! When the parking brake is applied, the neutralizer relay acts toshut off the electric current to the transmission solenoid valveand keep the transmission at neutral.

5. Transmission

PARKING BRAKE STRUCTURE AND FUNCTION

10-81

PARKING BRAKE

Outline 1. Transmission! The parking brake is a mechanically operated wet type multiple 2. Parking brake lever

disc brake which applies braking force to transmission output 3. Discshaft (5). 4. Plate

! Lever (2) is connected to the control cable, and when the lever 6. Ballis pulled, ball (6), which is between cover (7) and piston (8) 7. Coverconnected to the lever, moves on the slope of the piston groove. 8. PistonThe piston pushes the discs and plates together, and appliesbraking force to output shaft (5).

5. Transmission output shaft

STRUCTURE AND FUNCTION HYDRAULIC PIPING

10-82

HYDRAULIC PIPING

1. Bucket cylinder2. Boom cylinder (R.H.)3. Steering valve4. Hydraulic tank5. Priority valve6. Hydraulic pump7. Steering pump8. Main control valve9. Boom cylinder (L.H.)

HYDRAULIC PIPING STRUCTURE AND FUNCTION

10-83

Outline

! The hydraulic system consists of the work equipment circuit andthe steering circuit. The work equipment circuit controls theoperation of the boom, bucket, or other attachments.

! The oil from the hydraulic tank (4) is sent from the hydraulic andsteering pump (6)and steering pump (7) to the priority valve (5).The amount of oil flow is controlled and sent to main controlvalve (8). If the bucket and boom spools of main control valveare at neutral, the oil passes through the drain circuit of the maincontrol valve, is filtered by the filter inside hydraulic tank (4), andreturns to the tank.

! When the work equipment control lever is operated, the bucketor boom spool of main control valve (8) move, oil flows frommain control valve (8) to the boom cylinders (2) and (9) or tobucket cylinder (1), and operates the boom or bucket.

! The maximum pressure of the hydraulic circuit is controlled bypriority valve (5) and the relief valve inside the main controlvalve. A safety valve (with suction) is installed in the bucketcylinder circuit to protect the circuit.

! Hydraulic tank (4) is a pressurized sealed typed and has abreather with a relief valve. It pressurizes the inside of the tankand also prevents negitive pressure in order to prevent cavitationof the pump.

STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM

10-84

WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM(Engine low idling, work equipment in “HOLD”)

WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM STRUCTURE AND FUNCTION

10-85

WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM

1. Hydraulic tank 7. Overload valve 13. Boom spool2. Filter 8. Steering cylinder 14. Suction valve3. Steering pump 9. Cushion valve 15. Bucket cylinder4. Hydraulic pump 10. Relief valve 16. Boom cylinder5. Priority valve 11. Safety valve (with suction) 17. Oil cooler (option)6. Steering valve (Orbit-rol valve) 12. Bucket spool

STRUCTURE AND FUNCTION HYDRAULIC TANK

10-86

HYDRAULIC TANK

Outline! The oil from the hydraulic tank is sent from the pump through 1. Cap breather

the priority valve and main control valve to each cylinder. It 2. Air bleed plugmerges in the return circuit with the oil from various parts, is 3. Oil filter bypass valvefiltered by the oil filter, and returns to the tank. 4. Oil filer

! The oil filter filters the whole oil flow in the circuit. When the oil 6. Drain plugfilter becomes clogged, the bypass valve is actuated to allow theoil to return directly to the tank and prevent damage to the filter.

5. Oil level gauge

HYDRAULIC TANK STRUCTURE AND FUNCTION

10-87

OIL FILTER BYPASS VALVE

When the filter is clogged! By-pass valve (1) opens and the oil returns directly to the tank

without passing through the filter (2).

By-pass valve set pressure: 0.15 MPa (1.5 kg/cm²)

When negative pressure is formed in the return circuit.! By-pass valve (1) moves up and acts check valve.

Check valve set pressure: 0.024 MPA (0.24 kg/cm²)

STRUCTURE AND FUNCTION HYDRAULIC TANK

10-88

BREATHER

Preventing negative pressure inside tank! The tank is a pressurized sealed type, so if the oil level inside

the hydraulic tank goes down, there will be negative pressure inthe tank. If this happens, a sleeve (2) is opened by thedifference between the pressure inside the tank and theatmospheric pressure, and air is let in to prevent negativepressure from forming inside the tank.

Preventing rise in pressure inside tank! If the pressure in the circuit rises above the set pressure during

operations because of the change in the oil level in the hydrauliccylinders or the rise in the temperature, the poppet (5) isactuated to release the pressure inside the hydraulic tank.

1. Cover2. Sleeve3. Spring4. Spring5. Poppet6. Filter element

MEMORANDA STRUCTURE AND FUNCTION

10-89

- MEMORANDA -

STRUCTURE AND FUNCTION MAIN CONTROL VALVE

10-90

MAIN CONTROL VALVE2-SPOOL VALVE

A. To bucket cylinder rod endB. To boom cylinder rod endC. Drain port (to tank)D. To boom cylinder bottom sideE. To bucket cylinder bottom sideF. From pump

MAIN CONTROL VALVE STRUCTURE AND FUNCTION

10-91

1. Main relief valve2. Bucket spool3. Boom spool4. Magnet for boom5. Magnet for bucket6. Safety valve (with suction)7. Suction valve8. Check valve

STRUCTURE AND FUNCTION MAIN CONTROL VALVE

10-92

3-SPOOL VALVE

A. To attachment cylinderB. To bucket cylinder rod sideC. To boom cylinder rod sideD. Drain port (to tank)E. To boom cylinder bottom sideF. To bucket cylinder bottom sideG. To attachment cylinderH. From pump

MAIN CONTROL VALVE STRUCTURE AND FUNCTION

10-93

1. Main relief valve 6. Magnet for bucket2. Attachment spool 7. Safety valve (with suction)3. Bucket spool 8. Suction valve4. Boom spool 9. Check valve5. Magnet for boom

STRUCTURE AND FUNCTION MAIN CONTROL VALVE

10-94

RELIEF VALVE

FunctionThe relief valve is installed to the inlet portion of the main controlvalve. If the oil goes above the set pressure, the relief valvedrains the oil to the tank to set the maximum pressure for thework equipment circuit, and to protect the circuit.

Operation! Port A is connected to the pump circuit and port C is connected

to the drain circuit. The oil passes through the orifice in mainvalve (1), and fills port B. Pilot poppet (3) is seated in valve seat(2).

! If the pressure inside ports A and B reaches the set pressure ofpilot poppet spring (4), pilot poppet (3) opens and the oilpressure at port B escapes from port D to port C, so thepressure at port B drops.

! When the pressure at port B drops, a difference in pressurebetween ports A and B is created by the orifice of main valve (1).The main valve is pushed open and the oil at port A passesthrough port C, and the abnormal pressure is released to thedrain circuit.

! The set pressure can be changed by adjusting the tension ofpilot poppet spring (4). To change the set pressure, remove thecap nut, loosen the locknut, then turn adjustment screw (5) toadjust the set pressure as follows.TIGHTEN to INCREASE pressureLOOSEN to DECREASE pressure

1. Main valve2. Valve seat3. Pilot poppet4. Spring5. Adjustment screw

MAIN CONTROL VALVE STRUCTURE AND FUNCTION

10-95

SAFETY VALVE (WITH SUCTION)

Function! The safety valve is in the bucket cylinder circuit inside the main

control valve. If any abnormal pressure is generated by anyshock to the cylinder when the main control valve is at theneutral position, this valve relieves the abnormal pressure toprevent damage to the cylinder.

OperationOperation as safety valve! Port A is connected to the cylinder circuit and port B is

connected to the drain circuit. The oil pressure at port A is sentto port D from the hole in pilot piston (4). It is also sent to portC by the orifice formed from main valve (2) and pilot piston (4).Pilot piston (4) is secured to the safety valve, and the size of thecross-sectional surface (cross-sectional area) has the followingrelationship: d2 > d1 > d3 > d4.

! If abnormal pressure is created at port A, suction valve (1) is notactuated because of relationship d2 > d1>, but relationshipbetween port A and port C is d3 > d4, so main valve (2) receivesoil pressure equivalent to the difference between the areas ofd3 and d4. If the oil pressure reaches the force (set pressure) ofmain valve spring (3), main valve (2) is actuated, and the oilfrom port A flows to port B.

1. Suction valve2. Main valve3. Main valve spring4. Pilot piston5. Suction valve spring6. Valve body

STRUCTURE AND FUNCTION MAIN CONTROL VALVE

10-96

Operation as suction valve! If any negative pressure is generated at port A, port D is

connected with port A, so there is also negative pressure at portD. The tank pressure of port B is applied to port E, so thesuction valve (1) receives oil pressure a, which is equal to thedifference in the area of d2 and d1 because of the tank pressureat port E. Therefore, oil pressure e moves the valve in thedirection of opening, and oil pressure a acts to move suctionvalve (1) in the direction of closing.When the pressure at port A drops (and comes close tonegative pressure), it becomes lower than hydraulic pressure e.The relationship becomes oil pressure e > oil pressure a + forceof valve spring (5), and suction valve (1) opens to let the oil fromport B flow into port A and prevent any negative pressure fromforming at port A.

SUCTION VALVE

Function! This valve acts to prevent any negative pressure from forming

in the circuit.

Operation! If any negative pressure is generated at port A (boom cylinder

rod end) (when a pressure lower than tank circuit port B isgenerated), main poppet (1) is opened because of thedifference in area between d1 and d2, and oil flows from port Bat the tank end to port A at the cylinder port end.

1. Main poppet2. Sleeve3. Spring

MAIN CONTROL VALVE STRUCTURE AND FUNCTION

10-97

Boom and bucket spool at NEUTRAL position

Operation! The oil from hydraulic pump (1) passes through the priority

valve, and enters port A. The maximum pressure is set by reliefvalve (2).

! Bucket spool (3) is at the NEUTRAL position, so the bypasscircuit is open and the oil in chamber A passes around the spooland flows to port B. Boom spool (4) is also at the NEUTRALposition, so the bypass circuit is open and the oil in chamber Bpasses around the spool, enters chamber C of the drain circuit,passes through the filter, and returns to the tank.

STRUCTURE AND FUNCTION MAIN CONTROL VALVE

10-98

Boom spool at RAISE position

Operation! When the work equipment control lever is pulled, boom spool

(4) is pulled out to the RAISE position.

! The oil from the pump flows through the by-pass circuit of thebucket spool and flows to the by-pass circuit of boom spool (4).The by-pass circuit is closed by the spool, so the oil from port Bpushes check valve (5) open. The oil from port B then flowsfrom port E to the bottom end of the cylinder.

! At the same time, the oil at the cylinder rod end flows from portD to drain port C and returns to the tank. As a result, the boomis raised.

MAIN CONTROL VALVE STRUCTURE AND FUNCTION

10-99

Boom spool at LOWER position

Operation! When the work equipment control lever is pushed, boom spool

(4) is pushed in to the LOWER position.

! The oil from the pump flows through the by-pass circuit of thebucket spool and flows to the by-pass circuit of boom spool (4).The by-pass circuit is closed by the spool, so the oil from port Bpushes check valve (5) open. The oil from port B then flowsfrom port D to the rod end of the cylinder.

! At the same time, the oil at the cylinder bottom end flows fromport E to drain port C and returns to the tank. As a result, theboom is lowered.

STRUCTURE AND FUNCTION MAIN CONTROL VALVE

10-100

Boom spool at FLOAT position

Operation! If the work equipment control lever is pushed beyond the

LOWER position, boom spool (4) is pushed into the FLOATposition.

! The oil from the pump passes around the by-pass circuit of thebucket spool and flows to the boom spool by-pass circuit. Theoil in the by-pass circuit is sent to the drain circuit by the spooland cannot push open check valve (5). Both the RAISE circuitE and LOWER circuit D of the boom cylinder are connected tothe drain circuit, so the boom goes down under its own weight.

! When the bucket is in contact with the ground surface, thebucket can move up or down in accordance with the shape ofthe ground surface.

MAIN CONTROL VALVE STRUCTURE AND FUNCTION

10-101

Bucket spool at TILT BACK position

Operation! When the work equipment control lever is pulled, bucket spool

(3) is pulled out to the TILT BACK position.

! The by-pass circuit is closed by the spool, so the oil from port Apushes open check valve (7). The oil from port A then flows toport H of the bottom end of the cylinder.

! At the same time, the oil at the cylinder rod end flows from portG to drain port C, and returns to the tank. As a result, the bucketis tilted back.

STRUCTURE AND FUNCTION MAIN CONTROL VALVE

10-102

Bucket spool at DUMP position

Operation! When the work equipment control lever is pushed, bucket spool

(3) is pushed in to the DUMP position.

! The by-pass circuit is closed by the spool, so the oil from port Apushes open check valve (7). The oil from port A then flowsfrom port G to the rod end of the cylinder.

! At the same time, the oil at the cylinder bottom flows from portH to drain port C, and returns to the tank, As a result, thebucket is tilted forward.

WORK EQUIPMENT LEVER LINKAGE STRUCTURE AND FUNCTION

10-103

WORK EQUIPMENT LEVER LINKAGE

1. Bucket boom control lever2. Kick-down switch3. Lock lever4. Main control valve

STRUCTURE AND FUNCTION WORK EQUIPMENT LINKAGE

10-104

WORK EQUIPMENT LINKAGE

1. Bellcrank2. Bucket cylinder3. Boom cylinder4. Boom5. Bucket link6. Bucket

WORK EQUIPMENT LINKAGE STRUCTURE AND FUNCTION

10-105

STRUCTURE AND FUNCTION BUCKET

10-106

BUCKET

1. Bucket (1.7 m )3

2. Bolt-on cutting edge (BOC)

BUCKET POSITIONER AND BOOM KICK-OUT STRUCTURE AND FUNCTION

10-107

BUCKET POSITIONER AND BOOM KICK-OUT

1. Bucket cylinder rod2. Lever3. Proximity switch4. Proximity switch

STRUCTURE AND FUNCTION BUCKET POSITIONER AND BOOM KICK-OUT

10-108

BUCKET POSITIONER! The bucket positioner is an electrically actuated system which

is used to set the bucket to the desired angle when the bucketis moved from the DUMP position to the TILT position. Whenthe bucket reaches the desired position, the bucket control leveris returned from the TILT position to the HOLD position, and thebucket is automatically set to the suitable digging angle.

! Lever (2) is secured to the bucket cylinder rod (1) by bolts. Inaddition, proximity switch (3) is fixed to the cylinder by bolts.

! When the bucket is moved from the DUMP position to the TILTposition, the bucket cylinder rod moves to the left, and at thesame time, lever (2) also moves to the left. Proximity switch (3)separates from lever (2) at the desired position, and the bucketcontrol lever is returned to neutral.

BOOM KICK-OUT! The boom kick-out is an electrically actuated system. It acts to

move the boom control lever to the HOLD position and stop theboom at the desired position before the boom reaches themaximum height.

! Plate is fixed to the boom. In addition, proximity switch (4) is fixedto the frame. When the boom is moved from the LOWERposition to the RAISE position, the boom rises, and when itreaches the desired position, the proximity switch and levercome together and the system is actuated to return the boomcontrol lever to the HOLD position.

PROXIMITY SWITCH STRUCTURE AND FUNCTION

10-109

PROXIMITY SWITCHOperation! The proximity switches are installed to the boom and bucket

cylinders by a support. In accordance with the operatingcondition, a pulse is generated from the sensor at the desiredpoint when moving to the boom RAISE position and bucket TILTBACK position. This electric current is transmitted to a magnet,and the boom and bucket control lever is returned to neutral.Therefore, the main control valve also returns to neutral and themovement of the boom and bucket are stopped.

STRUCTURE AND FUNCTION PROXIMITY SWITCH

10-110

OPERATION OF THE PROXIMITY SWITCH

Bucket TILT BACK switch! If the bucket is dumped beyond the set position for

the bucket positioner, the detector plate is abovethe detector surface of the bucket proximity switch,so the proximity switch sends the battery current tothe magnet switch coil.

! When the bucket lever is operated to the TILTBACK position, the bucket spool is held at the TILTBACK position by the magnet at the bucket spooldetent of the main control valve, and the bucket istilted back.

! When the bucket tilts back and reaches the setposition for the bucket positioner, the detector plateseparates from the proximity switch detectorsurface. When this happens, the proximity switchcuts the electric current to the magent coil. Thebucket spool is then returned to the neutral positionby the return spring.

Boom RAISE switch! When the boom is lowered below the set position

for the boom kick-out, the detector plate is abovethe detector surface of the boom proximity switch,so the proximity switch sends the battery current tothe magnet switch coil.

! Now when the boom lever is operated to the RAISEposition, the boom spool is held at the RAISEposition by the boom spool detent magnet of themain control valve, and the boom rises.

! When the boom rises and reaches the set positionfor the boom kick-out, the detector plate seperatesfrom the proximity switch detector surface. Whenthis happens, the proximity switch cuts the electriccurrent to the magnet coil. The boom spool is thenreturned to the neutral position by the return spring.

ACTION OF THE PROXIMITY SWITCH

POSITION

Proximity switch When detector is positioned at detection When detector is separated from detectionsurface of proximity switch. surface of proximity switch.

Boom, Bucket Proximity switch sends electric current to Proximity switch cuts electric current toProximity Switch magnet coil. Magnet is actuated. magnet coil. Magnet is not actuated.

ROPS CAB STRUCTURE AND FUNCTION

10-111

ROPS CAB

STRUCTURE AND FUNCTION AIR CONDITIONER

10-112 Î

AIR CONDITIONERAIR CONDITIONER AND HEATER PIPING

1. Vent2. Air conditioner condenser3. Dry receiver4. Compressor5. Hot water inlet port6. Hot water outlet port7. Air conditioner unit8. Water valve

AIR CONDITIONER STRUCTURE AND FUNCTION

10-113 Î

ELECTRIC CIRCUIT DIAGRAM(Eagle air conditioner/ Heater)

NOTES:1. Position the ambient temperature probe near waist high level, out of air flow and sun load.2. Insert the sensing tube from present thermostat down into the evaporator coil, parallel to the coil face, between the

1st and 2nd rows, to a depth of the coil height minus 1 inch.

Wire chart

Socket Size Color Wire function1 10GA Red Battery positive in

2 18GA Red ½ evap coil thermostat in

3 18GA Black ½ ambient thermistor in

4 18GA Red ½ evap coil thermostat in

5 N/A N/A Not used

6 18GA Black ½ ambient thermistor in

7 14GA Orange Fan positive out

8 16GA Dk. Green Clutch out

9 18GA DK. Blue Ignition switch in

10 14GA Black Fan negative out

11 18GA Brown Condenser blown fuse in

12 16GA White Heat solenoid out

13 18GA Tan Pressure switch detect in

14 16GA Yellow Condenser fan relay out

15 12GA Black Battery negative in

16 N/A N/A Not used

STRUCTURE AND FUNCTION E.C.S.S.

10-114

E.C.S.S. (ELECTRONIC CONTROLLED SUSPENSION SYSTEM)

Outline 1. Accumulator (ACC1)! The E.C.S.S. is a system to suppress the travel vibration when 2. Accumulator (ACC2)

traveling on unpaved surfaces, snow, or other rough road 3. Solenoid valvesurfaces at high speed, or when traveling loaded. It is effective 4. Actuation selector switchin reducing the vibration of the chassis and makes it possible to 5. Main control valvecarry out stable travel operations.

E.C.S.S. STRUCTURE AND FUNCTION

10-115

E.C.S.S. HYDRAULIC, ELECTRICAL CIRCUIT DIAGRAM

System actuation table

Actuation selector Boom cylinder bottom pressure Solenoid valve actuation Actuation ofswitch system

MPa (kg/cm ) SOL1 SOL2 SOL32

OFF 0 - (0 -) - - - Not actuated

ON

0 - 5.9 (0 - 60) O O O ACC1 actuated

5.9 - 14.7 (60 - 150) O O - ACC2 actuated

14.7 - (150 -) - - - Not actuated

STRUCTURE AND FUNCTION E.C.S.S.

10-116

OPERATION

1. Boom cylinder 3. Accumulator 6. Solenoid selector switch2. Actuation selector switch 4. Pressure switch 7. Main control valve

! With this system, there are two interconnected ! For this reason, when traveling unloaded,accumulators (3) charged with gas under different accumulator (3) ACC1 acts as a spring, and whenpressures. These two accumulators are installed traveling loaded, ACC2 acts as a spring.between the bottom end of boom cylinder (1) and ! Even if the operator forgets to switch actuationmain control valve (6). selector switch (2) when operating, if the pressureThe two accumulators (3) are equipped with at the bottom end goes above PSW2, solenoidpressure switches (4) and solenoid selector valves selector valve (5) is automatically switched and the(5) to open and close the oil circuit. There is also a circuit of accumulator (3) is closed, so accumulatorfurther solenoid selector valve (5) between the (3) is protected from any axcessive pressurehead end of boom cylinder (1) and control valve (6) generated at the bottom end.to open or close the flow of oil to the cylinder head.

! The pressures (ACC1, ACC2) of the gas in the twoaccumulators (3) and the set pressure (PSW1,PSW2) of the two pressure switches (4) are set asfollows:’ ACC1 < Load pressure at bottom end when

empty < ACC2 < Load pressure at bottom endwhen loaded.

’ Load pressure at bottom end when empty <PSW1 < Load pressure at bottom end whenloaded < PSW2.

E.C.S.S. STRUCTURE AND FUNCTION

10-117

1. Actuation selector switch OFF! Solenoid selector valves (1), (2), and (3) are at the shut-off

position, so the system is not actuated.

2. Actuation selector switch ON, traveling unloaded, boomcylinder bottom pressure: 0 - 5.9 Mpa (0 - 60 kg/cm )2

! Accumulators ACC1 and ACC2 are both interconnected,but gas pressure of accumulator ACC2 > boom cylinderbottom pressure, so ACC2 is not actuated as a spring. Onlyaccumulator ACC1 is acyuated as a spring.

STRUCTURE AND FUNCTION E.C.S.S.

10-118

3. Actuation selector switch ON, traveling loaded, boomcylinder bottom pressure: 5.9 - 14.7 Mpa (60 - 150 kg/cm )2

! Electricity flows to pressure switch (1) and solenoid selectorvalve (3) is at the shut-off position, so only accumulatorACC2 is actuated as a spring.

4. Actuation selector switch ON, excess pressure generated,boom cylinder bottom pressure: above 14.7 Mpa (150kg/cm )2

! Electricity flows to both pressure switches (1) and (2), andsolenoid selector valves (1), (2), and (3) are at shut-offposition, so the system is not actuated, and no excesspressure is brought to bear on accumulator ACC1 or ACC2.

ELECTRICAL WIRING ILLUSTRATION STRUCTURE AND FUNCTION

10-119

ELECTRICAL WIRING ILLUSTRATION

1. Central panel 13. License lamp2. Bucket positioner proximity switch 14. Rear combination lamp3. Head lamp 15. Battery4. Transmission cut-off switch 16. Fuel level sensor5. Staring switch 17. Battery relay6. Combination switch 18. Transmission solenoid valve7. Fuse box 19. Directional lever8. Parking brake switch 20. Gear shift lever9. Slow blow fuse 21. Wiper switch10. Alternator 22. Horn11. Water temperature sensor 23. Boom kick-out proximity switch12. Working lamp

STRUCTURE AND FUNCTION CENTRAL PANEL

10-122

CENTRAL PANEL (CLUSTER GAUGE)

1. Service meter indicator 11. Working lamp switch 2. Fuel gauge 12. Parking brake pilot lamp 3. Turn signal pilot lamp 13. Engine oil pressure warning lamp 4. Speedometer 14. Battery charge warning lamp 5. Head lamp high beam pilot lamp 15. Transmission cut-off selector lamp 6. Coolant temperature gauge 16. Emergency steering lamp 7. Torque converter oil temperature gauge 17. Brake boost pressure warning lamp 8. Brake oil level warning lamp 18. Transmission cut-off selector switch 9. Working lamp pilot lamp 19. Emergency steering lamp10. Preheating pilot lamp 20. Service meter

SENSOR STRUCTURE AND FUNCTION

10-123

SENSORENGINE OIL PRESSURE

Function! The engine oil pressure sensor is installed to the engine block

and detects the oil pressure. If the oil pressure goes below thespecified pressure, it lights up the engine oil pressure warningpilot lamp on the cluster gauge to warn the operator of theabnormality.

BRAKE OIL LEVEL

Function! The brake oil level sensor is installed to the top of the brake oil

tank. When the brake oil goes below the specified level, thefloat goes down and the switch is turned on. This lights up thebrake oil level lamp on the cluster gauge to warn the operatorof the abnormality.

1. Plug2. Contact ring3. Contact4. Diaphragm5. Spring6. Terminal

1. Cap2. Ring3. Float4. Connector5. Tank6. Diaphragm

STRUCTURE AND FUNCTION ENGINE STARTING CIRCUIT

10-124

ENGINE STARTING CIRCUIT

Function! A neutral safety circuit is used to prevent the engine ! If the starting switch is turned to the START

from starting if the directional lever is not at the N position, current flows from starting switchposition. This ensures safety when starting the terminals B - C ö neutral relay terminals 5 - 3 öengine. starting motor terminal S ö ground, and a circuit is

Operation starting motor terminal B, so the engine starts.! When the directional lever is placed at the N ! If the directional lever is not at the N position, circuit

position, the N contacts of the directional lever (1) is not formed, so the engine does not start.switch are closed.

! When the starting switch is turned to the ONposition, Electric current flows from battery (+)östarting switch terminal B - BRö battery relay. Thebattery relay is closed, so current flows in thefollowing circuit: (1) battery(+)ö slow blowfuseödirectional switch terminal N ö neutral relayterminals 1 - 2 ö ground, and the relay coil isexcited. When this happens, neutral relay terminals3 - 5 are closed.

! In addition, electric current flows from switchterminal ACCUMULATOR ö Fuel shut-off solenoidö ground, and then releases the stop lever of thefuel injection pump to the FULL position to set theoperating condition.

also formed from the battery öbattery relay ö

ENGINE STOP CIRCUIT STRUCTURE AND FUNCTION

10-125

ENGINE STOP CIRCUIT

Function! The system is equipped with an electrical fuel cut device ( Fuel

shut-off solenoid) which makes it possible to start the engine byturning the switch ON or OFF. This improves the ease ofoperation.

Operation! When the starting switch is turned OFF, starting switch terminals

B and ACC are opened.! The current in the Fuel shut-off solenoid is shut off by the

starting switch, so the coil is not excited. Therefore, the stoplever of fuel injection pump is released to the stop position andshuts off the fuel supply to the injection pump, causing theengine to stop.

STRUCTURE AND FUNCTION AUTOMATIC PREHEATING CIRCUIT

10-126

AUTOMATIC PREHEATING CIRCUITQUICK HEATING SYSTEM (Q.H.S.)

OUTLINE! To make it easier to start the engine in cold weather, ! When the starting switch is turned to the START

a Q.H.S. (Quick Heating System) automatic position while preheating, it assumes the enginepreheating system is installed. This consist of a has started and immediately stops the preheating.controller, a water temperature sensor, and a large Operationcapacity ribbon heater. ! When the starting switch is turned to the ON

! The Q.H.S. automatically sets the preheating time to position, A signal flows from the starting switchmatch the coolant temperature simply by turning the terminal ACC to Q.H.S. controller terminal 4. Thestarting switch ON. It also acts to reduce the controller instantaneously detects the waterpreheating time. temperature and determines the length of time for

! When the starting switch is turned to the ON lighting up the preheating pilot lamp and theposition, the preheating pilot lamp lights up, and the preheating time for the ribbon heater.ribbon heater carries out preheating while the lamp ! Controller terminal 5 is connected to the ground,is lit up. The water temperature sensor detects the and lights up the preheating pilot lamp. At thewater temperature and the preheating time is set by same time, it sends a signal from terminal 2 to thethe controller. heater relay to actuate the heater relay and make

! While the preheating pilot lamp is lit up, preheating the ribbon heater red hot.is being carried out, so keep the starting switch at ! When the preheating end signal is sent from thethe ON position. When the engine reaches a controller, the heater relay is turned OFF andtemperature which makes it possible to start the preheating is completed.engine, the preheating pilot lamp goes out, so theengine can be started.

AUTOMATIC PREHEATING CIRCUIT STRUCTURE AND FUNCTION

10-127

! The diagrams on the right show the actuation sequence. (Fig.1, Fig. 2)

! The diagrams on the right show lighting up time T1 for thepreheating lamp and preheating/post heating time T2 accordingto the water temperature. (Fig. 3, Fig. 4)

STRUCTURE AND FUNCTION AUTOMATIC PREHEATING CIRCUIT

10-128

Q.H.S. CONTROLLER

1. Q.G.S. controller body2. Lead wire3. Connector

HEATER RELAY

AUTOMATIC PREHEATING CIRCUIT STRUCTURE AND FUNCTION

10-129

RIBBON HEATER

Q.H.S. WATER TEMPERATURE SENSOR

STRUCTURE AND FUNCTION ELECTRICAL TRANSMISSION CONTROL

10-130

ELECTRICAL TRANSMISSION CONTROL

Function1 Electrical control is used to actuate the transmission solenoid and select the F,R, or

Directional lever staring switch is turned to the START position. This is to prevent any accident if the

N position.

2 If the directional lever is not at the N position, the engine will not start even if the

machine should start suddenly. (For details, see ENGINE STARTING CIRCUIT)

3 When traveling in reverse, it lights up the backup lamp to warn people in thesurrounding area.

4 Gear shift lever Electrical control is used to actuate the transmission solenoid and select the speedrange.

5 Transmission cut-off This is used to select between actuation and non actuation of the transmission cut-selector switch off function.

6 Transmission cut-off When the left brake pedal is pressed, the transmission is returned to neutral and theswitch normal brake is actuated (transmission cut-off function)

7 Parking brake switch To prevent seizure of the parking brake, the transmission is returned to neutral whenthe parking brake is applied.

8 Kick-down switch When traveling in F2, it is possible to operate the switch to shift down to F1 with-outmoving the gear shift lever. If the gear shift lever is moved to the R or N position, thespeed range is automatically returned to the original 2nd position.

COMBINATION SWITCH STRUCTURE AND FUNCTION

10-131

COMBINATION SWITCH

Outline! The directional lever has three positions and the Each switch is positioned by two pins, and is secured to

speed lever switch has four positions. As an the body by three screws. When each lever is operatedindividual part, the switch does not have a detent to the desired position, the switch, which ismechanism; the detent mechanism is in the interconnected by a shaft, acts to allow electric currentcombination switch. to flow to that circuit only.

General locations, function1 Directional lever switch Switches between F, R, and N

2 Speed lever switch Selects speed range

3 Speed lever stopper Stopper used to prevent speed lever from entering 3rd or 4thduring operations

4 Turn signal indicators Direction indicator lamps used when turning left or right

5 Self cancel Turn signal indicator lever automatically returns to central positionafter machines turns left or right

6 Turn signal indicators Switches on clearance lamp, head lamp, parking lamp, etc.

7 Dimmer switch Selects high beam for travel and low beam for passing

8 Hazard switch Makes both left and right turn signal indicator lamps flash at thesame time

9 Emergency flashing pilot lamp Flashes at the same time as the emergency flashing lamp flashes

STRUCTURE AND FUNCTION TRANSMISSION CUT-OFF FUNCTION

10-132

TRANSMISSION CUT-OFF FUNCTIONOutline! If the transmission cut-off selector switch on the cluster gauge

is turned ON (pilot lamp lights up), the transmission cut-offswitch installed to the left brake pedal is actuated. When the leftbrake is operated, the brake is applied and the transmission isalso shifted to neutral at the same time.

! If the transmission cut-off selector switch is turned OFF (pilotlamp goes out), the transmission is not shifted to neutral and theleft brake operates in the same way as the right brake.

Operation1. Transmission cut-off selector switch ON! If the transmission cut-off selector switch is turned ! When the left brake pedal is depressed, the

ON, a voltage of +24V is applied to the transmission cut-off switch is turned OFF, and thetransmission F solenoid or R solenoid through the electric current to the FORWARD relay ortransmission cut-off switch to the neutralizer relay REVERSE relay is cut. As a result, theö FORWARD relay or REVERSE relay. transmission is shifted to neutral in addition to theElectric current flows from the directional lever to normal operation of the brake.the FORWARD relay or REVERSE relay, so therelay coil is excited and a circuit is formed.

COMBINATION SWITCH STRUCTURE AND FUNCTION

10-133

2. Transmission cut-off selector switch OFF! If the transmission cut-off selector switch is turned OFF, a

voltage of +24V is applied to the transmission F solenoid or Rsolenoid from the transmission cut-off selector switch öneutralizer relay ö FORWARD relay or REVERSE relay. Thetransmission cut-off switch does not form part of this circuit.

! If the left brake pedal is depressed, the transmission is notshifted to neutral. The brake is simply applied as a normalbrake.

STRUCTURE AND FUNCTION PARKING BRAKE FUNCTION

10-134

PARKING BRAKE FUNCTION

Outline! When the parking brake is applied, the transmission is kept at

neutral. This means that even when the engine is run at fullthrottle, there is no load on the parking brake, and this preventsany dragging caused by mistaken operation.

Operation! When the parking brake pedal is depressed, the parking brake

switch is turned ON, an electric current flows from theneutralizer relay coil to the parking brake switch ö ground, andthe neutralizer relay coil is excited.

! As a result, the neutralizer relay is actuated, so the circuit is cut.No electric current flows to the FORWARD relay or REVERSErelay and the transmission is placed in neutral.

KICK-DOWN SWITCH STRUCTURE AND FUNCTION

10-135

KICK-DOWN SWITCH

KICK-DOWN SWITCH

Operation! The kick-down (shifting down from 2ndû 1st) is actuated only

when traveling in F2.! When traveling in F2, if it is desired to shift down to lst without

operating the speed lever, operate the kick-down switch on theboom lever to ON to shift down to F1.

! After this, even if the kick-down switch is pressed, thetransmission is kept at F1.

Cancellation (or not actuated)! When directional lever is at N! When directional lever is at R! When speed lever is not at 2nd! When starting switch is OFF

STRUCTURE AND FUNCTION KICK-DOWN SWITCH

10-136

KICK DOWN ELECTRIC CIRCUIT DIAGRAMNormal operation

Directional lever operated to F Gear shift lever operated to 2nd! When the directional lever is operated to the F ! When the gear shift lever is at the 2nd position, no

position, current flows from battery ¾ ö directional electric current flows to solenoids (2), (3), or (4). In thislever switch terminals 1 - 2 ö FORWARD relay condition, the transmission valve is set to F2 by theterminals 5 - 6 ö ground. As a result, the action of solenoid (1).FORWARD relay is actuated and terminals 1 and 2 ! If the kick-down switch is not pressed, no electricand terminals 3 and 4 are connected. current will flow to the kick-down relay coil (relay

! Next, electric current flows from battery ¾ ö terminals 5, 6). Therefore, the kick-down relay is nottransmission cut-off switch ö neutralizer relay actuated and the transmission is held in F2.terminals 3 - 6 ö FORWARD relay terminals 3 - 4 ösolenoid (1) ö ground, and solenoid (1) is actuated. Solenoid actuation tableSpeed lever set to 2

F1 F2 F3 F4 N R1 R2 R3 R4

1 F M F F

2 F F F F

3 F F F F

4 F F F F

KICK-DOWN SWITCH STRUCTURE AND FUNCTION

10-137

KICK-DOWN SWITCH OPERATED(During operation or during travel when gear shift lever is at F2)

Kickdown switch pushed to ON position! When the kickdown switch is pushed, current flows ! In this way, if the kick-down switch is pressed when the

from battery ¾ ö directional lever switch terminal 1 ö gear shift lever is at F2, the gear is shifted down to F1.gear lever switch terminal 6 ö FORWARD relay The self-hold function of the kick-down relay thenterminals 1-2 ö kickdown switch ö kickdown relay keeps the transmission in F1 even if the kick-downterminals 5 - 6 ö ground. As a result, the kickdown switch is released or pressed several times.relay is actuated and terminals 1 and 2 and terminals3 and 4 are connected. Solenoid actuation table

! A circuit is formed from gear shift lever switchterminal 6 ö FORWARD relay terminals 1 - 2 ökick-down relay terminals 1 - 2 ö terminals 5 - 6 öground. From this point, even if the kick-down switchis returned, the kick-down relay continues to beactuated (kick-down relay self-hold circuit). When thekick-down relay is actuated and terminals 3 and 4 areconnected, electric current flows from battery ¾ ökick-down relay terminals 3 - 4 ö solenoid (4) öground, and solenoid (4) is actuated. Solenoid (1) isalso being actuated, so the speed range is set to F1.

F1 F2 F3 F4 N R1 R2 R3 R4

1 M F F F

2 F F F F

3 F F F F

4 M F F F

STRUCTURE AND FUNCTION KICK-DOWN SWITCH

10-138

KICK-DOWN SWITCH ACTUATION - CANCELED (1)(Directional lever at N or R)

! If the directional lever is moved to the R position, the terminals 1 and 2, and terminals 3 and 4 arecontacts of terminal F are turned OFF, so the current connected, and solenoid (2) is actuated.flowing from FORWARD relay terminals 5 - 6 ö ! Therefore, there is no electric current flowing toground stops flowing, the FORWARD relay is reset, solenoids 1, 3, or 4, so the transmission is set to R2, theand FORWARD relay terminals 1 and 2, and position of the gear shift lever.terminals 3 and 4 separate.

! When FORWARD relay terminals 1 and 2 separate, Solenoid actuation tablethe electric current stops flowing from kick-down relayterminals 1 - 2 ö terminals 5 - 6 ö ground, the kick-down relay is reset, and the self-hold circuit iscanceled. (The self-hold circuit is also canceled atthe N position.)

! When the kick-down relay is reset, the electric currentflowing from kick-down relay terminal 3 - 4 ösolenoid (4) ö ground stops flowing and the actuationof solenoid (4) is canceled.

! When the directional lever is moved to the R position,electric current flows from battery ¾ ö directionallever switch terminals 1 - 4 ö REVERSE relayterminals 5 - 6 ö ground, so REVERSE relay

F1 F2 F3 F4 N R1 R2 R3 R4

1 F F F F

2 F M F F

3 F F F F

4 F F F F

KICK-DOWN SWITCH STRUCTURE AND FUNCTION

10-139

KICK-DOWN SWITCH ACTUATION - CANCELED (2)(Gear shift lever at position other than 2nd)

! If the gear shift lever is moved to any position other ! If the gear shift lever is placed in 3rd, electric currentthan 2nd, the current flowing from gear shift lever flows from gear shift lever switch terminal 7 ö solenoidrelay terminal 6 ö FORWARD relay terminals 1 - 2 (3) ö ground, and solenoid (3) is actuated. Solenoidö kickdown relay terminals 1 - 2 ¾ ö terminals 5 - 6 (1) is being actuated, so the transmission is set to F3,ö ground stops flowing, and kickdown relay terminals the position of the gear shift lever.1 and 2, and terminals 3 and 4 separate.

! When kick-down relay terminals 1 - 2 separate, the Solenoid actuation tableself-hold circuit is canceled, and the kick-down is notactuated even if the gear shift lever is moved again toF2.

! At the same time, kick-down terminals 3 - 4 alsoseparate, so the actuation of solenoid (4) is canceled.

F1 F2 F3 F4 N R1 R2 R3 R4

1 F F M F

2 F F F F

3 M F F F

4 F F F F

STRUCTURE AND FUNCTION KICK-DOWN SWITCH

10-140

KICK-DOWN SWITCH ACTUATION - CANCELED (3)(Starting switch turned to OFF)

! When the starting switch is turned to the OFFposition, the battery ¾ power source is cut off bythe battery relay, and the kickdown self-hold circuitis canceled.

! When the starting switch is at the OFF position, thekick-down switch is not actuated even if the kick-down switch is pressed ON.

20-1 Î

20 TESTING AND ADJUSTINGStandard value table for engine . . . . . . . . . . . . . . . . 20- 2 ÎStandard value table for chassis . . . . . . . . . . . . . . . . . 20- 4Tools for testing, adjusting & troubleshooting . . . . . . . 20- 8Measuring engine speed . . . . . . . . . . . . . . . . . . . . . . 20-10Measuring engine lubrication oil pressure . . . . . . . . . 20-11Measuring fuel filter inlet restriction . . . . . . . . . . . . . . 20-11Measuring blow-by pressure . . . . . . . . . . . . . . . . . . . 20-11Measuring compression pressure . . . . . . . . . . . . . . . 20-12Measuring exhaust gas color . . . . . . . . . . . . . . . . . . . 20-13Measuring coolant temperature . . . . . . . . . . . . . . . . . 20-14Measuring and adjusting valve clearance . . . . . . . . . 20-14Measuring accelerator pedal . . . . . . . . . . . . . . . . . . . 20-15Measuring operating force, travel of speed lever . . . . 20-17Measuring stall speeds . . . . . . . . . . . . . . . . . . . . . . . 20-18Measuring torque converter, transmission, Measuring work equipment hydraulic pressure . . . . . 20-43

oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . 20-20Method of operating emergency manual spool . . . . . 20-22

Testing and adjusting steering wheel . . . . . . . . . . . . 20-24Measuring steering oil pressure . . . . . . . . . . . . . . . . . 20-26Measuring operating force, travel of brake pedal . . . 20-28Testing and adjusting brake pedal linkage . . . . . . . . 20-29Measuring brake performance . . . . . . . . . . . . . . . . . . 20-31Testing brake oil pressure . . . . . . . . . . . . . . . . . . . . . 20-32Testing for brake disc wear . . . . . . . . . . . . . . . . . . . . 20-33Bleeding air from brake system . . . . . . . . . . . . . . . . . 20-34Measuring parking brake performance . . . . . . . . . . . 20-35Testing and adjusting parking brake linkage . . . . . . . 20-36Testing wear of parking brake disc . . . . . . . . . . . . . . 20-37Measuring parking brake disc wear . . . . . . . . . . . . . . 20-38Measuring work equipment control lever . . . . . . . . . . 20-39Measuring stroke of work equipment valve spool . . . 20-42

Measuring work equipment . . . . . . . . . . . . . . . . . . . . 20-45Testing and adjusting bucket positioner . . . . . . . . . . 20-47Testing and adjusting boom kick-out . . . . . . . . . . . . 20-48Troubleshooting TABLE OF CONTENTS . . . . . . . 20-101

* See ENGINE SHOP MANUAL.

i When using the standard value tables to make judgement for testing, adjusting, and troubleshooting, the following precautions are necessary:1. The standard values in the tables are the values for a new machine and are given as reference values for the time when the machine

is shipped from the factory. These values should be used as a guide when estimating wear after the machine is operated, and whencarrying out repairs.

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

3. These standard values do not form a basis for judging claims.

When carrying out testing, adjusting, or troubleshooting, park the machine on level ground and use the safety pins and blocks to prevent themachine from moving

When carrying out work together with co- workers, always use signals and do not let unauthorized people near the machine.

When checking the coolant level, always wait for the coolant to cool down. If the radiator cap is removed when the coolant is still hot, thecoolant will spurt out and cause burns.

Be careful not to get caught in the fan, fan belt or other rotating parts.

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE

20-2 Î

STANDARD VALUE TABLE FOR ENGINE - In Chassis

Machine model WA180-3L

Engine model Komatsu S6D102E-1

Item Measurement condition Unit Standard value for Service limitnew machine value

Engine speeds rpmHigh idle 2650 ±50 2650 ±50

Low idle 850 ±25 850 ±25

Engine rating kW/rpm 88/2400 88/2400Rated gross power / ratedspeed

Intake manifold At T.C. stall and W.O.T.pressure (Wide Open Throttle)

mm Hg 850-950 850-950

Intake air restriction mm H O Max. 635At T.C. stall and W.O.T. at New element: 380restriction indicator port Used Element: 6352

Lubricating oil kPa 70 0.70pressure with SAE (kg/cm²) (0.70) (0.70)15W-40 oil & coolanttemperature in Minimum at rated speed & kPa 276 276operating range load (kg/cm²) (2.81) (2.81)

Minimum at low idle

Fuel filter inlet Maximum restriction at highrestriction idle

mm Hg 100 200

Blow-by pressure mm H O 180

Coolant temperature inoperating range:C Service Tool orifice size: 3605.613 mmAt T.C. stall and W.O.T.With SAE 15W-40 oil

2

Exhaust back Maximum at T.C. stall andpressure W.O.T.

mm Hg 77 77

Coolant temperature Maximum operatingtemperature

EC (EF) 100 (212) 100 (212)

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

20-3

Machine model WA180-3L

Engine model Komatsu S6D102E-1

Item Measurement condition Unit Standard value for Service limitnew machine value

Valve clearance Engine cold: mm 0.25 0.25Intake valves 0.51 0.51

Exhaust valves

Engine stall speeds: C Coolant temperature inoperating range

C Torque converter oil 2500 ± 100 2500 ± 200temperature in operating rpmrange

C Hydraulic oil at normaloperating temperature

Torque converter

Hydraulic 2500 ± 100 2500 ± 200

Full 1950 ± 200 1950 ± 300

p For further detailed information, refer to Engine Shop Manual.

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

20-4

Acc

eler

ator

ped

alD

irect

iona

l lev

erS

peed

leve

rT

rans

mis

sion

Val

veS

teer

ing

whe

elSTANDARD VALUE TABLE FOR CHASSIS

Cate Standard value Service limitgory for new machine value

Item Measurement Condition Unit

Operating Force N (kg)49-98 147(5-10) (15)

OperatingAngle

"1 48 ± 3 ---

deg.

"2 30 ± 2 ---

Stopper Height L1 mm 48 ± 5 ---

OperatingForce

N-FORWARD 5.9 +4.9, -2.9 13.7 (1.4)

C Engine stoppedC Torque converter oil

temperature: 60-80EC(140-176EF)

N (kgf)(0.6 +0.5, -0.3)

N-REVERSE 5.9 + 4.9, -2.9 13.7 (1.4)(0.6 +0.5, -0.3)

Travel mm

N-FORWARD 40 ± 10 40 ± 20

N-REVERSE 40 ± 10 40 ± 20

Operating 2ndþ3rd 5.9 +4.9, -2.9 13.7 (1.4)Force (0.6 +0.5, -0.3)

1st þ2nd 5.9 +4.9, -2.9 13.7 (1.4)

N (kg)

(0.6 +0.5, -0.3)

3rdþ4th 5.9 +4.9, -2.9 13.7 (1.4)(0.6 +0.5, -0.3)

Travel mm2nd ø 3rd 40 ± 10 40 ± 20

1st ø 2nd 40 ± 10 40 ± 20

3rd ø 4th 40 ± 10 40 ± 20

Priority valve pressure

C Torque converter oiltemperature: 60-80EC Mpa(140-176EF) (kg/cm )

C Engine speed: Low idling

2

2.3 ± 0.2 2.3 ± 0.2(23 ± 2) (23 ± 2)

Pilot reducing valve pressure 1.0 +0.1, -0.21.0 ± 0.1(10 ± 1) (10+1,-2)

Clutch pressure 2.3+0.3,-0.42.3 ± 0.2(23 ± 2) (23+3,-4)

Torque converter outlet portpressure

0.38 ± 0.05 0.38 ± 0.10(3.9 ± 0.5) (3.9 ± 1.0)

Play C Machine facing straight mm 20 ± 20 0 - 120C Engine speed: Low idling

to front

Operating Force N (kgf)C Flat, horizontal, straight,dry paved road surface

C Hydraulic oiltemperature: 45-55EC(113-131EF)

C Engine speed: Low idling

8.8 - 11.8(0.9 - 1.2)

Max. 21.6(Max. 2.2)

Operating time Sec.

Low idling Max. 3.9 Max. 6.0

High idling Max. 3.2 Max. 4.5

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

20-5

Whe

el B

rake

sP

arki

ng b

rake

Cate Standard value Service limitgory value

Item Measurement Condition Unit for new machineS

teer

ing

valv

e

Relief pressure C Hydraulic oil temperature:C Engine speed: High

45-55EC (113-131EF)

Mpa 18.6 ± 0.69 18.6+0.7,-1.1(kgf/cm ) (190 ± 7) (190+7,-11)2

Operating force ---

C Engine speed: Low idleC Engine water temperature

gauge: white rangeN 206

(kgf) (21)

Operatingangle

"2

deg.

18.5 ± 4 18.5 +8,-4

"148 ---

Performance m Max. 4.0 Max. 5.0

C Flat, horizontal, straight,dry paved road surface

C Speed when applyingbrake:20 km/h, braking delay: 0.1sec

C Brake pedal operatingforce: 294 N (30 kg)

C Tire inflation pressure:Specified pressure

Drop in hydraulic pressureC 4.1 Mpa (42 kg/cm ) in 5 Mpa Max. 0.34 Max. 0.342

min. (kg/cm ) (Max. 3.5) (Max. 3.5)2

Wear of disc C Thickness of discmm 1.08 ± 0.06 Min. 0.7

Performance (11E20') grade --- Stopped ---

C Tire inflation pressure:Specified pressure

C Flat paved road with 1/5

C Dry road surfaceMachine at operating condition

Piston stroke (X) mm 1.85 ± 0.28 Min. 3.5

CParking brake ON: a

C Parking brake OFF: b

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

20-6

Wor

k eq

uipm

ent c

ontr

ol le

ver

Ope

ratin

g fo

rce

Wor

k eq

uipm

ent c

ontr

ol v

alve

Ope

ratin

g F

orce

Tra

vel

Mai

n co

ntro

l val

veCate Permissiblegory Value

Item Measurement Conditions Unit Standard Value

Boom

HOLDºRAISE

C Engine speed: Low idleC Hydraulic oil N

temperature: 45-55EC (kgf) (113-131EF)

Max. 29.4 (Max. Max 44.1 (Max3.0) 4.5)

RAISE ºHOLD Max. 27.5 (Max 2.8)Max 44.1 (Max4.5)

HOLDºLOWER Max. 29.4 (Max 3.0)Max 44.1 (Max4.5)

LOWERºHOLD --- ---

LOWERºFLOAT Max. 46.1 Max 66.7(Max.4.7) (Max 6.8)

FLOATºHOLD Max. 27.5 (Max.2.8)Max 44.1 (Max4.5)

Bucket N (kgf)

HOLDºDUMP

C Engine speed: Low idleC Hydraulic oil

temperature: 60 - 80EC(140-176EF)

Max 29.4 (Max Max 44.23.0) (Max 4.5)

HOLDºTILT Max 29.4 (Max Max 34.33.0) (Max 3.5)

TILTºHOLD Max 31.4 (Max Max 34.33.7) (Max 3.5)

Boom 80 ± 15 80 ± 20

HOLDºRAISE

mm 75 ± 15 75 ± 20

80 ± 15 80 ± 20

HOLDºLOWER

LOWERºFLOAT

BucketHOLDºDUMP 70 ± 15 70 ± 20

HOLDºTILT 70 ± 15 70 ± 20

Relief pressure

C Hydraulic oiltemperature: 45 - 55EC Mpa 20.6 +0.4, -0.5 20.6 +0.4, -1.5

C Engine speed: High (kg/cm ) (210 +4, -5) (210 +4, -15)idle

2

Boom HOLDøRAISE 8 ---spooloperatingtravel C Hydraulic oil temp: 45 -

55EC (113-131EF) mmC Engine speed: Low idle

HOLDøLOWER 8 ---

HOLDøFLOAT 15.5 ---

Bucket spooloperatingtravel

HOLDøDUMP 7 ---

HOLDøTILT ---8

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

20-7

Wor

k eq

uipm

ent

Wor

k eq

uipm

ent s

peed

Hyd

raul

ic d

rift

Pro

xim

itysw

itch

Boom lifting time

C Hydraulic oil temp: 45 -55EC (113-131EF)

C Engine speed: Highidle

C Steering valve: NeutralC No load

Sec.

4.8 ± 0.3 Max. 5.8

Boom lowering time 2.5 ± 0.5 Max. 4.2

Bucket dumping time w/Standard bucket cylinder

1.1 ± 0.3 Max. 1.4

Bucket dumping time w/large bucket cylinder

1.3 Max. 1.6

Bucket At full stroketiltingtimestandard Bucket horizontalbucket

1.3 ± 0.3 Max. 1.9

1.0 ± 0.3 Max. 1.4

Bucket At full stroketiltingtimelarge Bucket horizontalbucket

1.5 Max. 2.1

1.3 Max. 1.6

Retraction of boomcylinder rod

C Hydraulic oil temp: 45 -55EC (113-131EF)

C Leave for 5 minutesafter stopping enginethen measure for next mm15 minutes

C Bucket empty, boom,bucket horizontal

C No load

Max. 17 Max. 20

Retraction of bucketcylinder rod

Max. 17 Max. 25

Clearance of bucket positionerswitch

C Hydraulic oil temp: 45 -55EC (113-131EF)

mm

3 - 5 ---

Clearance of boom kick-outswitch 3 - 5 ---

TESTING AND ADJUSTING TOOLS FOR TESTING ADJUSTING AND TROUBLE SHOOTING

20-8

TOOLS FOR TESTING, ADJUSTING & TROUBLESHOOTINGCheck or measurement item Symbol Tool Number Tool Description Remarks

Intake manifold pressure -- Pressure gauge See engine shop manual

Intake air restriction -- Water manometer See engine shop manual

Engine lubricating oil pressure -- Pressure gauge See engine shop manual

Fuel filter inlet restriction -- Vacuum gauge See engine shop manual

Exhaust back pressure -- Mercury manometer See engine shop manual

Measuring voltage and Commerciallyresistance values available

-- Tester ---

Engine speeds A1 799-203- 8001 Digital optical tachometer 9000) L: 60-2000 rpm

Digital display (799-203-

R: 60-19999 rpm

2 795-790-2500 Adapter kit See engine shop manual

Coolant and oil temperatures B 799-101-1502 Digital temperature gauge See engine shop manual

Oil pressure C Mpa (0-700 kg/cm )

1

799-101-5002 Analog hydraulic tester 5.88, 39.2, 58.8 Mpa (25,Pressure gauge 2.45,

60, 400, 600 kg/cm )2

790-261-1203 Digital hydraulic testerPressure gauge 0-68.6

2

2 799-401-2320 Hydraulic gauge 1.0 Mpa (10 kg/cm )2

3 Adapter790-261-1311 ---

790-261-1321 ---

Compression pressure D1 795-502-1590 Compression gauge kg/cm ) Kit part No. 795-

0 - 6.9 Mpa (0 - 702

502-1205

2 795-502-1700 Adapter

Kit Part No.799-201-1504

Blow-by pressure E

1 799-201-1541 Gauge

2 799-201-1571 Tube

3 799-201-1450 Adapter

4 795-790-1950 Nozzle ---

Valve clearance

F ---Commercially Feeler Gaugeavailable

F1 795-799-1130 Gear---

Exhaust color G

1 0-70% w/ standard color799-201-9000 Handy smoke detector Discoloration

% x 1/10 Bosch index

2 ---Commercially Smoke meteravailable

Troubleshooting of wiringharnesses and sensors

H 799-601-7400 T-adapter ---

Operating Force I Push-pull scale ---Commerciallyavailable

TESTING AND ADJUSTING TOOLS FOR TESTING ADJUSTING AND TROUBLE SHOOTING

Check or measurement item Symbol Tool Number Tool Description Remarks

20-9

Pushing force J Push gauge ---Commerciallyavailable

Stroke K ---Commercially Scaleavailable

Brake oil pressure L1 793-605-1001 Brake test kit 6.9 Mpa (70 kg/cm )2

2 790-101-1430 Coupler ---

Clearance measurement O 417-22-23250 Thickness feeler gauge ---

Speed P Stop watch ---Commerciallyavailable

Boom holding tool Q 793-463-1100 Stopper ---

Pushing angle R Angle gauge ---Commerciallyavailable

Length measurement S Slide calipers ---Commerciallyavailable

TESTING AND ADJUSTING MEASURING ENGINE SPEEDS

20-10

MEASURING ENGINE SPEEDSWhen removing or installing the measuring equipment, be careful not to touch any high temperature parts.

i Measure the engine speed under the following conditions.• Coolant temperature: Within operating range• Torque converter oil temperature: 70 to 90EC (158 - 194EF)• Hydraulic oil temperature: 45 to 55EC (113 - 131EF)

1. Install the digital optical tachometer using the instruction supplied with it.1) Remove the cap 1 of engine speed output, and then install adapter ass’y A2.2) Connect the tachometer A1 and adapter ass’y A2 with cable.

When measuring engine speeds, be careful not to touch any high temperature parts or rotating parts.

2. Start the engine, and measure the engine speed when it is set to the conditions for measuring.1) Measuring low idle and high idle speeds.2) Measure the speed at near the rated speed.

i When measuring speeds for items other than the above, such as torque converter stall, see the procedurefor the item as described in this section.

TESTING AND ADJUSTING MEASURING, OIL PRESS., FUEL FILTER RESTRICTION & BLOW-BY PRESS.

20-11

MEASURING ENGINE LUBRICATING OIL PRESSURE

Remove oil pressure sensor then install pressure gauge.

i Refer to ENGINE SHOP MANUAL for tools and properprocedure.

MEASURING FUEL FILTER INLET RESTRICTION

i Refer to ENGINE SHOP MANUAL for tools and properprocedure.

MEASURING BLOW-BY PRESSURE

i Refer to ENGINE SHOP MANUAL for tools and properprocedure.

TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE

20-12

MEASURING COMPRESSION PRESSURE

When removing or installing the measuring equipment, becareful not to touch any high temperature parts.

When measuring, be careful not to let your clothes getcaught in any rotating part.

1. Before measuring the compression pressure, check thevalue clearances. Refer to “Engine Shop Manual” and adjustthem if necessary.

2. Measurement conditionsEngine water temperature: 40 - 60EC (104 - 140EF)

3. Remove the nozzle holder of the cylinder which is necessaryto be measured.

4. Install adapter D2 and connect the compression pressureguage D1

5. Set the multi tachometer A.Refer to “Measuring engine speeds.”

6. Cut off fuel control rod and then fix the governor lever of fuelpump to “no inspection” position. After that, measurecompression pressure of cylinder while starting engine bystarter motor.

Do not crank the starting motor for periods longer than 30 seconds.Allow 2 minutes between the 30 second cranking periods so the starting motor can cool.

i Read scale of compression pressure guage after being stable.i Measure and check the engine speed while measuring compression pressure.i After measuring, install the nozzle holder again.

TESTING AND ADJUSTING MEASURING EXHAUST COLOR

20-13

MEASURING EXHAUST COLOR

i When measuring in the field when there is no air or powersupply, use smoker the checker; when recording official data,use the smoke meter.

Measuring with handy smoke checker G1

When measuring the exhaust gas color, be careful not totouch the exhaust pipe or any other high temperature part.

i Warm up the engine (oil temperature: 60EC 140EF) beforemeasuring the exhaust gas color.

1) Fit filter paper in too[ G1.2) Insert the exhaust gas intake port into the exhaust pipe,

accelerate the engine suddenly, and at the same timeoperate the handle to catch the exhaust gas on the filterpaper.

3) Remove the filter paper and compare it with the scaleprovided to judge the condition.

Measuring with smoke meter G2

When measuring the exhaust gas color, be careful not totouch the exhaust pipe or any other high temperature part.

i Warm up the engine (oil temperature: 60EC 140EF) beforemeasuring the exhaust gas color.1) Insert the probe into the outlet port of the exhaust pipe,

then tighten the clip to secure it to the exhaust pipe.2) Connect the probe hose, accelerator switch plug, and air

hose to tool G2.i The pressure of the air supply should be less than

1.5 MPa (15 kg/cm²).3) Connect the power cord to the AC100V outlet.

i When connecting the cord, check first that the powerswitch is OFF.

4) Loosen the cap nut of the suction pump, then fit the filterpaper.i Fit the filter paper securely so that the exhaust gasdoes not leak.

5) Turn the power switch.6) Accelerate the engine suddenly, and at the same time,

depress the accelerator pedal and operate the reliefvalve to catch the exhaust gas color on the filter paper.

7) Lay the filter paper used to catch the exhaust gas coloron top of unused filter papers (10 sheets or more)inside the filter paper holder, and read the indicatedvalue.

TESTING AND ADJUSTING MEASURING COOLANT TEMPERATURE AND ADJUSTING VALVE CLEARANCE

20-14

MEASURING COOLANT TEMPERATURE

i Refer to ENGINE SHOP MANUAL for tools and properprocedure.

MEASURING AND ADJUSTING VALVE CLEARANCE

i Refer to ENGINE SHOP MANUAL for tools and properprocedure.

TESTING AND ADJUSTING MEASURING COOLANT TEMPERATURE AND ADJUSTING VALVE CLEARANCE

20-15

MEASURING ACCELERATOR PEDAL

OPERATING FORCE OF ACCELERATOR PEDAL

1. Measuring1) Set push-pull scale “yy” at a position 150 mm from pedal

fulcrum “a”i Put the center of the push-pull scale “yy” in contact

with a point 150 mm from the pedal fulcrum.

2) Start the engine than measure the maximum value whenthe pedal is moved from the pushed position (low idling)to the end of its travel (high idling).

2. TESTING1) Stop the engine.2) Disconnect the cable (1) at the bottom of the accelerator

pedal, and check that the plate (2) and ball joint (3) atthe bottom of the pedal move smoothly.

i Carry out the above inspection, and adjust or replaceparts if necessary. Then carry out the measurement ofthe operating force again to check that it is within thestandard value.

TESTING AND ADJUSTING MEASURING ACCELERATOR PEDAL

20-16

OPERATING ANGLE OF ACCELERATOR PEDAL

1. Measuring1) Stop the engine.

2) Put angle gauge “R” in contact with the acceleratorpedal, and measure operating angle ""(""=""1-""2) whenthe pedal is operated from low idle position “""1” to highidle position ""2.

Adjusting1) Open the inspection cover of the engine hood.2) Set accelerator (1) to the FREE condition(lever (2) in

contact with U-bolt (3)), adjust cable (5) so that thegovernor lever (4) is at the low idle position, then tightennuts (6) and (7).

Locknuts (6), (7): 46.6 ± 12.3 Nm (4.75 ± 1.25 kgm)

Locknut (9): 3.9 ± 1.0 Nm (0.4 ± 0.1 kgm)

Mounting nut (10): 13.2 ± 1.5 Nm (1.35 ± 0.15 kgm)

3) Keep accelerator pedal (1) depressed, then adjuststopper bolt (8) so that the governor lever (4) is atthe high idle position.

i Screw in ball joint (3) at least 8 mm.

TESTING AND ADJUSTING MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER

20-17

MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER

i Measurement conditionsToque converter oil temperature: 60 - 80EC (140 - 176E F)

Block the tires securely.

OPERATING FORCE OF SPEED LEVER

1. Stop the engine.

2. Install push-pull scale “yy” or a spring balance to center of thecontrol lever knob, and measure the operating force whenthe lever is pulled in the direction of operation.

i Carry out the measurement for each speed range.

TRAVEL OF SPEED LEVER

1. Stop the engine.

2. Make mark “a” at the center of the control lever knob, andmeasure the travel when the lever is operated in the directionof operation.

TESTING AND ADJUSTING MEASURING STALL SPEEDS

20-18

MEASURING STALL SPEEDS

ÚÚ Measurement conditions! Engine water temperature: Within the white operating range

on the engine water temperature gauge.! Hydraulic oil temperature: 45 - 55EC (113 - 131EF)! Engine speed: High idle! Torque converter oil temperature: 60 - 80EC (140 - 176EF)

Apply the parking brakes and block the tires

When measuring each stall speed be careful not touchany rotating part or parts that are extremely hot.

i Check that the low idle and high idle are thestandard values.

i Before measuring each stall speed, remove cover(1) from the pickup port, install adapter A2 oftachometer A1, then connect the tachometer A1 andthe adapter with a cable.

i Check that the engine speed is the standard value.If it is not within the standard range , check for looselinkage or play.

TORQUE CONVERTER STALL SPEED

i Before starting the operation, check that the tires arechocked and release the parking brake.

1. Start the engine and run at low idle.

2. Place direction lever (4) at FORWARD OR REVERSE, andset speed lever (3) to the highest position.

3. Use the brakes to stop the machine, then use multi-tachometer A1 to measure the speed when the engine is athigh idle.

i Turn transmission cut-off selector switch (2) OFF anduse the left brake . (Check that the pilot lamp goes out.)

i Do not keep the stall condition for more than 20 seconds.Make sure that the torque converter oil temperature doesnot exceed 120EC.

TESTING AND ADJUSTING MEASURING STALL SPEEDS

20-19

HYDRAULIC STALL SPEED

1. Start the engine and run at high idle.

2. Operate the bucket or boom lever (4), set the cylinder to thestroke end, and activate the work equipment valve relief.

3. Use multi-tachometer A1 To measure the enginei Do not keep the stall condition for more than 20 seconds.

Operate the control lever quickly.

FULL STALL SPEED

! Measure the engine speed when the torque converter stalland the hydraulic stall are both carried out at the same time.i Before measuring the full stall, check that the torque

converter stall and hydraulic stall speeds are normal.If either of the stall speeds are abnormal, correct theproblem and measure again.

TESTING AND ADJUSTING MEASURING TORQUE CONVERTER, TRANSMISSION OIL PRESSURE

20-20

MEASURING TORQUE CONVERTER, TRANSMISSION OIL PRESSUREii Measurement conditions

C Engine water temperature: within white range on enginewater temperature gauge

C Torque converter oil temperature: 60 - 80EC (140 - 176EF)

Apply the parking brake and put blocks under the tires.

Preparatory Work

i The following preparatory work is necessary when measuringall oil pressures.

i Before starting the operation, check that there are blocksunder the tires, then release the parking brake.C Remove cover (1) on the left side of the rear frame.C Turn transmission cut-off selector switch (2) OFF and

use the left brake. (Check that the pilot lamp is OFF.)C Remove the plug from the measurement port of the

transmission valve.C Install hydraulic tester kit C1 to the measurement port,

extend the gauge to the operator’s compartment, thenstart the engine and measure the pressure.

i Check that no oil is leaking from any connection.

i After removing the measurement plug, always coat the plugwith adhesive.

Plug: sealing agent (LG-1)

TESTING AND ADJUSTING MEASURING TORQUE CONVERTER, TRANSMISSION OIL PRESSURE

20-21

1. Measuring pilot pressure1) Measurement port : 12) Start the engine and measure the oil pressure with the

engine at high idle.

2. Measuring priority pressure1) Measurement port : 22) Start the engine and measure the oil pressure with the

engine at high idle.

3. Measuring all clutch pressures1) Measurement port : 32) Start the engine and measure the oil pressure with the

engine at high idle.

4. Measuring torque converter outlet port pressure1) Measurement port : 42) Start the engine and measure the oil pressure at torque

converter stall.

5. Adjusting modulating timeTurn screw (A) to make the modulating time shorter orlonger.1) TIGHTEN screw to give PATTERN 1).2) LOOSEN screw to give PATTERN 2).

i The standard length is 6.75 mm (return fully, then screw in4 ½ turns

i Do not adjust excessively. After adjusting, always checkthat there are no abnormality in the pressure.

i Keep the range of the adjustment to within ± 1 turn

TESTING AND ADJUSTING METHOD OF OPERATING EMERGENCY MANUAL SPOOL

20-22

METHOD OF OPERATING EMERGENCY MANUAL SPOOL

Outline

The transmission valve is controlled electrically, but if thereshould be any failure in the electrical system, or if there is anyfailure in the solenoid valve or spool and the machine cannotmove, it is possible to operate the emergency manual spool tomove the machine.

This operation of the spool is designed only for use if themachine cannot be moved because of a failure in thetransmission control, and it is necessary to move themachine from a dangerous working area to a safe placewhere repairs can be carried out. This spool must not beoperated except when there has been a failure.

When carrying out this operation, keep strictly to the order ofoperation and pay careful attention to safety when movingthe machine.

To prevent the machine from moving, lower the bucketto the ground, apply the parking brake, and put blocksunder the tires.

Always stop the engine before operating the spool.

1. Remove cover (1) from the left side of the rear frame.

2. Remove lock plate (2) from emergency manual spool (3) ofthe transmission valve.i The lock plate can be removed simply by loosening the

mounting bolts.

3. Operate emergency spool (3) to the operating positionaccording to the direction of movement of the machine(forward or reverse).

i FORWARD: Push in the spool until it enters the detent.a = Approx. 8 mm

i REVERSE: Pull the spool until it enters the detent.b = Approx. 8 mm

TESTING AND ADJUSTING METHOD OF OPERATING EMERGENCY MANUAL SPOOL

20-23

4. Check that the area around the machine is safe, then removethe blocks from under the tires.

5. Sit in the operator’s seat and depress the left brake pedal (4)fully.

6. Start the engine, then release the parking brake and slowlylet the brake pedal out to start the machine.

When the engine is started, the transmission is alsoengaged and the machine will start, so always checkcarefully that the area around the machine and in thedirection of travel is safe and keep the brake pedaldepressed fully when starting the engine.

7. After moving the machine, stop the engine, then apply theparking brake and put blocks under the tires.

8. Return the manual spool to the neutral position and installthe lock plate.

TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING WHEEL

20-24

TESTING AND ADJUSTING STEERING WHEEL

Measuring steering wheel playi Measurement conditionsC Engine: Stopped.C Vehicle posture: Facing straight.

Measuring procedure1. Turn the steering wheel lightly clockwise and

counterclockwise two or three times to check that thesteering mechanism is in neutral, then put a mark “a” on theouter frame of the vehicle monitor.

2. Turn the steering wheel lightly clockwise, align the positionwhere it stops with mark “a”, and place mark “b” on thesteering wheel.

3. Turn the steering wheel lightly counterclockwise, align theposition where it stops with mark “a”, and place mark “c”on the steering wheel. Measure the straight distance “d”between mark “c” and the position marked in step 2.

MEASURING OPERATING FORCE OF STEERING WHEEL

ii Measurement conditions

CC Road surface: Flat, horizontal, dry paved surfaceC Engine water temperature: within white range on engine

water temperature gaugeC Hydraulic oil temperature: 45 - 55EC (113-131EF)C Tire inflation pressure: Specified pressureC Engine speed: Low idling (bucket empty)

Measurement method

1. Install push-pull scale “yy” to the steering wheel knob.

2. Start the engine.i After starting the engine, raise the bucket approx. 400

mm and remove the safety bar.

3. Pull push-pull scale “yy” in the tangential direction andmeasure the value when the steering wheel movessmoothly.i Avoid measuring when the steering wheel starts to

move.

TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING WHEEL

20-25

MEASURING OPERATING TIME FOR STEERING WHEEL

i Measurement conditions

C Road surface: Flat, horizontal, dry paved surfaceC Engine water temperature: Within green range on engine

water temperature gaugeC Hydraulic oil temperature: 45 - 55EC (113-131EF)C Tire inflation pressure: Specified pressureC Engine speed: Low and high idle

Measurement method

1. Start the engine.i After starting the engine, raise the bucket approx. 400 mm

and remove the safety bar.

2. Operate the steering wheel (1) to the end of its stroke toturn the machine to the left or right.

3. Measure the time taken to operate the steering wheel to theend of the stroke to the right (left).i Operate the steering wheel as quickly as possible

without using force.i Carry out the measurements both at low idling and high

idling, and to both the left and right.

TESTING AND ADJUSTING MEASURING STEERING OIL PRESSURE

20-26

MEASURING STEERING OIL PRESSURE

i Measurement conditions

C Hydraulic oil: 45 - 55EC (113 - 131EF)C Engine speed: High idle

METHOD OF MEASURING MAIN RELIEF PRESSURE

Loosen the oil filler cap to release the pressure inside thehydraulic tank, then turn the steering wheel several timesto release the remaining pressure inside the piping.

1. Fit safety bar (1) to the frame.

2. Remove cover (3) at the bottom right of floor frame (2).

3. Remove measurement plu (4) for the right turn steeringcircuit.

4. Install hydraulic tester kit (A1) to the measurement port.

5. Start the engine, run the engine at high idle, then turn thesteering wheel to the right and measure the pressure whenthe relief valve is actuated.i To measure the pressure when turning the steering

wheel to the left, remove the plug (5)for the left turnsteering circuit.

TESTING AND ADJUSTING MEASURING STEERING OIL PRESSURE

20-27

METHOD OF ADJUSTING MAIN RELIEF PRESSURE

Always stop the engine before adjusting the pressure.

1. Stop the engine.

2. Remove hose (2) and fitting (3) connected to port “T” of thepriority valve (1).

3. Remove double screw (4).

4. Turn adjustment screw (5) to adjust.i Pressure adjustment for one turn of adjustment screw:

Approx. 6.9 Mpa (70 kg/cm ).2

i Turn the adjustment screw to adjust the set pressure asfollows.TIGHTEN to INCREASE pressure.LOOSEN to DECREASE pressure.

i Tool “1" for turning adjustment screw: Size 7/32 inch,hexagonal

i If the relief pressure cannot be measured accuratelythen do not try to adjust the pressure.

Adjustment screw: (5): 4.5 ± 2.3 Nm (0.46 ± 0.23 kgm)

Double screw (4): 14.7 ± 2 Nm (1.5 ± 0.2 kgm)

TESTING AND ADJUSTING MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL

20-28

MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL

i Measurement conditions

C Engine water temperature: Within white range on enginewater temperature gauge

C Engine speed: Low idle

Operating effort of pedal1. Install push gauge (J) to the operator’s foot.

i Align the center of the push gauge with a point 150 mmfrom the fulcrum of the pedal.

2. Start the engine, run at low idle, and measure the operatingeffort when the pedal is depressed.

Travel of pedal1. Install push gauge (J) to the operator’s foot.

i Align the center of the push gauge ”a” with a point 150mm from the fulcrum of the pedal.

2. Start the engine and measure the pedal angle when runningat low idle with a pedal depressed with a force of 206 N (21kg).

3. Next, place angle meter (R) on the pedal and measure angle“""”with a pushing a force of 206 N (21 kg).It is also possiblle to measure ""1 and ""2 and calculate "" =""1 - ""2.

TESTING AND ADJUSTING TESTING AND ADJUSTING BRAKE PEDAL LINKAGE

20-29

TESTING AND ADJUSTING BRAKE PEDAL LINKAGE

Testing1. Check for play in linkage mounting pin (1), pin hole of lever

(2), and lever bushing.2. Measure length “X1" of rod and check that it is within the

standard value.i Standard length of rod “X1": 175 mmi Measure the length from the center of pin (1) to the

center of ball joint (6a).3. Measure the distance of movement of rod (8) and check that

clearance “a” is within the standard value.i Standard clearance “a”: 0 - 0.7 mmi When doing this, check that the brake pedal is in contact

with the stopper.

Adjusting1. Adjusting link X1

1) Remove pin (1) and ball joint (6a), remove rod andloosen locknut (5), then turn yoke (6) and ball joint (6a)to adjust the length.

2) After adjusting the length of rod X1, connect it to thebrake pedal.

TESTING AND ADJUSTING TESTING AND ADJUSTING BRAKE PEDAL LINKAGE

20-30

2. Adjusting rod X21) Loosen locknut (7), turn rod (8) so that tip C of rod

contacts the master cylinder piston, then turn rod (8)back 1/4 turn.i Standard length of rod “X2": 154.3i Movement for ½ turn of rod: 0.75 mm

2) Tighten locknut (7) to hold in position.

3. Adjusting transmission cut-off switches (left pedal)1) Loosen mounting screw of switch (9) and adjust switch

(9) so that protrusion of the tip of the switch from the endface of the transmission cut-off switch plate is dimension“b”.i Dimension”b”: 1.1 - 1.9 mmi When doing this, check that the switch is ON.

2) To adjust the cut-off timing, adjust plate (10) so that thedimension “d” from the center of the stopper bolt ofplate (10) to the end face of plate (10) is 24 mm.i When doing this, check that plate (10) contacts

portion “e” of the switch plate.i Adjust with the pedal in the FREE condition.

4. Adjusting Stop lamp switch (right pedal)Adjust with mounting nut (11) of stop lamp switch (12).1) Adjust with nuts (11) so that the tip of the switch is

dimension :”f”.i Dimension “f”: 3.5 - 5.0 mm

When doing this, check that the switch is OFF.i Adjust with the pedal in the FREE. condition

TESTING AND ADJUSTING MEASURING BRAKE PERFORMANCE

20-31

MEASURING BRAKE PERFORMANCE

i Measurement conditionsC Road surface: Flat, horizontal, dry paved surfaceC Travel speed: 20 km/h when brakes are appliedC Delay in applying brakes: 0.1 secC Tire inflation pressure: Specified pressure

Measurement method1. Start the engine and move the machine.

2. Set the speed lever to the highest speed position and drivethe machine.

3. When the travel speed reaches 20 km/h, depress the leftbrake pedal with the specified operating force.Specified operating force: 294 N (30 kg)i Before carrying out this operation, determine the run-up

path and the point for applying the brakes, then applythe brakes when the machine reaches that point.

4. Measure the distance from the point where the brakes wereapplied to the point where the machine stopped.

i Repeat this measurement three times and take theaverage.

TESTING AND ADJUSTING MEASURING BRAKE OIL PRESSURE

20-32

MEASURING BRAKE OIL PRESSURE

i Measurement conditionsC Engine water temperature: Within white range on engine

water temperature gaugeC Brake pressure: 4.1 Mpa (42 kg/cm )2

Apply the parking brake and put blocks under the tires.

Measuring1. Raise the boom, set support (1A) or tool “Q” in position,

then remove front cover (1).2. Stop the engine.

i When leaving the operator’s seat, apply the lock to thework equipment control levers securely.

3. Remove brake tube (2) on the side to be measured, thenremove adapter (3).

4. After removing the adapter, install tool L1, L2.i Connect the quick coupler of tool L1, L2.

5. Loosen bleeder screw (4) and bleed the air.i Operate pump 2 to bleed the air.

6. Tighten the bladder screw, operate pump 2, raise thepressure to 4.1 Mpa (42 kg/cm ), then tighten stop valve 3.2

7. After applying the pressue, leave for 5 minutes and measurethe drop in the pressure.i If the hose is moved while measuring the pressure, the

pressure will change, so do not move the hose.i When removing hydraulic test kit L1, L2 after testing,

operate pump 2 to lower the pressure of L1, L2, thenremove it.

i After completing the operation, install the brake tube,then bleed the air from the brake circuit.

TESTING AND ADJUSTING TESTING FOR BRAKE DISC WEAR

20-33

TESTING FOR BRAKE DISC WEAR

Apply the parking brake and chocks under the tires.

Measuring1. Loosen drain plug (1) and drain the axle oil.

Axle oil: 14R

2. Install measuring plug (2).

3. Lightly press the brake pedal.i Check that plate (4) and plate (5) are in tight contact with

disc (3).

Insert feeler gauge (O) between disc (3) and plate (4), andmeasure the clearance.

4. Fasten the drain plug and supply axle oil to the specifiedlevel through the oil supply port.

Axle oil: 14R

TESTING AND ADJUSTING TESTING FOR BRAKE DISC WEAR

20-34

BLEEDING AIR FROM BRAKE SYSTEM

Apply the parking brake and put blocks under the tires.

Procedure1. Raise the boom, set support (1A) or boom drop prevention

stopper “Q” in position, then remove front cover (1).

2. Remove cap (2) of the bleeder screw, insert vinyl hose (3)into the screw, and insert the other end in a container.

3. Start the engine.

4. Depress the brake pedal, then loosen the bleeder screw andbleed the air. Keep the brake pedal depressed, tighten thebleeder screw, then release the brake pedal slowly.i Add brake oil when necessary during the operation to

keep brake oil tank full.

5. Repeat this operation, and when no more bubbles come outwith the fluid from the hose, depress the pedal fully andtighten the bleeder screw while the oil is still flowing.i Repeat the operation to bleed the air from the other

cylinders, and after completing the operation, check thelevel in the oil tank and add more oil if necessary.

i To bleed the air completely, bleed the air first from thecylinder which is farthest from the brake pedal.

i After bleeding the air, carry out a brake performance testthen bleed the air again and check that there is no air inthe circuit.

TESTING AND ADJUSTING MEASURING PARKING BRAKE PERFORMANCE

20-35

MEASURING PARKING BRAKE PERFORMANCE

i Measurement conditionsC Tire inflation pressure: Specified pressureC Road surface: Flat, dry paved road surface with slope of 1/5

grade (11E20').C Machine: Operating conditionC Operating effort: 392.3 N (40 kg)

Measurement method1. Start the engine, set the machine facing in a straight line,

then drive the machine up a 1/5 grade slope with the bucketempty.

2. Depress the brake, stop the machine, set the directional leverto the neutral position, then stop the engine.

3. Depress the parking brake pedal, then gradually release thebrake pedal and check that the machine is held in position.i Carry out the measurement in two ways: Once with the

machine facing uphill, and once more with the machinefacing downhill.

TESTING AND ADJUSTING TESTING AND ADJUSTING PARKING BRAKE LINKAGE

20-36

TESTING AND ADJUSTING PARKING BRAKE LINKAGE

Apply the parking brake and put blocks under the tires.

TestingDepress the parking brake pedal with a force of approx. 294 N(30 kg). If the travel of brake pedal is more than 13 clicks, checkfor looseness of the control cable mount (pedal end and brakeend). If any looseness is found, tighten and then adjust asfollows.

Adjusting linkage1. Pull release lever (1) and release the parking brake.2. Loosen locknut (2) and remove clevis pin (4).3. Set lever (5) at the parking brake end in the release position.

i With lever (5) at the FREE position, move the link up bythe amount of play.

4. Screw in clevis (3), align the hole with the pin hole in lever (5)at the parking brake end, then assemble clevis pin (4) andtighten locknut (2).

5. After adjusting, depress parking brake pedal (6) with a forceof approx. 294 N (30 kg), and check that the travel of thepedal is 7 - 11 clicks.

If it is impossible to adjust only at parking brake end

6. Loosen locknut (7) at pedal (6) end, then remove clevis pin(9).

7. Screw in clevis (8) and adjust so that the mounting dimensionis X.i Standard dimension X: 148 mm

Adjusting parking brake switch1. Adjust with nut (11) so that the mounting dimension at the tip

of parking brake switch (10) is “c”.i Mounting dimension “c” of switch: 4 - 6 mmi When doing this, check that the parking brake switch is

OFF.

TESTING AND ADJUSTING TESTING PARKING BRAKE DISC WEAR

20-37

TESTING PARKING BRAKE DISC WEAR

Stop the machine on level ground, install the safety barto the frame, lower the bucket to the gruond, stop theengine, then apply the parking brake and put blocksunder the wheels.

i Check that there are blocks under the tires.i Carry out this operation with the drive shaft still installed.

Testing1. Check that the parking brake is applied.2. Remove plug (1).

! Width across flats of hexagon wrench: 6 mm3. Insert calipers “S” into the measurement port (2) and

measure dimension “a” from end face ”c” of the cover (3)to the piston (4).

4. Release the parking brake.5. Insert calipers “S” into the measurement port (2), and

measure dimension “b” from end “c” face of the cover (3)to the piston (4).! Piston stroke X = “a” - “b”

If X is 3.5 mm, the brake disc is worn and must bereplaced.

i For details of method of replacing the brake disc, seeDISASSEMBLY AND ASSEMBLY OF TRANSMISSION.

i After measuring, check the transmission oil level.

TESTING AND ADJUSTING MEASURING PARKING BRAKE DISC WEAR

20-38

MEASURING PARKING BRAKE DISC WEAR

Put blocks under the tires.

i If the braking effect is poor, or if the transmission has beenoverhauled, measure the wear of the parking brake disc.

i For details of method disassembling and assembling the parkingbrake see DISASSEMBLY AND ASSEMBLY OFTRANSMISSION.

Measuring

To measure rthe thickness of brake disc (1), check thatdimension “w” is greater than the value given below.

i Dimension “w”: Min. 1.97 mmi For details of the procedure for adjusting the parking

brake linkage, see TESTING AND ADJUSTING OFPARKING BRAKE PEDAL.

TESTING AND ADJUSTING MEASURING WORK EQUIPMENT CONTROL LEVER

20-39

MEASURING WORK EQUIPMENT CONTROL LEVER

ii Measurement conditionsC Engine water temperature: Within white range on engine

water temperature gauge.C Hydraulic oil temperature: 45 - 55ECC Engine speed: Low idling.

Install the safety bar to the frame.

Measurement method1. Operating force of work equipment control lever

Install push-pull scale “33” to the work equipment controllever and measure the operating force.i Install the push-pull scale to the center of the knob.i Operate the control lever at the same speed as for

normal operations, and measure the minimum value forthe force needed to operate the knob.

2. Travel of work equipment control leverMeasure travel at each position when operating the workequipment control lever.i Mark “a” the lever knob and use scale “K” to measure.i If the travel is not within the standard value, check for

play of the linkage and wear of the bushing.

Adjusting1. Adjusting work equipment control lever linkage

1) Remove the right control box (1), top cover (2), and frontcover (3).i Remove boot (4) first from the top cover.i When removing the top cover, be careful of the

wiring for the switches.

TESTING AND ADJUSTING MEASURING WORK EQUIPMENT CONTROL LEVER

20-40

2) Adjust with locknuts (8) and yoke (7) so that the length ofwork equipment control cable (5) is standard length “a” atmain control valve (6) end.i Standard value “a” : 173 mm

3) With work equipment control lever (9) at the neutral position,loosen locknuts (12) and (13) at the bottom of ball joint (11)so that the levers can be locked by lock lever (10), then turnjoint (14) to adjust length “b”.i Standard length “b” : 200.5 mm

(4) After adjusting the length, tighten locknut (12), then securejoint (14) with locknut (13).

TESTING AND ADJUSTING MEASURING WORK EQUIPMENT CONTROL LEVER

20-41

2. Adjusting stopper of work equipment control lever

(1) To adjust boom RAISE stopper bolt (1). connect controlcable (2). Then operate the work equipment controllever gradually to the RAISE position and adjust thelength of stopper bolt (1) so that stopper bolt (1) contactsthe control lever at the point where the control leversuddenly starts to feel heavy.

(2) To adjust boom FLOAT stopper bolt (3), connect controlcable (2). Then operate the work equipment controllever gradually to the FLOAT position and adjust thelength of stopper bolt (3) so that stopper bolt (3) contactsthe control lever at the point where the control leversuddenly starts to feel heavy.

(3) To adjust bucket DUMP stopper bolt (4), connect controlcable (5). Then operate the work equipment controllever gradually to the DUMP position and adjust thelength of stopper bolt (4) so that stopper bolt (4) contactsthe control lever at the point where the control leversuddenly starts to feel heavy.

TESTING AND ADJUSTING MEASURING STROKE OF WORK EQUIPMENT VALVE SPOOL

20-42

MEASURING STROKE OF WORK EQUIPMENT VALVE SPOOL

Stop the machine on level ground, install the safety barto the frame, lower the bucket to the ground, stop theengine, then apply the parking brake andput blocksunder the wheels.

i Measurement conditionsC Engine water temperature: Within white range on engine

water temperature gaugeC Hydraulic oil temperature: 45 - 55ECC Engine speed: Stopped

Measuring1. Adjusting stroke of valve spool

1) Put scale K in contact with spool (2) of main control valve(1) from the bottom of the front frame.

2) Measure the stroke of the valve spool when workequipment control lever (3) is moved to each position.i Carry out the measurement with two workers and

give signals while carrying out the operation.i One worker operates the control lever, and the other

worker measures the stroke.

TESTING AND ADJUSTING MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE

20-43

MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE

i Measurement conditionsC Engine water temperature: Within white range on engine

water temperature gaugeC Hydraulic oil temperature: 45 - 55ECC Engine speed: High idle

Work equipment relief valve pressure measuring procedure

Loosen the oil supply cap to release the pressure insidethe hydraulic oil tank, then operate the control levers twoor three times to release any pressure remaining in thepiping.

1. Remove bucket cylinder circuit oil pressure measuring plug(1).

2. Install hydraulic test kit C1 to the measuring port.i Check that there is no oil leakage from any joints.i Use a hose which is long enough to reach the operator’s

seat.

3. Start the engine, raise the boom about 400 mm, tilt back thebucket using the control lever, and measure the pressurewhen the relief valve is activated.

i Be careful not to apply any sudden pressure to thepressure gauge.

When removing the hydraulic pressure gauge, release the pressure inside the circuit in the same way as whenit was installed.

Adjusting

Apply the parking brake and put blocks under the tires.

Always stop the engine before adjusting the oil pressure.

1. Raise the boom, set support (1A) or tool Q in position, thenremove front cover (1).

TESTING AND ADJUSTING MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE

20-44

2. Remove the relief valve cap nut (2) at control valve (3).

3. Loosen lock nut (4), and turn adjust screw (5) to adjust.i Pressure adjustment for one turn of adjustment screw:

Approx. 2.5 Mpa (25 kg/cm )2

i Turn the adjustment screw to adjust the set pressure asfollows.TIGHTEN to INCREASE pressureLOOSEN to DECREASE pressure

i Do not carry out any adjustment if the relief pressurecannot be measured accurately.

TESTING AND ADJUSTING MEASURING WORK EQUIPMENT

20-45

MEASURING WORK EQUIPMENT

i Measurement conditionsC Engine water temperature: Within white range on engine

water temperature gaugeC Hydraulic oil temperature: 45 - 55ECC Engine speed: High idleC Steering position: NeutralC No load

Measurement method1. Boom RAISE time

Set the bucket at the lowest position from the ground with thebucket tilted back fully, then raise it and measure the timetaken for the bucket to reach the maximum boom height.

2. Boom LOWER timeSet the bucket horizontal, then lower the boom from themaximum height and measure the time taken for the bucketto reach the lowest position from the ground.

3. Bucket DUMP timeRaise the boom to the maximum height, and measure thetime taken to move the bucket from the tilt position (bucketfully tilted back) to the dump position ( bucket fully tippedforward).

4. Bucket TILT time1) Raise the boom to the maximum height, and measure

the time taken to move the bucket to the tilt position(bucket fully tilted back).

2) Set the bucket horizontal to the ground and measure thetime taken to move the bucket from the horizontalposition to the tilt position (bucket fully tilted back).

TESTING AND ADJUSTING MEASURING WORK EQUIPMENT

20-46

MEASURING HYDRAULIC DRIFT WORK EQUIPMENT

i Measurement conditionsC Engine water temperature: Within white range on engine

water temperature gauge.C Hydraulic oil temperature: 45 - 55EC (113 - 131EF)C Stop the engine, leave for 5 minutes, then measure for 15

minutes.C Boom: HorizontalC Bucket: HorizontalC No load

Apply the safety lock to the work equipment control levers.

Never go under the work equipment.

Measurement method1. Set the boom and bucket in a horizontal position, then stop

the engine.

2. Leave for 5 minutes, then start the measurement.

3. Wait for 15 minutes, then measure retraction amount A of thebucket cylinder rod and retraction amount B of the boomcylinder rod.

A: Retraction amount of bucket cylinder rodB: Retraction amount of boom cylinder rod

TESTING AND ADJUSTING TESTING AND ADJUSTING BUCKET POSITIONER

20-47

TESTING AND ADJUSTING BUCKET POSITIONER

i Measurement conditionsC Engine water temperature: Within white range on engine

water temperature gauge.C Hydraulic oil temperature: 45 - 55EC (113 - 131EF)

1. Testing1) With the engine stopped, check that clearance between

switch (1) and bar (2) is the standard value.

2) Start the engine, run at high idle and check the actuationposition. (Check three times and take the averagevalue.)

2. Adjusting1) Lower the bucket to the ground, operate the bucket to

the desired digging angle, then return the lever to HOLDand stop the engine.

2) Adjust so that clearance between bracket (3) anddetection bar (2) is “a”, then secure in position.

i Clearance “a” : 0.5 - 2.0 mm

3) Secure support (4) to bucket cylinder bracket so the tipof detection bar (2) is in line with the center of the switchsensing surface.

4) Adjust the switch so the clearance between the switchsensing surface and detection bar (2) is “b” then securein position.

Switch mounting nut: 17.7 ± 2 Nm (1.8 ± 0.2 kgm)

i Clearance: “b” 3 - 7 mm(The clearance must be less than 7 mm, and there mustbe no interference between the switch and detection bar(plate)

i After adjusting, operate the bucket lever and check thatthe bucket positioner is actuated at the desired position.

TESTING AND ADJUSTING TESTING AND ADJUSTING BOOM KICK-OUT

20-48

TESTING AND ADJUSTING BOOM KICK-OUT (IF EQUIPPED)

i Measurement conditionsC Engine water temperature: Within white range on engine

water temperature gauge.C Hydraulic oil temperature: 45 - 55EC (113 - 131EF)

1. Testing1) Stop the engine, and check that the clearance between

switch (1) and plate (2) is the stand value.

2) Start the engine, run at high idle, and check the actuationposition. (Check three times and take the averagevalue.)

2. Adjusting1) Raise the boom the desired position and mark it at the

position where the center of the switch is at lower end ofthe plate.

2) Adjust the position of the plate so that the center of theswitch (1) is in line with the bottom of plate (2), thensecure in position.

Plate mounting nut: 88.3 ± 34.3 Nm (9 ± 3.5 kgm)

3) Adjust the switch (1) so that the clearance “a” betweenthe switch (1) sensing surface and plate (2) is thestandard value, then secure the switch in that position.

TESTING AND ADJUSTING TESTING AND ADJUSTING BOOM KICK-OUT

20-49

Proximity switch actuation pilot lamp (red)The proximity switch is equipped with a pilot lamp which showswhen it is being actuated, so use this when adjusting.

TROUBLESHOOTING MEMORANDA

20-50

MEMORANDA

TROUBLESHOOTING TABLE OF CONTENTS

20-101

TROUBLESHOOTING

Points to remember when trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-103Sequence of events in troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-104Precautions when carrying out maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105Checks before troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-113Handling connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-114Precautions when troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-115Preventing recurrence of trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-117Method of using troubleshooting charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-119

Troubleshoting of engine system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-201

Troubleshooting of hydraulic and mechanical system (chassis related) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-401

Troubleshooting of Eagle Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-701

TROUBLESHOOTING MEMORANDA

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MEMORANDA

TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING

20-103

POINTS TO REMEMBER WHEN TROUBLESHOOTINGStop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.

When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not allow anyunauthorized person to come near.If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause burns, so wait for theengine to cool down before starting troubleshooting.Be extremely careful not to touch any hot parts or to get caught in any rotating parts.

When disconnecting wiring, always disconnect the negative (-) terminal of the battery first.

When removing the plug or cap from a location which is under pressure from oil, water or air, always release theinternal 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 preventreoccurrence of the failure.When carrying out troubleshooting, an important point is to understand the structure and function of the machine.However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possiblecauses of the failure that would produce the reported symptoms.

1. When carrying out troubleshooting, do not hurry to 5. Other maintenance items can be checkeddisassemble the components. If components are externally, so check any item that is considereddisassembled immediately after a failure occurs: to be necessary.! Parts that have no connection with the failure or 4. Confirming the failure.

other unnecessary parts will be disassembled. 1. Confirm the extent of the failure yourself, and judge! It will become impossible to find the cause of the whether to handle it as a real failure or as a

failure. problem with the method of operation, etc.It will also cause a waste of man hours, parts, or oil i When operating the machine to reenact theand grease. At the same time, it will also lose the troubleshooting symptoms, do not carry out anyconfidence of the user or operator. For this reason, investigation or measurement that may make thewhen carrying out troubleshooting, it is necessary to problem worse.carry out thorough prior investigation and to carry out 5. Troubleshootingtroubleshooting in accordance with the fixed 1. Use the results of the investigation and inspectionprocedure. in Steps 2 - 4 to narrow down the causes of the

2. Points to ask the user or operator. failure, then use the troubleshooting flowchart to1. Have any other problems occurred apart from the locate the position of the failure exactly.

problem that has been reported? b The basic procedure for troubleshooting is as2. Was there anything strange about the machine follows.

before the failure occurred? 1. Start from the simple points.3. Did the failure occur suddenly, or were there 2. Start from the most likely points.

problems with the machine condition before this? 3. Investigate other related parts or information.4. Under what conditions did the failure occur? 6. Measures to remove root cause of failure.5. Had any repairs been carried out before the 1. Even if the failure is repaired, if the root cause

failure? When were these repairs carried out? of the failure is not repaired, the same failure6. Has the same kind of failure occurred before? will occur again.

3. Check before troubleshooting. 2. To prevent this, always investigate why the1. Check the oil level. problem occurred. Then, remove the root2. Check for any external leakage of oil from the cause.

piping or hydraulic equipment.3. Check the travel of the control levers.4. Check the stroke of the control valve spool.

TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING

20-104

SEQUENCE OF EVENTS IN TROUBLESHOOTING

TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE

20-105

PRECAUTIONS WHEN CARRYING OUT MAINTENANCE

To maintain the performance of the machine over a long period, and toprevent failures or other troubles before they occur, correct operation,maintenance and inspection, troubleshooting and repairs must be carriedout. This section deals particularly with correct repair procedures formechanics and is aimed at improving the quality of repairs. For thispurpose, it gives sections on “Handling electric equipment” and “Handlinghydraulic equipment” (particularly gear oil and hydraulic oil).

PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT

1. Handling wiring harnesses and connectors.Wiring harnesses consist of wiring connecting onecomponent to another component, connectors used forconnecting and disconnecting one wire from another wire,and protectors or tubes used for protecting the wiring.Compared with other electrical components fitted in boxes orcases, wiring harnesses are more likely to be affected by thedirect effects of rain, water, heat or vibration. Furthermore,during inspection and repair operations, they are frequentlyremoved and installed again, so they are likely to sufferdeformation or damage. For this reason, it is necessary to beextremely careful when handling wiring harnesses.

a. Main failures occurring in wiring harness.i. Defective contact of connectors (defective contact

between male and female). Problems withdefective contact are likely to occur because themale connector is not properly inserted into thefemale connector, or because one or both of theconnectors is deformed or the position is notcorrectly aligned, or because there is corrosion oroxidization of the contact surfaces.

TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE

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ii. Defective crimping or soldering of connectors.The pins of the male and female connectors are incontact at the crimped terminal or soldered portion,but if there is excessive force brought to bear onthe wiring, the plating at the joint will peel andcause improper connection or breakage.

iii. Disconnections in wiring. If the wiring is held andthe connectors are pulled apart, or componentsare lifted with a crane with the wiring stillconnected, or a heavy object hits the wiring, thecrimping of the connector may separate, or thesoldering may be damaged, or the wiring may bebroken.

iv. High-pressure water entering connector. Theconnector is designed to make it difficult for waterto enter (drop-proof structure), but if high pressurewater is sprayed directly on the connector, watermay enter the connector, depending on thedirection of the water jet. Since the connector isdesigned to prevent water from entering, but at thesame time, if water does enter, it is difficult for it tobe drained. Therefore, it water should get into theconnector, the pins will be short-circuited by thewater, so if any water gets in, immediately dry theconnector or take other appropriate action beforepassing electricity through it.

TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE

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v. Oil or dirt stuck to connector. If oil or grease isstuck to the connector and an oil film is formed onthe mating surface between the male and femalepins, the oil will not let the electricity pass, so therewill be defective contact. If there is oil or greasestuck to the connector, wipe it off with a dry clothor blow dry with compressed air and spray it witha contact restorer.i When wiping the mating portion of the

connector, be careful not to use excessiveforce or deform the pins.

i If there is oil or water in the compressed air,the contacts will become even dirtier, soremove the oil and water from thecompressed air completely before cleaningwith compressed air.

2. Removing, installing, and drying connectors and wiringharnesses.a. Disconnecting connectors

i. Hold the connectors when disconnecting. Whendisconnecting the connectors, hold the connectorsand not the wires. For connectors held by ascrew, loosen the screw fully, then hold the maleand female connectors in each hand and pullapart. For connectors which have a lock stopper,press down the stopper with your thumb and pullthe connectors apart.i Never pull with one hand.

b. When removing from clipsi. When removing a connector from a clip, pull the

connector in a parallel direction to the clip.i If the connector is twisted up and down or to

the left or right, the housing may break.

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c. Action to take after removing connectorsi. After removing any connector, cover it with a vinyl

bag to prevent any dust, dirt, oil or water fromgetting in the connector portion.i If the machine is left disassembled for a long

time, it is particularly easy for improper contactto occur, so always cover the connector.

d. Connecting connectorsi. Check the connector visuallyii. Check that there is no oil, dirt, or water stuck to the

connector pins (mating portion).iii. Check that there are no deformation, defective

contact, corrosion, or damage to the connectorpins.

iv. Check that there is no damage or breakage to theoutside of the connector.i If there is any oil, water, or dirt stuck to the

connector, wipe it off with a dry cloth. If anywater has got inside the connector, warm theinside of the wiring with a dryer, but be carefulnot to make it too hot as this will cause shortcircuits.

i If there is any damage or breakage, replacethe connector.

v. Fix the connector securelyvi. Align the position of the connector correctly, then

insert it securely.vii. For connectors with lock stopper, push in the

connector until the stopper clicks into position.viii. Correct any protrusion of the boot and any

misalignment of the wiring harness.ix. For connectors fitted with boots, correct any

protrusion of the boot. In addition, if the wiringharness is misaligned, or the clamp is out ofposition, adjust it to its correct position.i If the connector cannot be corrected easily,

remove the clamp and adjust the position.x. If the connector clamp has been removed, be sure

to return it to its original position. Check also thatthere are no loose clamps.

TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE

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e. Drying wiring harness. If there is any oil or dirt on thewiring harness, wipe it off with a dry cloth. Avoidwashing it in water or using steam. If the connectormust be washed in water, do not use high-pressurewater or steam directly on the wiring harness. If watergets directly on the connector, do as follows.i. Disconnect the connector and wipe off the water

with a dry cloth.i If the connector is blown dry with compressed

air, there is the risk that oil in the air maycause defective contact, so remove all oil andwater from the compressed air before blowingwith air.

ii. Dry the inside of the connector with a dryer. Ifwater gets inside the connector, use a dryer to drythe connector.i Hot air from the dryer can be used, but

regulate the time that the hot air is used inorder not to make the connector or relatedparts too hot, as this will cause deformation ordamage to the connector.

iii. Carry out a continuity test on the connector. Afterdrying, leave the wiring harness disconnected andcarry out a continuity test to check for any shortcircuits between pins caused by water.i After completely drying the connector, blow it

with contact restorer and reassemble.

TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE

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3. Handling control boxa. The control box contains a microcomputer and

electronic control circuits. These control all of theelectronic circuits on the machine, so be extremelycareful when handling the control box.

b. Do not open the cover of the control box unlessnecessary.

c. Do not place objects on top of the control box.d. Cover the control connectors with tape or a vinyl bag.

Never touch the connector contacts with your hand.e. During rainy weather, do not leave the control box in a

place where it is exposed to rain.

i. Do not place the control box on oil, water, or soil,or in any hot place, even for a short time. (Place iton a suitable dry stand).

ii. Precautions when carrying out arc welding .When carrying out arc welding on the body,disconnect all wiring harness connectorsconnected to the control box. Fit an arc weldingground close to the welding point.

Points to remember when troubleshooting electric circuits1. Always turn the power OFF before disconnecting or connecting connectors.2. Before carrying out troubleshooting, check that all the related connectors are properly inserted.

i Disconnect and connect the related connectors several times to check.3. Always connect any disconnected connectors before going on to the next step.

i If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated.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.i If there is any change, there is probably defective contact in that circuit.

TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE

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Points to remember when handling hydraulic equipmentWith the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in thehydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to beparticularly careful.

1. Be careful of the operating environment. Avoid addinghydraulic oil, replacing filters, or repairing the machine in rainor high winds, or in places where there is a lot of dust.

2. Disassembly and maintenance work in the field. Ifdisassembly or maintenance work is carried out on hydraulicequipment in the field, there is danger of dust entering theequipment. It is also difficult to confirm the performanceafter repairs, so it is desirable to use a unit exchange.Disassembly and maintenance of hydraulic equipmentshould be carried out in a specially prepared dust proofworkshop, and the performance should be confirmed withspecial test equipment.

3. Sealing openings. After any piping or equipment isremoved, the openings should be sealed with caps, tapes,or vinyl bags to prevent any dirt or dust from entering. If theopening is left open or is blocked with a rag, there is adanger of dirt entering or of the surrounding area beingmade dirty by leaking oil. Do not simply drain oil out on tothe ground. Collect it and ask the customer to dispose of it,or take it back with you for disposal.

4. Do not let any dirt or dust get in during refilling operations.Always keep the oil filler and the area around it clean, andalways use clean pumps and oil containers. If an oilcleaning device is used, it is possible to filter out the dirt thathas collected during storage.

TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE

20-112

5. Change hydraulic oil when the temperature is high. Whenhydraulic oil or other oil is warm, it flows easily. In addition,the sludge can also be drained out easily from the circuittogether with the oil, so it is best to change the oil when it isstill warm. When changing the oil, as much as possible ofthe old hydraulic oil must be drained out. (Drain the oil fromthe hydraulic tank; also drain the oil from the filter and fromthe drain plug in the circuit.) If any old oil is left, thecontaminants and sludge in it will mix with the new oil andwill shorten the life of the hydraulic oil.

6. Flushing operations. After disassembling and assemblingthe equipment, or changing the oil, use flushing oil toremove the contaminants, sludge, and old oil from thehydraulic circuit. Normally, flushing is carried out twice:primary flushing is carried out with flushing oil and secondaryflushing is carried out with the specified hydraulic oil.

7. Cleaning operations. After repairing the hydraulic equipment(pump, control valve, etc.) or when running the machine,carry out oil cleaning to remove the sludge or contaminantsin the hydraulic oil circuit. The oil cleaning equipment isused to remove the ultra fine (about 3µ) particles that thefilter built into the hydraulic equipment cannot remove, so itis an extremely effective device,

20-113

CHECKS BEFORE TROUBLESHOOTING

Item Standard Remedy value

Checks Lubricating 1. Check fuel level -- Add fuelbefore oil, cooling 2. Check for dirt or water in fuel -- Clean, drainstarting water 3. Check hydraulic oil level -- Add oil

4. Check hydraulic oil strainer -- Clean, drain5. Check brake oil level -- Add oil6. Check engine oil level -- Add oil7. Check cooling water level -- Add water8. Check condition of dust indicator -- Clean or replace9. Check air pressure -- Refer to

troubleshooting

Item Electrical 10. Check for loose or corroded battery -- Tighten or replaceEquipment terminals

11. Check for loose or corroded -- Tighten or replacealternator terminals

12. Check for loose or corroded stating -- Tighten or replacemotor terminals

Other Hydraulic 13. Check for abnormal noise or smell -- Repaircheck items mechanical 14. Check for oil leakage -- Repair

components 15. Bleed air from system -- Bleed air

Electrical 16. Check battery voltage 23 - 26 V Replacecomponents (engine stopped)

17. Check level of battery electrolyte -- Add or replace18. Check for discolored, burnt, or bare -- Replace

wires19. Check for missing wiring clamps, -- Repair

hanging wires20. Checks for water leaking onto -- Disconnect connector

wiring (checks carefully water and dry connectionleakage at connectors andterminals)

21. Check for broken or corroded fuses -- Replace22. Check alternator voltage 27.5 - 29.5 V Replace

(engine running at over halfthrottle)

23. Noise when battery relay is -- Replaceoperated (switch startingswitch from ON to OFF)

TROUBLESHOOTING HANDLING CONNECTORS

20-114

HANDLING CONNECTORS

1. When removing connectors from clips, pull theconnector in a parallel direction to the clip.Ú If the connector is twisted to the left and right or

up and down, the housing may break.

2. When disconnecting male and female connectors,release the lock and pull in a parallel direction withboth hands.Ú Never try to pull apart with one hand.

3. When the wiring harness clamp of the connectorhas been removed, always return it to its originalcondition and check that is no looseness of theclamp.

TROUBLESHOOTING PRECAUTIONS WHEN TROUBLESHOOTING

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PRECAUTIONS WHEN TROUBLESHOOTING1. SAFETY b. Was there anything unusual before the

! Stop the machine on level ground, and machine broke down?check that the safety pins and parking brake c. Did the breakdown occur suddenly, or hadare correctly applied, and that the tires are there been signs of trouble before?blocked. d. What was the machine doing when break

! When working in groups, use agreed upon e. Had the machine been repaired before thesignals and do not allow unauthorized breakdown? If so, who carried out the repair,persons near machine. and when?

! Be careful not to get burned by hot parts orget caught in rotating parts. 2) Check the following items which can be

! Always disconnect the cable from the a. Check oil level.negative (-) terminals of the battery before b. Check for leakage of oil from piping ordisconnecting any wiring. hydraulic equipment.

! Always release the pressure before d. Check stroke of spool in control valves.removing the plugs or caps of any placeunder hydraulic or air pressure, and connect 3) Reenact the failure and check the condition ofall measuring tools correctly. the machine (particular conditions at the time of

2. METHODS FOR TROUBLESHOOTING a. Ask the user or operator if the decision aboutÚ Just because a failure occurs, do not the failure was made based on measured

immediately start to disassemble the machine. values, or by comparison, or by feeling.

! The machine may be disassembled in such a ! Check safety before carrying out anyway that the problem cannot be located, so the check.cause of the problem will be unknown. ! Did not make any check or measurement

As a result,

! The customer and operator will lose confidence The transmission system consists of thein you. transmission itself, the transmission control valve,

! Time will be wasted, and unnecessary costs willbe incurred for excess parts and greasing. In particular, when trouble occurs in the

To avoid these problems, use the following failure can be divided as follows;procedure when troubleshooting. ! Transmission itself, or transmission control

1) Ask the customer and operator the following ! Transmission electric control.questions about the breakdown.a. Have there been any other problems apart

from the one reported?

down occurred?

f. Had the same kind of failure occurred before?

checked simply by visual checks etc.

c. Check travel of control levers.

failure).

b. Compare extent of failure with standard values.

that will make the condition worse.

4) Try to locate the possible causes for the failure.

and the transmission electrical control.

transmission system, the probable location of the

valve.

TROUBLESHOOTING PRECAUTIONS WHEN TROUBLESHOOTING

20-116

To decide which of the two is the location of ! When removing parts, check their condition ofthe failure, refer to “JUDGMENT ON POWER mounting, and distinguish between front and rear,TRAIN”. left and right, and top and bottom.

5) Carry out troubleshooting using the ! Check the match marks, or make match marks totroubleshooting charts. prevent mistakes when installing.There are the following two types oftroubleshooting charts. ! If part cannot be removed even when the nuts and

1. TROUBLESHOOTING TABLE force to remove it. Check the part to see if there isPOWER TRAIN any problem with it and remove the problem beforeSTEERING SYSTEM trying to disassemble the part.BRAKE AND AIR SYSTEMWORK EQUIPMENT SYSTEM ! When installing or assembling, clean off all dust

2. TROUBLESHOOTING FLOW CHART all grease or oil before coating with gasket sealant.ELECTRICAL SYSTEM

The troubleshooting charts consist of:1) Items which can be checked easily.2) Items which are likely to be the cause of such

failures.

Follow theses charts to carry out troubleshooting.At the same time, do not forget the following points.! Check related items.! Check that there are no other failures or

breakdowns.

6) Investigate causes of breakdown! Even if the breakdown is repaired, if the

original cause of the problem is not removed,the same breakdown will occur again. Toinvestigate and remove the original cause, see"Actions to take to prevent failures fromoccurring again".

3. PRECAUTIONS WHEN REMOVING,INSTALLING, DISASSEMBLING ORASSEMBLING PARTS DURINGTROUBLESHOOTING

! Carry out the various testing and adjustingwhile observing the items on quality controlgiven in "Testing and Adjusting".

bolts have been removed, do not use excessive

and dirt and repair any scratches or dents. Remove

TROUBLESHOOTING PREVENTING RECURRENCE OF TROUBLE

20-117

PREVENTING RECURRENCE OF TROUBLE! The troubleshooting table is used to establish the direct cause of damage or breakdown of a part or piece of

equipment. It is not able to establish the root cause of the damage or failure, however.! Also, this table only describes the action to be taken with the particular part or piece of equipment. It does not

mention what action should be taken to prevent a recurrence of the root cause.! In order to remove the root cause of a fault so as to prevent a recurrence, carefully investigate the real cause while

referring to the following items.! Regarding the method of checking and adjusting each part or piece of equipment, refer to "Testing and Adjusting"

in the Shop Manual.

HYDRAULIC EQUIPMENT Sand: Oil replenishing or replacing1. Oil checks method, etc.

! The fundamental cause of almost all faults Rubber: Cylinder packing, etc.occurring in hydraulic equipment is the Metal: Wear or damage to hydraulicinclusion of water, air or other foreign matter in equipment such as pump andthe oil. Accordingly, it is necessary to check the motor, as well as transmissionoil to see whether or not it contains any of the and torque converter, etc.above substances, and then take appropriateaction. 3) Oil cleaning and replacement

1) Oil checks other foreign matter is discovered in the! Check for water contamination. oil, either wash the oil using an oil

Check the oil for possible water refresher or replace it.contamination by means of a diesel Ú If the oil is contaminated by water, it isengine oil checker or a hot plate. not possible to remove the water by

! Check for contamination of other means of an oil refresher.foreign matter. Remove the drain plug Ú When washing the oil, also wash orand filter, then check the bottom of the replace the strainer and replace thetank and also the filter to see if any filter.foreign matter has collected there.Check the degree of contamination by 2. Cleaning fragments of damaged partsmeans of a contamination checker. ! If a part becomes damaged, fragments may

! Viscosity check pass into the oil line. It is thus necessary toCheck the viscosity of the oil using a wash the oil.viscometer in order to confirm whether ! In addition, disassemble and wash such partsor not the oil is satisfactory. as valves and cylinders which are liable to

2) Check of contamination point collect metal fragments and other foreignIf, as a result of the above checks, it is matter, thus helping to prevent a recurrence ofdiscovered that the oil is contaminated by faults due to such fragments becoming lodgedwater or other foreign matter, it is in various parts of the engine or hydraulicnecessary to find out where the equipment.contamination is occurring and also to takesteps to prevent it.

Water: Oil storage tank, breather, etc.

! If a large amount of metal particles or

TROUBLESHOOTING MEMORANDA

20-118

MEMORANDA

TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS

20-119

METHOD OF USING TROUBLESHOOTING CHARTS1. Category of troubleshooting code number

Troubleshooting code No. Component

S-FF Troubleshooting of engine

M-FF Troubleshooting of main monitor

K-FF Troubleshooting of maintenance monitor

E-FF Troubleshooting of electrical system

T-FF Troubleshooting of hydraulic and mechanical system

D-FFTroubleshooting of ECSS (Electronically Controlled SuspensionSystem)

W-FF Troubleshooting of work equipment

2. Method of using troubleshooting table for each troubleshooting mode.1) Troubleshooting code number and problem.

The title of the troubleshooting chart gives the troubleshooting code, service code and failure mode (problemwith the machine). (See Example (1))

2) Distinguishing conditions.Even with the same failure mode (problem), the method of troubleshooting may differ according to the model,component, or problem. In such cases, the failure mode (problem) is further divided into sections marked withsmall letters (for example, (a)), so go to the appropriate section to carry out troubleshooting. If the troubleshooting table is not divided into sections, start the troubleshooting from the first check item in thefailure mode .(See Example (2))

3) Method of following troubleshooting chart.! Check or measure the item inside , and according to the answer, follow either the YES line or the

NO line to go to the next condition box. (Note: The number at the top right corner of the conditionbox 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 theCause column. Check the cause and take the action given in the Remedy column on the right .(SeeExample (3))

! Below the [ ] condition box, there are the methods for inspection or measurement, and the judgementvalues.If the judgement values below the condition box are correct or the answer to the question inside the condition box is YES, follow the YES line. If the judgement value is not correct, or the answer to thequestion in NO, then follow the NO line.

! Below the condition box is given the preparatory work needed for inspection and measurement, andthe judgement values. If this preparatory work is neglected, or the method of operation or handling ismistaken, there is the danger that it may cause mistaken judgement or the equipment may be damaged.Therefore, before starting inspection or measurement, always read the instructions carefully, and start thework in order from the first item 1.

4) General precautionsWhen carrying out troubleshooting for the failure mode (problem), precautions that apply to all the items aregiven at the top of the page and marked with a i. (See Example (4))The precautions marked i are not given in the condition box, but must always be followed when carryingout the check inside the condition box.

5) Troubleshooting toolsWhen carrying out troubleshooting, prepare the necessary troubleshooting tools. For details, see TOOLS FORTESTING, ADJUSTING AND TROUBLESHOOTING.

6) Installation position, pin number.A diagram or chart is given for the connector type, installation position, and connector pin number connection.When carrying out troubleshooting, see this chart for details of the connector pin number and location forinspection and measurement of the wiring connector number appearing in the troubleshooting flow chart foreach failure mode (problem).

TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS

20-120

< Example >(1) M-15 Abnormality in buzzer(2) (a) Buzzer does not sound when starting switch is turned ON (during self-check)

(3)

(4)i Before carrying out troubleshooting, check that all the related connectors are properly inserted.i Always connect any disconnected connectors before going on to the next step.

TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS

20-121

3. Using troubleshooting chart for engine-relatedfailure

This troubleshooting chart is divided into threesections: questions, check items, andtroubleshooting. The questions and check items areused to pinpoint high probability causes that can belocated from the failure symptoms or simple inspectionwithout using troubleshooting tools.

Next, troubleshooting tools or direct inspection are used tocheck the high probability causes to make the finalconfirmation.

[Question]Sections (A) and (B) in the chart below corresponds tothe items where the answers can be obtained from theuser. The items in (B) are items that can be obtainedfrom the user, depending on the user’s level.

[Check items]The serviceman carries out simple inspections tonarrow down the causes. The items under (C) in thechart below correspond to this. The servicemannarrows down the causes from information (A) that hehas obtained from the user and the results of (C) thathe has obtained from his own inspection.

[Troubleshooting]Troubleshooting is carried out in the order ofprobability, starting with the causes that have beenmarked as having the highest probability frominformation gained from [Questions] and [Checkitems].

TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS

20-122

The basic method of using the troubleshooting chart is as follows.Items listed for [Questions] and [Check Items] that have a relationship withthe Cause items are marked with F, and of these, causes that have a highprobability are marked with F" .

Check each of the [Questions] and [Check Items] in turn, and marke the For F" in the chart for items where the problem appeared. The vertical column(Causes) that has the highest number of points is the most probable cause,so start troubleshooting for that item to make the final confirmation of thecause.

1. For [Confirm recent repair history] in the Question section, askthe user, and mark the Cause column with a Î to use asreference for locating the cause of the failure. However, do notuse this when making calculation to narrow down the causes.

2. Use the Î in the Cause column as reference for [Degree of use(Operated for long period)] in the Questions section asreference. As a rule, do not use it when calculating the points forlocating the cause, but it can be included in necessary todetermine the order for troubleshooting.

TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS

20-123

MEMORANDA

TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS

20-124

!! Example of troubleshooting when exhaust gas is blackLet us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms have causalrelationship with this problem: [Exhaust gas slowly became black], [Power slowly became weaker], and [Dust indicatoris red]. If we look from these three symptoms to find the causes, we find that there is a relationship with five causes. Let usexplain here the method of using this causal relationship to pinpoint the most probable cause.

S-7 Exhaust gas is black (incomplete combustion)General causes why exhaust gas is black! insufficient intake of air! improper condition of fuel injection! Excessive injection of fuel

TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS

20-125

TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS

20-126

4. Method of using matrix troubleshooting tablesThe troubleshooting tables use the same method as for other troubleshooting table (YES/NO type) to locatethe causes of failures in the machine. The troubleshooting tables are divided broadly into categories for themain components, such as the steering system and work equipment hydraulic system. Follow the proceduregiven below and carry out troubleshooting to locate the problems accurately and swiftly.

Step 1. Questioning the operatorThe questions to ask the operator are given below the 1. Steering does not work ² Symptom [Example]failure symptom. If the answers to the questionsmatch the information given, follow the arrow to reachthe probable cause of the failure.Consider the contents of the questions and consult thetable while proceeding to Steps 2 and 3 to grasp thetrue cause.

Step 2. Checks before troubleshootingBefore starting the main troubleshooting andmeasuring the hydraulic pressure, first check theChecks before Starting items, and check for oilleakage and loose bolts. These checks may avoidtime wasted on unnecessary troubleshooting.The items given under Checks before Starting areitems which must be considered particularly for thatsymptom before starting troubleshooting.

Step 3. Using cross-reference table1 ) Operate the machine to carry out the checks in

the troubleshooting item column.Mark the items where the results match thesymptom.i It is not necessary to follow the

troubleshooting checks in order; follow anorder which is easiest to carry outtroubleshooting.

2) Find the appropriate cause from the causecolumn. If the symptom appears, the F', markson that line indicate the possible causes. (For itemNo. 2 in the table on the right, the possible causesare c or e.)If there is only one F:Carry out the other troubleshooting items (wherethe same cause is marked with check if thesymptom appears, then repair.If there are two F s:Go on to Step 3) to narrow down the possiblecauses.

Ask the operator about the following points. ! Did the steering suddenly stop working? ÿ

Breakage in steering equipment! Had the steering gradually been becoming

heavy? ÿ Internal wear of steering equipment,defective seal.

Checks efore starting [Example]

! Is the oil level and type of oil in the hydraulictank correct?

! Is there any leakage of oil from the steeringcontrol valve?

TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS

20-127

3) Operate the machine and check thetroubleshooting items other than those in 1).Operate the machine and check the items in thesame way as in 1) and if the symptom appears,mark that item. (In the chart on the right, thesymptom appears again for item 5).

4) Find the appropriate cause from the causecolumn. In the same way as in Step 2), if thesymptom appears, the F marks on that lineindicate the possible causes. (For item No.5 in thetable on the right, the possible causes are b or e.)

5) Narrow down the possible causes.There is one common cause among the causeslocated in Steps 2) and 4). (One cause marked F,appears on the line for both items.) This cause iscommon to both the symptoms in troubleshootingSteps 1) and 3).i The causes which are not common to both

troubleshooting items (items which are notmarked F for both symptoms) are unlikelycauses, so ignore them. (In the example givenon the right, the causes for TroubleshootingItem 2 are c or e, and the causes forTroubleshooting Item 5 are b or e, so cause eis common to both.)

6) Repeat the operations in Steps 3), 4) and 5) untilone cause (one common cause) remains.i If the causes cannot be narrowed down to

one cause, narrow the causes down as far aspossible.

7) RemedyIf the causes are narrowed down to one commoncause, take the action given in the remedycolumn.The symbols given in the remedy column indicatethe following:

X: Replace,Î : Repair, A; Adjust, C: Clean

TROUBLESHOOTING MEMORANDA

20-128

MEMORANDA

TROUBLESHOOTING TROUBLESHOOTING OF ENGINE SYSTEM

20-201

TROUBLESHOOTING OF ENGINE SYSTEMTABLE OF CONTENTS

S- 1 Starting performance is poor (Staring always take time) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-202S- 2 Engine does not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-203S- 3 Engine does not pick up smoothly (Follow up is poor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-206S- 4 Engine stops during operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-207S- 5 Engine does not rotate smoothly (hunting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-208S- 6 Engine lacks output (no power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-209S- 7 Exhaust gas is black (incomplete combustion) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-210S- 8 Oil consumption is excessive (or exhaust gas is blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-211S- 9 Oil becomes contaminated quickly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-212S-10 Fuel consumption is excessive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-213S-11 Oil is in cooling water, or water spurts back, or water level goes down . . . . . . . . . . . . . . . . . . . . . . . . 20-214S-12 Oil pressure lamp lights up (drop in oil pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-215S-13 Oil level rises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-216S-14 Water temperature becomes too high (overheating) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-217S-15 Abnormal noise is made . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-218S-16 Vibration is excessive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-219

TROUBLESHOOTING S-1

20-202

S-1 STARTING PERFORMANCE IS POOR (Starting always takes time)

General causes why starting performance is poor! Defective electrical system! Insufficient supply of fuel! Insufficient supply of air! Improper selection of fuel

(At ambient temperature of -10EC or below, use ASTMD975No. 1, and -10EC or above, use ASTM D975 No. 2 diesel fuel.)

! The specific gravity should exceed the value for the chargingrate of 70% in the below table

! In cold weather the specific gravity must exceed the value for thecharging rate of 75% in the below table.

TROUBLESHOOTING S-2

20-203

S-2 Engine does not start

(1) Engine does not turn

General cause why engine does not turn! Internal parts of engine seized

i If the internal parts of the engine are seized, carry out trouble shootingfor “Engine in power train”.

! Failure in power train! Defective electrical system

TROUBLESHOOTING S-2

20-204

(2) Engine turns but no exhaust gas comes out (Fuel is not being injected)

Genereal causes why engine turns but no exhaust gas comes out! Supply of fuel impossible! Supply of fuel is extremely small! Improper selectioon of fuel (particularlyin winter)

TROUBLESHOOTING S-2

20-205

(3) Exhaust gas comes out but engine does not start. (Fuel is being ejected)

General causes why exhaust gas comes out but engine does not start! Lack of rotating force due to defective electrical system! Insufficient supply of fuel! Insufficient intake of air! Improper selection of fuel

TROUBLESHOOTING S-3

20-206

S-3 Engine does not pick up smoothly (Follow up is poor)

General causes why exhaust gas comes out but engine does not start! Insufficient intake of air! Insufficient supply of fuel! Improper condition of fuel injection! Improper fuel used

TROUBLESHOOTING S-4

20-207

S-4 Engine stops during operations

General causes why engine stops during operations! Seized parts inside engine! Insufficient supply of fuel! Overheating

i If there is overheating and insufficient output, carry out troubleshooting for overheating.! Failure in power train

i If engine stops because of failure in power train,carry out troubleshooting for chassis.

TROUBLESHOOTING S-5

20-208

S-5 Engine does not rotate smoothly (hunting)

General causes why engine does not rotate smoothly! Air in fuel system! Defective governor mechanism! Defective engine throttle controller mechanism

(Engine throttle controller type)

TROUBLESHOOTING S-6

20-209

S-6 Engine lacks output (no power)

General causes why engine lacks output! Insufficient intake of air! Insufficient supply of air! Improper condition of fuel injection! Improper fuel used

(If non-specified fuel is used, output drops)! Lack of output due to overheating

i If there is overheating and insufficient output,carry out troubleshooting for overheating.

TROUBLESHOOTING S-7

20-210

S-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black! insufficient intake of air! Improper condition of fuel injection! Excessive injection of fuel

TROUBLESHOOTING S-8

20-211

S-8 Oil consumption is excessive (or exhaust gas is blue)

i Do not run the engine at idle for more than 20 minutescontinuously.. (Both low and high idle)

General causes why oil consumption is excessive! Abnormal combustion of oil! External leakage of oil! Wear of lubrication system

TROUBLESHOOTING S-9

20-212

S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated quickly! Intake of exhaust gas due to internal wear! Clogging of lubrication passage! Improper combustion! Improper oil used! Operation under excessive load

TROUBLESHOOTING S-10

20-213

S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive! Leakage of fuel! Improper condition of fuel injection! Excessive injection of fuel

TROUBLESHOOTING S-11

20-214

S-11 Oil is in cooling water, or water spurts back, or water level goes down

General causes why oil is in cooling water! Internal leakage in lubrication system! Internal leakage in cooling system

TROUBLESHOOTING S-12

20-215

S-12 Oil pressure lamp lights up (drop in oil pressure)

General causes why oil pressure lamp lights up! Leakage, clogging, wear of lubricating system! Defective oil pressure control! Improper oil used (improper viscosity)! Deterioration of oil due to overheating

TROUBLESHOOTING S-13

20-216

S-13 Oil level rises

i If there is oil in the cooling water, carry out troubleshooting for “Oil is in cooling water”.General causes why oil level rises! Water in oil (cloudy white)! Fuel in oil (diluted, and smells of diesel fuel)! Entry of oil from other components

TROUBLESHOOTING S-14

20-217

S-14 Water temperature becomes too high(overheating)

General causes why water temperature becomes too high! Lack of cooling water (deformation, damage of fan)! Drop in heat dissipation efficiency! Defective cooling circulation system! Rise in oil temperature of power train

i Carry out troubleshooting for chassis

TROUBLESHOOTING S-15

20-218

S-15 Abnormal noise is made

i Judge if noise is internal noise or an external noise.General causes why abnormal noise is made! Abnormality due to defective parts! Abnormal combustion noise! Air sucked in from intake system

TROUBLESHOOTING S-16

20-219

S-16 Vibration is excessive

i If there is abnormal; noise together with the vibration, carry out troubleshooting for “Abnormal noise is made”.General causes why Vibration is excessive! Defective parts (abnormal wear, breakage)! Improper alignment! Abnormal combustion

TROUBLESHOOTING MEMORANDA

20-220

MEMORANDA

TROUBLESHOOTING HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED)

20-401

TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED)TABLE OF CONTENTS

POWER TRAINT-1 Machine does not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-402T-2 Travel speed is slow, thrusting power is weak, lacks power on slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-404T-3 Excessive shock when starting machine or shifting gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-406T-4 Excessive time lag when starting machine or shifting gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-407T-5 Torque converter oil temperature is high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-408

STEERING SYSTEMS-1 Steering wheel does not turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-409S-2 Steering is heavy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-410S-3 Steering wheel shakes or there is excessive shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-411S-4 Deviates to one side when traveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-412S-5 Turning radius is different between left and right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-412S-6 Excessive shock to machine when steering wheel is turned fully to left or right . . . . . . . . . . . . . . . . . . . . . 20-412

BRAKE SYSTEMA-1 Brakes do not work or braking effect is poor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-413A-2 Brake is not released, brake drags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-414

WORK EQUIPMENTH-1 Boom does not rise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-415H-2 Boom movement is slow or boom lacks lifting power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-416H-3 When boom is raised, it moves slowly at a certain height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-417H-4 Bucket cannot be pushed with boom cylinder (bucket floats). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-417H-5 Excessive hydraulic drift of boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-417H-6 Boom shakes during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-417H-7 Boom drops momentarily when control lever is operated from HOLD to RAISE . . . . . . . . . . . . . . . . . 20-418H-8 Bucket does not tilt back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-419H-9 Bucket movement is slow or tilt-back lacks power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-420H-10 Bucket movement becomes slow during tilt-back operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-421H-11 Bucket cannot be pushed with bucket cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-421H-12 Excessive hydraulic drift of bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-421H-13 Bucket shakes during loading operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-422H-14 Bucket dumps momentarily when control lever is operated from HOLD to TILT . . . . . . . . . . . . . . . . . 20-422H-15 Boom, bucket control levers are heavy or do not move smoothly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-423

Explanation of symbols in TableThe following symbols are used on the Cause column to show the action to be taken to remove the cause.

X: Replace, Î: Correct, A: Adjust, C: Clean

TROUBLESHOOTING T-1

20-402

POWER TRAIN

T-1 Machine does not start

Ask the operator the following questions.! Did the problem suddenly start?

Yes = Internal part seized or broken! Was there any abnormal noise when this happened?

Yes = Component broken.

Checks before troubleshooting! Does the machine monitor function properly?! Is the transmission oil level correct?! Is the type of oil correct?! Is the transmission filter or strainer clogged?! Does the electrical circuit of the transmission control work

properly?! Is the transmission oil deteriorated?

Does the oil smell of burning?! Is there any damage or leakage of oil that can be seen

externally?! Is the drive shaft broken?! Is the wheel brake or parking brake locked?

TROUBLESHOOTING T-1

20-403

TROUBLESHOOTING T-2

20-404

T-2 Travel speed is slow, thrusting power is weak, lacks power onslopes

Checking for abnormalities! Measure digging operations and speed when traveling on level ground and on slopes, and check if

there is actually an abnormality or whether it is just the feeling of the operator.

Checks before troubleshooting! Is the transmission oil level correct?

Is the type of oil correct?! Is the transmission filter or strainer clogged?! Is there any oil leaking from the joints of the piping or valves?! Is there any dragging of the wheel brake or parking brake?! Is the tire inflation pressure and tread pattern normal?! Is the method of operation correct?

TROUBLESHOOTING T-2

20-405

TROUBLESHOOTING T-3

20-406

T-3 Excessive shock when starting machine or shifting gear

Checking for abnormalitiesIt is difficult to measure if the shock is excessive ornormal, so judge that the shock is excessive in thefollowing cases.! When it is clear that the shock has become greater

than before.! When the machine is compared with another machine

of the same class and the shock is found to be greater.

Checks before troubleshooting! Is the engine idling speed too high?! Is there play in any of the drive shafts?

TROUBLESHOOTING T-4

20-407

T-4 Excessive time lag when starting machine or shifting gear

Ask the operator the following questions.! Was there excessive time lag? Was there any abnormality

in the travel speed or thrusting force? Was there any lackof power when traveling up slopes?

Yes = Go to T-2 Travel speed is slow, thrusting poweris weak, lacks power on slopes

Checks before troubleshooting! Is the transmission oil level correct?! Is the type of oil correct?! Is there any oil leaking from the joints of the piping or

valves?

TROUBLESHOOTING T-5

20-408

T-5 Torque converter oil temperature is high

Ask the operator the following questions.! Does oil temperature rise during torque converter stall and

go down when there is no load?Yes = Selection of transmission range

! Does oil temperature rise only when carrying out scoopingwork?

Yes = Improvement in method of operation

Checks before troubleshooting! Are the radiator water level and fan belt tension correct?! Is the transmission oil level correct?! Is the type of oil correct?! Is the transmission filter or strainer clogged?

Checking for abnormalities! Measure the torque converter oil temperature. Is it actually

high?Yes = Defective oil transmission gauge

TROUBLESHOOTING S-1

20-409

STEERING SYSTEM

S-1 Steering wheel does not turn

Ask the operator the following questions.! Did the problem suddenly start?

Yes = Steering equipment damaged or broken! Was there previously any symptom, such as heavy steering?

Yes = Wear of internal parts of steering equipment, defective seal

Checks before troubleshooting! Is the hydraulic oil level correct?! Is the type of oil correct?! Has the safety bar been removed from the frame?

There is a close connection between the steering circuit and the work equipment circuit, so if any abnormality is feltin the steering, check the operation of the work equipment also.

TROUBLESHOOTING S-2

20-410

S-2 Steering is heavy

Ask the operator the following questions.! Did the problem suddenly start?

Yes = Steering equipment damaged or broken! Was there previously any symptom, such as heavy

steering?Yes = Wear of internal parts of steering equipment,defective seal

Checks before troubleshooting.! Is the hydraulic oil level correct? Is the type of oil correct?! Is there any leakage of oil from the hydraulic hoses, valves,

or cylinders?! Is there any scuffing of the center hinge pin bearing or

steering cylinder pin or bushing?! Is the tire inflation pressure correct?

Checking for abnormalities.! Measure the operating force of the steering wheel and the

time taken to turn the steering, and check the values in theStandard Value Table to see if there is really anyabnormality.

TROUBLESHOOTING S-3

20-411

S-3 Steering wheel shakes or there is excessive shock

Checks before troubleshooting! Is the hydraulic oil level correct? Is the type of oil correct?! Is there any play in the center hinge pin bearing or steering

cylinder pin or bushing?! Is there any variation in the tire inflation pressure?! Is the steering wheel play correct?

Checking for abnormalities! Operate at a safe place and check how the steering wheel

shakes and under what conditions.In cases where the steering wheel is heavy but does notshake, go to "T-7 Steering is heavy."

TROUBLESHOOTING S-4, S-5, S-6

20-412

S-4 Deviates to one side when traveling

Cause! Defect inside Orbit-Roll! Oil leakage inside steering cylinder! Variation in inflation pressure of tires

S-5 Turning radius is different between left and right

Cause! Defective cylinder piston packing! Defect inside Orbit-roll

S-6 Excessive shock to machine when steering wheel is turned fully to leftor right

Cause! Deteriorated, damaged, or missing front frame bumper

TROUBLESHOOTING A-1

20-413

BRAKE SYSTEM

A-1 Brakes do not work or braking effect is poor

Ask the operator the following questions! Did the problem suddenly start?

Yes = Brake equipment broken! Did the problem gradually appear?

Yes = Deterioration of seal, wear of lining, disc

Checks before troubleshooting! Is the brake oil level correct?! Is the brake pedal play correct?! Is there any leakage of oil from the brake tube or

connector?! Is there any deformation of the tube? Is the tire inflation

pressure and tread pattern normal?

Checking for abnormalities! Measure the braking force and compare with the Standard

Value Table to check if the braking effect is poor

TROUBLESHOOTING A-2

20-414

A-2 Brake is not released, brake drags

Checks before troubleshooting! Is the play of the brake pedal correct?

Checking for abnormalities! Does the machine travel smoothly under inertia on flat ground?! Jack up the four wheels and check the rotating resistance of the tires.

TROUBLESHOOTING H-1

20-415

WORK EQUIPMENT

H-1 Boom does not rise

Ask the operator the following questions.! Did the problem suddenly start?

Yes = Equipment seized, damaged Was there anyabnormal noise when this happened? (from where?)

! Was there previously any symptom, such as the speedbecoming slow?

Yes = Wear of internal parts, deterioration in spring

Checks before troubleshooting! Is the hydraulic oil level correct?! Is the travel of the boom control lever and spool properly

adjusted?

TROUBLESHOOTING H-2

20-416

H-2 Boom movement is slow or boom lacks lifting power

Checks before troubleshooting! Is the travel of the boom control lever and main control

valve spool properly adjusted?! Is there any seizure of the work equipment linkage? (Is

there any abnormal noise?)

Checking for abnormalities! There is a strong connection between lifting power and

speed, so this problem first appears as a lack of liftingspeed. Measure the boom lifting speed when the bucket isloaded and use the Standard Value Table to judge if thereis any abnormality.

TROUBLESHOOTING H-3, H-4, H-5, H-6

20-417

H-3 When boom is raised, it moves slowly at a certain height

Checks before troubleshooting! Can any deformation be seen in the boom cylinder?

Cause! Swelling or internal damage to boom cylinder tubei For other abnormalities when the boom is raised, go to "H-2 Boom movement is slow or boom lacks lifting

power."

H-4 Bucket cannot be pushed with boom cylinder (bucket floats)

See "H-2 Boom movement is slow or boom lacks lifting power."

Checks before troubleshooting! Is the stroke of the boom spool in the main control valve properly adjusted?Cause! Defective seating of suction valve at boom cylinder rod end of main control valve! Oil leakage from boom cylinder piston seal

H-5 Excessive hydraulic drift of boom

Ask the operator the following questions.! Did the problem suddenly start?

Yes = Dirt caught in valve, broken part! Did the problem gradually appear?

Yes = Worn partsChecks before troubleshooting! Is the boom spool at the neutral position?

Yes = Seized link bushing, defect in spool detentTroubleshooting and Cause! When measuring the hydraulic drift, is there any sound of oil leakage from inside the boom cylinder?

Yes = Defective cylinder packing

H-6 Boom shakes during operation

When digging or leveling operations are carried out with the boom control lever at HOLD, thebucket and boom move up and down to follow the shape of the ground.Troubleshooting and CauseMeasure the hydraulic drift of the boom and check if it is possible to lift the chassis with the boom cylinder.

1. If the hydraulic drift of the boom cylinder is outside the standard value, go to "H-5 Excessive hydraulic drift ofboom."

2. If the chassis cannot be raised with the boom cylinder, go to "H-4 Bucket cannot be pushed with boomcylinder."

3. If the hydraulic drift of the boom is normal, operate the boom several times, and operate the boom cylinder tothe end of its stroke. Is it now possible to raise the chassis with the boom cylinder?

Yes = Vacuum had formed inside cylinder

i However, if this problem appears frequently, the suction valve at the boom cylinder rod end is defective.

TROUBLESHOOTING H-7

20-418

H-7 Boom drops momentarily when control lever is operated fromHOLD to RAISE

Checking problem! When the engine is run at low idling and the boom control lever is operated slowly from HOLD to RAISE, the

boom goes down under its own weight. When the lever is operated fully to the RAISE position, the conditionreturns to normal.

Cause! Defective seating of check valve for boom spool in main control valve

TROUBLESHOOTING H-8

20-419

H-8 Bucket does not tilt back

Ask the operator the following questions.! Did the problem suddenly start?

Yes = Equipment seized, damaged Was there anyabnormal noise when this happened? (from where?)

! Was there previously any symptom, such as the speedbecoming slow?

Yes = Wear of internal parts, deterioration in spring

Checks before troubleshooting! Is the travel of the bucket control lever and spool properly

adjusted?

TROUBLESHOOTING H-9

20-420

H-9 Bucket movement is slow or tilt-back lacks power

Checks before troubleshooting! Is the travel of the bucket control lever and main control

valve spool properly adjusted?! Is there any seizure of the work equipment linkage? (Is

there any abnormal noise?)

Checking for abnormalities! Check if there is lack of tilt-back power during actual

operations.! Measure the operating speed of the bucket and use the

Standard Value Table to check if there is any abnormality

TROUBLESHOOTING H-10, H-11, H-12

20-421

H-10 Bucket movement becomes slow during tilt-back operation

Checks before troubleshooting! Can any deformation be seen in the bucket cylinder?

Cause! Swelling or internal damage to bucket cylinder tube! For other abnormalities when the bucket is operated, go to "H-9 Bucket movement is slow or tilt back lacks

power."

H-11 Bucket cannot be pushed with bucket cylinder

See "H-9 Bucket movement is slow or tilt back lacks power."

Checks before troubleshooting! Is the stroke of the bucket spool in the main control valve properly adjusted?

Cause! Defective seating of safety valve (with suction valve) at bucket cylinder rod end of main control valve! Oil leakage from bucket cylinder piston seal

H-12 Excessive hydraulic drift of bucket

Ask the operator the following questions.! Did the problem suddenly start?

Yes = Dirt caught in valve, broken part ! Did the problem gradually appear?

Yes = Worn parts

Checks before troubleshooting! Is the bucket spool at the neutral position?

Yes = Seized link bushing, defect in spool detent

Checking for abnormalities! Use the Standard Value Table to check if the hydraulic drift of the bucket is actually excessive.

Cause! Oil leakage inside bucket cylinder! Defective seating of safety valve (with suction valve) at bottom end! Defective oil tightness of bucket spool

TROUBLESHOOTING H-13, H-14

20-422

H-13 Bucket shakes during loading operation(Main control valve at HOLD)

Checks before troubleshooting! Is there play in the work equipment linkage pin, bushing? (Is there any abnormal noise?)

Cause! Defective bucket cylinder piston seal! Defective operation of safety valve (with suction valve) at bucket cylinder rod end. If any other problem occurs at

the same time, carry out troubleshooting according to the nature of the problem.

H-14 Bucket dumps momentarily when control lever is operated fromHOLD to TILT

Checking problem! When the engine is run at low idling and the bucket control lever is operated slowly from HOLD to TILT, the bucket

dumps momentarily under its own weight. When the lever is operated fully to the TILT position, the condition returnsto normal.

Cause! Defective seating of check valve for bucket spool in main control valve

TROUBLESHOOTING H-15

20-423

H-15 Boom, bucket control levers are heavy or do not move smoothly

Checking for abnormalities! Compare operating force of the lever with the value in the

Standard Value Table to see if it is actually excessive.

TROUBLESHOOTING MEMORANDA

20-424

MEMORANDA

TROUBLESHOOTING TROUBLESHOOTING-EAGLE AIR CONDITIONER

701

TROUBLESHOOTING

TroubleshootingSetup: Controller on Temp. 60E FDefrost “off”, Fan on high

Abbreviations: EC - Electric Condenser

(A) Problem - EO error message display on the controller:

Possible Cause Inspection Remedy

1. Open EC power circuit Check the EC circuit breaker for a) Repair the wiringpower, voltage, and continuity b) Replace open circuit breaker

2. Defective EC relay (circuit) Check for output voltage on the a) Repair the connections / wiringyellow wire, at the relay coil. Check b) Replace the defective relaythe voltage and continuity across therelay contacts.

3. Open EC voltage detection circuit Check for input voltage on the brown a) Repair the wiring or connectorwire, at the controller.

4. Improper wiring installation Applicable to systems without an EC a) See note #3

5. Defective controller Check for output voltage on the a) Replace the controlleryellow wire, at the controller.

(B) Problem - E1 error message display on the controller:

Possible Cause Inspection Remedy

1. Abnormal A/C refrigerant Check the refrigerant pressures with a) Check the condenserpressure(s). gauges. operation for air and refrigerant* Cool weather operation may blockage

cause low pressure short cycling High side greater than: b) Leak check system, repair the 320 psig (R12), or 350 psig (R134a). leaks and recharge the systemLow side less than: c) Relocate the low pressure 3 - 6 psig.* switch to the evaporator outlet

2. Opened compressor clutch Check for output voltage on the a) Repair the connections/wiringcircuit green wire at the compressor. Check b) Replace the defective

the wire connections. Check for switch(es) or the thermostatcontinuity across the pressure c) Replace the defectiveswitch(es) and thermostat. Check the compressor clutchcontinuity of the clutch solenoid toground.

3. Opened pressure switch Check for an input voltage on the tan a) Repair the connections/ wiringdetection circuit wire, at the controller.

4. Defective controller Check for output voltage on the a) Replace the controllergreen wire, at the controller.

TROUBLESHOOTING TROUBLESHOOTING-EAGLE AIR CONDITIONER

702

(B) Problem continued

False E1 error message / cold weather charging problems: (Occurs particularly when vapor charging in cold weather)

1. E1 error message may occur during charging when the low pressure switch (LPS) opens at 3 psig. Thesuction side pressure must rise above 45 psig to reset the E1 error message.

2. When the system is fully charged, the E1 error message should not appear under normal operatingconditions.

3. In order to continue charging, by-pass the LPS, turn the controller “off” then “on”, and set the controller to60E F. This will reset the controller and force into the air conditioning mode.

4. If the LPS can’t be easily reached, disconnect the clutch wire at the compressor, and run a hot wiredirectly to the compressor clutch solenoid. Take care not to short out the controller clutch circuit.

5. E1 error message may occur while charging, when the compressor is wired hot.

(C) Problem - No Heat

Possible Cause Inspection Remedy

1. Opened heat solenoid circuit. Check for an output voltage on the a) Repair connections/wiringPoor connection, loss of voltage. white wire, at the heat solenoid valve.

Check the solenoid continuity toground.

2. Defective heat solenoid or Check for coolant blockages in the a) Repair or replace the valve.improper installation. heat solenoid valve and hoses. b) Reverse the coolant hoses to

Check the direction of coolant flow the valve.(feel the hoses).

3. Defective controller Check for output voltage on the white a) Replace the controllerwire, at the controller.

TROUBLESHOOTING TROUBLESHOOTING-EAGLE AIR CONDITIONER

703

(D) Problem - No display, the blower fan will not turn off, when the power is turned on.

Possible Cause Inspection Remedy

1. Fan wires shorted to ground or Disconnect the controller from the a) Unground and repair thevehicle chassis external harness, Individually check shorted wiring.

the continuity of the orange and blackfan wires to ground, in the externalharness.

(E) Problem - Compressor clutch will not engage, unless defrost button is pushed.

Possible Cause Inspection Remedy

1. Defective preset thermostat inside Push, hold defrost / temperature a) If “CL”, go to step 2.evaporator. Opened preset decrease buttons simultaneously. b) If “OP”, repair connections orthermostat circuit. Broken Check display for “OP” or “CL” wiring to preset thermostat.thermostat wiring. Evaporator coil readout. Disconnect red leads, and c) Replace preset thermostat.temperature too cold for a/c check for continuity acrossoperation. thermostat terminals.

2. Ambient cab temperature too Set controller at 68-70E F, in a/c a) Verify if compressor clutch willcool (below 60E F). mode. Warm-up ambient pull in or not.

temperature probe with fingers or b) If not go to step 3.heat gun.

3. Opened ambient cab Push, hold temp. Decrease/increase a) If display reads 49F, at roomtemperature probe (thermistor) buttons simultaneously. Display will temperature, replace thermistor.

read 40F if probe is defective. b) Repair connections/wiring.Disconnect the controller, check for c) If 10K ohms +/- 20%,continuity across black probe leads. thermistor is good. If 100K-1MCheck resistance of thermistor. ohms, replace thermistor.

TROUBLESHOOTING TROUBLESHOOTING-EAGLE AIR CONDITIONER

704

Notes:

1. Wire colors may vary with installation. Refer to the wiring schematic.

2. For 24V controllers, resistor (R17) must be clipped and removed from the circuit board. (Refer to figure below) Ifthe resistor is not clipped on the 24V system, the controller display will light up, but the blower fan will not turn on.

3. For air conditioning systems that do not use an electric condenser, the blue and brown wires must be connectedtogether, on the external harness. The brown wire must be connected to the battery voltage, or the EO errormessage will result.

4. Care must be taken during installation, not to pinch or cut wiring from the controller. Shorted wiring may result indamage to the controller.

5. Improper probe location of the evaporator coil thermostat sensor, or ambient cab temperature sensor, may causeshort cycling of the compressor.

6. Eagle climate controllers are designed to use normally closed heat solenoid valves.

7. Disconnect the vehicle battery leads, if a machine is to be inactive, or put into storage, for a period of a week ormore. The current drain from the controller’s memory may result in a dead vehicle battery. An optional ignition relaymay be installed to disable the controller’s memory function, when the key switch is turned off.

TROUBLESHOOTING TROUBLESHOOTING-EAGLE AIR CONDITIONER

705

WIRING DIAGRAM

NOTES:1. Position the ambient temperature probe near waist high level, out of air flow and sun load.2. Insert the sensing tube from present thermostat down into the evaporator coil, parallel to the coil face, between

the 1st and 2nd rows, to a depth of the coil height minus 1 inch.Wire Chart CONNECTOR DETAIL

Scoket Size Color Wire function

1 10GA Red Battery positive in

2 18GA Red ½ evap coil thermostat in

3 18GA Black ½ ambient thermistor in

4 18GA Red ½ evap coil thermostat in

5 N/A N/A Not used

6 18GA Black ½ ambient thermistor in

7 14GA Orange Fan positive out

8 16GA Dk. Green Clutch out

9 18GA Dk. Blue Ignition switch in

10 14GA Black Fan negative out

11 18Ga Brown Condenser blown fuse in

12 16GA White Heat solenoid out

13 18GA Tan Pressure switch detect in

14 16GA Yellow Condenser fan relay out

15 12GA Black Battery negative in

16 N/A N/A Not used

30-1 Î

30 DISASSEMBLY AND ASSEMBLY

CONTENTS

METHOD OF USING MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5 Î

PRECAUTIONS WHEN CARRYING OUT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6 Î1. Precautions when carrying out removal work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6 Î2. Precautions when carrying out installation work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7 Î3. Precautions when completing the operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-8 Î

SPECIAL TOOL LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-9 Î

STARTING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-11 ÎREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-11 ÎINSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-11 Î

ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-12 ÎREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-12 ÎINSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-12 Î

FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-13 ÎREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-13 ÎINSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-13 Î

ENGINE OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-14 ÎREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-14 ÎINSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-14 Î

WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15 ÎREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15 ÎINSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15 Î

NOZZLE HOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16 ÎREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16 ÎINSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16 Î

THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17 ÎREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17 ÎINSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17 Î

TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-18 ÎREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-18 ÎINSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-18 Î

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19 ÎREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19 ÎINSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19 Î

RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20 ÎREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20 ÎINSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-23 Î

DISASSEMBLY AND ASSEMBLY TABLE OF CONTENTS

30-2 Î

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24 ÎREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24 ÎINSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31 Î

ENGINE HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-32 ÎREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-32 ÎINSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-33 Î

EXHAUST MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-34 ÎREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-34 ÎINSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-34 Î

AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-35 ÎREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-35 ÎINSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-35 Î

TORQUE CONVERTER CHARGING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-36 ÎREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-36 ÎINSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-36 Î

TORQUE CONVERTER, TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-37 ÎREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-37 ÎINSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-44 Î

TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-45 ÎDISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-45 ÎASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-47 Î

TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-49 ÎDISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-49 Î

DISASSEMBLY OF PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-58 ÎASSEMBLY OF PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60 Î

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-63 Î

TRANSMISSION CLUTCH PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-75 ÎI. DISASSEMBLY OF 1ST, REVERSE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-75 ÎII. DISASSEMBLY OF FORWARD, 2ND CLUTCH PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-77 ÎIll. DISASSEMBLY OF 3RD, 4TH CLUTCH PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-79 ÎASSEMBLY OF CLUTCH PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-81 Î

l. ASSEMBLY OF 1ST, REVERSE CLUTCH PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-81 ÎII. ASSEMBLY OF FORWARD, 2ND CLUTCH PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-86 ÎIll. ASSEMBLY OF 3RD, 4TH CLUTCH PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-90 Î

TRANSMISSION CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-95 ÎREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-95 ÎINSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-96 ÎDISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-98 ÎASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-100 Î

TRANSMISSION SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-102 ÎDISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-102 ÎASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-102 Î

TRANSMISSION ACCUMULATOR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-103 ÎDISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-103 ÎASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-104 Î

DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-105 ÎDISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-105 ÎASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-107 Î

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30-3 Î

FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-109 ÎREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-109 ÎINSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-110 Î

REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-111 ÎREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-111 ÎINSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-115 Î

DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-120 ÎDISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-120 ÎASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-124 Î

AXLE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-134 ÎDISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-134 ÎASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-139 Î

CENTER HINGE PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-147 ÎREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-147 ÎINSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-155 Î

PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-164 ÎREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-164 ÎINSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-165 Î

STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-166 ÎREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-166 ÎINSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-168 ÎDISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-169 ÎASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-172 Î

MAIN CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-177 ÎREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-177 ÎINSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-179 ÎDISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-180 ÎASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-182 Î

STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-184 ÎREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-184 Î

BRAKE BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-186 ÎREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-186 ÎINSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-188 ÎDISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-189 ÎASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-192 Î

PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-197 ÎREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-197 ÎINSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-199 Î

HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-200 ÎREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-200 ÎINSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-201 Î

HYDRAULIC FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-202 ÎREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-202 ÎINSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-202 Î

HYDRAULIC STEERING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-203 ÎREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-203 ÎINSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-204 Î

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30-4 Î

BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-205 ÎREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-205 ÎINSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-206 Î

BOOM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-207 ÎREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-207 ÎINSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-208 Î

HYDRAULIC CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-209 ÎDISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-209 ÎASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-211 Î

WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-213 ÎREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-213 ÎINSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-216 Î

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-219 ÎREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-219 ÎINSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-220 Î

COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-221 ÎREMOVAL OF LEFT AND RIGHT COUNTERWEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-221 ÎINSTALLATION OF LEFT AND RIGHT COUNTERWEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-221 ÎREMOVAL OF REAR COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-221 ÎINSTALLATION OF REAR COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-222 Î

INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-223 ÎREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-223 ÎINSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-223 Î

DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL

30-5 Î

METHOD OF USING MANUAL

1.When removing or installing unit assemblies

1. When removing or installing a unit assembly, the order of work and techniques used are given for the removaloperation; the order of work for the installation operation is not given.

2. Any special techniques applying only to the installation procedure are marked , and the same mark is

placed after the relevant step in the removal procedure to indicate which step in the installation procedure itapplies to.

(Example)REMOVAL OF ±± ±± ±± ±± ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Title of operation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions related to safety when carrying out the operation

1. XXXX (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step in operationi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technique or important point to remember when removing XXXX (1)2. - - - - (2) . . . . . . . . . . . . . . . . . . . . . . . . . indicates that a technique is listed for use during installation

3. 9 9 9 9 assembly (3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quantity of oil or water drained

INSTALLATION OF ±± ±± ±± ±± ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Title of operation! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carry out installation in the reverse order of removal.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technique used during installation

i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technique or important point to remember when installing - - - - (2)! Adding water, oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step in operationi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 giventogether as PRECAUTION WHEN CARRYING OUT OPERATION, so be sure to follow these precautions whencarrying out the operation.

3.Listing of special tools

(1) For details of the description, part number, and quantity of any tools (A1, etc.) that appear in the operationprocedure, see the SPECIAL TOOL LIST given in the manual.

DISASSEMBLY AND ASSEMBLY PRECAUTION WHEN CARRYING OUT OPERATION

30-6 Î

PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautionsgiven below when carrying out the operation.]

1. Precautions when carrying out removal work

! If the coolant contains antifreeze, dispose of it correctly.! After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.! When draining oil, prepare a container of adequate size to catch the oil.! Confirm the match marks showing the installation position, and make match marks in the necessary places before

removal to prevent any mistake when assembling.! To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting

the connectors.! Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.! Check the number and thickness of the shims, and keep in a safe place.! When raising components, be sure to use lifting equipment of ample strength.! When using forcing screws to remove any components, tighten the forcing screws alternately.! Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after

removal.

ii Precautions when handling piping during disassemblingFit the following blind plugs into the piping after disconnecting it during disassembly operations.

1. Hoses and tubes using sleeve nuts

Nominalnumber

Plug (nut end) 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

Nominalnumber

Flange (hose end) Sleeve head (tube end) Split flange

04 07379-00400 07378-10400 07371-30400

05 07379-00500 07378-10500 07371-30500

DISASSEMBLY AND ASSEMBLY PRECAUTION WHEN CARRYING OUT OPERATION

30-7 Î

3. If the part is not under hydraulic pressure, the following corks can be used.

Nominalnumber

Part NumberDimensions

D d L

06 07049-00608 6 5 8

08 07049-00811 8 6.5 11

10 07049-01012 10 8.5 12

12 07049-01215 12 10 15

14 07049-01418 14 11.5 18

16 07049-01620 16 13.5 20

18 07049-01822 18 15 22

20 07049-02025 20 17 25

22 07049-02228 22 18.5 28

24 07049-02430 24 20 30

27 07049-02734 27 22.5 34

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 with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or

damage, then coat uniformly with gasket sealant.! Clean all parts, and correct any damage, dents, burrs, or rust.! Coat rotating parts and sliding parts with engine oil.! When press fitting parts, coat the surface with anti-friction compound (LM-P).! After fitting snap rings, check that the snap ring is fitted securely in the ring groove.! When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely.! When using eye bolts, check that there is no deformation or deterioration, screw them fully, and align the direction

of the hook.! When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.i When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic

equipment removed for repair, always bleed the air as follows:1. Start the engine and run at low idle.2. Operate the work equipment control lever to operate the hydraulic cylinder 4 - 5 times, stopping 100 mm from

end of its stroke.3. Next, operate all hydraulic cylinders 3 - 4 times to the end of their stroke, then stop the engine and loosen air

bleed plug (1) to bleed the air from the hydraulic tank. After bleeding the air , tighten plug (1).4. Following this raise the engine speed , repeat the procedure in Step 3) to bleed the

air. Repeat this operation until no more air comes out from the plug hole. Plug: 11.3 ± 1.5 Nm (1.15 ± 0.15 kgm)

5. After doing this, run the engine at normal speed.

i When using the machine for the first time after repair or long storage, follow thesame procedure.

DISASSEMBLY AND ASSEMBLY PRECAUTION WHEN CARRYING OUT OPERATION

30-8 Î

3. Precautions when completing the operations

! If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the engine tocirculate the coolant through the system. Then check the coolant level again.

! If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run theengine to circulate the oil through the system. Then check the oil level again.

! If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been removed for repair,always bleed air from the system after reassembling the parts.

i For details, see TESTING AND ADJUSTING, Bleeding air.! Add the specified amount of grease (molybdenum disulfide grease) to the work equipment related parts.

DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST

30-9 Î

SPECIAL TOOL LISTNature of work Symbol Part no. Part Name Qty. Remarks

Disassembly, assembly oftransmission assembly

A 793-305-1600 Lifting tool 2 Removal, installation of rearhousing

B 793-310-2100 Lifting tool 1 Removal, installation ofclutch assembly

Disassembly, assembly oftransmission clutch packassembly

D 3 793-310-1360 Bar 1

1 793-310-1300 Stand 1

Disassembly, assembly ofclutch assembly

2 793-310-1330 Plate 1

4 793-310-1370 Pin 5

5 01541-01260 Nut 2

E1 793-415-1110 Lifting tool 1 F - R Jig for setting

piston seal

2 793-415-1120 Lifting tool 1 1st - 4th

Disassembly, assembly ofdifferential assembly 01010-31680 ! Bolt 5

A 793-510-1600 Mandrel 1 Positioning bearing ofdifferential pinion

B Insertion of brake piston01010-31640 ! Bolt 5

793-520-2202 Installer 1

793-520-2110 ! Plate 5

01643-31645 ! Washer 5

C Checking for oil leaks793-605-1001 Brake tester 1

799-101-5002 Hydraulic tester kit 1

790-101-1102 Pump assembly 1

Disassembly of axle Removal of axle shafthousing bearing

A 790-101-3100 Puller assembly 1

A 2 790-101-3120 ! Bolt 2

1 790-101-3110 ! Puller 1

3 790-101-3130 ! Nut 2

Assembly of axle housingB 2 793-520-2740 Bolt 4

1 793-520-2730 Seal support 2Holder for oil seal when

press fitting oil seal3 01016-30840 Adjustment bolt 6

C 793-510-1500 Holder 1 For adjusting shim

Disassembly, assembly ofhydraulic cylinder

A

790-502-1003or Cylinder repair stand 1

790-502-2000

790-101-1102 Pump 1

B Wrench assembly790-330-1100 1 Steering

Removal,installation ofround head790-102-3820 1 Boom,

Bucket

C installation of790-302-1290 1 Boom

790-102-1320 1 BucketSocket (with acrossflats: 70 mm)

Removal,

nylon nut

Socket (with acrossflats: 60 mm)

commercially Socket (with acrossavailable flats: 46 mm) 1 Steering

DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST

30-10 Î

Nature of work Symbol Part no. Part Name Qty. Remarks

Disassembly, assembly ofhydraulic cylinder

D 790-201-1811 Push tool 1 Boom

790-101-5021 Grip 1 Press fitting of coil bushingKit Part no.: 790-201-170201010-50816 Bolt 1

790-201-1781 Push tool 1 Bucket

790-201-1741 Push tool 1 Steering

E 790-201-1620 Plate 1 Boom

790-201-5021 Grip 1 Insertion of dust sealKit Part No.: 790-201-150001010-50816 Bolt 1

790-201-1590 Plate 1 Bucket

790-201-1550 plate 1 Steering

F 796-720-1630 Ring 1

1 790-720-1000 Expander 1 Installation of piston ring

2 Steering

796-720-1660 Ring 1 Boom,bucket07281-01159 Clamp 1

07281-00709 Clamp 1

796-720-1670 Ring 1Bucket

07281-01279 Clamp 1

Note: As for special tool of disassembly and assembly of engine components (engine oil cooler, fuel injection pump,turbocharger, nozzle holder, thermostats, cylinder head etc. ) Refer to “ENGINE SHOP MANUAL”

DISASSEMBLY AND ASSEMBLY STARTING MOTOR

30-11 Î

STARTING MOTOR

WARNING! Stop the machine on level ground and installthe safety bar on the frame. Lower the bucket to theground and stop the engine. Then apply the parkingbrake and put blocks under the wheels to prevent themachine from moving.

WARNING! Disconnect the cable from the negative (-)terminal of the battery.

REMOVAL 1. Disconnect negative (-) terminal (1) of the battery located

behind the radiator grille.

2. Open engine hood side cover and lock in position.

3. Remove washer tank and bracket (2) and two mounting boltswith nuts (3) from frame and position out of way.

4. Disconnect cable (4) and harness wires (5) and (6).

5. Remove ground connection (7) with two mounting bolts (8), thenremove starting motor assembly.

INSTALLATION

Ú Install starting motor assembly in reverse order of removal

Mounting bolt: 32 ±4 lbf.ft(43 ±6 Nm)(4.38 ±0.61 kgm)

DISASSEMBLY AND ASSEMBLY ALTERNATOR

30-12 Î

ALTERNATOR

WARNING! Stop the machine on level ground and installthe safety bar on the frame. Lower the bucket to theground and stop the engine. Then apply the parkingbrake and put blocks under the wheels to prevent themachine from moving.

WARNING! Disconnect the cable from the negative (-)terminal of the battery.

REMOVAL 1. Disconnect negative (-) terminal (1) of the battery located

behind the radiator grille.

2. Open engine hood side cover and lock in position.

3. Remove 5 mounting bolts of left fan guard half (2) and rotatedown out of way.

4. Install 3/8" drive breaker bar (3) in belt tensioner. Lift up onbreaker bar and remove belt (4) from alternator pulley.

5. Remove output (5) and ground (6) leads from back ofalternator.

6. Remove bottom mounting bolt (7). Supporting the alternator,remove top mounting bolt (8) and remove the alternator fromthe machine.

INSTALLATION

Ú Install starting motor assembly in reverse order of removal

Mounting bolt: 32 ±4 lbf.ft(43 ±6 Nm)(4.38 ±0.61 kgm)

DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP

30-13 Î

FUEL INJECTION PUMP

WARNING! Stop the machine on level ground and installthe safety bar on the frame. Lower the bucket to theground and stop the engine. Then apply the parkingbrake and put blocks under the wheels to prevent themachine from moving.

REMOVAL

1. Disconnect negative (-) terminal (1) of the battery locatedbehind the radiator grille.

2. Open engine hood right side cover and lock in position (3).

3. Disconnect the throttle linkage (4).

4. Disconnect the fuel inlet line (filter to pump line) (5).

5. Disconnect the return (6) and drain lines (7).

6. Disconnect the electrical wiring (8).

7. Disconnect the six fuel lines (pump to injectors) (9).

8. Remove the Fuel Injection Pump.Refer to “ENGINE SHOP MANUAL”.

INSTALLATION

Ú Install fuel injection pump assembly in reverse order of removal

DISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER

30-14 Î

ENGINE OIL COOLER

WARNING! Stop the machine on level ground and installthe safety bar on the frame. Lower the bucket to theground and stop the engine. Then apply the parkingbrake and put blocks under the wheels to prevent themachine from moving.

WARNING! Disconnect the cable from the negative (-)terminal of the battery.

REMOVAL

1. Disconnect negative (-) terminal (1) of the battery locatedbehind the radiator grille.

2. Open left gull wing side cover (2) on the engine hood and lockin position.

3. Drain the engine oil.Refer to “OPERATIONAL & MAINTENANCE MANUAL”.

4. Remove the alternator.Refer to “ENGINE SHOP MANUAL”.

5. Remove the turbocharger drain line (3).

6. Remove the Oil Filter.Refer to “OPERATIONAL & MAINTENANCE MANUAL”.

7. Remove the Engine Oil Cooler (4).Refer to “ENGINE SHOP MANUAL”.

INSTALLATION

Ú Install engine oil cooler in reverse order of removal.

DISASSEMBLY AND ASSEMBLY WATER PUMP

30-15 Î

WATER PUMP

WARNING! Stop the machine on level ground and installthe safety bar on the frame. Lower the bucket to theground and stop the engine. Then apply the parkingbrake and put blocks under the wheels to prevent themachine from moving.

WARNING! Disconnect the cable from the negative (-)terminal (1) of the battery.

REMOVAL1. Open engine hood left side cover and lock into position.

2. Drain water system (coolant) (2).Refer to “OPERATION & MAINTENANCE MANUAL”.

3. Remove the Fan Belt from the Alternator and BeltTennsioner.Refer to “ALTERNATOR ASSEMBLY”.

4. Remove the alternator.Refer to “ALTERNATOR ASSEMBLY”.

5. Remove the Water Pump (3).Refer to “ENGINE SHOP MANUAL”.

INSTALLATION

Ú Install the water pump assembly in reverse order of removal.Refer to “ENGINE SHOP MANUAL”.

DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER

30-16 Î

NOZZLE HOLDER

WARNING! Stop the machine on level ground and installthe safety bar on the frame. Lower the bucket to theground and stop the engine. Then apply the parkingbrake and put blocks under the wheels to prevent themachine from moving.

REMOVAL

1. Remove hood.Refer to “HOOD REMOVAL”.

2. Remove air cleaner (1) and bracket (2).Refer to “AIR CLEANER”.

3. Remove muffler (3) and mount bracket (4).Refer to “MUFFLER”.

NOTE: When the muffler bracket is removed, the airconditioner compressor and mount bracket comesoff with it.

4. Remove turbocharger crossover tube (5) (air intake).

5. Remove nozzel holder (6).Refer to “ENGINE SHOP MANUAL”.

INSTALLATION

Ú Install nozzel holder in reverse order of removal. Refer to“ENGINE SHOP MANUAL”.

DISASSEMBLY AND ASSEMBLY THERMOSTAT

30-17 Î

THERMOSTAT

WARNING! Stop the machine on level ground and installthe safety bar on the frame. Lower the bucket to theground and stop the engine. Then apply the parkingbrake and put blocks under the wheels to prevent themachine from moving.

REMOVAL

1. Drain water system of coolant (2).Refer to “OPERATION & MAINTENANCE MANUAL”.

2. Open engine hood, left side.

3. Disconnect screw clamp on thermostat and remove hoseconnection (3).

4. Remove thermostat.Refer to “ENGINE SHOP MANUAL”.

INSTALLATION

Ú Install thermostat in reverse order of removal. Refer to “ENGINESHOP MANUAL”.

DISASSEMBLY AND ASSEMBLY TURBOCHARGER

30-18 Î

TURBOCHARGER

WARNING! Stop the machine on level ground and installthe safety bar on the frame. Lower the bucket to theground and stop the engine. Then apply the parkingbrake and put blocks under the wheels to prevent themachine from moving.

REMOVAL

1. Open engine hood left side cover and lock into position (2).

2. Remove heat shield (3).

3. Disconnect muffler clamp (4), air intake clamp (5), oil drain line(6) and oil lube line (7).

4. Remove turbocharger.Refer to “ENGINE SHOP MANUAL”.

INSTALLATION

Ú Install turbocharger assembly in reverse order of removal. Referto “ENGINE SHOP MANUAL”.

DISASSEMBLY AND ASSEMBLY CYLINDER HEAD

30-19 Î

CYLINDER HEAD

WARNING! Stop the machine on level ground and installthe safety bar on the frame. Lower the bucket to theground and stop the engine. Then apply the parkingbrake and put blocks under the wheels to prevent themachine from moving.

REMOVAL

1. Remove hood.Refer to “HOOD REMOVAL”.

2. Remove air cleaner (1) and bracket (4).Refer to “AIR CLEANER”.

3. Remove muffler (3) and mount bracket (2).Refer to “MUFFLER”.

NOTE: When the muffler bracket is removed, the airconditioner compressor and mount bracket comesoff with it.

4. Remove turbocharger crossover tube (air intake).

5. Remove cylinder head.Refer to “ENGINE SHOP MANUAL”.

INSTALLATION

Ú Install cylinder head in reverse order of removal. Refer to“ENGINE SHOP MANUAL”.

DISASSEMBLY AND ASSEMBLY RADIATOR

30-20 Î

RADIATOR

WARNING! Stop the machine on level ground and installthe safety bar on the frame. Lower the bucket to theground and stop the engine. Then apply the parkingbrake and put blocks under the wheels to prevent themachine from moving.

WARNING! Loosen the oil cap slowly to release thepressure inside the hydraulic tank. Then operate thecontrol levers several times to release the remainingpressure in the hydraulic piping.

REMOVAL 1. Engine hood and side covers.

Refer to “REMOVAL OF ENGINE HOOD”.

2. DRAINING COOLANTLoosen radiator cap (1) to release internal pressure, and opendrain valve (2) and drain coolant from system.Ú When system is drained close the drain valve.Ú If the coolant contains antifreeze, dispose of it properly.

Coolant: 35R (9.2 US gals)

3. Fan guards.A) Remove left fan guard (3) and right fan guard (3A).

Ú Be careful not to damage radiator fins.

4. Rear cover.A) Remove cover (4) at the bottom rear of the radiator.

DISASSEMBLY AND ASSEMBLY RADIATOR

30-21 Î

5. Removal of cooling lines.A) Close petcock (5) to shut off heater hose, remove lower

radiator outlet tube (6) with hoses.

B) Disconnect engine vent line (7), remove radiator inlet tube(8), and disconnect roading trans cooler line (9) fromthermostat housing.

C) Disconnect torque converter cooler hoses (10) and (11)from radiator bottom tank.Ú Radiator fan shroud may have to be disconnected from

radiator and pushed aside to disconnect hoses (10) and(11).

6. Radiator removal.A) Disconnect radiator stay rod (12) at radiator, loosen at

frame and rotate forward.

DISASSEMBLY AND ASSEMBLY RADIATOR

30-22 Î

B) Install lifting eyes (13) and hook up hoist, remove radiatormounting bolts and rubber mounts (14), and lift radiatorassembly from machine.

Radiator: 110 lbs (50 kg)

DISASSEMBLY AND ASSEMBLY RADIATOR

30-23 Î

INSTALLATIONÚ Install radiator in reverse order of removal.

Ú Be careful not to damage the fins on the radiator assembly.

Ú Adjust so that the clearance between the shroud and fan isuniform.

Ú Install so that the clearance between fan and fan guard isuniform

Ú Temporarily tighten the mounting bolts and fix the position, thentighten fully.

Ú When installing the radiator, the difference in the clearancebetween the fan and radiator on the left and right must be within3mm (0.118").

Ú Install so that the clearance between the radiator fins and thefront face of the fan is uniform at the top, bottom, left, and right.

Ú The difference between the left and right in the position of theradiator in the front-to-rear direction must be within 5mm((0.197").

Ú Tighten hoses without twisting.Radiator mounting bolts:

82 ±8 lbf.ft (112.8 ±9.8 Nm) (11.5 ±1.0 kgm)

Radiator support mounting bolts: 82 ±8 lbf.ft (112.8 ±9.8 Nm) (11.5 ±1.0 kgm)

Torque converter cooler hoses: 130 ±22 lbf.ft (176.4 ±29.4 Nm) (18.0 ±3.0 kgm)

DISASSEMBLY AND ASSEMBLY ENGINE

30-24 Î

ENGINE

WARNING! Stop the machine on level ground and installthe safety bar on the frame. Lower the bucket to theground and stop the engine. Then apply the parkingbrake and put blocks under the wheels to prevent themachine from moving.

WARNING! Loosen the oil cap slowly to release thepressure inside the hydraulic tank. Then operate thecontrol levers several times to release the remainingpressure in the hydraulic piping.

WARNING! Disconnect the cable from the negative (-)terminal of the battery.

REMOVAL 1. Engine hood and side covers.

Refer to “REMOVAL OF ENGINE HOOD”.

2. Radiator and piping.Refer to “REMOVAL OF RADIATOR”.

3. Machines with Air Conditioning.Ú Note: There are shims (A) and (B) at bottom mounting bolt

between welded spacer and compressor. When removingkeep shims as they were removed.

A) Disconnect wire (1) from harness at top of compressor,loosen lower mounting bolt (2) and adjusting bolt (3)allowing for removal of compressor belt (4).

B) Unclip compressor lines (5) at air cleaner, and cut tie straps(6).

C) Remove hardware (2) and (7), keeping in mind the aforementioned shims and position the compressor out of way.

DISASSEMBLY AND ASSEMBLY ENGINE

30-25 Î

4. Right side of engine.A) Disconnect fuel inlet hose (8) and fuel outlet hose (9) and

remove muffler drain tube (10).

B) Disconnect the fuel cut-off sensor (11), oil pressure switch(12), and coolant lead (13). Unclamp harness at clamp(14).

C) Remove slow-blow fuse (15) from mounting bracket (16),open side door of fuse and disconnect harness lead (17).Replace screw, close door, and place fuse back inmounting bracket.

D) At intake manifold, disconnect heat switch cable (18) andunclamp at air cleaner bracket (19), and remove cable fromframe relay (20).

DISASSEMBLY AND ASSEMBLY ENGINE

30-26 Î

E) Unclip engine harness from floor harness (21).

F) Unclip harness and cranking motor cable at throttle bracket(22) at rear of engine (23), and shut off petcock (24), anddisconnect heater hose (25).

G) Disconnect throttle linkage rod at fuel pump lever (26),remove throttle bracket (22) and position assembly out ofway.

H) Remove remote engine oil drain bracket (27) from trunnion.

DISASSEMBLY AND ASSEMBLY ENGINE

30-27 Î

5. Left side of engine.A) Disconnect fuel sending unit (28), remove output (29),

ground (30) leads from back of alternator, and watertemperature switch (31).

B) Disconnect harness ground cable (32), remove starter relayand bracket (33) from engine block.

C) Cut tie straps (34), remove mounting bolts from washertank and bracket (35), and position out of way. Disconnectcranking motor leads (36) and (37).

D) Slide harness connector (38) from flywheel housing bracketand disconnect and remove engine harness. Disconnectcranking motor ground cable (39) at frame.

DISASSEMBLY AND ASSEMBLY ENGINE

30-28 Î

E) Remove air conditioning dryer and bracket (40) from frameand position out of way.

F) Disconnect heater hose (41) pass through clips (42) andposition out of way.

6. Top of engine.A) Remove turbo-charger shield (43), and loosen muffler

clamp (44) at turbo-charger.

B) Remove band (45), remove center mounting bolts (46), andlift off exhaust muffler (47).

DISASSEMBLY AND ASSEMBLY ENGINE

30-29 Î

C) Loosen clamps (48) on hose between air cleaner and turbo-charger, remove bands (49), and lift off air cleaner (50).

7. Engine assembly.A) Set jack stand (51) under transmission (52) and adjust the

height properly and set the stand into position.

B) Hook hoist to rear lifting eye (53), to front lifting eye (54),and to air conditioning compressor mounting bracket (55).

C) Remove torque converter housing to flywheel housing bolts(56).

DISASSEMBLY AND ASSEMBLY ENGINE

30-30 Î

D) Remove rear engine mounting bolts (57) from each side.

E) Using hoist guide the engine rearward to clear the torqueconverter housing, and lift from the machine.Ú Be careful not to damage the fuel tank breather tube

and the engine oil drain hose when removing theengine.

Engine assembly: 1190 lbs (540 kg)

DISASSEMBLY AND ASSEMBLY ENGINE

30-31 Î

INSTALLATION 1. Install the engine assembly in reverse order of removal.

Ú Check that there is an o-ring installed to the mating face ofthe torque converter.

Lubricate the outside circumference of O-ring:Soapy water

Ú When connecting the engine and torque converter, adjustthe height so that the torque converter pilot goes insmoothly. Never use force when connecting.

Ú When assembling rear engine mounting bolts never usegrease, oil, or soapy water on the rubber mounts.

Mounting bolt: 550 ±61 lb/ft 745 ±83 Nm 76 ±8.5 kgm

(Width across flats: 32mm)

2. Installation of radiator, refer to “REMOVAL AND INSTALLATIONOF RADIATOR”.

3. Installation of engine hood, refer to “REMOVAL ANDINSTALLATION OF THE ENGINE HOOD”.

4. Refilling with oils and coolant.Ú Tighten radiator drain valve and open the two heater hose

petcocks on the engine, and add the engine coolantthrough the radiator filler neck to the specified level.

Ú Check and if necessary add transmission oil through the oilfiller neck on the transmission to the specified level.

Ú Check and if necessary add engine oil through the oil fillerneck on the engine to the specified level.

Ú Run the engine (to operating temperature) and heater tocirculate the oil and engine coolant through the system.Then check the engine coolant and oil, and thetransmission oil levels again. Add oil or coolant if required.

DISASSEMBLY AND ASSEMBLY ENGINE HOOD

30-32 Î

ENGINE HOOD

WARNING! Stop the machine on level ground and installthe safety bar on the frame. Lower the bucket to theground and stop the engine. Then apply the parkingbrake and put blocks under the wheels to prevent themachine from moving.

WARNING! Disconnect the cable from the negative (-)terminal of the battery.

REMOVAL 1. Remove pre-cleaner assembly (1) from hood, cap opening of

air cleaner to prevent dirt from entering.

2 Install lifting eyes (A) and chain (B) on top of hood (2).

3. Remove overflow hose (3) for radiator sub-tank at radiator neck.

4. Open engine hood side covers and radiator grille and lock inposition. Remove six engine hood mounting bolts (4) and fourfender mounting bolts (5).

DISASSEMBLY AND ASSEMBLY ENGINE HOOD

30-33 Î

5. Disconnect wiring connectors (6) and (7) from engine hood.

6 Disconnect neg. (-) and (+) battery cables (8) and (9), andUnclip crossover light harness (10).

7. Remove the grease gun inside the left side of the enginecompartment, then remove the clips (11).

8. Lift engine hood (2) approximately 6 in. (150 mm), check thatthere is no interference, then lift off slowly.Ú Be careful not to hit the cab or rear wiper arm.

INSTALLATION

Ú Install engine hood in reverse order of removal.

Engine hood: 68 lbs (150 kg)

DISASSEMBLY AND ASSEMBLY EXHAUST MUFFLER

30-34 Î

EXHAUST MUFFLER

WARNING! Stop the machine on level ground and installthe safety bar on the frame. Lower the bucket to theground and stop the engine. Then apply the parkingbrake and put blocks under the wheels to prevent themachine from moving.

WARNING! Disconnect the cable from the negative (-)terminal of the battery.

REMOVAL 1. Engine hood and side covers.

Refer to “REMOVAL OF ENGINE HOOD”.

2. Exhaust muffler.A) Remove turbo-charger shield (1), and loosen muffler clamp

(2) at turbo-charger.

B) Remove band (3), remove center mounting bolts (4), and liftoff exhaust muffler (5).

INSTALLATION 1. Install the exhaust muffler in reverse order of removal.

DISASSEMBLY AND ASSEMBLY AIR CLEANER

30-35 Î

AIR CLEANER

WARNING! Stop the machine on level ground and installthe safety bar on the frame. Lower the bucket to theground and stop the engine. Then apply the parkingbrake and put blocks under the wheels to prevent themachine from moving.

WARNING! Disconnect the cable from the negative (-)terminal of the battery.

REMOVAL 1. Engine hood and side covers.

Refer to “REMOVAL OF ENGINE HOOD”.

2. Air cleaner.A) Loosen clamps (1) on hose between air cleaner and turbo-

charger, remove bands (2), and lift off air cleaner (3).

INSTALLATION 1. Install the air cleaner assembly in reverse order of removal.

DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER CHARGING PUMP

30-36 Î

TORQUE CONVERTER CHARGING PUMPREMOVAL

WARNING! Stop the machine on level ground and installthe safety bar on the frame. Lower the bucket to theground and stop the engine. Then apply the parkingbrake and put blocks under the wheels to prevent themachine from moving.

1. Cover, wiring1) Remove cover (1) under left center fender.2) Remove clamp and wiring clamp (2) of air conditioner hose.

2. Hydraulic piping1) Disconnect hose (3) between transmission strainer and

torque converter charging pump from torque convertercharging pump.

2) Disconnect tube (4) between torque converter chargingpump and filter from torque converter charging pump.

3. Torque converter charging pumpRemove mounting bolts, then remove torque converter chargingpump (5).

INSTALLATION! Carry out installation in reverse order to removal.

Tube flange mounting bolt:

66.2 ± 7.4 Nm (6.75 ± 0.75 kgm)

Tube flange mounting bolt:

30.9 ± 3.4 Nm (3.15 ± 0.35 kgm)

Mounting bolt:

Ú Be careful not to get the O-ring Caught when installing66.2 ± 7.4 Nm (6.75 ± 0.75 kgm)

DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER, TRANSMISSION

30-37 Î

TORQUE CONVERTER, TRANSMISSIONREMOVAL

WARNING! Stop the machine on level ground and installthe safety bar on the frame. Lower the bucket to theground and stop the engine. Then apply the parkingbrake and put blocks under the wheels to prevent themachine from moving.

Ú Remove cover (1) at the top of the hydraulic tank on the rightside, then remove covers (2) on the left and right under thefloor.

WARNING! Loosen the oil filler cap slowly to release thepressure inside the hydraulic tank. Then operate thecontrol levers several times to release the remainingpressure in the hydraulic piping.

! Loosen plug (3) to prevent the oil inside the hydraulic tank fromflowing out.

Ú Disconnect the cable from the negative (-) terminal of thebattery.

Ú Machines equipped with air conditioner! Release the gas at a point far from the compressor. Loosen the

hose connection slightly to release the gas.

1. Draining oilLoosen drain plug (3-1) and drain transmission oil.

Transmission oil: 28.0 R

2. Cover1) Sling left ladder rail (4), then remove mounting bolts, and lift

off together with center fender (5).Ú Carry out the operation in the same way

on the right side.Ú When lifting off the ladder, be careful of the center of

gravity.Ú Be careful not to damage the cab glass.

DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER, TRANSMISSION

30-38 Î

2) Disconnect connector for left brake oil level sensor.3) Remove brake oil tank mounting bracket (8) together with

oil tank (7) from under floor.Ú Leave the oil hose installed to the brake oil tank and tie it to

the top surface of the rear frame with wire.! For machines equipped with an air conditioner, it can be

placed on top of the condenser.Ú When carrying out this operation, do not disconnect the

brake oil hose. Move it to the side and tie it temporarily withwire.

3. Electric wiring! Disconnect following electric wiring from connector.! Disconnect front wiring (9) and rear wiring (10) from connectors

(1 1), (12), (13), (14), (15), (16), and (17).! For machines with cab, disconnect wiring for cab from

connector.! Disconnect ground wiring (18) from rear frame.! Disconnect transmission cut-off switch (19) and wiring connector

(20).! Remove wiring clamp and bracket (21) from rear frame (22).Ú Fit tags to identify the wiring.

4. Brake booster1) Remove locknut of ball joint (24) and brake linkage (23),

and pull out linkage rod.

2) Set block under brake booster (25), then remove mountingbolts (26).

DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER, TRANSMISSION

30-39 Î

5. Fuel control cable

then remove bracket (28) together with control cable.Ú For machines equipped with cab! Disconnect the washer hose from the tank, then coil up and

bend the end of the hose.! After removing the hose, fit a blind plug in the washer tank.

6. Transmission valve wiringDisconnect connectors (33) of transmission valve wiring.Ú Fit tags to identify the wiring.

7. Work equipment control cableDisconnect work equipment control cables (34) at valve end.Ú Fit tags to the cables before disconnecting.Ú Remove the cable clamp.

DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER, TRANSMISSION

30-40 Î

8. Parking brake cable1) Disconnect parking brake cable (38) from lever, and

remove bracket (40) from front faceof transmission (39).

Ú After removing the cable, tie it temporarily to the bottomsurface of the floor with wire.

2) Disconnect speedometer cable (41).

3) Remove transmission oil filler tube (42).

9. Steering piping1) Remove hoses (44) and (45) from steering valve (43).

2) Disconnect hoses (47), (48), and (49) between steeringvalve (43) and priority valve.

3) Remove hose (50) between steering valve and hydraulictank.Ú Fit blind plugs after disconnecting the hoses.

DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER, TRANSMISSION

30-41 Î

10. Floor frame, cab assemblySling floor frame and cab assembly (51), then remove mountingbolts, and lift off.

Ú When raising the floor frame and cab assembly, pull thebrake booster out gradually from the mounting bracket, andlift the cab slowly.

Ú The brake hose is not disconnected, so be careful not tocatch the brake booster.

Ú Check that there is no interference from the hoses andwiring, then lift it off.

Ú When raising the floor frame and cab assembly, lift slowlyfor approx 40-50 mm, stop and check that there is nointerference, then continue to lift.

Floor frame, cab assembly: 680 kg

Floor frame assembly: 155 kg

11. Drive shafts

1) Disconnect center drive shaft (52) at transmission end.2) Remove rear drive shaft (53).

12. Hydraulic, steering pump

1) Disconnect hose (55) between hydraulic, steering pumpand priority valve at priority valve end.

2) Loosen clamp of hose (56) between hydraulic tank andhydraulic, steering pump, then disconnect at tank end.Ú Remove hose clamp (56-1) between the main control

valve and the hydraulic tank first.3) Remove mounting bolts of hydraulic, steer-

ing pump (57), then remove.

DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER, TRANSMISSION

30-42 Î

13. Hydraulic piping

1) Disconnect drain hose (60) of brake booster at transmissionend.

2) Disconnect hose (61) between priority valve and maincontrol valve, then remove hose support bracket (62) fromrear frame.

3) Disconnect hose (58) between main control valve andhydraulic tank, then disconnect hose clamp (59).

14. Torque converter, transmission

1) Disconnect hose (63) between transmission valve andcooler from transmission valve(64).

2) Disconnect hose (65) between transmission and coolerfrom elbow under rear housing of transmission (68).

3) Remove oil filler tube (66) from transmission.

DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER, TRANSMISSION

30-43 Î

4) Set hydraulic jack (1) under engine.Ú Adjust the height properly and support the engine.

5) Remove left and right transmission mountbolts (67) and (67-1).

6) Sling torque converter and transmission (68), and removebolt connecting to engine (69). Ú Sling at two points.

7) Lift off torque converter and transmission(68).

Ú Check that there is no interference from the hoses andwiring, then lift off.

Ú Be extremely careful that the torque converter andtransmission does not hit the rear frame when lifting off.

Torque converter, transmission:480 kg

DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER, TRANSMISSION

30-44 Î

TORQUE CONVERTER, TRANSMISSIONINSTALLATION! Carry out installation in the reverse order to removal.

Ú Bend the cotter pin securely.

Ú Adjust the parking brake. For details, see TESTING

AND ADJUSTING, Adjusting parking brake.

Mounting bolt: 277 ± 32 Nm(28.25± 3.25 kgm)

Ú Be careful of the direction of the yoke, and align the pilotportion correctly to install.

Mounting bolt: 66.2 ± 7.4 Nm(6.75± 0.75 kgm)

Ú Install the hoses without twisting or interference.

Ú To position the transmission, adjust with the adjustmentscrew to make clearance "a” the specified value, thentighten the mounting bolts.

Ú When assembling the rubber, never use grease, oil, orsoapy water.Clearance "a": 1 - 2 mm

Mounting bolt: 745 ± 83.4 Nm (76 ± 8.5 kgm)

(Width across flats: 32 mm)

Ú Check that the O-ring is insertedsecurely in the mating surface of thetorque converter.

Outside circumference of O-ring:Soapy water

Ú When connecting the engine and torqueconverter, adjust the height so that thetorque converter pilot goes in smoothly. Never use force when connecting.

Ú Tighten the mounting bolts a little at a timeon the left and right, and be careful not todamage the O-ring.

Mounting bolt: 66.2 ± 7.4 Nm(6.75 ± 0.75 kgm)

!! Refilling with oil1 ) Tighten drain plug and add

transmission oil through oil filler to thespecified level.

Transmission oil: 28RR

2) Tighten plug and add hydraulic oilthrough oil filler to the specified level.

Hydraulic oil: 80R

Ú Run the engine to circulate the oilthrough the system. Then check theoil level again.

DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER

30-45 Î

TORQUE CONVERTERDISASSEMBLY1. Turbine case assembly

1) Remove stator shaft and pump assembly (2) from turbineand case assembly (3).

2) Disassemble turbine and case assembly as follows.I) Remove pilot (4).ii) Remove snap ring (5).

iii) Push boss portion of turbine (6) and remove from case(7).

iv) Remove bearing (8) from case.

DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER

30-46 Î

2. Stator1) Remove snap ring (9).

2) Remove stator (10).

3. Stator shaftUsing forcing screws (1), push from stator shaft(11) end, and disconnect from pump assembly(12).

4. GearRemove gear (13) from pump (14).

5 BearingRemove bearing (15) from gear (13).

DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER

30-47 Î

TORQUE CONVERTERASSEMBLY1. Bearing

Install bearing (15) to gear (13).

2. GearInstall gear (13) to pump (14).

Mounting bolt: 66.2 ± 7.4 Nm(6.75± 0.75 kgm)

3. Stator shaft1) Install seal ring (16) to stator shaft (11).

Seal ring: Grease (G2-LI)Ú Make the extension of the seal ring uniform.

2) Push inner race end of bearing, and installpump assembly (12) to stator shaft (11).

4. Stator1) Install stator (10).

2) Install snap ring (9).

5. Turbine, case assembly1) Assemble turbine and case assembly as follows.

i) Install bearing (8) to case.Ú Press fit until the ring contacts the case.

ii) Push inner race of bearing and install turbine (6) tocase (7).

DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER

30-48 Î

iii) Install snap ring (5).iv) Install pilot (4).

Mounting bolt:Thread tightener (LT-2)

Mounting bolt: 66.2 ± 7.4 NM(6.75± 0.75 kgm)

2) Install stator shaft and pump assembly (2) to turbine andcase assembly (3).

Mounting bolt:Thread tightener (LT-2)

Mounting bolt: 30.9 ± 3.4 NM(3.15± 0.35 kgm)

DISASSEMBLY AND ASSEMBLY TRANSMISSION

30-49 Î

TRANSMISSIONDISASSEMBLY

! After removing transmission assembly (9) from the chassis,remove the left and right mount brackets first.

! Remove the PTO lubrication tube.

1. Hydraulic pipingDisconnect hoses (1) and (2), and each tube.Ú Be careful not to crush tube (3) during the operation.Ú After removing the tubes, fit a cover to protect the thread.

2. Oil filter1) After removing each hose, remove mounting bracket (5) of

filter (4) with filter still installed.

2) Remove O-ring (8), cover (7), and speedometer pickup portassembly (6) of idler countershaft portion.

Ú After removing the speedometer pickup port assembly, becareful not to damage the gear portion of the idlercountershaft.

DISASSEMBLY AND ASSEMBLY TRANSMISSION

30-50 Î

3) Raise transmission assembly (9), and install to assemblystand.Ú After installing the transmission assembly to the

assembly stand, turn over, then set a support under theREVERSE and lst side. (To keep it parallel)

3. Strainer, rear coupling1) Pull out rear coupling (10).

Ú Fit a cover to prevent dirt or dust from entering.

2) Remove hose and tube (11) between strainer and pump.

4. Charging pumpAfter removing hoses, remove charging pump assembly (12)and O-ring.

5. Transmission control valve1) Remove accumulator valve (13).

2) Sling transmission control valve (14), thenremove mounting bolts and lift off.Ú After removing the mounting bolts, fit 2 guide bolts in

the bolt holes.

Transmission control valve: 46 kg

DISASSEMBLY AND ASSEMBLY TRANSMISSION

30-51 Î

6. Rear housing1) Install tool A to rear housing (15), then sling.

Ú Install tool A securely to prevent it from coming off.

2) Using forcing screws, raise rear housing(15), then use toolA to lift off.

Ú Remove slowly and be careful not to damage the sealring.

Ú When removing, install guide bolts to front housing (16)and lift off horizontally.

Rear housing, torque converter assembly: .160 kg

7. Torque converterLift off torque converter (17) from rear housing (15).Ú Before removing, make match marks on the housing and

torque converter mating face with a felt pen.Ú When turning over the rear housing, remove pilot cap (18)

or set the housing on blocks.

Torque converter: 35 kg

DISASSEMBLY AND ASSEMBLY TRANSMISSION

30-52 Î

8. Pump (torque converter, work equipment)1) Remove snap ring (19) at torque converter pump mount.

2) Turn over rear housing (15), and remove snap ring (21) ofpump gear (20), then remove ring washer (22) and splitspacer (23).

3) Insert screwdriver into stepped portion between rearhousing (15) and shaft (24), then lever with screwdriver,push shaft down and pull it out.

DISASSEMBLY AND ASSEMBLY TRANSMISSION

30-53 Î

4) Remove bearing (25) from shaft (24).Ú Carry out the operation in the same way at the work

equipment hydraulic pump end.

9. Seal ring1) Remove seal ring (26) from each clutch shaft.

2) Remove input shaft (27).

10. REVERSE, lst clutch assembly1) Install tool B to REVERSE and lst clutch assembly (28).

2) Using tool B, lift off REVERSE and lst clutch assembly (28).Ú Be careful not to hit the other gears when removing.

REVERSE, lst clutch assembly: 30 kg

11. FORWARD, 2nd clutch assembly1) Install tool B to FORWARD and 2nd clutch assembly (29).

DISASSEMBLY AND ASSEMBLY TRANSMISSION

30-54 Î

2) Using tool B, lift off FORWARD and 2ndclutch assembly (29).Ú When doing this, 3rd, 4th clutch assembly (30) and the

gear are engaged, so pull up each part in turn to a pointwhere the bearing comes out from the front housing.

FORWARD, 2nd clutch assembly:37 kg

3) When bearing of 3rd, 4th clutch assembly(30) comes out from housing, pull to output shaft end andtie with wire.

WARNING! Be careful not to get your fingerscaught between the gear and housing whencarrying out this operation.

12. 3rd, 4th clutch assembly1) Install tool B to 3rd and 4th clutch assembly

(30).Ú Install the lifting tool before removing the wire.

2) Using tool B, lift off 3rd and 4th clutch assembly (30).

3rd, 4th clutch assembly: 42 kg

13. Idler countershaft assembly1) Remove idler countershaft (31) from front

housing (16).

DISASSEMBLY AND ASSEMBLY TRANSMISSION

30-55 Î

2) Remove bearings (32) and (33), and gears(34) and (35) from shaft (31).Ú If speedometer worm gear (36) is installed, remove it

before carrying out the operation.

14. Rear dust seal, oil sealRemove dust seal (37) and oil seal (38).

15. CouplingRemove mounting bolts, then remove front coupling (39), holder(40), and O-ring.

16. Parking brake assembly1) Turn over front housing (16), and set support stand under

housing.2) Remove plug of portion "a" at parking brake front housing

end, and be sure to assemble set bolt (I for securing piston.Ú Set bolt for securing piston:

P = 1.25, M = 8, L = 35Washer: 01643-30825

3) Remove housing mounting bolts (42).Ú Install a guide bolt to prevent the housing from failing.Ú Before removing the parking brake assembly, sling the

output gear to prevent the output shaft bearing conefrom coming out from the bearing cup.

DISASSEMBLY AND ASSEMBLY TRANSMISSION

30-56 Î

4) Tighten 2 forcing screws in forcing screw hole, and removehousing and piston assembly (43).Ú Check that a set bolt is installed to hold

the part in position.Ú Using housing mounting bolts as forcing screws.

5) Loosen mounting bolts of parking brake retainer assembly(44), and pull out left and right shims (45).Ú For reference when installing, check the number and

thickness of the shims.

6) Remove hub spline (46), then remove parking brakeretainer assembly (44).

17. Output shaft gear1) Loosen mounting bolts of gear cover (47) and leave them

fitted temporarily, then turn over front housing (16).

DISASSEMBLY AND ASSEMBLY TRANSMISSION

30-57 Î

2) Remove mounting bolt (48), then remove gear cover (47)from bottom of housing.

WARNING! Be careful not to get your fingers caughtbetween the gear and housing.

3) Hold spline portion of output shaft gear assembly (49) andpull up.

WARNING! Be extremely careful not to get your fingerscaught between the gear and housing (16) when removing.

Ú Clearance (one side) between gear and housing:Approx. 20 mm

Ú If there is oil on the output shaft spline, wipe it offcompletely and be extremely careful when removing.

4) Remove bearing cone (51), snap ring (52), gear (53), andbearing cone (54) from shaft (50) in order.

18. Bearing cupRemove bearing cup of front housing with puller.Ú Do not remove unless necessary.

DISASSEMBLY AND ASSEMBLY TRANSMISSION

30-58 Î

DISASSEMBLY OF PARKING BRAKE

1. Plate, disc1) Remove holder bolts (6) from retainer assembly (44).

2) Remove separator plate (7), wave spring (8), and disc (9).

2. End plateRemove end plate (10), then remove hub spline (11).

3. RetainerTurn over retainer (4), and remove bearing cup (12) with puller.

DISASSEMBLY AND ASSEMBLY TRANSMISSION

30-59 Î

4. HousingRemove 2 set bolts 03 for securing piston, then remove piston(13) and balls (14).Ú If it is necessary to disassemble the lever portion, remove

lock bolt (15), check the match marks on inner lever (16)and outer lever (17), then pull out the inner lever, andremove bearings (18) and oil seal (19).

DISASSEMBLY AND ASSEMBLY TRANSMISSION

30-60 Î

ASSEMBLY OF PARKING BRAKE

1. Housing1) Press fit oil seal (20) and dust seal (21) to housing (5).

Ú Press-fitting dimension "a": 25.8 1.0 mmÚ Press-fitting dimension "b":Ú 18.3 1.0 mm

Lip of oil seal: Grease (G2-LI)

Ú Coat with grease when assembling the housing.

2) Press fit needle bearing (18) and oil seal (19) to housing (5)to specified dimensions.Ú Needle bearing press-fitting dimension

“c”: 38.5 ± 0.15 mm (lst)Ú Needle bearing press-fitting dimension

"d": 18.0 ± 0.5 mm (2nd)Ú Oil seal press-fitting dimension "e":

7.5 ± 0.3 mm

Lip of oil seal: Grease (G2-LI)

3) Insert outside lever (17) from oil seal end.Ú Clean and remove all oil and grease from the bolt hole

of the outside lever.

4) Align with match mark and assemble inside lever (16).

5) Tighten lock bolt (15).Ú Clean and remove all oil and grease from lock

bolt and bolt hole.Ú Be sure to assemble the washer.

Lock bolt: Thread tightener (LT-2)

Lock bolt: 30.9 ± 3.4 Nm(3.15± 0.35 kgm)

DISASSEMBLY AND ASSEMBLY TRANSMISSION

30-61 Î

6) Fit balls (14) in groove of housing (5), install piston (13)from top, then temporarily tighten 2 set bolts (3), forsecuring piston.Ú Assemble temporarily to prevent the pis-

ton from failing out during assembly.Ú Set bolt for securing piston:

P = 1.25, M = 8, L = 35

2. RetainerPress fit bearing cup (12) to retainer (4).Ú After press fitting the cup, check that there is no clearance

at portion "a".

3. End plateTurn over retainer and assemble end plate (10), then assemblehub spline (11) to center.Ú Use the hub spline as a guide when assembling the disc.

DISASSEMBLY AND ASSEMBLY TRANSMISSION

30-62 Î

4. Separator plate, disc1) Assemble separator plate (7), wave spring (8), and disc (9)

in order in turn.Ú Soak disc (9) in clean transmission oil

for at least 2 minutes before assembling.Ú Use one spring.Ú Insert pins (22) into the guide of the separator plate

spline.

2) Tighten holder bolt (6) of separator plate (7) to retainer (4).Ú Remove all oil and grease from the bolt thread and bolt

hole.

Holder bolt: Thread tightener (LT-2)Holder bolt: 53.9± 19.6 Nm

(5.5± 2.0 kgm)

5. Brake housing, retainerAssemble temporarily parking brake retainer assembly (44) andparking brake housing and piston (43).Ú When assembling housing and piston (43), do not remove

the 2 set bolts (3) for holding the piston.

DISASSEMBLY AND ASSEMBLY TRANSMISSION

30-63 Î

TRANSMISSIONASSEMBLYÚÚ Press fit the oil seal and dust seal before assembling each

clutch assembly.Ú Press fit the bearing cup fully to the stepped portion of the

housing so that there is no clearance.Ú Keep the front housing horizontal.

1. Bearing cupPress fit bearing cup (55) to front housing (16).

2. Output shaft gear1) Press fit bearing cone (54) to shaft (50), assemble gear (53)

and snap ring (52), then press fit bearing cone (51).Ú To prevent improper adjustment of the

end play, press fit the cone securely up to the shoulderof the shaft.

Ú Fit the snap ring securely in the shaft groove.

2) Assemble output shaft and gear assembly (49 )to bearingcup portion of front housing (16).

WARNING! Be careful not to get your fingers caughtbetween the gear and housing when carrying out thisoperation.

Ú Clearance (one side) between gear and housing:Approx. 20 mm

Ú If there is oil on the output shaft spline, wipe it offcompletely and be extremely careful when assembling.

3) Insert gear cover (47) from under housing,rotate gear cover a half turn and align mounting bolt holes.

WARNING! Be careful not to get your fingers caughtbetween the gear and housing when carrying out thisoperation.

DISASSEMBLY AND ASSEMBLY TRANSMISSION

30-64 Î

4) Remove all oil and grease from mounting bolt (48) and bolthole, coat thread of mounting bolt of gear cover (47) withgasket sealant, then tighten.

Mounting bolt:Thread tightener (LT-2)

Mounting bolt: 110.3 ± 12.3 Nm(1 1.25 ± 1.25 kgm)

3. Adjusting rotating torque of bearing1) Assemble O-ring (44-1) to parking brake retainer assembly

(44), and coat outside circumference thinly with grease.

O-ring outside circumference:Grease G2-LI)

2) Turn over front housing (16), and install guide bolt, alignwith guide bolt, assemble brake retainer assembly (44), andtemporarily assemble mounting bolts.Ú When doing this, check that the bearing cone is

properly fitted inside bearing cup “a", then assemble.

3) Insert desired shim (45) from left and rightof parking brake retainer assembly (44), then tightenmounting bolts.

Mounting bolt: 110.3 ± 12.3 Nm(1 1.25 ± 1.25 kgm)

Ú Do not install the hub spline until Step 6).

DISASSEMBLY AND ASSEMBLY TRANSMISSION

30-65 Î

Ú To settle the bearing, rotate the shaft while tightening.After tightening, hit the end face of the shaft severaltimes with a plastic hammer.

Ú Coat the bearing thoroughly with oil.Ú Standard shim thickness "a":

0.85 ± 0.83 mm

Bearing: Transmission oil

4) Tighten coupling mounting bolts to shaft (50), then measurerotating torque.Ú Rotating torque:

0.10 - 1.0 Nm (0.01 - 1.0 kgm)Ú If no small torque wrench is available, it is also possible

to measure as follows.Ú Fit measurement plate (56) to shaft (50), tighten the

coupling mounting bolts, then install a push-pull scaleto the tip of plate (56), and carry out the measurement.! Plate length : 100 mm! Push-pull scale reading: 1.0 -9.8 NM (0.1 - 1.0

kgm)Ú When measuring the rotating torque, do not measure

at the beginning of the movement. Measure the torquewhen the shaft is rotating.

Ú If the rotating torque is not within the standard value,add or remove shims to adjust again.

Ú If the rotating torque is within the standard value, checkthat the end plate is "0”.

5) Insert selected shim (45) from left and rightof parking brake retainer assembly (44), then tightenmounting bolts uniformly.Ú Insert the thim shims in the middle, and the thick shims

on the outside when assembling.

Mounting bolt: 110.3 ± 12.3 Nm(1 1.25 ± 1.25 kgm)

6) Align with parking brake disc spline, andassemble hub spline (46) to output shaft (50).Ú Use a screwdriver to align the discipline.Ú If the spline is not aligned, rotate lightly while

assembling. Never push with force.

DISASSEMBLY AND ASSEMBLY TRANSMISSION

30-66 Î

4. Parking brake assembly1) Assemble new gasket to mounting surface "b" for housing

and piston assembly on parking brake retainer assembly(44).

2) Align housing and piston assembly (43) with guide bolt andassemble.Ú Check that the lock set bolt is assembled.Ú When assembling, be careful not to damage the oil

seal lip.

3) Tighten mounting bolts (42) of housing and piston assembly(43) on diametrically opposite sides.

Mounting bolt: 110.3 ± 12.3 Nm(1 1.25 ± 1.25 kgm)

4) Remove lock set bolt and install plugs (41-1).

DISASSEMBLY AND ASSEMBLY TRANSMISSION

30-67 Î

5. CouplingCoat oil seal lip portion thinly with grease, assemble coupling(39), then tighten O-ring (57), holder (40), and mounting bolt(58).

Lip of oil seal: Grease (G2-LI)

Mounting bolt: 277 ± 32 NM.

Ú Slide the coupling several times to prevent the oil seal lipfrom turning over.

Ú Insert the O-ring into the shaft groove, and be careful not toget it caught.

Ú Check that the lock set bolt has been removed and the plughas been assembled in its place.

6. Rear oil seal, dust sealTurn over front housing (16), then press fit oil seal (38) and dustseal (37).

Lip of oil seal: Grease (G2-LI)

Press-fitting dimension "a": 29 ± 1 mmPress-fitting dimension "b": 21.5 ± 1.0 mm

7. Idler countershaft1) Assemble to shaft (31) so that oil groove of gear (34) is on

inside, then press fit bearing(32).

2) Assemble to shaft (31) so that oil groove of gear (35) is oninside, then press fit bearing(33).Ú Press fit the bearing securely to the face of the gear.

3) Assemble speedometer worm gear (36) to spline of shaft(31), then tighten mounting bolt (59).Ú Remove all oil and grease from the mounting bolts and

bolt holes.Mounting bolt:

Thread tightener (LT-2)

Mounting bolt: 30.9 ± 3.4 Nm(3.15± 0.35 kgm)

DISASSEMBLY AND ASSEMBLY TRANSMISSION

30-68 Î

4) Assemble idler countershaft (31) to front housing (16).Ú When assembling, be careful not to damage the

speedometer worm gear.

8. 3rd, 4th clutch assemblyUsing tool B, assemble 3rd and 4th clutch assembly (30) tohousing, then move it towards output shaft end.Ú Secure with wire in the same way as when

disassembling.Ú Do not fit the bearing at the bottom of the clutch into

position.

9. FORWARD, 2nd clutch assembly1) Using tool B, raise FORWARD and 2nd clutch assembly

(29).Ú Be careful that the stopper pin does not come out.

2) Mesh gear of 3rd, 4th clutch assembly (30) with gear ofFORWARD, 2nd clutch assembly (29), then lower slowly.Ú Do not fit the bearing at the bottom of the clutch into

position.

WARNING! Be careful not to get your fingers caught in thegear.

3) After checking that each gear is engaged, press fit bearingat bottom of 3rd, 4th clutch assembly (30) to front housing.Ú Check the meshing of each gear when

press fitting the bearing.Ú When doing this, the 3rd, 4th clutch gear and

FORWARD, 2nd clutch gear must be meshed.

DISASSEMBLY AND ASSEMBLY TRANSMISSION

30-69 Î

4) Press fit bottom bearing of FORWARD and 2nd clutchassembly (29) to front housing portion.Ú Coat the bearing press-fitting portion of the front

housing thinly with transmission oil.

Bearing press-fitting portion:Transmission oil

10. REVERSE, 1st clutch assemblyUsing tool B, press fit bottom bearing of REVERSE and 1stclutch assembly (28) to front housing.

WARNING! Be careful not to get your fingers caught in thegear.

11. Seal ring1) Press fit bearing (60) to input shaft (27), assemble gear (61)

so that oil groove of gear is on bearing side, then securewith snap ring (62).

2) Press fit bearing (63) to input shaft (27).

Bearing press-fitting portion:Transmission oil

Ú Fit the snap ring securely in the groove.

3) Assemble input shaft (27) to front housing (16).

DISASSEMBLY AND ASSEMBLY TRANSMISSION

30-70 Î

4) Install seal rings (26) to each clutch.Ú Coat the seal ring thoroughly with oil, then install, and

check that it rotates lightly by hand.

Seal ring: Oil (transmission oil)

12. Pump (Torque converter, work equipment)1) Press fit bearing (25) to shaft (24).

Ú Press fit so that there is no clearance at the steppedportion of the shaft.

2) Assemble gear (20) and snap ring (21) inside rear housing(15), and insert shaft (24) from pump mount end.

Ú Install the gear so that the oil groove of the gear is onthe pump mount side.

3) Assemble ring washer (22) and split spacer (23) to steppedportion of shaft (24), then install snap ring (21).

DISASSEMBLY AND ASSEMBLY TRANSMISSION

30-71 Î

4) Turn over rear housing (15), and assemble snap ring (19)at pump mount end.

Ú Carry out the operation in the same way at the workequipment pump end.

13. Torque converterUsing eyebolts, raise rear housing (15), set to mount of torqueconverter, then tighten mounting bolts (64).Ú Install guide pins to the torque converter.Ú Align the mounting bolt hole properly, and be careful of the

meshing with the pump gear when installing.Ú When installing, align the match marks made during

assembly.

Mounting bolt: 112.8 ± 9.8 Nm(1 1.5 ± 1.0 kgm)

14. Rear housing1) Using tool A, raise rear housing (15), and assemble to front

housing (16).Ú Install guide bolts (M = 10, P = 1.5, R

150 mm) to the front housing.

Mating surface of housing:Gasket sealant (Three Bond 1207B)

Ú Be careful not to coat with too much gasket sealant,and be sure that the gasket sealant is not squeezed outto the inside of the case.

DISASSEMBLY AND ASSEMBLY TRANSMISSION

30-72 Î

Ú When inserting the input shaft, be careful not to let thetip of the shaft contact portion "a" of the housing.

Ú Lower slowly until it meshes with the spline of the inputshaft.

Ú Mesh the spline of the input shaft securely.Ú Be careful not to damage the seal rings of each shaft.

Housing mounting bolt:112.8± 4.9 Nm (11.5 ± 0.5 kgm)

2) Install pilot cap (18).Remove all oil and grease from the mounting bolts andbolt holes.

Cap mounting bolt:Thread tightener (LT-2)

Pilot cap mounting bolt:66.2± 7.4 Nm (6.75 ± 0.75 kgm)

Remove tool A from rear housing (15).

15. Transmission control valve1) Install guide bolt to mount of control valve(14).

Ú Clean and removeall oil and grease from the mountingbolt thread and mounting bolt hole of the control valve.

2) Align with guide bolt, assemble gasket, then fit control valve(14) temporarily.Ú Use a new part for the gasket.

3) Coat mounting bolts of control valve (14) with threadtightener, and tighten.Ú Tighten the mounting bolts on diametrically opposite

sides, and be careful not to tighten too much.Ú The length of the mounting bolts is different, so be

careful when using them.(1): L = 120 mm (2): L = 130 mm(3): L = 135 mm (4) : L = 115 mm(5): L=100 mm

Mounting bolt:Thread tightener (LT-2)

Mounting bolt: 34.3 ± 4.9 Nm(3.5 ± 0.5 kgm)

DISASSEMBLY AND ASSEMBLY TRANSMISSION

30-73 Î

4) Assemble O-ring to accumulator valve (13), and install totransmission.Ú Remove all oil and grease from the mounting bolts and

bolt holes.

Mounting bolt:Thread tightener (LT-2)

Mounting bolt: 34.3 ± 4.9 Nm(3.5 ± 0.5 kgm)

16. Charging pumpAssemble O-ring to charging pump (12), and install totransmission.Ú Be careful not to get the O-ring caught.

Mounting bolt: 66.2 ± 7.4 Nm(6.75± 0.75 kgm)

17. Strainer, rear coupling1) Install hose and tube (11) between strainer and pump.

Ú Be careful not to get the O-ring caught.

Mounting bolt: 66.2 ± 7.4 Nm(6.75 ± 0.75 kgm)

2) Align center line of key groove to align rear coupling (10)with front coupling.Ú Coat the oil seal lip portion thinly with grease.Ú Slide the coupling to prevent the oil seal lip from turning

over.Lip of oil seal: Grease (G2-LI)

DISASSEMBLY AND ASSEMBLY TRANSMISSION

30-74 Î

18. Oil filter1) Sling transmission assembly (9), and lift off from assembly

stand.Ú When standing the transmission assembly, be careful

of the center of gravity (lift off slowly).

2) Install O-ring (8) to idler countershaft portion, then installspeedometer pickup port assembly (6) and cover (7).Ú Be careful not to get the O-ring caught.Ú Do not use force to mesh the gears.

Mounting bolt: 110.3 ± 12.3 Nm(1 1.25 ± 1.25 kgm)

3) Install oil filter (4) and bracket (5).

Mounting bolt: 112.8 ± 9.8 Nm(11.5± 1.0 kgm)

19. Hydraulic pipingInstall hoses (1) and (2) and tube.Ú Be careful not to crush tube (3) during the operation.Ú Install the hoses without twisting, and be careful not to get

the O-rings caught.! Connect PTO lubrication tube.! Install mount brackets to left and right of transmission

assembly (9).! Wipe the bracket mounting surface clean.

Mounting bolt: 277 ± 31.9 Nm(28.25± 3.25 kgm)

DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK

30-75 Î

TRANSMISSION CLUTCH PACK

I. DISASSEMBLY OF 1ST, REVERSE CLUTCH

WARNING! When setting the clutch pack on the stand, becareful not to let your hands slip because of oil, and beextremely careful not to get your fingers caught between thestand and the clutch pack

Ú Set with the lst side facing up, and set on tool D1.

1. BearingRemove bearing (1) with puller.

2. Gear Remove spacer (2), thrust washer (3), gear (4), needlebearing (5), and thrust washer (6).

3. End plate1) Install tools D2 and D3, tighten nut D5, and remove ring (7).

Ú Set the spacer in position and push in the end plate.Ú After removing the ring, remove tools D2 and D3.

DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK

30-76 Î

2) Remove end plate (8).

4. Clutch plateRemove plate (9), disc (10), and spring (11) from housing.

5. PistonBlow air in through oil hole at 1st end of shaft and remove piston(12).Ú If the piston is at an angle and does not

come out, push the piston in and try again.Ú If force is used to remove the piston, the inside

circumference of the cylinder will be damaged.

6. BearingÚ Set with the REVERSE side facing up, and set on tool D1.Remove bearing (13) with puller.

7. REVERSE gearRemove spacer (15), thrust washer (16), needle bearing (17),REVERSE gear (18), and thrust washer (19).Ú Disassemble the REVERSE gear in the same way as in

Steps 3 - 5 for the 1st gear.

DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK

30-77 Î

II. DISASSEMBLY OF FORWARD, 2ND CLUTCH PACK

Ú Set with the 2nd side facing up, and set on tool D1.

1. BearingUsing puller, remove 2nd gear (37) together with bearing (35).

2. 2nd gearRemove spacer (39) and thrust washers (36), then removeneedle bearings (38) from 2nd gear (37).Ú Remove the inside thrust washer after removing the clutch

plate.

3. End plate1) Install tools D2 and D3, tighten nut D5, then remove ring

(40).Ú Set the spacer in position and push in the end plate.Ú After removing the ring, remove tools D2 and D3.

2) Remove end plate (41).

DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK

30-78 Î

4. Clutch plateRemove plate (42), disc (43), and spring (44) from housing.

5. PistonBlow air in through oil hole at 2nd end of shaft and removepiston (45).Ú If the piston is at an angle and does not come out, push the

piston in and try again.Ú If force is used to remove the piston, the inside

circumference of the cylinder will be damaged.

6. BearingÚÚ Set with the FORWARD side facing up, and set on tool D1.Remove bearing (46) with puller.Ú When installing the puller, put the center in contact with the

plate.

7. FORWARD gearRemove spacer (47), thrust washer (48), needle bearing (49),FORWARD gear (50), and thrust washer (51).Ú Disassemble the FORWARD gear in the same way as in

Steps 3 - 5 for the 2nd gear.

DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK

30-79 Î

Ill. DISASSEMBLY OF 3RD, 4TH CLUTCH PACK

Ú Set with the 3rd side facing up, and set on tool D1.

1. BearingFit puller to bearing (53), then remove bearing (53).

2. 3rd gearÚ Remove spacer (54), thrust washer (55), 3rd gear (56), and

needle bearings (57).Remove the inside thrust washer at Step 4-2).

3. End plate1) Install tools D2 and D3, tighten nut D5, then remove ring

(58).Ú Set the spacer in position and push in the end plate.Ú After removing the ring, remove tools D2 and D3.

2) Remove end plate (59).

DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK

30-80 Î

4. Clutch plate1) Remove plate (60), disc (61), and spring (62) from housing.2) Remove inside thrust washer (71).

5. PistonBlow air in through oil hole at 3rd end of shaft and removepiston (63).Ú If the piston is at an angle and does not come out, push the

piston in and try again.Ú If force is used to remove the piston, the inside

circumference of the cylinder will be damaged.

6. BearingÚ Set with the 4th side facing up, and set onÚ tool D1.Using puller, remove bearing (64) and 3rd gear (65).

7. 4th gearRemove spacer (66), thrust washer (67), needle bearing (68),4th gear (69), and thrust washer (70).Ú Disassemble the 4th gear in the same way as in Steps 3 -

5 for the 3rd gear.

DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK

30-81 Î

ASSEMBLY OF CLUTCH PACK

l. ASSEMBLY OF 1ST, REVERSE CLUTCH PACK

WARNING! When setting the clutch pack on the stand, becareful not to let your hands slip because of oil, and beextremely careful not to get your fingers caught between thestand and the clutch pack.

Ú Set with the REVERSE side facing up, and set the shaft andhousing assembly on tool D1.

1. Piston sealAssemble piston seal (71-1) to piston (71).Ú When assembling a new piston seal, use

seal shaping jig El or E2 for approx. 2 - 3 minutes, thenassemble the piston seal.

Ú If the seal is installed to the piston without being shaped, theseal will be damaged.

Inside surface of shaping jig:Oil (transmission oil)

2. REVERSE pistonAssemble REVERSE piston (71).Ú Be careful not to damage the piston seal.

Sliding surface of piston seal:Oil (transmission oil)

3. Clutch plateInsert tool D4 in housing, then assemble plate (72), disc (73),and spring (74) in turn.Ú Soak disc (73) in clean transmission oil for at least 2

minutes before assembling.Ú Be careful not to let spring (74) and plate (72) rest on top of

each other.Ú Be careful not to let the plate or spring get caught in the ring

groove of the clutch housing when assembling.Ú A30 x 85 mm nail can also be used for tool D4.

DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK

30-82 Î

4. End plate1) Install tools D2 and D3, tighten nut D5 to

push in end plate (76), then remove tool D4.Ú Set the spacer in position and push in the end plate.

2) Assemble ring (77), then remove tools D2 and D3.Ú Check that ring (77) is fitted securely in the groove.Ú Check that the disc rotates smoothly by hand.

5. Thrust washerInstall thrust washer (19).

6. REVERSE gearUse a screwdriver to align the spline on the inside of the plate,and assemble REVERSE gear (18).Ú If the gear spline is not aligned, rotate lightly while

assembling. Never push with force.

7. BearingAssemble needle bearing (17), thrust washer (16), and spacer(15).Ú Check that the end face of thrust washer (16) is level with

or below the stepped portion of the shaft.

DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK

30-83 Î

8. BearingPress fit bearing (13).Ú Press fit completely so that spacer (15) is in tight contact

with the stepped portion of the shaft and bearing (13).

Ú After press fitting the bearing, check that clearance "a"between thrust washer (16) and spacer (15) is within thespecified range."a" = 0.07 - 0.93 mm

9. 1st piston1) Turn over clutch pack.

WARNING! When turning over the clutch pack, be carefulnot to get your fingers caught between the stand and clutchpack.

2) Assemble piston (12) in same way as for REVERSE piston.

Sliding surface of piston seal:Oil (transmission oil)

10. Clutch plateInsert tool D4 in housing and assemble plate (9), disc (10), andspring (11) in turn.Ú A 3i x 85 mm nail can also be used for tool D4.Ú Assemble in the same way as for REVERSE.

DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK

30-84 Î

11. End plate1) Install tools D2 and D3, tighten nut D5 to push in end plate

(8), then remove tool D4.Ú Set a spacer in position and push in the end plate.

2) Assemble ring (7) and remove tools D2 and D3.Ú Assemble in the same way as for REVERSE.

12. Thrust washerInstall thrust washer (6).

13. lst gearAssemble 1st gear (2).Ú Assemble in the same way as for REVERSE.

14. BearingÚAssemble needle bearing (5).

15. Thrust washer, spacerAssemble thrust washer (4) and spacer (3).Ú Check that the end face of thrust washer (4) is level with or

below the stepped portion of the shaft.

DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK

30-85 Î

16. BearingPress fit bearing (1).Ú Press fit completely so that the spacer is in tight contact with

the stepped portion of the shaft and bearing (1).

Ú After press fitting the bearing, check that clearance "b"between thrust washer (4) and spacer (3) is within thespecified range.b = 0.04 - 1.16 mm

17. Clutch pack operating testBlow in compressed air through oil hole of shaft and check ifeach clutch is actuated.Ú If the gear at the point where the air is blown in is held in

position, the clutch is working normally.

DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK

30-86 Î

II. ASSEMBLY OF FORWARD, 2ND CLUTCH PACK

WARNING!When setting the clutch pack on the stand, becareful not to let your hands slip because of oil, and beextremely careful not to get your fingers caught between thestand and the clutch pack.

Ú Set with the FORWARD side facing up, and set the shaft andhousing assembly on tool D1.

1. Piston sealAssemble piston seal (83-1) to piston (83).Ú When assembling a new piston seal, use

seal shaping jig El or E2 for approx. 2 - 3 minutes, thenassemble the piston seal.

Ú If the seal is installed to the piston without being shaped, theseal will be damaged.

Inside surface of shaping jig:Oil (transmission oil)

2. FORWARD pistonAssemble FORWARD piston (83).Ú Be careful not to damage the piston seal.

Sliding surface of piston seal:Oil (transmission oil)

3. Clutch plateInsert tool D4 in housing, then assemble plate (78), disc (79),and spring (80) in turn.Ú Soak disc (79) in clean transmission oil forat least 2 minutes

before assembling.Ú Be careful not to let spring (80) and plate (78) rest on top of

each other.Ú Be careful not to let the plate or spring get caught in the ring

groove of the clutch housing when assembling.Ú A 3i x 85 mm nail can also be used for tool D4.

DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK

30-87 Î

4. End plate1) Install tools D2 and D3, tighten nut D5 to push in end plate

(81), then remove tool D4.Ú Set the spacer in position and push in the end plate.

2) Assemble ring (82) and remove tools D2 and D3Ú Check that ring (82) is fitted securely in the groove.Ú Check that the disc rotates smoothly by hand.

5. Thrust washerInstall thrust washer (51).

6. FORWARD gearAssemble FORWARD gear (50), then assemble needle bearing(49).Ú If the gear spline is not aligned, rotate lightly while

assembling. Never push with force.

7. Thrust washerAssemble thrust washer (48).Ú Check that the end face of the thrust washer

is level with or below the stepped portion of the shaft.

8. BearingAssemble spacer 47), then press fit bearing (46).Ú After press fitting the bearing, check that clearance "e"

between thrust washer (48) and spacer (47) is within thespecified range. e = 0.07 - 0.93 mm

DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK

30-88 Î

9. 2nd piston1) Turn over clutch pack.

WARNING!When turning over the clutch pack, be carefulnot to get your fingers caught between the stand and clutchpack.

2) Assemble piston (45) in same way as for FORWARDpiston.

Sliding surface of piston seal:Oil (transmission oil)

10. Clutch plateInsert tool D4 in housing and assemble plate (42), disc (43), andspring (44) in turn.

Ú A 3i x 85 mm nail can also be used for tool D4.Ú Assemble in the same way as for FORWARD.

11. End plate1) Install tools D2 and D3, tighten nut D5 to push in end plate

(41), then remove tool D4.Ú Set a spacer in position and push in the end plate.

2) Assemble ring (40), then remove tools D2and D3.Ú Assemble in the same way as for FORWARD.

12. Thrust washerInstall thrust washer (36).

DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK

30-89 Î

13. 2nd gearAssemble 2nd gear (37), then assemble needle bearings (38).Ú Assemble in the same way as for FORWARD.

14. Thrust washer, spacerAssemble thrust washer (36) and spacer (34).Ú Check that the end face of thrust washer (36) is level with

or below the stepped portion of the shaft.

15. BearingPress fit bearing (35).Ú Press fit completely so that spacer (34) is in tight contact

with the stepped portion of the shaft and bearing (35).Ú After press fitting the bearing, check that clearance "f"

between thrust washer (36) and spacer (34) is within thespecified range.f = 0.04 - 1.16 mm

16. Clutch pack operating testBlow in compressed air through oil hole at 2nd end and checkif each clutch is actuated.Ú If the gear at the point where the air is blown in is held in

position, the clutch is working normally.

DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK

30-90 Î

Ill. ASSEMBLY OF 3RD, 4TH CLUTCH PACK

WARNING! When setting the clutch pack on the stand, becareful not to let your hands slip because of oil, and beextremely careful not to get your fingers caught between thestand and the clutch pack.

Ú Set with the 4th side facing up, and set the shaft and housingassembly on tool D1.

1. Piston sealAssemble piston seal (84-1) to piston (84).Ú When assembling a new piston seal, use seal shaping jig

E1 or E2 for approx. 2 - 3 minutes, then assemble thepiston seal.

Ú If the seal is installed to the piston without being shaped, theseal will be damaged.

Inside surface of shaping jig:Oil (transmission oil)

2. 4th pistonAssemble 4th piston (84).Ú Be careful not to damage the piston seal.

Sliding surface of piston seal:Oil (transmission oil)

3. Clutch plateInsert tool D4 in housing, then assemble plate (85), disc (86),and spring (87) in turn.Ú Soak disc (86) in clean transmission oil for at least 2

minutes before assembling.Ú Be careful not to let spring (87) and plate (85) rest on top of

each other.Ú Be careful not to let the plate or spring get caught in the ring

groove of the clutch housing when assembling.

Ú A 3i x 85 mm nail can also be used for tool D4.

DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK

30-91 Î

4. End plate1) Install tools D2 and D3, tighten nut D5 to push in end plate

(88), then remove tool D4.Ú Set the spacer in position and push in the end plate.

2) Assemble ring (89), then remove tools D2 and D3.Ú Check that ring (89) is fitted securely in the groove.Ú Check that the disc rotates smoothly by hand.

5. Thrust washerInstall thrust washer (70).

6. 4th gearAssemble 4th gear (69), then assemble needle bearing (68).Ú If the gear spline is not aligned, rotate lightly while

assembling. Never push with force.

7. Thrust washer, bearingAssemble thrust washer (67), and spacer (66), then insertbearing (64) to shaft.Ú Check that the end face of thrust washer (67) is level with

or below the stepped portion of the shaft.

DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK

30-92 Î

8. BearingPress fit bearing (64).Ú Press fit completely so that spacer (66) is in tight contact

with the stepped portion of the shaft and bearing (64).

Ú After press fitting the bearing, check that clearance "g"between thrust washer (67) and spacer (66) is within thespecified range. ..”g" = 0.07 - 0.93 mm

9. 3rd piston1) Turn over clutch pack.

WARNING! When turning over the clutch pack, becareful not to get your fingers caught between the standand clutch pack.

2) Assemble piston (63) in same way as for 4th piston.

Sliding surface of piston seal:Oil (transmission oil)

10. Thrust washerInstall thrust washer (71).Ú Assemble 3rd inside thrust washer (71) before assembling

the clutch plate.

DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK

30-93 Î

11. Clutch plateInsert tool D4 in housing and assemble plate (60), disc (61), andspring (62) in turn.

Ú A 3i x 85 mm nail can also be used for tool D4.Ú Assemble in the same way as for 4th.

12. End plate1) Install tools D2 and D3, tighten nut D5 to push in end plate

(59), then remove tool D4.Ú Set a spacer in position and push in the end plate.2) Assemble ring (58), then remove tools D2 and D3.Ú Assemble in the same way as for 4th.

13. 3rd gearAssemble 3rd gear (56), then assemble needle bearings (57).Ú Assemble in the same way as for 4th.

14. Thrust washer, spacerInstall thrust washer (55), then assemble space (54).Ú Check that the end face of thrust washer (55) is level with

or below the stepped portion of the shaft.

DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK

30-94 Î

15. Bearing

Ú Press fit completely so that spacer (54) is in tight contact withthe stepped portion of the shaft and bearing (53).

Ú After press fitting the bearing, check that clearance "h" betweenthrust washer (55) and spacer (54) is within the specified range.h = 0.04 - 1.16 mm

16. Clutch pack operating testBlow in compressed air through oil hole at 3rd end and check ifeach clutch is actuated.Ú If the gear at the point where the air is blown in is held in

position, the clutch is working normally.

DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE

30-95 Î

TRANSMISSION CONTROL VALVEREMOVAL

WARNING! Stop the machine on level ground and install thesafety bar on the frame. Lower the bucket to the ground andstop the engine. Then apply the parking brake and put blocksunder the wheels to prevent the machine from moving.

! Remove inspection cover (1) of the left side of the rear frame.! Remove cover (2) at the left side of the floor.

1. Electric wiring

1) Disconnect connectors (3), (4), (5), and (6) and wiring fortransmission solenoid valve.

2) Disconnect torque converter oil temperature sensorconnector (7).Ú When disconnecting the wiring connectors, fit tags to

identify the connectors.

2. Hydraulic piping

Hose (8) between brake booster and transmission valveHose (9) between transmission valve and oil coolerDisconnect hose (10) between torque converter oil filter andbrake booster, and remove hose clamp.

3. Transmission valve

Sling transmission valve (12) and remove mounting bolts,then lower under machine.

WARNING! The working space is confined, so beextremely careful.

Ú To prevent the valve from falling, remove 2 mounting bolts,then install guide bolts and insert wooden blocks.

Ú Remove the valve with a upper valve and lower valveassembled. Disassemble the upper and lower valve afterremoving.

Ú When fitting a lifting tool, avoid the connectors and fit thetool securely to the valve body.

Transmission valve: 46 kg(upper: 15.5 kg)(lower: 30.5 kg)

DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE

30-96 Î

TRANSMISSION CONTROL VALVEINSTALLATION

! Carry out installation in the reverse order to removal.

WARNING! The working space is confined, so be extremelycareful.

Ú Connect the wiring connector securely.

Ú Install the hoses without twisting or interference.

Nut of hose mouthpiece:176.5 ± 29.4 Nm (18 ± 3 kgm)

! Width across flats of hose mouth piece nut: 36 mm

Ú When installing the transmission valve, replace the gasketwith a new part.

Ú When installing the transmission valve, use guide bolts toprevent it from falling.

Ú Secure with upper and lower valve set bolts (13) and (14).Ú Remove all oil and grease from the valve mounting bolts

and mounting bolt holes.Ú The length of the mounting bolts is different, so be careful

when using them.(1) L = 120 mm (2) L = 130 mm (3) L = 135 mm(4) L = 115 mm (5) L = 100 mm (6) L = 100 mm

Ú To prevent distortion of the valve, tighten the transmissionvalve mounting bolts in the order shown in the diagram.

Mounting bolt:Thread tightener (LT-2)

Mounting bolt: 34.3 ± 4.9 Nm(3.5 ± 0.5 kgm)

DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE

30-97 Î

MEMORANDA

DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE

30-98 Î

TRANSMISSION CONTROL VALVEDISASSEMBLY

DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE

30-99 Î

1. DisconnectionRemove mounting bolts, and disconnect upper valve (1) andlower valve (2), then remove gasket (3).

2. Disassembly of upper valve1) Remove mounting bolts, remove cover

(4), then remove gasket (5), pilot valve (6), priority spring(7), quick return valve assembly (8), accumulator piston (9),and spring (10).

2) Remove sleeve (11) from quick return valve assembly, thenremove spring (12) and ball (13).

3) Remove plug (14) from sleeve (11).4) Remove mounting bolts, remove cover (15), then remove

gasket (16), main regulator valve (17), spring (18), priorityvalve (19), modulating valve assembly (20), accumulatorshaft (21), and springs (22) and (23).

5) Remove load pistons (24) and (25) from main regulatorvalve (17) and priority valve (19).

6) Remove plug (26) from modulating valve assembly (20),then remove retainer (27), springs (28) and (29), sleeve(30), and O-rings (31).

7) Remove nut (32) and washer (33) from cover (15), thenremove adjustment screw (34) and O-ring (35).

8) Remove plug (36) and main orifice (37) from upper valve(1).

3. Disassembly of lower valve1) Remove mounting bolts, remove solenoid valve assembly

(38), then remove spring (39), retainer (40), spring (41), andsleeve (42).

2) Remove mounting bolts, remove cover (43), then removegasket (44), torque converter regulator valve (45), shim,(46), spring (41A), sleeve (42A), F-R selector valve (47), H-L selector valve (48), range selector valve (49), springs(50), and spacers (51).

3) Remove mounting bolts, then remove pilot filter (52) and O-rings (53).

4) Remove plug (54) from F-R selector valve (47).5) Remove plugs (55) from lower valve (2) and cover (43).6) Remove orifices (56) from lower valve (2).

DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE

30-100 Î

TRANSMISSION CONTROL VALVEASSEMBLY

DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE

30-101 Î

1. Assembly of lower valve washer (33) and nut (32).1) Install orifices (56) to lower valve (2). Ú For details of the adjustment procedure,

Ú Screw in the orifice at least 2 mm from the see TESTING AND ADJUSTING.valve body. 3) Fit plug (26) to modulating valve (20), then

2) Install plugs (55) to lower valve (2) and assemble O-rings (31) to sleeve (30), and installcover(43). springs (28) and (29) and retainer (27).

Plug: Sealant (LG-1 or LG-5) regulator valve (27) and priority valve (19).

3) Install plug (54) to F-R selector valve (47). (7.0 ± 0.5 kgm)4) Install O-rings (53) to pilot filter (52), then set in

mounting position and tighten mounting bolts. 3. Connection

Mounting bolt: 68.6 ± 4.9 Nm and upper valve (1).(7.0 ± 0.5 kgm)

5) Install H-L selector valve (48), range selector valve (3.2 ± 0.3 kgm)(49), spacers (51), springs (50), F-R selector valve(47), sleeve (42A), spring (41A), shim (46), andtorque converter regulator valve (45), then setgasket (44) in position, and install cover (43).

Mounting bolt: 68.6 ± 4.9 Nm(7.0 ± 0.5 kgm)

6) Install sleeve (42), spring (41), retainer (40), andspring (39), then set gasket mount, and installsolenoid valve assembly (38) to lower valve (2).

Mounting bolt: 68.6 ± 4.9 Nm(7.0 ± 0.5 kgm)

2. Assembly of upper valve1) Install plug (36) and main orifice (37) to upper

valve (2).Ú Screw in the orifice at least 2 mm from

the valve body.

Plug: Sealant (LG-1 or LG-5)

2) Fit O-ring (35) to adjustment screw (34), then

set cover (15) in mounting position, and secure

4) Install load pistons (24) and (25) to main

5) Assemble springs (22) and (23), accumulatorshaft (21), modulating valve assembly (20),priority valve (19), spring (18), and main regulatorvalve (17), then set gasket (16) to mount, andinstall cover(15).

Mounting bolt: 68.6 ± 4.9 Nm(7.0 ± 0.5 kgm)

6) Assemble plug (14) to sleeve (11), then set ball(13) and spring (12) to quick return valve (8), andassemble sleeve (11).

7) Assemble spring (10), accumulator piston (9),quick return valve assembly (8), priority spring(7), and pilot valve (6),, then set gasket (5) tomount, and install cover (4).

Mounting bolt: 68.6 ± 4.9 Nm

Set gasket (3) to mount, then connect lower valve (2)

Mounting bolt: 31.4 ± 2.9 Nm

DISASSEMBLY AND ASSEMBLY TRANSMISSION SOLENOID VALVE

30-102 Î

TRANSMISSION SOLENOID VALVEDISASSEMBLY, ASSEMBLY

DISASSEMBLY plate (9).1. Remove mounting bolts from solenoid valve body (1),

then remove solenoids (2) and O-rings (4). 3. Install plate (3) to valve body (1).Ú Remove the connector from the plate.

2. Remove plate (3) from valve body (1). tighten bolts.

3. Remove lock plate (5), then remove emergencymanual spool (6) and O-ring (7). Mounting bolt: 68.6 ± 4.9 Nm (7.0 ± 0.51) Remove orifice (8) from emergency manual kgm)

spool (6).2) Remove plate (9).

4. Remove plugs (10) from solenoid valve body (1).

ASSEMBLY1. Install plugs (10) to solenoid valve body (1).

Plug: Sealant (LG-1 or LG-5)

2. Install orifice (8) and O-ring (7) to emergency manualspool (6), then secure with lock plate (5), and install

4. Assemble O-rings (4) to solenoid valve (2), and

Ú Be careful not to get the O-ring caught.

DISASSEMBLY AND ASSEMBLY TRANSMISSION ACCUMULATOR VALVE

30-103 Î

TRANSMISSION ACCUMULATOR VALVEDISASSEMBLY

1. Remove accumulator valve (4) from transmission assembly (3).2. Remove O-rings (1) and (2) from accumulator valve (4).3. Using pads, set accumulator valve body (9) in vice.

4. Remove mounting bolts (5) and (6), and assemble guide boltsA.! M =10,P = 1.5,L = Approx. 40.mm

5. Remove bolts (7) and (8), then remove cover(10) together with guide bolts A.

Ú The internal parts will come off together with the cover, sobe extremely careful not to damage them when removing.

6. Pull out valves (11), springs (12) and (14), stop-pers (13) and (15), and spacers (16) and (17)from cover (10).Ú Fit tags to each spring, stopper, spacer, and

use for reference when assembling.

Ú Reference

Spring Stopper Spacer

FWD R = 145 R = 95 R = 40

1ST R = 145 R = 95 R = 40

2ND R = 145 R = 95 R = 50

DISASSEMBLY AND ASSEMBLY TRANSMISSION ACCUMULATOR VALVE

30-104 Î

7. Remove plugs (19) and (20) from cover (10).! Plug : 5 mm (width across flats)Ú Do not remove the plugs unless necessary.Ú If plugs (19) and (20) have been removed, coat the thread

with thread tightener as shown in the diagram below, thentighten the plugs.

Ú Be careful not to let the thread tightener drip on to thehatched portion when coating with thread tightener.

Plug : Thread tightener (LG-1)

ASSEMBLY

1. Using pads, set accumulator valve cover (10) in vice.Ú Be careful not to tighten the vice on the cover with excessive

force.2. Assemble spacers (17) and (16), stoppers (15) and (13), and

springs (14) and (12) to accumulator valve cover (10), theninsert valves (1 1) from top of each spring.

3. Fit O-rings (22) and (21) in each groove of accumulator valvebody (9).Ú Assemble the O-ring securely in the body groove.

4. Assemble accumulator valve body (9) perpendicularly fromabove cover (10), then temporarily install with guide bolts.Ú Assemble the body carefully and be sure that the O-ringdoes not fall out.

5. Push in accumulator valve body (9), and remove guide bolts,then secure with standard bolt.

Mounting bolt :54 ± 19.6 Nm (5.5 ± 2.0 kgm)

! Mounting bolt : 8 mm (width across flats)

DISASSEMBLY AND ASSEMBLY DRIVE SHAFT

30-105 Î

DRIVE SHAFTDISASSEMBLY

1. Front drive shaft1) Shaft slip spline is permanently lubricated, and should not

be disassembled.

2) Loosen bolt (2), then remove coupling (3) and retainer.Ú Make match marks to prevent the coupling from being

installed in a different direction.

3) Using a press, remove flange bearing (4).

DISASSEMBLY AND ASSEMBLY DRIVE SHAFT

30-106 Î

2. Center drive shaft, rear drive shaft1) Shaft slip spline is permanently lubricated, and should not

be disassembled.

3. Spider, bearing1) Remove bolts (6) of spider and bearing assembly (5), and

tap with plastic hammer to remove.

DISASSEMBLY AND ASSEMBLY DRIVE SHAFT

30-107 Î

DRIVE SHAFTASSEMBLY

1. Spider, bearing

1) Ú Assemble so that the grease nipples face in the samedirection.

Ú Repeat the same procedure for the front, center andrear drive shafts.

2) Set spider and bearing assembly (5) to drive shaft mount,and lock with bolts (6).

Mounting bolt:54 ± 3 Nm

(5.5 ± 0.3 kgm)

Bearing cap: Grease (G2-LI)

2. Front drive shaft1) Press fit flange bearing (4).

Ú Do not hit the flange bearing directly with a hammer.

2) Align match marks, and tighten coupling (3) and retainer (9)with mounting bolt (2).Ú Tighten the bolt to the specified tightening torque after

installing to the machine.

Spline portion: Grease (G2-LI)

Mounting bolt: 279 ± 29 Nm (28.5 ± 3.0 kgm)

DISASSEMBLY AND ASSEMBLY MEMORANDA

30-108 Î

MEMORANDA

DISASSEMBLY AND ASSEMBLY FRONT AXLE

30-109 Î

FRONT AXLEREMOVAL

WARNING! Stop the machine on level ground and install thesafety bar on the frame. Lower the work equipment to theground and stop the engine. Then apply the parking brake andput blocks under the wheels to prevent the machine frommoving.

1. Jacking up the machinePut block (1) under front frame, and hold up machine.

Ú Raise the front frame with the bucket, and set blocks (1) inposition with the tires raised slightly from the ground.

2. Tire, wheelSling tire and wheel (1), remove mounting bolts, then lift off.

Tire, wheel: 180 kg

3. Drive shaftDisconnect front drive shaft (2).

4. Axle1) Disconnect brake tube (3).

DISASSEMBLY AND ASSEMBLY FRONT AXLE

30-110 Î

2) Using jack and hoist, sling axle (4), remove mounting bolts(5), then lift off.

Ú Adjust the height of the jack when removing themounting bolts.

Axle: 387 kg

3) Pull out axle from machine.Ú Use a hoist and jack to remove the axle.

FRONT AXLEINSTALLATION

! Carry out installation in the reverse order to removal.

Ú Raise the front frame slightly with the bucket, and removeblock (1).

Mounting bolt:927 ± 103 Nm (94.5 ± 10.5 kgm)

(Width across flats: 36 mm)

Drive shaft: 65.7 ± 6.9 Nm (6.7 ± 0.7 kgm)

Ú Be careful not to tighten the tube nut too far.

Tube nut: 11.8 ± 2.9 Nm (1.2 ± 0.3 kgm)

Ú When installing the axle, use the mounting bolts as a guideand align the mounting position.

Mounting bolt:740 ± 73 Nm (75.5 ± 7.5 kgm)

(Width across flats: 36 mm)

!! Bleeding air from brake system Bleed the air. For details, see TESTING AND ADJUSTING.

DISASSEMBLY AND ASSEMBLY REAR AXLE

30-111 Î

REAR AXLEREMOVAL

WARNING! Stop the machine on level ground and install thesafety bar on the frame. Lower the bucket to the ground andstop the engine. Then apply the parking brake and put blocksunder the wheels to prevent the machine from moving.

WARNING! Open the side inspection cover and apply the lock.

Ú Loosen drain valve (1) and drain fuel.

1. Fuel tank1) Disconnect fuel hose (2), fuel return hose(3), and fuel

gauge wiring connector (4).2) Remove return hose (5) from fuel filter.

Ú Remove the clamp of breather tube (5-1).

3) Remove inside cover (7), outside cover (8) and rubber offuel oil filler port (6) at left side of rear frame.

4) Set transmission jack under fuel tank, and support fuel tank(9) lightly.

5) Remove mounting bolts, then lower transmission jackslowly and remove.Ú When there is a clearance of approx. 50 mm from the

rear frame, stop and check that there is no interference.Ú The oil filler tube will hit the rear frame so move to the

right and remove carefully.

Fuel tank (dry): 70 kg

6) Pull out fuel tank (9) to right side of chassis.

DISASSEMBLY AND ASSEMBLY REAR AXLE

30-112 Î

2. Jacking up chassis1) Remove engine oil drain valve (11) from rear axle pivot

(10).

2) Set block (1) between left and right rear axles and rearframe.

3) Jack up chassis and put support stand under rear frame.Ú Raise the rear frame with a garage jack, and when the

tires come slightly off the ground, set stand in position.

3. Tire, wheelFit sling around tire and wheel (12), then remove mounting boltsand lift off.

Tire, wheel: 180 kg

4. Drive shaftRemove rear drive shaft (13).Ú Make match marks to show the mounting position.

DISASSEMBLY AND ASSEMBLY REAR AXLE

30-113 Î

5. Brake, grease tube1) Disconnect brake hose (14).

2) Remove grease tube (15) from rear axle pivot.

6. Axle1) Secure pivot (10) to axle with chain or wire.

Ú Fix securely so that the pivot does not move.

2) Sling one end of axle (16), set garage jack under axlehousing at other end, then remove mounting bolts.Ú Adjust the height of the garage jack when r emoving.Ú The pivot end will go down, so be extremely careful

when removing the axle.

Rear axle, pivot: 462 kg

3) Pull out axle assembly from chassis.Ú Use a hoist and jack to pull out the axle assembly.Ú After pulling the axle assembly out from the chassis,

remove the chain or wire.

7. Rear pivot1) Remove trunnion cap (16-1).

Ú Before removing the cap, remove the grease tube.Ú If there are shims installed, check the number and

thickness of the shims and use for reference whenassembling.

2) Remove thrust plate (17).

DISASSEMBLY AND ASSEMBLY REAR AXLE

30-114 Î

3) Lift off rear pivot (18).Ú Be careful that the hanging tool does not slip when lifting off

the rear pivot.

Rear pivot: 75 kg

4) Remove O-ring (19) and bushng (20) from pivot (18).

8. Front pivotRemove O-rings (22) and bushing (23) from pivot (21).

DISASSEMBLY AND ASSEMBLY REAR AXLE

30-115 Î

REAR AXLEINSTALLATION

1. Front pivotAssemble O-rings (22) and bushing (23) to pivot (21).Ú Assemble so that the chamfered side of the bushing is on

the axle housing side.Ú Set with the join of the bushing at the side.

O-ring, bushing: Grease (G2-LI)

2. Rear pivot1) Assemble O-ring (19) and bushing (20) to pivot (18).

Ú Set with the join of the bushing at the side.

O-ring, bushing: Grease (G2-LI)

2) Raise pivot (18), and insert to mounting portion of axle.Ú Be careful not to get the O-ring caught.

3) Install thrust plate (17) to mounting portion of axle.Ú Wipe the mating surface of the thrust plate clean.

Ú Assemble so that the i5 hole of thrust plate (17) is atthe top.

Outside circumference of pivot mount: Grease(G2-LI)

Mounting bolt: 112.8 ± 9.8 Nm(11.5 ± 1.0 kgm)

DISASSEMBLY AND ASSEMBLY REAR AXLE

30-116 Î

To make axle and pivot parallel, turn over trunnion cap (16-1) and tighten down with 8 bolts uniformly.

Mounting bolt: 68.6 9.8 Nm(7 ± 1 kgm)

Ú Check that the clearance between the pivot andtrunnion cap is uniform.

Ú Set on the mount on the machine body with the cap stillreversed.

3. AxleRaise axle (16) with jack and hoist, set in mounting position andtighten mounting bolts.Ú Use the bolts as guides when setting in the mounting

position.Ú When tightening the mounting bolts, do not tighten in one

pass. Tighten the mounting bolts in three stages.Ú After installing the axle assembly, remove the wire.

Mounting bolt:549 ± 58.8 Nm (56 ± 6 kgm)(Width across flats: 30 mm)

4. Adjusting shim at rear pivot1) Using depth micrometer (1), measure dimension "a" of

trunnion cap (16-1). Measure at 4 places at 90E anglesand take the average.

Ú Clean the probe contact surface before measuring.! Standard value "a": 12.2 - 12.33 mm

2) Assemble thrust washer (17) at rear pivot. Using depthmicrometer (1), measure dimension "b" at 4 places at 90Eangles and take the average.Ú Clean the contact surfaces of the thrust plate.Ú Clean the probe contact surface before measuring.! Reference value "b": 12.10 - 12.30 mm Ú Insert a feeler gauge around circumference "c" and at

the joint of the thrust plate, and check that there is noclearance.

DISASSEMBLY AND ASSEMBLY REAR AXLE

30-117 Î

Ú Joint rear pivot and trunnion cap! Standard clearance "d": 0.1 - 0.29 mm .!! “a" - "b" - (0.1 - 0.29) = t (shim thickness)Ú Shim size = 0.2 mm

3) Assemble selected shims between rear pivot (10) andtrunnion cap (16-1), then install mounting bolts.Ú Fill the trunnion cap with grease before installing.

Trunnion cap: Grease (G2-LI)

Mounting bolt: 112.8 ± 9.8 Nm(11.5 ± 1 kgm)

5. Brake, grease tube1) Secure grease tube (15) with mounting clamp.2) Connect brake hose (14).

Ú Be careful not to tighten the brake hose too much.

DISASSEMBLY AND ASSEMBLY REAR AXLE

30-118 Î

3) Install engine oil drain valve (11) in axle pivot (10).

6. Drive shaftInstall rear drive shaft (13).Ú Align the pilot correctly and install with the yoke facing in

the correct direction.

Mounting bolt: 31.4 ± 2.9 Nm(3.2 ± 0.3 kgm)

7. Tire, wheelSling tire and wheel (12), set in mounting position, and tightenmounting bolts.

Mounting bolts:927 ± 103 Nm (94.5 ± 10.5 kgm)

(Width across flats: 36 mm)

8. Lowering machine1) Pull out block (2) from under rear frame and lower

machine to ground.Ú Raise the rear frame with a garage jack, and remove

blocks (2) when the frame is raised slightly.

2) Remove block (1) between left and right rear axles andrear frame.

DISASSEMBLY AND ASSEMBLY REAR AXLE

30-119 Î

9. Fuel tank1) Pull in fuel tank (9) under chassis.

Ú Pull in from the right side of the rear frame.

2) Operate transmission jack and raise fuel tank (9) slowly,then set in mounting position, and fit mounting boltstemporarily.Ú When setting to the mount, move from the right to the

left, raise, and stop at a point where the oil fillerpasses the rear frame, then check that there is nointerference.

3) Position and tighten mounting bolt firmly.

Mounting bolt: 110.3 ± 12.3 Nm(11.25 ± 1.25 kgm)

4) Install inside cover (7), outside cover (8), and rubber of fuelfiller port (6) at left side of rear frame.

5) Install return hose (5) from fuel filter.

6) Install breather tube (5-1) and clamp.

7) Connect fuel hose (2), fuel return hose (3), and fuel gaugewiring connector (4).

8) Close drain valve (1).

10. Bleeding air from brake systemBleed air. For details, see TESTING AND ADJUSTING.

DISASSEMBLY AND ASSEMBLY DIFFERENTIAL

30-120 Î

DIFFERENTIALDISASSEMBLY

1. Brake tubeRemove brake tube (1).

2. Differential coverRemove bleeder screw (2), then remove differential cover (3).Ú Install the differential assembly in a stand.Ú Remove the axle housing.

3. Cage1) Screw in a forcing screw, then using guide bolt (4), remove

cage (5).Ú Check the number and thickness of the shims, and

keep them in a safe place.Ú Loosen mounting bolts of coupling, and temporarily

install the cage.

Cage: 17 kg

2) Remove O-ring from cage.

4. Brake pistonScrew in forcing screws (3 places) to raise evenly, thenremove piston (6).Ú If the O-ring of the piston is not damaged, it is possible to

install the bleeder screw and blow in air to remove thepiston.

DISASSEMBLY AND ASSEMBLY DIFFERENTIAL

30-121 Î

5. Bearing carrierScrew in forcing screws to raise bearing carrier evenly, andremove bearing carrier (7). Remove angle ring.Ú Check the number and thickness of the shims, and keep

them in a safe place.Ú Mark the left and right bearing carriers to avoid confusing

them.

6. Differential carrier1) Lift off differential carrier assembly (9) from differential

housing (8).Ú When removing the assembly, be careful that the lifting

tool does not slip.

Differential carrier assembly: 30 kg

2) Remove bevel gear (10), then remove bearing (11) frombevel gear.

3) Remove thrust washer (13) from differential carrier (12),then remove side gear (14).

DISASSEMBLY AND ASSEMBLY DIFFERENTIAL

30-122 Î

4) Remove lock pins (15), pull out shaft (16), then removepinion gears (17).

5) Remove side gear (18).

7. Coupling1) Remove mounting bolt (20), then remove holder (21),

coupling (22) and O-ring (23).Ú Do not remove the protector press fitted

to the coupling unless necessary.

2) Remove oil seal (24).

DISASSEMBLY AND ASSEMBLY DIFFERENTIAL

30-123 Î

3) Using a press, remove pinion gear (25) from cage, thenremove bearing (26).

4) Remove spacer (27) and bearing (28) from piinion gear(25).

5) Remove bearing cups (29) and (30) from cage (5).

DISASSEMBLY AND ASSEMBLY DIFFERENTIAL

30-124 Î

DIFFERENTIALASSEMBLY

1. Pinion gear1) Press fit bearing cone (28) in pinion gear (25), then

assemble spacer (27).Ú There must be no clearance at the contact faces of any

parts.

2) Press fit bearing cups (29) and (30) in cage (5).

3) Assemble pinion gear (25) in cage (5), then press fit bearingcone (26).Ú Apply pressure to the bearing at the specified load, and

rotate the case to settle the bearing.Ú Press load: 49 KN (5 ton)

Bearing: Oil (axle oil)

Ú When rotating the case at the specified load, rotatelightly by hand. If the rotation is not smooth, replace thebearing and spacer, and again rotate lightly by hand.

DISASSEMBLY AND ASSEMBLY DIFFERENTIAL

30-125 Î

4) Press fit oil seal (24) in cage (5).Ú Assemble oil seal (24) evenly so that it has the

specified depth "t".t = 6 ± 0.5 mm

Oil seal lip: Grease (G2-LI)

Pinion gear shaft: Grease (G2-LI)

2. CouplingInstall coupling (22), O-ring (23) and holder (21) to pinion gear(25), then tighten mounting bolts.Ú Tighten the mounting bolts partially. Tighten them fully after

the completion of assembly.Ú When inserting the coupling, be careful not to damage the

seal.

Mounting bolt: Thread tightener (LT-2)

Mounting bolt: 279 ± 29 Nm(28.5 ± 3.0 kgm)

3. Differential carrier assembly1) Install side gear (18) to differential carrier (12).

2) Install pinion gears (17) and shaft (16) to differentialcarrier (12), then insert lock pins (15).

Gears, shafts: Oil (axle oil)

DISASSEMBLY AND ASSEMBLY DIFFERENTIAL

30-126 Î

3) Assemble side gear (14) and thrust washer (13).

Sliding surface of thrust washer:Oil (axle oil)

4) Press fit bearing (11) on bevel gear (10).

5) Assemble bevel gear (10) in differential carrier (12), thentighten mounting bolts.

Mounting bolts:Thread tightener (LT-2)

Mounting bolts: 279 ± 29 Nm(28.5 ± 3.0 kgm)

Ú Coat the thrust washer with grease and stick it to thebevel gear to prevent it from falling off duringinstallation.

Ú Align the lock of the washer correctly with the groove inthe bevel gear.

4. Adjusting shim of cage1) Assemble cage (5) without shims in differential housing (8).

Mounting bolts: 112.8 ± 9.8 Nm(11.5 ± 1.0 kgm)

2) Insert measuring tool A in differential (8), and measuredistance between end face of bevel pinion gear and tool Awith an inside micrometer or a cylinder gauge.Ú When inserting tool A in the differential housing, coat

thinly with oil, and insert straight without twisting.

DISASSEMBLY AND ASSEMBLY DIFFERENTIAL

30-127 Î

3) Selecting shimst = C - (L + D/2)t :Shim thickness A: 157.5C: (A + a) - (B + b) B: 50.68L: Actual value a: Error for distance AD: Diameter of tool A b: Error for distance BÚÚ Use the actual value for distance D

Ú Shim thickness "t" must be within 0.5 -1.9 mm.The end face of the pinion gear is marked with anelectric pen as follows.

MD +0.10 [Distance “a”(mm)](-0.01) [Distance “b”(mm)]

Ú Always use the bevel pinion gear and bevel gear in aset with the same number.

4) Remove cage.

5. Bearing carrierPress fit bearing cups (32) and (33) in bearing carriers (7) and(31).

Press-fitting portion of bearing cup:Oil (axle oil)

6. Adjusting bearing carrier shims1) Raise differential carrier assembly (9), set in mounting

position, then install left and right bearing carriers (7)temporarily.Ú Assemble the differential carrier assembly with the

bevel gear on the right as seen from the cage mount.Ú Assemble the bearing carrier and adjust without the

angle ring and shim.

DISASSEMBLY AND ASSEMBLY DIFFERENTIAL

30-128 Î

2) Tighten carrier (31) at differential carrier end to specifiedtightening torque.

Mounting bolts: 113 ± 9.8 Nm(11.5

± 1.0 kgm)

3) Tighten 4 mounting bolts of carrier (7) at bevel gear end.Ú Rotate the bevel gear and coat the bearing with oil.

Bearing: Oil (axle oil)

Ú To settle all the parts, rotate the bevel gear whentightening.

Mounting bolts: 11.8 Nm (1.2 kgm)

4) Loosen 4 mounting bolts at bevel gear end until there is endplay at bearing.

5) Tighten 4 mounting bolts uniformly again.Mounting bolts: 3.9 Nm (0.4 kgm)

Ú When doing this, check that there is end play at thebearing, and rotate the bevel gear when tightening.

6) Using a feeler gauge at 2 places in groove of bearingcarrier (7) at bevel gear end, measure clearances T and1

T2

7) Selecting shimsShim thickness = (T + T )/2 ± 0.035 mm1 2

Ú Combine the following shims to give the necessaryshim thickness.0.07 mm, 0.20 mm, 0.30 mm, 0.80 mm

DISASSEMBLY AND ASSEMBLY DIFFERENTIAL

30-129 Î

8) Remove left and right bearing carriers (7),and assembleselected shims (32).Ú Rotate the bevel gear and tighten the mounting bolts of

the bearing carrier uniformly.

Mounting bolts: 113 ± 9.8 Nm(11.5 ± 1.0 kgm)

9) Using a spring balance, measure preload of bevel gear andcheck that it is within specified range.Ú Preload: 7.8 - 25.5 Nm ( 0.8 - 2.6 kgm)

(Target: 25.5 Nm (2.6 kgm))Ú If the preload is not within the specified range, change

the shim thickness to adjust.

7. Cage1) Assemble O-ring (34) in bearing cage.

O-ring: Oil (axle oil)

2) Install guide bolt, assemble shims (35) selected in Step 4,and install cage (5).

Mounting bolts: 113 ± 9.8 Nm(11.5 ± 1.0 kgm)

DISASSEMBLY AND ASSEMBLY DIFFERENTIAL

30-130 Î

8. Adjusting backlash1) Measure backlash of bevel gear with a dial gauge.

Ú First, measure with all the shims insertedat the bevelgear end.

Ú Measure the backlash at 3 places around thecircumference of the bevel gear. The variation betweenthe measurement must be within 0.1 mm.

2) To obtain backlash within specified range,move some of theshims from bevel gear side to opposite side.Ú When moving the shims, do not change the total shim

thickness. The total shim thickness on the left and rightmust remain the same.

Ú Adjust the backlash as follows.If backlash is too LARGE, move shims from B to AIf backlash is too SMALL, move shims from A to B

DISASSEMBLY AND ASSEMBLY DIFFERENTIAL

30-131 Î

9. Adjusting tooth contactCoat face of 7 or 8 teeth of bevel gear lightly with red lead. Hold the bevel gear by hand to act as a brake, rotatethe pinion gear forward and backward and inspect the pattern left on the teeth.

Tooth contact Cause Procedure for adjustment

The tooth contact pattern Adjust the pinion gear by adjusting the shims at the cage. should start from about 5 Adjust the bevel gear in the same way as when adjustingmm from the toe of the backlash.bevel gear and cover about50% of the length of thetooth. It should be in thecenter of the tooth height.

Bevel pinion gear is too far 1. Reduce shims at pinion gear to bringfrom bevel gear. closer to bevel gear.

2. Move bevel gear further away frompinion gear and adjust backlashcorrectly.

Bevel pinion gear is too 1. Increase shims at pinion gear to moveclose to bevel gear. away from bevel ear..

2. Move bevel gear closer to pinion gearand adjust backlash correctly.

Bevel gear is too close to 1. Reduce shims at pinion gear to bringpinion gear. closer to bevel gear.

2. Move bevel gear further away frompinion gear and adjust backlashcorrectly.

Bevel gear is too far from 1. Increase shims at pinion gear to movepinion gear. away from bevel gear.

2. Move bevel gear closer to pinion gearand adjust backlash correctly

Ú When adjusting the bevel gear, do not change the preload of the bearing. Adjust by moving shims between theleft and right. Always keep the same total thickness of shims.

DISASSEMBLY AND ASSEMBLY DIFFERENTIAL

30-132 Î

10. Bearing carrierRemove bearing carrier (7), assemble angle ring (36) togetherwith adjusted shims.Ú Coat the angle ring with grease, and be careful not to drop

it when installing.Ú When installing bearing carrier (7), the angle ring may come

out, so do not use a hammer to install the bearing carrier.

Angle ring: Grease (G2-LI)

Mounting bolt: 113 ± 9.8 Nm(11.5 ± 1.0 kgm)

11. Brake piston1) Assemble O-rings (37) and (38) securely in grooves of

brake piston (6) and bearing carrier (7).Ú Coat the brake piston and piston mount with grease to

prevent theO-ring from twisting or breaking.

Piston and piston mounting face:Oil (axle oil)

2) Install piston press fit tool B on housing, and tighten screws(39) evenly to press fit.Ú Press fit the piston completely until it contacts the

housing.Ú The O-ring and piston will be damaged if a plastic

hammer is used to press fit the piston.

12. Brake oil leakage test1) Install bleeder screw.2) Tighten screw (39) of piston press-fitting tool B completely,

then loosen one turn.3) Install hose of tool C to brake tube mount port (44), and

bleed air from inside cylinder.4) Operate pump and raise pressure to 1.4 MPa (14 kg/cm ).2

When the pressure is 1.4 MPa (14 kg/ cm ), leave for2

5 minutes. The drop in pressure should be less than0.34 MPa (3.5 kg/c m ).2

DISASSEMBLY AND ASSEMBLY DIFFERENTIAL

30-133 Î

5) If the test shows that there is no air leakage, raise pressureto 4.1 MPa (42 kg/cm ).2

Ú When the pressure is 4.1 MPa (42 kg/ cm ), leave for 52

minutes. The drop in pressure should be less than 0.34MPa (3.5 kg/c m ).2

Ú If there is any oil leakage, remove the brake piston,check the O-ring for damage, then assemble again.After checking for brake oil leakage, insert the pistonfully.

13. CouplingTighten mounting bolts of coupling (22) fully.

Mounting bolt: Thread tightener (LT-2)

Mounting bolts: 279 ± 29 Nm(28.5 ± 3.0 kgm)

14. Differential cover1) Install differential cover (3) to housing.Ú Use a guide bolt when installing to prevent thread tightener

from entering the mounting hole of the bleeder screw.

Cover contact surface:Gasket sealant (Loctite 515)

Mounting bolts: 113 ± 9.8 Nm(11.5 ± 1.0 kgm)

2) Remove guide bolt, install bleeder screw (2).Ú Check that there is no thread tightener stuck to the bleeder

screw hole before installing.

DISASSEMBLY AND ASSEMBLY AXLE HOUSING

30-134 Î

AXLE HOUSINGDISASSEMBLY

1. Draining oilLoosen drain valve (1) and drain oil

Axle oil: 14 R

2. Differential cover1) Remove bleeder screw (2), then using forcing screw,

remove differential cover (3).2) Install axle assembly to stand.

3. Axle housing assembly1) Sling axle housing (4), then remove housing mounting bolts.

Ú Put match marks on the housings to distinguish theleft and right housings.

2) Disconnect axle housing, and remove shaft (5), brake disc(6) and brake ring.Ú Be careful not to damage the surface of the brake

disc.

Axle housing: 88 kg

DISASSEMBLY AND ASSEMBLY AXLE HOUSING

30-135 Î

4. Brake outer ringRemove brake outer ring (7) and pin (8).Ú Be careful not to damage the surface in contact with the

brake disc.

5. Planetary carrier1) Remove axle shaft mounting bolt, then remove planetary

carrier (9).

2) Remove shims.Ú Check the number and thickness of the shims, and

keep them in a safe place.

6. Axle shaft1) Stand housing and shaft assembly upright, then sling

housing (10).

2) Tap end face of axle shaft (11) with a copper hammer toremove the shaft.

DISASSEMBLY AND ASSEMBLY AXLE HOUSING

30-136 Î

Ú When the axle shaft has been pulled out a little way,pull out portion "a" of oil seal (12) with a screwdriver toprevent the oil seal from being damaged by bearing(13).

3) Remove bearing (13) and seal (12) from shaft (11) Ú Never apply heat or use gas cutting to remove the bearing.

(This will affect the hardening of the shaft and reduce thestrength.)

Ú Remove the bearing as follows.

4) When removing bearing (13) of shaft (11), use ascrewdriver at point "b" of oil seal and sleeve (12), andpush towards flange uniformly around circumference.

5) Make clearance "c" in order to fit claws of puller toconnection of bearing (13) and sleeve (12A).

6) Install bolt (30) (5/8 - 18UNF, R = approx. 60mm) at point"d" to bearing puller A1.ÚÚ Screw in the bolt thread fully.

DISASSEMBLY AND ASSEMBLY AXLE HOUSING

30-137 Î

7) Set bearing puller A1 to clearance "c" between bearing(13) and sleeve (12A), then assemble bolt A2 and nut A3.Ú When doing this, fix securely to prevent any play in the

bearing puller.

8) Insert washer between bolt (30) and flange surface, turn indirection to loosen bolt (30), and remove bearing (13).Ú The puller has only a small grip on the bearing, so be

extremely careful not to let it come off the bearing.Ú If the length of the thread of bolt (30) is too short, add

extra washers to the flange surface to adjust the heightof bolt (30), and remove bearing (13).

Ú Replace the oil seal and sleeve assembly with newparts.

7. Ring gearUsing a puller, raise ring gear (14) evenly and remove.

8. Axle housingRemove bearing cups (15) and (16) from axle housing (10).

DISASSEMBLY AND ASSEMBLY AXLE HOUSING

30-138 Î

9. Planetary carrier1) Drive in spring pin (17).

Ú Be careful not to drive in the spring too far.

2) Using a press, remove shaft (18).

3) Remove spring pin (17) from shaft (18).

4) Remove pinion gear (19) from planetary carrier (9), thenremove bearing cone (20), spacer (21) and shims.

DISASSEMBLY AND ASSEMBLY AXLE HOUSING

30-139 Î

AXLE HOUSINGASSEMBLY

1. Axle housingPress fit bearing cups (15) and (16) in axle housing (10).Ú After press fitting the cups, check that there is no clearance

at portion "a".

2. Ring gearPress fit ring gear (14) in axle housing (10), then insert pins (17).Ú Cool ring gear (14) in dry ice to a temperature of about -

30EC before press fitting.Ú Align the pin holes of the housing and ring gear when

assembling.Ú Press fit the ring gear horizontally and be careful not to fit it

at an angle.

3. Axle shaft1) Using a press on axle shaft (11), press fit oil seal (12).

Ú Do not use a hammer as it may causedeformation.

Ú Coat the press-fitting portion of the sleeve surface "a"thinly with oil.

Press-fitting portion of sleeve:Axle oil

DISASSEMBLY AND ASSEMBLY AXLE HOUSING

30-140 Î

Set bearing (13) on press stand, and press fit axle shaft(11).Ú Be careful not to fit the bearing at an angle.

Press-fitting portion of bearing:Axle oil

4. Housing, shaft1) Stand shaft (11) upright and install too[ (B1).

Ú Using the adjustment bolt, adjust the height of the sealsupport. Set the top surface of tool B1 lightly in contactwith seal (12) and make the clearance uniform.

Ú Secure tool B1 with tool B2 so that it does not come outof position.

2) Raise housing (10) horizontally, and insertcarefully on shaft.Ú Stop housing (10) before press fitting the oil seal.

3) Align housing (10) with press-fitting portionfor oil seal, then lower housing slowly.Ú Use the weight of the housing to insert it.

DISASSEMBLY AND ASSEMBLY AXLE HOUSING

30-141 Î

4) Remove tool B1.

5) Press fit bearing (13) on shaft (11). Rotate housing by handand press fit until end play is 0.3 mm.Ú Do not make the end play 0 mm.

Press-fitting portion of bearing cone:Axle oil

Ú Press force: Approx. 19.6 KN (2 ton)Ú After assembling the housing, the face

of the seal must be level with the housing face. If thereis any clearance "b" at part "a", it must be uniform andwithin the standard range.Standard rangeClearance "b": 0.21 - 1.91 mm

5. Adjusting end play1) Stand axle shaft and housing assembly (22) upright, and

hold flange "a".

DISASSEMBLY AND ASSEMBLY AXLE HOUSING

30-142 Î

2) Install planetary carrier (9) to spline of axle shaft (11), thenassemble shim adjustment tool C to portion "c" of planetarycarrier, and install mounting bolts.Ú Assemble planetary carrier (9) without the gear.Ú Remove all thread tightener from the mounting bolts

and the bolt holes of the axle shaft.

3) Rotate axle housing (10) and tighten mounting bolt (26) ofretainer.

Bolt: 55 Nm (5.6 kgm)

4) Using a depth micrometer, measure distance H from shimadjustment tool to end face of axle shaft.

! Shim thickness X = (H - t) +O.15

+0.10

Ú When selecting the shims take the nearest value to X+ 0.10.

DISASSEMBLY AND ASSEMBLY AXLE HOUSING

30-143 Î

5) After selecting shims, loosen bolts, and remove planetarycarrier (9).

6. Planetary carrier1) Assemble bearing cone (20) on gear (19), then set spacer

(21) and pinion gear (19) in carrier (9).Ú Insert spacer (21) in the planetary carrier

before assembling.Ú There is no need to adjust with shims.Ú Reference value for end play: 0 - 0.17mm

DISASSEMBLY AND ASSEMBLY AXLE HOUSING

30-144 Î

2) Check alignment of shaft hole of gear and planetary carrieragain, then press fit shaft(18).Ú Align the hole of spring pin (17) and shaft (18), then

drive in the spring pin until it is level with the face of thecarrier.

Ú Press force: 49 KN (5 ton)

Shaft: Axle oil

3) Tap end face of shaft (18) and differential side of gear (19)to push back bearing (20) and allow gear to rotatesmoothly.Ú The gear must rotate smoothly.

7. Planetary carrier1) Assemble shims (24) selected in Step 5 in planetary carrier

(9) at axle shaft end face, then install mounting bolts.Ú Remove all oil and grease from the mounting bolts and

bolt mounting holes of the axle shaft.

Mounting bolt:Thread tightener (LT-2)

Mounting bolt: 279 ± 29.4 Nm(28.5 ± 3.0 kgm)

Ú Clean the end face of the shaft and the planetarycarrier spline before installing.

WARNING! When installing the planetary carrier, be careful notto get your fingers caught.

DISASSEMBLY AND ASSEMBLY AXLE HOUSING

30-145 Î

2) After settling bearing (23) fully, check "X" at drill hole "b" ofaxle housing (10).Ú Reference value! Rotation force "X":

Approx. 26.5 N (2.7 kg) or less

3) Install stand of dial gauge to axle housing, and measureend play of planetary carrier at end face of planetary carrier.! End play of planetary carrier:

0 - 0.098 mmÚ If the end play is more than 0.098 mm, repeat Step 5

and adjust again.

8. Brake outer ringAssemble brake outer ring (7) in axle housing.Ú Align pin and pin hole of outer ring to assemble.Ú Be careful not to damage the surface of the brake outer

ring.

9. Axle housing assembly1) Assemble brake ring (27), brake disc (6) and shaft (5) in

differential housing.Ú Be careful not to damage the surface of the brake ring

when assembling.Ú Soak the brake disc for 2 to 3 minutes in clean axle oil

before assembling.

DISASSEMBLY AND ASSEMBLY AXLE HOUSING

30-146 Î

2) Raise axle housing (10) horizontally, align spline grooveand hole of pin (28), then assemble carefully.Ú When assembling, be careful not to let the brake ring

or disc come out of place.Ú Remove all oil and grease, and clean the mounting

surface to the differential housing and axle housing,then coat with an unbroken film of gasket sealant.

Contact face of housing:Gasket sealant (Loctite 515)

Mounting bolt of housing:279 ± 29 Nm (28.5 ± 3.0 kgm)

10. Differential cover1) Install differential cover (3) to differential

housing.Ú Coat with an unbroken film of gasket

sealant.Ú Be careful not to let the gasket sealant enter the

mounting hole of the bleeder screw whenassembling.

Contact face of cover:Gasket sealant (Loctite 515)

Mounting bolt of cover:113 ± 9.8 Nm (11.5 ± 1.0 kgm)

2) Install bleeder screw (2).

11. Refilling with oilTighten drain plug and add engine oil through oil filler andgauge (29) to the specified level.

DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN

30-147 Î

CENTER HINGE PINREMOVAL

WARNING! Stop the machine on level ground and install thesafety bar on the frame. Lower the bucket to the ground andstop the engine. Then apply the parking brake and put blocksunder the wheels to prevent the machine from moving.Ú Before starting the operation, set a pallet under the bucket.Ú Remove cover (1) at the top of the hydraulic tank on the

right side, then remove covers (2) on the left and right underthe floor.

WARNING! Loosen the oil filler cap slowly to release thepressure inside the hydraulic tank. Then operate the controllevers several times to release the remaining pressure in thehydraulic piping.! Loosen plug (3) to prevent the oil inside the hydraulic tank

from flowing out.Ú Machines equipped with air conditioner

! Release the gas at a point far from the compressor.Loosen the hose connection slightly to release the gas.

Ú Disconnect the cable from the negative terminal of thebattery.

1. Cover1) Sling left side ladder rail (4), remove mounting bolts, then lift

off together with center fender (5).Ú Carry out the operation in the same way on the right

side.Ú When lifting off the ladder, be careful of the center of

gravity.Ú Be careful not to damage the cab glass.

2) Disconnect connector for left brake oil level sensor.

3) Remove brake oil tank mounting bracket (8) together withoil tank (7) from under floor.Ú Leave the oil hose installed to the brake oil tank and tie

it to the top surface of the rear frame with wire.! For machines equipped with an air conditioner, it can be

placed on top of the condenser.

DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN

30-148 Î

2. Electric wiringDisconnect following electric wiring from connector.! Connectors (11), (12), (13), (14), (15), (16), and (17) of

front wiring (9) and rear wiring (10).Ú For machines with cab, disconnect wiring for cab from

connector.! Disconnect ground wiring (18) from rear frame.! Disconnect transmission cut-off switch (19) and wiring

connector (20).! Remove wiring clamp and bracket (21) from rear frame

(22).Ú Fit tags to identify the wiring.

3. Brake booster1) Remove locknut of ball joint (24) of brake linkage rod

(23), and pull out linkage rod.2) Set block under brake booster (25), then remove

mounting bolts (26).

4. Fuel control cableDisconnect fuel control cable (27) at engine end, then removebracket (28) together with control cable.Ú For machines equipped with cab! Disconnect the washer hose from the tank, then coil up and

bend the end of the hose.! After removing the hose, fit a blind plug in the washertank.

DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN

30-149 Î

5. Transmission valve wiringDisconnect each connectors (33) from transmission valvewiring.Ú Fit tags to identify the wiring.

6. Work equipment control cableDisconnect work equipment control cables (34) at valve end.Ú Fit tags to the cables before disconnecting.Ú Remove the cable clamp.

7. Parking brake cable1) Disconnect parking brake cable (38) from lever, and

remove bracket (40) from front face of transmission (39).Ú Check that there are blocks under the tires.Ú After disconnecting the cable, tie it temporarily to the

bottom surface of the floor with wire.2) Disconnect speedometer cable (41).3) Remove transmission oil filler tube (42).

DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN

30-150 Î

8. Steering piping1) Remove hoses (44) and (45) from steering valve (43).

2 )Disconnect hoses (47), (48), and (49) between steeringvalve (43) and priority valve.

3) Remove hose (50) between steering valve and hydraulictank.Ú Fit blind plugs after disconnecting the hoses.

9. Floor frame, cab assemblySling floor frame and cab assembly (51), then remove mountingbolts (51-1) and lift off.Ú When raising the floor frame and cab assembly, pull the

brake booster out graduallyfrom the mounting bracket, and raise the cab slowly.

Ú The brake hose is not disconnected, so be careful not tocatch the brake booster.

Ú Check that there is no interference from the hoses andwiring, then lift off.

Ú When raising the floor frame and cab assembly, lift slowlyfor approx. 40 - 50 mm, stop and check that there is nointerference, then continue to lift.

Floor frame, cab assembly: 680 kg

Floor frame assembly: 155 kg

ÚÚ Eyebolts for removing cab assemblyM = 16mm, P = 2.0mm (4 bolts)

DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN

30-151 Î

10. Steering cylinder1) Disconnect hoses (52) and (53) between steering valve and

steering cylinder from connection with tube.Ú Disconnect both the left and right hoses.

2) Remove bottom lock bolt of steering cylinder, then removepin (54).

11. Drive shaftDisconnect center drive shaft (55) at transmission end.Ú When removing the drive shaft, set a block between the

rear frame and the drive shaft to prevent the grease fittingfrom being crushed.

12. Electric wiringRemove clamp mounting bolts (56) and (56-1) of front framewiring.

13. Brake tubeRemove clamp of brake hose and tube (57) for front axle fromframe.

DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN

30-152 Î

14. Hydraulic pipingRemove mounting bolts of dump and lift cylinder hose clampbrackets (60) and (60-1) for front frame (58) and rear frame(59) from frame.

15. Jacking up chassis1) Adjust height of rear frame and set block (1) in position.

2) Adjust height of front frame on left and right, and set block(3) in position.Ú Be extremely careful when adjusting the height of the

frame.

3) Set support stand (2) to counterweight.

16. Lower hinge pinRemove lock bolt, then pull out lower hinge pin (61).

DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN

30-153 Î

17. Upper hinge pin1) Remove locknut (62) and washer (63).2) Remove pin mounting bolts, then pull out

upper hinge pin (64).Ú There are shims between the retainer and frame, so

check the number and thickness of the shims, andkeep in a safe place.

18. Disconnection of frame1) Remove safety bar, jack up front differential and palleter

under bucket, then pull out to front of front frame.Ú Carry out this operation with 2 workers and rotate the

tires uniformly on the left and right.Ú Be extremely careful to maintain the balance when

carrying out this operation.Ú Be careful not to let the spacer at the bottom of the

upper hinge get caught in the rear frame, and insert abar between the rear frame and front frame to raise thefront frame while disconnecting.

2) After disconnecting frame, remove spacer (65).

19. Lower hinge1) Remove washer (66).2) Remove snap rings (67) and (68), then pull out bearing

(69).

DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN

30-154 Î

20. Upper hinge1) Remove spacer (70).2) Remove mounting bolt, then remove retainer (71).

Ú There are shims between the retainer and frame, socheck the number and thickness of the shims, andkeep in a safe place.

3) Remove dust seal (73) from retainer (72).

4) Remove bearing (74) and spacer (75) from front frame.

DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN

30-155 Î

CENTER HINGE PININSTALLATION

1. Upper hinge1) Press fit bearing (74) and spacer (75) on front frame.

Ú The clearance between the bearing and spacer isadjusted, so do not change the combination. Whenreplacing the bearing and spacer, replace as a set.

Ú When press fitting the bearing, press fit correctly andmake sure that there is no clearance from the contactsurface of the frame.

Bearing: Grease (G2-LI)

2) Install dust seal (76) and spacer (70) from under frontframe.Ú Be careful not to damage the seal lip, and install with

the lip on the outside.

Ú Outside circumference of dust seal:Thread tightener (Loctite 601)

Seal lip: Grease (G2-LI)

Inside circumference of spacer:Grease (G2-LI)

3) Press fit dust seal (73) on retainer (72).Ú When press fitting the dust seal, fit with the lip on the

outside.

Seal lip: Grease (G2-LI)

4) Tighten retainer (72) with 4 mounting bolts, then insertshims so that clearance "a" between retainer and frame isstandard value. Clearance "a": 0.1 - 0.2 mm

Mounting bolt (when adjusting shim):4.9 ± 0.98 Nm (0.5 ± 0.1 kgm)

Mounting bolt:66.7 ± 6.9 Nm (6.8 ± 0.7 kgm)

DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN

30-156 Î

2. Lower hinge1) Install snap ring (68), and press fit bearing (69).

2) Install snap ring (67), and install washer (66).

3. Connecting frameJack up front differential, move front frame towards rear frameand align pin holes.

WARNING! Use a bar to align the pin holes. Never useyour fingers.

Ú Be careful not to bite into the lower spacer (65) of the upperhinge when connecting the frames.

Ú Align the pin holes correctly.

Ú Install the safety bar.

DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN

30-157 Î

4. Upper hinge pin1) Insert upper hinge pin (64).2) Fit washer (63) and tighten lock nut (62) to specified

tightening torque. Select shims to give standard value forclearance "b" between rear frame and pin.Ú Temporarily tighten the mounting bolt

to act as a stopper when tightening the lock nut.Ú Clearance "b": Max. 0.4 mm

Lock nut: 559 ± 49 Nm (57 ± 5 kgm)

3) Assemble selected shims, and tighten mounting bolts of pin.Ú Before tightening the mounting bolts, tighten the lock

nut to the specified torque again.

Mounting bolt: 113 ± 9.8 Nm(11.5 ± 1.0 kgm)

5. Lower hinge pinInsert lower hinge pin (61), and secure with lock bolt.

Outside circumference of hinge pin:Grease (G2-LI)

DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN

30-158 Î

6. Lowering chassisRemove blocks (1) and (3) from front and rear frame andsupport stand (2) from counterweight, then lower chassis.

7. Hydraulic pipingInstall mounting bolts of dump and lift cylinder hose clampbrackets (60) and (60-1) for front frame (58) and rear frame(59) to frame.

8. Brake tubeConnect front axle brake hose (57) to tube.

9. Electric wiringInstall clamp mounting bolts (56) and (56-1) .for front framewiring.

DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN

30-159 Î

10. Drive shaftConnect center drive shaft (55) to transmission.Ú Be careful of the direction of the yoke, and align the pilot

portion correctly to install.

Mounting bolt: 65.7 ± 6.9 Nm.(6.7 ± 0.7 kgm)

11. Steering cylinder1) Install pin (54) to bottom of steering cylinder, and secure

with lock bolt.

2) Connect hoses (52) and (53) between steering valve andsteering cylinder.

12. Floor frame, cab assembly1) Raise floor frame and cab assembly (51), stop approx. 100

mm from mount, assemble mounting bracket (77) to brakebooster (76), and keep suspended.

2) Check mounting condition of brake booster, then install cabassembly (51) to rear frame.Ú Tighten floor mounting bolts (51-1) unIformly at left,

right, front, and rear.Ú Check that there is no interference with any hoses or

wiring when installing.

Mounting bolt: 274.6 ± 29.4 Nm(28.0 ± 3.0 kgm)

DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN

30-160 Î

13. Steering piping1) Connect hose (50) between steering valve and hydraulic

tank.2) Connect hoses (47), (48), and (49) between steering valve

(43) and priority valve.3) Connect hoses (44) and (45) to steering valve (43).

Ú Install the hoses without twisting or interference.

14. Parking brake cable1) Install bracket (40) of parking brake cable (38) to front face

of transmission, and connect parking brake cable (38) tolever.

2) Connect speedometer cable (41).3) Install transmission oil filler tube (42).Ú Adjust the parking brake. For details, see TESTING AND

ADJUSTING.

15. Work equipment control cableConnect work equipment control cables (34) to each spool ofvalve.Ú Install the clamp of the cable.

DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN

30-161 Î

16. Transmission valve wiringConnect each transmission valve wiring connectors (33).Ú When connecting, check the tags used to identify the wiring

17. Fuel control cableConnect fuel control cable (27) to engine end, and installbracket (28) to engine.Ú For machines with cab! Connect the washer hose to the tank end.

18. Brake booster1) Remove block under brake booster (25), and install

mounting bolts (26).Ú Tighten the mounting bolts uniformly and be careful not

to tighten them too much.

Mounting bolt: 110.3 ± 12.3 Nm(11.25 ± 1.25 kgm)

2) Insert brake linkage rod (23) in boot portion of brakebooster (25), and connect to linkage lever.

3) Connect ball joint (24) and tighten locknut.

Locknut: 29.4 ± 4.9 Nm(3.0 ± 0.5 kgm)

DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN

30-162 Î

19. Electric wiringConnect connectors to following electric wiring. ! Connectors (11), (12), (13), (14), (15), and (16) of front

wiring (9) and rear wiring (10). ! Connector (17) of cab wiring! Connect ground wiring (18) to rear frame. ! Connect transmission cut-off switch (19) and wiring

connector (20).! Install wiring clamp and bracket (21) to rear frame (22).Ú When connecting, check the tags used to identify the wiring

20. Cover1) Install brake oil tank mount bracket (8) together with oil tank

(7) to bottom of floor.

2) Connect connector for left brake oil level sensor.

3) Sling left ladder rail (4), then raise together with centerfender (5) and install.Ú Carry out the operation in the same way on the right

side.Ú When raising the ladder to install it, be careful of the

center of gravity.Ú Be careful not to damage the cab glass.

DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN

30-163 Î

21. Refilling with oilTighten drain plug and add hydraulic oil through oil filler to thespecified level.Ú Run the engine to circulate the oil through the system.

Then check the oil level again.

Hydraulic oil: Add oil

22. Bleeding air from brake system! If the hose has been disconnected from the brake booster,

bleed the air from the brake system.Ú For details of the procedure for bleeding air, see

TESTING AND ADJUSTING.

Ú Install cover (1) at the top of the hydraulic tank on the right side,and covers (2) on the left and right under the floor.

DISASSEMBLY AND ASSEMBLY PRIORITY VALVE

30-164 Î

PRIORITY VALVEREMOVAL

WARNING! Stop the machine on level ground and install thesafety bar on the frame. Lower the bucket to the ground andstop the engine. Then apply the parking brake and put blocksunder the wheels to prevent the machine from moving.Ú Turn the steering wheel to the left to articulate the chassis.Ú Remove cover (1) at the top of the hydraulic tank on the

right side, then remove covers (1-1) on the left and rightunder the floor.

WARNING! Loosen the oil filler cap slowly to release thepressure inside the hydraulic tank. Then operate the controllevers several times to release the remaining pressure in thehydraulic piping.

! Loosen plug (2) to prevent the oil inside the hydraulic tank fromflowing out.

1. Hydraulic piping

Disconnect following piping.! Hose (3) between hydraulic pump and priority valve.

Ú Remove rear right inspection cover (2-1), disconnecthydraulic pump, and remove hose (2-3) while stillinstalled to the priority valve.

Ú This operation can also be carried out by removingconnector mounting bracket (2-2) connecting the frontwiring and rear wiring.

Ú To prevent damage to the mounting bolts, remove hose(2-3) after removing the priority valve.

! Hose (4) between priority valve and main control valve! Hose (5) between steering valve and priority valve! Hose (6) between priority valve and hydraulic tank! Hose (7) between priority valve and steering valve

Ú Remove hose (7) after removing the priority valve.

DISASSEMBLY AND ASSEMBLY PRIORITY VALVE

30-165 Î

2. Priority valve

Remove mounting bolts (8), then remove priority valve (9).Ú Remove hose (7) after removing the priority valve.

PRIORITY VALVEINSTALLATION

Carry out installation in the reverse order to removal.

Hose (4) mouthpiece:176.5 ± 29.4 Nm (18 ± 3 kgm)(Width across flats: 36 mm)

Hose (7) mouthpiece:78.5± 19.6 Nm (8 ± 2 kgm)(Width across flats: 27 mm)

Ú Install to the rear frame after installing hose (3) to thepriority valve.

Hose mouthpiece:176.5 ± 29.4 Nm (18 ± 3 kgm)(Width across flats: 36 mm)

Mounting bolt (8): 31.4 Nm (3.2 kgm)

Ú If the mount plate had to be removed, assemble as shownin the diagram on the right.

Mounting bolt: 110.3 ± 12.3 Nm(11.25 ± 1.25 kgm)

DISASSEMBLY AND ASSEMBLY STEERING VALVE

30-166 Î

STEERING VALVEREMOVAL

WARNING! Stop the machine on level ground and install thesafety bar on the frame. Lower the bucket to the ground andstop the engine. Then apply the parking brake and put blocksunder the wheels to prevent the machine from moving.Ú Remove cover (1) at the top of the hydraulic tank on the

right side, then remove covers (1-1) on the left and rightunder the floor.

WARNING! Loosen the oil filler cap slowly to release thepressure inside the hydraulic tank. Then operate the controllevers several times to release the remaining pressure in thehydraulic piping.

! Loosen plug (2) to prevent the oil inside the hydraulic tank fromflowing out.

1. Column coverRemove steering column cover (4), then remove plugs (3) ofbottom boot (5), and roll up.

2. Hydraulic piping

Disconnect following hydraulic piping.! Hose (6) between steering valve and priority valve! Hose (7) between priority valve and steering valve! Tubes (8) and (9) between steering valve and steering

cylinder! Hose (10) between steering valve and priority valve! Hose (11) between steering valve and hydraulic tankÚ Fit tags to identify the piping.

DISASSEMBLY AND ASSEMBLY STEERING VALVE

30-167 Î

3. Steering valveÚ Carry out the steering valve removal operation with 2

workers, give signals to each other, and be extremelycareful when removing the steering valve.

1) Remove lock bolt (12) of spline connecting portion atsteering column end.Ú Be sure to remove lock bolt (12). If it is not removed,

the lock bolt will catch in the column shaft lock groove,and the steering valve will not come out .

2) Support from below, and remove bracket mounting bolt(14).

3) Remove steering valve (15).

Ú Remove the steering valve together with bracket (13).

4) Remove lock bolt (12-1) from steering valve (15), removecoupling (16) and mounting bolts (17), then remove bracket(13) and column assembly (18).

Ú Make match marks before removing column assembly(18) from the steering valve.

DISASSEMBLY AND ASSEMBLY STEERING VALVE

30-168 Î

STEERING VALVEINSTALLATION

! Carry out installation in the reverse order to removal.Ú Carry out the steering valve installation operation with 2

workers, give signals to each other, and be extremelycareful when installing the steering valve.

Ú Install the hoses without twisting or interference.Ú Hoses (7), (8), (9), (11)

Hose mouthpiece: 78.4 ± 19.6 Nm(8 ± 2 kgm)

Width across flats of hose mouthpiece:27 mm

Ú When assembling the lock bolt, align with the column shaftgroove and screw in.

Lock bolt (12): 24.5 ± 4.9 Nm(2.5 ± 0.5 kgm)

Column shaft spline: Grease (G2-LI)

Ú When assembling the lock bolt, align with the column shaftgroove and screw in.

Lock bolt (12-1): 28.4 ± 3.9 Nm(2.9 ± 0.4 kgm)

Ú Tighten mounting bolts (17) on diametrically opposite sides.

Mounting bolt (17): 41.7 ± 17.2 Nm(4.25 ± 1.75 kgm) (U3/8)

Ú If the oil seal of the column assembly has been replaced,coat the oil seal lip with grease.

Lip of oil seal: Grease (G2-LI)

! Refilling with oilTighten drain plug and add hydraulic oil through oil filler to thespecified level.Ú Run the engine to circulate the oil through the system.

Then check the oil level again.

DISASSEMBLY AND ASSEMBLY STEERING VALVE

30-169 Î

STEERING VALVEDISASSEMBLY

Ú Use a wire brush to remove all the dirt and dust stuck to the jointaround the outside circumference of the unit.

Ú Carry out the operation in a clean place to prevent dirt or dustfrom sticking to the valve.

Ú As far as possible, hold the valve in a vice when disassembling.

DISASSEMBLY OF ROTOR

1. Set rotor side facing up, and hold mounting flange lightly in vice(1).

Ú Put a copper plate in contact with the vice and be careful not totighten the vice too hard.

2. Remove screw (1), then remove end cap (2).

3. Remove O-ring (3) from end cap (2).

4. Pull out rotor set (4), then remove O-ring (5).

Ú Be careful not to drop the star inside the rotor set.

5. Remove spacer (6).

DISASSEMBLY AND ASSEMBLY STEERING VALVE

30-170 Î

6. Remove drive shaft (7).

7. Remove spacer plate (8).

8. Remove O-ring (9) from housing (10).

DISASSEMBLY OF CONTROL SIDE

9. Remove housing (10) from vice, and place on a clean cloth. Becareful not to damage the finished surface.

10. Raise tip of snap ring (11) with screwdriver, and remove fromhousing.

11. Turn spool and sleeve to place pin in a horizontal position, thenpush in spool and sleeve with your thumb, and remove bushing(12) from housing.

12. Remove X-ring seal (13) from bushing (12).

13. Remove dust seal (14) from bushing (12) with screwdriver.

Ú Be careful not to damage the bushing.

DISASSEMBLY AND ASSEMBLY STEERING VALVE

30-171 Î

14. Remove 2 bearing races (15) and thrust needle(16) from spool and sleeve.

15. Pull out spool and sleeve assembly (17) from housing (10) inthe direction of the arrow.

Ú To prevent the spool and sleeve assembly from catching inthe housing, rotate the spool and sleeve assembly slowly tothe left and right when pulling out from the housing.

16. Pull out pin (18) from spool and sleeve assembly (17).

17. Push spool (20) inside sleeve (19) slightly to front, and remove6 centering springs (21) from spool (20) carefully by hand.

18. Turn spool (20) slowly and pull out from rear of sleeve (19) (inthe direction of the arrow).

19. Remove O-ring (22) from housing.

20. Remove set screw (23) from housing.

21. Screw a threaded bar into check sheet (24), and pull out checksheet (24).

22. Remove O-rings (25) and (26) from check sheet (24).

23. Tap housing, and remove ball (27) and retainer (28).

DISASSEMBLY AND ASSEMBLY STEERING VALVE

30-172 Î

STEERING VALVEASSEMBLY

Ú Check all parts for damage or burrs.

Ú Wash all metal parts in clean solvent and blow dry with air.

Ú Do not use a file or polish any part with rough sandpaper.

Ú Coat the O-rings with clean grease. (No need to put grease onnew X-ring seals)

Ú Coat the O-ring for the rotor set with a small amount of grease.

ASSEMBLY OF CONTROL SIDE1. Insert retainer (28) in housing with tweezers.

Ú Check that the retainer is not inserted at an angle.

2. Insert ball (27).

3. Fit O-rings (26) and (25) in check sheet (24), and push checksheet (24) into housing.

Ú Be careful to set the top and bottom of the check sheetfacing in the correct direction.

4. Install set screw (23).

Ú Check that the set screw is set in slightly from the end faceof the housing.

Set screw: 11.8 Nm (1.2 kgm)

Set screw: Loctite

5. Assemble spool (20) and sleeve (19) so that spring groove is onsame side.

Ú Rotate the spool and slide it in.Ú Grip the splined portion of the spool lightly and check that

the spool rotates smoothly inside the sleeve.Ú If there are match marks, check that the match marks are

aligned.

DISASSEMBLY AND ASSEMBLY STEERING VALVE

30-173 Î

6. Align spring groove positions of spool (20) and sleeve (19), andset on flat plate, then insert spring (21) in spring groove.

Ú Set so that the notches at both ends are at the bottom.

7. Insert pin (18) in spool and sleeve assembly (17).

8. Insert spool and sleeve assembly (17) in housing (10) in thedirection of the arrow.

1) Keep pin horizontal and rotate to left and right a little at atime to insert.Ú Be extremely careful not to get it caught.

2) Make the spool and sleeve assembly flush with the rear endface of the housing.

Ú If it is inserted beyond the end face, the pin will fall out.3) Check that spool and sleeve rotate smoothly inside housing.

9. Install O-ring (22) to housing (10).

10. Fit 2 bearing races (15) and thrust needle (16) in case (10).

DISASSEMBLY AND ASSEMBLY STEERING VALVE

30-174 Î

11. Insert dust seal (14) in bushing (12).

12. Insert X-ring seal (13) in bushing (12).

13. Insert bushing (12) in spool, and rotate to install.! Tap with a plastic hammer to assemble to the specified

position.! It must be in contact horizontally with the bearing race.

14. Fit snap ring (11) in housing.

ASSEMBLY OF ROTOR

15. Hold flange of housing lightly in vice.

Ú Be careful not to tighten the vice too hard.Ú Check that the spool and sleeve are set in slightly from the

housing surface with fourteen holes.

16. Insert O-ring (9) in housing.

17. Put on spacer plate (8), and align positions of bolt hole and taphole of housing.

DISASSEMBLY AND ASSEMBLY STEERING VALVE

30-175 Î

18. Turn spool and sleeve assembly to make pin (18) and portsurface of housing parallel, then mesh pin and yoke of driveshaft (7).

Ú To position accurately, draw a line on the end face of thedrive shaft spline.

19. Insert O-ring (5) in rotor set (4).

20. Make O-ring (5) end of rotor set to spacer plate end, then aligninsert portion of star of rotor (4) with drive.

1) Check that lines A, B, C, and D are all parallel.2) Without removing joint of drive shaft (7), position bolt holes

of rotor set.Ú This procedure is very important for determining the valve

timing of unit.

21. Insert spacer (6) inside rotor set.

22. Set end cap (2) on rotor set, and align bolt hole.

DISASSEMBLY AND ASSEMBLY STEERING VALVE

30-176 Î

23. Coat thread of screw with grease, and tighten end cap.Ú Install the handle to the spool, and check

that the spool rotates.

End cap mounting screwFirst step: 14.7 Nm (1.5 kgm)Second step: 27.0 ± 1.5 Nm

(2.75± 0.15 kgm)

DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

30-177 Î

MAIN CONTROL VALVEREMOVAL

WARNING! Stop the machine on level ground and install thesafety bar on the frame. Lower the bucket to the ground andstop the engine. Then apply the parking brake and put blocksunder the wheels to prevent the machine from moving.Ú Raise the boom, set stand (1A) of boom holding stopper (U)

in position, then remove front cover (1).Ú Remove cover (2) at the top of the hydraulic tank on the

right side.

WARNING! Loosen the oil filler cap slowly to release thepressure inside the hydraulic tank. Then operate the controllevers several times to release the remaining pressure in thehydraulic piping.

! Loosen plug (3) at the top of the hydraulic tank filter to preventthe oil inside the hydraulic tank from flowing out.

1. Drive shaftDisconnect drive shaft (4) at front axle end.

Ú After disconnecting the drive shaft, move it to the left andsecure it with wire.

2. Electric wiringDisconnect electric wiring connectors (5) and (6) for maincontrol valve.Ú Fit tags with numbers to identify the wiring.

DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

30-178 Î

3. Control cablePull out snap pin and remove pins (7), then remove controlcables (8) from spools (9).

Ú Fit tags with numbers to identify the wiring.

4. Hydraulic piping

Disconnect following hydraulic piping.! Tubes (10) and (11) between main control valve and

boom cylinder! Hoses (12) and (13) between main control valve and the

pilot solenoid valve for the tilt cylinders.! Hose (14) between hydraulic pump and main control

valve! Hose (15) between main control valve and hydraulic tank! Between main control valve and oil return hose (16)

5. Main control valve1) Install eyebolt to front frame boss.

Ú Install the eyebolt to the boss portion securely.! M = 12, P = 1.75

2) Using eyebolt installed to front frame, fit lifting tool andsling main control valve (18).

3) Remove mounting bolts (19) on top of mounting bracketof main control valve (18), then remove main controlvalve.

Main control valve: 21 kg

Ú Loosen bottom bracket mounting bolts (20).Ú When removing the main control valve, remove the

top mounting bolts and lift off.

DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

30-179 Î

MAIN CONTROL VALVEINSTALLATION

Carry out installation in the reverse order to removal.

Ú Be careful of the direction of the yoke, and align the pilotportion correctly to install.

Mounting bolt: 65.7 ± 6.9 Nm(6.7 ± 0.7 kgm)

Ú Install the snap pin securely.

Ú Install the hoses without twisting or interference.

Tube mouthpiece:265 ± 29.4 Nm (27 ± 3 kgm) (Width across flats: 36 mm)

Hose mouthpiece:176.5 ± 29.4 Nm (18 ± 3 kgm)

(Width across flats: 36 mm)

Ú Align with the bottom bracket mounting bolts and install themain control valve.

Ú Be sure to tighten all of the bottom bracket mounting bolts.

Mounting bolt: 110.3 ± 12.3 Nm(11.25 ± 1.25 kgm)

! Refilling with oilÚ Tighten drain plug and add hydraulic oil through oil filler to

the specified level.Ú Run the engine to circulate the oil through the system.

Then check the oil level again.

DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

30-180 Î

MAIN CONTROL VALVEDISASSEMBLY

DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

30-181 Î

1. Spool assembly1) Remove mounting bolt (2) and plug (3) of detent assembly

(1).2) Holding spool (4) from moving, loosen bolt (5) inside detent

assembly (1), then remove detent assembly (1).Ú Remove joint (6) from spool (4).

3) Remove retainer (7), spring (8), retainer (9), oil seal (10)and plate (11).

4) Remove plate (12), then remove oil seal (10) and spool (4).

2. Main relief valve assembly1) Remove main relief valve assembly (13).2) Loosen nut (14), and screw out holder (15), then remove

retainer (16), spring (17), poppet (18), seat (19) and spring(20).

3) Remove plug (21), then remove valve (22) from sleeve(23).

Ú Valve (22) and sleeve (23) are not available as individualparts, so replace them as a set.

3. Remove safety valve assembly (25) with suction valve andsuction valve assembly (24).

4. Remove plug (26), then remove spring (27) and valve (28).

DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

30-182 Î

MAIN CONTROL VALVEASSEMBLY

DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

30-183 Î

1. Assemble valve (28) and spring (27) in body (29), and fit O-ringand tighten plug (26).

Plug: 107.8 ± 14.7 Nm (11 ± 1.5 kgm)

2. Fit O-rings and install suction valve assembly (24) and safetyvalve assembly (25) with suction valve.

Safety valve (with suction):142.2 ± 19.6 Nm (14.5 ± 2 kgm)

Suction valve: 142.2 ± 19.6 Nm(14.5 ± 2 kgm)

3. Main relief valve assembly1) Assemble valve (22) in sleeve (23), then tighten plug (21).2) Assemble spring (20), seat (19), poppet (18), spring (17)

and retainer (16) in sleeve.3) Screw nut (14) into holder (15), fit O-ring on holder, then

install the holder into sleeve (23) and tighten nut (14).4) Fit O-ring and backup ring and install main relief valve

assembly (13).

Main relief valve: 83.4 14.7 Nm(8.5 ± 1.5 kgm)

4. Spool assembly1) Assemble spool (4) in body, then install oil seal (10) and

plate (12).2) Pull out spool slightly, then assemble retainer (11), oil seal

(10), retainer (9), spring (8), and retainer (7).3) Holding spool from moving, turn bolt inside detent assembly

(1), and install joint (6) to spool (4).

Joint: 14.7 ± 4.9 Nm (1.5 ± 0.5 kgm)

4) Tighten bolt (5), then install detent assembly (1).5) Tighten plug (3).

Plug: 13.7 ± 3.9 Nm (1.4 ± 0.4 kgm)

DISASSEMBLY AND ASSEMBLY STEERING CYLINDER

30-184 Î

STEERING CYLINDERREMOVAL

WARNING! Stop the machine on level ground and install thesafety bar on the frame. Lower the bucket to the ground andstop the engine. Then apply the parking brake and put blocksunder the wheels to prevent the machine from moving.

! Remove cover (1-1) on the right under the floor.

WARNING! Loosen the oil filler cap slowly to release thepressure inside the hydraulic tank. Then operate the controllevers several times to release the remaining pressure in thehydraulic piping.

! Loosen plug (1) to prevent the oil inside the hydraulic tank fromflowing out.

1. Hydraulic piping

1) Disconnect steering cylinder rod hose (2) from steeringcylinder tube.

2) Disconnect steering cylinder bottom hose (3) from steeringcylinder tube.

2. Cylinder1) Remove lock bolt at rod end, then remove pin (4).

2) Remove lock bolt at bottom end, remove pin (5), thenremove cylinder (6).

Ú Be careful not to damage the rod plating.

DISASSEMBLY AND ASSEMBLY STEERING CYLINDER

30-185 Î

STEERING CYLINDERINSTALLATION

! Carry out installation in the reverse order to removal.

Ú Install the hoses without twisting or interference.

Ú Align the rod pin hole and assemble the shims so that clearance"b" between the cylinder and the frame is the specified value,then lock pin (4) with the mounting bolt.

WARNING! Always use a bar when aligning the pin holes.Never insert your fingers.

Clearance "b" = Max. 1.0 mm

Ú Align the bottom pin hole and assemble the shims so thatclearance "a" between the cylinder and the frame is thespecified value, then lock pin (5) with the mounting bolt.

WARNING! Always use a bar when aligning the pin holes.Never insert your fingers.

Clearance "a" = Max. 1.0 mm

! Add hydraulic oil through oil filler to the specified level.Ú Run the engine to circulate the oil through the system.

Then check the oil level again.

DISASSEMBLY AND ASSEMBLY BRAKE BOOSTER

30-186 Î

BRAKE BOOSTERREMOVAL

WARNING! Stop the machine on level ground and install thesafety bar on the frame. Lower the bucket to the ground andstop the engine. Then apply the parking brake and put blocksunder the wheels to prevent the machine from moving.

! Turn the steering wheel to the right to articulate the chassis.

1. Covers1) Remove cover (1) under cab or on left and

right sides of floor.2) Remove cover (2) at left side of rear frame.

2. Machines equipped with air conditioner1) Remove left ladder rail (3).

Ú Be careful not to catch the brake hose when removingthe ladder rail.

2) Remove condenser front cover (4).Ú Remove the hose clamp.

3) Remove condenser mounting brackets (5), and opencondenser (6) to rear.

DISASSEMBLY AND ASSEMBLY BRAKE BOOSTER

30-187 Î

3. Brake piping

1) Disconnect hose (7) between brake booster and torqueconverter filter from brake booster.

2) Disconnect hose (8) between brake booster andtransmission valve from brake booster.

3) Disconnect hoses (9) and (10) between brake oil tank andbrake booster from brake booster.

4) Disconnect tubes (11) and (12) between brake booster andfront and rear brake from brake booster.

5) Disconnect hose (13) between brake booster andtransmission oil filler tube from brake booster.

4. Brake booster1) Pull out ball joint (15) of brake linkage (14).2) Remove 4 mounting bolts (16), then remove

brake booster (17).

DISASSEMBLY AND ASSEMBLY BRAKE BOOSTER

30-188 Î

BRAKE BOOSTERINSTALLATION! Carry out installation in the reverse order to removal.

Ú Be careful not to catch the brake hose when installing the ladderrail.

Ú Install the hoses without twisting or interference.Ú Be careful to assemble correctly when connecting the hoses

between the brake booster and transmission.

Tube nut between front and rear brakes: 11.3 ± 3.4 Nm(1.15 ± 0.35 kgm)

Hose clamp between brake oil tanks: 3.3 ± 0.5 Nm(0.34 ± 0.05 kgm)

Ú Check that the cylinder rod is inserted in the brake booster pistongroove.

Ball joint nut: 29.4 ± 4.9 Nm(3.0 ± 0.5 kgm)

Rod locknut: 110.3 ± 12.3 Nm(11.25 ± 1.25 kgm)

Mounting bolt (16): 110.3 ± 12.3 Nm(11.25 ± 1.25 kgm)

!! Bleeding airBleed the air from the brake system.Ú For details, see TESTING AND ADJUSTING.

!! Adjusting rodAdjust the rod. For details, see TESTING ANDADJUSTING.

DISASSEMBLY AND ASSEMBLY BRAKE BOOSTER

30-189 Î

BRAKE BOOSTERDISASSEMBLY

1. Power master cylinder1) Remove linkage rod (2) and dust cover from power master

cylinder (1).Ú Mask the tip of the piston of the linkage rod to protect it

from damage.

2) Disconnect power cylinder (3) and master cylinder (4).

2. Piston assembly1) Remove snap ring (5) from body (4), then remove

secondary piston (6).

2) Remove stopper bolt (7), then hold brake oil hole (8) andstopper bolt hole (9) with finger. Blow in oil through brakeoil hole (10) and remove primary piston (11).Ú The piston may fly out, so do not blow the air in

strongly.

DISASSEMBLY AND ASSEMBLY BRAKE BOOSTER

30-190 Î

3) Remove spring (12) from inside body (4).Ú When removing the piston, be careful not to damage

the inside diameter of the body or the sliding surface onthe outside of the piston.

Ú If there is any problem with the primary or secondarypistons, replace the pistons as an assembly.

3. Fine disassembly of power cylinder1) Remove dust cover (13).

Ú Remove the elbow first.

2) Push in cylinder cover (14), remove snap ring (15), thenremove power piston (16), connector assembly (17), springseat (18), and springs (19) and (20).

WARNING! When removing the spring, the cylindercover is pushed out by the spring, so remove carefully.

3) Remove power piston (16) from connector assembly (17).

4) Remove snap ring (21), disconnect spool (22) andconnector, then remove thrust washer (23) and spring (24).

DISASSEMBLY AND ASSEMBLY BRAKE BOOSTER

30-191 Î

4. Relief valveRemove plug (25), then remove spring (26) and spool (27).

5. Power pistonRemove seal ring (28) from piston (16).

DISASSEMBLY AND ASSEMBLY BRAKE BOOSTER

30-192 Î

BRAKE BOOSTERASSEMBLY

1. ElbowInstall elbow (29) to power cylinder body (3).

2. Relief valveInsert spring (26) in spool (27), assemble in power body, theninstall plug (25).

3. Fine assembly of power cylinder1) Assemble spring (24) in connector (31).

2) Insert spool (22) in connector (31), and assemble thrustwasher (23), then secure with snap ring (21).

DISASSEMBLY AND ASSEMBLY BRAKE BOOSTER

30-193 Î

3) Set body (3) on block.

4) Insert springs (19) and (20), and spring seat(18) inside body (3).

5) Assemble connector assembly (17).

6) Assemble O-rings (32) and seal (33) in cylinder cover (14).

Seal: Oil (brake oil)

7) Assemble seal ring (28) in power piston (16).

Seal ring: Oil (brake oil)

DISASSEMBLY AND ASSEMBLY BRAKE BOOSTER

30-194 Î

8) Assemble power piston (16) and cylinder cover (14) tospool (22), then set guide shaft ..”a” in position.Ú To prevent power piston (16) and cylinder cover (14)

from dropping inside the body, stop them at the top ofthe body.

9) Push in guide shaft "a" with a press, bend springs (19) and(20), and keep in position.Ú Keep snap ring (15) until the completion of assembly.

10) Lower power piston (16) only, and push in evenly on the leftand right with both thumbs.Ú When assembling the power piston, do not hit it in with

a hammer.Ú When assembling the power piston (16), apply the

force evenly. Never use excessive force.

11) Check that there is no damage to O-ring of power piston(16), then assemble cylinder cover (14).

12) Secure cylinder cover (14) with snap ring (15).

DISASSEMBLY AND ASSEMBLY BRAKE BOOSTER

30-195 Î

13) Install dust cover (13).

4. Fine assembly of master cylinder1) Insert primary piston (11) in body (4).

Ú Insert the piston carefully to prevent damage to the sealcup. Never force it into position.

Body and piston: Oil (brake oil)

2) Push piston (13) and tighten stopper bolt (7) by hand.Ú After tightening as far as possible by hand, tighten fully.

Stopper bolt: 10.8 ± 2.0 Nm(1.1 ± 0.2 kgm)

3) Insert secondary piston (6) in body (4).

Body and piston: Oil (brake oil)

Ú When assembling the piston, be careful not to damagethe inside diameter of the body and the outsidediameter of the piston.

Ú Be careful not to get the O-ring caught.

4) Push in secondary piston (6), then install C-ring (5).Ú Fit the C-ring properly in the groove.

DISASSEMBLY AND ASSEMBLY BRAKE BOOSTER

30-196 Î

5. Power master cylinder1) Connect power master cylinder (3) and master cylinder (4).Ú Use a new O-ring for the connection of the master cylinder.

Connecting bolt (34): 31.9 ± 2.5 Nm(3.25 ± 0.25 kgm)

2) Assemble linkage rod (2) to power master cylinder (1).

Ú For details of adjusting the brake linkage, seeTESTING AND ADJUSTING.

DISASSEMBLY AND ASSEMBLY PARKING BRAKE

30-197 Î

PARKING BRAKEREMOVALÚ If further disassembly is necessary, see DISASSEMBLY AND

ASSEMBLY OF TRANSMISSION.

WARNING! Stop the machine on level ground and install thesafety bar on the frame. Lower the bucket to the ground andstop the engine. Then apply the parking brake and put blocksunder the wheels to prevent the machine from moving.Ú After putting blocks under the tires, release the parking

brake.! Loosen the plug of the transmission and drain the oil.

Transmission oil: 28 RR

1. Drive shaft1) Disconnect drive shaft (1) from transmission end.

Ú Set block â to the rear frame.2) Using hexagonal wrench, remove 2 plugs on opposite sides,

then install 2 piston lock set bolts ã

Ú Width across flats of hexagonal wrench: 6 mmÚ Piston lock set bolt: p = 1.25, M = 8, L = 35

2. CouplingRemove mounting bolt (7), then remove holder (4), O-ring (5),and coupling (6).

Ú Make match marks on the coupling.

3. Parking brake housingDisconnect cable (9) from parking brake lever (8).

Ú Check that there are blocks under the tires, then disconnectthe cable.

Ú Disconnect the cable with the parking brake released.

DISASSEMBLY AND ASSEMBLY PARKING BRAKE

30-198 Î

4. Parking brake1) Remove all mounting bolts (10) of parking brake housing

(11).

2) Tighten 2 forcing screws ä in forcing screw hole andremove parking brake housing (11).

Ú Use the housing mounting bolts as forcing screws.Ú Do not remove bolts (20) used for installing retainer

assembly (19).Ú The working posture is poor and the housing is

removed with the piston installed to the housing, so beextremely careful when removing.

Ú Install guide bolt å to prevent the housing from failing.Ú Be careful not to let the oil seal lip hit the shaft when

removing.

Parking brake housing: 15 kg

5. End plate1) Remove separator plate bolt (14).

2) Remove separator plate (13), wave spring (15), and disc(16) in turn, then remove end plate (17).

Ú If it is necessary to remove hub spline (18), remove it asit is.

DISASSEMBLY AND ASSEMBLY PARKING BRAKE

30-199 Î

PARKING BRAKEINSTALLATION

! Carry out installation in the reverse order to removal.

Ú Be careful of the direction of the yoke, and alignthe pilot portion correctly to install.

Mounting bolt: 65.7 ± 6.9 Nm(6.7 ± 0.7 kgm)

Ú Remove 2 piston lock set bolts ã and install theplug.

Ú Be careful not to get the O-ring caught.Ú Align with the coupling match mark, and

assemble so that there is no misalignment of thefront and rear couplings in the circumferentialdirection.

Mounting bolt: 277 ± 31.9 Nm(28.25 ± 3.25 kgm)

Ú After connecting the parking brake cable, bendthe cotter pin securely.

Mounting bolt: 110.3 ± 12.3 Nm(11.25 ± 1.25 kgm)

Ú The working posture is poor, so be extremelycareful when installing the parking brakehousing.

Ú Install a guide bolt to prevent the housing fromfalling.

Ú Use a new gasket.Ú Be careful not to let the oil seal lip hit the shaft

when installing.

Ú Remove all oil and grease from the separatorbolt thread and bolt hole.

Ú Tighten the separator bolts uniformly in turn.

bolt:Thread tightener (LT-2)

bolt: 53.9 ± 19.6 Nm(5.5 ± 2.0 kgm)

Ú Soak the disc in clean transmission oil for at least2 minutes before assembling.

Ú Use one spring.Ú When assembling the separator plate, be careful

that the hub spline does not rise up.

Refilling with oilÚ Install drain plug and add engine oil through oil

filler to the specified level.

Transmission oil: 28 RR

ÚÚ If it is necessary to adjust the parking brake cable,see TESTING AND ADJUSTING.

DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK

30-200 Î

HYDRAULIC TANKREMOVAL

WARNING! Stop the machine on level ground and install thesafety bar on the frame. Lower the bucket to the ground andstop the engine. Then apply the parking brake and put blocksunder the wheels to prevent the machine from moving.

WARNING! Loosen the oil filler cap slowly to release thepressure inside the hydraulic tank. Then operate the controllevers several times to release the remaining pressure in thehydraulic piping.! Loosen plug (1) at the top of the hydraulic tank filter to

prevent the oil inside the hydraulic tank from flowing out.! Remove covers (2) at the side first.

1. Ladder railLift off right ladder rail (3).

Ladder rail: 22 kg

2. Hydraulic piping1) Loosen clamp of hose (4) between hydraulic tank and

pump, and disconnect when removing hydraulic tank.2) Disconnect hose (5) between main control valve and

hydraulic tank from hydraulic tank.! Width across flats of hose mouthpiece (5): 36 mm

3) Disconnect hose (6) between steering valve and hydraulictank and hose (7) between main control valve and hydraulictank.! Width across flats of hose mouthpiece (6): 27 mm

3. Hydraulic tank1) Set palleter â and stand ã under hydraulic tank (8).2) Raise palleter â slowly to support hydraulic tank (8).

DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK

30-201 Î

3) Remove mounting bolts of hydraulic tank (8).Ú Be sure to remove all the mounting bolts.

4) Pull out palleter â and pull out hose between pumps whileremoving hydraulic tank (8).Ú When removing the hydraulic tank, tip it to the outside

and disconnect the hose.

Hydraulic tank (dry): 53 kg

HYDRAULIC TANKINSTALLATION! Carry out installation in the reverse order to removal.

Mounting bolt: 112.8 ± 9.8 Nm(11.5 ± 1.0 kgm)

! Refilling with oilAdd hydraulic oil through oil filler to the specified level.Ú Run the engine to circulate the oil through the system.

Then check the oil level again.

DISASSEMBLY AND ASSEMBLY HYDRAULIC FILTER

30-202 Î

HYDRAULIC FILTERREMOVAL

Loosen the oil filler cap slowly to release the pressure inside thehydraulic tank.

1. Hydraulic pipingDisconnect hydraulic hoses (1) and (2).

! Width across flats of hose mouthpiece (1): 36 mm! Width across flats of hose mouthpiece (2): 27 mm

2. CoverRemove mounting bolts, then remove cover (3).

WARNING! The cover is under the tension of a spring, sobe careful when removing it.

Ú Be careful not to damage the mating surface of the coverand the tank and O-ring (4).

3. FilterRemove spring (5) and bypass valve (6), then remove filter (7).

HYDRAULIC FILTERINSTALLATION

! Carry out installation in the reverse order to removal.

Ú Install the hoses without twisting or interference.

Ú Replace the O-ring with a new part.Ú Fit the O-ring securely in the groove and be careful not to

get it caught when assembling.Ú After installing the hydraulic tank and connecting the hose,

bleed the air from the hydraulic tank.

DISASSEMBLY AND ASSEMBLY HYDRAULIC STEERING PUMP

30-203 Î

HYDRAULIC STEERING PUMPREMOVAL

WARNING! Stop the machine on level ground and install thesafety bar on the frame. Lower the bucket to the ground andstop the engine. Then apply the parking brake and put blocksunder the wheels to prevent the machine from moving.Ú Disconnect the cable from the negative(-) terminal of the

battery.

1. Cover, wiring1) Remove cover (1) under right center fender.2) Remove covers (3) and (4) top of hydraulic tank.

Ú Remove the wiring clamps.

WARNING! Loosen the oil filler cap slowly to release thepressure inside the hydraulic tank. Then operate the controllevers several times to release the remaining pressure in thehydraulic piping.! Loosen plug (2) to prevent the oil inside the hydraulic tank

from flowing out.

3) Remove connector mounting bracket (7) connecting frontwiring (5) and rear wiring (6), then move to side.Ú Do not disconnect the connector at this point.

2. Hydraulic piping1) Disconnect tube (8) between hydraulic tank and hydraulic,

steering pump at hydraulic and steering pump end.

2) Disconnect hose (9) between hydraulic, steering pump andpriority valve at hydraulic and steering pump end.

3. PumpRemove mounting bolts, then remove hydraulic and steeringpump (10).

WARNING! The working space is confined, so beextremely careful when removing.

DISASSEMBLY AND ASSEMBLY HYDRAULIC STEERING PUMP

30-204 Î

HYDRAULIC, STEERING PUMPINSTALLATION

! Carry out installation in the reverse order to removal.

Ú Be careful not to get the O-ring caught when installing the tube.Mounting bolt: 66.2 ± 7.4 Nm

(6.75 ± 0.75 kgm)

Ú Install the hoses without twisting or interference.Ú Be careful not to get the O-ring caught when installing.

Mounting bolt: 34.3 ± 3.4 Nm(3.5 ± 0.35 kgm)

ÚÚ Be careful not to get the O-ring caught when installing.Ú Tighten the mounting bolts uniformly at the top and bottom.

Mounting bolt: 110.3 ± 12.3 Nm(11.25 ± 1.25 kgm)

! Refilling with oilÚ Run the engine to circulate the oil through the system. Then check

the oil level again.

DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER

30-205 Î

BUCKET CYLINDER

WARNING! Stop the machine on level ground and installthe safety bar on the frame. Lower the bucket to the groundand stop the engine. Then apply the parking brake and putblocks under the wheels to prevent the machine frommoving.

Loosen the oil filler cap slowly to release the pressureinside the hydraulic tank. Then operate the controllevers several times to release the remaining pressurein the hydraulic piping.

REMOVAL

1. Bucket positionerDisconnect connector (1).

2. Rod pin

Sling cylinder (7), then remove lock bolt, and remove pin (2).Ú Sling at 2 points, and be careful of the center of gravity.

3. Hydraulic piping

1) Disconnect rod hose (3) from cylinder.! Width accross flats of hose (3) mouthpiece: 36 mm

2) Disconnect bottom tube (4) at connection with hose (5)! Width accross flats of hose (3) mouthpiece: 36 mm

DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER

30-206 Î

4. Bucket cylinder

1) Remove lock bolt, then remove bottom pin (6).Ú If there are shims installed, check the number and

thickness of the shims, and keep in a safe place.

2) Lift off bucket cylinder (7).Ú Be cafeful not to damage the cylinder rod portion.

Bucket cylinder: 56 kg

INSTALLATION

! Carry out installation in the reverse order of removal.

WARNING! When aligning the position of the pin hole, usea bar. NEVER insert your fingers in the pin hole.

! Bucket positionerÚ For details of adjusting the bucket positioner, see TESTING

AND ADJUSTING (section 20).

Ú Install the hoses without twisting or interference.

WARNING! When aligning the position of the pin hole, usea bar. NEVER insert your fingers in the pin hole.

Ú Align the pin hole at the cylinder bottom, assemble shims so thatthe total for clearance “a” between the cylinder and frame iswithin the standard value, then assemble pin (6) and lock withbolt.

Clearance “a”: Max. 1.5 mm

DISASSEMBLY AND ASSEMBLY BOOM CYLINDER

30-207 Î

BOOM CYLINDER

WARNING! Stop the machine on level ground and installthe safety bar on the frame. Lower the bucket to the groundand stop the engine. Then apply the parking brake and putblocks under the wheels to prevent the machine frommoving.

Loosen the oil filler cap slowly to release the pressureinside the hydraulic tank. Then operate the controllevers several times to release the remaining pressurein the hydraulic piping.

Ú Set the support stand under the tip of the boom.

REMOVAL

1. Rod pin

1) Sling boom cylinder (1), then remove lock bolt, and removepin (2).Ú If there shims installed, check the number and

thickness of the shims, and keep in a safe place.2) Start the engine, and use the control lever to retrack

cylinder rod on side that was removed.Ú Retract the rod to a point 20 mm before the end of the

stroke.

2. Hydraulic piping

1) Disconnect rod tube (3) from connection of hose (4). 2) Disconnect bottom tube (5) from connection of hose (6).

Ú Do not forget to relieve the pressure in the hydraulicsystem before disconnecting tubes and hoses.

Ú After disconnecting the tubes and hoses, fit plugs toprevent the entry of dirt or dust.

3. Boom cylinder

1) Remove lock bolt, then remove bottom pin (7).Ú If there shims installed, check the number and

thickness of the shims, and keep in a safe place.2) Lift off boom cylinder (1).

Ú Be careful of the center of gravity, and lift off slowly.Ú Be cafeful not to damage the cylinder rod portion.

Boom cylinder: 62 kg

DISASSEMBLY AND ASSEMBLY BOOM CYLINDER

30-208 Î

INSTALLATION

! Carry out installation in the reverse order of removal.

WARNING! When aligning the position of the pin hole, usea bar. NEVER insert your fingers in the pin hole.

Ú Start the engine, operate the control levers, extend the rod.Align the pin holes and assemble shims so that clearance “b”is within the standard value, then assemble pin (2) and lock withthe bolt.

Clearance “b”: Max. 2 mm

Ú Install the hoses without twisting or interference.

WARNING! When aligning the position of the pin hole, usea bar. NEVER insert your fingers in the pin hole.

Ú Align the pin hole at the cylinder bottom, assemble shims so thatthe total for clearance “a” between the cylinder and frame iswithin the standard value, then assemble pin (7) and lock withbolt.

Clearance “a”: Max. 1.5 mm

DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER

30-209 Î

HYDRAULIC CYLINDERDISASSEMBLY

1. Set cylinder assembly (1) to tool A.

2. Raise lock portion of cylinder head (2), then using tool B,remove cylinder head (2) from cylinder.

3. Pull out cylinder head and piston rod assembly (3) from cylinder(4), and lift off.Ú Oil will flow out when the piston rod assembly is removed

from the cylinder, so place a container under the cylinder tocatch the oil.

4. Remove cylinder (4) from tool A.

5. Set cylinder head and piston rod assembly to tool A, then usingtool C, loosen nut (5).

Cylinder Width across flats (mm)

Boom 60

Bucket 70

Steering 46

6. Remove nut (5), then remove piston assembly (6), and retainerand cylinder head assembly (8) from rod (9).Ú The retainer is for the steering cylinder only.

DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER

30-210 Î

7. Disassembly of piston assembly1) Remove wear ring (11).2) Remove piston ring (12) from piston (13).

8. Disassembly of cylinder head assembly1) Remove snap ring (14), then remove dust seal (15).2) Remove rod packing (16).3) Remove bushing (17) from cylinder head (18).4) Remove O-ring (19) and backup ring (20).

DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER

30-211 Î

HYDRAULIC CYLINDER ASSEMBLY

Ú Clean all parts, and check for dirt or damage. Coat the slidingsurfaces of all parts with engine oil before installing. Be carefulnot to damage the rod packing, dust seals or O-rings whenassembling.

1. Assembly of cylinder head assembly1) Using tool D, press fit bushing (17) to cylinder head (18).Ú Be extremely careful not to deform the bushing when press

fitting.2) Install rod packing (16).Ú Be sure to install the rod packing facing in the correct

direction.3) Using tool E, Install dust sea[ (15) to head (18).4) Install snap ring (14).5) Install backup ring (20) and O-ring (19).

Ú Do not try to force the backup ring into position. Warmit in warm water (50 - 60EC) before fitting it.

2. Assembly of piston assembly1) Using tool F1, expand piston ring (12).

Ú Set the piston ring on the expander and turn the handle8 - 10 times to expand the ring.

2) Remove piston ring (12) from tool F1, then assemble topiston (13).

3) Using tool F2, compress piston ring (12).4) Assemble wear ring (11).

DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER

30-212 Î

3. Set piston rod (9) to tool A.

4. Assemble cylinder head assembly (8) and retainer and pistonassembly (6), and install nut (5).Ú The retainer is for the steering cylinder only.

5. Using tool C, tighten nut (5).

Rod thread: Thread tightener (LT-2)

Nut:

Cylinder Width across flats Tighening Torque(mm) Nm (kgm)

Boom cylinder 60 mm 1765 ± 176 (180 ± 18)

Bucket cylinder 70 mm 2599 ± 259 (265 ± 26.5)

Steering Cylinder 46 mm 784 ± 78 (80 ± 8)

6. Remove piston rod and head assembly from tool A, then setcylinder (4) to tool A.

7. Raise piston rod and head assembly (3), and assemble tocylinder (4).

8. Using tool B, tighten cylinder head nut (2).

Cylinder head nut:Cylinder Tightening torque Nm (kgm)

Boom 932 ± 93 (95 ± 9.5)

Bucket 980 ± 98 Nm (100 ± 10)

Steering 441 ± 44 (45 ± 4.5)

9. Bend lock into notch at cylinder end.

10. Remove cylinder assembly (1) from tool A.

DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT

30-213 Î

WORK EQUIPMENTREMOVAL

WARNING! Stop the machine on level ground and installthe safety bar on the frame. Lower the bucket to the groundand stop the engine. Then apply the parking brake and putblocks under the wheels to prevent the machine frommoving.

1. Bucket link1) Remove bucket link mounting pin (1).

Ú Tie the bucket link to the tilt lever with wire.

2) Remove left and right bucket hinge mounting pins (2).

WARNING! NEVER insert your fingers in the pin hole.

3) Drive machine in reverse and disconnect the bucket.

Bucket (BOC): 710 kg

2. Bucket cylinder mounting pinSling bucket cylinder (3), remove pin mounting (4), thendisconnect cylinder rod and bellcrank.Ú Set block â between cylinder bottom and frame

Bucket cylinder: 56 kg

3. Boom cylinder pinSling boom cylinder (5), then remove mounting pin (6).Ú Put support under the tip of the boom.Ú Insert block ã on top of the axle, then lower the cylinder.Ú If shims are inserted, check number and size of shims, and

put in a safe place.

Boom cylinder: 62 kg

DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT

30-214 Î

4. Boom, bellcrank, bucket link1) Remove bracket (7-1) of boom kick-out switch (7).

2) Sling boom bellcrank and bucket link (8), then removemounting pins (9) of boom, then lift off the boom.

Boom, bellcrank, bucket link: 662 kg

Ú If there shims installed, check the number andthickness of the shims, and keep in a safe place.

5. Bellcrank, bucket link1) Remove mounting pin (11) of bucket link (10), and remove

from bellcrank.

Bucket link: 17 kg

Ú Remove the wire holding the bucket to the bellcrank.

WARNING! When the pin is removed, the bellcrank willmove up suddenly, so keep your head and other partsaway.

Ú If there shims installed, check the number andthickness of the shims, and keep in a safe place.

2) Sling bellcrank (12), remove mounting pin (13), then lift offfrom boom.

Bellcrank: 125 kg

DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT

30-215 Î

6. Dust seal, bushing1) Remove dust seal (15) and bushing (16) from boom (14).

2) Remove dust seal (17) and bushings (18) from bellcrank(12).

3) Remove dust seal (19) and bushing (20) from bucket (10).

DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT

30-216 Î

WORK EQUIPMENTINSTALLATION

WARNING! When aligning the position of the pin hole, usea bar. NEVER insert your fingers in the pin hole.

1. Dust seal, bushingPress fit bushings (16) to bucket link, bellcrank, and boom with

press, and assemble dust seals (15)

Bushing: Grease (G2-LI)

2. Bellcrank, bucket link1) Align hole of boom (14) and bellcrank (12), and assemble

shims so that clearance “d” is specified value, thenassemble mounting pin (13), and lock with bolt.

Clearance “d”: Max. 2.0 mm

2) Align hole of bellcrank (12) and bucket link (10), and assembleshims so that clearance “e” is specified value, assemblemounting pin (11), and lock with bolt.

Clearance “e”: Max. 2.0 mm

Ú Secure the bucket link to the bellcrank with wire.

DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT

30-217 Î

3. Boom, bellcrank, bucket link1) Raise boom, bellcrank, and bucket link (8) and set in

mounting position, align front frame and boom mount holeso that clearance “a” is specified value, then assemblemounting pin (9) and lock with bolt.

Clearance “a”: Max. 1.5 mm

Ú After assembling the pins, set a stand under the tip ofthe boom.

2) Install bracket (7-1) of boom kick-out switch (7).

4. Boom cylinderSling boom cylinder (5), start engine, align cylinder rod withboom mount hole, insert shims so that clearance “f” is specifiedvalue, then assemble mounting pin (6) and lock with bolt.

Clearance “f”: Max.2.0 mm

WARNING! When starting the engine, check that thedirectional lever is at neutral and that the parking brake isapplied.

Ú Remove the block after assembling the mounting pins.

5. Bucket cylinderSling bucket cylinder (3), adjust control lever and align pin hole,then assemble mounting pin (4), and lock with bolt.Ú Remove the block after assembling the mounting pin.

DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT

30-218 Î

6. BucketOperate control lever and align hole of bucket mounting pin (2).Insert shims to make clearance “b” uniform on the left andright, then install mounting pin (2) and lock with bolt.

Ú Clearance “b”: Max. 1.5 mm

7. Bucket linkAlign hole of mounting pin (1) of bucket link (10). Insert shims tomake clearance “c” uniform on the left and right, then installmounting pin (1) and lock with bolt.

Ú Clearance “c”: Max. 2.5 mm

8. GreasingGrease all pins

DISASSEMBLY AND ASSEMBLY FUEL TANK

30-219 Î

FUEL TANKREMOVAL

WARNING! Stop the machine on level ground and install thesafety bar on the frame. Lower the bucket to the ground andstop the engine. Then apply the parking brake and put blocksunder the wheels to prevent the machine from moving.

WARNING! Disconnect the cable from the negative (-) terminalof the battery.

1. Open the side inspection cover and apply the lock, and openrear grill.

2. Loosen drain valve (1) and drain fuel.

3. Disconnect fuel hose (2), fuel return hose (3), and fuel gaugewiring connector (4).

4. Remove return hose (5) from fuel filter.Ú Remove clamp of breather tube (5-1).

5. Remove cover (6).

6. Remove outer cover (8), inner cover (7), and rubber at oil fillerport (6) on left side of rear frame.

DISASSEMBLY AND ASSEMBLY FUEL TANK

30-220 Î

3. Fuel tank

1) Set transmission jack under fuel tank, and support fuel tank(10) lightly.

2) Remove mounting bolts, then lower transmission jackslowly and remove.Ú When there is a clearance of approx. 50 mm from the

rear frame, stop and check that there is no interference.Ú The oil filler tube will hit the rear frame, so move to the

right and remove carefully.

Fuel tank (dry): 80 kg

3) Pull out fuel tank (9) to right side of chassis.

FUEL TANKINSTALLATION! Carry out installation in the reverse order to removal.

Ú Be sure to assemble the fuel hoses correctly.

Ú When raising the transmission jack, maintain the balance,keep the fuel tank horizontal, and set in the mountingposition.

Ú Tighten the bolts in turn on the left and right.

Mounting bolt: 113 ± 9.8 Nm(11.5 ± 1.0 kgm)

Refilling with oilTighten drain plug and add fuel through fuel filler.

DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT

30-221 Î

COUNTERWEIGHT

WARNING! Stop the machine on level ground and installthe safety bar on the frame. Lower the bucket to the groundand stop the engine. Then apply the parking brake and putblocks under the wheels to prevent the machine frommoving.

REMOVAL OF LEFT AND RIGHT COUNTERWEIGHTS

1. Remove left (1) and right (2) counterweights.1) Sling counterweights.2) Remove mount bolts.

Counterweight left: 100 kgCounterweight right: 170 kg

INSTALLATION OF LEFT AND RIGHT COUNTERWEIGHTS

Ú Install left and right in reverse order of removal.

Mounting bolt (A): 549 ±59 N@m (56 ±6 kgm)

Mounting bolt (B): 279 ±29 N@m (29 ±3 kgm)

REMOVAL OF REAR COUNTERWEIGHT

1. Removal of radiator grill.1) Disconnect battery cables at the battery (3).2) Disconnect electrical connections (4).3) Disconnect backup warning horn (power and ground wires)

(5).

2 Connect hoist (6) to radiator guard cover.1) Disconnect gas spring cylinders at the frame (7).2) Disconnect top mounting bracket.

3. TILT radiator guard cover from machine and set to the side.

DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT

30-222 Î

4. Rear counterweight.

Counterweight: 1210 kg

1) Using proper size hook and chain, hoist counter weight (torelieve pressure on mount bolts).

2) Remove four (4) mount bolts.

WARNING! Rear counterweight may swing out frommachine when the last bolt is removed.

3) Rest rear counterweight on a pallet (8).

INSTALLATION OF REAR COUNTERWEIGHT

Ú Install rear counterweight in reverse order of removal. Refer to“ENGINE SHOP MANUAL”.

Mounting bolt: 927 ±98 N@m (95 ±10 kgm)

DISASSEMBLY AND ASSEMBLY INSTRUMENT PANEL

30-223 Î

INSTRUMENT PANELREMOVAL

WARNING! Stop the machine on level ground and install thesafety bar on the frame. Lower the bucket to the ground andstop the engine. Then apply the parking brake and put blocksunder the wheels to prevent the machine from moving.Ú Disconnect the cable from the negative (-) terminal of the

battery.

1. Instrument panelRemove mounting bolts, then remove panel assembly (2) frominstrument panel mount guard (1), and pull up.

2. Tachometer cableDisconnect tachometer cable (4) from housing (3).Ú Remove the clip of the tachometer from the left side under

the floor frame.

3. Electric wiring

Disconnect following electric wiring connectors.! Connectors (5) and (6)Ú Remove the wiring from the clamp.

4. Panel1) Remove panel assembly (2).2) Remove each gauge from housing (3).

INSTRUMENT PANELINSTALLATION! Carry out installation in the reverse order to removal.

Ú After inserting the connectors, arrange the wiring so thatthere is no strain.

DISASSEMBLY AND ASSEMBLY INSTRUMENT PANEL

30-224 Î

MEMORANDA

40-1

40 MAINTENANCE STANDARD

Engine mount, transmission mount . . . . . . . . . . 40- 3Torque converter, charging pump . . . . . . . . . . . 40- 4Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . 40- 5Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40- 6Transmission control valve . . . . . . . . . . . . . . . . . 40-18Accumulator valve . . . . . . . . . . . . . . . . . . . . . . . . 40-22Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-23Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-25Final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-28Axle mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30Additional counterweight . . . . . . . . . . . . . . . . . . . 40-31Center hinge pin . . . . . . . . . . . . . . . . . . . . . . . . . 40-32Steering column . . . . . . . . . . . . . . . . . . . . . . . . . 40-34Steering cylinder mount . . . . . . . . . . . . . . . . . . . 40-35Priority valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-36Brake booster . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-37Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-38Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-39Hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40Main control valve . . . . . . . . . . . . . . . . . . . . . . . . 40-42Hydraulic cylinder . . . . . . . . . . . . . . . . . . . . . . . . 40-46Work equipment linkage . . . . . . . . . . . . . . . . . . . 40-48Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50Bucket positioner and boom kick-out . . . . . . . . . 40-51

MAINTENANCE STANDARD MEMORANDA

40-2

MEMORANDA

MAINTENANCE STANDARD ENGINE MOUNT, TRANSMISSION MOUNT

40-3

ENGINE MOUNT, TRANSMISSION MOUNT

MAINTENANCE STANDARD TORQUE CONVERTER CHARGING PUMP

40-4

TORQUE CONVERTER CHARGING PUMP

unit: mm

No. Check item Criteria Remedy

1 Side clearanceStandard clearance Clearance limit

Replace

0.05 - 0.10 0.15

2 0.060 -0.119 0.200

Clearance between insidediameter of plain bearing andoutside diameter of gearshaft

3 Depth for knocking in pinStandard size Tolerance

100

-0.5

4 2.0 -4.9 Nm (0.2 - 0.5 kgm)Rotating torque of splineshaft

- oil: EO10-CD -Discharge amount

oil temperature: 45-55E C

Rotating Standard delivery Deliveryspeed amount amount limit

Delivery pressure

3000 rpm 94 R/min 86 R/min2.9 MPa

(30 kg/cm²)

MAINTENANCE STANDARD TORQUE CONVERTER

40-5

TORQUE CONVERTER

Unit: mm

No. Check item Criteria Remedy

1 Outside diameter of pilotStandard size Tolerance Repair limit

Repairchrome

plating orreplace

42 41.75-0.009-0.034

2 100 100.5Inside diameter of retainer seal ring +0.035contact surface 0

3 Wear stator shaft sealring

Width 3 2.7-0.01-0.03

ReplaceThickness 4 - 3.6

4 0.15 - 0.42Backlash between PTO drive gearand drive gear

STRUCTURE AND FUNCTION TRANSMISSION

40-6

TRANSMISSION (1/3)

STRUCTURE AND FUNCTION TRANSMISSION

40-7

Unit: mm

No. Check item Criteria Remedy

1 Clearance between 4th shaft Shaft Holeand bearing (R)

Standard Standard Clearancesize clearance limit

Tolerance

Replace

30 -0 +0.021 -0.008 --0.012 -0.008 -0.033

2 72 -Clearance between 4th shaft 0 +0.018 -0.012 -bearing (R) and housing -0.013 -0.012 0.031

3 30 -Clearance between 4th shaft 0 +0.021 0.008 -and bearing (F) -0.012 +0.008 0.033

4 72 -Clearance between 4th shaft 0 +0.018 -0.012 -bearing (F) and housing -0.013 -0.012 0.031

5 50 -Clearance between pump +0.025 0 -0.037 -drive shaft and bearing +0.009 -0.012 -0.009

6 drive shaft bearing and 90 -Clearance between pump

housing0 +0.022 -0.013 -

-0.015 -0.013 0.037

7 35 -Clearance between pump -0.009 +0.041 0.034 -drive shaft and bearing -0.025 +0.025 0.066

8 drive shaft bearing and 47 -Clearance between pump

housing0 +0.014 -0.011 -

-0.011 -0.011 0.025

STRUCTURE AND FUNCTION TRANSMISSION

40-8

TRANSMISSION (2/3)

STRUCTURE AND FUNCTION TRANSMISSION

40-9

Unit: mmNo. Check item Criteria Remedy

1 Clearance between pump Shaft Holedrive shaft and bearing

Standard Standard Clearancesize clearance limit

Tolerance

Replace

50 -+0.025 0 -0.037 --0.009 -0.012 -0.009

2 drive shaft bearing and 80 -Clearance between pump

housing0 +0.018 -0.012 -

-0.013 -0.012 0.031

3 35 -Clearance between pump -0.009 +0.041 0.034 -drive shaft and bearing -0.025 +0.025 0.066

4 drive shaft bearing and 47 -Clearance between pump

housing0 +0.014 -0.011 -

-0.011 -0.011 0.025

5 35 -Clearance between input +0.009 0 -0.037 -shaft and bearing +0.025 -0.012 -0.009

6 shaft bearing and housing 72 -Clearance between input

earing0 +0.018 -0.012 -

-0.013 -0.012 0.031

7 50 -Clearance between input -0.009 0 0.037 -shaft and bearing -0.025 -0.012 0.009

8 90 -Clearance between input 0 +0.022 -0.013 -shaft bearing and housing -0.0151 -0.013 0.037

9 REVERSE, 1st clutch 90 -Clearance between

bearing (F) and housing0 +0.022 --0.013 -

-0.015 -0.013 0.037

10 REVERSE, 1st clutch 90 -Clearance between

bearing (R) and housing0 -+0.022 --0.013 -

-0.015 -0.013 0.037

11 110 -Clearance betweenFORWARD, 2nd cl;utch 0 +0.022 -0.013 -clutch bearing (F) and -0.015 -0.013 0.037housing

12 FORWARD, 2nd clutch 90 -Clearance between

bearing (R) and housing0 +0.022 --0.013 -

-0.015 -0.013 0.037

13 clutch bearing housing (F) 130 -Clearance between 3rd, 4th

and housing0 +0.026 -0.014 -

-0.018 -0.014 0.044

14 clutch bearing (R) and 90 -Clearance between 3rd, 4th

housing0 0 --0.013 -

-0.015 -0.015 0.037

STRUCTURE AND FUNCTION TRANSMISSION

40-10

TRANSMISSION (3/3)

STRUCTURE AND FUNCTION TRANSMISSION

40-11

Unit: mm

No. Check item Criteria Remedy

1 Clearance between output Shaft Holeshaft and bearing (F)

Standard Standard Clearancesize clearance limit

Tolerance

Replace

50 -+0.031 0 -0.043 - +0.015 -0.012 -0.015

2 90 -0.040 - 0 -Clearance between output 0 -0.015shaft bearing (F) and housing -0.015 -0.040

3 50 -Clearance between output +0.031 0 -0.043 - shaft and bearing (R) +0.015 -0.012 0.015

4 shaft bearing (R) and 90 -0.040 - 0 -Clearance between output

housing0 -0.015

-0.015 -0.040

5 90 -Clearance between output +0.170 +0.054 -0.170 - shaft oil seal (F) and housing +0.080 0 -0.026

6 90 -Clearance between output +0.170 +0.054 -0.170 - shaft oil seal (R) and housing +0.080 0 -0.026

7 0

Inside diameter of housingseal ring contact surface

Standard size Tolerance Repair limit

50 +0.05 0.05(Amount of wear)

Width of shaft seal ring grove 3.2 3.5+0.076

Width of seal ring 3.0 2.60-0.13

Thickness of seal ring 2.29 2.10-0.1

8 portion of coupling oil seal 65Outside diameter of sliding

(F)0 0.05

-0.074 (Amount of wear)

9 portion of coupling oil seal 65Outside diameter of sliding

(R)0 0.05

-0.074 (Amount of wear)

10 Clearance between parkingbrake housing and case

Standard size Standard clearance clearance limit

0.85 0.02 - 1.68 -

11 0.10 - 1.0 Nm (0.01 - 0.10 kgm)Free rotation torque of output Adjustshaft shim

STRUCTURE AND FUNCTION TRANSMISSION

40-12

RE

VE

RS

E1S

T

REVERSE, 1ST CLUTCH

Unit: mm

No. Check item Criteria Remedy

1 between pistonClearance

and cylinder

Standard Standard Clearancesize clearance limit

Tolerance

Replace2 between piston

Shaft Hole

Inside 85 0.24+0.102 +0.28 0.048 --0.090 +0.15 0.19

Outside 118 0.53-0.35 +0.08 0.30 --0.040 -0.05 0.48

Clearance

and cylinder

Inside 85 0.24+0.102 +0.28 0.048 -+0.090 +0.15 0.19

Outside 140 0.53-030 +0.13 0.048 --0.35 0 0.19

3 fitting portion of REVERSE 50 -Clearance at bearing press

clutch shaft+0.025 0 -0.009 -+0.009 -0.012 -0.037

4 fitting portion of 1st clutch 50 -Clearancet bearing press

shaft+0.025 0 -0.009 -+0.009 -0.012 -0.037

5 fitting portion of REVERSE, 51 -Clearance at spacer press

1st clutch shaft+0.025 0 -0.055 -+0.009 -0.012 -0.009

STRUCTURE AND FUNCTION TRANSMISSION

40-13

Unit: mm

No. Check item Criteria Remedy

6 1.8 ± 0.06 1.7Thickness of seperator plate

Standard size Tolerance Repair limit

Replace

Distortion of separator plate - 0.05 0.15

7Thickness of friction plate 3.0 2.65+0.05

-0.10

Distortion of friction plate - 0.07 0.14

8 Load of wave spring ± 902 N (± 92 kg) 731 N (74.5 kg) 902 N (92 kg)(Height: 2.975 mm)

9 5.0 ± 0.05 -Thickness of REVERSE, 1stclutch spacer

10 3.0 ± 0.1 2.7Thickness of REVERSE, 1stclutch thrust washer

11 End play of REVERSE gear 0.07 - 0.93

12 End play of 1st gear 0.04 - 1.16

STRUCTURE AND FUNCTION TRANSMISSION

40-14

FO

RW

AR

D2N

D

FORWARD , 2ND CLUTCH

Unit: mm

No. Check item Criteria Remedy

1Clearancebetweenpiston andcylinder

Standard Standard Clearancesize clearance limit

Tolerance

Replace

Shaft Hole

Inside 85 0.24+0.102 +0.28 0.048 - +0.090 +0.15 0.19

Outside 118 0.53-0.35 +0.08 0.30 - -0.40 -0.05 0.48

2 piston and

Clearancebetween

cylinder

Inside 85 0.24+0.102 +0.28 0.048 - +0.090 +0.15 0.19

Outside 140 0.53-0.30 +0.13 0.030 - -0.35 0 0.48

3 fitting portion of FORWARD 50 -Clearance at bearing press

clutch shaft+0.025 0 -0.037 - +0.009 -0.012 -0.009

4 fitting portion of 2nd clutch 50 -Clearance at bearing press

shaft+0.025 0 -0.037 - +0.009 0.012 -0.009

5 fitting portion of FORWARD, 51 -Clearance at spacer press

2nd clutch shaft+0.025 0 -0.055 - +0.009 -0.03 -0.009

STRUCTURE AND FUNCTION TRANSMISSION

40-15

Unit: mmNo. Check item Criteria Remedy

6 Thickness of FORWARD,2nd clutch thrust washer

Standard size Tolerance Repair limit

Replace

.03 ±0.1 2.7

7Thickness of separator plate 1.8 ±0.06 1.7

Distortion of separator plate - 0.05 0.15

8Thickness of friction plate 3.0 2.65+0.05

-0.10

Distortion of friction plate - 0.07 0.14

9 Load of wave spring ±90.2 N (±9.2 kg) 731 N (74.5 kg)902 N (92 kg)(Height: 2.975 mm)

10 5.0 ±0.05 -Thickness of FORWARD,2nd clutch spacer

11 0.07 - 0.93End play of FORWARDgear

12 End play of 2nd gear 0.04 - 1.16

STRUCTURE AND FUNCTION TRANSMISSION

40-16

3RD, 4TH CLUTCH

Unit: mm

No. Check item Criteria Remedy

1 Clearance betweenpiston and cylinder

Standard Standard Clearancesize clearance limit

Tolerance

Replace

Shaft Hole

Inside 85 +0.28 0.24+0.102 0.048 - +0.090 0.19

Outside 140 0.53-030 +0.13 0.30 - -0.35 0 0.48

2 of bearing press-fitting portion of 50 -Clearance at outside diameter

4th clutch shaft+0.025 0 -0.037 - +0.009 -0.012 -0.009

3 of bearing press-fitting portion of 60 -Clearance at outside diameter

3rd clutch shaft+0.030 0 -0.045 - +0.011 -0.015 -0.011

4 51 -Clearance at spacer press-fitting +0.025 0 -0.055 - portion of 4th clutch shaft +0.009 -0.03 -0.009

5 61 -Clearance at spacer press-fitting 0.030 0 -0.060 - portion of 3rd clutch shaft +0.011 -0.03 -0.011

6Thickness of separator plate

Standard size Tolerance Repair limit

1.8 ±0.06 1.7

Distortion of separator plate - 0.05 0.15

7Thickness of friction plate 3.0 2.65+0.05

-0.10

Distortion of friction plate - 0.07 0.14

8 Load of wave spring ±90.2 N (±9.2 kg) 731 N (74.5 kg)902 N (92 kg)(Height: 2.975 mm)

STRUCTURE AND FUNCTION TRANSMISSION

40-17

Unit: mm

No. Check item Criteria Remedy

9 washerThickness of 4th clutch thrust Standard size Clearance limitStandard

clearance

Replace

3.0 ±0.1 2.7

10 3.0 ±0.1 2.7Thickness of 3rd clutch thrustwasher

11 Thickness of 4th clutch spacer 5.0 ±0.05 -

12 Thickness of 3rd clutch spacer 5.0 ±0.05 -

13 End play of 4th gear 0.07 - 0.93

14 End play of 3rd gear 0.04 - 1.16

STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE

40-18

TRANSMISSION CONTROL VALVE

STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE

40-19

Unit: mm

No. Check item Criteria Remedy

1 Clearance between pilot valveand body

Standard Standard Clearancesize clearance limit

Tolerance

Replace

Shaft Hole

19 0.050-0.02 +0.013 0.020 --0.03 0 0.043

2 19 0.050Clearance between main -0.02 +0.013 0.020 -regulator valve and body -0.03 0 0.043

3 regulator valve and load 13.5 0.055Clearance between main

piston-0.02 +0.018 0.020 --0.03 0 0.048

4 19 0.050Clearance between priority -0.02 +0.013 0.020 -valve and body -0.03 0 0.043

5 12.5 0.055Clearance between priority -0.02 +0.018 0.020 -valve and load piston -0.03 0 0.048

6 28 0.044Clearance between quick -0.020 +0.013 0.020 -return valve and body -0.028 0 0.041

7 28 0.050Clearance between -0.02 +0.013 0.020 -modulation fill valve and body -0.03 0 0.043

8 modulation fill valve and 28 0.070Clearance between

sleeve-0.02 +0.033 0.040 --0.03 +0.020 0.066

9 modulation fill valve and 30 +0.025 0.100Clearance between +0.041

sleeve-0.04 0.065 --0.05 0.091

10 41 0.110Clearance between sleeve -0.050 +0.025 0.050 -and body -0.075 0 0.100

11 28 0.050Clearance between -0.02 +0.013 0.020 -accumulator valve and body -0.03 0 0.043

12 Main regulator valve spring 230 ± 11.5 N 207 N

Standard size Repair limit

Free Installedlength length Installed load Free length Installed load

82.55 62.6 79.3(23.46 ± 1.17 kg) (21.1 kg)

13 Priority valve spring 69.5 52.6 66.7254 ± 12.7 N 228 N(25.92 ± 1.30 kg) (23.3 kg)

14 Quick return valve spring 48.0 41.0 46.10.8 ± 0.04 N 0.7 N(0.08 ± 0.004 kg) (0.072 kg)

15 41.8 40.0 40.1Modulation fill valve spring 24.1 ± 1.2 N 21.7 N(inner) (2.46 ± 0.12 kg) (2.21 kg)

16 43.6 24.3 41.9Modulation fill valve spring 138 ± 7 N 125 N(outer) (14.07 ± 0.07 kg) (12.7 kg)

17 Accumulator spring (outer) 99.6 99.6 0 95.6 -

18 Accumulator spring (inner 1) 35.6 35.6 0 34.2 -

19 Accumulator spring (inner 2) 40.8 40.8 0 39.2 -

STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE

40-20

LOWER VALVE

Unit: mm

No. Check item Criteria Remedy

1 converter regulator valve -0.02 +0.013 0.020 -Clearance between torque

and body -0.03 0 0.043

Standar Standard Clearanced size clearance limit

Tolerance

Replace

Shaft Hole

19 0.050

2 19 0.050Clearance between F-R -0.02 +0.013 0.020 -selector spool and body -0.03 0 0.043

3 19 0.050Clearance between H-L -0.02 +0.013 0.020 -selector spool and body -0.03 0 0.043

4 19 0.050Clearance between range -0.02 +0.013 0.020 -selector spool and body -0.03 0 0.043

5 valve spring 70.3 66.1 (23.46 ± 1.17 67.5Torque converter regulator 55.7 ± 2.7 N

Standard size Repair limit

Free Installed Installedlength length loadInstalled load Free length

kg)50 N

(5.1 kg)

6 F-R selector spool spring 48.8 36 46.883.4 ± 4.2 N 75.5 N(8.5 ±0.43 kg) (7.7 kg)

7 48.0 36.7 (7.12 ± 0.036 46.1H-L range selector spool 62.8 Nreturn spring (6.4 kg)

69.8 ± 3.5 N

kg)

STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE

40-21

SOLENOID VALVE

Unit: mm

No. Check item Criteria Remedy

1 emergency manual spool ReplaceClearance between

and body

Standar Standard Clearanced size clearance limit

Tolerance

Shaft Hole

14 0.050-0.02 +0.013 0.020 --0.03 0 0.043

MAINTENANCE STANDARD ACCUMULATOR VALVE

40-22

ACCUMULATOR VALVE

Unit: mm

No. Check item Criteria Remedy

1 Clearance between piston -0.035 +0.025 0.035 -and body -0.045 0 0.070

Standard Standard Clearancesize clearance limit

Tolerance

Replace

Shaft Hole

32 0.08

2 FORWARD clutch 158 Naccumulator spring (16.1 kg)

Standard size Repair limit

Free Installed Installed Installedlength height load loadFree length

184.8 175 177.4 -

3 145 135 139.2 -1st clutch accumulator 78.8 Nspring (8.04 kg)

4 145 125 139+.2 -2nd clutch accumulator 157.9 Nspring (16.1 kg)

STRUCTURE AND FUNCTION DRIVE SHAFT

40-23

DRIVE SHAFT

STRUCTURE AND FUNCTION DRIVE SHAFT

40-24

MEMORANDA

MAINTENANCE STANDARD DIFFERENTIAL

40-25

DIFFERENTIAL (1/2)

Unit: mm

No. Check item Criteria Remedy

1 Bevel gear free rotating 1.2 -3.9 Nm (0.12 - 0.40 kgm)torque (7.8 - 25.5 N (0.8 - 2.6 kg)

Replace2 differential side bearing 0.085 - 1.295

Thickness of shim at

carrier (one side)

3 differential housing and 0.5 - 1.55Thickness of shim for

gauge assembly

4 Protrusion of pin 12

MAINTENANCE STANDARD DIFFERENTIAL

40-26

DIFFERENTIAL (2/2)

MAINTENANCE STANDARD DIFFERENTIAL

40-27

Unit: mm

No. Check item Criteria Remedy

1 differential sideClearance at

bearing

Standard Standard Clearancesize clearance limit

Tolerance

Replace

Shaft Hole

Outer 0 -0.024 0.059 -race -0.020 -0.059 -0.004105 -

Inner +0.051 0 -0.066 -race +0.032 -0.015 -0.03265 -

2 bearing and pinionClearance of

shaft gear end

Outer 0 -0.041 -0.076 -race -0.015 -0.076 -0.026110 -

Inner +0.039 0 -0.051 -race +0.025 -0.015 -0.02550 -

3 bearing and pinionClearance of

shaft coupling

Outer 0 -0.040 -0.75 -race -0.015 -0.075 -0.02590 -

Inner +0.037 0 -0.049 -race -0.026 -0.012 -0.02640 -

4 25.18 0.3Clearance between pinion -0.180 +0.02 0.16 -gear and spider -0.193 -0.02 0.213

5 differential housing 260.4 -Assembly portion of piston of

(housing and piston)-0.250 +0.05 0.20 --0.450 -0.05 0.50

6 bearing carrier 215.95 -Assembly portion of piston of

(piston, carrier)-0.250 +0.05 0.20 --0.450 -0.05 0.50

7 Backlash of bevel gear 0.15 - 0.030 Adjust

8 Backlash of differential gear 0.15 - 0.35

Replace

9 End play of pinion gear Max. 0.172

10 washer 1.55 ± 0.05 1.35Thickness of side gear

Standard size Tolerance Repair limit

11 8 -Wear of outside diameter of 0lock pin - 0.09

12 51.90 ± 0.025 -Height of spacer betweenpinion shaft bearings

13 150 149.6Outside diameter of axle - 0.043mount (rear differential) - 0.106

14 Axle mount (rear differential) 150 149.6- 0.043- 0.106

STRUCTURE AND FUNCTION FINAL DRIVE

40-28

FINAL DRIVE

STRUCTURE AND FUNCTION FINAL DRIVE

40-29

Unit: mm

No. Check item Criteria Remedy

1 Clearance between axle Shaft Holehousing and ring gear

Standard Standard Clearancesize clearance limit

Tolerance

Replace

276 -+0.100 +0.100 -0.100 -+0.030 0 0.07

2 Clearance of guide pin 12 -+0.025 +0.187 0.100 -+0.007 +0.125 0.180

3 housing bearingClearance at axle

press-fitted section

Outer +0.077 -0.038 -0.077 -race +0.052 0 -0.01412.661 -

Inner +0.050 -0.013 -0.050 -race +0.025 0 -0.01669.85 -

4 housing bearingClearance at axle

press-fitted section

Outer +0.025 -0.013 -0.076 -race 0 -0.051 -0.013127 -

Inner +0.063 +0.025 -0.063 -race +0.038 0 -0.01377.788 -

5 Axle shaft press-fitted section

Housing 130 - - -+0.0630

Shaft 93.5 - - --0-0.054

6 33.338 -Clearance between pinion gear +0.025 +0.013 -0.025 -bearing and shaft +0.013 0 0

7 End play of axle shaft Max. 0.98-

8 0.21 - 1.91Clearance between oil seal andhousing

MAINTENANCE STANDARD AXLE MOUNT

40-30

AXLE MOUNT

Unit: mm

No. Check item Criteria Remedy

1 Thickness of thrust plateStandard size Tolerance Repair limit

Replacesize clearance limit

12.2 ±0.1 +0.1-0.5

2 Clearance between hole and Shaft Holeshaft at front support end

Standard Standard ClearanceTolerance

150 --0.043 +0.550 0.093 --0.106 +0.050 0.656

3 150 -Clearance between hole and -0.043 +0.550 0.093 -shaft at rear support end -0.106 +0.050 0.656

4 0.2 (each) -Thickness of axle mountshim

DISASSEMBLY AND ASSEMBLY ADDITIONAL COUNTERWEIGHT

40-31

ADDITIONAL COUNTERWEIGHT

STRUCTURE AND FUNCTION CENTER HINGE PIN

40-32

CENTER HINGE PIN

STRUCTURE AND FUNCTION CENTER HINGE PIN

40-33

Unit: mm

No. Check item Criteria Remedy

1 hinge pin and rear frame -0.103 -0.05 0.153Clearance between upper -0.073 +0.05 0.023 -

Standard Standard Clearancesize clearance limit

Tolerance

Replace

Shaft Hole

66 -

2 50 -Clearance between upper -0.038 +0.100 0.038 - hinge pin and rear frame -0.068 0 0.168

3 50 -Clearance between upper -0.038 0 0.026 - hinge and bearing -0.068 -0.012 0.068

4 50 -Clearance between upper -0.038 +0.250 0.038 - hinge and spacer (top) -0.068 0 0.318

5 50 -Clearance between upper -0.038 +0.250 0.038 - hinge and spacer (bottom) -0.068 0 0.318

6 frame and upper hinge 105 -Clearance between front

bearing0 -0.02 -0.120 -

-0.015 -0.12 -0.005

7 69.85 0 - 0.11 -Clearance between lower -0.05 +0.05hinge pin and rear frame -0.06 -0.05

8 88.9 -Clearance between front 0 +0.05 -0.05 - frame and bearing -0.020 -0.05 0.07

9 69.85 -Clearance between bearing -0.050 +0.050 0.078 - and hinge pin -0.060 +0.028 0.113

10 surface of upper hingeWear of oil seal contact

spacer

Standard size Repair limit

63.45 0-0.20

11 23 ± 0.1Height (top), (bottom) ofupper hinge spacer

12 shims at upper hinge 1.3 0.1 - 0.2 -Clearance when adjusting

Standard size Standard clearance Clearance limit

Adjust

13 upper hinge and retainer 0.8 Max. 0.4 -Thickness of shim between

(rear frame portion)

MAINTENANCE STANDARD STEERING COLUMN

40-34

STEERING COLUMN

STRUCTURE AND FUNCTION STEERING CYLINDER MOUNT

40-35

STEERING CYLINDER MOUNT

Unit: mm

No. Check item Criteria Remedy

1 cylinder rod and frame -0.080 +0.080 0.222

Clearance between mountingpin and bushing atconnection of steering -0.050 +0.142 0.130 -

Standard Standard Clearancesize clearance limit

Tolerance

Replace

Shaft Hole

35 1.0

2 35 1.0Clearance between mountingpin and bushing at -0.050 +0.142 0.130 - connection of steering -0.080 +0.080 0.222cylinder bottom and frame

3 Connection between steeringcylinder and front frame

Width of boss Width of hinge clearanceStandard

(clearance a + b)

45+ 0.80 48 ± 1.5 (after adjusting with

Max. 1.0

shim)

4 48 ± 1.0 (after adjusting withConnection between steering 45+ 0.8cylinder and rear frame 0

Max. 1.0

shim)

STRUCTURE AND FUNCTION PRIORITY VALVE

40-36

PRIORITY VALVE

Unit: mm

No. Check item Criteria Remedy

1 Return spring Replacelength height load length load

Standard size Repair limit

Free Installed Installed Free Installed

63.4 45 62 ± 1218.7 N 175 N(22.3 kg) 17.9 kg)

STRUCTURE AND FUNCTION BRAKE BOOSTER

40-37

BRAKE BOOSTER

Unit: mm

No. Check item Criteria Remedy

1 piston and body -0.064 0 0.126Clearance between primary -0.025 +0.062 0.025 -

Standar Standard Clearanced size clearance limit

Tolerance

Replace

Shaft Hole

33.34 0.15

2 secondary piston and body 0.064 0 0.126Clearance between 0.025 +0.062 0.025 -33.34 0.15

3 piston and body -0.106 0 0.180Clearance between power -0.060 +0.074 0.060 -70 0.20

4 85.3 N 85.3 ± 12.7 NPrimary piston spring (8.7 kg) (8.7 ± 1.3 kg)

Standard size Repair limit

Free Installed Installedlength height load Free length Installed load

57.1 35.1 -

5 Secondary piston spring 72.8 48.3 -129.4 N 129.4 ± 18.6(13.2 kg) (13.2 ± 1.9 kg)

6 Spring 199.2 86 -294 N 294 ± 44.1 N(30 kg) (30 ± 4.5 kg)

7 Spring 143.75 80.25 -196 N 196 ± 29.4 N(20 kg) (30 ± 4.5 kg)

8 Reaction spring 48 40 -98 N 98 ± 18.6 N(10 kg) (10 ± 1.9 kg)

MAINTENANCE STANDARD BRAKE

40-38

BRAKE

Unit: mm

No. Check item Criteria Remedy

1 Thickness of inner ring -0.05

Standard size Tolerance Repair limit

Replace

6.6 5.80

2 Thickness of lining 1.08 0.89 (min.) -

Thickness of brake disc 8.697 ± 0.063 7.4

Depth of lining groove 0.838 ± 0.2 0.4

3 Thickness of outer ring 19.5 ± 0.12 0.3

MAINTENANCE STANDARD PARKING BRAKE

40-39

PARKING BRAKE

Unit: mm

No. Check item Criteria Remedy

1 Plate Distortion - 0.1 0.1

Thickness 1.7 ± 0.05 1.6

Standard size Tolerance Repair limit

Replace

2 Brake disk thickness

Thickness 2.2 ± 0.08 1.97

Depth oflining 0.45 0.3groove

+0.1750

Lining 0.5 ± 0.075 -

3 Wave spring load (Height: 2.2 mm) ( ± 10 kg) (83 kg)1010 N (103 kg) ± 98 N 814 N

MAINTENANCE STANDARD HYDRAULIC PUMP

40-40

HYDRAULIC PUMP

MAINTENANCE STANDARD HYDRAULIC PUMP

40-41

MEMORANDA

MAINTENANCE STANDARD MAIN CONTROL VALVE

40-42

MAIN CONTROL VALVE2-SPOOL VALVE

MAINTENANCE STANDARD MAIN CONTROL VALVE

40-43

Unit: mm

No. Check item Criteria Remedy

1 259 N 207 N

Relief valve spring Replacelength length load

Standard size Repair limit

Free Installed Installed Free length Installed load

41.1 32.6 39.4(26.4 kg) (21.1 kg)

MAINTENANCE STANDARD MAIN CONTROL VALVE

40-44

3-spool valve

MAINTENANCE STANDARD MAIN CONTROL VALVE

40-45

Unit: mm

No. Check item Criteria Remedy

1 259 N 207 NRelief valve spring Replace(26.4 kg) (21.1 kg)

Standard size Repair limit

Free Installed Installedlength length load Free length Installed load

41.1 32.6 39.4

MAINTENANCE STANDARD HYDRAULIC CYLINDER

40-46

HYDRAULIC CYLINDER

Unit: mm

No. Check item Criteria Remedy

1 ReplaceClearance -0.030 +0.271 0.105 -between Boom -0.104 +0.075 0.375piston rodand bushing

Name of Standard Standard Clearancecylinder size clearance limit

Tolerance

Shaft Hole

70 0.675

Bucket -0.104 +0.075 0.37570 0.675-0.030 +0.271 0.105 -

Steering -0.087 +0.006 0.21940 0.519-0.025 +0.132 0.031 -

DISASSEMBLY AND ASSEMBLY MEMORANDA

40-47

MEMORANDA

STRUCTURE AND FUNCTION WORK EQUIPMENT LINKAGE

40-48

WORK EQUIPMENT LINKAGE

STRUCTURE AND FUNCTION WORK EQUIPMENT LINKAGE

40-49

Unit: mmNo. Check item Criteria Remedy

1

Clearance between pin andbushing at both ends of -0.025 +0.142 0.105 -bucket link -0.064 +0.080 0.206

Standard Standard Clearancepin dia. clearance limit

Tolerance

Replace(Replace also ifthere is scuffing

of pin)

Shaft Hole

50 1.0

2

Clearance between pin andbushing at connection of 50 1.0boom and bucket

-0.025 +0.142 0.105 --0.064 +0.080 0.206

3

Clearance between pin andbushing at connection of and 60 1.0boom and frame

-0.030 +0.142 0.110 --0.076 +0.080 0.218

4

Clearance between pin andbushing at connection of -0.030 +0.142 0.110 -bucket cylinder bottom and -0.076 +0.080 0.206frame

60 1.0

5

Clearance between pin andbushing at connection of -0.025 +0.142 0.105 -bucket cylinder rod and -0.076 +0.080 0.218bellcrank

50 1.0

6

Clearance between pin andbushing at connection of 65 1.0bellcrank and boom

-0.030 +0.174 0.130 --0.076 +0.100 0.250

7

Clearance between pin andbushing at connection of -0.030 +0.174 0.130 -boom cylinder bottom and -0.076 +0.100 0.250frame

60 1.0

8

Clearance between pin andbushing at connection of 60 1.0boom cylinder rod and boom

-0.030 +0.174 0.130 --0.076 +0.100 0.250

9Connection of boom and 83 +3

bucket 0

Width of boss Width of hinge Standard clearance(Clearance a + b)

Insert shims onboth sides so

that clearance isless than 0.5

mm on both leftand rightConnection of bellcrank and 83 +2.2

85 ± 1.8 1.2 - 7.8

10Connection of bucket link 83 +2.2and bucket -0.6 88 ± 1.5 1.3 - 7.1

11 bucket link -0.6 88 ± 1.5 0.7 - 4.5

12Connection of bellcrank andboom 200 ± 0.5 204 ± 1.5 2.0 - 6.0

13Connection of bucket 80 +0.8cylinder and frame 0 83 ± 1.5 0.7 - 4.5

Clearance lessConnection of boom cylinder 85 +0.8 88 +3than 1.5 mmand frame 0 014 2.2 - 6.0

15Connection of boom and 85 +1.8 88 +3frame 0 0 1.2 - 7.8

16Connection of boom and 85 +1.8 Clearance lessboom cylinder 0 than 2.0 mm89 ± 0.8 1.4 - 6.6

17Connection of bucket 85 +0.8cylinder and bellcrank 0 88 ± 09091.5 0.7 - 4.5 Replace

DISASSEMBLY AND ASSEMBLY BUCKET

40-50

BUCKET

Unit: mm

No. Check item Criteria Remedy

1 Wear of cutting edge 22 15.5

Standard size Repair limitReplace

DISASSEMBLY AND ASSEMBLY BUCKET POSITIONER AND BOOM KICK-OUT

40-51

BUCKET POSITIONER AND BOOM KICK-OUT

Unit: mm

No. Check item Criteria Remedy

1 switchClearance at bucket positioner

3 - 7 mm (There must be no interference)Adjust2 switch

Clearance at boom kick-out

3 guideClearance between lever and 0.5 - 2.0 mm

MAINTENANCE STANDARDS MEMORANDA

40-52

Komatsu America International Company440 North Fairway DriveVernon Hills, IL 60061-8112 U.S.A.Attn: Technical PublicationsFax No. (847) 970-4186

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PFMR1 081696