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SEBM006104

Shop
Manual

WA380=
SERIAL NUMBERS

VVA380-3 - 50001

andw

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

April 1998

Copyright

1998 Komatsu America

International

Company

No. of page

01

GENERAL . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..~.......

01-I

10

STRUCTURE

10-l

20

TESTING

30

DISASSEMBLY

40

MAINTENANCE

00-2
0

AND FUNCTfON

AND ADJUSTING

.. . . . .. . . . . . . . . . . . . . ..*..............*.

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

AND ASSEMBLY

STANDARD

20-I

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

30-l

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..n..........

40-l

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SAFETY NOTICE

SAFETY

SAFETY
SAFETY NOTICE

I

IMPORTANT SAFETY NOTICE
Proper service and repair is extremely

important for safe machine

service and repair techniques recommended

operation.

The

by Komatsu and described in this manual

are both effective and safe. Some of these techniques require the use of tools specially
designed by Komatsu for the specific purpose.
To prevent injury to workers, the symbol A
manual. The cautions accompanying

is used to mark safety precautions in this

these symbols should always be followed care-

fully. If any dangerous situation arises or may possibly arise, first consider safety, and
take the necessary actions to deal with the situation.

GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous.
Read the Operation and Maintenance Manual
carefully BEFORE operating the machine.
1. Before carrying out any greasing or repairs,

read all the precautions given on the decals
which are fixed to the machine.
2. When carrying out any operation, always
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons
missing.
. Always wear safety glasses when hitting
parts with a hammer.
. Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a
trained, experienced welder carry out the
work. When carrying out welding work, always wear welding gloves, apron, hand
shield, cap and other clothes suited for welding work.
4. When carrying out any operation with two
or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any
step of the operation. Before starting work,
hang UNDER REPAIR signs on the controls
in the operator’s compartment.
5. Keep all tools in good condition and learn
the correct way to use them.

6. Decide a place in the repair workshop to
keep tools and removed parts. Always keep
the tools and parts in their correct places.
Always keep the work area clean and make
sure that there is no dirt or oil on the floor.
Smoke only in the areas provided for smoking. Never smoke while working.

PREPARATIONS FOR WORK
Before adding oil or making any repairs,
park the machine on hard, level ground, and
block the wheels or tracks to prevent the
machine from moving.
Before starting work, lower blade, ripper,
bucket or any other work equipment to the
ground. If this is not possible, insert the
safety pin or use blocks to prevent the work
equipment from falling. In addition, be sure
to lock all the control levers and hang warning signs on them.
9. When disassembling or assembling, support
the machine with blocks, jacks or stands
before starting work.
10. Remove all mud and oil from the steps or
other places used to get on and off the machine. Always use the handrails, ladders or
steps when getting on or off the machine.
Never jump on or off the machine. If it is
impossible to use the handrails, ladders or
steps, use a stand to provide safe footing.

00-3

SAFETY

SAFETY NOTICE

19. Be sure to assemble ail parts again in their
11. When removing the oil filler cap, drain plug

or hydraulic pressure measuring
plugs,
loosen them slowly to prevent the oil from
spurting out.
Before disconnecting or removing components of the oil, water or air circuits, first
remove the pressure completely from the
circuit.
12. The water and oil in the circuits are hot
when the engine is stopped, so be careful
not to get burned.
Wait for the oil and water to cool before
carrying out any work on the oil or water
circuits.
13. Before starting work, remove the leads from
the battery. Always remove the lead from
the negative (-1 terminal first.
14. When raising heavy components, use a hoist
or crane.
Check that the wire rope, chains and hooks
are free from damage.
Always use lifting equipment which has
ample capacity.
Install the lifting equipment at the correct
places. Use a hoist or crane and operate
slowly to prevent the component from hitting any other part. Do not work with any
part still raised by the hoist or crane.
15. When removing covers which are under internal pressure or under pressure from a
spring, always leave two bolts in position
on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.
16. When removing components, be careful not
to break or damage the wiring. Damaged
wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil
from spilling out. If any fuel or oil drips onto
the floor, wipe it up immediately. Fuel or oil
on the floor can cause you to slip, or can
even start fires.
18. As a general rule, do not use gasoline to
wash parts. In particular, use only the minimum of gasoline when washing electrical
parts.

00-4

original places.
Replace any damaged parts with new parts.
. When installing hoses and wires, be sure
that they will not be damaged by contact
with other parts when the machine is being operated.
20. When installing high pressure hoses, make
sure that they are not twisted. Damaged
tubes are dangerous, so be extremely careful when installing tubes for high pressure
circuits. Also, check that connecting parts
are correctly installed.
21. When assembling or installing parts, always
use the specified tightening torques. When
installing protective parts such as guards,
or parts which vibrate violently or rotate at
high speed, be particularly careful to check
that they are installed correctly.
22. When aligning two holes, never insert your
fingers or hand. Be careful not to get your
fingers caught in a hole.
23. When measuring hydraulic pressure, check
that the measuring tool is correctly assembled before taking any measurements.
24. Take care when removing or installing the
tracks of track-type machines.
When removing the track, the track separates suddenly, so never let anyone stand at
either end of the track.

GENERAL

FOREWORD

FOREWORD
GENERAL
This shop manual has been prepared

as an aid to improve the quality of repairs by giving the

serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to full
effect at every opportunity.

This shop manual mainly contains the necessary technical information for operations performed in a
service workshop. For ease of understanding, the manual is divided into the following chapters; these
chapters are further divided into the each main group of components.

STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give
an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as
adjustments to be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling
assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement

standards when inspecting disassembled

or

parts.

NOTICE
The specifications
contained
in this shop manual are subject to change at any
time and without any advance notice. Use the specifications
given in the book
with the latest date.

00-5

HOW TO READ THE SHOP MANUAL

FOREWORD

HOW TO READ THE SHOP MANUAL
VOLUMES

REVISED EDlTlON MARK

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

When

Chassis volume: Issued for every machine model
Engine volume: Issued for each engine series
Each issued as one
Elecbbl
volume:
volume
to cover all
Attachments volume:
I
models
These various volumes are designed to avoid
duplicating the same information. Therefore, to
deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available.
DlSTRlBUTlON

AND UPDATlNG

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

a manual

(@@@....I
pages.

is revised,

an edition

is recorded on the bottom

mark
of the

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

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

FlLlNG METHOD
1. See the page number on the bottom of the
page. File the pages in correct order.
2. Following examples show how to read the
page number.
Example 1 (Chassis volume):

J
Special technical precautions

10 -3

Yz

Item number (70. Structure
and Function)
Consecutive page number for
each item.

Example 2 (Engine volume):

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

Tightening
torque

;I

coatpEgbJfF%fjf~y
Oil.

3. Additional pages: Additional pages are indicated by a hyphen (-1 and number after the
page number. File as in the example.
Example:
10-4

12-203

IO-5

12-204

00-6

:
w

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

Water

T-

Drain

must be added: and the ca-

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

HOISTING

FOREWORD

INSTRUCTIONS

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

.

If a part cannot be smoothly removed from
the machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening
the part to the relative parts.
2) Check for existence of another part causing interference with the part to be removed.

WIRE ROPES
1) Use adequate ropes depending on the
weight of parts to be hoisted, referring to
the table below:
Wire ropes
(Standard “Z” or “S’ twist ropes
without galvanizing)
Rope diameter

*

-r

Allowable

load

mm

kN

tons

10

9.8

1.0

11.2

13.7

1.4

12.5

15.7

1.6

74

21.6

2.2

16

27.5

2.8

18

35.3

3.6

20

43.1

4.4

22.4

54.9

5.6

30

98.1

10.0

40

176.5

18.0

50

274.6

28.0

60

392.2

40.0

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

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

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

100%

88%

f!f
79%

71%

41%
sADoo479

3) Do not sling a heavy load with one rope
alone, but sling with two or more ropes
symmetrically wound onto the load.
Slinging with one rope may cause
LL
turning of the load during hoisting,
untwisting of the rope, or slipping of
the rope from its original winding
position on the load, which can result in a dangerous accident.
4) Do not sling a heavy load with ropes forming a wide hanging angle from the hook.
When hoisting a load with two or more
ropes, the force subjected to each rope
will increase with the hanging angles. The
table below shows the variation of allowable load kN {kg) when hoisting is made
with two ropes, each of which is allowed
to sling up to 9.8 kN (1000 kg] vertically,
at various hanging angles.
When two ropes sling a load vertically, up
to 19.6 kN 12000 kg} of total weight can be
suspended. This weight becomes 9.8 kN
11000 kg) when two ropes make a 120”
hanging angle. On the other hand, two
ropes are subjected to an excessive force
as large as 39.2 kN 14000 kg) if they sling
a 19.6 kN (2000 kg} load at a lifting angle
of 150”.
0
I3
&!
~~~~

30
Lifting

60
mole

90
(deoreel

120

150
SA0004e.0

00-7

COATING MATERIALS

FOREWORD

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

Category

<omatsu code
LT-IA

Part No.

Q’w

Container

790-I 29-9030

150 g

Tube

Main applications, features

1 Used to prevent rubber gaskets, rubber
cushions, and cock plug from coming out.

1 Used in places requiring an immediately
LT-1 B

790-I 29-9050

20 g

(2 pes.)

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

‘olyethylenc
container

8 Features: Resistance to heat and chemi‘olyethylenc
cals
container
1 Used for anti-loosening and sealant purpose for bolts and plugs.

LT-2

09940-00030

50 g

LT-3

790-129-9060
(Set of adhesive and
hardening
agent)

Adhesive:
1 kg
iardening
agent:
500 g

Can

LT-4

790-129-9040

250 g

‘olyethylen
container

Holtz
MH 705

790-126-9120

75 g

Tube

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

Adhesives

Three bond
1735

Aron-alpha
201

Loctite
646-50

LG-1

1 Used as sealant for machined holes.

* Used as heat-resisting sealant for repairing engine.

50 g

) Quick hardening type adhesive
‘olyethylenc 1 Cure time: within 5 sec. to 3 min.
- Used mainly for adhesion of metals, rubcontainer
bers, plastics and woods.

29

) Quick hardening type adhesive
D Quick cure type (max. strength after 30 min‘olyethylenc
utes)
container
* Used mainly for adhesion of rubbers, plastics and metals.

79A-129-9110

50 cc

9 Features: Resistance to heat, chemicals
‘olyethylenc m Used at joint portions subject to high temcontainer
peratures.

790-129-9010

200 g

790-129-9140

790-129-9130

Tube

) Used as adhesive or sealant for gaskets
and packing of power train case, etc.
Features: Resistance to heat
Used as sealant for flange surfaces and
bolts at high temperature locations, used
to prevent seizure.
9 Used as sealant for heat resistance gasket
for high temperature locations such as engine precombustion
chamber, exhaust
pipe, etc.
l

l

Gasket
sealant

00-8

LG3

790-129-9070

1 kg

Can

COATING

FOREWORD

Category

Komatsu code

Part No.

Container

Q’tv

Main applications, features
l

l

I

LG-4

790-129-9020

Tube

200 g

l

l

l

LG-5

~790-129-9060 1

1 kg

MATERIALS

/ p~$~;e/

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

‘.3b”,;;;;;raulic
piping_ plugs, elbows,
Used as sealant for tapered

Features: Silicon based, resistance to heat,
cold
Used as sealant for flange surface, tread.
9 Used as sealant for oil pan, final drive case,
etc.

l

Gasket
sealant

l

l

l

l

790-129-9090

l

Molybde_
num
disulphide
lubricant

L”-G

/ ogg40-ooo51 /

g

/

Can

/

09940-00040

200 g

G2-Ll

SYG2-4OOLI
SYG2-35OLI
SYG2-4OOLI-A
SYG2-160LI
SYGA-16OCNLI

GZ-CA

SYG2-400CA
SYG2-350CA
SYG2-4OOCA-A Various
SYG2-16OCA
SYGA-16OCNCA

Various

Molybdenum
disulphide
lubricant

SYG2-400M

400 g
(10 per
case)

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

l

l

General purpose type

Tube

Various

l

Grease

Used as heat-resisting sealant for repairing
engine.

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

l

LM-P

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

Various

l

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

Used for places with heavy load

Belows type

00-9

FOREWORD

STANDARD

TlGHTENlNG

TORQUE

STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUES OF BOLTS AND NUTS
Use these torques for metric bolts and nuts. (Always use torque wrench).
Thread diameter
of bolt

Width
across flats
I

I

mm

mm

Nm

6
8
10
12
14

10
13
17

13.2+1.4
31+3
66+7
113+10
177+19

1.35kO.15
3.2kO.3
6.7f0.7
11.5+1
18+2

z;

28.5+3
39f4
56+6
76F8.5
94.51 10.5

.

kw

16
18
20
22
24

30
32
36

279+30
382539
549f59
745&83
927+103

z
33
36
39

41
46
50
55
60

1320+140
172Otl90
2210+240
2750f290
3290f340

Thread diameter
of bolt

Width
across flats

mm

mm

Nm

kgm

6
8
10
12

10
13
14
27

7.85f1.95
18.6k4.9
40.2k5.9
82.35f7.85

0.8kO.2
1.9+0.5
4.1CO.6
8.4kO.8

135+_15
175+20
225+25
280&30
335f35

TlGHTENlNG TORQUE OF HOSE NUTS
Use these torques for hose nuts.
Nominal No.

Thread diameter

Width across flat

Tightening

torque

mm

mm

Nm

kgm

02
::

14
22
18

19
24
27

24.5k4.9
78.5k19.6
49k19.6

2.5kO.5
8&2
5-+2

05
06
10
12
14

24
30
33
36
42

32
36
41
46
55

137.3k29.4
176.5f29.4
196.1+49
245.2f 49
294.2f.49

14+3
18+3
20+5
25+5
30+5

TIGHTENING TORQUE OF SPLIT FLANGE BOLTS
Use these torques for split flange bolts.
Tightening torque

Thread diameter

Width across flat

mm

mm

Nm

kgm

10
12
16

14
17
22

65.7k6.8
112k9.8
279+29

6.7kO.7
11.5+1
28.5+3

00-10

,

STANDARD TIGHTENING

FOREWORD

TORQUE

TIGHTENING TORQUE OF O-RING BOSS CONNECTOR
Use these torques for O-ring boss connector
Nominal No.
02
03,04
05,06
10,12
14

Thread diameter

Width across flat

mm

mm

::
24
33
42

Tightening

torque

Nm

Varies depending on
type of connector.

kgm

34.3+ 4.9
93.1f9.8
142.lf 19.6
421.4k58.8
877.1k 132.3

3.5kO.5
9.5fl
14.5+2
43f6
89.5f13.5

TlGHTENlNG TORQUE OF O-RING BOSS CONNECTOR
Use these torques for O-ring boss connector
Nominal

No.

08
10
12
14
76
18
20
24
30
33
36
42
52

Tightenil

1 torque

Thread diameter

Width across fiat

mm

mm

Nm

kgm

8
10
12
14
16

14
17
19
22
24
27
30
32
32
-

7.35f 1.47
11.27kl.47
17.6421.96
22.54fl.96
29.4k4.9
39.2f 4.9
49f4.9
68.6f9.8
107.8+ 14.7
127.4k19.6
151.9k24.5
2>0.7+29.4
323.4144.1

0.75kO.15
1.15f0.15
1.8f.0.2
2.3kO.2
3kO.5
4kO.5
5+0.5
7+1
llk1.5
13+2
15.5k2.5
21.5k3
33+4.5

::
24
30
33
36
42
52

-I

36
-

TIGHTENING TORQUES OF FLARE NUT
Use these torques for O-ring boss connector
Thread diameter

Width across fiat

Tightening torque

mm

mm

Nm

kgm

14

19

24.5f 4.9

2.5kO.5

18
22

24
27

49+ 19.6
78.5f19.6

24
30

32
36

137.3k29.4
176.5k29.4

14f3
18f3

33
36
42

41
46
55

196.1+49
245.2+49
294.2F 49

20f5
25f5
30+5

5+2
8f2

00-l 1

FOREWORD

STANDARD TIGHTENING

TIGHTENING

TORQUE FOR 102 SERIES ENGINE (BOLT AND NUTS)

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

TIGHTENING

Tightening torque

mm

Nm

6
8
10
12

lo+2
24 + 4
43 + 6
77 zk 12

kgm
1.02
2.45
4.38
7.85

+
+
f
+

0.20
0.41
0.61
1.22

TORQUE FOR 102 SERIES ENGINE (EYE JOINTS)

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

Tightening torque

mm

Nm

6
8
10
12
14

8+2
lo+2
12&Z
24 k 4
36 + 5

kgm
0.81
1.02
1.22
2.45
3.67

f
+
*
f
+

0.20
0.20
0.20
0.41
0.51

TIGHTENING TORQUE FOR 102 SERIES ENGINE (TAPERED SCREWS)
Use these torques for inches tapered screws of 102 Series Engine.
Thread diameter
inches
l/ I6
l/8
l/4
3/8

112
314
1

00-12

Tightening torque
Nm
3&l
8+2
12 rt:2
15f2
24+4
36 f 5
60 f 9

kgm
0.31
0.81
I.22
1.53
2.45
3.67
6.12

+ 0.10
f 0.20
f 0.20
f 0.41
f 0.41
zk0.51
+ 0.92

TORQUE

CLASSIFICATION BY THICKNESS Applicable circuit 60 127 0.1 13.6 230 Starting BY COLOR AND CODE Charging Ground Starting Lighting Instrument Signal Other >ri_ Code W B B R Y G L narY Color White Black Black Red Yellow Green Blue BW RW YR GW LW Code WR - 2 Color White & Red i Black &White Red & White Yellow & Red Green & White-Blue & White 3 4 bciiary 5 /Code1 - Color - 6 - RL GL llow & White Green & Blue - 00-13 . This wire code table will help you understand WIRING DIAGRAMS.80 100 217 0.80 CLASSIFICATION Priority 1 63. Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.FOREWORD ELECTRIC WIRE CODE ELECTRIC WIRE CODE In the wiring diagrams. various colors and symbols are employed to indicate the thickness of wires.6 178 Starting 17.84 109.

276 0. so divide by to the left) to convert it to 55 mm.614 0.677 3.693 0.480 2.. (I) The number 550 does not appear in the table.402 60 2. then draw a perpendicular line down from 0.575 0..913 2..165 inches.543 3. 50 ..268 -3.717 3.142 1..346 3.. (2) Locate the number 5 in the row across the top.740 2..890 0.039 0. .536 1.008 ..858 2...622 3...07 1 3.362 2.512 0.953 3. Convert 550 mm into inches... take this as @I.307 3.638 3. .780 .. 55 mm = 2. Therefore..945 1..969 . For EXAMPLE .929 2.157 0.165 inches. (3) Take the point where the two lines cross as 0.504 3...906 1.795 70 3.433 0.. 2. so multiply point one place to the right) to return to the original value.118 0. 2.189 80 3..315 0._I .835 2.228 3.2. details of the method of using the Conversion Table.496 1..756 2..047 .827 1.669 1. .... (2) Carry out the same procedure as above to convert 55 mm (3) The original value (550 mm) was divided by 10..386 3.323 2.787 1.425 3. Method of using the Conversion Table to convert from millimeters to inches 1. Millimeters @-- 00-14 10 (move the decimal point one place to 2.. .874 3..457 1. Convert 55 mm into inches.354 0.032 3.260 1.283 2...220 1..339 1.079 0...850 0.654 0. take this as @.126 2.181 1..65 inches..2.150 3.110 3. 2.. (1) Locate the number 50 in the vertical column at the left side. .520 2.... . . then draw a horizontal line from @..992 3..866 1. to inches 1 mm = 0.709 1.063 1.03937 in 0 1 2 3 4 7 8 9 0 10 0 0. .087 .165 inches by 10 (move the decimal This gives 550 mm = 21.748 1.583 90 .661 3.819 2.472 0.G . . see the example given below...465 3..CONVERSION TABLE FOREWORD CONVERSION TABLE METHOD OF USING THE CONVERSION TABLE The Conversion Table in this section is provided to enable simple conversion of figures. I. This point @ gives the value when converting from millimeters to inches..2.701 2..244 2.551 0.898 1.102 1.2.299 1.394 20 30 40 0.441 2.732 0.

638 2.78 182.10 143.30 48.614 1.929 50 1.CONVERSIONTABLE FOREWORD Millimeters to Inches mm = 0.94 163.84 IO 22.126 2.09 46.906 0.504 90 3.205 2.898 0 Kilogram to Pound 1 ka = 2.91 55.386 3.575 1.024 1.30 145.64 116.61 8.890 1.41 103.27 37.34 70.913 2.66 30.37 81.087 2.39 189.62 202.91 152.23 112.480 2.118 0. 0.14 68.323 60 2.98 40 88.047 2.008 2.35 167.819 3.69 138.858 3.244 2.661 3.24 209.268 3.071 3.05 121.28 134.00 99.48 39.44 114.82 108.80 97.32 156.732 1.18 90.220 1.32 59.283 2.20 4.142 30 1.378 1.16 79.48 136.433 0.39 92.276 0.86 33.181 1.2046 /‘I2 I 3 O \ 0 0 lb I5 16I7 I8 I g i4 2.236 0.98 185.14 165.709 0.96 174.57 180.850 1.93 30 66.811 1.26 I I I 1 t I I I I 00-15 .02 13.953 2.441 2.598 2.835 2.339 1.87 130.07 35.46 125.496 1.78 85.23 15.62 105.079 0.25 26.063 1.59 94.622 3.536 40 1.583 3.559 2.520 2.654 1.89 141.66 127.551 0.53 61.472 0.21 101.44 211.57 83.96 77.110 80 3.669 0.394 0.032 3.354 IO 0.866 0.748 20 0.228 3.89 20 44.71 149.417 1.75 74.969 2.41 6.03937 0 I 1 2 3 4 5 I 6 I 7 8 9 in 0 0.780 3.874 2.984 1.260 1.543 3.315 0.827 0.197 0.21 90 198.756 2.102 1.701 3.80 194.630.71 51.53 158.46 28.05 24.425 3.465 3.677 2.19 187.43 17.299 1.17 80 176.07 60 132.307 3.50 50.55 72.64 19.346 3.25 123.05 218.82 11.165 2.362 2.42 200.64 213.512 0.772 1.992 3.12 57.51 147.83 205.591 0.85 119.717 70 2.189 3.457 1.01 196.85 216.039 0.787 0.73 63.03 50 110.37 178.76 171.12 70 154.740 3.693 1.60 191.157 0.73 160.402 2.150 3.795 2.68 41.55 169.945 0.03 207.

K.619 4.320 1.170 3.549 19.982 9.658 11.257 18.520 3.839 5.037 18.209 13.2642 U.246 9.019 6.281 11.058 16.398 15.159 6.399 4.220 0.858 14.888 12.889 26.718 40 10.227 4.697 18.540 1.K.950 4.418 13.599 6.378 4.?98 11.925 8.677 20.738 14.756 19.115 16.278 16.040 24.435 17.438 11.660 0.740 3.907 17.944 14.264 0.279 5.819 7.624 11.21997 U.978 60 13.860 3.179 20 4.797 20.341 20.117 21.917 19.511 90 23.416 12.849 2.598 17.700 17.133 7.938 17.799 9.618 15.S.340 30 7.198 13.775 24.758 12.152 12.039 7.604 6.568 24.939 6.698 3.559 10.640 2.078 14.318 12.304 24.039 10.880 1.359 11.638 13.Gallon Y- 0 l! = 0.077 20.529 14.926 22.300 3.076 6.777 0 00-M .869 7.737 60 15.379 30 6.605 20.567 10.459 9.228 18.457 20.019 9.001 14.440 0.661 8.577 90 19.S.491 4.586 16.719 22.585 10 2.139 8.760 1.774 10.321 1.247 23.850 70 8 9 1.778 50 lo.FOREWORD CONVERSIONTABLE Liter to U.964 18.718 16.492 18.189 8.119 10.625 25.969 7.080 3.322 15.239 9.100 1. Gal 1 2 3 4 5 6 7 8 9 0 0.498 16.339 10.420 2.477 18.113 2.361 25.178 70 15.059 5.134 21.755 5.379' 16.137 19.171 17. Gal 1 2 3 0 0.528 0.378 80 17.528 12.265 14.259 7.283 5.963 20 5.813 20.958 15.899 10.793 1.980 70 2.510 9.397 7.518 14.190 22.237 20.643 16.557 21.812.359 8. 6.098 12.200 2.719 5.662 21.831 11.680 12.454 8.679 9.473 13.058 15.499 5.479 7.818 18.298 14.642 2.795 15.020 19.434 3.095 50 13.832 25.906 3.057 1.096 25.579 40 8.878 12.303 11.153 4 5 6 7 \ 0 titer to U.398 21.285 19.158 17.017 20.897 21.357 19.870 80 21.919 8.455 22.983 23. Gallon 0 le = 0.337 21.838 16.548 5.

6 1236. lb 6 7 36.1 1128.9 65.9 1121.4 170 1129.7 896.8 745.6 274.6 1330.9 253.9 1432.1 1345.1 383.2 976.3 513.5 209.0 846.0 1186.3 419.0 441.6 585.6 708.5 954.8 1244.7 120 868.5 1294.9 998.0 224.0 535.6 180.9 1092.2 354.1 40 289.0 347.5 549.4 390.2 477.3 1258.9 687.5 1265.1 1034.0 875.7 180 1301.9 282.2 1316.3 1135.8 188.8 1150.8 1273.1 817.9 810.2 759.5 860.7 462.2 137.8 60 434.0 190 1374.7 28.1 1287.4 672.6 491.1 1251.2 14.8 1056.3 636.0 658.6 303.7 556.6 1359.6 925.8 962.0 130.5 332.8 499.3 296.2 1070.5 1171.5 766.5 455.6 802.1 100 723.9 470.6 86.7 368.7 151.9 1 4 5 ft.3 730.0 752.4 484.9 1215.7 1424.8 30 217.2 231.5 1388.2 542.3 1352.3 824.7 90 651.8 716.2 1193.1 911.7 990.7 340.3 1041.8 933.7 123.2 1099.4 140 1012.8 622.0 318.9 1027.3 947.1 1222.9 1309.1 694.0 101.0 1280.1 70 506.4 1200.3 1381.7 679.4 1106.4 110 795.0 160 1157.9 1338.8 405.5 426.4 889.4 20 144.2 448.5 737.4 173.9 159.3 79.2 571.7 1396.2 882.2 665.2 1410.8 839.7 773.3 853.4 918.9 593.1 1439.5 1077.6 1142.0 629.5 643.4 267.7 150 1084.9 376.6 831.5 1048.233 0 2 3 7.2 260.4 50.5 115.4 00-17 .6 57.6 397.3 1164.9 904.1 8 9 \ 0 0 10 72.5 520.3 607.5 21.8 1367.2 788.4 1417.4 701.2 1005.3 202.7 245.CONVERSIONTABLE FOREWORD kgm to ft.1 166.3 325.0 1403.0 969.2 43.7 1207.4 50 361.5 238.1 130 940.9 564.1 412.1 600.6 1113.1 195.7 1179.4 1323.8 94. lb 1 kgm = 7.0 1063.8 528.8 311.6 1019.5 983.9 781.4 80 578.3 108.6 614.

1 213.2 60 853.7 825.4 739.4 70 995.0 839.3 796.4 611.2233 lb/in* 0 1 2 3 4 5 6 7 8 9 \ 0 0 14.0 270.3 668.1 341.9 199.3 412.5 810.7 56.4 227.4 483.2 981.1 782.FOREWORD CONVERSiONTABLE kg/cm*to lb/in* lkg/cm* = 14.0 398.2 725.4 355.2 20 284.5 298.6 113.6 753.2 597.0 967.3 99.9 50 711.8 640.7 953.7 184.4 867.7 696.4 42.6 497.8 256.7 440.8 384.5 554.5 682.3 914.6 1010 1024 1038 1053 1067 1081 1095 1109 1124 80 1138 1152 1166 118-I 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 'I906 1920 1934 1949 1963 1977 140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119 150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262 160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404 170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546 180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688 190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830 200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973 210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115 220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257 230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399 240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542 00-18 .9 455.6 625.2 156.1 910.9 327.0 526.5 30 426.6 369.8 768.1 469.7 40 568.6 881.2 28.7 312.9 71.1 654.5 938.9 583.8 896.8 128.5 170.1 85.8 512.0 10 142.3 540.6 241.

7 2 35.6 5.0 -13.1 97 206.4 -40 -40.0 79.9 120 248.6 -2.4 67 152.4 -2.7 98 208.6 31 87.8 32.2 1 33.2 45 113.0 -6.3 155 311.2 -17 1.1 34 93.2 -35 -31.0 -17.9 75 167.4 28.2 -6 17.4 6. degrees.0 0 32.4 73.6 2.6 13 55.0 -22.0 -11.2 9.6 16.6 -5 23.0 -9.8 27 80.7 170 338.0 4 39.9 -20 -4.2 72 161.0 -25.4 94 201.8 -6.2 -23.4 -21.CONVERSION FOREWORD TABLE Temperature Fahrenheit-Centigrade ture reading .8 5.8 -22.6 33.2 -20.3 56 132.6 57.2 -28.6 8.8 27.8 13.9 39 102.4 -5.0 23 73.8 -3.9 7 44.8 -27.7 145 293.3 8 46.2 62.0 -19.4 14.1 88 190.0 -12.3 -1 30.0 -18.2 90 194.6 69 156.3 47 116.2 23.8 73 163. degrees.8 54.4 130 266.9 66 150.1 43 109.4 3.6 -14 6.0 -13 8.8 -0.6 36.8 35.4 60.7 71 159.6 105 221.6 -27.6 87 168.3 110 230.1 30 86.10.2 28.2 48.4 33.4 17.2 28 82.1 12 53.4 24 75.0 -12.6 22.0 -11.0 66 186. 1°C = 33.3 38 100.4 -23.4 -7.4 31.6 22 71.6 71.2 -7. consider the center column as a table of Centigrade values.2 20.8 100 212.4 -3 26.2 76.9 16 60.6 -5.3 -19 -2.8 24.0 4.0 5 41.0 -16.4 175 347.8 -15.2 34. on the right.2 -1.7 -7 19.8 -9 15.9 57 134.9 46 118.0 65.0 -1.1 52 125.9 93 199.8 -37.2 10 50.8 21.1 115 239.0 32.4 0.4 -30 -22.1 21 69.1 160 320.2 26.0 50 122.8 68.7 125 257.6 78 172.3 17 62.4 -12 10.6 25.6 19.4 36.4 40 104.9 -11 12.0 41 105.2 -8.0 -18.8 -18 -0.0 95 203.6 30.4 85 785.4 25.8 -25.8 40.2 19 66.1 70 158.2 81 117.4 58 136.0 -28. consider the in the column center column as a table of Fahrenheit at the left.0 37.2 -26.6 -24.4 20. temperature reading in the center or boldface temperature to Fahrenheit temperature a Fahrenheit table into a Centigrade column tempera- of figures.0 -17.0 29.7 -25 -13.3 -10 14.6 -34.0 -3.0 140 284.6 33 91.2 1.8”F “C OF “C “F “C OF “F “C -40.6 13.2 3.6 51 123.0 1.4 8.0 -15.8 2.2 135 275.0 -14.1 -15 5.8 37 98.6 27.1 -6 21.2 63 145.0 -13.8 18.3 74 165.6 11.0 26.8 46 114.4 22.0 -20.4 49 120.2 31.7 44 111.8 7.0 7.0 10.9 -2 28.8 55 131.0 23.2 -4.4 46.7 29 84.7 11 51.4 6 42.8 .0 14 57.8 64 147.2 12.6 96 204.0 59 138.7 53 127.4 -26.7 20 68.2 37.3 26 78.0 35.0 77 170.8 30.1 61 141.6 43.4 11.6 0 32 89.0 21.2 6.6 60 140.8 91 195.0 51.8 18 64.7 80 176.2 99 210.2 36 96.7 -16 3.0 -10.3 65 149.6 ’ 00-l 9 .2 54 129.6 42 107.0 -10.0 -4 24.8 16.2 15.4 15 59.2 17.9 165 329.1 79 174.3 92 197. Conversion a simple way to convert or vice versa is to enter the accompanying These figures If it is desired temperatures refer to the temperature to convert from in either Fahrenheit and read the corresponding If it is desired to convert from Centigrade and read the corresponding Fahrenheit Fahrenheit to Centigrade Centigrade or Centigrade degrees.0 69 154.0 15.1 3 37.7 89 192.4 -31.9 25 77.0 18.6 150 302.4 76 168.9 84 183.0 12.4 -8.8 9 48.0 -16.3 83 181.8 82 179.7 62 143.7 35 95.6 -21.

............. Weight table ................................ OlOlOlOl- 2 4 7 9 01-l 0 .. Specifications ... List of lubricant and water ........................................01 GENERAL General assembly drawing ...........................................................

GENERAL GENERAL ASSEMBLY DRAWING GENERAL ASSEMBLY DRAWING Serial No.L) 08LZ 01-2 0 II= .L. 50001-52999 1.8) ‘392 W (.

53001 and up GENERAL ASSEMBLY DRAWING .GENERAL Serial No.

180 8.960 7.120 1.300) Gradeability deg 25 25 mm 5.85 (16.5 31.8 REVERSE 3rd km/h 21.5 Max.2 kN (kg) 48.2 20.395 3.120) FORWARD 1st km/h 7.750 7.475 5.925 Dumping reach (tip of BOC) mm 1.0 21. rimpull kN {kg) 159.965 Overall width (chassis) mm 2.475 Bucket capacity (piled) m3 3.455 Wheelbase mm 3.4 FORWARD 3rd km/h 20.0 REVERSE 4th km/h 32.160 Min.030 Dumping clearance (tip of BOC) mm 2.GENERAL SPECIFICATIONS SPECIFICATIONS Machine model WA380-3 Serial No.2 (5.200 Tread mm 2.4 7.850 2.1 3.4 REVERSE 2nd km/h 11.345 5.170 Bucket dump angle deg 49 49 Bucket tilt angle (SAE caning position) deg 48 50 Digging depth (IO0 dump) (with BOC) mm 340 345 Rated load Travel speed Mb:.960) 50.:“‘““8 Overall height 01-4 0 .905 2.2 FORWARD 4th km/h 31.440 Distribution (front) kg 7.430 Overall length mm 7.5 REVERSE 1st km/h 7.5 32. f 5000 l-52999 53001 and up Operating weight kg 16.370 6.965 Distribution (rear) kg 8.915 4.905 (top of ROPS cab) mm 3.64 (4.315 (Bucket raised) mm 5.8 11.200 3.475 mm 6.695 Bucket width (with BOC) mm 2. ground clearance mm 390 390 Height of bucket hinge pin mm 3.4 11.300) 159.140 16.1 FORWARD 2nd km/h 11.85 {16.1 7.160 2.695 2.

5 kW 24 V Alternator 12V Battery 35A 150Ahx2 3-element.bore x stroke Piston displacement 24 V Starting motor 7. semi-floating Tire 20. 6-cylinder.108 x 130 e {cd 7. l-stage. torque proportioning Final drive Planetary gear. wet-type disc brake 01-5 0 . single-phase (Komatsu TCA37-2A) Torque converter Spur gear. water-cooled. hydraulically actuated.500 Fuel consumption ratio g/kWh {g/HPhI 218 (162) High idling speed rpm 2.200 Maximum torque Nm IkgmYrpm 804 {821/l .15 {7.00 x 25-1.450 Low idling speed rpm 760 No.5-25-16PR (L3) Wheei rim 17. constant-mesh multiple-disc. 53001 and up Komatsu S6D108 Model 4-cycle. semi-floating Rear axle Center pin support type.51 - Front/rear wheel independent braking wet-type sealed disc brakes with hydraulic power-doubling device Main brake Parking brake I Thrust shaft (transmission shaft) braking. direct injection. of cylinders . modulation type Transmission Spiral bevel gear Reduction gear Differential Straight bevel gear.7TlL inflation pressure Front tire kPa {kg/cm*1 343 13. with turbocharger Type mm 6 .1501 Flywheel horsepower kW {HPYrpm 140 {1871/2.SPECIFICATIONS GENERAL WA380-3 Machine model I 50001-52999 Serial No.51 Rear tire kPa Ikg/cm*I 343 13. single reduction Drive type Front/rear-wheel drive Front axle Fixed-frame. in-line.

. 224+112+81+57 MPa kg/cm3 Spool type 20. .6 (2 101 Boom cylinder No.bore x stroke mm Reciprocating piston 1 .GENERAL SPECIFICATIONS T Machine model Serial No.180 x 503 Steering cylinder No.160 x 713 Bucket cylinder No.bore x stroke mm Reciprocating piston 2 . Type Structure 53001 and up Articulated tipe Gear type (SAL(3)100+50+36+(1)25) pump) Delivery (/min.6 (2101 MPa If@cm3 Spool type 20.80 x 442 Set pressure for work equipment Set pressure for steering Link type Bucket edge type 01-6 0 5000 l-52999 Fully hydraulically power steering Hydraulic pump type Wydraulic+Steering+Switch+F’PC WA380-3 I Single link Flat edge with BOC r? . .bore x stroke mm Reciprocating piston 2 .

583 Axle pivot Counten.52999 730 Boom cylinder (each) 165 Bucket cylinder I 166 54 Engine hood (with side panel) I 191 700 Front frame i 1. 50001-52999 Machine model Unit: kg I Serial No.veight Wheel (each) Fuel tank 179 Battery (each) 44 Hydraulic tank Hydraulic.52999 Serial No. PPC pump I I 1.020 1.GENERAL WEIGHT TABLE WEIGHT TABLE A This weight table is a guide for use when transporting or handling components. Serial No.406 25 Rear frame I 1. I WA380-3 50001 . Switch. Cab assembly I 670 Cab I 295 193 Air conditioner unit I 14 46 Operator’s seat 38 Main control valve 01-7 0 .199 22 Bucket link I 56 Bellcrank I 309 Boom (including bushing) I Bucket (with BOC) I I 164 1. Steering.170 Floor. Engine Radiator I Torque converter I Transmission I Center drive shaft I Front drive shaft I WA380’3 Machine model 50001 .

5300 1 and up Serial No. Switch.GENERAL WEIGHT TABLE Serial No. 53001 and up Unit: kg Machine model WA380-3 Machine model Serial No. Engine I Radiator 730 Bucket cylinder 165 Engine hood (with side panel) Torque converter Wheel (each) Battery (each) Main control valve Boom cylinder (each) 01-8 0 I 191 1.465 Bellcrank I WA380-3 Front frame Bucket link Tire (each) I I I 56 309 Floor.230 Boom (including bushing) Hydraulic. Cab assembly I 677 Floor freme assembly I 375 Air conditioner unit 14 46 Operator’s seat 38 71 ROPS canopy I 164 ROPS cab I 398 635 . PPC pump I Rear frame Rear drive shaft 207 53001 and up 1. Steering.

use only recommended oil as follows. See the Operation & Maintenance Manual. DONAX lT or TD SHELL: RPM TRACTOR HYDRAULIC FLUID CALTEX: CHEVRON: TRACTOR HYDRAULIC FLUID TEXACO: TDH OIL MOBILAND SUPER UNIVERSAL MOBIL: It is possible to substitute engine oil CLASS-CD SAE30 for axle oil.GENERAL LIST OF LUBRICANT AND WATER LIST OF LUBRICANT RESERVOIR KIND OF FLUID AND WATER AMBIENT TEMPERATURE -22 -4 -30 -20 14 -10 32 0 50 10 68 20 86 30 CAPACITY 104122'1 40 5OY Specified / Refill 31 e Engine oil pan 28 e -I- Engine oil 42 Q Transmission case 40 e I 190 L Hydraulic system Axle (Front and rear) (Each) See Note 138 e 1 Pins Grease =r Pins (with autogreasing system) Fuel tank Cooling system Diesel fuel Water 287 Q - 53 Q Add antifreeze I % ASTM D975 No. 1 *: NLGI No. If noise comes from the brake. Note 1: For axle oil. below 01-9 0 . 0 When operating a machine with the auto-greasing system (if equipped) at temperatures -2O”C. set the greasing time to 20 minutes. it is no problem of durability.

Change oil according to the following table if fuel sulphur content is above 0. Fuel sulphur content Change interval of oil in engin oil pan 0.5%.LIST OF LUBRICANT AND WATER GENERAL REMARK When fuel sulphur content is less than 0. sure to add single grade oil that matches the temperature in the table. ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers API: American Petroleum Institute 01-10 0 G 3 . CC. Use API classification CD as engine oil and if API classification interval to half. change oil in the oil pan every periodic maintenance hours described in this manual. but be We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment applications. Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.5%.0% l/Z of regular interval Above 1.0% I l/4 of regular interval When starting the engine in an atmospheric temperature of lower than O’C. Specified capacity: Total amount of oil including oil for components and oil in piping. even though an atmospheric temperature goes up to IO’C more or less in the day time. be sure to use engine oil of SAEIOW. 15W-401. SAElOW-30 and SAE15W-40.5 to 1. reduce the engine oil change There is no problem if single grade oil is mixed with multigrade oil :SAE!OW-30.

........ IOIO- 3 4 IO- 6 IO- 8 IO- 9 IOIOIOIOIOIOIOIOloIOIOIOloIO- IO 12 14 24 46 47 49 53 54 56 57 58 72 76 IO....... lo-792 Electric parking brake control .... lo-182 Kick-down switch ........................... Transmission hydraulic circuit diagram ................................................................... Parking brake solenoid valve .............................. Parking brake emergency release solenoid valve ................ transmission piping ............... ....................................77 IO...............S.............. Emergency steering pump ......... ......................... ..... IO-103 Work equipment hydraulic system diagram ............ Steering valve ..84 IO...82 IO................................... IO-180 Preheating circuit ............. Transmission hydraulic system diagram ................................................... IO-175 Engine starting circuit..................... .......................................................... Steering column ....................... IO-179 Engine stop circuit .................................................................. ............................................. 10-l 16 Main control valve ............................. Axle ....78 IO..................................................C.......... Accumulator charge valve.. ....... .... Parking brake.................................................... IO-110 PPC relief valve ....... 1 O-185 Kick-down electric circuit diagram ........................................................................ IO-194 10-101 10-l 0 ................................... center hinge pin ....................._.................................. ................................... Brake hydraulic circuit diagram................. 10-l 18 Work equipment linkage . IO-186 Transmission cut-off switch ................. Transmission control valve .......................................... Parking brake control.......... Torque converter............ IO-108 PPC valve ..95 IO.. IO-181 Electric transmission control.................................................. Diverter valve ..................... Torque converter. ............. . Axle mount... Drive shaft............................................ IO-134 Bucket ...... Final drive .............................................................. ... Brake piping ...98 IO.........................................83 IO........... Torque converter oil filter .......... IO-143 ROPS cab ............................... 1 O-137 Cab............. Power train system ................................ .............................................................. IO-107 Hydraulic tank...............99 IO-100 Hydraulic piping ..............................................89 lo............97 lo....................................... Brake ........... IO-136 Bucket positioner and boom kick-out........................10 3 2 3 STRUCTURE AND FUNCTION Power train ..S.. ...... Stop valve ...... IO-155 Main monitor ......... lo-156 Maintenance monitor.............................. ...................................................................................93 IO......................... IO-191 Transmission cut-off function ......................... Transmission ................... 10-l 43-2 Air conditioner..................................... IO-146 Machine monitor system ................. Orbit-roll valve.............................. Differential ..................................................................... 1 O-l 15 Accumulator (for PPC valve)......... ...................... IO-161 Work equipment control system ......................................... Steering piping .................................. IO-144 Electric circuit diagram ........ Brake valve ............................................... IO-105 Work equipment lever linkage.. ........ lo-164 E.......... ... IO-171 Sensors ................................ ........ Parking brake valve........... .................. 1 O-l 04 Work equipment hydraulic circuit diagram .................... Accumulator (for brake) .................................... ........................

Transmission 2. The transmission speed ranges are selected manually.POWER TRAIN STRUCTURE AND FUNCTION POWER TRAIN 1. and these provide four speed ranges for both FORWARD and REVERSE. 6. Front axle Front drive shaft Center drive shaft 7. Rear drive shaft Rear axle Outline l l The motive force from engine (3) passes through the engine flywheel and is transmitted to torque converter (21. l The motive force from the output shaft of the transmission passes through center drive shaft (61. The transmission has six hydraulically actuated clutches. 1o-3 . Engine (S6D108) 4. which is connetted to the input shaft of transmission (I). front drive shaft (5) and rear drive shaft (71. and is then transmitted to front axle (4) and rear axle (8) to drive the wheels. 5. 8. Torque converter 3.

STRUCTURE AND FUNCTION POWER TRAIN SYSTEM POWER TRAIN SYSTEM -8 20 8 -9 \ -10 5 0 n 1o-4 5 5 .

flange bearing (71. 4. and is then transmitted to the sun gear shaft through the differential mechanism. 9. 13. Front tire Final drive Wet type multiple disc brake Differential Front axle Front drive shaft Flange bearing Center drive shaft Parking brake Transmission Rear drive shaft Final drive Wet type multiple disc brake Differential Rear axle Rear tire Engine (S6D108) Torque converter Hydraulic. 6. The motive force transmitted to front axle (5) and rear axle (151 has its speed reduced by the bevel gear and pinion gear of differentials (4) and (141. and is transmitted to hydraulic. 5. 19. and front drive shaft (6). The motive force of the sun gear is rduced further by the planetary mechanism and is transmitted to the wheels through the axle shaft. steering switch. 3. 8. 14. 2. 7. The torque converter uses oil as a medium. 11. At the rear.STRUCTURE AND FUNCTION 1. 16. 10. 1o-5 . the power is transmitted to rear axle (15) through rear drive shaft (11). At the front. PPC Pump Torque converter charging pump POWER TRAIN SYSTEM Outline l l l l l The motive force from engine (17) passes through the flywheel and is transmitted to torque converter (I 8). 12. PPC Pump (19) and torque converter charging pump (20) to drive each pump. The transmission speed range is selected manually. and transmits the motive force to the input shaft of the transmission. 17. the motive force of the engine passes through the pump drive gear of the torque converter. In addition. It converts the transmitted torque in accordance with the change in the load. the power is transmitted to front axle (5) through center drive shaft (8). and actuates the six hydraulically actuated clutches to select one of the four FORWARD or REVERSE speeds. The output shaft of transmission (IO) transmits the power to the front and rear axles. steering switch. 15. 18. Transmission (IO) operates the directional spool and speed spool of the transmission valve through the solenoid valves. 20.

TRANSMISSION PIPING STRUCTURE AND FUNCTION TORQUE CONVERTER. Oil cooler 1 O-6 PIPING %woo422 5. 8. Radiator 4. Torque converter 3.TORQUE CONVERTER. 7. converter charging pump Transmission control valve Pilot oil filter Oil filter . TRANSMISSION 8 1. Transmission 2. Torque 6.

STRUCTURE AND FUNCTION TRANSMISSION (Engine 6 TRANSMISSION HYDRAULIC SYSTEM DIAGRAM stopped) rI J 1 I 14 I B 13 : - 1 O-8 HYDRAULIC SYSTEM DIAGRAM --A2 I I’ .

28. Accumulator 22. 12. Transmission case Strainer Hydraulic pump (SAL45+20) Oil filter Pilot reducing valve Modulation valve Quick return valve Maih relief valve Emergency manual spool Pilot oil filter Priority valve Solenoid valve (Ist. Parking brake valve valve 27. 2nd) 15. Solenoid valve (3rd.STRUCTURE AND FUNCTION TRANSMISSION TRANSMISSION HYDRAULIC HYDRAULIC CIRCUIT DIAGRAM CIRCUIT DIAGRAM P 22 23 I I O-23MPa p 24 p 25 J? i@= 26 t# 28 sLww424 1. 2nd) 16. 4th) 14. J. 32. H-L selector valve 19. 23. 2. 8. 27. Directional selector valve 20. 24. 30. 9. Solenoid valve (REVERSE. 29. ‘I 4. 6. 26. 4th) 13. Solenoid valve (FORWARD. 10. 31. 1st clutch 2nd clutch 3rd clutch 4th clutch REVERSE clutch FORWARD clutch Parking brake Torque converter Oil cooler Transmission lubrication Torque converter outlet valve 1o-9 . 5. 7. 25. 11. Solenoid valve (parking brake) 17. Range selector valve 18.

1 Stall torque ratio: 3. 3. 9. 2. Housing PTO gear (drive) Pump Output shaft (Transmission input shaft) Specifications Model: TCA37-2A Type: 3 element.TORQUE CONVERTER STRUCTURE AND FUNCTION TORQUE CONVERTER 1. 7. Turbine Drive case Stator Pilot Stator shaft 10-10 6.1 stage. 4. 5. 8.37 phase .

and enters the pump again. However. and transmits the energy of the oil to the turbine. part of the oil is sent from the stator through outlet port B to the cooler. so the motive force is transmitted to the transmission input shaft. Flow of oil The oil supplied from the torque converter charging pump enters inlet port A. The motive force of drive case (4) is used as the motive force to drive the gear pump through PTO gear (drive) (6). enters turbine (21. and PTO gear (drive) (6) are each secured by bolts and are rotated directly by the rotation of the engine. The motive force of pump (5) uses oil as a medium to rotate turbine (2) and transmit the motive force to transmission input shaft 2 l . pump (51.STRUCTURE AND FUNCTION TORQUE Path of motive force The torque converter is installed between the engine and the transmission. Turbine (2) is fixed to transmission input shaft (1 I). The oil from turbine (2) is sent to stator (31. The oil is given centrifugal force by pump (51. 5 CONVERTER 6 (11). Drive case (41. The motive force from the engine enters drive case (4) from flywheel. and flows to pump (5). l 8 10-l1 . passes through the oil passage of stator shaft (81.

If element (2) becomes clogged with dirt. Relief valve Element Center bolt Drain plug Specifications Filter mesh size: IO microns 8900 cm* Filtering area: Relief pressure: 0. the oil from inlet port A opens relief valve (I) and flows directly to outlet port B in order to prevent damage to the pump or element (2). It is filtered from the outside of element (2) to the inside. 3. 4. and flows to outlet port B.34 MPa (3. The oil from the torque converter charging pump enters filter inlet port A. 2. IO-12 SEW00015 B To Transmission control valve .5 kg/cm*) SEW00014 A - 0 To Transmission control valve Operation .TORQUE CONVERTER OIL FILTER STRUCTURE AND FUNCTION TORQUE CONVERTER OIL FILTER 1. or the oil temperature is low and the pressure rises at inlet port A. LLU lA_ .

STRUCTURE AND FUNCTION TRANSMISSION TRANSMISSION E4 A ---I .6 10-14 .

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3. b. 7. 3rd clutch 3rd gear Thrust washer Spacer 8 9 a 1st clutch oil port 3rd clutch oil port Lubrication oil port 2ND. 4th shaft 4th gear Thrust washer Idler gear 7 8 a. 9. c. 4. c. 4TH CLUTCH -1 1. 3rd shaft Idler gear 1st gear 1st clutch 5. 9 2nd clutch oil port 4th clutch oil port Lubrication oil port 10-17 . 9. 2 _ Idler gear 2nd gear 2nd clutch 2nd.TRANSMISSION STRUCTURE AND FUNCTION IST. 3RD CLUTCH 1 2 1. 5. 8. Ist. 8. 2. b. 4th cylinder 4th clutch 3 4 6. 7. 2. 5 6 7 a. 4. 3rd cylinder 3 4 6. Ist. 3. 5 6 2nd.

the oil at the rear face of the piston is drained by centrifugal force through oil drain hole (5). and goes to the rear face of piston (6) to actuate the piston. lo-18 5 6 7 4 1 . When not actuated . The oil sent from l l the transmission valve passes through the oil passage inside shaft (I). If the oil from the transmission l . When piston (6) is actuated. Oil is drained from oil drain hole (5) at this time. the pressure of the oil acting on the rear face of piston (6) drops. preventing the clutch from remaining partially engaged. so shaft (I) and clutch gear (4) are separated. separator plate (2) is pressed against clutch disc (3) and forms shaft (I) and clutch gear (4) into one unit to transmit the motive force.STRUCTURE AND FUNCTION TRANSMISSION Operation of clutch When operated . but this does not affect clutch operation since less oil is drained than supplied. valve is shut off. The piston is returned to its original position by wave spring (71. When the clutch is disengaged.

The motive force from the torque converter is transmitted from input shaft (9) via forward clutch (8) to forward gear (23). the motive force transmitted to 1st and 3rd cylinder gear (32) is transmitted from 1st gear (25) via the 1st clutch to 2nd and 4th cylinder gear (331. then transmitted to 1st and 3rd cylinder gear (32). then transmitted to output shaft (14) via 2nd and 4th shaft (171. clutch (20) are from the torque put shaft (9) is i l 1‘4 forward clutch (8) and 1st engaged. The clutch discs of forward clutch (8) and 1st clutch (20) are held by the hydraulic pressure applied to the piston. 10-19 .STRUCTURE AND FUNCTION TRANSMISSION 23 8 9 FORWARD 1ST 3k Operation . idler gear (31) and output gear (34). In forward Ist. SAW@3439 Since the 1st clutch is engaged. The motive force converter transmitted to intransmitted to output shaft (14).

clutch (18) are from the torque put shaft (9) is 14 forward clutch (8) and 2nd engaged. The clutch discs of forward clutch (8) and 2nd clutch (18) are held by the hydraulic pressure applied to the clutch piston. The motive force from the torque converter is transmitted from input shaft (9) via forward clutch (8) to forward gear (231. The motive force converter transmitted to intransmitted to output shaft (14). idler gear (31) and output gear (34). the motive force transmitted to the 2nd gear is transmitted from 2nd and 4th cylinder gear (33) via the 2nd clutch to output shaft (14) via 4th shaft (17). . Since the 2nd clutch (18) is engaged. then transmitted via 1st and 3rd cylinder gear (321.STRUCTURE AND FUNCTION TRANSMISSION FORWARD 2ND 34 Operation In forward 2nd. and idler gear (29) to 1O-20 SAWOWO 2nd gear (26). 1st and 3rd shaft (191.

. 10-21 . 14 forward clutch (8) and 3rd engaged. The motive force converter transmitted to intransmitted to output shaft (14). In forward 3rd. the motive force transmitted to 1st and 3rd cylinder gear (32) is transmitted from 3rd gear (27) via the 3rd clutch. idler gear (31) and output gear (34). SAW00441 Since 3rd clutch (11) is engaged. The clutch discs of foward clutch (8) and 3rd clutch (11) are held by the hydraulic pressure applied to the clutch piston. The motive force from the torque converter is transmitted from input shaft (9) via forward clutch (8) to foward gear (231.STRUCTURE AND FUNCTiON FORW‘ARD 3RD TRANSMISSION 8 \ ? \ I ? 32 ‘30 34 Operation . then to 1st and 3rd cylinder gear (32). clutch (11) are from the torque put shaft (9) is . then to output shaft (14) via 2nd and 4th shaft (171.

The motive force converter transmitted to intransmitted to output shaft (14). 1o-22 l Since the 4th clutch is engaged. .STRUCTURE AND FUNCTiON TRANSMISSION FORWARD 4TH 32 Operation In forward 4th. the motive force transmitted to the 4th gear is transmitted from 2nd and 4th cylinder gear (33) via the 4th clutch. then to output shaft (14) via 2nd and 4th shaft (171. idler gear (31) and output gear (34). then transmitted via 1st and 3rd cylinder gear (32) to 4th gear (28). The motive force from the torque converter is transmitted from input shaft (9) via forward clutch (8) to forward gear (231. clutch (12) are from the torque put shaft (9) is sAbvox42 forward clutch (8) and 4th engaged. The clutch discs of forward clutch (8) and 4th clutch (12) are held by the hydraulic pressure applied to the clutch piston.

1 O-23 . The direction of rotation is reversed by idler gear SAWCOW (211. In reverse Ist. The motive force from the torque converter is transmitted from input shaft (9) via reverse clutch (7) to reverse gear (24). The clutch discs of reverse clutch (7) and 1st clutch (20) are held by the hydraulic pressure applied to the piston. idler gear (31) and output gear (34). Since the 1st clutch is engaged. The motive force converter transmitted to intransmitted to output shaft (14).STRUCTURE AND FUNCTION REVERSE 1ST TRANSMISSION 24 7 \ \ 25 34 Operation . and the motive force is then transmitted to 1st and 3rd cylinder gear (32) via idler gear (29) and 1st and 3rd shaft (19). clutch (20) are from the torque put shaft (9) is l l 14 reverse clutch (7) and 1st engaged. the motive force transmitted to 1st and 3rd cylinder gear (32) is transmitted from 1st gear (25) via the 1st clutch to 2nd and 4th cylinder gear (331. then transmitted to output shaft (14) via the 2nd and 4th shaft.

An accumulator valve is installed to reduce time lag and shocks when shifting gears. and this oil actuates the clutch. H/L. parking brake circuit and clutch operation circuit. range and parking brake spools when the solenoids turn ON and OFF. b. 1. The oil is divided by the priority valve and passes into the pilot circuit. 4. f. The oil which flows into the parking brake circuit controls the parking brake release oil pressure through the parking brake valve. thereby reducing gearshifting shock. The oil which flows into the clutch operation circuit passes through the main relief valve. 5. 2. 1o-24 l . d. The modulation valve smoothly increases the clutch oil pressure when shifting gears by the action of the quick return valve and accumulator. C. spool h. Lower valve Upper valve Emergency manual Pilot oil filter Modulation valve 9. its pressure is regulated with the modulation valve.STRUCTURE AND FUNCTION TRANSMISSION TRANSMISSION CONTROL VALVE CONTROL VALVE a 9 b f SBWIXWA a. e. The oil released by the main relief valve is supplied to the torque converter. and this is the oil pressure which actuates the FORWARD/REVERSE. 3. The pressure of the oil which flows into the pilot circuit is regulated by the pilot pressure reducing valve. The priority valve controls the flow so that the oil flows with priority into the pilot circuit and parking brake circuit to keep the oil pressure constant. From pump To oil cooler Clutch oil pressure measurement port Main oil pressure measurement port Torque converter inlet port oil pressure measurement Pan Torque converter outlet port oil pressure measurement Pan Parking brake oil pressure measurement port (priority measurement port) Pilot oil pressure measurement port Outline l l l The oil from the pump passes through the oil filter and enters the transmission control valve. .

Torque converter outlet port valve Main relief valve Pilot reducing valve 1o-25 . Upper valve body Emergency manual Quick return valve 2. z36wcma 4.2 .STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE UPPER VALVE . 3. spool 5.3 4 A-A 1. 6.

Priority valve 9. 4th orifice 2nd orifice . 5.STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE LOWER VALVE i 1. 6. Solenoid valve (H-L selector) sAwowl a. 7. Solenoid valve (Parking brake) IO. Solenoid valve (FORWARD) Directional selector valve Lower valve body H-L selector valve Solenoid valve (REVERSE) Range selector valve Parking brake valve 1O-26 A-A 8. b. 4. 3rd. 2. Solenoid valve (Range selector) 11. 3.

The oil at a and b is blocked by solenoid valves (4) and (51. As a result. Solenoid valve ON When the speed lever is operated. activating the FORWARD/ REVERSE. For the parking brake solenoid valve. the pressure in the circuits at ports a and b drops. Operation 1. the oil from the pump flows to the 2nd clutch. As a result. 8 2 From pump 3 6 a- 2. H-L or range spool.STRUCTURE AND TRANSMISSION FUNCTION From pump TRANSMISSION CONTROL VALVE 2 SOLENOID VALVE Lower valve Function l When the gear shift lever is operated to move in forward or reverse. and the spools are moved to the left in the direction of the arrow by return springs (6) and (7). electric signals are sent to four solenoid valves mounted on the transmission valve. refer to the section “Parking Brake Solenoid Valve”. Actuation table for solenoid valve and clutch 0 : Current flows From pump SWW 1 O-27 . The oil at ports a and b of selector spools (2) and (3) flows from ports c and d to the drain circuit. Solenoid valve OFF The oil from pilot reducing valve (1) flows to ports a and b of H-L selector spool (2) and range selector spool (3). . Therefore. the oil . according to the combination of solenoid valves which are opened and closed. the drain ports of solenoid valves (4) and (5) open.at port e flows to the 4th clutch and switches from 2nd to 4th. so selector spools (2) and (3) are moved to the right in the direction of arrow.

range selector spool. For this reason.b of pilot reducing spool (11. This overcomes the tension of spring (4) and moves pilot reducing spool (1) to the right in the direction of the arrow. enters spools (2) and (3) in the lower valve.STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE From pump 2 PILOT REDUCING VALVE 4 / Lower valve Function The pilot reducing valve controls the pressure used to actuate the directional selector spool. l sBwoo451 From pump Frompump l When the pressure in the pilot circuit rises. and parking brake spool. the pressure at port c also rises. so the pressure at port c is maintained. Solenoid valve From pump 1 O-28 2 . l Operation The oil from the pump enters port a. port a at port b are shut off. passes through port . H-L selector spool. The oil at port b passes through the orifice and flows to port c. and fills the pilot circuit.

The main relief valve regulates the pressure of the oil flowing to the clutch circuit and distributes the oil flow between the clutch circuit and the torque converter.STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE MAIN RELIEF VALVE Function . the oil which has passed through main relief valve (I) orifices c and d presses poppet (Z). maintaining the pressure at the specified value. The oil from the pump passes through the priority valve. and flows to the clutch valve. moving main relief valve (1) to the right. To clutch To torqueconverter circuit % % From priority valve SBWL-Q45& Operation 1. The oil released from port E flows to the torque converter. and is released to port E. To clutch circuit To torqueconvert& From&iority valve SBWCO456 lo-29 . 2. 0 z! 4 If the pressure is above the specified value. then through ports A and B of until the main relief valve (1) specified pressure is reached.

TRANSMISSION STRUCTURE AND FUNCTION CONTROL VALVE TORQUE CONVERTER OUTLET PORT VALVE Function . When the pressure at port a rises. The oil at port a passes through the orifice From torque converter To cooler in spool (I) and flows to port c. spool (1) is moved further to the left in the direction of the arrow. Ooeration . This overcomes the tension of spring (2) and moves spool (I) to the left in the direction of the arrow to allow oil to flow from port a to port b. . and the oil flows from port a to port b and drain port d. (Cold relief) From torque converter To cooler SEW00060 1O-30 . From torque converter To cooler . the pressure at port c also rises. The torque converter outlet port valve is installed in the outlet line of the torque converter and adjusts the maximum pressure of the torque converter. If the pressure at port a becomes even higher.

The oil from the pump enters port a and separates into the oil flowing to parking brake valve (I). To main To pilot relief valve valve sAimJ458 Tor!!n ‘.pilot To relief valve valve s~w~)459 If the oil pressure at port c reaches a level above the measured value. priority valve (2) and the pilot circuit. . 2. priority valve (2) moves to the left and the oil flows to port d. protecting the hydraulic circuitry. the priority valve acts as a relief valve. 3. From pump + + To pilot To main relief valve valve sAwoo457 The oil at port a passes through priority valve (2) orifice b and flows to port c. priority valve (2) moves further to the left and is connected to the drain circuit from port e.STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE PRIORITY VALVE Functio’n The priority valve regulates the pump’s discharge pressure and provides the pilot oil pressure and parking brake release oil pressure. If the pressure in the circuit reaches a level above the measured oil pressure. 1 l Operation 1. 10-31 . releasing the pressure to protect the hydraulic circuitry. When the oil pressure at port c overcomes the force of return spring (31.

the quick return valve sends the pressure in the accumulator acting on the modulation valve spool momentarily to the drain circuit when the transmission is shifted. Operation 1. After engine is started.STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE QUICK RETURN VALVE Function To allow the modulation valve to raise the l clutch pressure smoothly. clutch completely engaged (clutch pressure at point A) (FORWARD I - I (Clutchfully engaged) 1st) or I 1st clutch 1 A T P 2nd clutch S Torque converter 3rd clutch Oil filter Accumulator 1 O-32 4th clutch SAW00460 .

and the oil in accumulator (8) is drained suddenly from port c. the oil pressure at port a of quick return valve (6) drops.4 REVERSE clutch e From accumulator + 7 B 6 H . and the oil at port b flows to port a. but while the oil is filling the inside of the clutch. 1o-33 . the oil from the pump flows to REVERSE clutch (5). Accumulator (8) is returned to the right end by the force of spring (9).STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE When switching from FORWARD to REVERSE (clutch pressure at point B) 9 1 3 or 2nd clutch S Torque converter 3rd clutch Oil filter 4th clutch FORWARD clutch . quick return valve (6) is moved to the left in the direction of the arrow by the accumulator oil pressure. At the same time. FORWARD solenoid (I) closes and REVERSE solenoid (2) opens. the clutch oil pressure drops. At the same time. check valve (7) opens. Directional spool (3) is moved to the right in the direction of the arrow and the oil at FORWARD clutch (4) is drained from the drain circuit. l ‘C SAWCO463 As a result. l When the directional lever is shifted from FORWARD to REVERSE.

STRUCTURE AND FUNCTION 3. Clutch pressure beginning pressure at point C) TRANSMISSION CONTROL VALVE to rise (clutch / m 2ndclutch roque converter Oil filter I Accumulator FORWARD clutch REVERSE clLltch Parking brake From accumcAstor l The oil from the pump fills the REVERSE clutch and the clutch circuit pressure starts to rise. the pressure at port a rises and quick return valve (6) is moved to the right in the direction of the arrow to close drain port c. As a result. 1o-34 + .

When this oil flows in. Because of the differential pressure created by modulation valve (ll). 10 To accumulator SAW00467 1o-35 . When the piston in accumulator (8) moves to the end of its stroke. so the accumulator pressure rises. . AND FUNCTION TRANSMISSION CONTROL VALVE Start of accumulator operation. the rise in the oil pressure at port d is completed and the specified pressure is maintained to completely engage the REVERSE clutch.STRUCTURE 4. The clutch oil pressure also rises because of this rise in the accumulator pressure. the oil passing through orifice (IO) of the quick return valve flows as a constant amount into accumulator (8). the accumulator moves to the left in the direction of the arrow and compresses spring (9). clutch completely engaged (clutch pressure at point DI : clutch 2nd clutch 3rd clutch 4th clutch FORWARD clutch RMRSE clutch Parking .

. Solenoid valves (4) and (5) are OFF and the drain port is closed.TRANSMISSION STRUCTURE AND FUNCTION CONTROL VALVE DIRECTIONAL SELECTOR VALVE Operation 1. solenoid valve (4) is switched ON and drain port d opens. and the oil at port c flows to port e and is supplied to the FORWARD clutch. Therefore. In this condition. When When this happens. P1 + spring force (1) = P2 + spring force (21. When at neutral l . From pilot reducing valve Accumulator FORWARD clutch e REVERSE clutch b pi 2 IFrom 1O-36 . From pilot reducing valve Accumulator 4 5 When at FORWARD the directional lever is placed at the FORWARD position. The oil which is filling port a is drained. the directional spool moves to the left. so PI + spring force (I) < P2+ spring force (2). The oil from the pilot circuit passes through the oil hole in the emergency manual spool and fills ports a and b of the directional spool. 2. the ‘oil at port c does not go to the FORWARD or REVERSE clutch. so the balance is maintained.

The oil in the clutch circuit passes from H-L selector spool (4) port a through range selector spool (5) port b and is supplied to the 2nd clutch. electric signals are sent to the solenoid valves paired with the H-L selector valve and range selector valve. 10-37 . l Operation 3rd clutch 2nd clutch 1stclutch 4th clutch From modulation valve From pilot valve SBWWA70 1. making it possible to select the speed (1st to 4th).STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE H-L SELECTOR VALVE AND RANGE SELECTOR VALVE . Function The H-L and range selector valves are operated according to the combination of the solenoid valves. l 2nd speed When solenoid valves (I) and (2) are OFF. When the gear shift lever is operated. The oil PI from the pilot circuit overcomes the force of the H-L selector spool (4) and range selector spool (5) springs (3) and moves spools (4) and (5) to the left. the drain port is closed.

and the oil in the clutch circuit passes from H-L selector spool (4) port c through range selector spool (5) port f and is supplied to the 3rd clutch. so H-L selector spool (4) and range selector spool 6) are moved to the right by the force of springs (3). . solenoid valve (1) is OFF. 1st and 3rd speeds For the 1st speed. solenoid valve (2) is ON. and the oil in the clutch circuit passes from H-L selector spool (4) port a through range selector spool (5) port e and is supplied to the 1st clutch. For the 3rd speed. 1 O-38 3. l . . the drain port is open. solenoid valve (2) is OFF.STRUCTURE AND FUNCTION TRANSMISSION 2ndclutch ‘. solenoid valve (1) is ON. The oil in the clutch circuit passes from H-L selector spool (4) port c through range selector spool (5) port d and is supplied to the 4th clutch./ 1 4 CONTROL VALVE 3rdclutch ’ itBI\ “+ c + From From blot valve modulationvalve swm471 2. 4th speed When solenoid valves (I) and (2) are ON. The oil from the pilot circuit passes through solenoid valves (I) and (2) and is drained.

The oil from the pilot valve passes through emergency manual spool (I). 3=f.VALVE EMERGENCY MANUAL SPOOL Function . . From pilot valve ARD clutch SBWW473 1o-39 . not into port “b”. the oil from the pilot valve passes through emergency manual spool (1) and flows only into directional spool (2) port “a”. the emergency manual spool actuates the forward and reverse clutches manually. directional spool (2) moves to the left. enters the lower valve directional spool (2) ports “a’ and “b” and is sealed by forward solenoid valve (4) and reverse solenoid valve (3). J 3- SBWCG472 2. This generates a pressure difference between ports “a” and “b”. When the emergency manual spool is actuated (to the forward side) When emergency manual spool (I) is pulled out. oil flows into the forward clutch and the clutch is engaged.B From pilot 553 &B valve 1 Operation 1. Should the electric system malfunction and the forward/reverse solenoid valves cannot be actuated. When the emergency manual spool is at neutral (during normal operation) .TRANSMISSION STRUCTURE AND FUNCTION CONTROL .

TRANSMISSION STRUCTURE AND FUNCTION MODULATION VALVE 1 2 3 A-A 1. 2. Valve body Fill valve Accumulator 1O-40 valve CONTROL VALVE . 3.

To clutch 10-41 . SAwoodM Quick rtum valve I Fill valve t From priority valve t Acc&wlator From torgue converter outlet valve sBww475 a 2. (Clutchfully engaged) Operation 1. and port d opens. I sec. l . At this time. The modulation valve consists of a fill valve and an accumulator. This causes. The diagram shows the clutch fully engaged (point A). When shifted from forward to reverse (point B) When the directional lever is switched from forward to reverse. so quick return valve (2) moves to the left. the oil in the accumulator to drain from quick return valve (2) port a. the pressure in chamber b and chamber c decreases. the force of spring (3) moves fill valve (41 to the left.STRUCTURE TRANSMISSION AND FUNCTION CONTROL VALVE Function . It controls the pressure and flow of the oil flowing to the clutch and increases the clutch pressure. the pressure of the clutch circuit decreases while oil is filling the reverse clutch.

. . Since pressure P2 increases by the amount of increase of pressure P4. Fill valve (4) moves to the right. shutting off port d and preventing the clutch pressure from rising suddenly. because of the relationship P2 = PI + P3 + P4 (the pressure at port f which varies according to the engine speed). the oil which has passed through port d passes through fill valve (4) and enters port b. Thus. AND FUNCTION Beginning of rise in clutch pressure (point C + point D) The pressure in the clutch circuit begins to rise when the oil from the priority valve fills the clutch piston. The pressure at the torque converter outlet changes according to the engine speed. pressure P2 changes by the same amount as pressure P4. it is possible to create oil pressure characteristics corresponding to the engine speed. while maintaining the relationship P2 = Pl + P3 (oil pressure equivalent to spring (3) tension). Quick return valve (2) moves to the right.STRUCTURE 3. This action is repeated. The oil at port d flows into the clutch circuit. and since P2 > PI + P3 it simultaneously passes through quick return valve (2) orifice e and flows into accumulator chamber c. and the clutch pressure gradually rises. Both pressures PI and P2 increase. the relationship between pressures Pl and P2 of the accumulator section is P2 > PI + P3 (oil pressure equivalent to spring (3) tension). 1 O-42 TRANSMISSION CONTROL VALVE To clutch From priority valve From torque converter outlet valve sBWGo477 f’ Pk * From priority valve From torque converter outlet valve DEW53478 . The pressure at the torque converter outlet is released to fill valve port f. At this time. When the quick return valve’s drain circuit closes. and the drain circuit in the accumulator is closed. and the pressure P2 of chamber b begins to rise.

2. 6. 1o-43 . and filters dirt from the oil flowing to the pilot circuit. Oil filter heat Element Case A. Inlet port Outlet port Specifications 170 cm* Filtering area: Filter mesh size: 105 p Outline l The pilot oil filter is mounted on the transmission lower valve.STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE PILOT OIL FILTER 1. 3.

the accumulator valve slowly reduces the oil pressure to the clutch that was first engaged in order to prevent loss of torque and to reduce the transmission shock when shifting gear.STRUCTURE AND TRANSMISSION FUNCTION CONTROL VALVE ACCUMULATOR VALVE 13 6 11 10 9 8 A-A 1. 2. 10. 13. H-L spool and range spool of the transmission control valve. 12. 5. 6. 7. there are throttles installed in the directional spool. 2nd clutch circuit. 8. 14. The accumulator valve is installed in the FORWARD. 3. 4. (To make it possible to reduce the oil pressure to the clutch slowly. Piston (1st clutch) Piston (FORWARD clutch) Piston (2nd clutch) Body Spring (2nd clutch) Stopper (2nd clutch) Spacer (2nd clutch) Spring (FORWARD clutch) Spacer (FORWARD clutch) Stopper (FORWARD clutch) Spacer (1st clutch) Spring (1st clutch) Cover Stopper (1st clutch) 10-44 Outline . 9. It temporarily stores the clutch oil pressure in order to allow gear shifting to be carried out smoothly without any time lag. When the transmission shifts gear.) . Ist. 11.

1st clutch oil pressure REVERSE clutch oil pressure. This makes it possible to reduce the loss of torque due to the reaction force to the product being handled. the R2 clutch is engaged. FORWARD clutch oil pressure. the Fl clutch is engaged. 2nd clutch oil pressure CONTROL VALVE 1st clutch oil pressure maintained so remains of torque a Tze SDWOOO40 Moving out after digging (Fl + R21 When the transmission is in Fl. it is possible to shift gear smoothly without losing the torque. oil pressure is stored in the accumulator for the FORWARD clutch and 1st clutch. In this way. oil pressure is. When the kick-down is operated. Shifting down when digging (kick-down F2 + Fl) When the transmission is in F2. and to move back smoothly without shock. 2nd clutch oil pressure 11 ? 2 Oil pressure maintained so torqe is lowered 0 k = g I U 0 SDW00041 1o-45 . stored in the 2nd clutch accumulator. but the oil pressure for the FORWARD clutch and 1st clutch is maintained in the accumulator. but the oil pressure in the accumulator is maintained for the 2nd clutch until the torque is transmitted to the 1st clutch. When shifting to R2 after completing digging operations.TRANSMISSION STRUCTURE AND FUNCTION Operation 1.

This enables the drive shaft to transmit the motive force when the machine is articulated and to protect the components from damage from shock when the machine is being operated or shock from the road surface when the machine is traveling. 4. The drive shaft has a universal joint and sliding joint to enable it to respond to changes in the angle and length. 1O-46 l The drive shaft has the following purpose in addition to simply transmitting the power. while the rest goes from center drive shaft (3) through flange bearing (2) and front drive shaft (I) to the front axle.motive force from the engine passes through the torque converter and the transmission. Some of it is transmitted from rear drive shaft (4) to the rear axle. 2.STRUCTURE AND FUNCTION DRIVE SHAFT DRIVE SHAFT 1. 3. The -. . Front drive shaft Flange bearing Center drive shaft Rear drive shaft Outline .

STRUCTURE AND FUNCTION AXLE AXLE FRONT AXLE /1 2 3 4 5 A-A 6 1. 3. 7. Oil 2. plug Coupling Differential Wet-type multi-disc Final drive Axle housing Axle shaft Drain plug supply port and level brake 1o-47 . 4. 6. 8. 5.

AXLE STRUCTURE AND FUNCTION REAR AXLE / 1 2 3 4 5 7 6 SAW03487 1. 5. 8. Oil A-A 1 O-48 2. supply port and plug Coupling Differential Wet-type multi-disc Final drive Axle housing Axle shaft Drain plug level brake . 3. 6. 7. 4.

4. 6. 3. 2. 5. Side gear (Teeth 12) Pinion gear (Teeth 9) Shaft Bevel gear (Teeth 41) Sun gear shaft Bevel pinion (Teeth 9) 1o-49 .STRUCTURE AND FUNCTION DIFFERENTIAL DIFFERENTIAL FRONT DIFFERENTIAL SAW00488 1.

’ Pinion gear (Teeth 9) 3.STRUCTURE AND FUNCTION REAR DIFFERENTIAL 1. 4. 6. Side gear (Teeth 12) 2. Shaft Bevel gear (Teeth 41) Sun gear shaft Bevel pinion (Teeth 9) 1O-50 DIFFERENTIAL . 5.

and the motive force of carrier (6) is transmitted equally to the left and right sun gear shafts (2) via the pinion gear (4) and side gear (3). so pinion gear (4) and side gear (3) in the differential assembly rotate according to the difference in the left and right rotation speeds. is transmitted from bevel pinion (I) to bevel gear (5). SEW00078 When slewing When slewing. and transmitted to the axle shaft and wheel. and transmitted to sun gear shaft (2) via pinion gear (4). so pinion gear (4) in the differential assembly does not rotate. the transmission and the propeller shaft. the motive force. l SEW00079 1O-51 . The motive force of the sun gear is further reduced by planetary gear-type final drive. and the motive force of carrier (6) is transmitted to the sun gear shafts (2). the speed of rotation of the left and right wheels is unequal. . l l SEW00077 E3 : 2 When moving straight forward * When moving straight forward. the speed of rotation of the left and right wheels is equal. In the axle.STRUCTURE AND FUNCTlON DIFFERENTIAL Outline The motive force from the engine is transmitted to the front and rear axles via the torque converter. shifted 90’ and reduced.

the tire life can be increased by 20 . . .DIFFERENTIAL STRUCTURE AND FUNCTION TORQUE PROPORTIONING DIFFERENTIAL Function . and the tires will not slip. the difference between the resistance from the road surface to the left and right tires is less than 38%). . so drive force will be given to both side gears. the ability to work as a loader is reduced. If the resistance from the road surface to the left and right wheels is the same. the distance between the pinion gear and the meshing point “a” of the left side gear becomes longer than the distance between the pinion gear and the meshing port “b” of the right side gear.30%. When traveling on soft ground (resistance from road surface to left and right tires is different) . . if the tires slip.38 (that is. and this changes the traction of the left and right tires. Because of the nature of their work. The torque proportioning differential is installed to overcome this problem. and at the same the operating efficiency is also increased. the distance between pinion gear (4) and meshing point “a” of left side gear (7) is the same as the distance between pinion gear (4) and meshing point “b” of right side gear (3). Because of the difference in the resistance from the road surface. but differential pinion gear (4) has an odd number of teeth. Ordinary differential SEW00080 Torque proportioning differential Operation When traveling straight (equal resistance from road surface to left and right tires) .axTL=bxTR The ratio between the distances to “a” and “b” can change to 1 : 1. In structure it resembles the differential of an automobile. The position is balanced as follows. Therefore when the ratio of the distances to “a” and “b” is less than 1 : 1. the position of meshing of pinion gear (4) and side gear (3) changes. 4-wheeldrive loaders have to work in places where the road surface is bad. 1 O-52 Spider rotating direction Spiden rotating direction t . and also the life of the tire is reduced. the pinion gear will not rotate freely. . Because of this effect. if the tire on one side slips. In such places. Therefore the left side traction TL and the right side traction TR are balanced. Because of this rotation. On soft ground. the meshing of pinion gear (4) and side gear changes.38. If left side gear (7) rotates slightly forward. the side gear of the tire on the side which has least resistance from the road surface tries to rotate forward.

2.FINAL DRIVE STRUCTURE AND FUNCTION FINAL DRIVE SAW00493 : 9 1 1. SAW00494 . . 4. The increased driving force is transmitted to the tires via planetary gear (2) and axle shaft l 2 (3). 3. 5. Planetary Planetary Axle shaft Ring gear Sun gear gear (Teeth 27) carrier (Teeth 72) shaft (Teeth 18) Outline As the final function the final drive operates to reduce the rotative speed of the motive force from the engine and increases the driving force. Ring gear (4) is press-fitted in the axle housing and fixed in place by a pin. increasing the driving force. . The motive force transmitted from the differential to the sun gear shaft (5) is reduced using a planetary gear mechanism.

AXLE MOUNT. 4. 5. CENTER HINGE PIN CENTER HINGE PIN 6 I A-A B-B sEwccl495 1o-54 1. 6. Front axle Rear axle Front frame Rear frame Upper hinge pin Lower hinge pin . 3. 2.STRUCTURE AND FUNCTION AXLE MOUNT.

STRUCTURE AND FUNCTION AXLE MOUNT. Front frame (3) and rear frame (4) are joined by hinge pins (5) and (6) through the bearings. 1o-55 . CENTER HINGE PIN . Rear axle (2) has a structure the which allows the center of rear frame (4) to float so that all the tires are in contact with the ground surface. the steering cylinders are connected to the left and right front and rear frames. and the angle of articulation of the frame (the turning angle) is adjusted according to the movement of the cylinders. even when traveling on soft ground. In addition. REAR AXLE . CENTER HINGE PIN c-c SLWO0496 FRONT AXLE . Front axle (1) is fixed directly to front frame (3) by tension bolts so that it receives force during operations directly.

STRUCTURE AND FUNCTION

STEERING PIPING

STEERING PIPING
6

1

sEw01220

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

Steering cylinder
Steering valve
Orbit-roll valve
Hydraulic pump
Hydraulic tank
Oil filter
Oil cooler
Stop valve

1O-56

STEERING COLUMN

STRUCTURE AND FUNCTION

STEERING COLUMN

3
=z-_-__
-..-_ ::.tJ
-Ii-

-__-_--------------__-_--__
- ---_---_
__ -_-_----__
--_----__-__ -*_-_________

1.
2.

3.
4.

Steering wheel
Steering column
Joint
Orbit-roll

1o-57

STEERING VALVE

STRUCTURE AND FUNCTION

STEERING VALVE

D-D

sLwo1zzz

1. Safety valve (with suction)
2. ‘Check valve
3. Steering spool
4. Relief valve
5. Demand spool

1 O-58

A: To steering cylinder
6: To steering cylinder
Pa: From orbit-roll
Pb:
From orbit-roll
PI: From steering pump
P2: From switch pump
PB:To main control valve
T: Drain (to oil cooler)

STEERING VALVE

STRUCTURE AND FUNCTION

OPERATION OF DEMAND VALVE
STEERING SPOOL AT NEUTRAL

To Orbit-roll
valve

+

C

To Orbit-roll
valve

+

To cut-off valve
(Main cotrol valve)

pump-1
I

.

.

.

I

I

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

l

,

sLw01223

When the pressure at pressure-receiving
chamber (I) reaches a certain value (set by
spring (511, notch (f) opens, and the oil from
the steering pump flows to the drain circuit.
At the same time ,notch (g) closes, and the
oil from the switch pump all flows to the
main control valve.

1o-59
0

STRUCTURE AND FUNCTION

STEERING VALVE

STEERING SPOOL OPERATED
.

Engine

at low speed

From Orbit-roll
valve
I)

_, To cut-off valve
(Main control valve)

SLwo1224

When steering spool (2) is pushed (operated), pressure-receiving
chamber
(II) and
the drain circuit are shut off, and at the same
time notch (c) opens.
When this happens, the pressure in pressure-receiving
chamber
(II) rises, and demand spool (I) moves to the right in the
direction of the arrow until notch (h) closes.
The passage from port B to the main control valve is shut off, so the oil from the
switch pump pushes up merge check valve
(3), and merges with the oil at port A from
the steering pump.

1 O-60
0

l

l

The merged oil passes through notch (cl and
notch (d), pushes up load check valve (41,
and flows to the cylinder. The oil returning
from the cylinder passes through notch (e)
and enters the drain circuit.
In this condition, the pressure before passing through notch (c) goes to pressure-receiving chamber
(I), and the pressure after
passing notch (c) goes to pressure-receiving
chamber
(II). Demand
spool (I) moves to
maintain the pressure difference on the two
sides of notch (c) at a constant value. Therefore, a flow corresponding
to the amount of
opening
notch (c) is discharged
from the
cylinder
port. These pressure
differences
(control pressure) are set by spring (5).

STRUCTURE AND FUNCTION

.

STEERING VALVE

Engine at high speed

From Orbit-roll
valve I,

Orbit-roll

valve

B
k

4

(Main control valve)

SLWO1225

.

.

The extra oil from the switch pump is not
needed, so the steering pump pressure rises
until notch (g) closes, and shuts off the
merge passage at port B.
The pressure difference on the two sides of
notch (c) is controlled only by notch (f), so
the excess oil from the steering
pump is
drained from notch (f) to the drain circuit
(when this happens, notch (g) is completely
closed).

.

.

The oil from the steering
pump passes
through notch (c) and notch (d), pushes up
load check valve (41, and flows to the cylinder. The oil returning
from the cylinder
passes through notch (e) and flows to the
drain circuit.
Notch (g) is closed, so the oil from the switch
pump is sent from port B to the main control valve.

1O-61
0

STRUCTURE

FLOW

AND

STEERING

FUNCTION

AMP

li
1.
2.
3.
4.

Steering spool
Valve housing (body)
Spring seat
Return spring

.

Operation of flow amp
Spool at neutral (Orbit-roll

1.

5.
6.
7.

A:
B:
c:

Cap
Capscrew
Flow amp notch

valve not actuated)

1

ki

From Orbit-roll valve
From Orbit-roll valve
Passage (inside housing)

4

Orbit-roll

/\

-

Relief
valve

I

I
sLwmz7

.

VALVE

When the Orbit-roil
valve is not actuated,
both pilot port PiA and pilot port PiB are
connected through the Orbit-roil to the drain
(return) circuit, so steering spool (I) is kept
at neutral by return spring (4).

I O-62

SLWO1226

STRUCTURE

2.

STEERING

AND FUNCTION

Spool actuated

(oil flows to port PiA)

B

1

4

Relief
valve

I

7

3

l

A

t

pump

l

VALVE

When oil flows to port PiA, the pressure inside the cap at end A rises and moves steering spool (1) in the direction of the arrow.
The oil entering
from port PiA passes
through the hole in spring seat (3), through
flow amp notch (7) in steering spool (I), and
then flows to the opposite end (B end).

l

l

sLwo1z28

Port PiB is connected
to the drain circuit
through the Orbit-roil valve, so the oil flowing to end B is drained.
The pressure generated
at port PiA is proportional to the amount of oil flowing in, so
steering spool (1) moves to a position where
the opening of the flow amp notch balances
the pressure generated with the force of return spring (4).

1O-63

STEERING VALVE

STRUCTURE AND FUNCTION

3.

Spool returning (steering
of oil to port PiA cut)

wheel

stopped,

flow

PiB

AA

r

1

stop valve

Stop valve

Ii
Orb&roll

.

When the steering wheel (Orbit-roll valve) is
stopped, ports PiA and PiB are both connected to the drain circuit through the Orbitroll valve.
For this reason, steering spool
(1) is returned to the neutral position by
return spring (4).

1O-64

STRUCTURE

AND

FUNCTION

STEERING

VALVE

OPERATION OF STEERING VALVE
NEUTRAL

_ To Orbit-roll

To Orb&roll
valve
*

valve

_

To cut-off valve
(Main control valve)

l

l

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

l

When the pressure at ports A and B rises,
demand spool (4) moves to the left in the
direction of the arrow.
The oil form the
steering pump passes through port C of the
spool and is drained. The oil form the switch
pump passes through port D and all flows
to the main control valve.

1O-65
0

STRUCTURE AND FUNCTION

TURNING

STEERING VALVE

RIGHT

c

From CkbJ;roll

To cut-off
valve
(Main control valve)

SLvm1231

.

When the steering wheel is turned to the
right, the pressure oil from the Orbit-roll
valve acts on steering spool (I), and steering spool (I) moves to the left in the direction of the arrow.
The oil from the steering pump enters port
A, passes through demand spool (2), and
flows to steering spool (I). It pushes open
load check valve (4) of the spool, and the oil
flows to the bottom end of the left cylinder
and the rod end of the right cylinder to turn
the machine to the right.

1O-66
0

The oil from the left and right cylinders
passes through load check valve (3) of the
steering spool, and is drained.
The oil from the switch pump enters port B,
flows through
demand
spool (21, pushes
open check valve (51, and merges with the
oil form the steering pump.

STRUCTURE AND FUNCTION

STEERING VALVE

TURNING LEFT

To Orbit-roll
valve

From

I)

To cut-off valve
(Main control valve)

sLw01232

l

When the steering wheel is turned to the
left, the pressure oil from the Orbit-roll valve
acts on steering spool (I), and steering spool
(1) moves to the right in the direction of the
arrow. The oil form the steering pump enters port A, passes through demand spool
(21, and flows to steering spool (I). It pushes
open load check valve (3) of the spool, and
the oil flows to the rod end of the left cylinder and the bottom end of the right cylinder
to turn the machine to the right.

The oil from the left and right cylinders
passes through load check valve (4) of the
steering spool, and is drained.
The oil from the switch pump enters port B,
flows through
demand
spool (21, pushes
open check valve (5). and merges with the
oil from the steering pump.

1O-67
0

STEERING VALVE

STRUCTURE AND FUNCTION

STEERING RELIEF VALVE
1.
2.
3.
4.
5.

SEWOOG97

Function
.
The steering

relief valve is inside the steering valve, and sets the maximum circuit pressure of the steering circuit when the steering valve is actuated.
When the steering
valve is being actuated, if the steering circuit goes above the set pressure of this valve,
oil is relieved from this valve. When the oil
is relieved, the flow control spool of the demand valve is actuated, and the oil is drained
to the steering circuit.

1O-68

Adjustment
screw
Spring
Plug
Pilot poppet
Valve seat

STEERING VALVE

STRUCTURE AND FUNCTION

OPERATION OF RELIEF VALVE

*To

From Orbit-roll r,
valve

When the pressure in the circuit rises, and it
reaches the pressure set by adjustment
screw
(I) and spring (2), pilot poppet (4) opens, and
the oil is drained.
When this happens, the balance in pressure between pressure-receiving
chamber (I) and pressure-receiving
chamber
(II) is lost, so demand
spool (6) moves to the left in the direction of the
arrow.

l

Orbit-roll
valve

When demand spool (6) moves, the oil
from the steering pump is drained, and
the oil from the switch pump is released
to the main control valve. This prevents
the pressure in the steering circuit from
going above the set value.

1O-69
0

STRUCTURE

AND

STEERING

FUNCTION

SAFETY VALVE (WITH SUCTION)

1.
2.
3.
4.
5.

Function
.
The overload relief valve is installed to the
steering valve. It has the following two functions: When the steering valve is at neutral,
if any shock is applied to the cylinder, and
an abnormal
pressure is generated,
the oil
is relieved from this valve. In this way, it
functions as a safety valve to prevent damage to the cylinder or hydraulic piping. On
the other hand, if negative pressure is generated at cylinder end, it functions as a suction valve to prevent a vacuum from forming.

d

Operation
Acting as relief valve
.
Port A is connected to the cylinder circuit
and port B is connected to the drain circuit.
Oil passes through the hole in poppet (I)
and acts on the different areas of diameters
dl and d2, so check valve poppet (3) and
relief valve poppet (2) are firmly seated in
position.
l

When the pressure at port A reaches the set
pressure of the relief valve, pilot poppet (4)
opens. The oil flows around pilot poppet (41,
passes through the drill hole, and flows to
port B.

1O-70

A
\

Poppet
Relief valve poppet
Check valve poppet
Pilot poppet
Spring

VALVE

STRUCTURE AND FUNCTION

.

When pilot poppet (4) opens, the pressure
at the back of poppet (I) drops, so poppet
I:i moves and is seated with pilot poppet

.

Compared with the pressure at port A, the
internal pressure is low, so relief valve poppet (2) opens. When this happens, the oil
flows from port A to port B, and prevents
any abnormal pressure from forming.

STEERING VALVE

SEW00095

Acting as suction valve
.
When negative pressure is formed at port A,
the difference in area of diameters d3 and d4
causes check valve poppet (3) to open. When
this happens, the oil from port B flows to
port A, and prevents any vacuum from forming.

d

SEW00096

1o-71

Stator 11. 7.ORBIT-ROLL VALVE STRUCTURE AND FUNCTION ORBIT-ROLL VALVE A-A 6 9 11 B-B SFbVOl234 1. Needle bearing Center spring Drive shaft Valve body 1 O-72 5. Rotor Cover Center pin Sleeve 9. 2. 3. Check valve . Lower cover 12. Spool 10. 4. 8. 6.

and the Girotor set (a combination of rotor (8) and stator (911. broadly speaking. and they are connected to the pump circuit. \. so it cannot be operated) when the steering pump or engine have failed and the supply of oil has stopped. and as a hand pump (in fact.center pin SBww718 1o-73 . and is connected to sleeve (5) by center pin (4) (it does not contact the spool when the steering wheel is at neutral) and centering spring (12). . The steering l valve is connected directly to the shaft of the steering wheel. which acts as a hydrauiic motor during normal steering operations. consists of the following components: rotary type spool (3) and sleeve (51. sswm715 + Connected to steering wheel shafi Groove for meshing with. the operating force of the steering wheel is too high. The top of drive shaft (6) is meshed with center pin (41. which have the function of selecting the direction.I Structure .STRUCTURE AND FUNCTION ORBIT-ROLL VALVE Outline . There are four ports in valve body (21. while the bottom of the drive shaft is meshed with the spline of rotor (8) of the Girotor. and forms one unit with sleeve (5). tank circuit. the oil can be sucked in directly from the tank by this check valve. to the drive shaft of the steering wheel. If the pump or engine fail. It switches the flow of oil from the steering pump to the left and right steering cylinders to determine the direction of travel of the machine. The pump port and tank port are connected by the check valve inside the body. and the circuits at the head end and bottom end of the steering cylinders. Spool (3) is directly connected . The steering valve.

ports 1. 2. . f. k. and are connected to ports i. j. In this case. and h. and k are connected by the vertical grooves in the spool to the pump side. In the condition in Fig. and I are connected to the head end of the left steering cylinder in the same way. d. g. 2. If the steering wheel is turned 90”. and are connected to ports d. and 3 are the suction ports. b. 6. and 7 are the discharge ports. so the oil is sent to the cylinder. ports 1. 1. c. 1o-74 SSWCO726 Suctiion / discharge port / SBWCO727 . f. 6. ports b. Ports 5. i. and 7 are connected and the oil flows in from the pump. the condition changes to the condition shown in Fig. At the same time. h. and c. The diagrams above show the connections with the sleeve ports used to connect the suction and discharge ports of the Girotor. and 3 are the discharge ports of the Girotor set. If the steering wheel has been turned to the right.STRUCTURE AND FUNCTION ORBIT-ROLL VALVE CONNECTION BETWEEN HAND PUMP AND SLEEVE SSWW725 . They are connected to ports I. 2. e. Ports 5. and d. ports a.

so no more oil is sent to the cylinder and the oil pressure rises. so the steering wheel returns to the NEUTRAL position. In this way. FUNCTION OF CENTER SPRING Centering spring (12) consists of four layers of leaf springs crossed to form an X shape. when the turning of the steering wheel is stopped. the inner teeth of the Girotor gear advance one position so the oil flow from the pump is adjusted by this movement. When the steering wheel is turned. the oil delivered from the pump is directly proportional to the amount the steering wheel is turned. the ports in the spool and sleeve are connected and oil is sent to the cylinder. the spring is compressed and a difference in rotation (angle variation) arises between the spool and the sleeve. To prevent this. The ports acting as suction ports are connected to the pump circuit. l ORBIT-ROLL VALVE AND FUNCTION In this way. the Girotor also stops turning. the action of the centering spring only allows it to turn by an amount equal to the difference in angle of rotation (angle variation) of the sleeve and spool. When the turning of the steering wheel is stopped.STRUCTURE . the ports of the Girotor acting as delivery ports are connected to ports which are connected to the end of the steering valve spool. The springs are assembled in spool (3) and sleeve (5) as shown in the diagram on the right. Because of this. l 2 2 5 fQ 4 +%Q$+ SDwo1236 3 5 + Angle Variation 12 SDWO123-l 1o-75 . Adjusting delivery in accordance with angle of steering wheel: For every l/7 turn of the steering wheel.

6. 5. Boot Wiper Seal -Poppet Spring Spool Spring 1O-76 A: From orbit-roll B: To steering valve DR: To drain . 3.STRUCTURE AND FUNCTION STOP VALVE STOP VALVE 1 2 3 4 5 6 7 Circuit diagram 1. 4. 7. 2.

5. 2.2 cc/rev 20. Direction of revolution: Theoretical delivery: . delivery pressure: l Possible to rotate both 40. Drive gear (Teeth 12) Front cover Gear case Rear cover Driven gear (Teeth 12) Specifications . Model: SUM(2)-050 .6 MPa (210 kg/cm? direction 1o-77 . 3. 4.STRUCTURE AND EMERGENCY EMERGENCY FUNCTION STEERING STEERING PUMP PUMP 6 A-A Z 1. Max.

SEW01240 From steering pump To steering valve To hydraulic tank Sensor mounting port Emergency pump port Emergency pump port From hydraulic tank . G. C. and it becomes impossible to steer. B. 1 O-78 A. F. Diverter valve Valve body Check valve Check valve FUNCTION . If the engine stops or the pump seizes during machine traveiing. D. E.STRUCTURE AND FUNCTION DIVERTER DIVERTER VALVE VALVE x-x 1. 2. 4. 3. the rotation of the transmission is used to turn the emergency steering pump to make steering possible.

so it pushes spool (3) in the direction of the arrow. Pump and engine are working normally. and the machine can be steered. steering pump. so oil from port A of the diverter valve pushes open check valve (2) and enters port B. the emergency steering pump is rotated by the transmission. ic tank To stewing cylinder 1o-79 Co . and switch pump are rotated by the engine.eerino CYI inder From steerino cylinder 4 Hvdraui .STRUCTURE AND FUNCTION DIVERTER VALVE OPERATION . oil is sent to the steering valve. the hydraulic pump. Therefore. To st. the oil from port B flows to port C and is drained to the hydraulic tank. Pressure oil from the steering pump is flowing to port D. When the steering pump and engine are working normally. As a result. In addition.

Ir The emergency steering pump is designed so that it can rotate both directions. As a result. The steering pump is not rotating. To steering cylinder Hydraulic From steering cylinder tank svwo2909 If there is a failure in the pump or engine when the machine is traveling. spool (3) is pushed in the direction of the arrow by spring (4). the rotation of the wheels is transmitted through the transfer to rotate the emergency steering pump.STRUCTURE AND FUNCTION DIVERTER VALVE Failure in pump or engine when machine is traveling. so no pressure oil is formed at port D. The oil from the emergency steering pump passes from port A through port B and flows to the steering valve to make steering possible. 1 O-80 0 Emergency steering pump .

STRUCTURE AND FUNCTION 1.valve. 10. actuates the piston. Front axle (with multi-disc Right brake valve Left brake valve Accumulator charge valve Hydraulic oil tank Accumulator Hydraulic pump (series of Accumulator Rear axle (with multi-disc Transmission valve Emergency parking brake 1 O-82 BRAKE PIPING brake) Outline . 6. 11. 8. the oil sent from the pump passes through the accumulator charge. When the brake valve is activated. shuts off the drain circuit in the valve. 2. four pumps) brake) valve . 3. 7. 5. 9. and activates the front and rear brakes. 4.

11. 8 1 Hydraulic pump (SAL (3) 100 + 50 + 36 + (I) 25) Work equipment pump Steering pump Switch pump PPC and brake pump Strainer Accumulator charge valve Safety relief valve PPC relief valve Check valve Low pressure switch -I 6. 15. 4. 2. 8. Parking brake emergency release switch 18. Parking brake switch 1 O-83 . ID. 9. 13. 12. 16. 3A. 7. Transmission pump 23. Parking brake solenoid 21. Parking brake pilot lamp switch 20.s_lc_. Parking brake 19. IB. 3B. 10. 3. Rear brake accumulator Front brake accumulator Emergency brake switch Left brake valve Transmission cut-off switch Right brake valve Pilot lamp switch Accumulator Rear brake cylinder Front brake cylinder Emergency parking brake valve 16A.STRUCTURE AND FUNCTION BRAKE HYDRAULIC BRAKE HYDRAULIC CIRCUIT DIAGRAM CIRCUIT DIAGRAM 6 22 \ 23 I From pilot circuit ---.Aly f I p 1 8 T IA IB 5 L 1. IA. ’ __-_I-_--- ----j r---. Parking brake valve 22. 5. IC. Parking brake emergency release solenoid 17. 14.

C. lo-84 9. E. right brake) Rod (right brake) Pilot piston (right brake) Spool (right brake) Upper cylinder (right brake) Spool (right brake) Lower cylinder (right brake) Rod (left brake) 2. D. 6.BRAKE VALVE STRUCTURE AND FUNCTION BRAKE VALVE BRAKE VALVE (RIGHT) 2 3 1. 4. 5. Pilot port (right brake) To rear brake (right brake) To front brake (right brake) Drain (left. right brake) To pilot port (left brake) . 3. Spool (left brake) 10. Brake pedal (left. 7. B. a. Cylinder (left brake) A.

oil is sent to the right pedal to apply the brakes in the same ‘way as when the right pedal is depressed.STRUCTURE AND FUNCTION BRAKE VALVE SRAKE VALVE !LEFT) 8 SDWOO108 Outline l l l There are two brake valves installed in parallel under the front of the operator’s cab. When the right pedal is depressed. In addition. 1O-85 . oil is sent to the brake cylinder to apply the brakes. the left brake pedal operates the transmission cut-off switch to actuate the transmission solenoid valve electrically and set the transmission to neutral. When the left pedal is depressed. and these are actuated by depressing the pedal.

When brake pedal (I) is depressed. l The oil entering pilot port PP enters port G from orifice d. drain port b is closed. and the oil from the pump and accumulator flows from port B to port D and actuates the front brake cylinders. and pushes piston (II). The spring pushes spool (3) down.STRUCTURE AND FUNCTION BRAKE VALVE Operation Brake applied (right brake valve) Upper portion l When brake pedal (1) is depressed. Lower portion . so the oil flowing to port F flows to pilot port PP of the right brake valve. and drain port c is closed. and the oil from the pump and accumulator flows from port A to port C and actuates the rear brake cylinders. When this happens. the operating force is transmitted to spool (3) through rod (2) and spring (4). so the operation is the same as when the right brake valve is depressed. When pedal (7) is depressed. spool (5) is also pushed down by plunger (6). drain port a is closed. Port F of the left brake valve and port PP of the right brake valve are connected by a hose. goes down. l z& Acbumulator )\\ *To. . When spool (3) goes down. The oil from the pump and the accumulator flows from port E to port F. From pump 6 B’ m ‘D Brake applied (left brake pedal) . spool (IO) is pushed up by rod (8) and spring (91.rear brake cyknder ~TO front brake From pump 1 O-86 l . Right brake 10 From DumD . When spool (3). the operating force is transmitted to spool (3) through rod (2) and spring (4).

and the pressure in the space in the lower portion is balanced with the pressure in the space in the upper portion. the effect of the brake can be adjusted by the amount that the pedal is depressed. Even if there is leakage of oil in the upper piping. Therefore. the upper portion is actuated normally. Even if there is leakage of oil in the lower piping. spool (5) is moved down mechanically when pedal (I) is depressed. the circuits between ports A and C and between ports Band D are fully opened. Drain port b is closed. From pump @ From pump @ To front brake sLwoc513 1 O-87 . l g z f Lower portion . Applying brake when lower valve fails (right brake valve) . and the lower portion is actuated normally. so the pressure in the circuit between port B and port D rises. It pushes up spool (3) and shuts off the circuit between port A and port C. When spool (3) in the upper portion moves up and the circuit between port A and port C is shut off. so the oil entering the brake cylinder is held. oil also fills the front brake cylinder at the same time. The pressure in the space in the upper portion is balanced with the operating force of the pedal. The upper brake is not actuated. and shuts off port B and port D. When spools (3) and (5) move to the end of their stroke. The oil entering port J from orifice f of spool (5) pushes up spool (5) by the same amount that spool (3) moves. When this happens. drain port a stays closed. so the pressure in the space in the upper and lower portions and the pressure in the left and right brake cylinders is the same as the pressure from the pump.STRUCTURE AND FUNCTION BRAKE VALVE Applying brake when upper valve fails (right brake valve1 . . the oil entering port H from orifice e of spool (3) pushes against spring (4). so the oil entering the brake cylinder is held and the brake remains applied. When actuation is balanced Upper portion When oil fills the rear brake cylinder and the pressure between port A and port C becomes high. up to the point where the piston moves to the end of its stroke. and the brake is applied.

1O-88 r c L v To rear brake cylinder - To front brake . At the same time. Drain port b is opened and the oil from the brake cylinder flows to the hydraulic tank return circuit to release the front brake. Lower portion .STRUCTURE AND BRAKE VALVE FUNCTION Brake released (right brake valve) Upper portion . When pedal (1) is released and the operat- ing force is removed from the top of the spool. Drain port a is opened and the oil from the brake cylinder flows to the hydraulic tank return circuit to release the rear brake. spool (3) in the upper portion moves up. When the pedal is released. the back pressure from the brake cylinder and the force of the spool return spring move spool (3) up. the back pressure from the brake cylinder and the force of the spool return spring move spool (3) up.

Drain Function The accumulator charge valve is actuated to maintain the oil pressure from the pump at the specified pressure and to store it in the accumulator. To brake valve PP. l l 1O-89 0 . the oil from the pump is connected to the drain circuit to reduce the load on the pump. To brake valve P. From pump T. When the oil pressure reaches the specified pressure.ACCUMULATOR STRUCTURE AND FUNCTION CHARGE VALVE ACCUMULATOR CHARGE VALVE Serial No. To PPC valve ACC.(oh PP ACC PP T A SDWMJ114 A. 50003-50034 .

5. 2. 3.STRUCTURE AND FUNCTION ACCUMULATOR A-A 1. c-c D-D Valve body Safety relief valve (R3) Relief valve (RI) PPC relief valve (R2) Relief valve (HI) E-E 1O-90 CHARGE VALVE . 4.

ACCUMULATOR STRUCTURE AND FUNCTION CHARGE VALVE Serial No. When the oil pressure reaches the specified pressure. 10-90-l 0 . 50035 and up 6 X ACC PP T A D-4 A. To brake valve P. To brake valve PP. the oil from the pump is connected to the drain circuit to reduce the load on the l l pump. From pump T. To PPC valve ACC. Drain SOW02804 Function The accumulator charge valve is actuated to maintain the oil pressure from the pump at the specified pressure and to store it in the accumulator.

Safety relief valve (R3) Relief valve (RI) PPC relief valve (Rz) Relief valve (HI) Filter 1O-90-2 0 SDWO2805 . 5. 6.STRUCTURE AND FUNCTION ACCUMULATOR CHARGE VALVE A-A D-D E-E 1. Valve body 2. 3. 4.

and flows from port A to the PPC valve. pushes spool (15) to the right at a low pressure equivalent to the load on spring (14). Front accumulator When oil is supplied to accumulator 1) Cut-in condition . . and the pressure at port P also rises in the same way. The oil from the pump enters port P. it also passes through orifices (17). Valve seat (7) and poppet (6) are brought into tight contact. case. When no oil is being supplied to accumulator (cut-out condition) l l 2. so piston (8) is forcibly pushed up by the oil pressure at port B. 50001 and up 1. The spring chamber at the right end of spool (15) is also shut off from port T. At the same time. and flows to the tank. In this. piston (8) is pushed back down by spring (5). The pressure at port B is higher than the set pressure of the relief valve (RI). When the pressure at port B is lower than the set pressure of the relief valve (Rl). it is decided by the size (area) of orifice (17) and the pressure difference (equivalent to the load on spring (14)) generated on both sides of the orifice. ront accumulator l P 17 15 SDWW117 10-91 0 . A fixed amount is supplied regardless of the engine speed. The spring chamber at the right end of spool (15) is connected to port C of the relief valve (RI). Poppet (6) is opened. so the pressure becomes the tank pressure. and the remaining oil flows to port A. so the pressure rises. the supply of oil to the accumulator starts immediately.STRUCTURE AND FUNCTION ACCUMULATOR CHARGE VALVE Operation Serial No. so port C and port T are short circuited. When the pressure at port P goes above the pressure at port B (accumulator pressure). and port C and port T are shut off. (18). and (16).

. poppet (61 is forcibly opened. . The pressure at port P drops in the same way to a pressure equivalent to the load on spring (141. and port C and port T are short circuited. . The spring chamber at the right end of spool (15) is connected to port C of the relief valve (RI). a pressure difference is generated above and below piston (81. When the pressure at port B (accumulator pressure) reaches the set pressure of the relief valve (RI). SDWOOl 18 3.STRUCTURE AND FUNCTION ACCUMULATOR 2) When cut-out pressure is reached . Safety relief valve (R3) If the pressure at port P (pump pressure) goes above the set pressure of the relief valve (R3). so the pressure becomes the tank pres- CHARGE VALVE Front accumulator sure. When the circuit is relieved. poppet (6) separates from valve seat (71. so an oil flow is generated and the circuit is relieved. the oil from the pump pushes spring (3). so piston (8) moves up. Front accumulator accumulator -p’ 1 O-92 SDWGOllS . . so this sets the maximum pressure in the brake circuit and protects the circuit. Ball (11) is pushed up and the oil flows to the tank circuit. so the supply of oil to port B is stopped.

Function . Specifications Gas used: Charge amount: Charging pressure: Nitrogen gas 3000 cc 3. Valve Top cover 3.5 kg/cm? (at 50°C) 10-93 .15 MPa (35 + 1. Piston 2. The accumulator is installed between the charge valve and the brake valve.4 + 0. Cylinder 4. It is charged with nitrogen gas between cylinder (3) and free piston (41. and uses the compressibility of the gas to absorb the pulse of the hydraulic pump or to maintain the braking force and to make it possible to operate the machine if the engine should stop.STRUCTURE AND FUNCTION ACCUMULATOR ACCUMULATOR (FOR BRAKE) (FOR BRAKE) 1.

ACCUMULATOR STRUCTURE AND FUNCTION 1. Nitrogen gas is injected between cylinder (I) and free piston (21. The accumulator is installed between the brake valve and brake cylinder.05 MPa (3 + 0. and its compression is used to maintain braking force operability when the engine is stopped. 1o-94 Specifications Gas used: Charge amount: Charging pressure: Nitrogen 45 cc gas 0. 4. (FOR BRAKE) Top cover Piston Cylinder End cover Plug SAww516 Function . 2. 3. 5.3 + 0.5 kg/cm*) (at 50°C) .

STRUCTURE 1 BRAKE 1. 1o-95 . and is coupled by the sun gear shaft’s spline. 5. 4. inner ring (31. l 4 5 6 Axle housing Sun gear shaft Spring Brake housing Bearing carrier Linings are provided on both sides of disc (4). IO. 8. disc (41. 7. 3. . 2. 2 3 6. The disc is incorporated between inner ring (3) and outer ring (51. outer ring (5) and spring (8). and consist of piston (2). BRAKE AND FUNCTION Differential Piston Inner ring Disc Outer ring housing Outline . 9. The brakes have a wet-type multi-disc strutture. The brake cylinder consists of differential housing (I) and bearing carrier (IO). and incorporates piston (2). Inner ring (3) and outer ring (5) are coupled by the brake housing (9) spline.

The linings attached to disc (4) are provided with latticed grooves. Therefore. a gap is produced between inner ring (3) and outer ring (51. oil flows in these grooves. 1O-96 - 5 8 4 3 2 . When l FUNCTION the brakes I are released When the oil pressure is released. and disc (4) is freed. piston (21 returns to its original position by the return force of spring (81. cooling the linings. When the disc is turning. disc (41. BRAKE are activated When the brake pedal is pressed. the oil which has passed from the hydraulic oil tank via the pump through the accumulator charge valve acts on the piston in the brake cylinder and piston (2) slides. stops rotating and the machine is braked. which is between inner ring (3) and outer ring (51.STRUCTURE AND Operation When the brakes l .

and uses the pushing force of a spring to apply the brake mechanically‘and hydraulic power to release the brake. Emergency release switch (2) for the parking brake is installed for use when moving the machine if the machine has stopped (the parking brake is automatically applied) because of trouble in the engine or drive system. It is installed to the output shaft bearing. the neutralizer relay shuts off the electric current to the transmission solenoid valve and keeps the transmission at neutral.PARKING BRAKE CONTROL STRUCTURE AND FUNCTION PARKING BRAKE CONTROL 1. parking brake solenoid valve (3) installed to transmission control valve (4) shuts off the oil pressure and applies the parking brake. When the parking brake is applied. When the parking brake switch is turned OFF. 5. 2. Transmission control valve Emergency parking brake valve Transmission (built-in parking brake) . Parking Parking Parking brake switch brake emergency release brake solenoid valve switch 4. When parking brake switch (1) installed in the operator’s compartment is switched ON. the oil pressure in the cylinder releases the parking brake. . 6. 3. 1o-97 . Outline l l The parking brake is a wet-type multipledisc brake built into the transmission.

PARKING BRAKE STRUCTURE AND FUNCTION PARKING BRAKE 7 1. It is a wet-type multi-disc brake which brakes the transmission’s output shaft . (4). 6 Parking brake manual release bolt Piston Spring Transmission output shaft Disc Plate Spring 1 O-98 4 5 Outline . . 7. 5. braking output shaft (41. 4. 2. The pushing force of spring (3) pushes piston (2) against disc (5) and plate (6). 3. The parking brake is activated mechanically by spring (3). 6.

and the oil in the pilot circuit from the transmission pump flows from the IN port to the OUT port and opens the drain circuit. 1o-99 . the solenoid valve is turned ON (electric current flows). A. l . l Operation Parking brake applied When the parking brake switch in the operator’s compartment is turned ON.STRUCTURE AND FUNCTION PARKING PARKING BRAKE SOLENOID BRAKE SOLENOID VALVE VALVE 1. Coil Valve assembly Body IN port OUT port SLvvmm Function This solenoid valve is controlled by the parking brake switch in the operator’s compartment and acts to switch the flow of oil to the parking brake. B. the solenoid valve is turned OFF (electric current is cut). 2. Parking brake released When the parking brake switch in the operator’s compartment is turned OFF. The valve closes and the flow of oil in the pilot circuit to the drain circuit is shut Off. 3.

. Parking brake released When the parking brake switch is turned OFF. solenoid valve (I) is turned OFF and the drain circuit is opened. 1o-1 00 PARKING BRAKE VALVE . . solenoid valve (I) is turned ON. and the drain circuit is closed. Operation 1. the transmission control valve and lower valve. so the oil from the main circuit flows from port b to port c to actuate the brake cylinder and release the parking brake. This shuts off the drain circuit of the brake cylinder.STRUCTURE AND FUNCTION PARKING BRAKE VALVE Function . Therefore. Parking brake applied When the parking brake switch is turned ON. and the oil in the brake cylinder flows to the drain circuit. it pushesagainst spring (3) and moves spool (2) to the right in the direction of the arrow. The oil in the main circuit is shut off by spool (2). l 2. and controls the parking brake cylinder. The oil in the pilot circuit from the pump then flows to drain circuit. When the oil pressure at port a rises. the parking brake is applied by the force of the spring (4) in the parking brake cylinder. .

If the engine breaks down and no oil pressure is supplied from the transmission pump. 2. To paking brake From paking brake valve 2 From brake circuit Operation . solenoid valve (2) is actuated and the pressure stored in accumulator (4) enters from port P. When parking brake emergency release switch (3) is turned ON. 10-101 . so the oil flows from port A to the parking brake to release the parking brake. This allows the accumulator charge pressure in the brake circuit to flow to the parking brake cylinder. The circuit is switched by the pilot pressure. VALVE Valve assembly Solenoid valve A: To parking brake B: From parking brake valve c: From pilot circuit T: Drain P: From brake (accumulator circuit) SLwoG525 Function l The emergency stalled between release the solenoid transmission valve is inand the From pilot circuit transmission control valve. it is possible to actuate the solenoid for the parking brake release switch in the operator’s compartment.STRUCTURE AND FUNCTION PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE PARKING BRAKE EMERGENCY RELEASE SOLENOID 1.

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6. 8.WORK EQUIPMENT STRUCTURE AND FUNCTION WORK EQUIPMENT 6 5 LEVER LINKAGE LEVER LINKAGE 7 8 SLwo1248 1. 2. 7. Solenoid valve for bucket lever Solenoid valve for boom lever Safety lever PPC valve 10-107 . Boom lever Kick-down switch Bucket lever Attachment lever 5. 4. 3.

5. In addition. the filter bypass valve is also activated when a vacuum is generated in the circuit. 6. and returns to hydraulic tank (6). Some of this oil is cooled by the oil cooler. flows into the tank.STRUCTURE AND FUNCTION HYDRAULIC TANK HYDRAULIC TANK 1. 3. . The oil sent to the cylinders from the hydraulic tank via the pump and through the work equipment control valve merges with the oil of the various parts in the return circuit. If the oil filter is clogged. 4. is filtered by oil filter (4). 2. Breather Filter bypass valve Oil filler Oil filter Sight gauge Hydraulic tank Outline . preventing the oil from returning directly to the tank and causing damage to the oil filter. lo-108 l Oil filter (4) is of a type which filters all the oil in the circuit. the filter bypass valve is activated.

26 kg/ cm2) @To main control vatve JJ SBWO3534 BREATHER .16 MPa (1. * Checking pressure: 0. Preventing negative pressure inside tank The tank is a pressurized sealed type. and air is let in to prevent negative pressure from forming inside the tank. so if the oil level inside the hydraulic tank goes down. Check valve set pressurei 0. Bypass valve set pressure: 0.125 MPa (1. 2.27 kg/ cm*) ~ From main control vah fe When negative pressure is formed in the return circuit. Valve (2) moves up and acts check valve. li Suction pressure: 3 KMPa (0. 3.03 kg/cm*) Preventing rise in pressure inside tank If the pressure in the circuit rises above the set pressure during operations because of the change in the oil level in the hydraulic cylinders or the rise in the temperature. Body Filter element Poppet Sleeve SEW00141 10-109 .025 MPa (0.STRUCTURE AND FUNCTION HYDRAULIC TANK OIL FILTER BYPASS VALVE When the filter is clogged Bypass valve (I) opens and the oil returns directry to the tank without passing through the filter. If this happens. the sleeve is actuated to release the pressure inside the hydraulic tank.6 kg/cm*) 1 2 4 1. a poppet is opened by the difference between the pressure inside the tank and the atmospheric pressure. . 4. there will be negative pressure in the tank.

To bucket cylinder bottom end P2. From PPC pump PI. Drain 10-l10 P3 P4 PI . To boom cylinder bottom end P4.PPC VALVE STRUCTURE AND FUNCTION PPC VALVE P2 P. To bucket cylinder head end T. To boom cylinder head end P3.

Body c-c SEW00143 spring spring 10-111 . 6. 5. 7. 2.PPC VALVE STRUCTURE AND FUNCTION ‘9 A-A 1. 8. Bolt Piston Plate Collar Retainer Centering Metering Valve 9. 4. 3.

STRUCTURE AND PPC VALVE FUNCTION OPERATION OF PPC VALVE To cylinder To tank PA1 \ To cylinder PBl t t t From pump - Function . so the oil is drained from relief valve (1). At the same time. the oil at port PAI of the main control valve is drained from port f of spool (8). the oil at port PBI is drained from port f of spool (8). In addition. The circuit is closed by spool (81. The oil :from the pump enters port P. 10-112 I .

so the pressure at port P4 escapes to drain chamber D. 1) Ports PAI. 2. so the pressure at port P4 also rises in proportion to the travel of the control lever. When this happens. The spool of the control valve ‘moves to a position where the pressure of port PA1 (same as pressure at port P4) and the force of the return spring of the control valve are balanced. When the pressure at port P4 rises. P4. Control lever operated slightly (fine control) (Fig. (Fig. 2) sEwco145 sEwoo146 10-113 . valve (8) is pushed back. Therefore. At almost the same time it is connected to drain chamber D. fine control hole (f) is shut off from drain chamber D. PBI and PI are connected to drain chamber D through fine control hole (f) in valve (8). Control lever at “hold” (Fig. Valve (8) moves up and down until the force of spring (7) is balanced with the pressure of port P4. and the pilot pressure of the control valve is sent through fine controi hole (f) to port PI.STRUCTURE AND FUNCTION PPC VALUE FUNCTION OF PPC VALVE The PPC valve supplies pressure oil from the charging pump to the side face of the spool of each control valve according to the amount of travel of the control lever. At almost the same time it is connected to pump pressure chamber PP. retainer (5) is pushed. The position of valve (8) and body (9) (when fine control hold (f) is midway between drain chamber D and pump pressure chamber PP) does not change until the head of valve (8) contacts the bottom of piston (2). 2): When piston (2) starts to be pushed by plate (IO). Fine control hole (f) is shut off from pump pressure chamber PP. spring (7) is compressed in proportion to the travel of the control lever. This pressure oil actuates the spool. Valve (81 is also pushed by spring (7) and moves down. I) (Fig. Operation 1.

4): Plate (IO) pushes piston (2) down. (Fig. When the spool of the control valve returns. sEwco147 Control lever operated to end of travel (Fig. The extra oil then flows through port PI to chamber PBI. 3) 4. Fine control hole (f) is shut off from drain chamber D. so the oil at port P4 escapes.STRUCTURE 3. 3): When plate (IO) starts to be pushed back. and at almost the same time it is connected to pump pressure chamber PP. If the pressure at port P4 drops too far. and flows from port P4 to chamber PAI to push the spool of the control valve. and is connected to pump pressure chamber PP. At the same time. the oil in drain chamber D flows in from fine control hole (f’) of the valve which has not moved. 4) 10-114 SEW00148 . and piston (2) forcibly pushes in valve (8). (Fig. The pump pressure is supplied until the pressure at port PA1 returns to a pressure equivalent to the position of the lever. fine control hole (f) of valve (8) is connected to drain chamber D. The oil returning from chamber PBI flows from port PI through fine control hole (f’) to drain chamber D. pressure oil from the charging pump passes through fine control hole (f). piston (2) is pushed up by a force corresponding to the force of centering spring (6) and the pressure at port P4. Fine control hole (f) is shut off from drain chamber D. Therefore. valve (8) is pushed down by spring (7). AND PPC VALVE FUNCTION Control lever moved back from slightly operated position to hold (Fine control) (Fig.

Main valve (I) is opened by the pressure at port A and the oil at port A is drained to port C to relieve the circuit.-__-__-__-__-__-__-_. 2. or when any abnormal pressure is generated. The oil passes through the orifice in main valve (1) and fills port B. 6. The PPC relief valve is between the PPC. 3. Port A is connected to the pump circuit and port C is connected to the drain circuit. pilot poppet (4) is seated in valve seat (3). When the pressure at port B goes down. 1. 4. When the PPC pump is not being actuated. Main valve Spring Valve seat Pilot poppet Spring Screw \ 6 SDWO0149 Function .STRUCTURE AND FUNCTION PPC RELIEF VALVE PPC RELIEF VALVE _. SDWOOlE. a difference in pressure is generated at ports A and B by the orifice of main valve (I).0 A C 1 B 2 SDW00151 10-115 . l The relief valve is installed to the charge valve. 5. brake pump and the PPC valve._-_. Operation l . the oil sent from the pump is relieved from this valve to prevent any damage to the pump or circuit. When the pressure at port A and port B reaches the set pressure. pilot poppet (4) opens and the oil pressure at port B escapes from port D to port C to lower the pressure at port B. In addition.

.4 MPa (35 kg/cm*) 1. 4. Even if the engine stops when the boom is raised. When the PPC valve is operated. When this happens. After the engine stops. 2.9 MPa (30 kg/cm2). . actuation pressure: Function The accumulator is installed between the hydraulic pump and the PPC valve. the bladder is expanded by the pressure of the nitrogen gas in chamber A. 10-l16 Before operation After operation .STRUCTURE AND ACCUMULATOR FUNCTION ACCUMULATOR (FOR PPC VALVE) (FOR PPC VALVE) 1. Gas plug Shell Poppet Holder Bladder Oil port Specifications Type of gas: Nitrogen gas Gas amount: 500 cc Max. 5. the oil pressure in chamber B goes below 2. Operation . chamber A inside the bladder is compressed by the oil pressure in chamber B. actuation pressure: 3.2 MPa (12 kg/cm21 Min. and the oil inside chamber B is used as the pilot pressure to actuate the main control valve. 3. if the PPC valve is at hold. 6. it is possible to lower the boom and bucket under their own weight by using the pressure of the nitrogen gas compressed inside the accumulator to send the pilot oil pressure to the main control valve to actuate it.

From PPC I. From work equipment pump From switch pump (via steering To bucket cylinder rod side To boom cylinder rod side Drain port (to tank) To boom cylinder bottom side 10-l 18 valve) K G. E. From PPC cylinder bottom valve port Pl valve port P3 valve port P4 valve port P2 side . B. To bucket H. From PPC J. C. F. D.MAIN CONTROL VALVE STRUCTURE AND FUNCTION MAIN CONTROL VALVE Z-SPOOL B D A G E G J A. From PPC K.

8. 5. 4. 3. 7. 11. IO. Cut-off valve assembly Unload valve Bucket spool Boom spool Check valve Suction valve Cut-off relief valve Screen Safety valve (with suction) Check valve Main relief valve 10-l 19 . 2.STRUCTURE AND FUNCTION MAIN CONTROL VALVE 6 D-D B-B A-A G-G E-E F-F 1. 6. 9.

C. G.STRUCTURE AND FUNCTION MAIN CONTROL VALVE 3-SPOOL T D GF r A. 0. F. M. From From From From From From From work equipment pump attachment PPC valve PPC valve port PI PPC valve port P3 attachment PPC valve PPC valve port P4 PPC valve port P2 . K. From switch pump (via steering To attachment cylinder To bucket cylinder rod side To boom cylinder rod side Drain port (to tank) To boom cylinder bottom side To bucket cylinder bottom side To attachment cylinder 10-120 valve) I. E. N. L. D. H. J. B.

3. 10.I0 11 G-G ‘IO E-E H-H F-F 1. 11. Cut-off valve assembly Unload valve Attachment spool Bucket spool 5. 6. Screen Safety valve (with suction) Check valve Main relief valve 10-121 . 4. 2. 7. Boom spool Check valve Suction valve Cut-off relief valve 9.STRUCTURE MAIN AND FUNCTION CONTROL VALVE 6 D-D B-B A-A . 8. 12.

To change the set pressure. a difference in pressure between ports A and B is created by the orifice of main valve (I). When the pressure at port B drops. 2.STRUCTURE AND FUNCTION MAIN CONTROL VALVE RELIEF VALVE 1. and fills port B. and to protect the circuit. . The oil passes through the orifice in main valve (I). 3. then turn adjustment screw (5) to adjust the set pressure as follows. Main valve Valve seat Pilot poppet Spring Adjustment screw SAWCE41 Function The relief valve is installed to the inlet portion of the main control valve. . The set pressure can be changed by adjusting the tension of pilot poppet spring (4). If the pressure inside ports A and B reaches the set pressure of pilot poppet spring (41. to the pump circuit and port C is connected to the drain circuit. Port A is connected . If the oil goes above the set pressure. the relief valve drains the oil to the tank to set the maximum pressure for the work equipment circuit. loosen the locknut. The main valve is pushed open and the oil at port A passes through port C. 5. so the pressure at port B drops. TIGHTEN to INCREASE pressure LOOSEN to DECREASE pressure 1o-1 22 C D A B / A I 34 SAWWSb3 B SAWE-W . pilot poppet (3) opens and the oil pressure at port B escapes from port D to port C. Operation . Pilot poppet (3) is seated in valve seat (2). remove the cap nut. 4. and the abnormal pressure is released to the drain circuit.

so main valve (2) receives oil pressure equivalent to the difference between the areas of d3 and d4. Pilot piston (3) is secured to the safety valve. and the size of the cross-sectional surface (cross-sectional area) has the following relationship: dz > dl > d3 > da. this valve relieves the abnormal pressure to prevent damage to the cylinder. If the oil pressure reaches the force (set pressure) of main valve spring (4). but relationship between port A and port C is d3 > d4. and the oil from port A flows to port B. suction valve (I) is not actuated because of relationship dz > dl >. If abnormal pressure is created at port A.STRUCTURE AND FUNCTION MAIN CONTROL VALVE SAFETY VALVE (WITH SUCTION) 1 2 3 4 5 1. 4. 6 Suction valve Main valve Pilot piston Main valve spring Suction valve spring Valve body Function . A2 B C 3 D SALVE546 D 1O-l 23 . The oil pressure at port A is sent to port D from the hole in pilot piston (3). 6. main valve (2) is actuated. 2. It is also sent to port C by the orifice formed from main valve (2) and pilot piston (3). 3. If any abnormal pressure is generated by any shock to the cylinder when the main control valve is at the neutral position. The safety valve is in the bucket cylinder circuit inside the main control valve. . Operation Operation as safety valve . 5. Port A is connected to the cylinder circuit and port B is connected to the drain circuit.

VALVE a SUCTION VALVE . and suction valve (I) opens to let the oil from port B flow into port A and prevent any negative pressure from forming at port A. A B Main poppet Sleeve Spring SAW00549 pres- Operation . If any negative pressure is generated at port A. and oil pressure a acts to move suction valve (I) in the direction of closing. so there is also negative pressure at port D. When the pressure at port A drops (and comes close to negative pressure). The tank pressure of port B is applied to port E.STRUCTURE AND FUNCTION MAIN Operation as suction valve . Therefore. main poppet (1) is opened because of the difference in area between dl and dz. d’l lo-124 5 D a 1. The relationship becomes oil pressure e > oil pressure a + force of valve spring (51. 1 CONTROL . it becomes lower than hydraulic pressure e. oil pressure e moves the valve in the direction of opening. 2. port D is connected with port A. so the suction valve (I) receives oil pressure a. If any negative pressure is generated at port A (boom cylinder rod end) (when a pressure lower than tank circuit port B is generated). Function This valve acts to prevent any negative sure from forming in the circuit. 3. and oil flows from port B at the tank end to port A at the cylinder port end. which is equal to the difference in the area of dz and dl because of the tank pressure at port E.

STRUCTURE MAIN AND FUNCTION CONTROL VALVE OPERATION OF CUT-OFF VALVE Function The cut-off valve is mounted between the switch pump and work equipment valve. It switches the oil flow from the switch. 2. When the work equipment valve is held The oil at the switch pump (the oil from the steering valve) presses up check valve (I). merges with the oil from the work equipment pump and flows to the work equipment valve. according to operating conditions. W 655 M Steeringpump Switchpump SBwco744 10-725 . pump between the working equipment valve and the drain. When the work equipment valve is activated 1) When the work equipment pump pressure is lower than the cut-off pressure As when the work equipment valve is held. merges with the oil from the work equipment pump and flows to the work equipment valve. the oil at the switch pump (the oil from the steering valve) presses up check valve (11. and controls the speed of the work equipment. Cut-off operation conditions c: Cut-off (drain) x: Not actuated (to main control valve) l l 8 Fi 4 Operation 1.

The oil in unload valve (3) chamber d passes through orifices e and f. and the oil in unload valve (3) chamber b passes through cutoff valve (2) chamber c and is drained. and unload valve (3) to open. Thus. the pressure of the oil in chamber a opens cut-off valve (2). and into chamber b causing the oil pressure in chamber d decrease. W Steering pump Switch pump lo-126 CONTROL VALVE .STRUCTURE 2) AND MAIN FUNCTION When the work equipment pump pressure is higher than the cut-off pressure When the cut-off pressure is reached. the oil from the switch pump is drained.

Since the bucket spool (2) is at the neutral position. the oil at port B passes around the spool and returns to the tank from the drain circuit. lo-127 . The boom (3) spool is also . The oil from the switch pump which has passed through the cut-off valve and the work equipment pump’s oil enter port A and the maximum pressure is regulated by relief valve (1). . The oil from the PPC pump enters PPC valve port L.STRUCTURE AND FUNCTION MAIN CONTROL VALVE MAIN CONTROL VALVE QPERATION BOOM AND BUCKET SPOOL HOLD POSITION Accumulator From PPC valve From work equipment pump 1 ($zff k * From switch pump SLWOOSiX Operation . the bypass circuit is open. the oil returns to the tank from the PPC relief valve. and the oil at port A passes around the spool and flows to port B. so the bypass circuit is open. but since the boom and bucket levers are at the neutral position. at the neutral position.

The oil on the cylinder rod side enters drain port F from port E and returns to the tank. The oil from check valve (5) flows to port D and to the cylinder bottom side. . causing the boom to raise. When boom lever (4) is pulled. The oil from the pump passes through the bucket spool (2) bypass circuit and flows to lo-128 . the boom spool (3) bypass circuit. STRUCTURE AND FUNCllON MAIN CONTROL VALVE BOOM SPOOL AT RAISE POSITION Accumulator \ \ I I M N * From PPC valve J QaFrom work equipment pump I %P I-- From switch pump Operation . The l oil at port T passes through port M and flows to the drain circuit.. The oil pressure at port S presses boom spool (3) and sets it to the RAISE position. oil flows from PPC valve port L to port N and port S. The bypass circuit is closed by boom spool (31. so the oil pushes open check valve (5).

oil flows from PPC valve port L to port M and port T. The oil from the pump passes through the bucket spool (2) bypass circuit and flows to the boom spool (3) bypass circuit.MAIN CONTROL VALVE STRUCTURE AND FUNCTION BOOM SPOOL AT LOWER POSITION 4 lator li From PPC valve I--* Ek From work equipment pump * From switch pump Operation l . The oil on the cylinder bottom side enters drain port F from port D and returns to the tank. The by- . pass circuit is closed by boom spool (31. and the oil at port S flows to the drain circuit. so the oil pushes open check valve (5). The oil pressure at port T pushes boom spool (3) and sets it to the LOWER position. When boom lever 14) is pushed. causing the boom to lower. 10-129 . The oil from check valve (5) flows to port E and to the cylinder rod side.

Boom spool (3) causes the oil in the bypass circuit 10-130 n From PPCvalve From work equipment pump to flow to the drain circuit. When the bucket is touching the ground. boom spool (3) moves further from the LOWER position and is set to the FLOAT position. The oil from the pump passes through the bucket spool (2) bypass circuit and flows to the boom spool (3) bypass circuit. In addition. When boom . so the check valve (5) cannot be pushed open. it can move up and down in accordance with the ground surface contour. lever (4) is pressed in further from the LOWER position (to the FLOAT position). boom cylinder raise circuit D and lower circuit E are both connected to the drain circuit. . so the boom lowers under its own weight.MAIN CONTROL VALVE STRUCTURE AND FUNCTION BOOM SPOOL AT FLOAT POSITION LI I I I---* Operation .

Since the bypass circuit is closed by bucket spool (21. the oil at port A pushes open check valve (7). the oil pressure at PPC valve port L is released from port P to port R. l l The oil from port A passes from check valve (7) through port G and to the bottom side of the bucket cylinder.MAIN CONTROL VALVE STRUCTURE AND FUNCTION BUCKET SPOOL AT TiLT POSITION Accumulator fl1-i From PPCvalve I--* c/-- From work equipment pump * From switch pump SLWlm558 Operation l l When bucket lever (6) is pulled. causing the bucket to tilt. IO-131 . The oil on the bucket cylinder’s rod side flows from port H to drain port F and returns to the tank. and the oil at port V flows to the drain circuit. The oil pressure at port R sets bucket spool (2) to the TILT position.

sure at PPC valve port L is released from port Q to port V. causing the bucket to dump. the oil pres- . Since the bypass circuit is closed by bucket spool (21. The oil on the bucket cylinder’s bottom side flows from port G to drain port F and returns to the tank. the oil at port A pushes open check valve (7).STRUCTURE AND FUNCTION MAIN CONTROL VALVE BUCKET SPOOL AT DUMP POSITION Accumulator From PPC valve I--* 1 zy$off k From work equipment pump c Fromswitchpump Operation . When bucket lever (6) is pushed. . The oil from port A passes from lo-132 l check valve (7) through port H and to the rod side of the bucket cylinder. The oil pressure at port V sets bucket spool (2) to the DUMP position. and the oil at port R flows to the drain circuit.

WORK EQUIPMENT STRUCTURE AND FUNCTION WORK EQUIPMENT 6 1. 2. 3. Bellcrank Bucket cylinder Boom cylinder 10-134 LINKAGE 4 5 4. 6. Boom Bucket link Bucket 3 SAwoosM) LINKAGE . 5.

STRUCTURE AND FUNCTION WORK EQUIPMENT Fa A-A D-D G-G LINKAGE -yLI B-B E-E H-H c-c F-F J-J sAwoo561 1o-1 35 .

1 m3) Bolt-on cutting edge 3. lo-136 (BOC) . Bucket (3.STRUCTURE AND FUNCTION BUCKET BUCKET A4 I 1 2 A-A 1. Plate 2.

BUCKET POSITIONER AND BOOM KICK-OUT AND BOOM KICK-OUT Proximity switch Plate Bucket cylinder rod Lever Proximity switch A-A SBwoo563 10-l 37 .STRUCTURE AND FUNCTION BUCKET POSITIONER 1. 4. 5. 3. 2.

. Plate (2) is fixed to the boom. proximity switch (5) fixed to the cylinder by bolts. In addition. Lever (4) is secured to bucket cylinder rod (3) by bolts. When the boom is moved from the LOWER position to the RAISE position. lever (4) also moves to the left. BOOM KICK-OUT . and when it reaches the desired position.STRUCTURE AND FUNCTION BUCKET POSITIONER . In addition. . The bucket positioner . 1O-l 38 BUCKET POSITIONER AND BOOM KICK-OUT . It acts to move the boom lever to the HOLD position and stop the boom at the desired position before the boom reaches the maximum height. When the bucket reaches the desired position. The boom kick-out is an electrically actuated system. is an electrically actuated system which is used to set the bucket to the desired angle when the bucket is moved from the DUMP position to the TILT position. the bucket cylinder rod moves to the left. and at the same time. the proximity switch and lever come together and the system is actuated to return the boom lever to the HOLD position. proximity switch (I) is fixed to the frame. Proximity switch (5) separates from lever (4) at the desired position. When the bucket is moved from the DUMP position to the TILT position. the bucket lever is returned from the TILT position to the HOLD position. and the bucket is automatically set to the suitable digging angle. the boom rises. and the bucket lever is returned to neutral.

The relay switch is turned OFF and the current for the solenoid is shut off. Boom lever Cam Detect . When the boom lever is moved to the RAISE position.STRUCTURE AND FUNCTION Operation of proximity BUCKET POSITIONER AND BOOM KICK-OUT switch Boom RAISE l When the boom is lower than the set position for the. and the boom rises. kick-out. the detector (steel plate) is not above the detection surface of the proximity switch. Proximity switch for boom kick-out Kick-outrelay Kick-outsolenoid Boom lever Proximity switch Proximity switch for boom kick-out . the boom spool is held at the RAISE position by the cam follower and cam on the lever. so the proximity switch load circuit is shut off.

STRUCTURE AND FUNCTION l BUCKET POSITIONER AND BOOM KICK-OUT When the boom rises and reaches the set position for the kick-out. an electric current is sent to the solenoid by the action of the prqximity switch and relay circuit. ttie solenoid is actuated. As a result. the detector (steel plate) is in position on the detection surface of the proximity switch. in other words. Proximity switch for boom kick-out Boom lever Cam Proximity switch 3m Detector Action of proximity switch Position Proximity actuation switch display When detector is in position at detection surface of proximity switch Lights up When detector is separated from detection surface of proximity switch Goes out Proximity switch load circuit (relay switch circuit) Current flows Current is shut off Relay switch load circuit (solenoid circuit) Current flows Current is shut off 10-140 . so the boom spool is returned to the HOLD position by the return spring. and the cam is pulled away from the cam detent.

rj PPCvalve S&VUX70 10-141 . so electric current flows in the proximity switch load circuit. the detector (steel plate) is not above the detection surface of the bucket proximity switch. The relay switch is turned OFF and the current for the solenoid is shut off. To battery relay r relay P Bucket lever Cam De&&r Proiimity switch u. and the bucket tilts. When the bucket lever is moved to the TILT position.STRUCTURE AND FUNCTION Operation of proximity BUCKET POSITIONER AND BOOM KICK-OUT switch Bucket TILT l Proximity switch for When the bucket is lower than the set position for the auto-leveler. PPCvalve Proximm/ switch for U . the bucket spool is held at the TILT position by the cam follower and cam on the lever. To battery relay r relay Bucket lever Detector Proximityswitch k<.

ProximiD/switch for To battery relay Jr II Positioner relav P Bucket lever Cam Detector Proximity switch u-. electric current is sent to the ‘solenoid by the action of the proximity switch and relay circuit. so the bucket spool is returned to the HOLD position by the return spring. in other words. and the cam is pulled away from the cam detent. the solenoid is actuated.STRUCTURE AND FUNCTION l BUCKET POSITIONER AND BOOM KICK-OUT When the bucket tilts and reaches the set position for the bucket leveler. C. Action of proximity switch Position Proximity actuation switch display Proximity switch load circuit (relay switch circuit) Relay switch load circuit (solenoid circuit) lo-142 SSWOCS71 PPC valve When detector at detection proximity When detector is separated from detection surface of proximity switch is in position surface of switch Goes out Lights up Current Current flows is shut off I Current is shut off Current flows . As a result. the detector (steel plate) separates from the detection surface of the proximity switch.

Front glass 2. Door 10-143 0 . Front wiper 3.STRUCTURE AND FUNCTION CAB CAB Serial No. 50001-52999 I \ 4 1. Rear wiper 4.

STRUCTURE AND FUNCTION CAB Serial No. 3. 2. 10-143-l 0 Front glass Front wiper Rear wiper Door . 4. 53001 and up i cz I SOW02807 1.

53001 and up 4 SOW02743 1. Front glass Front wiper Rear wiper Door lo. 4. 2. 3.STRUCTURE AND FUNCTION ROPS CAB ROPS CAB Serial No.143-2 0 .

Hot water inlet port Hot water outlet port Air conditioner unit . 6.STRUCTURE AND FUNCTION AIR CONDITIONER AIR CONDITIONER AIR CONDITIONER PIPING SBWw572 1. 3. 7. 4. Vent Air conditioner Dry receiver Compressor 10-144 condenser 5. 2.

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STRUCTURE AND FUNCTION ELECTRIC CIRCUIT DIAGRAM ELECTRIC CIECUIT DIAGRAM AUTO-GREASING /I -1 I u L __- SDW01267 .

l * There are also various switches built into the monitor panel which function to operate the machine. It processes this information swiftly and displays it on the monitor panel to inform the operator of the condition of the machine. Air cleaner clogging sm750 Outline l l . When the optional controller are installed. Engine oil level 6. alarm buzzer. The displays can be broadly divided into the following: Cautions displayed on the monitors (abnormalities in the machine where an alarm is given) and normal conditions which are always displayed on the instrument panel (pilot lamps and readings for the gauges. switches.MACHINE STRUCTURE AND FUNCTION MACHINE MONITOR MONITOR SYSTEM SYSTEM Attemator terminal R Starting motor Auto-greasing controller 0 E. and power source. Fuel level 2. Engine oil pressure 8. Torque converteroil temperature 4. maintenance monitor. speedometer. The machine monitor system consists of the main monitor. The machine monitor system uses the sensors and other devices installed to various parts of the machine to observe the condition of the machine. relays. sensors. the main monitor communicates with the controller through the network wiring and functions to display the controller failure action code and failure code together with the time elapsed since the failure (trouble data display mode).S controlle sensor?2 1. 10455 . Enginewater temperature 3.S. Brake oil pressure 7. Enginewater level 5. and service meter).C.

A liquid crystal display and LEDs are used for the display. 2.S. for the speedometer and other gauges and a switching function to control the electric cornponents and controllers. There is one CPU (Central Processing Unit) installed internally. Shift indicator Speedometer Parking brake Emergency steering Preheating Failure action code Outline . 41. Transmission cut-off switch the sensors and outputs the dis- play. Working lamp (front) switch 5D. E. Working lamp (rear) switch 5E.STRUCTURE AND FUNCTION MAIN MONITOR AIN MONITOR 4H 3A 5c 5D 5A 5E 58 1. 4E. Auto-greasing switch 5B. The switches are embossed sheet switches. 3. 4G. Turn signal (right) 4D. . The main motor has a display function . Turn signal (left) 48. 4C. 4F. switch 5C. Emergency steering actuated Pilot item 4A. 4. 4H. CHECK lamp CAUTION lamp Caution item 3A.S. Hi beam normal signals - from Switches 5A. and this processes the IO-156 5.C.

see TROUBLE DATA DISPLAY MODE) Emergency normal Shift indicator When range steering speed code preheating lights up display 10-157 . or CALL and E 0 q (action code) are displayed in turn Digital display Buzzer sounds (For details of the travel data display mode.99 km/h Digital display (display switches between tachometer and speedometer) Shift indicator 1 . MAINTENANCE MONITOR DISPLAY FUNCTION) Display flashes Parking brake actuated. transmission not at neutral Display sounds flashes When there abnormality maintenance Display flashes (buzzer may also sound) (for details. right) When operated Display lights up Parking When operated Display lights up Buzzer sounds when parking brake is applied and shift lever is not at N brake When normal (oil is flowing in hydraulic circuit) Display Preheating When Lights up Lighting up time changes according to engine water temperature when starting switch is turned ON (for details.4.STRUCTURE AND FUNCTION MAIN MONITOR MAIN MONITOR DISPLAY FUNCTION Display Check item Display there 1When abnormality Check maintenance Emergency actuated steering Caution cI> CAUTION lm Q D Failure action code is display on monitor actuated Display method Display flashes (for details.N Digital Failure action When controller detects failure and action by operator is needed. CALL is displayed. see MAINTENANCE MONITOR DISPLAY FUNCTION) Caution is display on monitor see and buzzer Hi beam When operated Display lights up Turn signal (left. see PREHEATING OUTPUT FUNCTION) Travel 0 .

MAIN MONITOR STRUCTURE AND FUNCTION MAIN MONITOR SWITCH FUNCTION Item Function Display I I Actuation Lights up (goes out Auto-greasing control actuated momentarily when (automatic greasing carried switch is turned ON) out at fixed interval) Auto-greasing Forced greasing is carried out while switch is being pressed when display is lighted up I Flashes (slowly) Flashes (rapidly) I Grease empty Abnormality in auto-greasing controller system Auto-greasing controller not E.S.S.S. function stopped Lights up Front working lamp lights up Goes out Front working lamp goes out H y Lights up Rear working lamp lights up Goes out Rear working lamp goes out Lights up Cut-off function actuated Goes out Cut-off function stopped 3 .C.C. Goes out E.S. Working lamp (front) Working lamp (rear) Transmission cut-off lo-158 E.S.C.__. function is actuated or stopped each time switch is pressed Front working lamp lights up or goes out each time switch is pressed when side lamps are lighted up Rear working lamp lights up or goes out each time switch is pressed when side lamps are lighted up Transmission cut-off function is actuated or stopped each time switch is pressed .S.

STRUCTURE MAIN AND FUNCTION MONITOR PREHEATING OUTPUT FUNCTION Actuation Item QGS (Quick glow system Power source ON Starting signal OFF (terminal C) r-l I t I ON Display I I Tl OFF output OFF+ 1 T2 1 T2 h Relationship between engine water temperature and display and output time Tl T2 I 8 ! 3 Display time Tl (set) Output time T2 (set) : 20 - - ‘p - Tl \ -T2 : -10 5 60 - Engine water temperature (‘C) sAwc%s¶ 10-159 .

a uo work equipment 0 0 0 Method of sending failure code Press working lamp (front) switch Failure code and time elapsed since failure change to next item. the failure display mode functions. Failure code for problem now occurring (flashing display) cannot be cleared. Actuation All switch displays (LED4 go out. controller) is installed. D ‘27 Cl P 0 0 e SOW00243 Resetting from travel data display mode Changes to normal display Press 2nd switch from top on left side of main monitor (switch below emergency steering display) and working lamp (front) switch simultaneously for at least 5 seconds.STRUCTURE AND FUNCTION MAIN MONITOR TROUBLE DATA DISPLAY MODE * When the optional controller (auto grease. and failure code is displayed on speedometer display and time elapsed since failure is displayed on failure action code display. The display for the failure now occurring flashes and the display for past failures lights up. CC is displayed (000 is displayed for time elapsed since failure) (2) The time elapsed since failure is displayed as a three-digit number to show how long ago the failure occurred (the oldest failure time is displayed. Clearing failure code Press working lamp (rear) switch for at least 2 seconds Failure code and time elapsed since failure being displayed are cleared. press 2nd switch from top on left side of main monitor (switch below emergency steering display) and working lamp (front) switch simultaneously for at least 5 seconds. Item Switch operation Method of switching to trouble data display mode With engine stopped and starting switch turned ON. ti 10-160 . If there is no failure. travel damper. (3) A maximum of 9 items are stored in memory for the failure code. (1) Failure code is a two-digit display given in numbers or letters. Any time greater than 999H is displayed as 999H). or start the engine.

The maintenance monitor consists of the monitor module. 6. The switches are embossed sheet switches. Remote boom positioner RAISE position set switch 4D. service meter. 7. case. MAINTENANCE $4 3l3 2C 2A ?B 2B iD qC 4D . Engine water temperature 3C. Torque converter oil temperature Work equipment control switches 4A. Engine oil pressure 2B. switch module. Air cleaner (1A. Brake oil pressure 2D. 4. Service meter RUN pilot lamp Monitor module Switch module The monitor module has a built-in CPU (Central Processing Unit). Bucket auto-leveler auto-mode switch monitor has a display function for the caution items and gauges. and carries out the display and output. A liquid crystal display and LEDs are used for the display portions. Fuel level 3B. Battery charge 2C. Service meter numeric display 5B. Engine oil level Caution items (warning items) 2A. IA IB / 7 2. Check items (Checks before starting) IA. Remote boom positioner RAISE/ LOWER selector switch Service meter 5A.STRUCTURE AND FUNCTION MAINTENANCE .A ‘5B \ I 6 5 3. l l 5. sLww591 Gauge items 3A. 4C. It processes the signal from the sensors. Engine water level) Outline . lo-161 . Engine water level IB. and other mechanisms. Bucket auto-leveler set switch 4B. and switch functions to control the work equipment controller (if equipped). The maintenance l MONITOR MONITOR 3A 1.

MAINTENANCE STRUCTURE AND FUNCTION MAINTENANCE Display category Symbol MONITOR DISPLAY FUNCTION Display item Display method Display range Engine water level IBelow low level Engine oil level IBelow low level Engine water level IBelow low level Engine oil pressure Below specified pressure Brake oil pressure Below specified pressure Displays when engine is stopped and starting switch is ON Display when normal: OFF Display when abnormal: Flashes CHECK lamp flashes Check I0 b- MONITOR Displays when engine is running Display when normal: OFF Display when abnormal: Flashes CAUTION lamp flashes Buzzer sounds I I 09 Engine water temperature f Above 102% I Caution 0 lap Torque converter oil temperature Above 120°C Fuel level Below low level ___----------------Buzzer sounds if above 105°C __-----_____------Buzzer sounds if above 130°C I I3 b rn I- Battery charge When charge is defective Air cleaner Above specified negative pressure Service meter 0 .9h Displays when engine is running Display when normal: OFF Display when abnormal: Flashes CAUTION lamp flashes Displays when engine is running Display when normal: OFF Display when abnormal: Flashes CHECK lamp flashes c---l II Service meter 0 * Service meter indicator Lights up when service meter is running Fuel level All lamps light up below applicable level Flashes when level is 1 Engine water temperatun e One place lights up to show applicable level Flashes when level is 6 or 7 I3 b Gauges Torque converter oil temperature 1O-l 62 Actuated when charge is normal Advances 1 for every hour 8 ?I ?I .9999.

5 set) Sets stopping position positioner when is recorded) in stopping positioner in RAISE auto mode OFF boom position of LOWER Bucket auto-leveler Goes out boom Selection remote (2.MAINTENANCE STRUCTURE AND FUNCTION MAINTENANCE MONITOR SWITCH FUNCTION Display Function Item Bucket auto- Setting leveler angle for bucket (bucket setting (if equipped) when automatic switch stopping is pressed Flashes is Goes out Bucket auto- Switches leveler ON and OFF each time switch auto mode between Lights up I Actuation Sets stopping angle Bucket auto-leveler auto mode ON is pressed mode (if equipped) Remote boom positioner position RAISE setting (if equipped) Sets stopping direction positioner switch position for remote (boom is pressed Sets remote boom direction RAISE function pressed) each time Flashes (2.5 set) angle recorded) auto MONITOR positioner Goes out Goes out (switches switch Remote boom function OFF Remote boom is RAISE lights up stop function (if equipped) LOWER RAISE. lights up LOWER Remote boom LOWER stop function Remote boom RAISE/LOWER light up positioner RAISE ON positioner ON positioner stop function ON L 10-163 .

This makes it easy to control operations such as removing the load from the bucket. carrying out digging operations. .STRUCTURE AND FUNCTION WORK EQUIPMENT WORK EQUIPMENT CONTROL CONTROL SYSTEM SYSTEM SYSTEM STRUCTURE DIAGRAM Boom RAISE switch & @ @I (3 @ Auto mode 0 Level set Remote positioner set switch Remote positioner RAISE/LOWER selection switch Proximity switch l -D c -D 0 D 0 . 10-164 With the remote positioner control. the angle of the work equipment to the ground changes according to the height. or approaching dump trucks. The auto-leveling control keeps the angle to the ground constant regardless of the height of the work equipment. and makes it safer and easier to operate the machine when moving back. This makes the movement smooth when starting or stopping the boom. the operator can set the boom stopping (lever kickout) position to the desired position. D 0 0 Boom cylinder bottom pressure sensor @ Model selection signal 0 I A: D: P: II H 0 0 I Analog signal Digital signal Pulse signal D -I 0 I 7 CONTROL FUNCTIONS Auto leveling function Bucket angle compensation Bucket automatic Remote positioner stop control function Boom LOWER/RAISE position Boom RAISE stop position Remote & leveling function Sensor adjustment function Model selection Troubleshooting control stop set function function Outline Because of the structure of.the Z-bar link work equipment.

STRUCTURE WORK AND FUNCTION EQUIPMENT CONTROL SYSTEM STRUCTURE OF WORK EQUIPIVIENT CONTRQL CIRCUlT 101 f ” G.Buzzeroutput ’ i! Lever kick-out solenoids Ii 3. @ 1 1 ip @Modelselection signal Enginespeed 7 Work equipment controller Bucket auto-leveler r----a electric control r---b valve -L-J-- &!yy--+ 1 Bucketcylinder L-_ b L-(0&----J I PPC pump Boom lever detentswitch 10-165 .4 .

1) Setting desired stop position i) Operate the bucket lever to determine the position (-30” +15”). . ii) Press the auto-leveler set switch. 2. The control range is determined by the position of the bucket and boom. the auto-leveler set lamp will flash.STRUCTURE WORK AND FUNCTION WORK EQUIPMENT CONTROL SYSTEM FUNCTION Auto-leveling function 1. iii) When the auto-leveler lamp goes out. the stop position is written to memory. this is only if the work equipment is within the control range. T. the auto. and the horizontal angle is set. ii) Press the auto-leveler set switch. the auto-leveler set lamp will flash. Control range (from horizontal 0”) l Anale of bucket to around Boom angle . The range for the control is limited.he set position is retained even if the key is turned OFF.) 8 G Z!J . the angle to the ground when the lever is returned to neutral will become the new control target angle.leveler lamp lights up. (This horizontal angle is the standard for the machine. then set the lever to HOLD. then set the lever to HOLD. -300 - cl 50 Above horizontal Manual (lever control) priority: If the bucket lever is operated during this control and the bucket is set to the desired angle. iv) Press the auto-leveler set switch while the lamp is flashing. and if they are outside the range. . When the bucket reaches the horizontal position (or the desired set position). Bucket angle compensation control The controller always calculates the angle of the work equipment to the ground from the value of the voltage of the potentiometer (angle sensor) installed to the rotating part of the bucket and boom. so the work equipment may not necessarily be horizontal to the ground for reasons such as the weight of the work equipment or the angle of the machine. this control is carried out by setting to the auto mode. .5 set) l lo-166 2) EQUIPMENT CONTROL SYSTEM iv) When the auto-leveler set lamp goes out and the auto-leveler lamp lights up. The control is carried out to keep the angle constant by automatically controlling the bucket tilt and dump solenoids according to the angle to the ground (which changes in comparison with the angle (position) of the boom). iii) When the auto-leveler lamp goes out. and if the work equipment is within the range.) Bucket automatic stop control Set the bucket to the maximum dump and place the bucket lever in the detent. (2. the lever detent is released and the bucket stops. (However. v) The auto-leveler set lamp goes out immediately. Setting horizontal position stop i) Operate the bucket lever to determine the position (-30” +15”). the control is not carried out.

When the lamp is lighted up.44. Table 1 LOWER WA320-3 0” . l 2) LOWER boom stop (LOWER lamp ON) If the boom lever is placed at the FLOAT or LOWER position and the boom goes down to the set position. For details.8” -27” WA380-3 0” .) 10-167 . (2. The setting position is retained even when the key is turned OFF. If the lever is placed at HOLD. RAISE 0 0 +c5l +c3 LOWER 0 = LOWER 0 - RAISE 0 Lamp ON 2. the detent is released. press the remote positioner set switch. it will rise as normal. and the horizontal angle is set. then return the lever to the neutral. iv) While the lamp is flashing. then return the lever to the neutral. the boom will automatically stop at that position. the boom will stay stopped. iii) The RAISE lamp will go out and the remote positioner set lamp will flash. and at the same time. the stop position is written to memory. The RAISE position (which the operator can set to the desired position) and the LOWER stop position differ according to the model. If the boom is at any position other than the RAISE detent. (This horizontal angle is the standard for the machine. iii) The RAISE lamp will go out and the remote positioner set lamp will flash. VI The remote positioner set lamp goes out immediately and the RAISE lamp lights up.40.STRUCTURE AND WORK FUNCTION EQUIPMENT CONTROL SYSTEM REMOTE PQSITIONER FUMCTKWd 1. Boom RAISE/LOWER position stop The controller always detects the direction of operation of the lever from the pressure switch installed to the boom PPC valve and the angle (position) of the from boom angle boom the potentiometer. If the lever is moved back slightly. so the work equipment may not necessarily be horizontal to the ground for reasons such as the weight of the work equipment or the angle of the machine. see Table 1.38” -26” The setting of the control can be changed in the order given below by pressing the mode positioner RAISE/LOWER selector switch. :0 RAISE 0 RAISE 0 *c-i? LOWER 0 . 1) RAISE kick-out (RAISE lamp ON) When the boom lever is placed in the RAISE detent and the boom rises to the set position. ii) Press the remote positioner set switch.5” -27” WA420-3 0” . ii) Press the remote positioner set switch. set the stop position as desired. the boom will go down again.LOWER 0 Lamp OFF : 0 Setting remote positioner (setting RAISE stop position) When the RAISE lamp is ON.5 set) iv) When the remote positioner set lamp goes out and the RAISE lamp lights up. it will slow down and stop. 2) Setting horizontal stop position i) Operate the boom lever to move the boom to a position above horizontal. I) Setting stop position Operate the boom lever to decide i) the position (above horizontal). it slows down and then stop.39” -260 WA470-3 0” .

This controller has data tables for four models.) k 5 . Table 2 Hi: Connect to CNl @ (Sensor power source) GND: Connect to CN2 @ (Signal ground) TROU’BLESHOOTING FUNCTION l . The boom will fall under its own weight.) 10-168 CONTROL SYSTEM MODEL SELECTION FUNCTION l l . . the selected model is displayed for 2 seconds on the controller LED. a damping solenoid is used to reduce the boom speed from just before the set stopping point in order to reduce the shock when the work equipment stops. The bucket tilt control is started regardless of the position. Always carry out the adjustment when the controller. displays the abnormality as a failure code on the main monitor. potentiometer. (See Table 2) When the key is turned ON. and warns the operator of the abnormality.WORK EQUIPMENT STRUCTURE AND FUNCTION REMOTE LEVELING FUNCTION When using the auto mode with the remote positioner LOWER lamp ON. For both Items 1) and 21. see TESTING AND ADJUSTING. or work equipment are replaced. (For details. the following bucket control can be carried out by operating the boom lever.81 is displayed. If any abnormality should occur in these devices. so the work equipment moves quickly. (For details. 2) Boom lever FLOAT detent . the boom is stopped at the LOWER stop position. the controller judges that there is an abnormality. and the bucket is set horizontal to the ground. 18. the bucket tilt is controlled and the bucket stops at the LOWER position with the bucket horizontal to the ground. FUNCTION This function offsets any error caused by the installation of the potentiometer and makes it possible to detect the correct position data for the work equipment. SENSOR ADJUSTMENT . if there is any error in the model selection. 1) Boom lever LOWER detent When the boom is lower than the horizontal position. and the solenoids which receive the output signals) are functioning normally. and can handle these by means of the following selection signals when the key is turned ON. The controller always observes if the electronic devices (the potentiometers which receive the input signals. see TROUBLESHOOTING OF WORK EQUIPMENT CONTROLLER SYSTEM.

2. 12 NETWORK 13 Sensor I 1 1Remote positioner set 1Auto-leveler set switch 4 Remote positioner 5 Boom RAISE 6 Boom LOWER input l+24V) 3 4 switch pressure set LED 8 I Boom lever detent I Sisnal GND output 10 I Potentiometer relay 11 1Bucket neutral source 18 19 21 8 I Auto-leveler 9 I Pressure lever LED set LED LED sensor signal (+5V) 16 Bucket positioner 1Auto-leveler ify= 1Solenoid power source input I Power source input (+24V) 1GND lever Remote 7 14 20 1 Boom signal t+24V) ‘I 17 speed switch signal signal 6 switch switch power Engine 5 switch pressure 9 I switch 7 Cc) positioner CNL28 kick-out kick-out output (+24V) 1Auto-leveler 19 I Boom 20 1Buzzer positioner LOWER LED output _- 17 18 Remote Bucket angle angle switch potentiometer potentiometer output 10-169 .STRUCTURE AND FUNCTION WORK EQUIPMENT 1. Model selection Connector display portion CNl28 CNLZ7 CNi26 CONTROL SYSTEM sAwoo595 CONNECTOR SIGNALS CNL26 1 1 NETWORK 2 / Proximity 3 I 1 signal switch signal 2 3 8 1TILT solenoid I Power source 9 I GND 7 CNL27 10 1 Remote 11 1Auto-leveler.

4.STRUCTURE AND FUNCTION WORK EQUIPMENT CONTROL SYSTEM POTENTIOMETER 1 \ __ Q 7 2 6 5 3 4 A4 A-A SEW00266 1. They act to detect the angle of the work equipment. or other abnormality in the potentiometer system. . Connector Case Shaft Element 5. 2. if the correct position cannot be detected. short circuit. 7. 3. the controller shuts off the control output and displays a failure code on the main monitor. the hatched area is the abnormal detection area. 6. Bearing Contact Mold Boom angle potentiometer output 5 E m 4 B T 3 Budet angle potentiometer output 2 p” = 3 ‘j a2 s O 1 0 B f Q 2 z 1. it judges that there is a disconnection. 0 -60 0 Potentiometer angle ( ’ 60 ) -60 60 0 60 WA470 0 -65 Except WA470 Potentiometer angle ( O) SDWCQ267 Function The boom angle potentiometer is installed to the front frame boom mount and the bucket angle potentiometer is installed to the boom bellcrank mount. Inside the potentiometer the 5V power source voltage from the angle is converted to a signal voltage by the resistance value of the variable resistor. 10-170 In the diagrams above. and this is sent to the controller. In addition. and if the controller receives this signal.

and improves the operating efficiency. travel speed sensor.S. Structure of system The E.S. WA420. low I pressure accumulator) Sneeri rRnnPsdpriinn communication +24V !I i7!7 Solenoid 7737 I I I I to main monitor Model selection wiring harness SEW00268 10-171 . The controller carries out automatic control of these in accordance with the travel condition of the machine to give resilience to the up and down movement of the work equipment and to suppress the vibration of the chassis when traveling at high speed.STRUCTURE AND FUNCTION E. . speed range selection wiring harness 3) Output devices: solenoid valves (relief valve.S.C.S switch (system switch). . With this system.S. WA380. Main -Serial monitor 2.C.S.S. In this way. model selection wiring harness. low pressure) and the opening and closing of the relief valves.S controller (M type controller) 2) Input devices: E. (Electronically Controlled Suspension System) f2 a 5 1.C.C. .S. (Electronically Controlled Suspension System) .C. consists of the following electronic devices. pressure switch (boom cylinder Pressure switch bottom pressure). Special solenoid valves (ON-OFF valves) are used to control the ON-OFF switching of the accumulator (high pressure.S.S. it is possible to handle four models (WA320. E.S. and WA4701 with the same system simply by changing the connections of the model selection wiring harness. prevents spillage of the load. Trave’ ” 1) E. it improves the ride for the operator. high pressure accumulator. E.C. This system uses a combination of relieving the hydraulic oil from the work equipment and switching ON/OFF an accumulator which is charged with high pressure gas.

The next time that the starting switch is turned ON.S. 5 km/h Note ON Solenoid (1) (relief) 1 Output OFF 3km/h I 5kmlh - Travel speed 2 2 . and when the travel speed goes below 3 km/h.E. the output stays ON until the travel speed reaches 3 km/h.S. .S switch on the main monitor.S. the output is turned OFF.S.C. OFF: X X X 0 0 X Note 3: Input speed pulse frequency is 1 km/h OPEN when travel Note 4: If the travel speed exceeds 5 km/h when the output is OFF.C. When the system is ON.S. the controller carries out the output on the right side to control the system. When the output is ON. 5 km/h Min.S LED display on the main monitor lights upThe ON-OFF condition of the system is retained even after the engine stops or the starting switch is turned OFF. c: ON x: OFF Input E. STRUCTURE AND FUNCTION 3.C. operating the E.S.C.S switch (system ON-OFF) Speed range [Note 21 H-L Speed output Travel speed [Note 31 Pressure switch - ON OFF OFF OFF ON ON ON OFF OFF OFF ON ON ON Min. the system is set to the same condition as before it was turned OFF. Output ON I H-L ON: Solenoid (3) (low pressure) _ Speed range Shift position Solenoid (2) (high pressure) Min. the output is turned ON.C. (Main monitor function) Starting switch OFF + Machine stops + Starting switch ON When system is ON + System ON [ When system is OFF + System OFF I Note 2: Relationship between speed range signal and shift oosition Speed 1st OFF ON 2nd OFF OFF 3rd ON OFF 4th ON ON lo-172 +24V. Content of control In response to the input on the left side of the table below. the E. 5 km/h 1: The E.S system is switched ON-OFF by.

~pi.C. . AND FUNCTION E. LED codes I Pressure switch ON (disDlavs onlv when 55 ON) Error / d2 / ~~~~~. the error codes are reset and not w’ritten to memory. It turns all the output OFF and displays the error code (failure code) in the self.STRUCTURE 4.. see MAIN MONITOR TROUBLE DATA DISPLAY. Self-diagnostk fwxtion This system always observes the condition of the system.. . Error code displays [El 3 Idxl (where x is a numeral from 0 to 4 in the table above) repeatedly in turn.diagnostic display portion and the main monitor. If there is any abnormality in the controller itself or in the input or output devices. read the code with the connector facing down. code rl.S. . For details.~s”le. If more than one abnormality occurs at the same time. .. see table below) in the controller self-diagnostic display portion. “9 d4 1) I /Abnormal Abnormality in travel speed sensor system Abnormality in model selection (non-available combination is selected) Displays on controller . When the starting switch is turned OFF (controller power OFF. l 2) 10473 .“. Displays on main monitor . and displays the condition of the system (LED code. the controller carries out troubleshooting of the abnormality. When checking the LED display.S.. all the appropriate error codes are displayed in turn..

2. CNAW CNAL2 _ I output output table 1 CNAL2-1 1 CNAL2-2 1 CNAL2-3 / CNAL2-4 1 WA320 1 X X X. Controller 1. 13 14 15 16 .C.S. - m Controller Self-diagnostic display . WA380 1 X X 0 X WA420 1 X 0 X X 0: GND WA470 ) X 0 0 3 X: OPEN 10-174 j c.S.. CNAL2 CNALI CNAL3 SDWOO270 input/output CNALl signals 6 1 7 I 18 19 20 21 I Solenoid power source Input (+24’.STRUCTURE AND FUNCTION 5.‘) Power source input (c24V) GND Solenoid (high pressure) Solenoid (relief) Model selection 1 2 3 4 5 6 7 8 9 Ill - Model Model Model Model selection selection selection selection 1Pressure 1Network I Input switch H 18 j 19 I - Il-lpUU oumut Input Input Input Input Name of signal NO. E.

the engine oil pressure uses a relay to reverse the sensor signal. 10-175 . 2. 3. However. 4. l Sensor item detection Sensor method When normal Engine oil level Contact ON OFF Contact ON OFF - - - Tvt. When the oil goes below the specified level. the float goes down and the switch is turned OFF. the panel judges the signal to be normal. The signal from the sensor is input directly to the monitor panel.ator water Engine water temperature Resistance Torque converter oil temperature Resistance Fuel level Resistance - Electromagnetic - Engine speed Engine oil pressure Contact When abnormal OFF ON ENGINE OIL LEVEL SENSOR 1 3 2 A Structure of circuit SEW00292 Function l 1. This makes the maintenance monitor flash to warn of the abnormality. and when the contacts are closed. Connector Bracket Float Switch This sensor is installed to the side face of the oil pan.SENSORS STRUCTURE AND FUNCTION SENSORS Function The sensors are a contact type sensor with one end grounded to the chassis. The check lamp also lights up at the same time to warn of the abnormality.

STRUCTURE AND FUNCTION

SENSORS

RADIATOR WATER LEVEL SENSOR

m

n

1

0

‘0

0

2

2

1.

2.
3.

Structure ofcircuit

Function

Float
Sensor
Connector

l

This sensor is installed to the top of the
radiator. if the coolant goes below the specified level, the float goes down and the switch
is turned OFF. The caution lamp and alarm
buzzer are also actuated at the same time to
warn of the abnormality.

8
%
5

ENGINE WATER TEMPERATURE SENSOR
TORQUE CONVERTER OIL TEMPERATURE SENSOR
1

P

@=D

Structure of circuit

1.
2.
3.

Connector
Plug
Thermistor

lo-176

Function
l

SEW00294

These sensors are installed to the engine
cylinder block and transmission
case. The
change in the temperature
changes the resistance of the thermistor,
and a signal is
sent to the maintenance
monitor to display
the temperature.
If the display on the maintenance monitor reaches the specified position, the lamp flashes and the buzzer sounds
to warn of the abnormality.

STRUCTURE AND FUNCTION

SENSORS

FUEL LEVEL SENSOR

F

E
K

Structure

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

Connector
Float
Arm
Body
Spring
Contact
Spacer

Y
of circuit

Function
.
The fuel level sensor is installed

to the side
face of the fuel tank. The float moves up
and down as the level of the fuel changes.
As the float moves up and down, the arm
actuates a variable resistance, and this sends
a signal to the maintenance
monitor to display the fuel level. When the display on the
maintenance
monitor reaches the specified
level, the warning lamp flashes.

10-177

SENSORS

STRUCTURE AND FUNCTION

ENGINE SPEED SENSOR
2

1

3

4
5
i i

a

o.mfG

,

0.85fG 2

Structure of circuit

1.
2.
3.
4.
5.

SBwooM)6

Function
.
The engine speed sensor is installed to the
ring gear portion of the flywheel housing. A
pulse voltage is generated by the rotation of
the gear teeth, and a signal is sent to the
monitor panel.

Magnet
Terminal
Case
Boot
Connector

ENGINE OIL PRESSURE SENSOR

1

2345

6

63

Structure

of circuit

SEW00290

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

Plug
Contact ring
Contact
Diaphragm
Spring
Terminal

lo-178

Function
.
This sensor is installed to the engine block
and the diaphragm detects the oil pressure.
If the pressure goes below the specified pressure, the switch is turned ON, and a relay is
actuated to turn the output OFF. This makes
the maintenance
monitor flash to warn of
the abnormality. The caution lamp and alarm
buzzer are also actuated at the same time to
warn of the abnormality.

STRUCTURE AND FUNCTION

ENGINE STARTING

ENGINE STARTING CIRCUIT

CIRCUIT
End

Engine stop
motor relav

w

Preheat
relay

Noncontrnuous
,,,’
ihatched portion)

Monitor oreheat
Alternator

relay

m

E

Slow-blow fuse

5

Function
.
A neutral safety circuit which inhibits engine

l

starting when the directional lever is at any
position other than N (neutral) is used to
assure safety.
.

Operation
.
When the starting switch is set to the START

.

.

position, voltage flows in the following
circuit: Starting switch terminal BR + stopping
motor relay terminals
1 and 2 + ground
connection. This excites the relay coil.
The current from the battery flows in the
following circuit: Engine stopping motor terminals A and B -+ relay terminals 5 to 3 +
motor. This turns the motor.
(The cable
stretches.)
When the motor turns, terminal D also turns.
When the non-continuous
section of terminal D reaches terminal B, the circuit from
terminal A to terminal B opens and the current from the battery to the motor is interrupted. The motor tends to keep turning due
to inertia, but when the non-continuous
section of terminal
D comes in contact with
terminal B, both motor poles are grounded,
so the motor stops turning.

l

.

l

In this status, the stopping motor cable is
fully extended, the fuel injection pump’s
stopping lever is at the FULL position, and
the operating status is set.
The current also flows in the following
circuit: Starting switch terminal BR + battery relay coil + ground connection.
This closes the battery relay switch.
When the directional lever is set to the N
(neutral)
position, the directional
lever
switch’s neutral contact is closed. At this
time, current flows to neutral relay terminals 1 and 2 and the coil is excited.
This causes current to flow in the following circuit a>: Starting switch terminal
C
+ neutral relay terminals 5 to 3 + starter
terminal C.
The following circuit is formed: + battery
relay -+ starter terminal
B. The engine
then starts. When the directional lever is
at a position other than N (neutral), circuit
@ is not formed, so the engine does not
start.

10-179

ENGINE STOP CIRCUIT

STRUCTURE AND FUNCTION

ENGINE

STOP CIRCUIT
End

Start

Engine stop
motor relay

L--p1

Engine stop motor

To preheating relay

Slow blow fuse

e
2%

To neutral

Noncontinuous
portion
(hatched portion)

Alternator

Starting motor

1OA

Function
l

The system is equipped with an electrical
fuel cut device (engine stop motor) which
makes it possible to start or stop the engine
by turning the starting switch ON or OFF.
This improves the ease of operation.

.

Operation
.
When the starting switch is turned OFF, starting switch terminals B, BR and C are opened.
l

.

The current in the stop motor relay is shut
off by the starting switch, so the coil is not
excited. Therefore,
terminals
3 and 6 are
closed.
The current from the battery flows from engine stop motor terminals
A - C + relay
terminals
6 - 3 -_j motor to rotate the motor. (The cable is pulled in)

lo-180

.

When the motor rotates, terminal D also rotates at the same time. When the non-continuous portion of terminal D reaches terminal C, the circuit from terminal A to C opens,
and the current from the battery to the motor is shut off. The motor attempts to continue rotating under inertia, but when the
continuous
portion of terminal
D contacts
terminal C, both poles of the motor are connected to the ground, and the motor stops
rotating.
In this condition, the stop motor cable is
completely
pulled in, and the fuel injection
pump lever is set to the STOP position to
stop the engine.

STRUCTURE AND FUNCTION

PREHEATING CIRCUIT

PREHEATING CIRCUIT
QUiCKGLOW SYSTEM (QGSI
Starting switch

*

I

Battery relay

tl

I I

Battery

QGS sensor

I

I
CNL05

Outline
l

l

l

I

/

Main monitor

The quick glow system (QGS) is provided to
improve engine starting performance
in cold
regions. The QGS acts to reduce preheating
time, and also sets the preheating
time automatically according to the water temperature when the starting switch is operated.
When the starting switch is turned from OFF
to ON (ACC), the preheat pilot lamp on the
main monitor panel lights up and the engine is preheated with the glow plug. The
preheating time is set by the QGS controller
in the main monitor, which detects the water temperature
using the QGS water temperature sensor in the engine.
When the pilot lamp is lighted, the engine is
being preheated. Set the starting switch to
the ON position. If the starting
switch is
turned to the START position, preheating
is
canceled.

CNLOG

CNL07

SLWcc611

Operatibn
When the starting switch is set to the ON
(ACC) position, a signal flows from starting
switch terminal
BR to the controller in the
main monitor, and the preheat output is connected to the ground. The preheat relay coil
is excited, the preheat relay is activated, and
this activates the glow relay.
A current flows in the following circuit: Battery + battery relay -+ glow relay + glow
plug. This sets the preheating mode.
When the signal indicated that preheating is
completed
is sent from the controller, the
preheat relay turns OFF, the glow relay also
turns OFF, and preheating is completed.

lo-181

ELECTRIC TRANSMISSION

STRUCTURE AND FUNCTION

ELECTRIC TRANSMISSION

CONTROL

CONTROL
Maintenance monitor

, Relays

Kick-down switch

Speed lever
Directionallever
Parking brake
switch,
\
i
Transmission cut-off
selector Switch

Brake pedal (left)
Transmissioncutoff
switch
Speed sensor

Transmission control valve

Function
1

Selection of F, R. and N positions

Using directional lever

2

Selection of speed range

Using speed lever

3

Kick-down switch

without using the speed lever. If directional lever is operated to R or N,

4

Transmission cut-off function

Transmission

When traveling in F2, it is possible to shift down to 1st using this switch
speed range automatically returned to 2nd.
is shifted to neutral when left brake is operated

It is possible to select whether to actuate or not actuate the
transmission cut-off function. In this way, it is possible to obtain the
5

Transmission

cut-off selector function

same or greater ease of operation as on conventional loaders with the
left brake when carrying out scooping work or when loading or unloading
the machine from a trailer.
To prevent seizure of the parking brake when traveling with the parking

Neutralizer

brake applied, the transmission is shifted to neutral when the parking
brake is applied.
If the directional lever is not at the N position, the engine will not start

Neutral safety function

when the starting switch is turned. This prevents the machine from
starting suddenly. (For details, see STARTING CIRCUIT.)

Warning function

When traveling in reverse, the backup lamp lights up and the backup
horn sounds to warn people in the area.

lo-182

STRUCTURE AND FUNCTION

ELECTRIC TRANSMISSION

CONTROL

COMBINATION SWITCH

b

IO

i

6

Outline
.
The directional

lever has three positions and
the speed lever switch has four positions. As
an individual part, the switch does not have
a detent mechanism; the detent mechanism
is in the combination
switch.
Each switch is
positioned by two pins, and is secured to the

body by three screws. When each lever is
operated to the desired position, the switch,
which is interconnected
by a shaft, acts to
allow electric current to flow to that circuit
only.

General locations, function
1

Directional

2

Speed

lever switch

3

Speed

lever stopper

4

Turn signal

lever switch

Switches
Selects

between
speed

Stopper

F, R, and N

range

used to prevent

speed

lever from

entering

3rd or 4th during

operations

indicators

Direction

indicator

Turn signal

5

Self cancel

6

Lamp switch

Switches

7

Dimmer

Selects

8

Hazard

after

switch

machines

Makes

switch

lamps

indicator
turns

turning

left or right

returns

to central

position

left or right

on clearance
high beam

used when

lever automatically

lamp,

for travel

head lamp,

parking

and low beam

both left and right turn signal

lamp,

etc.

for passing

indicator

lamps

flash at the

same time
9
10

Emergency
Parking

flashing

brake switch

pilot lamp

Flashes

at the same time as the emergency

Applies

or releases

parking

flashing

lamp flashes

brake

1O-l 83

STRUCTURE

AND

FUNCTION

ELECTRIC TRANSMISSION

CONTROL

Operation
Directional
lever (l)and
shaft
(2) of the
speed lever of the combination
switch form
one unit with magnet
(3). and magnet (3)
also moves together with lever (1).
Control switch (5) with built-in hole IC (4) is
installed at the bottom of magnet (31, and
hole IC (4) is positioned
on the board to
match each position.
When directional
lever (I) is operated to the
F position, magnet (3) is immediately
above
hole IC (4) for the F position of the control
switch. The magnetism
from magnet (3)
passes through the gap and case (61, and
magnetism
is applied to hole IC (4).
When this happens,
hole IC (4) is inside a
magnetism
detection circuit, so it detects the
magnetism
of magnet (3)and
sends the F
position signal to the electric current amplification circuit. In the electric current amplification circuit, a signal is output to actuate
the transmission.
SLWw613

lo-184

STRUCTURE AND FUNCTION

KICK-DOWN

KICK-DOWN SWITCH

SWITCH

1.
2.
3.

4.

Kick-down switch
Spring
Side cap
Wiring harness

SEW00303

KICK-DOWN SWITCH
Operation
l

l

l

The kick-down (shifting down from 2nd +
1st) is actuated only when traveling in F2.
When traveling in F2, if it is desired to shift
down to 1st without operating
the speed
lever, operate the kick-down switch on the
boom lever to ON to shift down to Fl.
After this, even if the kick-down switch is
pressed, the transmission
is kept at Fl.

Cancellation (or not actuated)
l

l

l

.

When directional.lever
is at N
When directional lever is at R
When speed lever is not at 2nd
When starting switch is OFF

lo-185

STRUCTURE AND FUNCTION

KICK-DOWN ELECTRIC CIRCUIT DIAGRAM

KICK-DOWN ELECTRIC CIRCUIT DIAGRAM
Normal operation
(directional lever at F, speed lever at 2nd)

H-L
v

Speed
Schoid
4

R
Solenoid
J2_I

pa**ing
J

CNL68
Kickdown
&lV

CNW
REVERSE
relay

CNLE6
FORWARD
relay

CNL.55
TE?nullGsion
clrt-afffelay

Directional lever set to F
When the directional
lever is set to the F
position, electric current flows from the battery @ + directional lever switch terminal 1
- 2 -_j FORWARD
relay terminal
5 - 6 +
ground.
As a result, the FORWARD relay is actuated
and terminals 1 and 2 and terminals 3 and 4
are connected.
.
Next, the current flows from the battery @
+ parking brake safety relay terminal 5 - 3
+ parking brake switch terminal
3 - 2 +
neutralizer
relay terminal
1 - 2 + ground,
and neutralizer relay terminal 3 - 5 are connected.
In addition,
electric current flows
from the battery @ + transmission
cut-off
relay terminal
1 - 2 + monitor, and transmission cut-off relay terminals 3 - 5 are connected.
.
Electric current flows from the battery 0 +
neutralizer
terminal 3 - 5 + transmission
cut-off relay terminal 3 - 5 + FORWARD
relay terminal 1 - 2 -+ solenoid 1 + ground,
and solenoid (1) is actuated.
l

10-186

CNL58

CNLY
stop lamp
rekV

CNL57
Neutral
=hV

lamp
wmh

brake
%%ZlUlid
valve

Speed lever set to 2nd
.
When the speed lever is at position 2nd, no
electric current flows to solenoids (2), (31, or
(4). In this condition, the transmission
valve
is set to F2 by the action of solenoid (I).
No current flows to the coil (relay terminals
5 - 6) of the kick-down relay if the kick-down
is not pressed. Therefore, the kick-down relay is not actuated, and the transmission
is
held in F2.

Solenoid actuation table

STRUCTURE

AND FUNCTION

KICK-DOWN

ELECTRIC CIRCUIT

DIAGRAM

Kick-down switch operated
(When operating or traveling in F2)
(When kick-down switch is pressed ON)

SLwol616

l

l

When the kick-down switch is pressed, electric current flows from the battery @ +
speed lever 2 + FORWARD relay terminal 3
- 4 -$ kick-down switch + kick-down relay
terminal 5 - 6 + ground.
As a result, the kick-down is actuated, and
kick-down relay terminals 1 and 2 and terminals 3 and 4 are closed. A circuit from
kick-down relay terminal 1 - 2 + kick-down
relay terminal 5 - 6 + ground is formed, so
the kick-down relay continues to be actuated even if the kick-down switch is returned.
(Self-hold circuit of kick-down relay)
When the kick-down relay is actuated and
terminals
3 and 4 are closed, electric current flows from the battery @ + kick-down
relay terminal 3 - 4 + solenoid 4 + ground,
and solenoid (4) is actuated. Solenoids (1)
and (4) are actuated, so the transmission
is
set to Fl.

In this way, if the kick-down switch is pressed
when the speed lever is at F2, the transmission
will shift to F’f. At the same time, it will be held
in Fl by the self-hold function of the kick-down
relay even when the kick-down
switch is released.
However
many times the kick-down
switch is pressed, the transmission
will stay in
Fl.

Solenoid

actuation

Solenoid

.Fl

FORWARD

t(l)1 0

REVERSE

(2)

H-L select

(3)

table
F2
10

F3

F4

t 0

10

0

0

I

SDeed select (4)

N
1

Rl
tI

R2
1
I

R3 R4
1
I

1
I

0000

0

0

0
3

c
0

lo-187

STRUCTURE

AND

FUNCTION

Canceling actuation
of kick-down switch
(Directional
lever moved to N or RI

.

.

.

KICK-DOWN

CIRCUIT

DIAGRAM

(Case I)

When the directional lever is moved to the R
position, the F terminal contacts are turned
OFF, so the electric current stops flowing
from the battery @ + directional lever F +
FORWARD
relay terminal 5 - 6 + ground,
and the FORWARD
relay is reset.
FORWARD
relay terminals 1 and 2 and terminals 3 and 4 are opened, so the electric
current stops flowing to the solenoid of the
kick-down
relay, and the kick-down relay is
reset.
In this way, the self-hold circuit of the kickdown relay is canceled, and terminals 3 and
4 are opened,
so solenoid (4) is no longer
actuated.
(When
the directional
lever is
moved to the N position, the actuation is the
same as above and the kick-down
relay is
canceled.)
In addition,
FORWARD relay terminal
1 and
2 are opened, so solenoid (I) is no longer
actuated.

1o-1 88

ELECTRIC

.

.

When the directional lever is moved to the
R position, current flows from the battery @
+ directional lever R + REVERSE relay terminal 5 - 6 + ground, so the REVERSE relay
is actuated and REVERSE terminals
1 and 2
and terminals 3 and 4 are closed.
As a result, electric current flows from the
battery @ + REVERSE relay terminal 1 - 2
+ solenoid 2 + ground, and solenoid 12) is
actuated. Therefore, only solenoid (2) is actuated, and the transmission
is set to the R2
position.

Solenoid

actuation

table

STRUCTURE

AND FUNCTION

KICK-DOWN

ELECTRIC CIRCUIT

DIAGRAM

Canceiing actuation of kick-down
switch (Case III
(speed lever moved to position other than 2nd)

Parkingswitch
lied1
H-L
speed
R
F
Solenoid Solenoid Sole&d Solenoid

CN37

CM8

SLWCC618

.

l

.

If the speed lever is moved to any position
other than 2nd, the electric current stops
flowing from the battery @ + speed lever
2nd + FORWARD relay terminals 3 - 4, and
the current to the kick-down
relay is also
shut off.
Therefore,
the kick-down relay is canceled,
and solenoid (4) is no longer actuated.
If the speed lever is moved to 3, solenoid (3)
is actuated. In addition, the directional lever
is at the F position, so solenoid (1) is actuated. Therefore,
solenoids (I)
and (3) are
actuated and the transmission
is set to F3.

Solenoid

actuation

table

lo-189

STRUCTURE

Canceling

AND

actuation

KICK-DOWN

FUNCTION

of kick-down

switch

(Case

ILlI

(starting switch turned OFF)
.

l

.

When the starting switch is turned OFF, the
electric current stops flowing from the battery @ + speed lever 2nd + FORWARD
relay terminal 5 - 6 -_j ground, and the kickdown relay is reset.
Therefore, the kick-down relay is canceled.
If the starting switch is turned ON again, the
self-hold circuit of the kick-down relay has
been canceled, so the transmission will work
as normal.

10-190

ELECTRIC CIRCUIT

DIAGRAM

TRANSMISSION

STRUCTURE AND FUNCTION

TRANSMISSION

CUT-OFF SWITCH

CUT-OFF SWITCH

I

8

\

7

SDWOO373

1.
2.
3.
4.

Case
Seal film
Disc
Vinyl tape

Outline
l

When the left brake pedal is operated, the
switch detects the oil pressure in the brake
circuit, shuts off the electric power to the
solenoid
valve circuit for the directional
clutch, and shifts the transmission
to neutral.

5.
6.
7.
8.

Tube
Connector
Cover
Spring

Specifications
Voltage
value
c;;r;;t

Mi:-i.
Max.
Min.
Max.

18 V
32 V
10 mA
2.3 A

10-191

the contacts of the transmission cut-off switch are opened. and the transmission is also shifted to neutral at the same time. When the left brake pedal is depressed. If the transmission cut-off selector switch on the main monitor is turned ON (pilot lamp lights up). and the transmission is shifted to neutral at the same time. If the transmission cut-off selector switch is turned ON. Transmission cut-off selector switch ON . +24V voltage is applied through only the transmission cut-off switch to transmission control valve solenoids R and F. the transmission is not shifted to neutral even when the brake is operated. so the left brake functions only as a brake in the same way as the right brake.5 are not connected. In this condition. the brakes are applied.STRUCTURE AND FUNCTION TRANSMISSION TRANSMISSION CUT-OFF FUNCTION CUT-OFF FUNCTION Transmission cut-off Switch combination switch Outline . so the voltage to solenoids R and F is shut off. the transmission cut-off relay solenoid is not excited. l . As a result. the brakes are applied as normal. When the left brake pedal is operated. so transmission cutoff relay terminals 3 . If the transmission cut-off selector switch is set to the OFF position (pilot lamp goes out). the transmission cut-off switch installed to the left brake pedal is actuated. lo-192 Operation 1.

STRUCTURE AND FUNCTION TRANSMISSION CUT-OFF FUNCTION n Transmission cut-off switch I KicGown switch 2. and transmission cut-off relay terminals 3 . the transmission is not shifted to neutral. the transmission cut-off relay solenoid is excited. Transmission CNL 68 Kick-down relay CNL 67 REVERSE relay CNL 66 FORWARD relay CNL 65 Transmission cut-offrelay CNL56 Neutralizer relay From parking brake switch (battery power) CNL57 Neutral relay cut-off selector switch OFF If the transmission cut-off selector switch is turned OFF. In this condition. +24V voltage is applied to transmission solenoids R and F regardless of the position of the transmission cut-off switch. 10-193 . even when the left brake pedal is depressed.5 are connected. As a result.

9. 7. 5. 2.STRUCTURE AND ELECTRIC PARKING FUNCTION BRAKE CONTROL ELECTRIC PARKING BRAKE CONTROL Outline . The parking brake is a wet-type multipledisc brake built into the transmission. 8. 3. the oil pressure from the transmission pump is applied to the parking brake cylinder and the parking brake is released. and the oil pressure inside the parking brake cylinder passes through the parking brake valve and is drained. 6. 10-194 1. When the electric current is cut. the oil pressure from the transmission pump is shut off. When an electric current flows to the parking brake valve (solenoid valve). 4. . The parking brake is then applied by the force of the brake spring. 10. Parking brake switch Parking brake emergency release switch Parking brake safety relay Parking brake emergency release relay Neutralizer relay Parking brake solenoid valve Transmission control valve Accumulator Parking brake emergency release valve Transmission (built-in parking brake) .

To overcome this. This sends the accumulator charge pressure in the brake piping to the parking brake cylinder to release the parking brake. the circuit is designed so that the transmission is not shifted to neutral when the emergency brake is applied. Applying and releasing parking brake The parking brake is applied or released by using the parking brake switch (combination switch). It is dangerous 5. Emergency brake If the pressure in the oil pump should drop because of damage to the hydraulic circuit and the braking force can not be ensured.STRUCTURE AND ELECTRIC FUNCTION Function 1.safety if the parking brake can be released simply by turning the starting switch ON after the automatic parking brake has been applied. To prevent this problem. Therefore. when the parking brake is applied. the braking distance will become longer if the transmission is shifted to neutral when the emergency brake is applied. the parking brake is automatically applied to prevent the machine from running away when the operator is away from his seat. Automatic parking brake When the engine stops (when the starting switch is OFF). Neutralizer The parking brake may seize if the machine is driven with the parking brake still applied. 4. However. to ensure safety. PARKING BRAKE CONTROL Parking brake emergency release solenoid valve If the supply of pressure oil from the transmission pump should stop because of some failure. 6. the parking brake is applied automatically to act as an emergency brake. the caution lamp lights up and the alarm buzzer sounds to warn the operator of the mistaken operation. 70-l 95 . Parking brake . 3. In addition to this. the transmission is forcibly shifted to neutral to make it impossible to drive the machine. it is possible to actuate the emergency relief solenoid valve with the parking brake emergency release switch in the operator’s compartment. It may also be necessary to move the machine if it stops in places where it is prohibited to stop (such as on railway crossings). the system is designed so the brake cannot be released unless the starting switch is turned ON and then the parking brake switch is also turned ON.

STRUCTURE AND FUNCTION ELECTRIC PARKING BRAKE CONTROL PARKING BRAKE EMERGENCY RELEASE SWITCH Connection table ml EMERGENCY BRAKE SWITCH 10-196 .

Case Base connection diagram SEW00321 10-197 .STRUCTURE AND FUNCTION ELECTRIC PARKING BRAKE CONTROL PARKING SAFETY RELAY NEUTRALIZER RELAY n i. ii Relay actuation table 6 5 3 1 2 Internal 1. 2.

so the parking brake is actuated.itch (manual) Parking brake safety relay Neutralizer relay Battery relay Starting switch To transmission directionalcircuit + i To transmission speed circuit (installedto accumulator) . the battery relay is opened. Starting switch OFF Parking brake sw. regardless of whether the parking brake switch is ON (applied) or OFF (released).ELECTRIC PARKING BRAKE CONTROL STRUCTURE AND FUNCTION OPERATION 1. if the starting switch is at the OFF position. When the starting switch is turned OFF. For this reason. so electricity does not flow to the parking brake circuit. (Automatic parking brake) 1O-l 98 . no electric current flows to the parking brake solenoid valve.

When this happens. .3 + parking safety relay terminal 1 . neutralizer relay terminals 3 and 5 are open.2 + ground.5 are closed. 10-199 . so electric current does not flow to the transmission directional circuit. in this condition. the parking safety relay is actuated and safety relay terminals 3 . l l In this condition. In this way. electric current does not flow to the parking brake solenoid valve. circuit @ is formed from the battery @ + battery relay + parking safety relay terminal 5 . electric current flows in circuit @ from the battery @ + battery relay + parking brake switch terminal 1 . so the parking brake is actuated. When this happens. the parking safety relay is in the condition of circuit @ until the starting switch is turned OFF. The electric current flows in circuit @ from the battery @ + starting switch + battery relay coil -+ ground. From this point.2 + ground. so the battery relay is closed.3 -+ parking brake safety relay terminal 1 . and the transmission is shifted to neutral. In addition.STRUCTURE 2. Starting 2-1 When AND FUNCTION switch parking ELECTRIC PARKING BRAKE CONTROL ON brake switch is ON (actuated) before starting switch is turned ON Parking brake switch (manual) Parking brake safety relay Neutralizer relay Starting switch Emergency brake switch (installedtb accumulator) .

the electric current does not flow to the parking brake solenoid valve. . so the parking safety relay is not actuated. so the machine does not move. so the battery relay is closed. However. Electric current flows in cjrcuit @ from the battery 0 + starting switch + battery relay coil + ground. in this case. the parking brake is not released automatically even when the starting switch is turned ON. the parking brake switch is OFF (released).STRUCTURE 2-2 When AND parking FUNCTION ELECTRIC brake switch is OFF (actuated) before starting switch PARKING is turned BRAKE CONTROL ON Parking brake switch (manual) OFF (Released Battery relay Starting switch r-----. 1O-200 Emergency brake switch (installedto accumulator) l In addition. the electric current does not flow to the transmission directional circuit.+ To transmission directional circuit To transmission speed circuit . so after the automatic parking brake is applied. For this reason.

For this reason. electric current flows in circuit @ from the battery @ + battery relay + parking brake safety relay + parking brake switch. 1O-201 .5 + transmission directional circuit. Parking brake switch When the parking ELECTRIC PARKING BRAKE CONTROL QFF (released) brake switch is turned from ON to OFF after the starting switch is turned ON Parking brake swth (manual) Parking brake safety relay Neutralizer relay Battery relay Starting switch D Y’ I Alternator terminal R - I To transmission directionalcircuit To transmissionspeed circuit . If the parking brake switch is turned from ON (actuated) to OFF (released). the circuit for terminals 2 and 3 of the parking brake switch is connected. Emergency brake switch (installedto accumulator) @ This circuit is formed from the emergency brake switch + parking brake solenoid valve -+ ground. so when the directional lever is operated. and the parking brake is released. @ This circuit is formed from the battery @ + battery relay + neutralizer relay terminal 3 .STRUCTURE AND FUNCTION 3. the machine will move. and then flows to circuits @ and @ given below. and the parking brake safety relay is also actuated.

so the circuit between terminals 3 and 5 is opened. At the same time. the circuit in the diagram above is formed. the oil pressure inside the parking brake cylinder passes through the parking brake valve and is drained. at the same time. Parking brake switch ON (actuated) Parkingbrake switch (manual) Parkingbrake safety relay + Neutralizer relay To transmission directional circuit + t To transmission weed circuit . . and no electricity flows to the transmission directional circuit. the neutralizer relay is reset. In addition. so the transmission is shifted to neutral. so the parking brake is applied by the force of the spring. Electric current does not flow to the parking brake solenoid valve. .ELECTRIC PARKING BRAKE CONTROL STRUCTURE AND FUNCTION 4. This kind of neutralizer relay shuts off the electric current going to the transmission solenoid valve when the parking brake is applied and shifts the transmission to neutral to prevent seizure of the parking brake if the operator should drive the machine with the parking brake still applied. 1O-202 Emergency brake switch (installedto accumulator) . If the parking brake switch is turned ON lapplied) after carrying out operations with the parking brake switch OFF (released). so the oil pressure from the transmission pump to the parking brake cylinder is shut off.

For this reason. because there is electric current flowing to the neutralizer relay coil. in this case. If the oil pressure in the main brake line drops. if the emergency brake has been applied and it is necessary to move the machine (for example. At the same time. electric current flows to the transmission directional circuit. and it is possible to engage the transmission clutch. if the emergency brake is applied when the machine is on a railway crossing). When main brake oil pressure drops (emergency brake actuated) Parking brake switch (manual) Battery relay n Starting switch _ Alternator terminal R 1 To transmissiondirectional circuit To transmission speed circuit (installedto accumulator) Operation . 1 O-203 . the emergency brake switch installed to the accumulator is opened. it is possible to use the engine brake when the emergency brake is applied. the electric current stops flowing to the parking brake solenoid valve. However. In this way. so the braking distance becomes shorter. so the oil pressure inside the parking brake cylinder is drained and the parking brake is applied. . the condition is different from the case where the parking brake switch is ON (applied).ELECTRIC PARKING BRAKE CONTROL STRUCTURE AND FUNCTION 5. For this reason. it is possible to move the machine by operating the transmission lever.

The oil pressure stored in the accumulator in the main brake line then flows to the parking brake cylinder to release the parking brake. When this happens. the buzzer sounds. The emergency release switch should normally be kept at the OFF position and should be returned to the OFF position after the emergency release. 1 O-204 . Parking brake emergency ELECTRIC PARKING BRAKE CONTROL release (Released) Parking brake emmergency Battery Battery relay n To battery power BrakzCC low pressure switch I-arK . and at the same time.--A --‘-void relearn SUIG’I t valve e aLWoca6 Operation . When the emergency release switch is turned on (released). . electric current flows to the emergency parking brake release solenoid valve. the oil pressure from the transmission pump to the parking brake cylinder is shut off and the parking brake is applied. the oil pressure in the main brake line is stored in the accumulator.STRUCTURE AND FUNCTION 6. If the machine should stop because of engine trouble.

so it is necessary to turn the parking brake switch ON to form the circuit.3 + parking brake safety relay terminal 1 + ground. Parking brake switch Transmission cut off switch I J-I-J I 43= II power source Transmission combination switch ke Kick-down switch CNL 66 Kickdown relay CNL 67 REVERSE relay CNL 66 FORWARD relay C% 65 Transmission cut-off relay CNL58 Neutralizer relay CNL 57 Neutral relay CNL59 Parking brake safrty relay Operation When the parking brake is actuated (ON). For this reason. so terminal 3 and terminal 5 of the neutralizer relay are separated. When the parking brake is applied. 3. so when the parking brake is applied. this relay keeps the transmission at neutral to prevent dragging of the parking brake due to mistaken operation.STRUCTURE AND FUNCTION ELECTRIC PARKING BRAKE CONTROL FUNCTION OF BARKING BRAKE NEUTRALIZER RELAY Outline . When the parking brake is actuated. no electric current flows to the neutralizer relay coil. the circuit in Item 1 is not formed. When the engine is started with the parking brake switch OFF (released). No electric current flows to the transmission directional circuit. the safety relay coil is actuated. terminals 3 and 5 of the safety relay are connected. the transmission is kept at neutral. and this circuit is formed. 1O-205 . electric current flows from the battery relay + parking brake switch terminal 1 .

....20.........20Measuring parking brake performance .. These standard a When safety carrying out testing............. .........20Measuring steering oil pressure ..................... ...........15 Measuring exhaust color ..20...20-30 Method of operating emergency manual spool ..... ........ or troubleshooting... ..................... adjusting............... travel of speed lever ................... .. .... 20Adjusting main monitor (speedometer module) .. 20-14 Testing and adjusting fuel injection timing ..........20Testing and adjusting boom kick-out ... .. g A When checking the water level........................ park the pins and blocks to prevent the machine from moving...................... ...................... ................. ................ 20TROUBLESHOOTING ......... 20-l a ....... values do not form a basis for judging out work together with other workers................................................................ 20-28 Measuring torque converter............20Measuring operating force............. .20Bleeding air from brake system... The standard values in the table are the values for a new machine and are given as reference values for the time when the machine is shipped from the factory....... ......20-19 Measuring engine oil pressure ................................. ..... so they should be used together with the information on the repair condition and other information such as the operating history of the machine when judging the condition of the machine....17 Measuring intake air pressure (Boost pressure) ....................................... bucket angle potentiometer..................................... .................... . 20-21 Testing and adjusting fan belt tension ..... the water Be careful not to get caught wait for the water to cool down... 20Adjusting boom........ 20-23 Measuring accelerator pedal ..... ........... the 1..................20-12 Measuring compression pressure......20...................... always machine use signals on level ground and use the and do not let unauthorized people near the machine..13 Measuring blowby pressure . 20-20 Measuring engine speed.....20Testing wear of parking brake disc .. ...........20-22 Method for adjusting engine stop motor cable.............20Measuring brake performance ..... parking brake oil pressure .... transmission...............7 Tools for testing. 20......... fan belt............20Measuring work equipment.......... .... and troubleshooting................... If the radiator cap is removed when will spurt out and cause burns......... always the water is still hot........ ........ and when carrying out repairs...........................20.. 20Measuring work equipment hydraulic pressure .....................20Testing brake oil -pressure .................20Measuring PPC valve pressure ... 2...................... The permissible values given in the table are values estimated 3....11 Adjusting valve clearance ...... 20-34 Testing and adjusting steering wheel . 20Measuring work equipment control lever .................20 TESTING AND ADJUSTING Standard value table for engine ................... g When carrying based on the results of various tests carried out on the machines shipped from the factory.................. in the fan......20Testing for brake disc wear.......... .......................... These values should be used as a guide when estimating wear and tear after the machine is operated.................20.................. and troubleshooting .......20-25 Measuring operating force............. .......... . adjusting..... or other rotating parts.........3 Standard value table for electrical system ..................... ......... . 20Testing and adjusting bucket positioner.... . ... ............. 20-18 Measuring exhaust gas temperature... claims...................2 Standard value table for chassis............... 20-27 Measuring stall speed .... 20Manual release method for parking brake .20Testing and adjusting steering control ....20-32 Measuring clearance between tire and wheel ....... ......... following precautions are necessary..................... travel of brake pedal .... ................ 20- 35 38 39 41 42 43 44 45 46 47 48 49 51 53 55 57 58 60 61 101 * When using the standard value table to make judgement for testing and adjusting...................20.................

) resistance (intake air temp.07 (0.Fan pulley) mm 5- 10 5- 10 .2) 0. 0.0.66 valve Oil temperature: 40 .9 (Min.200 750 20°C) gas color Bosch index Max.450 t value 100 +lOO 760-m 2.300 rpm) At rated output Blowby (SAE30 pressure oil) (Water temperature: Operating range) (Water temperature: Operating range) At high idling (SAE30) MPa At low idling Oil pressure (SAEBO) kg/cm At high idling At low idling Whole speed range (inside oil pan) Oil temperature Fuel injection timing Fan belt tension 0 1 22 2 1 Before top dead center Deflection when pressec with finger force of approx.0 2.200 Max.25 .1.29 .8) (SAEl OW) Min.450 2 50 Permissible 2. 1.7) (SAEl OW) 0.18 (1. 0.1 (Min.5.1) Min.650 700 950 . 5.12 (Min. 1.0 .60°C (engine MPa kg/cm*) Min.5 Max.0) 0. 1.07 (0. 80 160 0.5 7. (Alternator 20-2 “C pulley .21 (2.0. 30) nmf Max.0 0.0) 0.5 . 2.5) 0.7) 90-110 120 speed: 250 .4. 6 kg.34 lnta ke valve Valve clearance (cold) Standard All speed At sudden Exhaust S6Dl08 I “C (Turbine FOR ENGINE WA380-3 I Engine Exhaust TABLE VALUE TABLE FOR ENGINE Machine Engine VALUE mm Exhaust pressure 0.49 (3.TESTING AND ADJUSTING STANDARD STANDARD model Item I Measurement conditions Unit speed vm Low idling Rated speed temperature I I High idling intake inlet temp.44 (2. At rated output mmHg acceleration At high idling Compression (SAE30 oil) value 2.

1 1) 0. (21.:f) 0.3 (23 2.:.9 (30 2..925 + 200 58. 5 +as -1.5) 108 (II) Operating angle deg.s (10:.305 + 200 1.$ (30 “-.44 $j” (4.7. (28 ‘. ) (23 2 ) 1 2.7 $2. 2.5) 0.5 $:.2 ) 0.3 2:.290 * 100 2.5 High idling Low idling MPa (kg/cm21 * + ? + * * 0.1 3:. ) 20-3 0 .12 (3.1 (21.9 $:.73.98 $1.8 .: (28 “-.80°C I Travel 2nd tf 3rd 1 mm I 3rd ts 4th Priority pressure 40+ 10 I 40 f 20 40+ 10 I 40 a 20 10 I 40 + 20 40+ 2.98 (IO 2.34 + 0.5) 0.5) 2.lf 1 2.5 (6 .2 2 ) 0. 11 I 31 f 3 - I Stopper height Operating force Operating force ‘El -Gizq l Engine stopped Torque converter oil temperature: 60 .7 (28 0.5) 0.5 2.7 (28 + * * * + ? + + 0.7 $1...15 1. 2.5 :y:g) 0.8) 0.TESTING AND ADJUSTING STANDARD Cate w! STANDARD VALUE TABLE FOR CHASSIS VALUE TABLE FOR CHASSIS Item Measurement conditions Unit Standard I m-n Operating force value 2.5 -+ 0.08 (3.44 (4.34 +c”J* -0.290 ir 50 1 2.305 + 100 I 2.15 1.925 + 100 1.15 1.34 3.05 0.5) 0.

5 deg.55°C Operating time Max. dry paved road surface Speed when applying brake: 20 km/h.5 5.TESTING AND CateWY STANDARD ADJUSTING Measurement Item l A Fitting of wheel lock ring conditions Unit Tire inflation pressure: Specified pressure . 1 (210:. brakingdelay:0.34 (Max.6 $1. straight.5 - Engine stopped Machine facing straight to front dry paved road surface Hydraulic oil temperature: 45 . 3.0 Sec.19.5) 4.sssble value TEW00004 9 Flat. 2. 20 mm High idling E 2 Perrai.3 (3. 50 11. straight.55°C Low idling MPa (kg/cm? 20.5 2TEWoooo3 Play $ f VALUE l Flat. Brake pedal operating force: 265Nt27kg) Tire inflation pressure: Soecified pressure m Max.2. 0.0) 34.2 .200rpm mm 45 . Operating force TABLE FOR CHASSIS Max. l Clearance between front frame and rear frame Pal ‘%z E? Y.5) Thickness of disc 1 mm / 8.6 (1.-E IClearance of wheel lock ring l ? ‘= 8 Z Standard l l low idling - Max..1 sec.7 6.8 .55°C Play - 45 15+ a2 l l Performance l l l Drop in hydraulic pressure / 20-4 0 - 12 Max. l l Relief pressure l l Operating force l Engine speed: Hydraulic oil temperature: Engine speed: Hydraulic oil temperature: Engine speed: Hydraulic oil temperature: 1.4 (30 f 3) 45 . (210:: 20.55°C High idling 45 .5) Max. 4. 3.2 1 . 5 Max. horizontal.34 (Max.0 f 0. 0. 5 Max.15 MPa - 1 I 7.0 2.7 f 0..9 MPa (50 kg/cm2’ in 5 minutes I(kg/cm?I Max.62:. a1 Operating angle - 40 t 5 294 + 29.’ 472 (43) I - 5 + 0. 4. horizontal.

2.6) Max.3 2.7 (Max. 23.3 8.5 5.7 1.5) 37.5 (2.4) 35.7 zrz0.3) 67+ 15 67 i 30 53+. 14.8 20-5 0 .8 f 0. 2.96(210 + 20) 5.3 (3.5 (Max.2 + 0.7 (Max.3 (3. 2.2 f 0.“) 0 1 Boom lifting time 1 l l Bucket horizontal temperature: 45 .3 (3.3 1.5 (Max.4) 35.1 1.8) LOWER+ FLOAT FLOAT -_)HOLD HOLD + DUMP l Bucket HOLD -+ TILT l Engine speed: Low idling Hydraulic oil temperature: 45 .6) RAKE + HOLD Max. 15.3 (3. 2.6) 23.5) 22..6 +1. 23. 24.55°C Engine speed: High idling Steering valve: Neutral Sec.:.3 2.7 2.4) HOLD + LOWER Max.6) Max.3 (3.83 HOLD + RAISE Max.08 2.STANDARD VALUE TABLE FOR ENGINE TESTING AND ADJUSTING I Category Measurement Item l l Performance l conditions Unit Tire inflation pressure: Soecified oressure Flat paved road with l/5 (11020’) grade Dry road surface Machine at operating condition Standard - value - Stopped I 3. 1.3 * 0.8) Wear of disc l mm Thickness of disc -I- Boom - LOWER+ HOLD I 37. 20.75 I 53 * 30 67 f 15 I 67 I? 30 60+ 15 I 60 + 30 6Of: 15 I 60 f 30 ~~~+LzG&G 20.5 (Max.(210:. 23.6 (2.0 1.5 (Max.4) 35.4 * 0.55°C TILT -3 HOLD HOLD-+ RAISE Boom I HOLD-+ LOWER mm HOLD + FLOAT I I HOLD + DUMP Bucket HOLD + TILT Max.6+_. 1.

STANDARD VALUE TABLE FOR ENGINE of bucket switch l Max.0 20 mm l l 3-7 - 3-7 - l mm ..0 20 Max. 15. z al > I conditions Hydraulic oil temperature: 45 . bucket horizontal No load Hydraulic oil temperature: 45 .is&ble l Retraction of boom .TESTING AND ADJUSTING Cate-’ WY $1 .E. 15.55°C Leave for 5 minutes after stopping engine then measure for next 15 minutes Bucket empty.E Clearance positioner E 2 Q Clearance of boom kick-out switch 20-6 0 Measurement item W *= :. cylinder rod Retraction of bucket cylinder rod > Cc E o .55°C I Unit I Standard value Pe’vm.-. boom.

cE()2nOnected 1) f$$ing switch 2) Ring terminal disconnected Ring terminal letween alternator erminal R Ind chassis 2) CNB13 disconnected LNBOB disconnected disconnected Normal if as follows: Engine oil pressure sensor switch 2) CNElO disconnected Normal if as follows: Dust indicator 2) CNROG disconnected Noncontinuous Normal if as follows: Engine oil level sensor switch 2) CNT07 disconnected CNT07 (male) Normal if as follows: Radiator water lever sensor 1) S&. Judgment Measurement conditions table Normal if as follows: Fuel level sensor 1) ga$ing 2) CNR07 disconnected CNR07 (male) Normal if as follows: I Engine water temperature sensor I I I 1) gtFting CNROG (male) Radiator water level normal _ Between @and Radiator water level abnormal 7) g. 1) Engine started 20-7 0 .a$ing switch Continuous @ CNElO (male) Brake oil pressure sensor CNB13 (male) CNB08 (male) r 1) z. the voltage may not rise directly after the engine is started.5 to 29.:ing 1) gEaFrtingswitch Brakeoil pressurenormal Between Brakeoil pressure abnormal aand Continuous @ Noncontinuous Normal if as follows: CNE19 (male) CNE20 (female) Alternator 1) Starting switch OFF 2) CNE19 F.Fningswitch 2) CNEOG disconnected CNEOG (male) Normal if as follows: To&e converter oil temperature sensor switch When engine is running (l/2 throttle or greater) --f 27.TESTING AND ADJUSTING STANDARD sys tern STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM VALUE TABLE FOR ELECTRICAL SYSTEM Name of component Zonnectol No.5V * In cold regions or if the battery is weak.

g -:._ CNTOZ (male) R.vl E’ g CNT04 (male) 20-8 0 * % .5V .$ing switch 2) Connector disconnected .P z .r z $ Normal if as follows: CNTIP (male) * 05 2E SE .STANDARD TESTING AND ADJUSTING w Name of component terr - Measurement conditions Judgment table Between alternator terminal R and chassis Alternator VALUE TABLE FOR ELECTRICAL SYSTEM 1) Engine started When engine is running (l/Z throttle or greater) & + 27. solenoid m _c g 1) Starting switch BetweenOand@ CNTOG (male) 5 : k . the =? voltage may not rise directly after the engine is started.z 2 E I= valve E $Z m Modulation solenoid >I ‘) ~i?%ected Normal if within the following range: 1) g$ng 500to 1000 !A switch 2) CNTOG disconnected CNTOl (male) F.II 2 zz “E 1) Starting switch OFF 2) Connector disconnected Normal if within the following range: Between 0 and @ Between @I and chassis 46 to 58 R 1 MR or greater 1) Starting switch OFF 2) Connector disconnected Normal if within the following range: Betweenaand@ Between 0 and chassis 46 to 58 R 1 MR or greater 1) Starting switch OFF 2) Connector disconnected Normal if within the following range: Between@and@ Between 0 and chassis 46 to 58 Q 1 MQ or greater 1 Normal if within the following range: Between 0 and @ Between 0 and chassis 12 to 15 a 1 MR or greater 1) g.4 In cold regions or if the battery is weak.5 to 29.” 31 0: aQ. solenoid E aal :E SE . E 0 E 2 CNT03 (male) HL. >” 3 i CNE05 (male) E . solenoid Qal ZE SE .szJ 3% aa & = 3 a: 5 g Speed solenoid ‘ZJ .

. Bucket tilt solenoid if within the following CNF26 (male) 80..ing switch CNL29 (male) 2) Connector disconnected CNF21 1) Starting switch OFF 2) Connector disconnected Normal if within the following range: Between 0 and 0. STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM Inspection Judgment method Normal if within the following Bucket dump .8 to 20. cE 32 .8 R Between 1s and chassis 1 MR or greater range: if within the following range: switch 1) Starting switch OFF 2) Connector disconnected 1) za$ing switch 1) g.II 3 $% ua E Normal if within Between the following Boom lever raise pressure switch range: (3 and @ 18.TESTING AND ADJUSTING sys. boom lever operated Boom lever iower pressure switch 1) ga$ing 2) Connector disconnected CNF28 (male) Normal Bucket angle potentiometer switch 2) Connector disconnected Normal if within the following Boom angle potentiometer range: CNF24 (male) E solenoid 1) ga$ing 2) Connector disconnected (male) Normal Dumping range: CNF25 . ten Name of component Connector No. solenoid- Measurement conditions table CNF22 1) gpFting switch 2) Connector disconnected 20-9 0 .

ing <I) and 0 20 to 40 R switch switch 2) CNAFG disconnected I) Starting switch OFF 2) CNAF7 disconnected CNAF7 (male) E: E Speed sensor CNTOG (male) Q)(I) FE SE W v) 2 ‘3 $ 20-10 0 Normal if within the following Between % and :z range: 1) S&rting 500 to 1000 R 2) CNTOG switch disconnected 5 5 .ztor STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM Inspection method Judgment Measurement conditions table E 8Q Relief solenoid CNAF4 (male) I ES .- Name of component ten 1 - Con.!!? 3 :: !Jz[T’L.$ 3 $I a: 8. E I) Starting switch OFF 2) CNAF4 disconnected Between Normal @ and a 20 to 40 R if as follows: Between 2) CNAF5 disconnected 1) F.TESTING AND ADJUSTING SYS ..rting 2ia High pressure solenoid CE CNAFS (male) SE .E 5 $3 UQ’ E Between 0 and 8 20 to 40 R E 1) F. Low pressure solenoid Pressure switch CNAFG (male) E dE SE .

6.500mmHg gauge I - Tester - 1Push-pull scale Commercially available Thickness Commercially available Angle Commercially available Push gauge Commercially available Scale I 0 . and exhaust temperatures Compression 799-203-8001 A measurement I R I Commercially available . ADJUSTING. 400.OOOrpm : 60 .30kg) - gauge - gauge 1 i I - Brake oil pressure P 793-605-1001 1Brake test kit Length Q Commercially available Slide calipers - Stop watch - Speed temperature G ___ 2 Intake air pressure exhaust 1Pressure gauge 2.9 MPa (0 .TOOLS FOR TESTING.70 kg/cm21 Kit Part No.45. oil. 600 kg/cm2) - 1 Pushing Measure hydraulic : 60 . Check or measurement ADJUSTING. TESTING AND ADJUSTING TOOLS FOR TESTING. AND TROUBLESHOOTING AND TROUBLESHOOTING 1 Part I Name Remarks Digital Engine speed 799-101-1502 Digital temperature 799-201-I Wiring harness 799-101-5002 Analog hydraulic 790-261-1203 Digital 799-401-2320 Hydraulic 7 795-502-1590 Compression 2 795-502-1370 [Adapter I 1 79szol-1511 /Tool I 2 799-201-1541 Gauge 3 799-201-1571 Tube 4 799-201-1450 Adapter Commercially available Feeler gauge 799-201-9000 Handy smoke pressure I) pressure Commercially available Smoke meter 799-401-2310 Pressure 799-601-7400 1T-adapter tester F color f H Troubleshooting of wiring harnesses and sensors Commercially available 7gA-264-0020 Pressure gauge 49. Part item Symbol No.2.19.999rpm - E- Valve clearance Exhaust 110 display L H gauge C Oil pressure Blowby Multi-tachometer B Coolant.0 MPa gauge (IO kg/cm*) 0 .294N (0 .loratron % x l/10 + Bosch checker M angle 1. 60.70 % (with standard color) !Cm)$e.88. 58.8 MPa (25. 39. 795-502-1205 gauge - Kit Part No.2. 799-201-7504 Discoloration 0 .0 MPa (500 kg/cm*) tester 1. 5.

watch the function of the 6th cylinder’s intake valve. 6.1 f 4. . adjust the 1st cylinder. adjust the adjust screw (IO) so that it turns gently. Disconnect the two dust indicator wires (I). ADJSTING VALVE CLEARANCE Lift and remove the engine hood. then disconnect intake connector (2). l Intake valve * l l Exhaust valve * 2 1 4 3 l 0 c! 5 l 6 c! C : l . Turn the crankshaft forward.5 kgm) Set the 1st cylinder to the upper compression dead point. then remove cylinder head cover (5).34 Exhaust side: 0.66 w Locknut: 44. 4. insert filler gauge F between locker lever (8) and valve stem (91. . turn 120”.Z To adjust. then turn the crankshaft 360” in the forward direction and adjust the valves indicated with Y. 2. VALVE CLEARANCE .6TOP” line (6) on the crank pulley with the pointer (7).5 + 0.9 Nm (4.6 .3 .2 . and line up the “1. and adjust the valve clearance for all cylinders in this way in the order of ignition. 3. Remove air cleaner assembly (3). Order of ignition: 1 . 5. If the 1st cylinder is at the upper compression dead point. Valve clearance (when cold) Intake side: 0.5 .4 After tightening the locknut.TESTING AND ADJUSTING ADJUSTING 1. check the valve clearance once again. * Valve arrangement Cylinder no. 9 20-l 2 0 8 10 . Remove intake connector (41.. then tighten locknut (I I). adjust the valves indicated with “0” in the valve layout table.I1 .

Connect 6. fan belt or other rotating parts. Install adapter Dz in the mount of the nozzle holder of the cylinder to be measured. Warm up the engine (oil temperature: 40 . Remove spill tube (1) and disconnect fuel injection pipe (2). R Be careful not to let dirt or dust get in. m Nozzle holder mounting bolt : 44. and tighten to the specified torque. 4. 8 : s compression gauge DI to adapter D2. Remove nozzle holder (3) and pull out nozzle assembly (4). or to get your clothes caught in the fan. Ir For details of the standard value for the compression pressure.5 kgm) 5. * If the adapter mount is coated with a small amount of oil. 3.5 f 0. it will reduce leakage. then crank the engine with the starting motor and measure the compression pressure at the point where the pressure gauge indicator remains steady. For details. Adjust the valve clearance. set to the NO INJECTION position.60°C) before measuring the compression pressure. see ADJUSTING VALVE CLEARANCE.TESTING AND ADJUSTING MEASURING PRESSURE MEASURING COMPRESSION PRESSURE COMPRESSION measuring the compression A When careful not to touch’ the exhaust pressure.1 f 4.9 Nm (4.3 . 1. see STANDARD VALUE TABLE FOR ENGINE. . be manifold or muffler.’ 2. Disconnect connector (6) of stop motor (51.

then connect tools E3 and Ez. Run the engine at the rated output and measure the blow-by pressure. defective exhaust gas color. * 20-14 a BLOW-BY PRESSURE BLOW-BY * . Blow-by varies greatly according to the condition of the engine. Therefore. In this case.TESTING AND ADJUSTING MEASURING PRESSURE Raise the coolant temperature to the operating range before measuring the blow-by pressure. and prematurely ditty or deteriorated oil. check for problems connected with defective blow-by. If it is impossible to check at rated output or stall speed. if the blowby value is considered abnormal. * The blow-by should be measured with the engine running at rated output. MEASURING E4 El TBW007 14 . Install tools El and El to the tip of engine breather hose (I). be careful not to touch any high temperature parts or rotating parts. the blow-by value will be about 80% of the value at rated output. 1. a similar value can be obtained at stall speed. 2. When measuring in the field. A When measuring the blow-by pressure. . such as excessive oil consumption. measure at high idling.

Gently turn the crankshaft in the forward direction and align the crankshaft pulley’s injection timing line (1) with the pointer (2). m Nut (3): 66. * If they are not aligned. s With the 1st cylinder at the top position. the delivery valve copper gasket and 0 ring must be replaced with new ones.7 2 7. 2. 2. move the injection pump. as follows: “Mark alignment adjustment” for mounting the injection pump on the original engine without repairing it. ADJUSTING FUEL INJECTION TIMING I There are two methods for testing and adjusting the injection pump fuel injection timing.8 + 0. ‘? \ \ \ \ cm% . loosen long-hole nut (3) and pump installation nut (41. “Delivery valve adjustment” for injection pumps which have been repaired or replaced. Remove Remove the 1st cylinder fuel injection delivery valve holder (7).8 kgm) Testing and adjusting using “delivery valve adjust- ment” 1. 8 k 3. then tighten the nuts. align the lines.8 Nm (6. Refer to the section “Adjusting Valve Clearance” and set the 1st cylinder to the upper compression dead point’before testing and adjusting. Prepare these new parts beforehand. Check that line a on the injection pump side is aligned with line b on the injection pump drive case side.TESTING AND ADJUSTING TESTING TESTING AND ADJUSTING FUEL INJECTION TIMING and adjusting using “mark alignment ad- justment” 1. turn the crankshaft 30 to 40” in the reverse direction. When using “delivery valve adjustment”. Testing AND tube (5).

Set the fuel control lever to the full-speed position. in the forward 2) Gently turn the crankshaft direction and carefully align the pulley injection timing line (I) with the pointer (2). After testing and adjusting. With the 1st cylinder at the top position. the injection pump installation 4) Tighten flange’s long-hole nut and the pump instaiiation nut. slowly turn the crankshaft forward. If the injection timing is off. * if the injection timing line has moved past the pointer : The injection timing is slow. use the following procedure to adjust it. turn the pump side flange little by little. operate the priming pump. turn the crankshaft 30 to 40” in the reverse direction. * If the injection timing line has not reached the pointer : The injection timing is fast. then reassemble delivery valve holder (7). 20-16 0 FUEL INJECTION TIMING e 0 7 . check that the crankshaft pulley injection timing line (I) and pointer (2) are aligned. 4. operate the priming pump. 5.TESTING AND ADJUSTING 3. and stop at the position where fuel stops flowing from the delivery valve holder. and check the position at which the f!ow of fuel from the delivery valve holder stops: At the position at which the fuel flow stopped. Align marks a and b and stamp. i) * 5) * * Retest the injection timing and check that it is accurate. Always replace the delivery valve’s copper gasket and 0 ring with new ones. do not forget to reassemble the spring and delivery valve. 3) Loosen the injection pump installation flange long-hole nut (3) and pump installation nut (4). * TESTING AND ADJUSTING Remove spring (8) and delivery valve (9) from delivery valve holder (71.

2) Connect the probe hose. gas color. Measuring a EXHAUST with smoke meter gas color. and read the indicated value. use the smoke meter. be carepipe or any other TEWOOO21 Warm up the engine (oil temperature: 60%) before measuring the exhaust gas color. depress the accelerator pedal and operate the relief valve to catch the exhaust gas color on the filter paper. * Warm up the engine (oil temperature: 60°C) before measuring the exhaust gas color. accelerator switch plug. 7) Lay the filter paper used to catch the exhaust gas color on top of unused filter papers (IO sheets or more) inside the filter paper holder. and at the same time. * The pressure of the air supply should be less than 1. 20-l 7 0 . use smoker the checker. 4) Loosen the cap nut of-the suction pump. when recording official data. be carepipe or any other Gz When measuring the exhaust ful not to touch the exhaust high temperature part. 1) Insert the probe into the outlet port of the exhaust pipe. Measuring Ir COLOR When measuring in the field when there is no air or power supply. then tighten the clip to secure it to the exhaust pipe. 5) Turn the power switch. then fit the filter paper. check first that the power switch is OFF. 6) Accelerate the engine suddenly. 1) Fit filter paper in tool GI. 2) Insert the exhaust gas intake port into the exhaust pipe. and at the same time operate the handle to catch the exhaust gas on the filter paper. 3) Remove the filter paper and compare it with the scale provided to judge the condition. accelerate the engine suddenly. and air hose to tool G2.TESTING AND ADJUSTING MEASURING + MEASURING EXHAUST COLOR with handy smoke checker GI g When measuring the exhaust ful not to touch the exhaust high temperature part.5 MPa (15 kg/cm% 3) Connect the power cord to the ACIOOV outlet. Ir Fit the filter paper securely so that the exhaust gas does not leak. * When connecting the cord.

Insert the gauge about half way. and use the self-seal portion of the gauge to bleed the oil from inside the hose. be careful not to touch any high temperature parts. and repeatedly open the self-seal portion to bleed the oil. removing or installing the measuring equipment. . Run the engine at the rated speed and measure the pressure indicated by the gauge. AWhen carrying out the measurement. Connect oil pressure measurement hose (3) to coupler (2) and pressure gauge H (1500 mmHg). Remove intake air pressure measurement plug (1) (PT l/8) and install coupler (2) of oil pressure gauge kit C. f 3. Note: Run the engine at a mid-range speed or above. The gauge does not work if there is any oil inside the hose.TESTING AND ADJUSTING MEASURING MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) A When 1. 2. be careful not to touch any high temperature parts or rotating parts. so always be sure to bleed all the oil. 20-18 0 INTAKE AIR PRESSURE (BOOST PRESSURE) .

then install temperature sensor (2). and this is continued until the sensor core heats up and a stable value is obtained. t Use the PEAK mode function (the maximum value can be recorded) of the temperature gauge. cancel the hydraulic relief. If it does not go down and continues to go up. 1) Use the full stall (torque converter stall + hydraulic relief) to raise the exhaust gas temperature . or 6215-71-8170 (cable length: 490 mm) 2. 1. When measuring maximum value for exhaust gas temperature Carry out actual work and measure the maximum value when operating. so if the machine has been operated. 2) From the above condition. and carry out only torque converter stall. wait for the manifold to cool down before installing the sensor. * Raise the coolant temperature range before measuring. the torque converter will overheat. tempeiature to the operating gauge 6 with Measurement procedure 1. Connect to digital wiring harness. 3) When the temperature record the stable temperature.) starts to go down. X type dp-mector Temperature sensor #3-naIeI~~ Harness Tmwo716 20-l 9 0 . make the temperature setting at 1) higher. (The temperature will start to go down. Remove plug (1) from the exhaust manifold. Measuring at torque converter stall If the exhaust gas temperature is measured only at torque converter stall.TESTING AND ADJUSTING MEASURING MEASURING EXHAUST TEMPERATURE EXHAUST GAS TEMPERATURE GAS AThe temperature sensor is installed to the exhaust manifold. * 8 z 3 2. . Temperature sensor : 6215-1 l-8180 (cable length: 610 mm).

Install coupler (I) on the oil pressure release port. 4. Remove plug. 3. When measuring the oil pressure. 2. always measure at the specified oil temperature. Attach hose (2) to coupler (1) and install tool C (gauge: 0. Always stop the engine before removing or installing any oil pressure sensor or oil pressure gauge. Start the engine and measure the oil pressure. 20-20 0 MEASURING ENGINE OIL PRESSURE . get caught ENGINE OIL be careful not to let your in any rotating part. 1.98 MPa (IO kg/cm*)).TESTING AND ADJUSTING MEASURING PRESSURE g When clothes Ir Ir measuring.

be careful not to touch any high temperature parts. Connect tachometer cable. be careful not to touch any high temperature parts or rotating parts. see the procedure for each item. * When measuring items other than the above (during torque converter stall). * Measure the engine speed under the following conditions.MEASURING TESTING AND ADJUSTING MEASURING ENGINE SPEED ENGINE SPEED A When removing or installing the measuring equipment.55°C 1. Start the engine. then TBW00413 2. A and the adapter with the AWhen carrying out the measurement. 3. I) Coolant temperature: Within operating range 2) Torque converter oil temperature : 60 . TBW00414 20-Z 1 0 . Remove cap (I) from speed pick-up install adapter @ of tachometer A. 1 port. and measure the engine speed when the engine is at low idling and high idling.80°C 3) Hydraulic oil temperature : 45 .

a force of approximately 6 kg to the fan belt midway between the fan pulley and alternator pulley and check its deflection “a”. Loosen the alternator assembly installation bolt and nut (I) and belt tension adjustment bolt (2).. Move the alternator using a pipe. the fan belt tension Apply .TESTING AND ADJUSTING TESTING AND ADJUSTING FAN BELT TENSION TESTING AND ADJUSTING FAN BELT TENSION Testing 1. then the alternator installation bolt. 20-22 0 . Belt deflection a : 5 to IO mm TBwoo415 Adjusting the fan belt tension 1. then first tighten the adjustment nut. 2. check the belt (3) tension. . etc.

20-23 0 . and temporarily assemble the cable (2) to the bracket (5).2. secure the cable at a point where stop lever (4) contacts engine STOP stopper. l/2 turns). Ir Engine stop motor (1) is at the engine STOP position with cable (2) pulled.5 mm. and temporarily assemble to the bracket with locknuts (6). Adjust with nut (6). then install the ball joint to the stop lever of the injection pump.(7).TESTING AND ADJUSTING METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE 1 TBWOO417 1. 3.5 .(7) which secures the cable to the bracket or carry out fine adjustment by changing the depth that ball joint (3) is screwed in. 4 TBWO3418 Adjust stop lever (4) of the injection pump and STOP stopper at the stop end so that clearance a is 0. Temporarily install ball joint (3) to cable (2) of engine stop motor (I) (screw in fully. Pull stop lever (4) of the injection pump by hand to the engine stop position (no injection of fuel). 2. Ir Stop lever (4) of the fuel injection pump is at the RUN position when the lever is free (it is pulled by a spring to the RUN side). then turn back approx. When this is done.

5 mm when the engine is stopped. * There is a loose spring inside the engine stop motor.ine stop adjustment does not Engine does not give full output because of drop in amount of fuel injected .TESTING AND ADJUSTING METHOD 4. 1) Check visually that there is slack in the engine stop motor cable when the engine is running. and check that the engine stop motor and cable work smoothly. if this is absorbed by the loose spring in the engine stop motor. all nuts and bolts. However.2. there is slack in the engine stop motor cable. so depending on the machine model. then carry out the following checks again. there are built-in limit switches at both ends of the cable stroke. and that the stop lever of the fuel injection pump has returned fuliy to the RUN position. 20-24 0 FOR ADJUSTING * l l Problems of engine ENGINE STOP MOTOR CABLE caused by improper stop motor cable When engine stop motor cable is pulled and clearance between stop lever and STOP stopper is too large When cable is free and clearance between stop lever and RUN stopper is too large l l Eng. Tighten 5. and this absorbs the error in the stop motor when the engine is stopped.5 . * With the engine stop motor. this system may not be possible to use. 2) Check that the clearance between the stop lever (4) and stopper at the STOP end is 6. there is a danger of problems arising with the injection pump if the clearance between the stop lever and the stopper at the STOP end is set to 0 when the engine is stopped. force is brought to bear on the injection pump. Turn the engine starting switch repeatedly to the ON and OFF positions. With such models. * Engine stop motor stroke: 35 mm Fuel injection pump stop lever stroke: 30 mm Ir When the engine is running. and the RUN position is maintained by the action of a spring (this is frequently built into the fuel injection pump).

98Nm(1. MEASURING Set push-pull scale from pedal fulcrum * Put the center contact with a pedal fulcrum. ACCELERATOR PEDAL . and check that there is no heaviness in the cable. detach cable (2) at the injection pump connection.4 -CO. ACCELERATOR Engine water temperature: Within green on engine water temperature gauge OPERATING 1. of push-pull scale K in point 150 mm from the Start the engine. QZZI Cable joint nut: 13. Testing 1) Stop the engine.lkgm) Carry out the above inspection. Then carry out the measurement of the operating force again to check that it is within the standard value. and adjust or replace parts if necessary.TESTING AND ADJUSTING MEASURING PEDAL * l Measurement conditions range FORCE OF ACCELERATOR PEDAL K at a position a. s: 2 5 2) 3) * Disconnect cable (I) at the bottom of the accelerator pedal and check that there is no heaviness in the accelerator pedal linkage. 150 mm Measuring 1) 2) 2. Connect cable (I) at the bottom of the pedal.7 f 0. then measure the maximum value when the pedal is moved from the pushed position (low idling) to the end of its travel (high idling).

ad when 2. 2) Loosen nut (I). and adjust bolt (2) so that installed height L of the accelerator pedal stopper is within a range of 51 f 5 mm.4 + 0. a (a = at . * Adjust the travel of the governor lever with joint (4). Measuring 1) Stop the engine. Adjusting 1) Remove the cover at the bottom of the cab. and open the inspection cover of the engine hood. 2) Put angle gauge M in contact with the accelerator pedal.98 Nm (1. * Check that the injection pump governor contacts the low idling stopper when the accelerator pedal is let back to the low idling position. measure each part again and check that it is within the standard value.1 kgm) * After carrying out the above adjustment. 20-26 0 TBWCOb25 . 3) Loosen locknut (3) and adjust the length of the cable so that the injection pump governor lever contacts the high idling stopper when the accelerator pedal is depressed (high idling).7 +_ 0.TESTING AND ADJUSTING MEASURING ACCELERATOR PEDAL OPERATING ANGLE OF ACCELERATOR PEDAL 1. and measure operating angle the pedal is operated from low idling position al to high idling position ~(2. w Cable joint nut: 13.

OPERATING FORCE OF SPEED LEVER 1. TRAVEL OF SPEED LEVER MEASURING OPERATING FORCE. install push-pull scale K or a spring balance to the center of the control lever knob. Make mark a at the center of the control lever knob. TRAVEL OF SPEED LEVER * . TRAVEL OF SPEED LEVER 1. a Measurement Engine Torque conditions stopped converter oil temperature: 60 . 2. Stop the engine. 2. 20-27 0 . * Carry out the measurement for each speed range. and measure the travel when the lever is operated in the direction of operation. Stop the engine.TESTING AND ADJUSTING MEASURING OPERATING FORCE. and measure the operating force when the lever is pulled in the direction of operation.80°C Block the tires securely.

tachometer A to measure the speed when the engine is run at high idling. Engine water temperature: Within green range on engine water temperature gauge Hydraulic oil temperature: 45 . J. Use the brakes to stop the machine. Start the engine 2.55°C Engine speed: High idling Torque converter oil temperature: 60 . then use multi. 20-28 0 and run at low idling.MEASURING TESTING AND ADJUSTING MEASURING STALL SPEED * Measurement . If it is not within the standard range. .80°C . Place the speed lever at the highest FORWARD or REVERSE. Apply the parking the tires. check for loose linkage or play. 3. Check that the engine speed is the standard value. Turn transmission cut-off selector switch OFF and use the left brake. Before measuring each stall speed. brake and put blocks under TORQUE CONVERTER STALL SPEED Check that the tires are chocked parking brake. * * * conditions Check that low idling and high idling are the standard values. (Check that the pilot lamp goes out. position for STALL SPEED . and release the 1.) Do not keep the stall condition for more than * 20 seconds. Make sure that the torque converter oil temperature does not exceed 120°C. install multitachometer A to speed pickup port (I) on the engine block. .

Operate the control lever quickly. If either of the stall speeds are abnormal. 20-29 0 . Measure the engine speed when the torque converter stall and hydraulic stall are both carried out at the same time. and activate the work equipment valve relief valve. 2. * Before measuring the full stall.TESTING AND ADJUSTING HYDRAULIC MEASURING STALL SPEED STALL SPEED 1. set the cylinder to the stroke end. 3. check that the torque converter stall and hydraulic stall speeds are normal. Start the engine and run at high idling. FULL STALL SPEED . correct the problem and measure again. Operate the bucket (4) or boom lever (51. Use multi-tachometer to measure the engine * Do not keep the stall condition for more than 20 seconds.

TESTING AND ADJUSTING MEASURING TORQUE CONVERTER. 6 plug: Sealing agent (LG-11 TBWCOb35 20-30 0 . . PARKING BRAKE OIL PRESSURE MEASURING TORQUE CONVERTER. then start the engine and measure the pressure. . Preparatory brake and put blocks under work The following preparatory work is necessary when measuring all oil pressures. TRANSMISSION. Remove cover (I) on the left side of the rear frame. Install hydraulic tester kit C to the measurement port. PARKING BRAKE OIL PRESSURE * Measurement . . extend the gauge to the operator’s compartment.80°C . Check that no oil is leaking from any connection. (Check that the pilot lamp is OFF. After removing the measurement plug. Turn transmission cut-off selector switch (2) OFF and use the left brake.) . TRANSMISSION. Remove the plug from the measurement port of the transmission valve. always coat the plug with adhesive. A conditions Apply the parking the tires. Engine water temperature: Within green range on engine water temperature gauge Torque converter oil temperature: 60 .

Clutch pressure I) Measuring port (P4. and measure the pressure when the gear shift lever is operated. 2. PT1/8) 2) Start the engine and measure the pressure. Ir Remove hose (1) and elbow (2) and attach the hydraulic test kit to nipple (3). MEASURING TORQUE CONVERTER. PARKING BRAKE OIL PRESSURE procedure Priority pressure I) Measuring port (Pl or P5. 5. PTV8) 2) Start the engine and measure the pressure at low and high idle. PT1/8) 2) Start the engine and measure at low and high idle. Torque converter output pressure 1) Measuring port 1P2. PTV8) 2) Start the engine.TESTING AND ADJUSTING Measuring 1.P5 the pressure P2 3. Parking brake pressure I) Measuring port (PI or P5. Pilot pressure I) Measuring port (P3. 20-3 1 0 . TRANSMISSION. set the forward/reverse lever to neutral. Pl. PTV8) 2) Start the engine and measure the pressure when the parking brake is released. P3 4.

lower the the parking brake. Operate emergency spool (3) to the operating position according to the direction of movement of the machine (forward or reverse). REVERSE: Push in the spool until it enters the detent. 8 mm until it enters the . but if there should be any failure in the electrical system. stop the engine before operating the 1. 3. and put blocks under the tires. keep strictly to the order of operation and pay careful at-tention to safety when moving the machine. a = Approx. b = Approx. apply moving. Ir The lock plate can be removed simply by loosening the mounting bolts. . prevent the machine from A To bucket to the ground. 8 mm . a When carrying out this operation. AAlways spool. or if there is any failure in the solenoid valve or spool and the machine cannot move. Remove lock plate (2) from emergency manual spool (3) of the transmission valve. 2. it is possible to operate the emergency manual spool to move the machine. Remove frame. 20-32 0 cover (I) from the left side of the rear FORWARD: Puil the spool detent. This spool must not be operated except when there has been a failure. and it is necessary to move the machine from a dangerous working area to a safe place where repairs can be carried out. &This operation of the spool is designed only for use if the machine cannot be moved because of a failure in the transmission control.TESTING AND ADJUSTING METHOD OF OPERATING EMERGENCY MANUAL SPOOL METHOD OF OPERATING EMERGENCY MANUAL SPOOL Outline The transmission valve is controlled electrically.

then release the parking brake and slowly let the brake pedal out to start the machine. 5. 8. Start the engine. the transmission is also engaged and the machine will start. seat and depress OF OPERATING EMERGENCY MANUAL SPOOL the left position 20-33 0 . 6. 7. and keep the brake pedal depressed fully when starting the engine. then apply the parking brake and put blocks under the tires. then remove the blocks from under the tires. After moving the machine. Return the manual spool to the neutral and install the lock elate. Check that the area around the machine is safe. so always check carefully that the area around the machine and in the direction of travel is safe. stop the engine.TESTING AND ADJUSTING METHOD 4. Sit in the operator’s brake pedal fully. A When the engine is started.

measure dimensions A and B at four places around the circumference. TEWOM)85 20-34 0 . Measurement Tire inflation conditions pressure: Specified pressure Method of measuring 1.TESTING AND ADJUSTING MEASURING CLEARANCE BETWEEN TIRE AND WHEEL MEASURING CLEARANCE BETWEEN TIRE AND WHEEL * . Clearance of wheel Measure dimension lock ring C. 2. Fitting of wheel lock ring Using feeler gauge.

Vehicle STEERING WHEEL Ld. 8 c: 2. Engine: Stopped. 3 20-35 0 . Turn the steering wheel lightly clockwise. and place mark “b” on the steering wheel. align the position where it stops with mark “a”. play posture: Facing straight Measuring procedure 1. align the position where it stops with mark “a”. and place mark “c” on the steering wheel. . Measure the straight distance “d” between mark “c” and the position marked in step 2. then put a mark “a” on the outer frame of the vehicle monitor. Turn the steering wheel lightly clockwise and counterclockwise two or three times to check that the steering mechanism is in neutral. Turn the steering wheel lightly counterclockwise.TESTING AND ADJUSTING TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING WHEEL Measuring steering wheel * Measurement conditions . 3.

* After starting the engine. raise the bucket approx. l . Measurement conditions method install knob. 400 mm and remove the safety bar. horizontal. wheel STEERING WHEEL . Start the engine. * Avoid measuring when the steering wheel starts to move. Pull push-pull scale K in the tangential direction and measure the value when the steering wheel moves smoothly.55°C Tire inflation pressure: Specified pressure Engine speed: Low idling (bucket empty) l .TESTING AND ADJUSTING MEASURING ING WHEEL OPERATING TESTING AND ADJUSTING FORCE OF STEER- * Measurement . dry paved surface Engine water temperature: Within green range on engine water temperature gauge Hydraulic oil temperature: 45 . 2. Road surface: Flat. 20-36 0 push-pull scale K to the steering 1. 3.

conditions method Start the engine. Operate the steering wheel as quickly as possible without using force. Measurement 1.55% Tire inflation pressure: Specified pressure Engine speed: Low and high idling . After starting the engine. Carry out the measurements both at low idling and high idling. 400 mm and remove the safety bar.TESTING AND ADJUSTING MEASURING OPERATING STEERING WHEEL TIME Measurement . 8 c: 5 TESTING AND ADJUSTING * * 20-37 0 . 2. horizontal. * STEERING WHEEL FOR * . Measure the time taken to operate the steering wheel to the end of the stroke to the right (left). . . dry paved surface Engine water temperature: Within green range on engine water temperature gauge Hydraulic oil temperature: 45 . Road surface: Flat. Operate the steering wheel to the end of its stroke to turn the machine to the left or right. 3. raise the bucket approx. and to both the left and right.

Ir When measuring the clearance. * When measuring the clearance. Start the engine and operate the steering the front and rear frames straight. dry paved surface Tire inflation pressure: Standard pressure Testing 1. 2) Run the engine at low idling and operate the steering slowly to contact the frame stopper. 5) Loosen stopper bolt (1) 8. 3) Turn the stopper bolt until the head of stopper bolt (1) contacts the end face of the spool of stop valve (3).5) for both the left and right sides. 3. 6) Carry out steps 1) . Adjusting 1. l Measurement conditions Hydraulic oil temperature: 45 . 2. Start the engine and measure clearance “a” between the front frame and rear frame stopper when the steering wheel is turned fully to the left and right. then lock it in position with locknut (2). .55°C Engine speed: 1. 2. . Check the bolt (1). check that the end face of the spool of stop valve (3) is in contact with the head of the stopper bolt. horizontal.TESTING AND ADJUSTING TESTfNG AND ADJUSTING STEERING CONTROL TESTING AND ADJUSTING STEERING CONTROL * . Adjust the stopper bolt. Start the engine and measure clearance between the front frame and rear frame stopper when the steering wheel is turned fully to the left and right. check that the end face of the spool of stop valve (3) is in contact with the head of the stopper bolt. and stop the engine.5 turns. looseness of locknut to set (2) of stopper I . 20-38 0 aWf5mm) . 4) Set the machine facing straight. I) Screw in stopper bolt (1) to make it the minimum length.200 rpm Road surface: Flat.

Start the engine. Hydraulic oil: 45 . then turn the steering wheel to the right and measure the pressure when the relief valve is actuated.55°C Engine speed: High idling METHOD SURE STEERING OIL PRESSURE OIL conditions OF MEASURING MAIN RELIEF PRES- ALoosen the oil filler cap to release the pressure inside the hydraulic tank. Apply safety bar (1) to the frame. 2. measurement circuit. plug (2) for the right turn tester kit C to the measurement :’ TBW00613 TBWW614 20-39 0 . run the engine at high idling. z!? : ?I 1. 4. remove the plug for the left turn steering circuit. then turn the steering wheel several times to release the remaining pressure inside the piping. * To measure the pressure when turning the steering wheel to the left. . Install hydraulic port. Remove steering 3.TESTING AND ADJUSTING MEASURING PRESSURE MEASURING STEERING * Measurement .

2. TIGHTEN to INCREASE pressure LOOSEN to DECREASE pressure Do not carry out any adjustment if the relief pressure cannot be measured accurately. + * * 20-40 0 Pressure adjustment for one turn of adjustment screw: Approx. ’ v-n--n--* I 6 hhhil TLWK%SS . 14. Stop the engine.TESTING AND ADJUSTING MEASURING STEERING OIL PRESSURE Adjusting g Always stop the engine before adjusting the pressure.8 MPa (751 kg/cm*) Turn the adjustment screw to adjust the set pressure as follows. Loosen relief valve (4) lock nut (5) and turn adjust screw (6) to adjust. 1.

Push the brake pedal lightly by hand. 3. Fit push gauge N to your foot. 150 mm 2. Start the engine. It is also possible to measure a1 and a~ and calculate a = al . TRAVEL OF BRAKE PEDAL Ir Measurement . Set the push gauge at a position from the pedal fulcrum. * Set the push gauge at a position from the pedal fulcrum. 2.an. Install angle gauge M on the brake pedal and measuring pushing angle a with a pushing force of 294N (30 kg). TRAVEL OF BRAKE PEDAL MEASURING OPERATING FORCE. and measure pedal angle @ when the pedal starts to become heavy. Engine water temperature: Within green on engine water temperature gauge Engine speed: Low idling . ‘150 mm 3 the pedal pushing Travel of pedal 1. Fit push gauge N to your foot. Start the engine and measure the pedal pushing angle at low idle with a pedal pushing force of 294N (30 kg). Start the engine and measure force at low idle.TESTING AND ADJUSTING MEASURING OPERATING FORCE. conditions range Operating force of pedal 1. Pedal play 1. * 2. 20-41 0 .

horizontal. speed posi- Point where brakina effect started - point Stopping distance Point where operator foot on brake bedal (qperation point) out Run-up path TDW00113 20-42 0 .Delay in applying brakes: 0. Set the speed lever to the highest tion and drive the machine. Measure the distance from the point where the brakes were applied to the point where the machine stopped. Measurement conditions Road surface: Fiat. * Switch the transmission cut-off switch ON when carrying out this operation.MEASURING TESTING AND ADJUSTING BRAKE PERFORMANCE MEASURING BRAKE PERFORMANCE * . . dry paved surface Travel speed: 20 km/h when brakes are applied . determine the run-up path and the point for applying the brakes. 3.1 set Tire inflation pressure: Specified pressure Measurement method 1. 4. Stopping and move the machine. Start the engine 2. depress the left brake pedal with the specified operating force. * Repeat this measurement three times and take the average. l . then apply the brakes when the machine reaches that point. Specified operating force: 265N (27 kg) f Before carrying out this operation. When the travel speed reaches 20 km/h.

Loosen bleeder screw (3) and bleed the air.9 MPa (50 kg/cm*). Measuring procedure Stop the engine.9 MPa (50 kg/cml) Apply the parking brake and chocks the tires. Disconnect brake tube (1) on the side to be measured. activate pump 0 and lower the pressure of hydraulic test kit C before removing the test kit. activate pump 0. as this will cause pressure fluctuations. increase the pressure to 4.TESTING AND ADJUSTING TESTING ir . Do not move the hose while the pressure is being measured. Disconnect union (2). then tighten stop valve 8. Let sit for five minutes with pressure applied and check the pressure decrease. install joint :z! and attach hydraulic test kit C '1 TBWCG616 * Use the O-ring installed on the union. install the brake tube and bleed the air from the brake circuit. f Bleed the air by activating pump 0. When testing is completed. After testing. 20-43 0 . l a Measurement TESTING BRAKE OIL PRESSURE BRAKE OIL PRESSURE conditions Engine water temperature: Within engine water temperature gauge green range Testing pressure: 4. Tighten bleeder screw (31. (Oring: 07002-02034) * Connect the hydraulic test kit quick coupler.

the disc has reached its usage limits. use the oil level plug attached to the axle housing. If there is no clearance in the gauge plug or if it cannot be inserted. * Note that forcing in the gauge plug may damage the springs (6). conditions Measuring 1.TESTING TESTING AND ADJUSTING TESTING FOR BRAKE DISC WEAR FOR BRAKE DISC WEAR f Measurement a Engine water temperature: Within engine water temperature gauge green range Apply the parking brake and chocks the tires. * For gauge plug (51. Axle oil: 32 e 2. Axle oil: 32 e 20-44 0 TBWW461 . Install measuring plug (2). Lightly press the brake pedal. Fasten the drain plug and supply axle oil to the specified level through the oil supply port. The disc has not reached its usage limit if l there is a clearance when the gauge plug is inserted. 3. Loosen - : drain plug (I) and drain the axle oil. Check that the piston is pressed f against the disc. 5. insert gauge plug (5) between the plates (3) and check the wear of disc (4). 4. .

3) Repeat this operation until there are no air bubbles in the fluid coming from the vinyl hose. Remove the front frame front cover (I).TESTING AND ADJUSTING BLEEDING AIR FROM BRAKE SYSTEM BLEEDING AIR FROM BRAKE SYSTEM a a . set the engine to low idle. 1. Apply the parking brake and securely chocks the tires. start the engine to increase it. Slowly release the brake pedal after tightening the bleeder screw. g : 5 2. insert vinyl hose (3) into the front axle bleeder screw (2) and place the other end in a container. 20-45 0 . 4) Use the same procedure to bleed the air from the other side. check the hydraulic oil level. J. stop the engine. * If the accumulator pressure drops. 2) Press the brake pedal. When air bleeding is completed. then press the pedal in fully and tighten the bleeder screw while oil is flowing out. Bleeding air from rear axle brake circuit Bleed the air from rear axle brake circuit in the same way as for the front. Bleeding air from front axle brake circuit 1) Once pressure has accumulated in the accumulator. and add oil if necessary. Securely apply the boom drop prevention prop. loosen the bleeder screw and bleed the air.

Depress the brake. Turn the parking brake switch ON. set the machine facing in a straight line.TESTING AND ADJUSTING MEASURING PARKING PERFORMANCE * . . . dry paved road surface with slope of l/5 grade (11’20’). the parking brake is automatically switched ON. set the directional lever to the neutral position. stop the machine. then stop the engine. * Carry out the measurement in two ways: Once with the machine facing uphill. 2. Measurement MEASURING PARKING BRAKE PERFORMANCE BRAKE conditions Tire inflation pressure: Specified pressure Road surface: Flat. * When the engine is stopped. 20-46 0 I TDW00124 I TDW00125 . Start the engine. 3. Machine: Operating condition Measurement method 1. and once more with the machine facing downhill. then drive the machine up a l/5 grade slope with the bucket empty. then gradually release the brake pedal and check that the machine is held in position.

then remove bolt (3) (3 places). A Always stop the engine before carrying out this procedure. This method must not be used except when there has been a failure. then install lock plate (2) at portion “a”. Loosen bolt (11. bolt (I) to secure lock plate (2) from lock plate (2) in posi- 20-47 0 . so if there should be any failure in the solenoid valve and it becomes impossible to release the parking brake. lower the bucket to the ground and put blocks under the tires. 2. AThe manual release of the parking brake is designed only to move the machine from a dangerous working area to a safe place where repairs can be carried out. Tighten tion. Tighten bolts (3) at 3 places in turn as far as the mounting position for the plate at portion “a”. 1. * Bolt (3) pushes piston and releases the parking brake. it is possible to release it manually to move the machine. ATO prevent the machine from moving.TESTING AND ADJUSTING MANUAL RELEASE METHOD FOR PARKING BRAKE MANUAL RELEASE METHOD FOR PARKING BRAKE * The parking brake is controlled by hydraulic pressure. 3. * Tighten all three bolts uniformly a little at a time.

Ir Piston stroke (L) = a . check thickness W of brake disc (5). For details. ATo prevent the machine from moving.83 mm TBwmm . lower the bucket to the ground and put blocks under the tires. 2. Dimension W: Min 2.4 f 20-48 a If the piston stroke is greater than 7.TESTING AND ADJUSTING TESTING WEAR OF PARKING BRAKE DISC TESTING WEAR OF PARKING BRAKE DISC * If the parking brake becomes the piston stroke as follows. REMOVAL OF PARKING BRAKE DISC. 7. weak. . Measure dimension “a” with the three manual release bolts (31 in contact lightly with brake pistons (4). 3. see DISASSEMBLY AND ASSEMBLY. ioosen bolt (l). AAlways stop the engine before procedure.4 mm. Tighten the three manual release bolts (3) in turn and measure dimension “b” when brake piston (4) is pushed in fully. carrying measure out this f.b L = Max. then remove lock plate (2) from parking brake manual release bolt (3) 13 places).

Measurement MEASURING range method 1. Measurement WORK EQUIPMENT CONTROL LEVER WORK CONTROL LEVER conditions . 2. f Mark the lever knob and use scale to meas- TBWOO463 ure. t Install the push-pull scale to the center of the knob.55°C Engine speed: Low idling a install the safety bar to the frame. Engine water temperature: Within green on engine water temperature gauge Hydraulic oil temperature: 45 . and measure the minimum value for the force needed to operate the knob. 20-49 0 .TESTING AND ADJUSTING MEASURING EQUIPMENT * . t Operate the control lever at the same speed as for normal operations. Travel of work equipment control lever Measure travel at each position when operating the work equipment control lever. Operating force of work equipment control lever Install push-pull scale K to the work equipment control lever and measure the operating force.

5 mm * Set the bucket lever and boom lever at the HOLD position. Dimension C: 0 .1 mm T&VW721 20-50 0 . fix the solenoid in position so that the clearance between cam (3) and. If cam (31. With solenoid (6) pulled. Remove 2. \ TEW00136 TEWO0137 ’ TEWOOldO Buck& lever Operate the lift lever and adjust the length of rod (2) so that roller (7) is dimension C at the notch at both ends of cam (8). Dimension b: 0 . * replace them before adjusting.TESTING AND ADJUSTING MEASURING WORK EQUIPMENT CONTROL LEVER Adjusting 1. Dimension a: 0 . roller (4) is dimension a. Boom lever Operate the boom lever and adjust the length of rod (2) so that roller (4) is dimension b at the notch at both ends of cam (3). roller (41. 3.0. or spring (51 are broken.1 mm cover (I 1.

g HYDRAULIC WORK HYDRAULIC Measurement conditions Engine water temperature: Within green on engine water temperature gauge Hydraulic oil temperature: 45 . and measure the pressure when the relief valve is activated. check that both points “a” and “b” on the bottom of the bucket are touching the ground. 2. l l MEASURING PRESSURE range Work equipment relief valve pressure measuring procedure + Raise bucket tip “a” 30 to 50 mm and ground the bucket at point “b”. then operate the control levers two or three times to release any pressure remaining in the piping. f After operating the levers. * Use a hose which is long enough to reach the operator’s seat. Loosen the oil supply cap to release the presg sure inside the hydraulic oil tank. tilt back the bucket using the control lever. Install hydraulic test kit C to the measuring port. 1.TESTING AND ADJUSTING MEASURING EQUIPMENT PRESSURE * . Ir Check that there is no oil leakage from any joints. Remove bucket cylinder measuring plug (I). raise the boom about 400 mm. Start the engine. 3. I a b TEW00149 pressure pressure When removing the hydraulic pressure gauge.55°C Engine speed: High idling * WORK EQUIPMENT circuit oil Be careful not to apply any sudden to the pressure gauge. release the pressure inside the circuit in the same way as when it was installed. then stop the engine. 20-5 1 0 .

7 kg/cm2) * Turn the adjustment screw to adjust the set pressure as follows. inspection cover (I).TESTING AND ADJUSTING Adjusting work equipment MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE relief valve pressure ABe sure to stop the engine pressure. move front frame A Set the prop securely. and the re- the relief valve cap nut (2). Loosen lock nut (31. set the boom prop. when adjusting 1.5 MPa (35. TIGHTEN to INCREASE pressure LOOSEN to DECREASE pressure * Do not carry out any adjustment if the relief pressure cannot be measured accurately.’ Raise the boom. and turn adjust screw (4) to adjust. * Pressure adjustment for one turn of adjustment screw: Approx. 2. Remove 3. 8 TBbWQ472 20-52 a k 4 . 3.

. loosen the oil supply cap. 3. 20-53 0 . * After the accumulator pressure is completely released. Check that there is no oil leakage from any joints. then stroke the bucket control lever between the tilt and neutral positions at least 40 times to completely release the accumulator pressure. and measure the pressure when the relief valve is activated. set the bucket to an angle of approximately 45” (not to the maximum dump position) and remove front cover (3). . release the pressure inside the circuit in the same way as when it was installed. Raise boom (I). Use a hose which is long enough to reach the operator’s seat. A When removing the hydraulic pressure gauge. Connect the hose after installing the hydraulic test kit 90” elbow to the measuring port. 5. set boom prop (21. Install hydraulic test kit C to the measuring port. Stop the engine. * Be sure to stop the engine before operating the lever.TESTING AND ADJUSTING MEASURING PRESSURE * . raise the boom about 400 mm. tilt back the bucket using the control lever. set the bucket lever to the dump position and check that the bucket does not dump. a Set the prop securely. MEASURING PPC VALVE PRESSURE PPC VALVE Measurement conditions Engine water temperature: Within engine temperature gauge green range Hydraulic oil temperature : 45 to 55°C Engine speed : High idle water Apply the parking brake and blocks the tires. Start the engine. Be careful not to apply any sudden pressure to the pressure gauge. Remove the work equipment dump cylinder circuit pressure measurement plug (4). 2. Measuring 1. . release the pressure inside the hydraulic oil tank. . 4.

I MEASURING TESTING AND ADJUSTING PPC VALVE PRESSURE Adjusting when adjusting the oil g Always stop the engine pressure.79 MPa (18. * The. * Pressure adjustment for one turn of adjustment screw: Approx.3 kg/cm*) * Turn the adjustment screw to adjust the set pressure as follows. on the left front L?mm(Adjustment amount) TEW00147 20-54 0 .PPC relief valve is installed of the rear frame. TIGHTEN to INCREASE pressure LOOSEN to DECREASE pressure It Do not carry out any adjustment if the relief pressure cannot be measured accurately. 1. then turn adjustment screw (3) to adjust. 1. Loosen locknut (21.

2. then raise it and measure the time taken for the bucket to reach the maximum boom height.TESTING AND ADJUSTING MEASURING EQUIPMENT * . Bucket DUMP time Raise the boom to the maximum height. Bucket TILT time TDWGUl56 20-55 0 . l l . Boom LOWER time Set the bucket horizontal. then lower the boom from the maximum height and measure the time taken for the bucket to reach the lowest position from the ground. Boom RAISE time TOW00155 Set the bucket at the lowest position from the ground with the bucket tilted back fully. Set the bucket horizontal to the ground and measure the time taken to move the bucket from the horizontal position to the tilt position (bucket fully tilted back). TOW00156 3. and measure the time taken to move the bucket to the tilt position (bucket fully tilted back). Bucket TILT time I) 2) Raise the boom to the maximum height.55°C Engine speed: High idling Steering position: Neutral No load range I /d Boom RAISE time Measurement method 1. Measurement MEASURING WORK EQUIPMENT WORK conditions Engine water temperature: Within green on engine water temperature gauge Hydraulic oil temperature: 45 . and measure the time taken to move the bucket from the tilt position (bucket fully tilted back) to the dump position (bucket fully tipped forward). . ! /!=A Bucket DUMP time TDW00157 4.

leave for 5 minutes. g. then stop the engine. Engine water temperature: Within green range on engine water temperature gauge Hydraulic oil temperature: 45 .TESTING MEASURING AND ADJUSTING MEASURING MENT HYDRAULIC DRIFT WORK EQUIP- * Measurement . Leave for 5 ment. . conditions a Apply the safety lock to the work equipment control levers. then measure retraction the bucket cylinder rod and retracB of the boom cylinder rod.55°C Stop the engine. Boom: Horizontal Bucket: Horizontal No load . Measurement method 1. Never go under the work equipment. then measure for 15 minutes. Set the boom and bucket in a horizontal tion. 2. Wait for 15 amount A of tion amount 3. WORK EQUIPMENT posi- minutes. i TOW00160 A: Retraction amount of bucket cylinder rod 6: Retraction amount of boom cylinder rod 20-56 0 . . then start the measureminutes. .

then secure the switch in position. Check that the switch sensing surface and the angle are not in contact. Start the engine. Using shims. run at idling and check the actuation position.7 f 2 Nm (1. Stop the engine and check that the clearance between switch (1) and angle (2) is the standard value.1. (Check three times and take the average value.0 mm w Switch mounting nut: 17.TESTING AND ADJUSTING TESTING AND ADJUSTING BUCKET POSITIONER TESTING AND ADJUSTING BUCKET POSITIONER Testing 1. adjust the switch protector so that the clearance b between the switch (I) sensing surface and angle (2) is the standard value. then return the lever to HOLD and stop the engine. Clearance b: 3 .8 + 0.7 mm a 3 1 TBWCO478 20-57 0 . operate the bucket lever and check that the bucket positioner is actuated at the desired position. Adjust nut (4) of switch (I) so that clearance a from the tip of switch protector (3) to the switch sensing surface is the standard value. Adjust with shims so that the clearance between the switch sensing surface and the angle is the standard value at the full stroke of the angle. then secure the switch in that position.2 kgm) 3. operate the bucket to the desired digging angle. Check that the switch sensing surface and angle do not slip from the center. After adjusting. Lower the bucket to the ground.) Adjusting 8 z 5 1.5 . * Clearance a: 0. then lock them in position. 2. 2. then lock in position.

then secure the switch in that position. and check the actuation position. Stop the engine. (Check three times and take the average value. 2. 2.7 +_2. run at high idling. Adjust the switch so that the clearance a between the switch (I) sensing surface and plate (2) is the standard value. 20-58 a a . Start the engine.0 Nm (1. * Clearance a: 3 to 7 mm * After adjusting. then lock in position.) Adjusting 1. Adjust the plate position so that the center of switch (I) is aligned with the lower end of plate (2) as marked. operate the boom lever and check that the kick-out is actuated at the desired position. m Switch installation bolt: 17.TESTING AND ADJUSTING TESTING AND ADJUSTING BOOM KICK-OUT TESTING AND ADJUSTING BOOM KICK-OUT Testing 1.8 + 0. Raise the boom to the desired position and mark it at the position where the center of the switch is at the lower end of the plate.2 kgm) 4. A Be sure to apply the safety lock to the control lever. Lower the boom and stop the engine. 3. and check that the clearance between switch (1) and plate (2) is the standard value.

so use this when adjusting.TESTING AND ADJUSTING TESTING AND ADJUSTING Proximity switch actuation slot lamp (red) The proximity switch is equipped with a pilot lamp which shows-when it is being-actuated. BOOM +tuation KICK-OUT pilot lamp - ?roximity switc actuation pilot lamp Detector positio Lights up Goes out _ When detector is positioned surface of proximity at detectio switch When detector detection 3ucket )ositioner - Proximity switch’ Ditector has moved surface o-_ away from of proximity switch -P -I 0 7 % Proximity switch’ Detector TEWOOl67 TEWOOl66 Proximity switch Proximitv switch / 3oom kick-out I I TEW00170 TEW00169 Boom Proximity 3oom kick-out machines equipped with vlDC monitor) I / \ TEW00171 20-59 0 .

S.S. so it is necessary to adjust to give the correct travel speed. a rotary switch can be seen inside. _*. In addition.C.S. Rear of main monitor 1 TDW00173 Adjustment procedure . (3). the switches at the back of the Setting machine model 1) 2) > 3 aswitch Remove the rubber caps from dipswitches (I). 2 ON 3 4 ON ON position Reference Amount 4 With E. Adjust the setting if the E. (Eiectronitally Controlled Suspension System) is installed. (2).C.3 DIP SW 4 When the cap is removed from dipswitch (4) at the back of the speedometer. ON OFF 4) After completing the adjustment. It is also necessary to change the switches if the optional E. The speedometer on the main monitor is a common part for all machines. Turn off the power. fit the rubber caps securely and install the main monitor. Switch Switch No. and (4) at the back of the speedometer. ’ Without E. 1. Switch Tire size 1 (model selection) Switch 2 (speedometer correction) Switch 3 (tachometer input selection) DIP SW 1. Using a flatheaded screwdriver. then remove the main monitor and adjust speedometer.2. When the rubber cap is removed. turn this switch to adjust it to the settings in the table below.S. . 20-60 0 Adjustment TDW00176 TDWO0175 of correction for’switch (2) ) correction (%) +14 +I2 +I0 +8 +6 +4 +2 +0 .S. (Electronically Controlled Suspension System) is installed. and the input signal for the travel speed differs according to the machine.C.C.S. so it is necessary to adjust the monitor for use with the particular model.S. . an ON/OFF switch can be seen. the tire diameter also differs according to the type of tire fitted.TESTING AND ADJUSTING ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE) ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE) .S. .

Potentiometer output voltage range When correctly installed Boom angle signal input (CNL27 (9) .(19)): 0. height Bucket: Max. potentiometer. The range which can be adjusted is as shown in the table with the posture in Step 2-l). Method of adjusting sensor I) Set the work equipment to the following posture. Boom angle potentionieter Bucket angle ootentiometer I TEWOOl78 Auto leveler Remote positioner RAISE position set Auto mode TDW00179 If the potentiometers have been adjusted from the condition in Step 3. If the lamps flash in Step 2-31 The potentiometer output is not within the range that can be offset. BUCKET ANGLE POTENTIOMETER l The work equipment control system is equipped with a sensor adjustment function to compensate for any error in the mounting of the potentiometer and to make it possible to detect the correct position data for the work equipment.6 . (Sensor adjustment mode) 3) The remote positioner set lamp and auto leveler set lamp will light up for 2 seconds and then both lamps will go out.3 . In addition. the condition of the lamp corresponds to each potentiometer. or work equipment are replaced. When the remote positioner set lamp and auto leveler set lamp light up. Always carry out adjustment when the controlier.(20)): 0. release the switch. Boom: Max. so adjust the installation of the potentiometer.4. 20-61 0 . (Offset written to memory) F2 3 5 3. 4. 1.TESTING AND ADJUSTING ADJUSTING BOOM.3 V 2. dump 2) Keep the remote positioner set switch and auto leveler set switch pressed continuously for at least 3 seconds at the same time. BUCKET ANGLE POTENTIOMETER ADJUSTING BOOM.7 v Bucket angle signal input (CNL27 (9) . always carry out Step 2 again and check that the lamps are actuated as in Step 3) (set lamps light up for 2 seconds and then go out).4.

............ of events in troubleshooting......................................................... 20-104 20-I 12 ......... 20-401 .......................................................................................................................... 20-128 (S mode) ................................ 20-501 20-101 0 .... ... of using troubleshooting Connection i............................................... (E mode) .......... Connector pin arrangement locations table for connector ...................................................................................................... out maintenance Checks before troubleshooting Method .............................................................................................................................. Troubleshooting of hydraulic B k Troubleshooting of ECSS (Electronically f Troubleshooting of work equipment system Controlled controller (Chassis Suspension system related) System) 20-251 20-301 20-351 (T mode)............................................................................................ ............... Connector 20-103 20-l 11 ....................................................... 20-451 (D mode) (W mode) ............................................................... diagram. 20-201 Troubleshooting of engine system Troubleshooting of main monitor system monitor (M mode) system Troubleshooting of maintenance Troubleshooting of electrical system and mechanical ................................TROUBLESHOOTING Points to remember Precautions when carrying connectors Handling types and mounting charts ........................................................... ............................................................................. when troubleshooting 20-I 14 20-122 20-123 pin numbers ................................................................................................................... (K mode) ............................. Sequence 20-102 .................................................................................................................................................... .....................................

of manhours. chine to carry ternally. keep strictly brake are securely near. or air. symptoms. failure occurs: . in any rotating is to ask the operator the components. When of troubleshooting carrying disconnect is hot. a location which is under pressure from oil. any hot parts or to get caught the plug or cap from pressure of possible When wiring. the structure questions 4) eration. the carry failure? 6) and function. blocks. related parts or in- formation. then and indown the use the troubleshoot- to locate the position of the exactly. ure or other unnecessary ing. condition been carried 2) 3) spool. accordance so wait for to be necessary. for troubleshooting 1) Start from the simple 2) Start from the most Investigate be- of oil from equipment. carrying signals. the basic cause troubleshooting If components . Use the results 3) Check before of the control’valve whether When causes with the machine what conditions Has the some ment that may make the problem prior fore? 3. water. always release installing a short cut to effective to disassemble to the agreed fitted. hot water the negative measuring is to pinpoint causes of the failure and important that would out troubleshooting. cause. when before TROUBLESHOOTING pin. person to come to cool down WHEN WHEN TROUBLESHOOTING in a level place. starting not to touch reoccurrence However. For this reason. and parking with two or more workers. likely points. 1. do not hurry immediately 4. II of the battery and judge become It will also cause a waste 2.4 to narrow of failure. in spection occurred about failure the t ma- these same or were there before did the failure occur? repairs kind out before carried of failure the Check the oil level Check any external or hydraulic Check the travel it as a real fail- the machine of op- to reenact symptoms. ing flowchart apart from occurred? occur suddenly. etc. out repairs ure or as a problem to find the cause Points to ask user or operator 3) various 5) . of the control yourself. Was of the failure. with the fixed procedure. out troubleshooting. when carrying to carry parts. Parts that have no connection produce oil or grease. anything before When 5. and do not of the failure. the confidence 2) be sure to connect the reported of the failure. with the method The basic procedure problem leakage failure to handle operating of the failure out? occurred troubleshooting 1) of the troubleshooting To prevent the piping ex- is as follows. levers. if the root cause is not repaired. and to carry out troubleshooting problems it properly. of the user or operator.POINTS TROUBLESHOOTING POINTS TO REMEMBER A Stop the machine A When allow A carrying out the operation If the radiator cap is removed A Be extremely A When disconnecting When removing A careful the internal The aim prevent When the engine always first. repairs were for idea items can be checked extent Troubleshooting . Even if the failure is repaired. to form failure Confirm out troubleshoot- strange the failure Did the failure Had any and to so check any item that is considered the this? 5) Confirming f or that has been reported? there Under Check the stroke Other maintenance will also lose out thorough Have any other problems the problem 4) swiftly. point is of course to understand sembled. Measures to remove root cause of failure . are disassembled It will may spurt out and cause burns. out any investigation do not or measureworse. any with the fail- and at the same time. 6. always occurred. the same failure will occur again. other points. troubleshooting. investigate Then. and check that the safety any unauthorized the engine TO REMEMBER this. (-1 terminal parts. equipment. of the investigation in Items 2 . remove why the the root :: g 5 . parts will be disas- impossible it is necessary investigation first.

\ Step 2 Determining 1) probable location Look at the troubleshooting shop manual to find TEWOOl83 of cause section locations ) 5 < of the of possible causes. Operating - Past history.. 2) Hydraulic pressure gauge kit. Ask questions IO gain an outiine lenl.a. - Decide 1) Before action to take the necstarting repair 21 simple - Check before starling Other check items See the Troubleshooting that - troubleshooting. etc.. Look in the parts book and prepare essary Pinpoint locations (carry out replacement parts. step of failure troubleshooting) the and judge flowchart and carry machine if there out to confirm is really a 4 IGo Ask operator Was there questions anything to strange chine before the failure Did the failure confirm about details of the ma- occurred? occur suddenly? Had any repairs been carried out before the 20-l 03 0 . environment details of maintenance. T-adapter .1.11 i ? ci$ TEW00184 step 3 Preparation of troubleshooting tools] oa 1) Look at the table of troubleshooting the shop manual and prepare tools in the necessary tools.1*.l!. . I *llullll. Condition of failure * of the pro TEWOO182 Work being carried out at the time of the failure . * manual. . etc. etc. . operate the condition locate failures. Drive select matches and and items Section of the shop a troubleshooting the symptoms.TROUBLESHOOTING SEQUENCE SEQUENCE OF EVENTS IN TROUBLESHOOTING OF EVENTS IN TROUBLESHOOTING mber of machine 2) Details of jobsite.

water. and to prevent failures or other troubles before they occur. or because there is corrosion or oxidization of the contact surfaces. correct operation. so they are likely to suffer deformation or damage. during inspection and repair operations they are frequently removed and installed again. 20-l 04 0 TEw00191 Improper insertion TEW00192 . or vibration. connectors used for connecting and disconnecting one wire from another wire. and protector or tubes used for protecting the wiring. it is necessary to be extremely careful when handling wiring harnesses. Furthermore. it gives sections on “Handling electric equipment” and “Handling hydraulic equipment” {particlularly hydraulic oil).TROUBLESHOOTING PRECAUTIONS PRECAUTIONS WHEN CARRYING WHEN CARRYING OUT MAINTENANCE OUT MAINTENANCE To maintain the performance of the machine over a long period. PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT I) Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component. 1. For this purpose. Compared with other electrical components fitted in boxes or cases. and repairs must be carried out. or because one or both of the connectors is deformed or the position is not correctly aligned. Main failures occurring in wiring harness (I) Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. heat. troubleshooting. wiring harnesses are more likely to be affected by the direct effects of rain. For this reason. maintenance and inspection.

If there is oil or grease or dirt stuck to the connector. the compression of the connector may be lost. and spray it with a contact restorer. so there will be defective contact. it is difficult for it to be drained. Therefore. the pins will be short-circuited by the water. The connector is designed to prevent water from entering. or the wiring may be broken. if water should get into the connector. but if high-pressure water is sprayed directly on the connector. \ TEW00194 (5) Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins. or components are lifted with a crane with the wiring still connected. wipe it off with a dry cloth or blow dry with air. be careful not to use excessive force or deform the pins. but there is excessive force on the wiring. immediately dry the connector or take other appropriate action before passing electricity through it. and the plating peels to cause improper correction or breakage. TEwoo193 (4) High pressure water entering 8 k 4 connector The connector is disigned to make it difficult for water to enter (drip-proof structure). so clean with air from which all the water and oil has been removed. (3) Disconnections in wiring If the wiring is held and the connectors are pulled apart. but at the same time. * If there is water or oil in the air. TEW00195 I TEWW196 . ::o if any water gets in. * When wiping the mating portion of the connector.TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE (2) Defective compression or soldering of connectors The pins of the male and female connectors are in contact at the compressed terminal or soldered portion. if the water does enter. or the soidering may be damaged. it will increase the contamination of the points. or a heavy object hits the wiring. water may enter the connector depending on the direction of the water jet. the oil will not let the electricity pass.

corrosion. * If there is any oil. For connectors held by a screw. dirt. 20-106 0 TEWOOl98 L . Connecting connectors (I) Check the connector visually. dirt. loosen the screw fully. Check that there is no. or water stuck to the connector pins (mating portion). cover it with a vinyl bag to prevent any dust. a. breakage to the outside of the connector. defective contact. but be careful not to make it too hot as this will cause short circuits.oil. press down the stopper with your thumb and pull the connectors apart. Check that there is no damage or C. or damage to the connector pins. -k If there is any damage or breakage. warm the inside of the wiring with a dryer. Check that there is no deformation. For connectors which have a lock stopper. wipe it off with a dry cloth. then hold the male and female connectors in each hand and pull apart. or dirt stuck to the connector. water. or water from getting in the connector portion. and wiring PRECAUTIONS WHEN CARRYING OUT MAINTENANCE installing. and drying connectors harnesses Disconnecting connectors (1) Hold the connectors when disconnecting. If any water has got inside the connector.TROUBLESHOOTING 21 Removing. When disconnecting the connectors. b. oil. TEW00197 (2) Action to take after removing connectors After removing any connector. hold the connectors and not the wires. replace the connector.

TROUBLESHOOTING

PRECAUTIONS

WHEN

CARRYING

OUT

MAINTENANCE

(2) Fix the connector securely.
Align the position of the connector correctly, then insert it securely.
For connectors with lock stopper
Push in the connector until the stopper
clicks into position.
Cliks into position

(31 Correct any protrusion of the boot and
any misalignment
of the wiring harness
For connectors fitted’with
boots, correct
any protrusion or the boot. In addition,
if the wiring harness is misaligned,
or
the clamp is out of position, adjust it to
its correct position.
*
When blowing with dry air, there is
danger that the oil in the air may
cause improper contact, so clean with
air from which all the water and oil
has been removed.
Drying wiring harness
If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use
high pressure water or steam directly on the
wiring harness. If water gets directly on the
connector, do as follows.
(I) Disconnect the connector and wipe off
the water with a dry cloth.
*
If the connector is blown dry with
air, there is the risk that oil in the air
may cause defective contact, so avoid
blowing with air.

(2) Dry the inside of the connector

with a
dryer.
If water gets inside the connector, use a
dryer to dry the connector.
+ Hot air from the dryer can be used,
but be careful not to make the connector or related parts too hot, as
this will cause deformation
or damage to the connector.

TEW00196

TROUBLESHOOTING

PRECAUTIONS

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

WHEN

CARRYING

OUT MAINTENANCE

T-adapter

TEW00203

3)

Handling control box

(I) The control

(2)
(3)
(4)
(5)

(6)

(7)

box contains a microcomputer and electronic control circuits.
These control all of the electronic
circuits on the machine,
so be extremely
careful when handling the control box.
Do not open the cover of the control box
unless necessary.
Do not place objects on top of the control box.
Cover the control connectors
with tape
or a vinyl bag.
During rainy weather,
do not leave the
control box in a place where it is exposed to rain.
Do not place the control box on oil, water, or soil, or in any hot place, even for
a short time. (Place it on a suitable dry
stand)
Precautions when carrying out arc welding
When carrying out arc welding
on the
body, disconnect all wiring harness connectors connected to the control box. Fit
an arc welding ground close to the weiding point.

20-108
0

I

TEW00204

TROUBLESHOOTING

2.

POINTS TO REMEMBER
WHEN
DLING HYDRAULIC
EQUIPMENT

PRECAUTIONS

WHEN

CARRYING

OUT MAINTENANCE

HAN-

With the increase in pressure and precision of
hydraulic equipment,
the most common cause
of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when
disassembling
or assembling
hydraulic equipment, it is necessary to be particularly careful.

1) Be careful of the operating

environment.
Avoid adding hydraulic oil, replacing filters,
or repairing the machine
in rain or high
winds, or places where there is a lot of dust.

2)

s
2
3
3)

4)

Disassembly
and maintenance
work in the
field
If disassembly
or maintenance
work is carried out on hydraulic equipment
in the field,
there is danger of dust entering the equipment. It is also difficult to confirm the performance after repairs, so it is desirable to
use unit exchange. Disassembly
and maintenance of hydraulic equipment
should be
carried out in a specially prepared dustproof
workshop, and the performance
should be
confirmed with special test equipment.
Sealing openings
After any piping or equipment
is removed,
the openings should be sealed with caps,
tapes, or vinyl bags to prevent any dirt or
dust from entering. If the opening is left open
or is blocked with a rag, there is danger of
dirt entering or of the surrounding
area being made dirty by leaking oil so never do
this.
Do not simply drain oil out on to the ground,
collect it and ask the customer to dispose of
it, or take it back with you for disposal.

TEW00207

TEW00208

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

TEWOO209

20- 109
0

TROUBLESHOOTING

PRECAUTIONS

5)

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

6)

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

71

Cleaning operations
After
repairing
the hydraulic
equipment
(pump, control valve, etc.) or when running
the machine,
carry out oil cleaning to remove the sludge or contaminants
in the hydraulic oil circuit.
The oil cleaning equipment
is used to remove the ultrafine (about 3~) particles that
the filter built into the hydraulic equipment
cannot remove, so it is an extremely
effectivm
1_device.

I

20-110
0

WHEN

CARRYING

OUT MAINTENANCE

TEW00211

TROUBLESHOOTING

HANDLING
1.

HANDLING

CONNECTORS

CONNECTORS

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

I

I
2.

When disconnecting
male and female connectors, release the lock and pull in parallel with
both hands.
f
Never try to pull out with one hand.

3.

When the wiring harness clamp of the connector has been removed, always return it to its
original condition and check that there is no
looseness of the clamp.

mwoo485

CHECKS BEFORE TROUBLESHOOTING

TROUBLESHOOTING

CHECKS BEFORE TROUBLESHOOTING
item

Judgement
standard

Remedy
Add fuel

1. Check fuel level, type of fuel
2. Check for dirt or water in fuel

-

Clean, drain

3. Check h,ydraulic oil level

-

Add oil

4. Check filter (hydraulic, transmission, torque converter)

-

Replace

5. Check oil level

-

Add oil

6. Check engine oil

-

Add oil

7. Check coolant level

-

Add water

8. Check clogging of dust indicator

-

Clean or check

9. Check for loose or corroded battery terminals or wiring

-

Tighten or replace

IO. Check for loose or corroded alternator terminals or wiring

-

Tighten or replace

Il.

-

Repair or replace

12. Check operation of gauges

-

Repair or replace

13. Check for abnormal noise or smell

-

Repair

14. Check for oil leakage

-

Repair

15. Bleed air from system

-

Bleed air

16. Check effect of brakes

-

Adjust or repair

Check for loose or corroded starting motor terminals or wiring

17. Check battery voltage (engine stopped)
18. Check battery electrolyte level

24 - 26V

Repair or replace

-

Add electrolyte or
replace

i9. Check for discolored, burned, or bare wiring

-

Replace

!O. Check for missing wiring clamps, hanging wires

-

Repair

!I.

-

Check for water on wiring

Dry place affected by
water

(check carefully for water at connectors and terminals)
!2. Check for broken or corroded fuses

-

Replace

!3. Check alternator voltage (engine running at over half throttle)

-

Replace

(If the battery charge is low, it may reach approx. 25 V

!8.5 - 29.5V

Repair or check

immediately after starting)
!4. Noise when battery relay is operated
(turn starting switch ON-OFF)

20-112
0

-

Replace

TROUBLESHOOTING

METHOD

2.

METHOD

OF USING

OF USING TROUBLESHOOTING

TROUBLESHOOTING

CHARTS

CHARTS

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

l

20-114
a

“0
5
zl

METHOD

TROUBLESHOOTING

< Example
(1)

OF USING

TROUBLESHOOTING

CHARTS

>

M-15 Abnormality

in buzzer

(2) (a) Buzzer does not sound

when

starting

switch

is turned

ON (during

self-check)

Remedy

Cause

Defective contact, or
disconnection in wiring
harness between CNLOG
(female) (8) and CNL43
(male)

(3)
YES

After inspectior
repair or replac

Does buzzer
2 YES
1) Turn starting
2) Contact CNL43
(female) to
chassis ground.

Defective buzzer

Replace

Defective contact, or
disconnection in wiring
harness between CNL42
(female) and CNFSP (9)

After inspection
repair or replac

CNL42 (female)

1)20-30V
2) Turn starting
switch ON.

NO

CNLIS

CNFS2 @ ,
+24V

CNL42

Buzzer output
i

CNLOG

Maintenance

monitor

(1

Buzzer

CNL43

TAWO0722

(4)
*
Before carrying out troubleshooting,
check that all the related connectors are properly
*
Always connect any disconnected
connectors before going on the next step.

inserted.

20-115
0

TROUBLESHOOTING

3.

Using troubleshooting
failure

METHOD OF USING TROUBLESHOOTING

chart for engine-related

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

20-l 16
0

CHARTS

TROUBLESHOOTING

METHOD

OF USING TROUBLESHOOTING

CHARTS

The basic method of using the troubleshooting
chart
is as follows.
items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with 0, and of these, causes that have a high probability are marked with Q.
Check each of the [Questions] and [Check items] in
turn, and marked the o or 0 in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is
the most probable cause, so start troubleshooting
for that item to make final confirmation of the cause.
’ %I. For [Confirm recent repair history] in the
[Questions] Section, ask the user, and mark
the Cause column with @to use as reference
for locating the cause of the failure. How3
ever, do not use this when making calculations to narrow down the causes.
,*x2. Use the 4 in the Cause column as reference
for [Degree of use (Operated for long period)] in the [Questions] section as reference.
As a rule, do not use it when calculating the
points for locating the cause, but it can be
included if necessary to determine the order
for troubleshooting.

20-117
a

TROUBLESHOOTING

.

METHOD

OF USING

TROUBLESHOOTING

CHARTS

Example of troubleshooting
when exhaust gas is black
Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three
symptoms have causal relationship with this problem: [Exhaust gas slowly became black], [Power
slowly became weaker], and IDust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with
five causes. Let us explain here the method of using this causal relationship to pinpoint the most
probable cause.

combustion)
s-7 Exhaust gas is black (incomplete
General causes why exhaust gas is black
.
Insufficient intake of air
.
Improper condition of fuel injection
.
Excessive injection of fuel

Legend

20418
0

TROUBLESHOOTING

METHOD OF USING TROUBLESHOOTING

ic

CHARTS

7 7

Five causes
Step 1

Clarify the relationship between the three
symptoms in the [Questions] and [Check items]
section and the five Cause items in the vertical
column.
J

Three symptoms

Step 2
Add up the totai of Oand 0 marks where the
horizontal lines for the three symptoms and the
vertical columns for the causes intersect.
(I 1 Clogged air cleaner element:
000
(2) Air leakage between turbocharger
and head:
00
(3) Clogged, seized injection nozzle:
0
(4) Defective contact of valve, valve seat: 0
(5) Worn piston ring, cylinder:
0
Step 3
The calculation in Step 2 show that the closest
relationship is with [Clogged air cleaner
element]. Follow this column down to the
troubleshooting
area and carry out the
troubleshooting
item marked 0. The Remedy is
given as [Clean], so carry out cleaning, and the

20-119
0

TROUBLESHOOTlNG

4.

METHOD

OF USING

TROUBLESHOOTING

CHARTS

Method of using matrix troubleshooting
tables
The troubleshooting
tables use the same method as for other troubleshooting
table (YES/NO type)
to locate the causes of failures in the machine. The troubleshooting
tables are divided broadly into
categories for the main components,
such as the steering system and work equipment
hydraulic
system. Follow the procedure given below and carry out troubleshooting
to locate the problems
accurately and swiftly.

Step 1. Questioning
the operator
The questions to ask the operator are given
below the failure symptom. If the answers
to the questions match the information given,
follow the arrow to reach the probable cause
of the failure.
Consider the contents of the questions and
consult the table while proceeding to Steps
2 and 3 to grasp the true cause.

1.

Step 2. Checks before troubleshooting
Before starting the main troubleshooting
and
measuring the hydraulic pressure, first check
the Checks before Starting items, and check
for oil leakage and loose bolts. These checks
may avoid time wasted on unnecessary troubleshooting.
The items given under Checks before Starting are items which must be considered particularly for that symptom
before starting
troubleshooting.

Checks before

Step 3. Using cross-reference table
li Operate the machine to carry out the
checks in the troubleshooting
item column.
Mark the items where the results match
the symptom.
f
It is not necessary to follow the troubleshooting
checks in order; follow
an order which is easiest to carry
out troubleshooting.
2) Find the appropriate
cause from the
cause column. If the symptom appears,
the 3 marks on that line indicate the possible causes. (For item No. 2 in the table
on the right, the possible causes are c or
e.)
If there is only one 0:
Carry out the other troubleshooting
items
(where the same cause is marked with
01, check if the symptom appears, then
repair.
If there are two OS:
Go on to Step 3) to narrow down the
possible causes.

Steering

does not work c

Symptom

[Exam-

plel
Ask the operator about the following points.
.
Did the steering suddenly stop working? + Breakage in steering equipment
.
Had the steering gradually been becoming heavy? + Internal wear of steering
equipment,
defective seal
starting

Is the oil level

[Example

[Example]
and type

of oil in the

II

NO.
Steering does not work to the left or right
Same as Item 1, but abnormality in actuation of work equipment
Steering can only be operated to one side.
Steering wheel is heavy and cannot be turned.

[Example

21

TROUBLESHOOllNG

3)

4)

5)

6)

7)

METHOD OF USING TROUBLESHOOTING

CHARTS

Operate the machine and check the troubleshooting items other than those in 1).
Operate the machine and check the items in
the same way as in I), and if the symptom
appears, mark that item. (In the chart on the
right, the symptom appears again for item
5).
Find the appropriate cause from the cause
column. In the same way as in Step 2), if the
symptom appears, the o marks on that line
indicate the possible causes. (For item No.5
in the table on the right, the possible causes
are b or e.)
Narrow down the possible causes.
There is one common
cause among the
causes located in Steps 2) and 4). (One cause
marked o appears on the line for both items.)
This cause is common to both the symptoms in troubleshooting
Steps 1) and 3).
*
The causes which are not common
to
both troubleshooting
items (items which
are not marked o for both symptoms)
are unlikely causes, so ignore them.
(In the example given on the right, the
causes for Troubleshooting
Item 2 are c
or e, and the causes for Troubleshooting
Item 5 are b or e, so cause e is common
to both.)
Repeat the operations in Steps 3), 4) and 5)
until one cause (one common
cause) remains.
If the causes cannot be narrowed down
*
to one cause, narrow the causes down
as far as possible.
Remedy
If the causes are narrowed down to one common cause, take the aciton given in the remedy column.
The symbols given in the remedy column
indicate the following:
X: Replace, a: Repair, A; Adjust, C: Clean

-

It- Applicable troubleshooting item located in Step 3).
-Applicable

troubleshooting item located in Step 1).
these causes

Common causes

Action to take

20-l 21
0

TROUBLESHOOTING

CONNECTOR

TYPES AND

MOUNTING

LOCATIONS

CONNECTOR TYPES AND MOUNTING
LOCATIONS
Ir The Address column in the table below shows the address in the connector arrangement
(3-dimensional

drawing).

(l/3)
Mounting location

Mounting location

Front combination

CNFRI

S type

zo- 122
0

10

~~~~ef:~me wiring

Dl

drawing

.

TROUBLESHOOTING CONNECTOR PIN ARRANGEMENT DIAGRAM CNL68 CNL64 CNL58 CNl57 CNL52 r”3 2 Front I’ c.125 0 . __ CNA14 / / CNL03 CNAS CNLOI CNL02 CNLO6 CNL07 CNL08 CNLOS CNL63 1 CNA7 I CNAG CNL04 20.ul_48 CNL48 CNL53 !2 CNFS3 CNAR -.

y&. ( I ..-..~. 1L.L I motor 1Alternator 1 Dust indicator 1 1Dust indicator E6 I 14 Engine wiring ZO-126 0 .pc.rtemperature / B5 1 CNE08 - 1 Glow relay D6 CNEOS X type 2 Glow relay D6 CNE13 X type 2 Starting F2 CNE15 - 1 Alternator A4 ICNE16 1 - 1 7 1Alternator 1 A4 1 ICNE17 1 I I A3 I CNEIS lCNE20 - . 8 F3 harness I CNERP E6 I I I Engine wiring harness F3 I DIAGRAM .TROUBLESHOOTING CNEOG IX type ( CONNECTOR PIN ARRANGEMENT 2 ~/~. CNERI .!.

TROUBLESHOOTING CONNECTOR PIN ARRANGEMENT DIAGRAM CNE04 CNEO5 CNEl5 CNElG CNE17 TO rear frame harness CNERl CNERZ / &El2 CNElO ZO-127 0 .

of pins TABLE FOR CONNECTOR PIN NUMBERS PIN NUMBERS the terms male housing and female housing X type connector Male (female housing) Female (male housing) 1 TEW00220 at 2 0 TEWO0221 TEW00222 TEW00223 TEW00224 TEwoo225 20-128 0 3 1 4 2 TEW00226 . No. while refer to the mating portion of the housing.TROUBLESHOOTING CONNECTION CONNECTION Ir TABLE FOR CONNECTOR The terms male and female refer to the pins.

of pins CONNECTION r AMP040 Male (female TABLE FOR CONNECTOR type connector housing) Female 4 8 8 12 (male housing) 4 TEWO0227 6 PIN NUMBERS TEW00228 12 6 7 1 12 1 7 TEW00229 8 TEW00230 16 16 8 16 TEWOO231 TEW00232 20.129 0 .TROUBLESHOOTING No.

TROUBLESHOOTING No.housing) Female (male housing) 1 4 6 CEII I 1 bk 6 3 TEW00235 1 \ / TEWOOZ36 5 8 4 8 TEW00237 1 14 20-130 0 4 8 11 11 8 4 1 . of pins CONNECTION T TABLE FOR CONNECTOR PIN NUMBERS SWP type connector Male (female.

CONNECTION TROUBLESHOOTING No. of pins r TABLE FOR CONNECTOR PIN NUMBERS M type connector Male (female Female housing) (male housing) 2 TEW00244 TEW00243 3 2 m 1 4 2 TEW00246 6 ‘6 TEW00247 TEW0024E 20-l 31 0 .

TROUBLESHOOTING No. of pins CONNECTION r TABLE FOR CONNECTOR PIN NUMBERS S type connector Female (male housing) Male (female housing) r 8 1 TEWO0249 TEWOOZSO TEW00251 TEWO0252 6 10 $3 12 6 1 16 7 8’ ‘1 \ 5 TEW00253 8 1 1s i TEW00254 16 20-132 0 TEWO0255 TEW00256 .

133 0 .CONNECTION TROUBLESHOOTING TABLE FOR CONNECTOR PIN NUMBERS L type connector No. of pins Male (male En 6 Female housing) 1 1 2 2 (female housing) q m FFE3 TEW00258 TEWOO257 No. of pins Diode type connector Male (male Female housing) (female housing) 2 TEW00261 TEW00262 zo. MIC type connector of : pins c Male (female Female housing) (male housing) 21 i L TEW00260 TEwoo259 No.

134 0 TEWO0265 .TROUBLESHOOTING No. of pins CONNECTION T Simple Male (male connector housing) TABLE FOR CONNECTOR PIN NUMBERS (ring connector) Female (female housing) 1 TEW00263 TEWOO26d 2 8 k 4 TEWOO263 zo.

.......................................20-211 20-212 20-213 20-214 .....TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) s- I s....................8 Oil consumption s..........................................5 Engine does not rotate smoothly S............6 Engine lacks output s..... does not start (Fuel is being injected).........................................................................3 operations ...................................... ..............20-215 20-216 .............................................. noise is made ................................................................... spurts back............................. gas is black (incomplete is excessive contaminated (or exhaust quickly is excessive water.........................................20-202 Engine does not start .......................................................................... (hunting) ............................................... (3) Exhaust J ......................................................................................................4 Engine stops during s........................ ........................ combustion). is excessive ................................... gas is blue)................................................................................................................ (no power)... temprautre becomes too high (overheating) . or water level goes down............ gas comes gas comes out (Fuel is not being out but engine injected) Engine does not pick up smoothly s.........9 Oil becomes s-10 Fuel consumption S-l 1 Oil is in cooling s-12 Oil pressure s-13 Oil level rises ...................... ................................................... ...................... 20-205 (Follow-up is poor)................................... or water .................................2 performance Starting is poor (Starting 20-203 (1) Engine 20-203 does not turn .......................................................................... 20-206 20-207 20-208 20-209 20-210 ................... s-14 Water s-15 Abnormal S-q6 Vibration 20-204 ....................................... .............20-217 20-218 20-219 20-20 1 0 ...................................................... ......... (2) Engine turns but to exhaust !z 7 always takes time)...... s............................................................ ........................................ lamp lights up (drop in oil pressure) .............. ..........................................................7 Exhaust S...............

it is found to be ’ When fuel filter.23 1.kr 20-202 0 l l . Legend 0 : Possible causes (judging from Questions and check items) 0 : Most probablecauses (judgingfrom Questions and Check items) A : Possible causes due to length of use (used for a long period) $ Replacement of filters has not been carried out according to snmanual icator is red cified fuel has been used 1) Little fuel comes out even when injection pump sleeve nut IS loosenea 2) Little fuel comes out even when fuel filter air bleed plug is loosened Leaka9e from fuel piping There is hunting from engine (rotation is irregular) 0 on I I I I I __ I I z L change in engine speed.10°C or above.22 0°C 1. that cylinder is not working When check is made using delivery method.“.26 1.25 1.24 I I The specific gravity should exceed the value for the charging rate of 70% in the above table.TROUBLESHOOTING S-l S-l Starting performance is poor (Starting always takes time) Gelieral causes why starting performance is poor .28 1. it is found to be clogged l l E. Insufficient supply of fuel . (At ambient temperature of .“d’relement is inspected directly. Insufficient intake of air . injection timing is found to be incorrect I I I I I I I”1 I I I 0 00 00 00 010 When compression pressure is measured.24 1.2a 1.30 1.kcrcg$X$:zb.“. it is found to be heavy or does not return (when blind plug at rear of pump is removed. Charging rate 75% 1 100% 1 90% 80% \ 70% I . 2 diesel fuel. use ASTM D975 No. and . they are found to be clogged I I lnl Inl I I 000 1 / l Illlllllllll’ll 1 I I I I I I I I I I I I I I l When control rack is pushed.25 1. 1. In cold weather the specific gravity must exceed the value for the charging rate of 75% in the above table.27 1. it is found to be low 1010 y’.10°C or below.26 1.23 -10°C 1. use ASTM D975 No.24 1. Defective electrical system .“. it can be seen that plunger control sleeve does not move) When fuel cap is inspected directly.29 1. strainer are inspected directly.) * Battery charging rate.

engine starts 21 When terminal B and terminal C of starting motor are connected. connect the cord. and carry out troubleshooting at ON 1) When terminal B and terminal C of starting switch are connected. pinion moves out. engine starts 3) When terminal B and terminal C of safety relay are connected. engine starts 5) There is no 24V voltage between battey relay terminal B and terminal E Nhen ring gear is inspected directly. turn the starting switch IFF. . carry out troubleshooting for “Engine stops during operations”. but Soon disengages again Makes rattling noise and does not turn When starting switch is turned to START. pinion does not move out 0 When starting switch is turned to ON.3 . there is no clicking sound Battery terminal is loose .5). z ‘ij ol joecific aravitv of electrolvte. tooth surface is found o be chipped Ioes not move even when engine stop motor linkage is Gsconnected - I Remedy 20-203 0 . Failure in power train Defective electrical system l l Legend 0: Possible causes (judging from Questions and check items) 0 : Most probable causes (judging from Questions and Check items) A: Possible causes due to length of use (used for a long period) l : Items to confirm the cause. When starting switch is turned to ON.TROUBLESHOOTING s-2 S-2 Engine does not start (II Causes Engine does not turn General causes why engine does not turn internal parts of engine seized * If internal parts of the engine are seized. linkage does not move 1When battery is checked. battery electrolyte is found to be low . I Confirm recent repair history 2 ~ I d Degree of use Operated for long period Condition of horn when starting switch is turned ON Horn sound level is low Horn does not sound 0 Rotating speed is slow Makes grating noise When starting switch is turned to START. voltaae of battew is low :or the following conditions 1) . engine starts 4) When terminal of safety switch and terminal B of starting motor are connected.

or does not return Check feed oumo diractlv When fuel filter. they are found to be clogged When feed pump strainer is inspected directly. it is found to be heavy. it is found to be clogged When fuel cao is insoected directlv.TROUBLESHOOTING s-2 (2) Engine turns but no exhaust gas comes out (Fuel is not being injected) General causes why engine turns but no exhaust gas comes out . strainer are inspected directly. Confirm recent reoair historv Degree of use Operated for long period Exhaust gas suddenly stops coming out (when starting again) Replacement of filters has not been carried out according to operation manual Fuel tank is found to be emotv There is leakaae from fuel oioina Mud is stuck to fuel tank cao When startina switch is turned ON. Improper selection of fuel (particularly in winter) Causes f//////l/ Standards for use of fuel Ambient temprature Type of fuel I ’ _** _4 I-30 -20 .4 32 w 68 -10 0 10 20 86 30 104122°F 40 50% I /. it is found to be cloaoed Does not move even when engine stop motor linkage is disconnected I- Remedy 20-204 0 I I I .1 0 : Most probable causes (judging from Duestions and Check items) A: Possible causes due to length of use fused for a long period) l: Items to confirm the cause. I) lniection Dump couplina dose not rotate 2) No fuel comes out even when fuel filter air bleed plug is loosened 3) No fuel spurts out even when injection pipe sleeve nut is loosened Rust and water are found when fuel is drained Check injection pump directly When control rack is pushed. fuel does not come out When engine is cranked with starting motor. Supply of fuel impossible . Supply of fuel is extremely small .~I~/ Diesel fuel Legend 0: Possible causes (judging from Questions and check items. linkaae does not move When fuel filter is drained.

temperature of some cylinder is low When fuel filter is drained.TROUBLESHOOTING s-2 (31 Exhaust gas comes out but engine not start (Fuel is being injected) does General causes why exhaust gas comes out but engine does not start . or pump is heavy 20-205 0 . they are found to be clogged When feed pump strainer is inspected directly. no fuel comes out Remove head cover and check directly When control rack is pushed. Lack of rotating force due to defective electrical system . it is found to be low When fuel filter. or does not return When compression pressure is measured. there is no response. Insufficient supply of fuel . 1) Little fuel comes out even when injection pump sleeve nut is loosened 2) Little fuel comes out even when fuel filter air bleed plug is loosened There is leakaae from fuel oioina When exhaust manifold is touched immediately after starting engine. it is found to be clogged When air element is inswed directly.of fuel &I 0: 0: a: When engine is cranked. it is found to be clogged Glow plug mount does not become warm Either specific gravity of electrolyte or voltage of battery is low When feed pump is operated. it is found to be heavy. it does not contact stopper When engine is cranked with starting motor. strainer are inspected directly. Insufficient intake of air . Improper selection . abnormal noise is heard from around head Enoine oil must be added more freouentlv Non-specified fuel has been used Replacement of filters has not been carried out according to operation manual Rust is found when fuel is drained Dust indicator is red Indicator lamp does not light up / Startina motor cranks enaine slowlv Mud is stuck to fuel tank cap When fuel lever is placed at FULL position.

it is found to be clogged I When feed pump is operated. but speed suddenly drops when load is applied @@ 0 There is hunting from engine (rotation is irregular) 000 0 When exhaust manifold is touched immediately after starting engine. itisfoundto beclogged 1. insufficient intake of air . that cylinder is not working 0 When control rack is pushed. it is found to be heaw When valve clearance is checked directly. it is found to be heavy.1 When fuel filter.TROUBLESHOOTING s-3 S-3 Engine does not pick up smoothly (Follow-up is poor) General causes why engine does not pick up smoothly . strainer are inspected directry. it is found to be clogged I I I I I I I I 0 Stop fuel injection to one cylinder at a time. Insufficient supply of fuel . or does not return When compression pressure is measured. If there is no change in engine speed. they are found to be clogged I 1. improper condition of fuel injection .1 When feed pump strainer is inspected directly. it is found to be low When turbocharaer is rotated bv hand. temperature of some cylinders is low 00 1 Blow-by gas is excessive 1 1 I 1 1 I I ] I I I I I When aireiementisinspecteddirectly.1I i When fuel cap is inspected directly. operation is too light or too heavy Remedy 20-206 0 . it is found to be outside standard value I I I I I I I 1. Improper fuel used I Dearee 1Ooeratedforlonaoeriod of use Replacement of filters has not been carried out according to operatron manual lAlA!Al Q Q 0 I I I I Noise of interference is heard from around turbocharger / 0 0 Engine pick-up suddenly became poor Clanoina sound is heard 0 Blue under light load Color of exhaust gas Black from around cvlinder I I I 00 8 0 8 I C 0 I 0 I 101 I I I I I I I I I I IQ1 head Mud is stuck to fuel tank cao There is leakage from fuel piping High idling speed under no load is normal.

. Insufficient supply of fuel Overheating * If there is overheating and insufficient output. there is no response or it is heavy 00 I Mud is stuck to fuel tank cap I I I 0 0 0 Engine turns. it is fond to be heavy or does not return 1 I I I I I I I44 I I I t2 Kw I I I I lolol I I I z I I I I I I I I I I I 20-207 0 . Failure in power train Ir If the engine stops because of a failure in the power train. carry out troubleshooting for overheating.TROUBLESHOOTING S-4 S-4 Engine stops during operations General causes why engine stops during operations Seized parts inside engine . carry out troubleshooting for the chassis. but stops when transmission control lever is operated Rust and water are found when fuel is drained Metal particles are found when oil is drained When control rack is pushed. l Causes l Legend 0 : Possible causes (judging from Questions and check items) 0 : Most probable causes (judgingfrom Questions and Check items) n : Possible causes due to length of use (used for a long period) l : Items to confirm the cause. Abnormal noise was heard and engine stopped suddenly Condition when engine stopped 0 Engine overheated and stopped @ 0 Engine stopped slowly 000 There was hunting and engine stopped 000 Fuel gauge lamp lights up 0 Fuel tank is found to be empty @ Replacement of filters has not been carried out according to 1 operatron manual I II 00 3 080000 I I I I I 0 fifi 1~1~1 Non-specified fuel has been used 000 When feed pump is operated.

TROUBLESHOOTING s-5 S-5 Engine does not rotate smoothly (hunting) General causes why engine does not rotate smoothly . ~Confirm recent repair history Degree of use Operated for long period Occurs at certain speed range Occurs at low idling Condition of hunting Ocuurs even when speed is raised 5 Fuel tank is found to be empty Replacement of filters has not been carried out according to operation manual Rust is found when fuel is drained Leakage from fuel oioina When feed pump is operated. it is found to be clogged When fuel filter. Air in fuel system . it is found to be cloggec When feed pump strainer is inspected directly. it is found to be heavy. they are found to be clogged Remedy 20-208 0 B 5 Ocuurs on slopes . return is normal Enoine weed sometimes rises too hiah Enaine is sometimes difficult to stoo Seal on iniection oumo has come off When governor lever is moved it is found to be stiff When injection pump is tested. return is ouick 2) No resoonse. lioht. strainer are inspected directly. 1) No resoonse. Defective engine throttle controller mechanism (engine throttle controller type) Legend 0: Possible causes (judging from Questions and check items) 0 : Most probable causes (judgingfrom Questions and Check items) a: l Possible causes due to length of use (used for a long period) : Items to confirm the cause. liaht. Defective governor mechanism . governor is found to be improperly adjusted When control rack is pushed. or does not return When fuel cap is inspected directly.

Insufficient intake of air . but speed suddenly drops when load is applied I When exhaust manifold is touched immediately after startw ‘. temoerature of some cvlinders is low 0 00 I I I I I I I I I I I / I / I I I I I l s found to be clogged When feed pump strainer are inspected directly. or dose not return When valve clearance is checked directly. it is found to be outside standard value When lever is placed at FULL position. carry out troubleshooting for overheating. If there is no change in engine speed. output drops) Lack of output due to overheating If there is overheating and insufficient * output. it is found to be clogged I 0 c 2 z c c . operation is too light or too heavy When fuel cap is inspected directly. that cylinder is not working When control rack is pushed.L s Remedy 1 Y-Y 20-209 0 . Improper fuel used l (if non-specified fuel is used. Improper condition of fuel injection .’ engrne. High idling speed under no load is normal.TROUBLESHOOTING S-6 Engine lacks output S-6 (no power) General causes why engine lacks output . it does not contact stopper 0 When feed pump is operated. Insufficient supply of fuel . it is found to be heavy. it is found Stop fuel injection to one cylinder at a time.

Excessive injection of fuel Causes Legend 0 : Possible causes (judging from Questions and check items) 0 : Most probable causes (judging from Questionsand Check items) A : Possible causes due to length of use (used for a long period) l : Items to confirm the cause. exhaust gas color returns to normal When control rack is pushed. that cylinder is not working When check is made using delivery method. If there is no change in engine speed.TROUBLESHOOTING S-7 Exhaust s-7 gas is black (incomplete combustion) General causes why exhaust gas is black . it is found to be heavy. it is found to be heavy When air cleaner is inspected directly. or does not return 20-2 10 0 000 Q 0 0 8 j I 1 I I 1 I I p/ 1 ( I I I I IQ ! I 0 l I I 1 1 1l / 1 1 1 1 1 !01 1 IIIIIII I I I I. loose clamp When turbocharger is rotated by hand. it is found to be low Stop fuel injection to one cylinder at a time. temoerature of some cvlinders is low Muffler is crushed Leakage of air between turbocharger and head. Improper condition of fuel injection .I I I I I I I l l 0 0 . insufficient intake of air . injection timing is found to be incorrect Injection pump test shows that injection amount is incorrect When valve clearance is checked directly it is found to be outside standard value When muffler is removed. Color of exhaust gas Dust indicator is red glow-by gas is excessive Engine pickup is poor and combustion is irregular @ 0 When exhaust manifold is touched immediately after startina enaine. it is found to be clogged When comuression oressure is measured.

1 ti. / . There is external leakage of oil from engine 0 Pressure-tightness test of oil cooler shows there is leakage Excessive play of turbocharger shaft Check rear seal directly When intake manifold is removed..S-8 TROUBLESHOOTING S-8 Oil consumption is excessive (or exhaust gas is blue) + Do not run the engine at idling for more than 20 minutes continuously. it is found to be low When breather element is inspected. dust is found inside ! . 1. . inside is found to be dirty I I I I I I I I I I I I IN I Remedy .noir”fake manifold is removed. (Both low and high idling) General causes why oil consumption is excessive Abnormal combustion of oil External leakage of oil Wear of lubrication system l l l Legend and check items) estions and Check items) (used for a long period) Area around engine is dirty with oil There is oil in engine cooling water Inside of turbocharger intake pipe is dirty with oil 6 Oil level in clutch or TORQFLOW transmission damper chamber rises Clamps for intake system are loose I I When compression pressure is measured.0. it is found to be clogged with dirty oil 0.

intake of exhaust gas due to internal wear . Improper oil used . When breather element is inspected directly. Clogging of lubrication passage . it is found to be clogged with When safety valve is directly inspected.TROUBLESHOOTING S-9 Oil becomes contaminated s-9 quickly General causes why oil becomes contaminated quickly . spring is found to be catching or l broken Remedy z d 2 20-2 0 12 IT t 4 2 cd z d : $ : $ 4 E d 5 0 oz 1 . Improper combustion . Operation under excessive load Causes Legend 0 : Possible causes (judging from Questions and check items) 0 : Most probable causes (judgingfrom Questionsand Check items) A: Possible causes due to length of use (used for a long period) l : Items to confirm the cause.

TROUBLESHOOTING S-IO Fuel consumption s-10 is excessive General causes why fuel consumption is excessive . Excessive injection of fuel Causes / I Legend 0: Possible causes (judging from Questions and check items) : Most probable causes (judgingfrom Questionsand Check items) : Possible causes due to length of use (used for a long period) l : Items to confirm the cause.1 I 20-213 0 . it is found to be heavy. injection timing is found to be incorrect Remove head cover and check directly Remove feed pump and check directly When engine speed is measured. 0 n I Confirm recent reoair historv Dearee of use Ooerated for lona oeriod I I lnlnl I I More than for other machines of 0 same model I I I I I lal 0 Condition of fuel consumption GraduaHv increased Exhaust gas color 00 I I I lolol Suddenlv increased I Slack lwl White I Seal on injection pump has come off I I lol I I I I Ic loI I lol I I I I I I I There is irregular combustion 0 When exhaust manifold is touched immediately after starting engine. improper condition of fuel injection .1 I I I I I I I I I. or does not return When check is made using delivery method. Leakage of fuel .1 I I I I I I 1~ -11 I i i M I / I I I I I I I I I I. low idling speed is found to be high I i@l 1 I I I I. temperature of some cylinders is low 00 Match mark on injection pump is misaligned 0 There is external leakage of fuel from engine 0 0 0 Engine oil level risesand smells of diesel fuel Engine low idling speed is high 00 Q Injection pump test shows that injection amount is excessive Stop fuel injection to one cylinder at a time.1 I I I I I I. that cylinder is not working When control rack is pushed. If there is no change in engine speed.

TROUBLESHOOTING S-11 S-l 1 Oil is in cooling water. down or water spurts back. transmission oil is drained. Internal leakage in cooling system I Causes ions and check items) estions and Check items) (used foi a long period) When hydraulic oil. torque converter. water is found I I I I / . or water level goes General causes why oil is in cooling water . Internal leakage in lubrication system .

Leakage. Improper oil used (improper viscosity) .TROUBLESHOOTING S-12 s-12 Oil pressure lamp lights up (drop in oil pressure) General causes why oil pressure lamp lights UP . Deterioration of oil due to overheating Standards for engine oil selection Selection of oii SAE number according to ambient temperature Type of oil -22 -30 -4 -20 14 -10 32 0 50 10 68 20 86 30 104122OF 40 5oYI Causes Engine oil Legend estions and check items) Questionsand Chockitems) se (used for a long period) ration manual Condition when oil pressure . Defective oil pressure control . clogging. wear of lubricating system .

an 1Engine oil smells of diesel fuel I I I I I I I I I I I lololal I I I I Fuel is added more frequently When pump auxiliary equipment is removed. and smells of diesel fuel) . Fuel in oil (diluted. Entry of oil from other component Legend 0: Possible causes (judging from Questions and check items) 0 : Most probable causes (judging from Questions and Check items) a : Possible causes due to length of use (used for a long period1 l : Items to confirm the cause. When engine is run at idling. seal is found be broken i to 20-2 16 a I .TROUBLESHOOTING S-13 s-13 Oil level rises * If there is oil in the cooling water. carry out troubleshooting for “Oil is in cooling water”. 8 c3 4 Leave radiator cap open. General causes why oil level rises l Water in oil (cloudy white) .

water spurts back I E 6 ( 101 Radiatorshroud. it is found to be clogged When measurement is made with radiator cap tester. no light passesthrough Y B I I I I lot I I (i f ] I I I I I I { 1 101 I 1 I I ) I I Power train oil temperature enters red range before engine water temperature I I I 1 / I Id 101 I I I I I IQ 1 / I I I I I 161 I I I I I I Water is leaking because of cracks in hose or loose clamps Belt tension is found to be slack 1 I 0 I I I 101 I 1 I Engine oil level has risen. l : Items to confirm Water temperature gauge Does not go down from red range Radiator water level sensor lights up Fan belt whines under sudden load Cloudy white oil is floating on cooling water I Cooling water flows out from overflow hose I I I I I I I I loI Excessive air bubbles inside radiator. Drop in heat dissipation efficiency . Defective cooling circulation system . oil is cloudy white There is play when fan pulley is rotated c I I I I I I I I Temperature difference between top and bottom radiator When water temperature is measured. it isfound to be low 20-2 0 17 . set pressure is found to be low When compression pressure is measured. Legend 0 : Possible causes (judging from Questions and check items) 0 : Most probable causes (judgingfrom Questions and Check items) A: Possible causes due to length of use fused for a long period) the cause.s-14 TROUBLESHOOTING Causes S-14 Water temperature (overheating) becomes too high General causes why water temperature becomes . insideof underguard are clogged with dirt or mud When light bulbis held behind radiator. Rise in oil temperature of power train * Carry out troubleshooting too high of fan) for chassis. Lack of cooling water (deformation. damage . it is found to be normal When oil cooler is inspecteddirectly.

Air sucked in from intake system l l Legend 0 : Possible causes (judging from Questions and check items) 0 : Most probable causes (judgingfrom Questions and Check items) n : Possible causes due to length of use fused for a long period) l : Items to confirm f 0 the cause.TROUBLESHOOTING S-55 Abnormal s-15 noise is made Causes * Judge if the noise is an internal noise or an external noise. General causes why abnormal noise is made Abnormality due to defective parts Abnormal combustion noise . Non-specified fuel has been used Engine oil must be added more frequently / I loIn I lal I Blue under Color or exhaust gas Black Metal particles are found in oil filter 0 Blow-by gas is excessive 0 Noise of interference is heard from around turbocharger 0 0 Engine pickup is poor and combustion is irregular 01 When exhaust manifold is touched immediately after starting engine. temperature of some cylinders is low 00 Seal on injection pump has come off 00 Abnormal noise is loud when accelerating engine Clanging sound is heard from around cylinder head Leakage of air between turbocharger and head. loose clamp Vibrating noise is heard from around muffler 20-218 0 ~ I I I .

.1 I I I I I I I . break- . play I.S-16 TROUBLESHOOTING S-16 Vibration is excessive * If there is abnormal noise together with the vibration. Defective parts (abnormal wear. carry out troubleshooting for “Abnormal noise is made”. age) Improper Abnormal alignment combustion Causes Legend Possible causes (judging from Questions and check items) 0 : Most probablecauses (judgingfrom Questionsand Check items) n : Possible causes due to length of use (used for a long period) l : Items to confirm the cause. 0: Non-specified fuel has been used V Metal particles are found in oil filter Metal particles are found when oil is drained 00 Oil pressure is low at low idling 00 s Vibration occurs at mid-range speed 8 Vibration follows engine speed C Y 6 I I I I Exhaust gas is black Seal on injection pump has come off Remove oil pan and check directly Remove side cover and check directly Check directly for worn support pilot. General causes why vibration is excessive .

.... ......................... ...................................... ............................ ....... (b) Always carries out preheating for 1 minute....................... ..... (b) Parking lamp stays lighted up............... ............ L.......... .......... cut-off function is not switched and 20-271 display is not given .... ............. (a) When parking brake is applied.................. ......... .................................................. ... ......... ................. .... turn signal does not light up ............. ................... ......... Abnormality in front working lamp ...... .......................... .................... ... ......... .......... in preheating system IQGS) ....................5 M.......................................1 M................ Night lighting does not light up .............................................. 3rd ...... ................... and caution lamp flashes ..................................................... ... 4th ................ ........ .................................................. .... ...... 20-272 (c) Monitor display lights up but cut-off function is not actuated .... ...... (b) Working lamp lights up but monitor display does not light up.................. ......................................................................... .... ...................... ........ ...................TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE) TROUBLE M............................... ....................... (a) Parking lamp does not light up ............... .. ......... ... ...... ..... 20-255 20-256 20-257 20-258 20-258 20-258 20-258 20-259 20-259 20-259 20-260 20-260 20-261 20-262 20-262 20-262 20-263 20-263 20-263 20-264 20-264 20-265 20-265 20-266 20-267 20-268 20-268 20-268 20-268 20-269 20-269 20-269 20-269 20-271 Abnormality in transmission cut-off ................................ .......... all lamps stay lighted up .... ...... ................................................... buzzer sounds (intermittently) 20-273 even when directional lever is at N........................ (c) Monitor lights up but working lamp does not light up.. (b) When parking brake is applied....................................................................................................... ................. .. ..................... ................... (c) Monitor lights up but working lamp does not light up....... ............................................................................ Abnormality in rear working lamp ......... Abnormality in parking display ................... ...................... ..........................................................................................H....................... Id) Preheating time becomes shorter.... ...................... ........... ....... .............. ....................... ............... ............20-273 20-25 1 0 .. 2nd ...... .......... (b) R.............. ........... (g) Does not display 2nd.................4 M............................................... (b) Stays at N even when directional (c) Does not display N even when directional lever is at N and displays R when directional lever is at F ... Turn signal display does not light up ....... ....... ........... (c) Preheating stays on ................................. or there ‘is variation.................... (d) Does not display N even when directional lever is at N and displays F when directional lever is at R.... 4th... ....................................9 M-10 M-11 M-12 M-13 DATA DISPLAY ......... ......... Abnormality (a) Does not carry out preheating ..................... . ...... (a) Neither monitor display nor rear working lamp light up....... (a) When monitor switch is pressed................................................... .... ........... ............ ................ ......................... High beam does not light up .................7 M... ....... ............. ............................................................... ........................ ...... ................................................................. ................ ..................... 20-253 Main monitor does not work ................. ................................. lever is at R .............................................................. (e) Does not display Ist............. ........ ............................ ........... (a) Stays at N even when directional lever is at F ........... ............ ............................................................................................. ........... 20-27’1 (b) Monitor display goes out but cut-off function stays on ........6 M.......................................................... (f) Does not display 3rd.................. buzzer does not sound and caution lamp does not light up even when directional lever is at position other than N ....... ......H........................ Speedometer Abnormality in shift indicator ............................................... turn signal does not light up ...................... ................................................ ........... ....... When starting switch is turned ON and engine is started immediately..... ...................... .2 M....3 M... ......... .................... (a).......... ................... ....... ........................ display does not work properly.................... ......................................................... (a) Neither monitor display nor front working lamp light up .................... 20-273 Abnormality in parking brake dragging warning ................................ ........ ............................. (h) Does not display Ist.............._...... ..... (b) Working lamp lights up but monitor display does not light up ..............................................................8 M.................

.......................................... 20-280 (b) Monitor display flashes rapidly (2 times/set).......... ............................. Abnormality 20-278 (a) Emergency steering normal display does not light up ....................................................................................................... monitor display flashes rapidly (2 times/set) 20-281 (d) Monitor display flashes slowly (1 time/set)............ Abnormality ................................................................................................................ 20-275 in buzzer................................................................................................................... 20-279 (b) Emergency steering actuation display stays lighted up ..................................................M-14 M-15 M-16 M-17 M-18 M-19 M-20 M-21 M-22 M-23 When parking brake dragging warning is given....... Abnormality 20-282 (a) Display does not change when switch is pressed ............................................................. Abnormality 20-279 (a) Emergency steering actuation display does not light up....................... 20-282 (b) Monitor display lights up but ECSS function does not work ........................................... (b) Time for time elapsed since failure on failure display mode does not advance .................................................................................................................20-274 (b) Not actuated .................... 20-276 Condition of monitor switches is not stored in memory ............................. ................................... 20-274 (a) Actuated continuously ..... 20-281 (e) Monitor display goes out........................ Abnormality (a) Buzzer does not sound when starting switch is turned ON (during self-check)....................................... 20-278 (b) Emergency steering normal display stays lighted up .............................. 20-277 in failure display mode .... ............................................................. Buzzer does not sound when auto-leveling 20-283 in network) .............................................20-28 0 (c) When no more grease remains......................................................................... 20-277 (a) Does not enter failure display mode ~.................................. Failure code is not sent to main monitor (abnormality 20-252 0 g c) $ ..... 20-282 in ECSS system ........................................... ........................... ........................................................ ............ ...20-27 7 20-278 in emergency steering normal display ................ .............................................................. buzzer and caution lamp 20-274 are actuated continuously................. Abnormality 20-280 (a) Forced greasing cannot be carried out .......................... ....................................... 20-282 switch is actuated . ....................... ...... 20-280 in auto-greasing system ..................................................... or they are not actuated ........................................................................................................................ 20-279 in emergency steering actuation display ...............................................................................................20-275 20-275 (b) Buzzer always sounds ................

see Item 4. and CALL. If a ure occurs suddenly. see Item 5. The signals betieen the main monitor and each controller are transmitted in serial through the network circuit. and takes action. For details of the method of operating and transferring data to the trouble data display mode. Outline The speedometer display on the main monitor is used to display the troubleshooting for each control system. (Only the engine controller uses a special parallel signal. Failure code and time elapsed since failure The failures detected by each controller are changed to a code and displayed. The failure codes for failures that are now occurring flash. E03+CALL. one of these codes is shown on the speedometer display. failure code. The nature of the troubleshooting is displayed as the failure action code. the failure code and the time elapsed since failure are displayed to make it easy to check failures that are not occurring at present. so the codes for failures which can only be detected when the engine is operating light Example: When action code CALL is displayed f SPEED ‘\ Action code TDW00283 Example: When failure code “41” has occurred 27 hours before f SPEED . Failure code . such as stopping the machine immediately.Time elapsed since failure upFor the correspondence between the failure codes for each controller and the failed system. Abnormality in failure action code This code informs the operator directly of the abnormality. For failures that have occurred and been reset. it is impossible to switch to the trouble data display mode. and the codes for failures that are not occurring light up. For details of the action taken by operator for the action codes. EOl+CALL (EOI and CALL are displayed alfailternately).TROUBLESHOOTING TROUBLE DATA DISPLAY TROUBLE DATA DISPLAY 1. and the time elapsed since failure. see STRUCTURE AND FUNCTION for the main monitor.) 2. so carry out troubleshooting for the applicable controller. It is possible to tell from this code which system in which controller has failed. Note: If the engine is not stopped. There are four types of action code: EOO. 20-253 0 .

Boom RAISE-LOWER system leveler system d3 Abnormality ! selection 20-254 0 Relief solenoid High pressure I switch I in model I system system solenoid Low pressure system solenoid Speed system sensor Abnormality selection relay system relay system I ECSS control I system I iijLzJ 48 alternately Alarm buzzer Action by operator source Boom movement is slow Stops remote positioner function. oossible that code chart equipment control system solenoid solenoid -r d0 41 Dump/tilt system 42 Bucket tilt solenoid 43 Damping solenoid system 44 Damping solenoid system 45 Damping solenoid system d.TROUBLESHOOTING 4. Failure Work means that EKI Work Action EOl+ CALL DATA DISPLAY in model Yes controller is burnt out Stop machine immediately. turn starting switch OFF. possible that control- dump 54 control system and CALL are displayed Wiring harness on return side of damping solenoid is short circuiting with power source 5. bucket moves. then call for service . dump) solenoid short circuiting with power ler is burnt out Stops auto leveling function. Action Action TROUBLE code table code: “EClCl+CALL” code Problem Dumping circuited source CALL equipment system Action solenoid is short to+terminal of power 24V of machine Wiring harness on return side of buckethilt. Bucket kickout 50 Auto 5.

TROUBLESHOOTING M-l Ir * M-l Main monitor does not work Before carrying out troubleshooting. 2) Disconnect CNLOB. or disconnection in wiring After inspection harness between CNL05 repair or replacf (female) (3) and CNLR2 (11) Power source Maintenance monitor Buzzer Battery relay TDW00285 20-255 0 .(3) normal? 1)20-30V 2t Tur~c~t~~ng _ YES 2 Is there continuity between CNL05 NO (female) (3) and chassis ground? 1) Turn starting switch OFF. Remedy main monitor 1 Is voltage between CNLOS (1). or disconnection in wiring harness between CNL05 (female) (1). (2) . (2) and CNFS2 (9) After inspection repair or replace Defective contact. Cause YES 1 Defective inserted. check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. NO Defective contact.

Defective main monitor Replace Defective contact.M-2 TROUBLESHOOTING M-2 When starting switch is turned ON and engine is started immediately. check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. Remedy Cause 1 YES Is voltage between CNL05 (4) and chassis ground normal? 1)20-30V 2) Turn starting switch START. all lamps stay lighted up Ir * Before carrying out troubleshooting. NO Neutral inserted. or disconnection in wiring harness between CNLOB (female) (4) and CNL57 (3) After inspection repair or replact relav Start signal. neutral signal Starting motor CNL57 Rear frame 20-256 GND .

CNTL2 (11. 3) Disconnect CNL07.M-3 TROUBLESHOOTING M-3 Speedometer * * * display does not work properly Before carrying out troubleshooting. (2) After inspection repair or replace Defective soeed sensor Replace NO Speedometer CNL07 CNTLZ CNTOG G 3 G 3 Speed sensor /MY 20-257 0 . (2) . (2)-CNTOG (1). Remedy Replace . H NO Defective contact. check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. or disconnection in wiring harness between CNL07 (female) II ). Check that the gap between the speed sensor and gear is normal.-- YE j between CNL07 (female) (I) and 1 (2) normal? 1 1)500R-7 kQ 2) Turn starting switch OFF. between CNTOG (male) (1) and (2) 1)500R-1 kc2 2) Turn starting switch OFF. inserted. 3) Disconnect CNTOG.

/ NO Eontact of power source vith wiring harness After inspection. 3) Directional lever: N 20-258 0 . check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. or defective ontroi lever . or lisconnection in wiring rarness between CNLOS female) (8) and CNL04 (4) After inspection. 3) Directional lever: R main monitor Replace Iefective contact. Cause (a) Stays at N even when directional 1 YES Iefective I between CNLOB (7) and chassis ground normal? (b) Stays NO at N even when directional l)ZO-30V 2) Turn starting switch ON. repair or replace jefective main monitor Replace (cl Does not display N even when directional lever is at N and displays R when directional lever is at F 1 YES Is voltage between CNLO8 (8) and chassis ground normal? l)O-5v 2) Turn starting switch ON. Check that the transmission shifts. or lisconnection in wiring rarness between CNLOS female) (7) and CNL04 (2) After inspection. 1 NO main monitor lefective contact. repair or replace lefective Replace lever is at R 1 YES Is voltage between CNL08 (8) and chassis ground normal? Remedy lever is at F Is voltage 1)20-30V 2) Turn starting switch ON.TROUBLESHOOTING M-4 Abnormality * * * M-4 in shift indicator Before carrying out troubleshooting. between CNLOB (female) (81 repair or replace Ind CNL04 (4). 3) Directional lever: F inserted.

3) Directional lever: N (e) Does not display - I- 1120-30V 2) Turn starting switch ON. 4th YES between CNL05 (13) and chassis Defective contact.30 V L : ov CNL05(13) I fter inspection epair or replacr Display I 2 L H 3 H H 4 I 20-259 0 . or disconnection in wiring harness between CNLOB [female) (13) and CNL04 (7) 1)20-30V 2) Turn starting switch ON. 3) Speed lever: 1 (R Defective main monitor leplace Contact of power source with wiring harness between CNL08 (female) (7) and CNL04 (2). or disconnection in wiring harness between CNLOB (female) (12) and CNL04 (5) ifter inspection epair or replact Defective main monitor :eplace lst. 4th 1 YES Is voltage between CNL05 (12) and chassis ground normal? Remedy NO Does not display 3rd. or defective control lever ifter inspection epair or replacc Defective main monitor leplace Defective contact.TROUBLESHOOTING M-4 [d) Does not display N even when directional lever is at N and displays F when directional lever is at R Cause Is voltage between CNL08 (7) and chassis ground normal? NO l)O-5v 2) Turn starting switch ON. 3) Speed lever: 3 Relationship between monitor input signal and display CNL0912) I L H L : 20 .

or defective transmission lever NO l)O-5v 2) Turn starting switch ON. repair or replace Defective main monitor Replace 1st. 31 Speed lever: 2 Defective main monitor CNL04 Transmission range FORWARD relay CNL66 0 20-260 0 REVERSErelay CNL67 0 After inspection.M-4 TROUBLESHOOTING Remedy Cause (91 Does not display 2nd. 3) Speed lever: 2 thl Does not display Replace Contact of power source with wiring harness between CNL05 (female) (12) and CNL04 (5). or defective control lever After inspection. repair or replace Transmission lever . 3rd 1 YES Is voltage between CNLOB (12) and chassis ground normal? NO l)O-5v 2) Turn starting switch ON. 2nd 1 YES Is voltage between CNL05 (13) and chassis ground normal? Contact of power source with wiring harness between CNL05 (female) (13) and CNL04 (71.

check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. check that the lamp bulb is not blown. 2) Disconnect 1)20-30V 2) Turn starting switch ON.TROUBLESHOOTING M-5 M-5 High beam does not light up * * * Before carrying out troubleshooting. head lamp TOW00290 20-26 1 0 . inserted. Before starting troubleshooting.H. 3) Dimmer switch: Hi After inspection repair or replacl Defective contact. Cause Remedy Replace chassis ground? disconnection in wiring harness between CNLOG (female) (13) and CNLOZ (3) NO between CNLOG (12) and chassis switch OFF. or After inspection disconnection in wiring repair or replacl harness between CNLOG (female) (12) and CNFSZ (2) NO beam CNLOG CNFS2 r gl $-j Lamp switch Dimmer CNLRI CNFRI @ 8 @ 3 switch CNFOI R.

check that the tamp bulb of the turn signal indicator on the monitor is not blown. 2) Turn starting switch ON. Cause Remedy (a) L. NO teplace main monitor Iefective contact.M-6 TROUBLESHOOTING M-6 Turn signal display does not light up * * * Before carrying out troubleshooting. or %sconnection in wiring iarness between CNLOG female) (15) and CNLOB (3) NO \fter inspection epair or replacf To turn signal lamp t f CNL03 Turn signal switch Hazard switch Turn signal unit TDW00291 20-262 0 .H. Turn signal CNLOG main monitor Iefective contact. Always connect any disconnected connectors before going on the next step. check that all the related connectors are properly inserted. 2) Turn starting switch ON. Before starting troubleshooting.H. turn signal does not light up YES Iefective between CNLOG (14) and chassis 1) Repeat OV and 20-30V. turn signal does not light up Is voltage between CNLOG (15) and chassis ground normal? 1) Repeat 0 V and 20-30V. or kconnection in wiring larness between CNLOG female) (14) and CNL03 (4) ifter inspection epair or replacx Iefective teplace (b) R.

qeplace main monitor After inspection .M-7 TROUBLESHOOTING M-7 Abnormality * * in parking display Before carrying out troubleshooting. or disconnection in wiring harness between CNTOS (female) (2) . or lisconnection in wiring tarness between CNLOG female) (11) . 3) Turn parking switch ON.epair or replace Defective contact. 1) Disconnect CNTOS.CNT08 (female: 1) short circuiting with :hassis ground NO 1)20-30V 2) Turn starting switch ON.CNTL2 (3) ZNTOS (female) (1) NO NO NO Vter inspection . Defective parking brake ndicator switch l)O-2v 2) Turn starting switch ON. Iefective contact. YES 1 1 YES switch ON. 3) Turn parking switch OFF. 21 Turn starting switch ON.CNTLl (8) chassis ground After inspectior repair or replao Defective parking brake indicator switch Replace Parking signal CNTL2 CNT08 Parking brake indicator switch 3 20-263 0 . 3) Turn parking switch ON. (al Parking lamp does not light up * Before starting ‘troubleshooting. Remedy check that the lamp bulb is not blown. 3) Turn parking switch OFF.epair or replacf )efective main monitor YES between CNLOG (1 I) and chassis ground normal? Is there continuity between CNTOS _ (male) (1) and (2)? Iefective up 3 YES Is there continuity YES between CNTOS (female) (2) and chassis ground? 1 qeplace Miring harness between :NL06 (femaie) (11) ZNTL2 (3) . check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. fb) Parking lamp stays lighted 1I Disconnect CNTOS. Cause inserted.

CNEOB female) short circuiting Nith chassis ground ifter inspection epair or replacf Defective engine water emperature sensor leplace Defective glow plug leolace Defective heater relay teplace Defective contact.CNER’l :4) .CNLR4 2) . 3) Min.CNERl(8) . 4 kR NO 1) Disconnect CNL05. 1)20-30V 2) Turn starting switch ON.CNLR4 (7) . or disconnection in wiring ?arness between CNL56 :3) . NO 20-264 0 3 YES Is voltage L between CNE08 NO . o oetween CNEOS (female) 12) . NO and chassis ground normal? 1)20-30V 2) Turn starting switch ON.M-8 TROUBLESHOOTING M-8 Abnormality * * in preheating system (QGS) Before carrying out troubleshooting. check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. 3) Min. (al Does not carry out preheating * Check that the water temperature is below (1) Monitor display also does not light up inserted. 5°C.CNERP (5) -chassis around Uter inspection epair or replacc Is resistancebetween YES CNLOS (female) (7) and chassis ground 1 - normal? Is resistance 1) Disconnect CNE05.CNEOS (female) (1). 2 YES Defective monitor panel leplace Wring harness between ZNL05 (female) (7) . 2) Turn starting switch OFF. 4 kR between CNEOB (male) and chassis ground normal? NO (2) Only monitor display lights up YES 2 YES 1 Is vottage between CNEOS (1) and (2) normal? Is voltage between CNE07 and chassis ground normal? 1) 20-30V 2) Turn starting switch ON. or disconnection in wiring larness between CNEOB snd slow blow fuse ifter inspection epair or replace Defective contact. 2) Turn starting switch OFF.

YES between CNLOG (4) and chassis 2 ground normal? _ 1)20-3ov 2) Turn starting switch ON.CNLR4 (2) CNERl (8) . 2 YES Is resistancebetween YES CNL05 (female) (7) and chassisground 1 normal? Is resistance between CNE05 (male! and chassis ground normal? 1)Max.TROUBLESHOOTING M-8 lb) Always carries out preheating for 1 minute * Check that the water temperature is below -10°C. 3) Disconnect CNE05. _ (cl Preheating NO 1) Max. I NO NO relay Wiring harness between CNLOG (female) (4) and CNL56 (2) short circuiting with chassis ground Vter inspection epair or replace Contact of power source with wiring harness between CNL56 (3) CNLR4 (7). 2) Remove preheating relay. 3) Disconnect CNL05. Is voltage Does preheating NO stop? 1) Turn starting switch ON.8kQ 2) Turn starting switch OFF.CNEO5 (female IVter inspection r‘epair or replace 1 Defective engine water temperature sensor Fkplace Defective main monitor FIeplace Defective preheating f3eplace stays on YES 1 I YES Does preheating stop? XJ 0 Turn starting switch ON. or disconnection in wiring harness between CNL06 (female) (7) . NO Remedy Cause Defective main monitor fqeplace Defective contact. CNLOS (19) After inspection epair or replace 20-265 0 . 2) Disconnect CNLOG. 8 !& 2) Turn starting switch OFF.

3 Preheating I----+- Starting Remedy motor SWRZ signal TDW00293 CNLR5 Water temperature signal @Battery% HII CNL05 CNERl CNE05 Engine water temperature sensor Tow00294 20-266 0 .5 kR) -10 -8 -6 -4 -2 0 2 4 7. or leak from chassis ground 4fter inspection. or there is variation Cause 3 YES Is voltage YES between CNLDB (3) and chassis 2 ground normal? Is resistancebetween 1) Max.0 5. No Temperature(%) Resistance Defective main monitor qeplace Defective contact of wiring harness between CNLOB (3) .M-8 TROUBLESHOOTING (d) Preheating time becomes shorter.5 5. Is resistance between CNEOS (male) and chassis ground normal? 11 Are temperature and resistance value as shown in table below? 2) Turn starting switch OFF.CNRllchassis ground \fter inspection.7 4.CNLR4 (2) CNERl (8) . p NO 1) Are temperature and resistance value as shown in No table below? 2) Turn startin switch OFF.CNLR5 (3) .5 6. repair or replace Defective engine water temperature sensor Replace (Tolerance Table valueM2) f 0.1 4.CNEOB.1 V YES CNLOSIfemale)(71 2) Turn starting and chassis ground If normal? switch ON.1 6. 0.7 7. pepair or replace Defective contact of wirin( harness between CNLOB (female) (7) .

NO Side CNL05 Remedy Defective main monitor Replace Defective contact. Before starting troubleshooting. check that the lamp bulb is not blown. check that all the related connectors are properly Always connect any disconnected connectors before going on the next step.TROUBLESHOOTING M-9 M-9 Night lighting does not light up Ir Ir Ir Before carrying out troubleshooting. inserted. or disconnection in wiring harness between CNL05 (female) (16) and CNFSZ (5) After inspection repair or replact Side lamp (right) CNFS2 CNL02 Lighting switch I I 1 TDW00295 20-267 0 . 3) Turn side lamp switch ON. Cause 1 YES Is voltage between CNLOB (16) and chassis ground normal? ll20-30V 2) Turn starting switch ON.

CNLOB (17).. NO 1 NO lamp lights up but’monitor 1 ‘II inserted. NO (c) Monitor lights up but working lamp does not light up 20-268 0 . (a) Neither monitor display nor front working lamp light up YES .CNFS5 (1) ifter inspectior epair or replac Defective main monitor leplace Defective contact. check that all the related connectors are properly A’. Before starting troubleshooting. or blown working lamp bulb Uter inspectior epair or replac display does not light up YES Is voltage between CNL05 (77) and chassis ground normal? 1)20-30V 2) Turn starting switch ON. (b) Working .?vays connect any disconnected connectors before going on the next step.M-10 TROUBLESHOOTING M-10 + * * Abnormality in front working lamp Before carrying out troubleshooting. Is voltage between CNLGO (6) and chassis t ground normal? l)O-3v 2) Turn starting switch ON. (5) . 4 YES Is voltage i between CNLOG NO (1) and chassis ground normal? l)O-3v 2) Turn starting switch ON. check that the monitor lighting is lighted up. between CNLGO (1) and chassis YES l)O-3v 2) Turn starting ON. I Cause Remedy Defective contact. . I 1)20-30V 2) Turn starting switch ON. or disconnection in wiring harness between CNLGO (1) .CNCLl (7) -front working lamp. or disconnection in wiring harness between CNLGO ( 1) . CNCLl (7) bfter inspectior spair or replac Defective front working lamp relay ieplace Defective contact. or disconnection in wiring harness between CNLGO (2). or disconnection in wiring harness between CNLOS (female) (17) and CNLGO (1) \fter inspectior epair or replac Defective contact. or disconnection in wiring harness between CNLOG (1) and CNLGO (6) &ter inspectior epair or replac Defective main monitor leplace Defective contact.

rear working lamp.CNLRl (12) . Before starting troubleshooting. inserted. Defective contact. check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. check that the monitor lighting is lighted up. After inspectiol repair or replac (b) Working lamp lights up but monitor display does not light up 1 YES Replace Is voltage between CNLOS (78) and chassis ground normal? l)ZO-3ov 2) Turn starting switch ON. After inspectiol repair or replac 1)20-3ov 21 Turn starting switch ON.TROUBLESHOOTING M-l1 * * * Abnormality M-l 1 in rear working lamp Before carrying out troubleshooting.CNLOB (18). CNLRl (12) ES Defective rear working lam0 relay YES 3 between CNL61 (1) and chassis I is voltaae -I I I I 4fter inspection repair or replac Replace . Replace 1)20-30V 2) Turn starting switch ON. or blown working lamp bulb After inspectiol repair or replac i 20-269 0 . or disconnection in wiring harness between CNLOB (female) (18) and CNL61 NO After inspectior repair or replac (1) (cl Monitor lights up but working lamp does not light up ’ Defective contact. or disconnection in wiring harness between CNL61 (1) . Remedy (a) Neither monitor display nor rear working lamp light up F== disconnection in wiring harness between CNL61 (1) .

TROUBLESHOOTlNG M-11 F Working lamp relay CNL60 Working lamp F CNL05 \ CNCLI i * 0 To front working lamp CNFSS +24V R Working lamp relay CNL61 Working lamp R To rear working lamp +24V TDWOOz96 20-270 0 .

or disconnection in wiring harness between CNL65 (3) and CNLIP (female) (1 After inspectior . or disconnection in wiring harness between CNL65 (5) and CNL12 (female) (2 After inspectior *epair or replac Defective contact. I 1)20-30V 21 Turn starting switch ON. (al When monitor switch is pressed. check that all the related connectors are properly Always connect any disconnected connectors before going on the next step.izzI iaround normai? between CNLOG (3) and chassis ground normal? l)O-3v 2) Turn starting switch ON. 2) Turn starting switch ON. 4) Remove cut-off relay. or disconnection in wiring narness between CNL65 :l) and CNFSZ (8) Uter inspection epair or repiacf Defective contact.M-12 TROUBLESHOOTING M-12 Abnormality * * in transmission cut-off Before carrying out troubleshooting. l)O-3v 2) Turn starting switch ON. Remedy Cause is not switched and display is not given Defective main monitor leolace Defective contact. 3) Turn parking switch OFF. ‘NO 5 YES Defective transmission off relav cu: teplace YE ‘El_ 4 --I Is voltage A between CNL65 (3) and chassis ground normal? 1)20-30V 2) Turn starting switch ON. JO NO Defective contact. 3) Turn parking switch OFF. 5) Stop machine cut-off function. or disconnection in wiring harness between CNLOS :female) (3) and CNL65 (2) ifter inspection epair or replace Defective main monitor teplace (b) Monitor display goes out but cut-off function stays on Is voltage YES between CNL65 .epair or replacl 20-271 0 . cut-off function inserted.

repair or replace 2 Is voltage YES between CNL65 (2) and chassis ground normal? 1 - 4 1) Turn starting switch ON.TROUBLESHOOTING (c) Monitor display M-12 lights up but cut-off function Cause is not actuated YES Defective cut-off relay Replace Defective main monitor Replace Wiring harness between CNLOG (female) (3) and CNL65 (2) short circuiting with chassis ground After inspection. 3 YES L Does cut-off ND function work? L 1) Turn starting switch ON. repair or replace Contact of wiring harness between CNL65 (3) and (5). 2) Remove cut-off relay. 1)20-30V 2) Turn starting switch ON. or defective cut-off switch After inspection. 2) Disconnect CNL06. I NO NO Transmission Transmission cut-off relay Remedy CNL65 cut-off a ’ 6 CNFS2 - +24V lever CNL12 Transmission 3 3 I I I 1 Neutralizer relay CNL58 20-272 a FORWARD CNL66 relay CNTLl J I REVERSE CNL67 relay cut-off switch .

inserted. f?eplace I Wer inspectior r. neutral signal main monitor F relav lI?A Starting 1 motor CNL57 a ear frame GND TDWOO286 20-273 0 .TROUBLESHOOTING M-13 M-13 Abnormality Ir Ir in parking brake dragging warning Before carrying out troubleshooting.~ 2) Turn starting main monitor NO (male) (8) and (3) Iefective NO 1)3kR-4kR 2) Turn starting switch OFF. 3) Disconnect CNLOS. buzzer does not sound and caution lamp does not light up even when directional lever is at position other than N * Check that the synchronous flash signal is normal.epair or replac. and caution lamp flashes Cause Iefective Remedy main monitor Iefective contact. or jisconnection in wiring larness between CNL05 female) (8) and CNL04 (3) NO 11 20-30V 21 Turn starting switch ON. (b) When parking brake is applied. YES 1 Iefective I i?eplace Iontact of power source with wiring harness / Ifter inspection mween CNLOB (female) (8:I r epair or replacr BndCNL04 (female) (3) ~~~. (a) When parking brake is applied. check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. buzzer sounds (intermittently) even when directional lever is at N. Neutral Start signal.

2) Connect CNL07 (6) to chassis ground. NO lefective maintenance monitor eplace lefective contact.M-14 TROUBLESHOOTING M-14 -k f When parking brake dragging warning is given. or they are not actuated Before carrying out troubleshooting. check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. 2) Disconnect CNL07. NO Vter inspectior epair or replacl I:Iefective main monitor 7eplace I NO Synchronous CNL07 20-274 0 Wring harness between :NL07 (female) (6) and :NL19 (female) (5) short :ircuiting with chassis Etround flashing signal CNL19 . or isconnection in wiring arness between CNL07 ‘emale) (6) and CNL19 ‘emale) (5) ifter inspection epair or replacf refective main monitor Leplace jefective maintenance nonitor teplace NO (b) Not actuated 2 YES I II YES Do buzzer and 1 r lamp work? Do buzzer and lamp work? I 1) Turn starting switch ON. buzzer and caution lamp are actuated continuously. 1) Turn starting switch ON. 2) Connect CNL19 (female) (5) to chassis ground. I 2) Disconnect CNLl9. Cause inserted. _. Remedy (a) Actuated continuously 2 YES YES Does buzzer stop and lamp go out? 1 Does buzzer stop _ and lamp go out? 1) Turn starting switch ON. 1) Turn starting switch ON.

CZ Buzzer output Wiring harness between CNLOG (female) (8) and CNL43 (male) short circuiting with chassis ground ifter inspectior . Remedy Cause (a) Buzzer does not sound when turned ON (during self-check) starting switch is Defective contact. chassis ground. (b) Buzzer always inserted. .CNL42 . or disconnection in wiring harness between CNL42 (female) and CNFS2 (9) 4fter inspectior epair or replac Defective main monitor. qeolace sounds YES 1 Does buzzer stop? I) Turn starting switch ON. 2) Disconnect CNL19. YES Go to Troubleshooting maintenance monitor 2 Does buzzer NO Stop? 1) Turn starting switch ON. M-15 Abnormality * Ir in buzzer Before carrying out troubleshooting. 2) Disconnect CNLOG.epair or replac Defective buzzer qeplace Defective contact. ml Maintenance monitor for Buzzer CNL43 TDW00301 20-275 0 . 2) Disconnect CNL43. 4fter inspectior .M-15 TROUBLESHOOTING. or disconnection in wiring harness between CNLOG (female) (8) and CNL43 (male) YES 1 ~ NO 1)20-30V 2) Turn starting switch ON. check that all the related connectors are properly Always connect any disconnected connectors before going on the next step.epair or replac Defective buzzer Replace ND CNFS2 @ . . 3 YES Does buzzer NO Stop? 1) Turn starting switch ON.

or disconnection in wiring harness between CNL07 (female) (10) and CNLOS (2) After inspection repair or replacf switch ACC CNLOS CNL07 Starting CNLR4 I-/$$ ) e To battery switch relay TDWO0302 20-276 a inserted. Remedy Cause 1 YES Is voltage between CN LO7 (10) and chassis ground normal? 1)20-30V 2) Turn starting switch ON. .M-16 TROUBLESHOOTING M-16 * * Condition of monitor switches is not stored in memory Before carrying out troubleshooting. NO Starting Defective main monitor Replace Defective contact. check that all the related connectors are properly Always connect any disconnected connectors before going on the next step.

Remedy NO Defective main monitor Xeplace Contact of power source with wiring harness between CNLOS (female) (51. Always connect any disconnected connectors before going on the next step. 4 Charge Alternator CNL05 CNLR4 CNERI CNE16 20-277 0 . or I disconnection in wiring After inspection epair or replacf 1)20-30V 2) Start engine. check that all the related connectors are properly .alternator terminal R. or defective alternator Mer inspection .CNLR4 (6) . Cause (a) Does not enter failure display mode 1 YES Is voltage between CNLOB (5) and chassis ground normal? l)O-5v 2) Turn starting switch ON.epair or replace IbI Time for time elapsed since failure on failure display mode does not advance -I Defective main monitor voltage between CNL05 (5) and chassis ground normal? Ieplace Is I 8 : Defective contact. inserted.CNERl (9) .TROUBLESHOOTING M-17 Ir Ir Abnormality M-17 in failure display mode Before carrying out troubleshooting.

Defective emergency steering normal sensor kplace Defective main monitor teplace Wiring harness between CNLOS (female) (10) CNTLl (2) . ’ l)O-2v 2) Turn starting switch ON. NO 1)20-30V 2) Turn starting switch ON.CNTLI (8) chassis ground 4fter inspectior epair or replac up 3 YES Is voltage YES between CNLOB (10) and chassis 2_ ground normal? NO NO 11Disconnect CNTlO. check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. or disconnection in wiring harness between CNL05 (female) (10) . 2) Turn starting switch ON. or disconnection in wiring harness between CNTlO (female) (2) . Defective emergency steering normal sensor NO Emergency steering normal CNL05 CNTLI CNTlO a . Remedy Cause (a1 Emergency steering normal display does not light up YES 1 Is there continuity between CNTlO (male) cl) and (2)? _ 2 YES Is voltage i between CNLOS NO (10) and chassis ground normal? I) Disconnect CNTlO. .TROUBLESHOOTING M-18 * * M-18 Abnormality in emergency steering normal display Before carrying out troubleshooting.CNTLl (2) CNTlO (female) (1) 4fter inspectior epair or replac Defective contact. 2) Turn starting switch ON. (b1 Emergency steering normal display stays lighted Is there continuity YES between CNTlO (female) (2) and 1 chassis ground? Is there continuity between CNTlO (male) (7) and PI? 1) Disconnect CNTlO.D @ 3 Emergency steering normal sensor rf7 TOW00307 20-278 0 inserted.CNTlO (female (1) short circuiting with chassis ground 4fter inspectior epair or replac Defective main monitor teplace Defective contact.

repair Or rep’ace Replace actuation CNTLI CNL05 CNTI 1 1. or disconnection in wiring harness between CNTll (female) (2) . Defective contact.2) Turn starting (female) (21 and switch ON. inserted.TROUBLESHOOTING M-19 M-19 Abnormality + * in emergency steering actuation display Before carrying out troubleshooting.CNTLl (8) chassis ground NO Defective emergency steering actuation sensor NO Emergency Defective emergency steering function sensor up 3 YES Is voltage YES between CNL05 (Ill and chassis 2 ground normal? is there continuity l)O-2v YES between CNTll . Emergency steering actuation display stays lighted 1) Disconnect CNTll. I-I-J \ r I I I I \ J Emergency steering actuation sensor n - 20-279 0 . NO 1)20-30V 2) Turn starting switch ON. P NO Replace Defective main monitor Replace Wiring harness between CNL05 (female) (11) CNTLl (1) -CNTll (female) (1) short circuiting with chassis ground ~p~~~pee~orrr Defective main monitor Replace Wiring harness between CNL05 (female) (11) CNTLl (1) . r Cause (a1 Emergency steering actuation dispfay does not light up YES 1 Is there continuity between CNTll (male) (1) and (2)? _ (b) 2 YES Is voltage between CNL05 NO (11) and chassis ground normal? 1) Disconnect CNTll. check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. 1 chassis ground? Is there continuity between CNTll (male) (1) and (2)? steering Remedy After inspection. 2) Turn starting switch ON.CNTll (female) (1) short circuiting with chassis’ground A$~~pecec~~~. 1) Disconnect CNTll. 2) Turn starting switch ON.

(b) Monitor lperation maintenance nanual for handling uto-greasing system YES display flashes rapidly YES (5) and chassis 1)20-30V 2) Turn starting switch ON. l)O-3v 2) Turn starting switch ON. NO - display Iefective 1 between CNL07 (I 1) and chassis rfter inspectior epair or replac . 20-280 0 jefective main monitor Ieplace jefective main monitor ieplace Iefective contact. check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. or iisconnection in wiring larness between CNL07 female) (11) and CNGRE (2) 50 to operation maintenance nanual for handling auto-greasing system After inspectio . or lisconnection in wiring larness between CNLO6 female) (5) and CNGRE (1) (2 timeskec) I .o to operation maintenance nanual for handling auto-greasing system NO 1)20-30V 2) Turn starting switch ON. 3) Turn autogreasing switch ON. Cause (al Forced greasing cannot be carried inserted.epair or replag - . Iefective contact. flashes rapidly (2 timeskec) YES 1 Is voltage 1)20-30V 2) Turn starting switch ON. or lisconnection in wiring ramess between CNLO6 female) (5) and CNGRE (3) \her inspectio epair or replan monitor 2 YES I1 between CNGRE NO (2) and chassis ground normal? L 1) 20-30V 2) Turn starting switch ON.TROUBLESHOOTING M-20 M-20 Abnormality f f in auto-greasing system Before carrying out troubleshooting. 3) Turn autogreasing switch ON. 2 YES between CNGRE NO (3) and chassiis Iground nom tal? (cl When no more grease remains.oto 2 Is voltage between CNGRE (I) and chassis ground normal? YI 1 Is voltage between CNLOG (5) and chassis iaround normal? l)O-3v 2) Turn starting switch ON. Remedy out . - main monitor Iefective contact.

3) Disconnect CNGRE.TROUBLESHOOTING M-20 Cause (d1 Monitor display flashes slowly Remedy (1 time/set) Go to operation maintenance manual for handling auto-greasing system (e) Monitor display goes out YES Is voltage ‘II between CNL07 (11) and chassis mound normal H I l)O-3v 2) Turn starting switch ON. ~0 2 YES Is voltage between CNGRE (female) (2) and chassis ground normal? 8 2 CNL07(11) between CNL08(5) 5 L Defective main monitor Replace Contact of power source with wiring harness between CNL07 (female) (11) and CNGRE (female) (2) After inspection repair or replace Go to operation maintenance manual for handling auto-greasing system NO l)O-3v 21 Turn starting switch ON. Relationship and display - - input signal Display L Rapid flashing (2 timeskec) L Slow flashing (I time/set) H OFF H ON Auto-greasing CNLOG \ CNGRE I 3 3 CNLO7 -3 A CNL08 TDW00309 20-281 0 .

Cause I inserted. NO ECSS CNDP2 CNLQG TDW00310 M-22 Buzzer does not sound when auto-leveling switch is actuated Cause 2 YES Is resistancebeh~een byte 2) Disconnect CNL34. 3) Connect CNLOI (6) to power source. Remedy (al Display does not change when switch is pressed I lb) Monitor display lights up but ECSS function Defective main monitor Replace Defective ECSS controller Go to Troubleshootirq for ECSS controller Defective contact.M-21. check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. or disconnection in wiring harness between CNL08 (female) (6) and CNL34 (male) (7) After inspection. - II NO l)O-3v 2) Turn starting switch ON. TROUBLESHOOTING M-21 * * Abnormality M-22 in ECSS system Before carrying out troubleshooting. repair or replace Defective main monitor Replace I . NO ECSS CNL08 CNL34 - TAW00493 20-282 0 Remedy Defective auto-leveling controller Go to Troubleshooting for auto-leveling controller Defective contact. or disconnection in wiring harness between CNLOG (7) and CNDPZ (1) After inspection repair or replacf Defective main monitor Replace does not work 2 YES Is voltage YES between CNDPZ 1 r (1) and chassis Is voltage between CNLOG (7) and chassis ground normal? l)O-3v 2) Turn starting switch ON.

(2) 1 Between (2) . 3) Disconnect connector to be measured. is Defective contact. I Between (1) . 1) Repeat OV and 12v. 3) Disconnect CNL08. Set dipswitch 3 at the rear of the main monitor to “F”. Remedy Cause 2 YES Is voltage normal Applicable controller defective k YE between CNL08 (male) (1) and (2) 1) Repeat OV and 12V? 2) Turn starting switch ON. 2) Turn starting switch ON. CNL08 ffemale) (2)(4)-applicable connector pins 1 NO inserted. check that all the related connectors are properly Always connect any disconnected connectors before going on the next step.TROUBLESHOOTING M-23 * * * M-23 Failure code is not sent to main monitor (abnormality in network) Before carrying out troubleshooting. (eplace rfter inspectior epair or replac Defective main monitor IO ii z 2 Table I Connector 1 CNL34(female) I CNDPS(female) Pin No.(3) I CNDP2 Network (If equipped) Auto 20-283 a . or disconnection in wiring harness between CNL08 (female) (f)(3).

.................................2 on maintenance in maintenance lamp (CHECK lamp............................................. 20-314 Night lighting does not light up when lamp switch ..................................................... 20-318 (a) Abnormality in fuel gauge .............................................................................................. ................... 20-313 (a) CHECK lamp ..................................................... all lamps maintenance (a) All lamps on maintenance monitor do not does not work................................................................. 20-310 flashes ..................1 When starting switch is turned light up for 3 seconds..... 20-317 items ..... .................................................................................................................... CAUTION 20-307 20-307 .............. monitor do not light up for 3 seconds..................................................................4 When is started 3 seconds)....................................................... There is no abnormality warning K-10 monitor is turned flashes.............................. ............... .................................................................. CHECK items flash ..................... is turned (a) Engine oil pressure 8 ON (engine level display (b) Battery charge after starting ... 20-316 Service meter does not work.. 20-313 (b) CAUTION 20-313 lamp...(only lighting of maintenance does not light up) ................................................... starting immediately all lamps on maintenance switch is turned (a) Engine oil level display (b) Engine water K...................TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE) K................................ 20-308 20-309 ............ -20-319 20-320 20-301 0 .... oil temperature gauge .......................................................... Night lighting monitor lights up even when lamp switch is turned ON 20-315 is OFF............ stopped).................................... ...........20-302 20-302 lamps do not light up ......................................................... 20-314 (a) CHECK lamp .......................................................... ...... but alarm lamp (CHECK lamp.... flashes flashes started)...................................................................... .............................................. all lamps on maintenance monitor 20-303 light up 20-303 but do not go out..........................8 CAUTION K................................................ display but warning ................................................................... 20-314 (b) CAUTION lamp ......... 20-318 (b) Abnormality in engine water (c) Abnormality in torque converter in gauge temperature gauge .................................................................................................9 K-II ON do not go out..........................6 CAUTION K......... CAUTION monitor lamp) display but lights up ..7 There is no abnormality K....... .........................................................3 When engine (within K.................................................................. level display (c) Brake oil pressure switch flashes ..... .................................................................................... night lighting stays lighted up ............................................. K.................................................................................................... ON (engine display flashes display 20-305 20-305 20-306 CAUTION items flash........................................ 20-317 K-13 Service meter K-14 Abnormality K-12 is running even when engine is stopped .. items are flashing but alarm in monitor items are flashing buzzer does not sound........................................................20-311 buzzer sounds.... .................. ON. 20-304 20-312 lamp) does not light up .......... (b) Some K.........................................................................................................................................5 When starting switch z 5 (d) Air cleaner display K.......................................... ............... monitor When starting switch is turned ON......................

or replace fuse Defective contact. all lamps on maintenance monitor do not light up for 3 seconds. Fuse box I NO inserted. or disconnection in wiring harness between CNLl8 (3) . (2) .chassis ground Repair wiring harness or replace Slow blow fuse Battery relay rfr TDW00314 20-302 0 .battery relay. 2) Disconnect NO CNL18. or disconnection in wiring harness between CNFSl (female) (2) . (a) All lamps on maintenance monitor do not light up for 3 seconds YES 1 Is voltage between CNL18 (1). 1) Turn starting switch OFF. or replace fuse Defective contact. NC (female) (3) and 3) Turn starting chassis ground? switch ON. maintenance monitor does not work Before carrying out troubleshooting. replace. or blown fuse Repair wiring harness. (2) .CNFSl (male) (2). replace. YES $ 3 Is voltage between YES CNFS~ (female) (2) and chassis ground normal? 2_ . or blown fuse Repair wiring harness.CNLR4 (12) .CNLRG (1) slow blow fuse .CNFS2 (9) -fuse box . check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. or disconnection in wiring harness between CNLl8 (female) (l).(3) normal? 1)20-30V 2) Turn starting switch ON.K-l TROUBLESHOOTING K-l * * When starting switch is turned ON. Remedy Cause Defective maintenance monitor module Replace Defective contact.is there continuity 1)20-30V 2) Disconnect between CNL18 CNFSl.

check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. Remedy ?eplace 20-303 0 .TROUBLESHOOTING K-l. K-2 Remedy (b) Some lamps do not light up F Replace K-2 When starting switch is turned ON. all lamps on maintenance monitor light up but do not go out * * Before carrying out troubleshooting. Cause Defective maintenance monitor module inserted.

~ When engine. all lamps on maintenance monitor do not go out * * Before carrying out troubleshooting. or disconnection in wiring harness between CNL19 (female) (1) and neutral relav Repair wiring harness or replace CNLOS Starting Speed switch lever I Neutral relay TDW00315 20-304 0 . 4) Measure when starting motor is turning. check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. starting ‘_YES is voltage between CNLIS (female) (1) and chassis ground normal? _ - 1)20-30V 2) Disconnect CNL19. 31 Start engine. 1 Remedy Defective maintenance monitor module Replace Defective contact. NO Cause inserted.TROUBLESHOOTING K-3 K-3 When engine is started immediately after starting switch is turned ON (within 3 seconds).

1)Turn starting switch OFF.CNLR4 (4) CNERl (3) .‘. check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. 2) Disconnect NO CNL~S.CNEIO (female) (7) Defective engine oil level sensor NO CNL18 CNLR4 CNERl CNEIO Engine Repair wiring FzarB”. Remedy I check the engine 2 YES Is there continuity YES between CNL18 1(female) (13) and chassis ground? Is there continuity between CNElO _ 1) Turn starting (male) (1) and switch OFF. CHECK items Before carrying out troubleshooting. (a) Engine oil level display flashes * Before starting troubleshooting. oil level again.TROUBLESHOOTING K-4 K-4 When starting switch is turned flash * * ON (engine stopped). chassis ground? . Cause inserted. 2) Disconnect CNElO. disconnection in wiring harness between CNL78 (female) (131.a”T Or Replace oil lever sensor TDW00316 20-305 0 1 .

CNLR3 (2) CNROG (female) (1) Repair wiring harness or replace Defective contact. 3 YES YI 1 Is there continuity between CNROG Is there continuity YES between CNL18 (female) (8) and 3 2 \-. (female) (1) and 2) Disconnect chassis ground? CNLIB. or disconnection in wiring harness between CNLl8 (female) (8) . 1) Turn starting switch OFF. or disconnection in wiring harness between CNROG (female) (21 and chassis ground Repair wiring harness or replace Defective radiator water level sensor Replace Radiator water level sensor ’ . check the engine water level again. NO 2) Disconnect CNROG. CNLR3 Ocl 2 CNROG 3 3 20-306 0 Defective maintenance monitor module Replace Defective contact. 2) Disconnect CNROG. chassis ground? P P Is there continuity NO 1) Turn starting between CNROG switch OFF. 1) Turn starting switch OFF.K-4 TROUBLESHOOTING (bl Engine water level display flashes * Before starting troubleshooting.

replace. Is voltage between L ring terminal and NO chassis ground normal? 1) Disconnect CNLIS. CNLR4 CNERI essure sensor Engine oil pressure relay TDWOO318 20-307 0 . NO 1)20-30V 2) Remove ring terminal. or defective relay Repair wiring harness. 3) Start engine.CNERI (2) . Cause (a) Engine oil pressure display inserted. replace. check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. or replace relay Contact of ground with Niring harness between ring terminal . or disconnection in wiring harness between CNL18 (female1 (10) -engine oil pressure relay-chassis ground. CAUTION Before carrying out troubleshooting.TROUBLESHOOTING K-5 K-5 When starting items flash * * switch is turned ON (engine started). 2) Turn starting switch OFF. Remedy flashes YES Defective engine oil pressure sensor Replace Defective maintenance monitor module Replace Defective contact.CNLR4 (3) -engine oil oressure relay. or defective relay Repair wiring harness. or replace relay 1 3 YES Does display go out when ring terminal is removed? YE jZj!ZJZJHP 2 1) Start engine.

CNLRO 6) ZNERl (9) -alternator terminal R NO Replace - Replace Defective alternator NO Repair wiring harness or replace Starting motor Alternator CNR04 CNR12 Battery 20-308 0 relay . 1)20-30V 2) Start engine.K-5 TROUBLESHOOTING Remedy Cause (b) Battery charge Is level display flashes Defective maintenance monitor module voltagebetween YES CNL18 (female) (12) and chassis 1 ground normal? Is voltage between alternator terminal R _ and chassis ground normal? 1)20-30V 2) Start engine. Disconnection in wiring harness between CNLl8 [female) (12) .

or between CN41 (female) (I) .CNBRl (6) . Defective contact.CNLR2 ~(8) . or between CNB08 (female) (2) CNBRl (4) -chassis ground IO between CNB13 Remedy I) Start engine. 2)0-3V YE 2 between CNB13 (female) (2) and chassis ground? 1) Stan engine.TROUBLESHOOTING K-5 Cause (c) Brake oil pressure display flashes YES YE between CNLl8 (11) and chassis I) Start engine. Defective Repair wiring harness. or defective diode 11 Turn starting switch OFF.CN813 (female) (I). Defective maintenance monitor module Defective contact. or replace diode Repair wiring harness or replace brake accumulator charge oil pressure switch (CNB13 end) 1 NO Replace Replace CN41 CNLR2 CNB13 CNBRI @ @- ciJ/ -3 CNB08 _ Brake accumulator pressure switch oil -3 20-309 0 . 21 Disconnect CNBOI. 2) Disconnect CNBIS. replace. 2) Disconnect CNB13. or disconnection in wiring harness between CNB13 (female) (2) and CNBOB (female) (I). or disconnection in wiring harness between CNL18 (female) (I I) and CN41 NC (female) (2).

or YIES 1) Start engine. or between CNL80 (female) (6) .CNLREi r.K-5 TROUBLESHOOTING Cause (d) Air cleaner display Remedy flashes YES I Ez!! CNE19 (female) (1) 1) Turn starting switch ON. or disconnection in wiring harness between CNL18 Rlepair wiring (female) (15) and CNL80 h arness.CNLR4 (5) . 21 Disconnect CNE19.eplace. or rm (female) (2) with chassis r’eplace relay ground. or contact of wiring harness between lepair wiring CNE19 (female) (1) . (female) (3). Defective dust indicator sensor NO defective dust indicator relay Short circuit. 2) Disconnect CNLIB.CNWO eplace.CNER’ I F hlarness. 3)20-30V switch OFF. or rieplace relay (2) -chassis ground. (5) . or defective dust indicator relay hIO +24 Dust indicator CNER2 CNE20 CNLR5 Dust indicator CNL80 20-310 0 relay TDW00321 . 2) Disconnect CNEl9. R:eplace Defective maintenance monitor module R:eplace Defective contact.

K-6 TROUBLESHOOTlNG K-6 CAUTION * Ir * items are flashing but alarm buzzer does not sound The buzzer does not sound for CHARGE or ENGINE OIL LEVEL. check that all the related connectors are properly Always connect any disconnected connectors before going on the next step.Y*.CNFSP (9) - ’ +24V CNFS2 CNL42 Repair wiring harness or replace Alarm buzzer 1 Maintenance CNLIS monitor CNL43 TOW00322 20-311 0 ._. CNL42 (female) 11) h Replace switch ON. _.. 3 Defective maintenance monitor module 2 YE inset-ted.l--- I . Defective contact.. or in wiring I disconnection . - 1)20-30V 2) Disconnect CNL42.... Replace when CNL19 (female) pin (4) is connected Replace to chassis ground? 1 I) Turn starting switch ON.“.. 3) Turn starting switch ON...___ (female) (1) . Before carrying out troubleshooting.

Before carrying out troubleshooting. check that all the related connectors are properly inserted. check that there is no abnormality display on the main monitor. Cause YES 1 Is there continuity between CNL43 (female) (1) and Ichassis ground? 1) Turn starting switch OFF. 2) Disconnect CNL43. Always connect any disconnected connectors before going on the next step. 2 YES Is there continuity _ between CNLl9 NO (female) (4) and chassis ground? 1)Turn starting switch OFF. 2) Disconnect CNL19. +24V NO CNFS2 CNL42 1 Maintenance monitor CNLIS Main monitor CNLOG 20-3 12 0 CNL43 Remedy Defective buzzer Seplace Contact of chassis ground with wiring harness between CNL19 (female) (4) and CNL43 (male) (1) Repair wiring harness or replace Defective maintenance monitor module Replace Alarm buzzer .K-7 TROUBLESHOOTING K-7 There is no abnormality sounds Ir * * in monitor display but alarm buzzer Before carrying out troubleshooting.

or disconnection in wiring harness between CNL19 (female) (2) and CNLOG (female) (10) :epair wiring arness or splace Defective main monitor eplace Defective maintenance monitor module eplace 1) Disconnect CNLOG. B Defective maintenance monitor module eplace Defective contact. check that there are no blown lamp bulbs. Maintenance CNL19 NO monitor Defective contact. 1) 2 YES Does caution lamp light up when . check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. 2) Turn starting switch ON.CNLOG(male) pin (91 NO is connected to chassisground? 1) Disconnect CNLOG. 2) Turn starting switch ON. Cause inserted. 2) Turn starting switch ON.TROUBLESHOOTING K-8 CAUTION CAUTION * * * K-8 items are flashing but warning lamp) does not light up lamp (CHECK lamp. Before carrying out troubleshooting. Remedy (a1 CHECK lamp chassisground? 2) Turn starting switch ON. or disconnection in wiring harness between CNL19 (female) (3) and CNLOG (female) (9) repair wiring larness or eplace Qefective main monitor ieplace Main monitor CNLOG TDW00324 20-3 13 . lb1 CAUTION lamp z 3 YES 1 Does caution lamp light up when CNL19 (female) pin (3) is connected to chassis ground? Disconnect CNL19. Before carrying out troubleshooting.

CAUTION lamp) lights up * * * Before carrying out troubleshooting. check that all the related connectors are properly inserted. 2) Disconnect CNLIS. Always connect any disconnected connectors before going on the next step.K-9 TROUBLESHOOTING K-9 There is no abnormality in maintenance monitor display but warning lamp (CHECK lamp. (b) CAUTION ND lepair wiring larness or eplace lefective maintenance nonitor module leplace Contact of chassis ground vith wiring harness aetween CNL19 (female) 3) and CNLOG (female) (9) tepair wiring rarness or eplace Iefective maintenance nonitor module teplace lamp 1 YES Is there continuity between CNL19 (female) (3) and chassis ground? 1) Turn starting switch OFF. Zontact of chassis ground vith wiring harness between CNL19 (female) 2) and CNLOG (female) 10) ND Maintenance CNLIS monitor Main monitor CNLOG TDW00324 20-3 0 14 . 2) Disconnect CNL19. Before carrying out troubleshooting. check that there is no abnormality display on the main monitor. Cause Remedy (a) CHECK lamp 1 YES Is there continuity between CNLIS (female) (2) and chassis ground? 1) Turn starting switch OFF.

21 (female) (1) and (2) normal? 1)20-30V 2) Disconnect CNL21.K-10 TROUBLESHOOTING K-‘IO * * Ir Night lighting does not light up when lamp switch is turned (only lighting of maintenance monitor does not light up) Before carrying out troubleshooting. check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. Cause Disconnection in wiring harness of lamp holder 1 YES Is voltage between CNL. 4) Turn lamp switch ON. Remedy Reolace Defective contact. check that there are no blown lamp bulbs. Before carrying out troubleshooting.harness or harness between CNL21 replace (female) (1) and CNFSZ (51 NO Fuse box Lighting CNL21 CNFS2 +24V CNL02 f Lamp switch 3 -3 c TDWO0326 20-3 15 0 . or Repair wiring disconnection in wiring . 3) Turn starting switch ON. ON inserted.

CNFS2 (5) .z. I Remedy Contact of +24V with Gring harness between CNFSS (male) (4) -fuse box . night Before carrying out troubleshooting.CNL21 (female) (1) Repair wiring harness or replace Contact of +24V with wiring harness between CNLOP (female) (5) and CNFS2 (female) (4) Repair wiring harness or replace Defective lamp switch Replace Fuse box Lighting CNL21 CNFS2 +24V yL. 3) Check that continuity between CNLO2 (male) (1) and (5) is as shown in table below when lamp switch is turned ON-OFF.K-l 1 TROUBLESHOOTING K-II Ir f Night lighting lights up even when lighting stays lighted up lamp switch is OFF. LaBh CNLR5 77%’ TDW00326 20-3 16 0 . 4) Turn starting switch ON. 1) Turn starting switch OFF. NO NO inserted.Is lamp switch Inormal? Is voltage between YES CNFSP (female) (4) 7 and chassis ground normal? 1p 1)OV 2) Disconnect _ CNFS2. 2) Disconnect CNLOP. Cause . 3) Turn lamp switch OFF. check that all the related connectors are properly Always connect any disconnected connectors before going on the next step.

K-12. or repair. K-13 TROUBLESHOOTING K-12 * * Service meter does not work Before carrying out troubleshooting. inserted. 3) Disconnect CNL22.CNLRB (2) chassis ground Repair wiring harness or replace Defective alternator Replace even when engine is stopped Before carrying out troubleshooting. 1)20-30V 2) Start engine. or disconnection in wiring harness between CNL22 (female) (1) . 4 K-13 * * Service meter is running NO Defective service meter Replace Defective contact. Cause YES between CNL22 (female) (2) and YE 1)20-30V 2) Start engine.CNLRI (6) . 2) Disconnect CNL22. replace wiring harness Starting motor Service meter Alternator TDW00328 20-3 17 a . check that all the. re!ated connectors are properly Always connect any disconnected connectors before going on the next step. 3) Disconnect CNL22. 2 Is voltage between alternator terminal h 3 4 R and chassis ground normal? WP switch OFF. or contact of wiring harness between CNL22 (female) (2) . or disconnection in wiring harness between CNL22 (female) (21. r 1 YES Is voltage between CNL22 (female) (2) and (1) normal? l)O-4v 2) Turn starting switch ON. NO I Cause inserted. Remedy Defective service meter Replace Defective alternator.CNLR4 (6) CNERl (9) -alternator terminal R Repair wiring harness or replace Defective contact. check that all the related connectors are properly Always connect any disconnected connectors before going on the next step.CNERl (9) alternator terminal R with +24V Replace alternator.

2) Disconnect CNRO7. inserted. check the fuel level again. check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. (al Abnormality in fuel gauge * (1) Before carrying out troubleshooting.CNLR4 (10) .a 20-3 0 18 . 1) Turn starting switch OFF. NO Contact of chassis ground with wiring harness between CNR07 (female) (1) . or disconnection in wiring harness between CNR07 (female) (1) .K-14 TROUBLESHOOTING K-14 * * Abnormality in gauge items Before carrying out troubleshooting.CNLR4 (10) CNLlS (female) (6) Repair wiring harness or replace Defective contact.CNLl8 (female) (6) Repair wiring harness or replace Defective maintenance monitor module Replace Fuel sensor CNLR4 CNR07 3 . 2) Connect short connector to CNR07 (female). 2) Disconnect CNR07. 2) Turn starting switch ON. or disconnection in wiring harness between CNR07 (female) (2) and chassis ground Repair wiring harness or replace (2) Display always shows FULL and does not move YES Defective fuel sensor 1 Do all display areas on fuel gauge go out? 2 YES _ 1) Disconnect CNR07. 31 Disconnect CNL18. 2) Connect short 3) Turn starting switch ON. Little or nothing is displayed in the display area 3 YES 1 BHP I 1) Disconnect CNR07. Is there continuity L between CNR07 NO (female) (I) and chassis ground? 1) Turn starting switch OFF. ND Defective fuel sensor Replace Defective maintenance monitor module Replace Defective contact. 1) Turn starting switch OFF.

emperature sensor FXeplace 1 B k 5 Do all display areas on engine water temperature gauge go out? 3 YES Is there continuity YES between CNL18 (female) (4) and 2 chassis ground? 1) Disconnect Is there continuity CNEOG. connector to 3) Turn starting 1) Turn starting CNEOG (female). 2) Disconnect CNEOG. l- Cause (Iontact of chassis ground .$J 3 TDWOO330 20-319 0 . 1) Turn starting 2) Connect short .CNERl (7) C:hassis ground Alepair wiring hiarness or rleplace Water temperature sensor . switch ON.CNERl (6) C:NLRQ (1) . with wiring harness -t )etween CNEOG (female) ( 1) . CNEOG.TROUBLESHOOTING (b1 AbnormaMy (I) K-14 in engine water Nothing is displayed temperature in the display r gauge Remedy area C)efective engine water t emperature sensor YES 1 Does engine water’ temperature gauge _ display minimum level? 1) Disconnect CNEOG.CNL16 (.larness between CNEOG t Female) (2) . 3) Disconnect 2) Disconnect CNLIS.female) (4) Rlepair wiring h arness or nsolace f Iefective contact. (21 Display shows lowest module Fteplace I Fqepair wiring tlarness or *‘eplace FIeplace level and does not move _I Iefective engine water t.between CNEOG switch OFF. NO (female) (2) and connector to 2) Connect short chassis ground? CNEOG (female). or Clisconnetiion in wiring -i.CNERl (6) -CNLR4 ( 1) . NO CNLR4 CNERI IIefective maintenance nconitor module P NO CNEOG fqeplace cjefective contact.CNLl8 (female) (4) 2 YES Is there continuity L between CNEO6 NO (female) (1) and chassis ground? IIefective maintenance I nonitor 1) Turn starting switch OFF. 2) Turn starting switch ON. switch OFF. or dlisconnection in wiring _h larness between CNEOG (1female) (1) .

or disconnection in wiring harness between CNT07 (female) (2) .CNLl8 (female) (5) Repair wiring harness or replace Defective maintenance monitor module Replace (2) Display shows lowest level and does not move 1 . 2) Disconnect CNT07. switch OFF. Do all display areas on torque converter oil temperature gauge go out? Defective torque converter oil temperature sensor I I Is there continuity YES between CNLl8 (female) (5) and 2 chassis ground? 1) Disconnect Is there continuity CNT07. 1) Turn starting 2) Connect short _ between CNT07 switch OFF.CNTLZ (5) CNLR4 (12) -chassis ground Repair wiring harness or replace CNT07 Torque converter oil temperature sensor /f+JjQ . 1) Turn starting switch OFF. or disconnection in wiring harness between CNT07 (female) (1) . NO 3 YES I NO CNTL2 @:a:- 20-320 0 Defective maintenance monitor module Replace Defective contact. NO Defective torque converter oil temperature sensor Reolace Contact of chassis ground with wiring harness between CNT07 (female) (1) .CNTU (4) CNL18 (female) (5) Repair wiring harness or replace Defective contact.K-14 TROUBLESHOOTING (c) Abnormality (II in torque converter oil temperature gauge Cause Remedy Nothing is displayed in the display area YES 9 1 switch ON.CNTL2 (4) . 3) Disconnect 2) Disconnect CNL18. NO (female) (2) and connector to 21 Connect short chassis ground? CNT07 (female). connector to 3) Turn starting 1) Turn starting CNT07 (female) switch ON. CNT07.

........................................................... 20-358 Engine stops when 20-358 machine brake has no effect when parking (b) Parking brake has no effect when brake pressure drops ... Kick-down Kick-down -20-378 in REVERSE circuit ...................................................................... ............................................................................................................ 20-364 in H-L circuit ...... brake is applied E............................................................................................................................................3 E......................................................... 20-367 in 4th circuit (does not enter 4th) ..:.......... 4th) .............20-392 20-351 0 ........... E..... (i) (I) (always 20-362 (b) Problem (f) circuit for transmission 20-359 in common (e) Contact E-12 machine brake switch 20-359 (a) Problem (d) Problem E-II ...........................................................................................1 Engine does not start ............. ................................................ ......................................................................................................................................................................................... (k) Contact in FORWARD parking is normal) .............................................................................9 20-352 (a) Starting in 2nd ..................... (m) Problem 20-366 in speed circuit ..................................................................20-362 parking brake is applied......................... (a) Parking Parking E-10 is traveling............................................. 20-367 Contact (g) Contact 20-368 20-370 in 4th circuit (always 20-372 stays in 4th)....................... be canceled............................................6 Parking brake is released E...... .................................. in H-L circuit ............ 20-360 is turned ON ............................................. circuit ............................................. (h) Problem Contact stays in 2nd) ................ 20-374 is normal) ... in common circuit for FORWARD switch does not work .............................. ................................................. Kick-down works only when in position)(self-holding operation kick-down function)) cannot switch is ON (Kick-down ....................................................... 20-359 ....................... 20-366 (c) Problem in speed circuit ............................................................................... 20-356 E................................. ............................................................................................. 20-388 20-390 .............................................................7 Transmission E............................ in FORWARD Problem in REVERSE circuit (FORWARD (j) Problem in common circuit (REVERSE circuit for FORWARD (does not travel forward................... brake does not work ...................... 20-388 even when (becomes 20-382 20-384 relay does not hold (a) Not canceled Kick-down 20-380 and REVERS _ ........................... switch is actuated 20-386 ..................... motor does not turn ................................................................................................................... ...................................... 20-352 (b) Starting motor turns ...................................................... 20-376 and REVERSE brake is normal) .......................................................TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) E.....................5 E....... switch ...........................2 E....................... ...............................................................................................................8 Transmission when when does not change does not work is traveling starting switch to neutral normally when is turned on....4 Parking Engine does not stop...................... directional (6) Not canceled lever is moved from even when speed lever is moved from 2nd to other position by mistake when traveling 20-388 F to N or R ..................

3ov YE ~~!iiizJzpl 1) Turn starting switch OFF. 6 I Is vottaae 20 . 2) Check voltage between chassis and both terminals connected by thick cable. I N0 0 - Go to A on next page I . 1) Turn starting switch ON. 1Is there continuitv 1) Disconnect CNE13.30 V? 1) Turn starting switch ON. connect to the connector specified as CNOU After checking. 1 between CNE13 (female) (I) and chassis 20 .E-l TROUBLESHOOTING E-l * * * Engine does not start When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out checks. When connecting the T-adapter (or socket adapter). 2) Directional lever: Neutral 3) Turn starting switch to START.30 V? 20-352 0 4 1) Starting switch ON -OFF. 1. YES I (a) Starting motor does not turn YES L Is voltage between starting motor terminal (B) and . i 1) Turn starting switch ON.I YI ES both battery relay chassis 20 . always turn the starting switch OFF before starting. connect the disconnected connectors and disconnect the T-adapter immediately to return to the original condition before going on to the next check.

repair or replac or defective contact. or disconnection in starting motor ground cable After inspectior repair or replac 20-353 0 .CNR03 After inspectior Idiode) .CNRl2 (female). j NO After inspection repair or replac Replace Replace Defective contact. or disconnection in cable between battery relay and starting motor After inspectior repair or replac * If answer is NO for both terminals: Defective contact or disconnection in wiring harness between battery and ‘battery relay . or disconnection in wiring harness between starting switch terminal BR . or disconnection in wiring harness between CNRl3 and chassis ground Defective starting switch Defective contact.30 V? 1) Turn starting switch ON.If answer is NO for one terminal: Defective battery relay Defective battery relay YES 0-l a 2 1 7 Is voltage between starting switch terminal BR and chassis 20 .CNLOS (2) .CNLR4 (9) .TROUBLESHOOTING E-l Cause Remedy Defective starting motor assembly Defective contact.

1) Replace neutral relay fCNL57) with stop lamp relay (CNL53). 2) Disconnect CNL57.30 V? 6 .E-l TROUBLESHOOTING 1 YEiS 1) Disconnect CNL57. 2) Directional lever: Neutral 3) Turn starting switch ON.30 V? 1) Turn starting switch OFF. 9 N 1) Turn starting switch OFF. 5 . YES :E~ZZZg&bZejj Is voltage between -I L starting switch NC terminal B and chassis 20 . 2) Directional lever: Neutral 3) Turn starting switch to START. 2) Directional lever: Neutral 3) Turn starting switch to START. NO 1) Turn starting switch to START. 2) Turn starting switch ON. 2) Turn starting switch to START. Is there continuity 1) Disconnect CNL04. 1) Connect Tadapter to CNL04. 20-354 0 NO YES FH-IZ-J 1) Starting switch ON *OFF. a YES YE EHP 1) Disconnect CNL57. Is voltage YE S between CNL04 (female) (1) and chassis 20 . NO page .

slow blow fuse 30A . or disconnection in wiring harness between CNL57 (female) (2) and chassis After inspection. or disconnection in wiring harness between CNL04 (female) (3) and CNL57 I (female) (1 I 1 DzD.E-l TROUBLESHOOTING Remedy Cause Defective neutral relay Replace Defective contact..CNE13 (female) (1) Aher inspection..battery relay Defective contact. e .CNFSZ (8) .CNLR4 (8) CNROl.I I Defective starting switch After inspection / repair or replace/ 1CNR17 . repair or replace / Replace I YES jg1 .CNERl (10) .ive directional lever / After inspection.CNL04 (female) (1) NO I Defective contact. or disconnection in wiring harness between battery relay-slow blow fuse 80A -CNR15-CNLRG(l)CNFSl (2) -fuse . repair or replace battery and battery relay + If answer is NO for one terminal: Defective batter-v relay l 7____ 2) Check voltage between chassis ana both terminals connected by thick cable.~~e If answer is NO for both terminals: Defective contact or disconnection in wiring harness between After inspection. 02 {diode) . Defective contact. repair or replace 20-355 0 . or disconnection in wirina harness between CNL57 (female) (3) . repair or replace I.\ Amf$~~r$.

2) Disconnect CNL62. 1 1 NO . between CNEOB 1) Turn starting switch OFF. 20-356 0 r YES 1) Turn starting switch OFF. j (female) (2) and between CNL62 1 1) Disconnect 2) Turn starting switch ON.E-l TROUBLESHOOTING (b) Starting motor turns YES 3 YIES between CNEO3 (7) and chassis 20 Does engine stop motor work? 1) Connect Tadapter to CNE03. 1) Turn starting switch ON * OFF and check visually. 4 F motor work when relay is replaced? 1) Replace engine stop relay (CNL62) with stop lamp relay (CNL53). 2) Turn starting switch ON OFF and check visually. 2) Disconnect CNE03. 2) Turn starting switch ON.

CNER2 (4) CNLRB (6) . or disconnection in wiring harness between CNL62 (female) (2) and chassis ground After inspeck repair or replac Defective contact. or disconnection in wiring harness between CNF2 (female) (11) . or defective contact. NO Defective contact.CNL62 (female) (3) Defective contact.CNERP (3) _ CNLR3 (5) . 2) Turn starting switch ON.CNLR (3)-CNERP(tI-CNE03 m{ A$~~pr~t~~~ ( After inspectior repair or replac’ (female) (4) I I 20-357 0 . or disconnection in wiring 1chassis ground Defective engine stop relay YES Defective engine stop motor I I Replace I Replace I between CNE03 (female) (5) and 1) Disconnect CNE03. or between CNE03 (female) (7) . or defective contact.TROUBLESHOOTING E-l Cause Remedy Defective adjustment of wire between engine stop motor and lever Adjust Defective engine stop motor.CNL62 (female) (5). or disconnection in wiring harness between CNL62 (female) (1) and CNLOS (female) (2) After inspectiol repair or replan Blown fuse. or disconnection in wiring harness between CNEOB (female) (5) .

or defective relay CNL62) Wter inspection epair or replacc 1L . 2) Turn starting switch OFF.30 V? Iefective notor 1) Connect T-adapter to CNE03. E-l(a) (Engine does not start).CNERZ (2) :NLR3 (4) . 20-358 0 Defective engine stop motor YES I 1) Turn starting switch ON ~1 OFF and check visually. 1. When connecting the T-adapter (or socket adapter).CNERZ (4) 3NE03 (female) 7). or disconnection in wiring harness between starting switch terminal RR CNLOS (2) . If it does not turn.CNFSZ :female) (11).epair or replac’ Defective adjustment between engine stop motor and stop lever 4diust E-3 Engine stops when machine is traveling * Check if the starting motor turns. always turn the starting switch OFF before starting. connect to the connector specified as CNOIY After checking. check _ i ~0 YES Is voltage between CNL62 (female) (21 and (female) (1) 20 -3OV? 1) Disconnect CNL62 (engine stop relay). Is voltage between CNE03 ) (4) and (8) 20 .CNL62 (female) (1) After inspectior repair or replac . or between :NL62 (female) (3) :NLR3 (6) . or blown fuse Vter inspectior . or fisconnection in wiring tarness between CNE03 female) (3) .and (8) No z%ygr 3 ‘” 1) Connect T-adapter to CNEOB. connect the disconnected connectors and disconnect the T-adapter immediately to return to the original condition before going on to the next check. E3 TROUBLESHOOTING E-2 Engine does not stop * When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out checks. <ES 3 Is voltage between CNE03 NO (3) and (8) 20 .Il Does engine stop I motor work? -1 1) Turn starting switch ON c--( OFF and check visually.CNL62 female). 2) Turn starting switch ON.30 V? 1) Connect T-adapter to CNE03 (engine stop motor connector) 18 pin). NO Defective engine stop relay Defective contact. * * Cause YES Remedy Defective adjustment jetween engine stop notor and stop lever \djust jefective engine stop notor teplace >efective contact. Does engine stop _ motor work? 2 Doesv&age between CNEOBi-7. or disconnection in wiring qarness between CNE03 :female) (4) .30 ’ V? i_-_t 1) Connect T-adapter to CNE03. I engine stop 3efective contact.E-2. 2) Turn starting switch ON ~1 OFF. YES H ” L Is voltage between CNEOB NO (7) and (8) 20 . 2) Turn starting switch OFF.CNERZ (2) CNLR3 (3) .

When connecting the l-adapter (or socket adapter). stop the machine on flat ground.OFF. 2) Start engine. ND 20-359 a . 4) Disconnect CNL59. 31 Disconnect CNL58.E-4 TROUBLESHOOTING E-4 Parking brake does not work * When carrying out troubleshooting of the brake system. When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out checks. 2 1 Is problem I) Turn starting ND switch ON. 1) Connect T-adapter to CNTOS. (Charge brake oil pressure) 3) Turn parking brake switch ON. YES removed when CNR22 is disconnected? 1) Turn starting switch ON.. connect to the connector specified as CNOLV ). 2) Turn parking brake switch ON .. always turn the starting switch OFF before starting. Ir * * Ia) Parking brake has no effect when parking brake switch is turned Cause Remedy ON (parking) YES 1 I Is problem removed when CNLOI is disconnected? YES 2 defective parking brake witch leplace Contact of wiring harness It CNLOl (female) (2) end tnd (3) end dter inspectior epair or replac defective parking brake solenoid leplace Contact of wiring harness rt CNLOl (female) (2) end rnd (I) end Uter inspectior epair or repiac Iefective emergency xake switch CNR21 leplace Iefective emergency Drake switch CNR22 teplace Defective parking brake . NO (b) Parking brake has no effect when brake pressure drops (Does not work as emergency brake) YES 1 I gijFjg. connect the disconnected connectors and disconnect the T-adapter immediately to return to the original condition before going on to the next check. 2) Turn parking brake switch ON .olenoid seplace 1) Disconnect (Charge brake oil pressure) 1) Disconnect 2) Turn starting switch OFF. . After checking.OFF. .

TROUBLESHOOTING E-5 E-5 Parking brake is applied * * * * when machine is traveling When carrying out troubleshooting of the brake system. (Charge brake oil pressure) h removed when short connector is 1) Connect short connector to CNR20 (female) and CNR21 (female). 2) Start engine. After checking. 2 YES I Is there continuity between CNTOB (female) (2) and chassis? NO 1) Disconnect CNT05.. 2) Turn starting switch OFF. \ iS - YI I. 3) Operate parking brake switch ON/OFF. (Charge brake oil oressure) 3 Is continuity of CNLOl (male) (1 )(Z)(3) as shown in Table l? I 1) Disconnect CNLOl. stop the machine on flat ground. lo . connect to the connector specified as CNOCI( 1. When connecting the T-adapter (or socket adapter).(3) Continuity No continuity !l! and 1 1) Disconnect CNL59. always turn the starting switch OFF before starting. connect the disconnected connectors and disconnect the T-adapter immediately to return to the original condition before going on to the next check. YES 4 removed when relay is replaced? between CNTOB (female) (1) and chassis 20 . 2) Turn starting switch OFF. 2) Start engine.(3) ON (parking) No continuity OFF (travel) Continuity 20-360 0 3etween terminal (1) . (Charge brake oil pressure) 1) Connect T-adapter to CNTOS. When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out checks.yaleI 6 Is voltage between CNL59 (female) (5) and 1) Disconnect 2) Turn starting switch ON. 2) Start engine.3OV? I) Replace parking brake safety relay (CNL59) with stop lamp relay (CNL53). 2) Turn starting switch OFF. Table 3 1 Operation Between terminal (2) .

epair or replac Defective parking brake switch leplace 20-36 1 a . 2) Turn starting switch ON. 3) Turn parking brake switch ON + OFF. 3) Turn parking brake switch ON. 3) Turn parking brake switch ON * OFF.nect NO y Is voltage YES between CNR21 (female) (1) and chassis 20 30 V? 9 p Is there continuity YES between CNL59 (female) (2) and 8 chassis? 1) Disconnect CNL59. or disconnection in wiring harness between CNTOS (female) (2) and chassis After inspectio repair or replan Defective parking brake safety relay Replace Defective emergency brake switch Replace Defective contact. or disconnection in wiring harness between CNL59 (female) (2) and chassis Wter inspectio . NO Defective contact.CNFSL (7) ‘use 4her inspectiol .30 VI 10 p 1) FiD2.epair or replac >efective contact. or disconnection in wiring harness between CNR21 (female) (1) and CNLOl (female) (2) 4fter inspectio pepair or replan Defective contact.epair or replan Defective contact.epair or replac Defective contact. . or disconnection in wiring harness between CNl59 :l) and CNL59 (3) 4fter inspectio. between CNL59 (female) (1) and chassis 20 . or disconnection in wiring harness between CNL59 (female) (1) and CNLOl [female) (3). 2) Turn starting switch ON.30 V? 1) Disconnect CNL59. or jisconnection in wiring iarness between CNL59 female) (5) . NO 2) Turn starting switch ON.TROUBLESHOOTING E-5 Cause Remedy Defective parking brake solenoid YES 11 Is voltage YES between CNR20 (female) (1) and chassis 20 . 2) Turn starting switch OFF. or between FS2 (female) (7) and LO1 [female) (1) Wter inspectio . or disconnection in wiring harness between CNRPl (female) (2) and CNR20 (female) (1) 4fter inspectio vepair or replan Defective contact. L RIO 1) Disconnect - CNRPl. or disconnection in wiring harness between CNR20 (female) (2) and CNT05 (female) (I) Mter inspectio repair or replan Defective contact.

E-6. Remedy Cause YES removed when relay is replaced? 1) Replace parking safety relay (CNL59) with h stop lamp relay (CNL53). (Charge-brake oil pressure) 3) Turn starting switch ON. NO E-7 Transmission does not change to neutral when parking brake is applied (but parking brake works normally) neutralizer relay CNL58 (female) (5) -chassis20-30V? 1) Disconnect neutralizer relay NO CNL58. 2) Start enaine. and check each voltage. (Charge brake oil pressure) 3) Turn starting ’ switch ON. 2) Start engine. N. connect the disconnected connectors and disconnect the T-adapter immediately to return to the original condition before going on to the next check. E-7 TROUBLESHOOTING E-6 Parking brake is released when starting * * * switch is turned ON When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out checks. and Ft.epair or replao Contact of wiring harness retween CNLOl (1) and (2 female) Wter inspectior . CNLGI female) (1). 2) Turn starting switch OFF.epair or repiac Abnormal contact of viring harness between :NL58 (female) (5) :NL12 (female) (11. always turn the starting switch OFF before starting. 3) Shift directional lever between F. 20-362 0 refective parking brake afety relay <eDlace defective parking brake wrtch leplace Contact of wiring harness between CNL59 (5) and 3)(l) (female) Uter inspectior . CNL67 female) (1) vith +24V wiring harness Wter inspectior repair or replac Iefective neutralizer relay . When connecting the T-adapter (or socket adapter). CNLG! female) (31. 1. or between :NL12 (female) (2) :NL65 (female) (5). 3) Turn parking brake switch OFF. 2) Turn starting switch ON. I 1) Disconnect CNL59. connect to the connector specified as CNOU After checking.

o to E-S(d) Contact in H .or does not travel ~). 2) Turn starting switch ON.o to E-S(e) Contact in speed circuit 50 to E-S(f) Contact in 4th circuit .x (lfx. connect the disconnected connectors and disconnect the T-adapter immediately to return to the original condition before going on to the next check. 2) Turn parking switch ON + OFF.L circuit .$t?. and REVERSE to Travels in only check condition. stop the machine on flat ground. 3) Turn parking switch ON OFF. . If condition is as shown in 2) Turn starting Table 4 . I ’ I If condition is as shown in Table 4 . After checking.1 (REVERSE is normal) I I r direction. When connecting the T-adapter (or socket adapter).a.. and between CNTOP ‘-l(I) (female) and 1chassis.fe. ___ CL voltage in either between (:NTOl (1) 1) Start engine..W and 1 1) Disconnect CNTOJ and CNTOI.jsyt ..6 (does not travel switch ON. is as shown in If condition is as shown Table 2 .n in If condition is as shown in Table 3 or Table 4 . (female) atnd chassis. Cause If condition is as shown in Table 2 . FORWARDor 3 REVERSE.5 (FORWARD is 1) Disconnect CNTOl and CNT02-.1 (transmission is always in 2nd) Remedy Problem in common :ircuit for transmission ioto E-S(a) Problem in H-L circuit .o to E-S(g) Problem in FORWARD circuit 20 to E-S(h) Problem in REVERSE circuit Go to E-S(i) Problem in common circuit for FORWARD and REVERSE Go to E-S(j) Contact in FORWARD circuit Go to E-S(k) Contact in REVERSE circuit Go to E-S(l) Problem in common circuit for FORWARD and REVERSE Go to E-S(m) If condition is as shown in If condition is as shown in 2 l.E-8 TROUBLESHOOTING E-8 Transmission * * f + does not work normally When carrying out troubleshooting of the transmission system. connect to the connector specified as CNOU 1. 3) Turn parking switch ON OFF. When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out checks. always turn the starting switch OFF before starting.8 fi. NEUTRAL. 4) Operate directional lever with speed lever in all positions (1st to 4th) to check condition._. 3) Operate directional lever FORWARD * REVERSE. 4) Operate speed lever with directional lever at FORWARD.oto E-S(b) Problem in speed circuit io to E-S(c) Problem in 4th circuit . % Go 20-364 0 to applicable item.

.

chassis Between CN04(8) .3OV7 between CNT03 (female) (2) and 1) Disconnect CNT03.L solenoid Defective contact. or disconnection in wiring harness between CNL04 (female) (7) . 3) Speed lever: 3rd N 20-366 0 I 3 YES Is voltage between CNL04 NO (7) and chassis 20 .chassis 1 0 0 0 0 2 0 a 0 0 3 0 0 0 0 4 0 0 0 0 (bl Problem in H-L circuit I YES 1 I ‘ES (female) (1) and chassis 20 .chassis CN04(6) . 1) Disconnect CNTOB. 2) Turn starting switch ON.CNTLl (5) CNTOB (female) (1) Wer inspection. 2) Turn starting switch OFF. 2) Turn starting switch ON. 3) Shift speed lever and check. 3) Speed lever: 3rd NO Cause Remedy Defective H .5 v Between CN04(5) Between . E-8 (cl YES _ Defective speed lever switch NO 1) Connect T-adapter to CNL04.chassis Between CN04(7) .0. . 2) Turn starting switch ON.E-8 TROUBLESHOOTING (a) Problem in common circuit for transmission (always stays in 2nd) Cause 1 Is voltage between CNL04 (5)(6)(7)(8) and chassis as shown in fable? I Remedy Problem in H-L circuit and speed circuit * Go to E-8 (b).epair or replace Defective speed lever switch Defective contact.3OV? 1 I Connect T-adapter to CNL04. Replace .epair . or disconnection in wiring harness between CNTO3 (female) (2) and chassis ground Wter inspection .30 v 0: 0 . : 20 .

30 V? NO 1) Connect T-adapter to CNLOL. or lisconnection in wiring tarness between CNT04 female) (2) and chassis ground Kter inspection epair or replac 4th) lefective contact. 3) Speed lever: 4th NO YES Remedy Defective speed solenoid leplace Iefective contact. 2) Turn starting switch ON.3OV? 1) Connect T-adapter to CNLOO. 3) Speed lever: 1st NO in 4th circuit (does not enter YES between CNL04 (8) and chassis around 20 . 2) Turn starting switch ON. (d) Problem 3 Is voltage _ between CNL04 _ NO (5) and chassis 20 . 2) Turn starting switch ON. or lisconnection in wiring rarness between CNL04 female) (5) .30 V? A 1) Disconnect CNT04. 3) Speed lever: 1st 11Disconnect CNT04. or fisconnection in wiring tarness between CNL04 Mer inspectior female) (8) .E-8 TROUBLESHOOTING (c! Prcblem in speed circuit Cause YES 2 Is voltage Y‘E!5 between CNT04 I 1 Is there continuity between CNT04 (female) 12) and (female) (7) and chassis 20 .CN38 :NTLl (male) (5) Defective speed lever rwitch Ieplace 20-367 0 .CN37 epair or replac :NTLl (male) (6) or CNLOg4 female) (8) .CNTLl (6) :NT04 (female) (1) kfter inspectior epair or replac Defective speed lever iwitch teplace Iefective contact. 2) Turn starting switch OFF.

2) Disconnect CNTLI. 3) Disconnect CNL64.30 V? . 3) Disconnect CNTLl. 3) Turn starting switch ON. YES 1) Disconnect CNT03. 1 1) Turn starting switch OFF. 2) Disconnect CNTLl 3) Turn starting switch ON.TROUBLESHOOTING E-8 (e) Contact in H-L circuit YES 1 between CNT03 (female) (1) and chassis 20 . 2) Disconnect CNTLl . 2) Disconnect CNTOS.30 V? YES 1) Disconnect CNTLl. Is there continuity between CNTLI I) Turn starting switch OFF. g 1 YES 5 NO Is there continuity between CNL04 (female) (7) and (lKZH3)(4)(6)? I) Turn starting switch OFF. 2) Disconnect CNLD4. 4) Disconnect CNL66. 3) Disconnect CNL04. YES 3 ts voltage between CNTLl (male) (5) and I chassis 20 . 20-368 0 _ NO .

CNTOl (female (l). CNTLl (male) (6) .epair or replac’ Abnormal contact of wiring harness between CNTLl (male) (5) and CNL04 (male) (7) with +24V wiring harness Mer inspection epair or replao Abnormal contact of wiring harness between CNTLl (male) (51 and CNL04 (female) (7) with wiring harness betwean CNTLI (male) (31.E-8 TROUBLESHOOTING Cause Remedy Abnormal contact of wiring harness between CNTOB (female) (1) and CNTLl (female) (5) with +24V wiring harness After inspectior .CNL66 (female) (2).epair or replac Abnormal contact of wiring harness between CNTLl (female) (5) and CNT03 (female) (I) with wiring harness between CNTLl (female) (3) .CNT04 (female) (1) After inspectior .CNL04 (female) (5) Uter inspection epair or replace Abnormal contact of wiring harness between CNL04 (female) (7) and CNTLl (male) (5) with wiring harness between CNL04 (male) (1) -CNFS2 (female) (8) or CNL04 (female) (2) CNL66 (female) (5) or CNL04 (female) (3) . CNTLl (female) (4) CNTOZ (female) (11. CNTLl (male) (4) CNL67 (female) (2). CNTLl (female) (6) .CNL67 (female (51 or CNL04 (female) (6) CNL66 (3) ifter inspection epair or replace /““-“‘mission 20-369 0 .CNL67 (female) (1) or CNL04 (female) (4) .

2) Disconnect CNL68. 3) Turn starting switch ON. YES between CNTLI 1) Turn starting switch OFF. between CNTLl 1) Disconnect CNTLI. 4) Disconnect CNLOI. 5) Disconnect CNL66. 3) Disconnect CNL68.TROUBLESHOOTING E-8 (f) Contact in speed circuit YES 1) Disconnect CNTOA 2) Disconnect CNTLI. 2) Disconnect CNTLl. 2) Disconnect CNTLl. 4) Turn starting switch ON. 2) Disconnect CNT04. 4) Disconnect CNL04. 3) Disconnect CNL04. 20-370 0 NO . 3) Disconnect CNL68. YES 57 Is there continuity between CNL04 1) Turn starting switch OFF. 3) Disconnect CNTLl . Is there continuity between CNTLl N 1) Turn starting switch OFF.

or abnormal contact of CNL68 (3)(4) (male) Mter inspectior repair or replac 20-371 0 . Abnormal contact of wirin: harness between CNTLl (male) 16) and CNL04 (female) (5) with wiring harness between CNTLl (male) (3) .CNFS2 (female A (8) or CNL04 (female) (2) CNL66 (female) (5) or CNL04 (female) (3) .TROUBLESHOOTING E-8 I Cause Abnormal contact of wiring harness between CNT04 (female) (1) and CNTLl (female) (6) with +24V wiring harness Remedv 4fter inspectior spair or replac Abnormal contact of wiring harness between CNTLl (female) (6) and CNT04 Wer inspectior gpair or replac (I). CNTLl (female) (4) CNT02 (female) (1).CNL66 (female) (2). CNTLl (female) (5l. CNLGZ (female) (4) with +24V wiring harness Wter inspectior .CM03 (female) (1) Abnormal contact of wiring harness between CNTLl (male1 (6) and CNL04 (female) (5).CNL67 (female (5) or CNLOQ(female) (6) CNL66 (female) (3) After inspection epair or replace I Defective transmission controi switch. CNTLl (male) (5) .CNL57 (female) (I) or CNL04 (female) (4) .epair or replac. CNTLl (male) (4) CNL67 (female) (2).CNL04 (female) (7) Uter inspection epair or replacl Abnormal contact of wiring harness between CNL04 (female) (5) and CNTLl (male) (6) with wiring harness behrveen CNL04 (female) (1) .

CN37 (female) (2). 2) Turn starting switch ON. 20-372 0 YES I No Remedy Abnormal contact of CNL04 (female) (8) . CN38 (female: (2) with +24V wiring harness \Rer inspection epair or replao Defective speed lever switch ?eplace .E-8 TROUBLESHOOTING (g) Contact in 4th circuit (always stays in 4th) Cause 1 between CNL04 (female) (8) and chassis 20 .3OV? 1) Disconnect CNL04.

TROUBLESHOOTING E-8 (h) Problem in FORWARD circuit (REVERSE is normal) 2 YES YESKzKGzl between CNTOl (female) (2) and chassis? 1 1Is voltage I NO 1) Disconnect CNTOl. 2) Turn starting switch OFF. NO 1) Disconnect CNL66. 2) Turn starting switch ON. 3) Turn parking switch ON + OFF. 2) Turn starting switch ON. YES I I between CNTOI (female) (1) and chassis 20 . 3) Directional lever: FORWARD JO . between CNL66 (female) (2) and 1) Disconnect CNL66. JO NO 1) Disconnect CNL66. 2) Turn starting switch OFF.3OV7 1) Disconnect CNTOl.. 4) Directional lever: FORWARD 20-374 0 7 YES YE N 1::-“-.. 3) Turn parking switch ON + OFF. 2) Start engine. 2) Turn starting switch OFF. 4) Directional lever: FORWARD 6 YE 1 between CNL66 (female) (6) and 5 YE 4 between CNL66 2) Turn starting switch ON. relay is replaced? 1 t Replace FORWARD solenoid relay (CNL66) with REVERSE solenoid relay (CNL67). 3) Turn parking switch ON -+ OFF.

“llllr”Ll”. harness between CNT& (female) (2) and chassis I Replace Defective FORWARD relay Replace After inspection. repair Or rep’ace I 20-375 0 .zr*nne&Tmq in wirino After inspection. repair or replace “la. repair or replace Defective directional lever switch Replace After inspection. or Ai.CNTLI (3) CNTOl (female) (1) After inspection. or disconnection in wiring harness between CNL66 (female) (2) . repair or replace Defective contact.E-8 TROUBLESHOOTiNG Remedy Cause Defective contact..

h 4) Directional lever: REVERSE ES EH I (female) (6) and 1) Replace REVERSE solenoid relay (CNL67) with FORWARD solenoid relay (CNL66). 2) Turn starting switch OFF. 2) Start engine. 2) Turn starting switch ON. NO 7 YES 1) Disconnect CNTOZ. 1) Disconnect CNL67.YES YE Is there continuity between CNTOL (female) (2) and chassis? 1) Disconnect CNTOZ. 3) Turn parking switch ON * OFF.E-8 TROUBLESHOOTING (iI Problem in REVERSE circuit (FORWARD is normal) 2 . 2) Turn starting switch OFF. 2) Turn starting switch OFF. 20-376 0 1) Disconnect CNL67. 4) Directional lever: REVERSE 5 YE 4 between CNL67 (female) (1) and ‘I) Disconnect 2) Turn starting switch ON. 31 Turn parking switch ON + OFF. 3) Directional lever: REVERSE Is there continuity YE S between CNL67 removed when NO between CNL67 (female) (2) and 1) Disconnect CNL67. 2) Turn starting switch ON. IUO NO B i N0 z 5 . 3) Turn parking switch ON -+ OFF.

or directional After inspection. repair or replace I 20-377 0 .TROUBLESHOOTING E-8 Cause Remedy Defective contact.CNTLl (4) CNTO2 (female) (1) Defective contact. or disconnection in wiring harness between CNL67 (female) (2) . or disconnection in wiring harness between CNT02 (female) (2) and chassis I Defective rve 1 contact. repair Or rep’ace After inspection. or disconnection in wiring harness between CNL67 (female) (6) and chassis Defective contact. repair or replace After inspection. or disconnection in wiring harness between CNL66 (female) (1) and CNL67 (female) (1) I Replace After inspection. repair or replace lever Defective contact.

2) Turn starting switch OFF.30 V? 1) Disconnect CNL58. 2) Turn starting switch ON. 2) Start engine.chassis N 0 0 R 0 0 . turned OFF? I when shonconnector is connectedinstead of transmissioncut-off 1) Connect short connector to CNLl2 (female). 6 Is voltage YES between CNL58 removed when relay is replaced? 8 1 I Replace neutralizer relay (CNL58) with stop lamp relay (CNL53).5 v 0: 20-378 0 Between CN04(2) .30 V? 1) Disconnect CNLOL. parking brake is normal) YES YEiS Is voltaoe b 3YES I I T-adapter to CNL04. NO YES I Q 11Start engine. 11 5 (female) (1) and YE 1) Disconnect CNL66.chassis Between CN04(4) . Is there continuity between CNL58 _ (female) (2) and chassis? 1) Disconnect CNL58. NO .E-8 TROUBLESHOOTING (j) Problem in common circuit for FORWARD and REVERSE (does not travel forward. 3) Turn parking brake switch ON + OFF. 2) Start engine. 3) Directional lever:FdN-rR NL04 NO (female) (1) and chassis 20 . (female) 13) and chassis 20 . 3) Turn transmission cut-off selector switch ON. 2) Turn starting switch ON. YE between CN L58 1) Disconnect CNL58. 2) Turn starting switch ON. 2) Turn starting switch ON. l : 20 .30 v 0 .0. 3) Turn parking brake switch ON + OFF. 2) Turn starting switch ON.

. or between CNL12 (female) (2) CNL66 (female) (1). CNL67 (female) (1) After inspectior repair or replac Defective contact.CNFSl (male) (21 After inspectior repair or replac After inspectior repair or replac Defective contact...CNFS2 (8) fuse .. or disconnection in wiring harness between CNL58 (female) (1) and CNLOl (female) (2) After inspectior repair or replac 20-379 a ... -. or between CNLIP (female) (2) and CNL65 (female) (5) After inspectioc repair or replac Defective neutralizer relay Replace Defective contact. or disconnection in wiring harness between CNL58 (female) (5) and CNLlZ (female) (1)._......_ ““.TROUBLESHOOTING E-8 Remedy Go to E-8 (hj and (9 / DzI.. or disconnection in wiring ...“. or disconnection in wiring harness between CNL58 (female) (3) .ive directional lever I Replace Defective contact.. (female) (8) and CNL04 (female) (1) After inspection repair or replac Replace Defective contact. or disconnection in wiring harness between CNL65 (female) (3) and CNL12 (female) (1). _..

3) Disconnect CNTLl. 4) Directional lever: FORWARD 2 YES between CNTOl (female) (1) and chassis 20 . 3) Turn starting switch ON. 2) Disconnect CNL66. 2) Disconnect CNL66. 31 Disconnect CNL66. ‘ES between CNTLl 1) Disconnect CNTLl. 3) Turn starting switch ON. 21 Disconnect CNTLl. h ‘ES between CNTLl (female) (3) and 1) Turn starting switch OFF. YES I I between CNL04 (l)(3)(4)(5)(6)(7)(8)? 1) Turn starting switch OFF. 3) Turn parking brake switch ON + OFF. 2) Disconnect CNTLl . 20-380 0 L NO .TROUBLESHOOTING E-8 (k) Contact in FORWARD circuit YI removed when relay is replaced? 1) Replace FORWARD relay (CNL66) with F working lamp relay (CNLGO). 2) Disconnect CNTOl.30 V? 11 Disconnect CNTOl. h 2) Start engine. between CNTLl 1) Turn starting switch OFF. 3) Disconnect CNL04.

CNTLl (male) (6) .CNTLl (male) (5). CNTLl (male) (5) CNL04 (female) (7).CNTOZ (female (l). CNL04 (female) (7) . CNL04 (female) (6) .CN37 (2) or CN36 (2) rmission Aher inspectior I repair Or replac’ Replace 20-38 1 0 . CNL04 (female) (5) .CNL66 (female) (31.CNT04 (female) (1) After inspection repair or replace Abnormal contact of wiring harness between CNTLl (female) (3) and CNL66 (female) (2) with +24V wiring harness After inspection repair or replace Abnormal contact of wiring harness between CNTLl (male) (3) and CNL66 (female) (2) with wiring harness between CNTLl (male) (4) .E-8 TROUBLESHOOTING Cause Remedy Defective FORWARD relay Replace Abnormal contact of wiring harness between CNTOl (female) (1)and CNTLl (female) (3) with +24V wiring harness After inspection repair or replace Abnormal contact of wiring harness between CNTLI (female) (3) and CNTOl (female) (1) with wiring harness between CNTLl (female) (41.CNTLl (male) (6). CNTLl (female) (5) CNT03 (female) (l). CNL04 (female) (6) .~~Ye’ CNL04 (female) (4)‘CNL67 (female) (5).CNL04 (female) (5) After inspection repair or replace I Abnormal contact of wiring harness between CNL04 (female) (2) and CNL66 (female) (5) with wiring harness between CNLO4 1ljlg?oY~~~~. CNTLl (female) (6) .CNL67 (female) (2).

Is there continuity between CNTLI Y ES h 1) Turn starting switch OFF. between CNTLl I chassis 20 . 5 Is there continuity between CNTLI NO (male) (4) and (3)(51(6)? I 1) Turn starting switch OFF. 3) Turn parking brake switch ON .30 V? I) Disconnect CNTOS. 21 Disconnect CNTLl. 20-382 0 NO . 2) Disconnect CNTLl .30 V? 1) Disconnect CNTLl. 3) Disconnect CNTLl. 3) Turn starting switch ON. 2) Disconnect CNT02. _ 3) Turn starting switch ON. 2) Disconnect CNL67. 4) Directional lever: REVERSE 2 Is voltage between CNTOS (female) (1) and chassis 20 .OFF. 2) Disconnect CNL67. r r YES between CNL04 switch OFF.TROUBLESHOOTING (I) E-8 Contact in REVERSE circuit 1 Is problem removed when relay is replaced? - 1) Replace REVERSE relay (CNL67) with F working lamp _ relay (CNLGOL NO 21 Start engine. 3) Disconnect CNL04. 3) Disconnect CNL67.

CNL57 (female) (I).CN37 (2) or CN38 (2) Defective transmission control switch Replace 20-383 0 . repair or replace I (male) (6) . repair or replace Abnormal contact of wiring harness between CNTLl (male) (4) and CNL67 After inspection.CNT04 (female) (1) Abnormal contact of wiring harness between CNTLl (female) (4) and CNL67 (female) (2) with +24V wiring harness After inspection. CNL04 (female (7) . CNTLl (female) (6) . CNLO4 (female After inspectiol (3) .CNLGE (female) (3). repair or replace Abnormal contact of wiring harness betwean CNTLl (female) (4) and CM02 (female) (1) with wiring harness between CNTLl After inspect (female) (3) -CNTOl (female) repair or rep1 (1). CNTLI (female) (5) CNT03 (female) (1).CNFS2 (female) (81.CNLGE repair or replac (female) (5).CNL04 (female) (5) I Abnormal contact of wiring harness between CNLOO (female) (4) and CNL67 (female) (5) with wiring harness between CNL04 (female) (1) . Defective REVERSE relay Replace Abnormal contact of wiring harness between CNTOZ (female) (1) and CNTLl (female) (4) with +24V wiring harness After inspection. CNLO4 (female) (6) .CNTLl (male) (5). CNLOO (female (5) .CNTLl (male) (6).TROUBLESHOOTING E-8 Remedy Cause . CNLO4 (female) (6) . CNL04 (female) (2) .

2) Disconnect CNLOL. nd CNL66 (female) (5) witt’ tiring harness between :NL04 (female) (4) and :NL67 (female) (5) &her inspection epair or replact befectiue transmission ontrol switch Leplace . 20-384 0 NO Cause Remedy ontact of wiring harness etween CNTOl (female) (1 nd CNL66 (female) (2) witt tiring harness between :NT02 (female) (1) and :NL67 (female) (2) Jter inspection apair or replace :ontact of wiring harness etween CNL04 (female) (2.E-9 TROUBLESHOOTING (m) Problem in common circuit for FORWARD and REVERSE YES 1 ~~~~.- 1) Turn starting switch OFF.

5 YI (female) (5) and CNL15 (female) I2)? 4 Is there continuity between CNL68 1) Disconnect CNL68. 2) Turn starting switch OFF. Is problem removed when relay is replaced? 1) Replace kickdown relay (CNL68) with REVERSE solenoid relay (CNL67). 20-386 0 r YES 1) Disconnect CNL68 and CNLl5. After checking. connect to the connector specified as CNOLV I. JO between CNLlS (female) (1) and CNL66 (female) (4)? 1) Disconnect CNL15 and CNL66. removed when 6 1)Replace 1 Is there continuity between CNL15 1) Disconnect CNL15. connect the disconnected connectors and disconnect the T-adapter immediately to return to the original condition before going on to the next check. 2) Press kick-down switch. always turn the starting switch OFF before starting. YE FORWARD solenoid relay (CNL66) with REVERSE solenoid relay (CNL67). 2) Turn starting switch OFF. 2) Start engine. 3) Turn starting switch OFF. When connecting the T-adapter (or socket adapter).E-9 TROUBLESHOOTING E-9 Kick-down switch does not work (the regular F’l to F4 shifts normally) Ir * Jr When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out checks. JO NO . 2) Turn starting switch OFF. 2) Start engine.

Remedy Defective kick-down relay Replace Defective FORWARD solenoid relay Replace Defective contact. or disconnection in wiring harness between CNL68 (female) (3) and CNL04 (female) (6) After inspectior repair or replac Defective contact. 2) Speed lever: 2nd 3) Turn starting switch ON. or disconnection in wiring harness between CNL68 (female) (41 and CNL04 (female) (5) After inspectiol repair or replac Defective contact. or disconnection in wiring narness between CNL68 Ifemale) (6) and chassis ground After inspectior .TROUBLESHOOTING E-9 Cause s YES I Yf 7 between CNL66 (female) (3) and 7) Disconnect CNL66. 2) Speed lever: 2nd 3) Turn starting switch ON.epair or replac Defective kick-down switch Xeplace 20-387 0 . 9 I NO YES Is voltage between CNL04 (6) and chassis 20 . or disconnection in wiring harness between CNL66 (female) (3) and CNL04 (female) (6) After inspectior repair or replac Defective speed lever switch Replace Defective contact. or disconnection in wiring harness between CNL68 [female) (5) and CNLl5 [female) (2) Mter inspectior repair or reptac Defective contact. or disconnection in wiring harness between CNL15 [female) (1) and CNL66 (female) (4) After inspectior repair or replac Defective contact. 2) Speed lever:Znd 3) Turn starting switch ON. h between CNL68 (female) (3) and 1) Disconnect CNL68.3OV? NO 1) Connect T-adapter to CNL04.

or disconnection in wiring harness between CNL66 (female) (4) .CNL68 (female) (5) After inspection. 2) Start engine. connect the disconnected connectors and disconnect the T-adapter immediately to return to the original condition before going on to the next check.CNL68 (female) (1) or CNL68 (female) (2) .E-10. 2) Start engine. repair or replace cannot be canceled lever is moved from F to N or R Cause 1 Is problem removed when relay is replaced? 1) Replace FORWARD solenoid relay (CNL66) with REVERSE solenoid relay (CNL67). connect to the connector specified as CNOLV 1. After checking. E-11 (a) NO Kick-down Not canceled operation even when directional Defective kick-down relay Replace Defective contact. When connecting the T-adapter (or socket adapter). 20-388 YES Defective solenoid FORWARD relay Contact between NO (3) and of wiring harness CNL66 (female) (4) Remedy Replace After inspection. E-l 1 TROUBLESHOOTING E-10 Ir Kick-down works only when kick-down switch is ON (Kick-down switch relay does not hold in position (self-holding function) ) When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out checks. always turn the starting switch OFF before starting. * * 1 YES Is problem removed when relay is replaced? - 1) Replace kickdown relay (CNL68) with REVERSE solenoid relay (CNL67). repair or replace .

lr 4 Is “Cjitage L __ oetween CNL66 YES -‘hq ‘(-Tale) (4) and I”” . F I --I 1) Disconnect CNL66. switch OFF. 3) Disconnect CNL66. ND (female) 12) and 3) Disconnect chassis 20 . zz iS - j_ 2 f . switch ON. 2) Disconnect I CNL04. 3) Disconnect CNL66. CNL04 (female) (5)? 3) Turn starting 1) Turn starting switch ON.1=11 chas. 2) Disconnect CNL04. I) ursconnect 51 CNL66. 6 1) Disconnect 4) Turn starting Is there continuity CNL68.E-II TROUBLESHOOTING (b) Not canceled even when speed lever is moved from 2nd to other position (becomes 4th) between CNL04 (female) (1) and CNL04 (female) W? 11 Turn starting switch OFF.sis 20 .30 V? CNL15. Is voltage 2) Disconnect \ between CNL68 _ CNL68. 3) Disconnect CNFTI. 2) Disconnect CNL04. _. 20-390 0 Is there continuity between CNLD4 r 1) Turn starting switch OFF. _ between CNL04 2) Disconnect ND (female) (1) and CNL15. 3) Turn starting switch ON.30 V? L_. 2) Disconnect CNL04.

2) Disconnect CNTLl. repair or replace Abnormal contact of wiring harness between CNL04 (female) (2) (6). repair or replace 20-391 0 . repair or replace Abnormal contact of wiring harness between CNL68 (female) (2) CNL68 (female) 15). NO Abnormal contact of wiring harness between CNL6i (female) (4) CNL68 (female) (1). repair or replace Abnormal contact of wiring harness between CNL04 (female) (1) (5) After inspection. 3) Disconnect CNL04. repair or replace Abnormal contact of wiring harness between CNLOI (female) (5) CNL68 (female) (4). repair or replace I YES 7 Is voltage between CNL68 (female) (4) and chassis 20 .3OV? 1) Disconnect CNL68.TROUBLESHOOTING E-l 1 I Cause Remedy Abnormal contact of wiring harness between CNL04 (female) (1) (6) After inspection. 4) Starting switch ON. CN37 (female) (l). CNL15 (female) (1) with +24V wiring harness After inspection. or defective speed lever switch After inspection. CNTLl (male) (6) with +24V wiring harness. or defective speed lever switch After inspection. repair or replace Abnormal contact of wiring harness between CNTLl (6) and CNTO4 (1) with +24V wiring harness After inspection. repair or replace After inspection. CNL15 (female) (2) with c24V wiring harness After inspection.

3) Directional lever: N 4 YES - Is there continuity between CNL68 (female) (1) and CNL68 (female) W? 1) Disconnect CNL68.(4)? 1) Disconnect kick_ down relay ND (CNL68). 2) Turn starting switch OFF. When connecting the T-adapter (or socket adapter).E-12 TROUBLESHOOTING E-12 Kick-down * + + switch is actuated by mistake when traveling in 2nd When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out checks.(21 and (3) . Cause Defective kick-down switch between CNL15 YES CNL15 (male) 12)? I) Disconnect CNL15. connect to the connector specified as CNOfY After checking. 3) Directional lever: N NC Contact of wiring harness between CNL15 (female) (1) (2) Vter inspection epair or replao Contact of wiring harness between CNL68 (female) (1) (2) Vter inspection . 20-392 0 h Remedy qeplace Defective kick-down relay 2 Is there continuity between CNL66 (male) (1) . always turn the starting switch OFF before starting.epair or replac Contact of wiring harness between CNL68 (female) (3) (4) Wter inspection . YES 3 Is there continuity between CNL15 _ (female) (1) and CNLl5 (female) l2)? _ 1) Disconnect NO CNL15. connect the disconnected connectors and disconnect the T-adapter immediately to return to the original condition before going on to the next check.epair or replaci . 2) Turn starting switch OFF. 1. 21 Turn starting switch OFF. 2) Turn starting switch OFF. 3) Do not press kick-down switch.

............. 20-413 or brake drags .......................... drift of bucket...................................20-411 shock..... lacks power ......................................................................... -z J is slow or boom T-15 Boom movement T-16 When T-17 Bucket cannot be pushed T-18 Excessive T-19 Boom shakes during T-20 Boom drops momentarily T-21 lacks lifting power..5 Torque STEERING 20-402 does not start .......................................................................... Bucket does not tilt back .................................20-420 20-421 20-421 20-421 20-422 from HOLD to TILT........................................................................9 Machine steers to one side when traveling ........ T......1 converter power is weak......................... bucket control loading momentarily 20-417 .............................................................................. gear................................................................................................................. Bucket movement is slow or tilt-back T-23 Bucket movement becomes T-24 Bucket cannot be pushed with bucket cylinder ..................................... .....20-411 effect is poor .............. .........................8 Steering wheel wobbles T..................3 Excessive shock when T.................TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED) (T MODE) POWER TRAIN Machine T. .........................................................................20-414 T-13 Parking brake is not released WORK EQUIPMENT T-14 Boom does not rise ........................................... hydraulic when control lever is operated from HOLD to RAISE ................................ ......... operation T-22 hydraulic 20-415 operation when ................................. A: Correct......20-407 or shifting 20-408 is high ..................... . ....................... thrusting T...... ....................................................................... .......................4 Excessive time lag when T............................................................. A: Adjust............. 20-410 ........ . T-25 Excessive T-26 Bucket shakes during T-27 Bucket dumps T-28 Boom............ 20-411 T-10 Turning radius to left and right is different ................... .............. ......2 Travel speed is slow........20-423 Explanation of symbols in Table The following symbols are used on the Cause column to show the action to be taken to remove the cause......... C: Clean 20-40 1 0 ..........20-417 boom is raised. ... ............. machine starting or shifting machine starting lacks power 20-404 on slopes ............... control lever is operated 20-418 20-419 ................... ....................... slow during tilt-back operation ............................................................. T....................................... X: Replace........................................................ 20-422 levers are heavy or do not move smoothly..... 20-416 height. ......................7 Steering wheel or there is excessive 20-409 :.................. .....................................6 Steering does not turn..........................................................................................20-406 gear ............. oil temperature SYSTEM T.......................................................................................................................................... it moves slowly at a certain with boom cylinder 20-417 (bucket floats) ..................................................................................................................... T.. 20-417 drift of boom ............................................................ is heavy ..................20-412 BRAKE SYSTEM 8 T-II Brakes do not work or braking T-12 Brakes are not released or brakes drag......... ............

) stuck to filter or strainer 20-402 0 0 0 . Is the transmission oil level correct? Is the type of oil correct? . Is the drive shaft broken? . Checks before troubleshooting . Did the problem suddenly start? Yes = internal part seized or broken Was there any abnormal noise when this happened? Yes = Component broken. Is the wheel brake or parking brake locked? l / a Remedy in certain transmission ranges 8 Transmission clutch pressure does not rise in certain speed ranges 9 Metal particles (aluminium.T-l TROUBLESHOOTING POWER TRAIN T-l Machine does not start Ask the operator the following questions. . Does the electrical circuit of the transmission control work properly? . Is there any damage or leakage of oil that can be seen externally? . copper. etc. Is the transmission filter or strainer clogged? . iron. Does the machine monitor function properly? . Is the transmission oil deteriorated? Does the oil smell of burning? .

TROUBLESHOOTING T-l 20-403 0 .

pressure I* / Transmission Metal particles 0 speed 0000 is low in every transmission Low in certain oil level range Cut-off work 0 ranges and fluctuates violently 20-404 0 valve does not cut-off circuit 0 illill chanaes stuck to transmission equipment 0 00 strainer or torque converter filter 13 0 00000 transmission is unstable 00 speeds pressure Indicator 10 11 and low idling Low relief converter Transmission clutch from 00 Torque 5 9 noise comes oil overheats 4 8 _ is low. and check if there is actually an abnormality or whether it is just the feeling of the operator. Is the method of operation correct? When oil temperature abnormal Abnormality in high idling 6 Abnormality in each stall engine 7 Torque converter . thrusting slopes power is weak. Checks before troubleshooting . even when is hight hydraulic pressure in I 0 0 I on . lacks power Checking for abnormalities . Is the tire inflation pressure and tread pattern normal? . Is the transmission oil level correct? Is the type of oil correct? . Measure digging operations and speed when traveling on level ground and on slopes.T-2 TROUBLESHOOTING T-Z Travel speed is slow. Is there any dragging of the wheel brake or parking brake? . Is the transmission filter or strainer clogged? . Is there any oil leaking from the joints of the piping or valves? .

TROUBLESHOOTING T-2 l////// Ill I 20-405 0 .

. . Is there play in any of the drive shafts? B k 4 20-406 0 . When it is clear that the shock has become greater than before. so judge that the shock is excessive in the following cases. Is the engine idling speed too high? . Checks before troubleshooting .TROUBLESHOOTING T-3 Excessive shock when starting T-3 machine or shifting gear Checking for abnormalities It is difficult to measure if the shock is excessive or normal. When the machine is compared with another machine of the same class and the shock is found to be greater.

TROUBLESHOOTING T-4 Excessive time lag when starting T-4 machine or shifting gear Ask the operator the following questions. Is the transmission oil level correct? Is the type of oil correct? . thrusting power is weak. Was there excessive time lag? Was there any abnormality in the travel speed or thrusting force? Was there any lack of power when traveling up slopes? Yes = Go to T-2 Travel speed is slow. lacks power on slopes l Checks before troubleshooting . Is there any oil leaking from the joints of the piping or valves? Clutch pressure is low in every transmission range 4 Clutch oil pressure is low in transmission ranges where time lag is excessive 00 0 20-407 0 .

. 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 . thrusting force. Is it actually high? Yes = Defective oil transmission No. . oil temgauge Problems 1 When oil temperature is low. and gradeability in all o transmission ranges o 5 Abnormality in travel speed. and gradeability in certain transmission ranges 6 1Toraue -I o 0 o o 0 o 0 cow 7 Transmission clutch pressure d 0 9 L0W In cena’n ’ I 10 I Trysnyission 11 Metal particles stuck to transmission strainer or torque converter filter 20-408 0 0 0 00 0 0 0 o 0 . thrusting force. Does oil temperature rise only when carrying out scooping work? Yes = Improvement in method of operation Checks before troubleshooting . Does oil temperature rise during torque converter stall and go down when there is no load? Yes = Selection of transmission range . abnormal noise comes from charging pump 2 Abnormality in high idling and low idling speeds 0 0 3 Abnormality in each stall engine speed 0000 4 Abnormality in travel speed. Measure the torque converter perature. .T-5 TROUBLESHOOTING T-5 Torque converter oil temperature is high Ask the operator the following questions.

20-409 0 . .TROUBLESHOOTING T-6 STEERING SYSTEM T-6 Steering does not turn Ask the operator the following questions. Has the safety bar been removed from the frame? * There is a close relationship between the steering circuit and work equipment circuit. Did the problem suddenly happen? . so if any abnormality is felt in the steering. Is the oil level and type of oil in the hydraulic tank correct? . + Part broken in steering related equipment Had the steering been heavy before. check also the operating condition of the work equipment. or had there been any other symptom? + Internal wear or defective seal in steering related equipment Checks before troubleshooting .

Did the problem suddenly happen? + Part broken in steering related equipment . Is the oil level and type of oil in the hydraulic tank correct? . or cylinders? . Is there any oil leakage from the hydraulic hoses. Had the steering been heavy before. check also the operating condition 20-410 0 0 0. and compare with the Standard Values Table to judge if there is any abnormality. Is there any abnormality in the column? . .T-7 TROUBLESHOOTING T-7 Steering wheel is heavy Ask the operator the following questions. valves. Tire inflation pressure Checking for abnormalities. valves. Measure the operating force of the steering wheel and the time taken for the steering to turn. Is there any scuffing or the center hinge pin bearing and steering cyinder pin or bushing? . or cylinders? . SO if any of the work equipment. . . Is there any oil leakage from the hydraulic hoses. equipment circuit. or had there been any other symptom? + internal wear or defective seal in steering related equipment Checks before troubleshooting . * 5 Steering wheel is heavy and there is jerking 6 Hydraulic oil overheats 7 Pressure in steering circuit is low 8 Pressure rises in steering cylinder return piping 8 k f 0 0 000 0 There is a close relationship between the steering circuit and work abnormality is felt in the steering.

T-10 T-8 Steering wheel wobbles or there is excessive shock Checks before troubleshooting Is the oil level and type of oil in the hydraulic tank correct? . T-9.” Valves a bc Remedy/AA No. . * If there is wobble of the steering wheel. Is there any variation in the inflation pressure of the tires? .TROUBLESHOOTING T-8. T-9 Machine steers to one side when traveling Cause: Defective steering valve Spool out of position Leakage of-oil inside steering cylinder Variation in tire inflation pressure l T-10 Turning radius to left and right is different Cause: Dividing of steering to left and right. relief noise can be heard from valve) 20-411 0 . go to “T-7 Steering wheel is heavy. and check how the steering wheel wobbles and under what conditiions. lock position of stopper (At end of steering. Is there any play in the steering? l l Checking for abnormalities Drive the wheel loader in a safe place. and in addition the steering wheel is heavy or there are other problems. a I I I 0 101 I I 1 0 0 n is turned to left or right lock. of stop valve stopper.1 Problems 1 Steerina wheel wobbles when travelina on row gh road surfaces 2 Steering wheel wobbles or suddenly turns when operating or traveling 3 Steering wheel wobbles when traveling at speed * Excessive shock when steering Improper adjustment Cause: d /a/. Is there any abnormality in the column? Is there any play in the center hinge pin bearing and steering cylinder pin bushing? .

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.T-l 1 TROUBLESHOOTING BRAKE SYSTEM T-11 Brakes do not work or braking Ask the operator the following . wear effect is poor of Checks before troubleshooting . Is the brake pedal play correct? . buzzer sounds 13 There is a time lag in effect of brake 20-412 0 0 000 000 0 -L . start? broken appear? seal. Did the problem gradually Yes = Deterioration of lining. Is the hydraulic oil level correct? . Is there any leakage of oil from the brake tube or connector? Is there any deformation. Did the problem suddenly Yes = Brake equipment .of the tube? . disc questions. heels rotate quickly 11 Number of times of braking effect is small when engine is stopped 12 Accumulator is not charged.

When engine is stopped and parking brake is released. Problems 1 Brake remains applied even when brake pedal is released When brake pedal is released and oil is bled from air bleeder. Is there any abnormal heat from brakes? .TROUBLESHOOTING T-12 Brakes are not released T-12 or brakes drag Checks before troubleshooting .ground? the un- No. certain wheels are heavy when they 20-413 0 . Does the brake pedal come back fully? . circuit pressure goes down and brake is released Jack up 4 wheels and set axles on stand. Is the parking brake fully released? Checking for abnormalities . Does the machine travel smoothly der inertia on level .

parking l When emergency parking brake switch is turned ON.T-13 TROUBLESHOOTING T-13 Parking brake is not released or brake drags Checks before troubleshooting . damaged piston seal 20-414 0 . Breakage in wiring harness in line for emergency parking brake cancel switch c. Is the parking brake always applied automatically when the engine is stopped? rking brake switch is turned OFF. a. parking brake is not released In such a case. the probable cause is following. Insufficient gas pressure in brake accumulator. Defective operaction of emergency parking brake cancel valve b. parking brake is not and engine is stopped. Is the emergency parking brake cancel switch OFF? (it is always canceled when this switch is ON) .

deterioration in spring Checks before troubleshooting .T-14 TROUBLESHOOTING WORK EQUIPMENT T-14 Boom does not rise Ask the operator the following questions. damaged Was there any abnormal noise when this happened? (from where?) . such as the speed becoming slow? Yes = Wear of internal parts. steering operation is too is running at full throttle. Was there previously any symptom. Is the travel of the boom control and spool properly adjusted? 1 2 3 4 5 6 7 Bucket cannot be operated Chassis can be raised bucket can be operated Boom when can be raised there boom but boom when there cannot but boom cannot be raised cannot lolololol be raised. Did the problem suddenly start? Yes = Equipment seized. is no load but cannot noise Excessive hydraulic engine comes from hydraulic drift of boom 0 I i I I I loi lol engine and slow I loi loi O be raised pump 0 cylinder I I I 101 I 00 0 I is running at full throttle. Is the hydraulic oil level correct? . steering operation is heavy 0 0 light and fast When lol lolol or be raised is a load Abnormal When with and boom lever 0 I I lol I I I I I I 20-4 15 0 . .

steering operation is too 20-416 0 . 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. Measure the boom lifting speed when the bucket is loaded and use the Standard Value Table to judge if there is any abnormality. but lifting speed is particularly slow when oil n engine is running at full throttle. l Bucket tilting power and speed are abnormal and boom lifting As in item 1.TROUBLESHOOTING T-15 Boom movement T-15 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? . so this problem first appears as a lack of lifting speed.

20-47 7 0 . operate the boom several times. When measuring the hydraulic drift. T-18. Troubleshooting and Cause Measure the hydraulic drift of the boom and check if it is possible to lift the chassis with the boom cylinder. the suction valve at the boom cylinder rod end is defective. drift of the boom cylinder is outside the standard value. Oil leakage from boom cylinder piston seal T-18 Boom from inside the boom Boom shakes during operation When digging or leveling operations are carried out with the boom control lever at HOLD. Defective seating of suction valve at boom cylinder . go to “T-18 Excessive hydraulic drift of boom.T-16. if this problem appears frequently. T-19 TROUBLESHOOTING T-16 When boom is raised. go to “T-15 boom lacks lifting power.” 2. Did the problem gradually appear? Yes = Worn parts Checks before troubleshooting . broken part . Is it now possible to raise the chassis with the boom cylinder? Yes = Vacuum had formed inside cylinder 1: However. defect in spool detent Troubleshooting and Cause . If the chassis cannot be raised with the boom cylinder. 1. Did the problem suddenly start? Yes = Dirt caught in valve. T-17. the bucket and boom move up and down to follow the shape of the ground. If the hydraulic drift of the boom is normal. Is the boom spool at the neutral position? Yes = Seized link bushing. and operate the boom cylinder to the end of its stroke. If the hydraulic.” Checks before troubleshooting Is the stroke of the boom spool in the main control Cause . it moves slowly at a certain height Checks before troubleshooting Can any deformation be seen in the boom cylinder? Cause .” T-17 Bucket cannot be pushed with boom See “T-15 Boom movement is slow or boom is slow or cylinder (bucket floats) valve properly adjusted? rod end of main control valve Excessive hydraulic drift of boom Ask the operator the following questions. is there any sound of oil leakage cylinder? Yes = Defective cylinder packing T-19 movement lacks lifting power. . go to “T-17 Bucket cannot be pushed with boom cylinder.” 3. Swelling or internal damage to boom cylinder tube Sr For other abnormalities when the boom is raised.

When the lever is operated fully to the RAISE position. Cause . When the engine is run at low idling and the boom control lever is operated slowly from HOLD to RAISE.T-20 TROUBLESHOOTING T-20 Boom drops momentarily HOLD to RAISE when control lever is operated from Checking problem . the boom goes down under its own weight. the condition returns to normal. Defective seating of check valve for boom spool in main control valve 20-4 18 0 .

such as the speed becoming slow? Yes = Wear of internal parts. deterioration in spring l Checks before troubleshooting . Did the problem suddenly start? Yes = Equipment seized. steering operation is heavy O and slow 20-419 0 .TROUBLESHOOTING T-21 T-21 Bucket does not tilt back Ask the operator the following questions. Is the travel of the bucket control and spool properly adjusted? 7 lever When engine is running at full throttle. damaged Was there any abnormal noise when this happened? (from where?) Wasthere previously any symptom. .

steering operation is too unning at full throttle. steering operation is heavy 20-420 0 lacks power . Is the travel of the bucket control lever and main control valve spool properly adjusted? . .TROUBLESHOOTING T-22 Bucket movement T-22 is slow or tilt-back Checks before troubleshooting . Measure the operating speed of the bucket and use the Standard Value Table to check if there is any abnormality When engine is running at full throttle. Is there any seizure of the work equipment linkage? (Is there any abnormal noise?) Checking for abnormalities l Check if there is lack of tilt-back power during actual operations.

Defective seating of safety valve (with suction valve) at bottom . Did the problem gradually appear? Yes = Worn parts Checks before troubleshooting .T-23. Defective seating of safety valve (with suction valve) at bucket cylinder valve Oil leakage from bucket cylinder piston seal rod end of main control l T-25 Excessive hydraulic drift of bucket Ask the operator the following questions. .22 Bucket tilt-back lacks power.” l T-24 movement is slow or Bucket cannot be pushed with bucket cylinder See ‘7-22 Bucket movement is slow Checks before troubleshooting . l end 20-42 0 1 . 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 Cause Oil leakage inside bucket cylinder . go to “T. broken part . Defective oil tightness of bucket spool excessive. For other abnormalities when the bucket is operated.” in the main control valve properly adjusted? Cause . Is the stroke of the bucket spool or tilt-back lacks power. Did the problem suddenly start? Yes = Dirt caught in valve. T-24. T-25 TROUBLESHOOTING T-23 Bucket movement becomes slow during tilt-back operation Checks before troubleshooting Can any deformation be seen in the bucket cylinder? l Cause Swelling or internal damage to bucket cylinder tube .

carry out troubleshooting according Bucket dumps momentarily HOLD to TILT rod end. 7 (Is there any abnormal bucket cylinder piston seal operation of safety valve (with suction valve) at bucket cylinder occurs at the same time. T-27 TROUBLESHOOTING T-26 Bucket shakes during loading (Main control valve at HOLD) Checks before troubleshooting .T-26. Defective problem problem. Cause . Is there play in the work equipment Cause . bushing. If any other to the nature of the when control lever is operated Checking problem . When operated fully to the TILT position. the bucket dumps momentarily under its own weight. When the engine is run at low idling and the bucket control lever is operated HOLD to TILT. Defective 20-422 0 seating noise?) of check valve for bucket spool in main control valve from slowly from the lever is . T-27 operation linkage pin. Defective . the condition returns to normal.

T-28 TROUBLESHOOTING T-28 Boom. bucket control levers are heavy or do not move smoothly Checking for abnormalities Check the values in the Standard Value Table to check if the operating force of the lever is actually excessive. Al I- xx Problems 1 Levers are heavy when there is a load and oil pressure is high 00 0 2 Levers become heavy as oil temperature changes 00 0 3 Levers become heavy at places during operation regardless of oil pressure or temperature 4 Levers are always heavy during operation regardless of oil pressure or temperature 0 Levers are still heavy after control lever link is disconnected at valve connection 0 5 I 0 0 000 0 I I I I I I I I I I I 20-423 0 . l Main control valve Remedy NO.

........................TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) (D MODE) Judgement D. ..............................................._...... ............ 20-463 does not give abnormality 20-463 display ............................ D.......... ...................... ........... ......................... D...... ..... ..20-461 D.... D...... ............ . ........ (R No abnormality display 20-456 is given ....................................... ............................................... s 20-451 0 ......... .............5 Output is turned ON when transmission is in 4th ............................................... ............. .................................. .... ........................ .......................................... 20-455 (e) Error code Id41 is displayed ........ 5 km/h) (deviates around 5 km/h) ................1 Table for controller electrical 20-452 ECSS does not work .......... D......... ................... ... ...................................... 20-454 (b) Error code [dll is displayed ...3 Output 20-456 20-460 is turned ON (travel speed does not become 8 z system ...... ..... ....6 Controller D.................. ..................... ............ .......................... 20-455 (d) Error code [d31 is displayed ..........2 ECSS cannot be canceled ................... ...................................... ....... ...................................... ....... ... .......................................................... ............ ........... 20-453 (a) Error code [dOI is displayed ......................................... .......... ........................... ...... ... ....................................... .......................20-461 20-462 .................... 20-454 (c) Error code id21 is displayed .......... ..................... ........7 ECSS is abnormal LED code is not displayed but main monitor .......... ........4 Output is turned ON when transmission is in 1st . .......

. does not become 5 km/h (deviates) rI.tp.“h’i.JUDGEMENT TROUBLESHOOTING JUDGEMENT Self-diagnosis Solenoid (relief) system mode ECSS does not work or does not work properly ECSS cannot canceled be Output is turned ON but travel speed. FOR CONTROLLER ELECTRICAL SYSTEM TABLE FOR CONTROLLER ELECTRICAL SYSTEM Error code Failure TABLE table (abnormality Travel speed Solenoid Solenoid (high pressure) (low pressure) sensor system system system display) Model selection abnormality d0 dl d2 d3 d4 D-l (a) D-l (b) D-l (c) D-l (d) D-l (e) Troubleshooting code when no abnotmalii displayisgiven D-l (f) D-2 D-3 turned transmission 1st is in D-4 Output is turned ON when transmission is in 4th D-5 LED code display is not given D-6 ECSS is abnormal but main monitor does not give abnormality display D-7 20-452 0 .

check that all the related connectors are proper!y Always connect any disconnected connectors before going on the next step. 50 to Item (d) Is there en abnormality display? 50 to Item (e) .TROUBLESHOOTING D-l * * f + D-l ECSS does not work Before carrying out troubleshooting. Carry out troubleshooting with the starting switch ON.o to Item (f) 20-453 0 . I- So to Item (c) 6 Displaying [d31. Cause inserted. Remedy Go to Item (a) Go to Item (b) 2 Which code is monitor displaying? IDisplaying [d2]. Check that the ECSS switch on the main monitor is ON.

NO .CNTLI (8) CNCLl (12) -chassis ground After inspection repair or replacc is displayed YES 1 Is resistancebetween CNALl (female1 (201 and chassis ground normal? -m 1) Disconnect CNALl. 2) DC resistance: 20-40R 2 L between CNALl NO (female) (20) and chassis ground? 1) Disconnect CNALI. F 2) Disconnect CNAF5. (b) Error code. 3) Connect short connector to CNAR (female).I\ n:___ I 1) Disconnect CNAF4. CNAFC 3) Connect short connector to CNAF4 (female).CNAFS (female) (1) After inspection repair or replace Disconnection in wiring harness between CNAF5 (female) (2) .CNTLI (8) CNCLl (12) -chassis ground After inspection repair or replace Defective controller Replace Defective solenoid Replace Disconnection in wiring harness between CNALI (female) (20) .CNSAS (5) . 20-454 0 3 1Is there continuity YES 1 1 CNAF5. [dll t I NO Remedy Defective controller Replace Defective solenoid Replace Disconnection in wiring harness between CNALl (female) (21) .CNSAS (4) . 2) DC resistance: 20-40R YES 21 Is there betweel NO (female chassis .CNAF4 (female) (1) After inspection repair or replace Disconnection in wiring harness between CNAF4 (female) (2) .D-l TROUBLESHOOTING (a) Error code Id01 is displayed Cause YES Is resistancebetwean CNALl (female) I211 and chassisground normal? P 1) Disconnect CNALl.

. 1) Disconnect 3) Connect short CNAFG.CNTLl (8) (INCLI (12) -chassis saround Mter inspection pepair or replact (d) Error code id31 is displayed YES r: N” 3 - 1 Does error display go off? 2 YES Is there continuity between CNAL3 1) co nnect short NO 4 (female) (4) and CO!tnector ~~ to CNTOG (female). [Iisconnection in wiring tiarness between CNAL3 I4) .epair or replace If any other :ontroller is sbnormal.CNAFG i NO After inspection repair or replact (female) (1) IIisconnection in wiring ttarness between CNAFG -( female) (2) . connector to CNAFG (female). ON.CNSAS (10) After inspection . h$ (female) (2) and 2) Disconnect I chassis ground? 1 CNAFG.CNSAS (9) or CNAL3 I 12) . check all the wiring mrnesses for the speed sensor system) 20-455 0 .CNSAS (6) YES 1) Disconnect CNALl.[Iefective controller qeplace qeplace _ connector to CNTOG (female).D-l TROUBLESHOOTING ICI Errsr code [d21 is displayed Cause Remedy -t Iefective controller Replace -t Defective solenoid Replace 1 Is resistancebetween CNALl (female) I111 ‘ES and chassis ground WXRWI? 1) Disconnect CNALl 2) DC resistance: 20-40R 2 there continuity between CNAL’l NO (female) (11) and chassis ground? Is IIisconnection in wiring tlarness between CNALl (female) (11) . 2) Connect short I:Defective speed sensor . -_ fT2)? 2) Turn starting ‘L I) Disconnect switch OFF CNAW.

(4) and chassis ground as shown in table? 1) Disconnect CNAL4. or disconnection in wiring harness between CNAL4 (female) and chassis ground. 2) Is continuity between CNAL2 (female) (1) .w~rmg harnesses normal? - 1 NO 1) Disconnect Is connection of wiring harnesses normal? - CNAL2. or contact with chassis ground ifter inspectiol epair or replac Table ~ (f) WA420 No Yes No No No Yes No NO WA470 No Yes Yes Yes No Yes Yes Yes No abnormality display is given (1) Does not work at all 3efective controller 1 Is voltage between CNALZ (15) and chassis ground normal? 2 YES _ l)O-3v 2) Turn starting switch ON.(2).(3). 20-456 0 30 Defective main monitor Is voltage between L CNLOG (female) (7) NO snd chassis ground normal? 1)20-30V 2) Disconnect CNLOG. or contact with chassis ground &her inspectiol epair or replac Defective contact.cpntinuity of . NO Disconnection in wiring harness between CNALZ [female) (15) .(5) -chassis ground as shown in table? Remedy Defective controller leplace Disconnection in wiring harness between CNAL2 (female) and CNAL4 (male).CNDPZ (1) CNLOG (female) (7) to troubleshootin! 3f main monitc After inspectia repair or repla . 2) Is continuity NO between CNAL4 (female) (1 j.D-l TROVSLESHOOTING Id41 is displayed (e) Error code Cause 2 YES YES Is. 3) Turn main monitor ECSS switch ON.

_ 1) Turn starting switch ON. leplace Contact of chassis ground with wiring harness between CNALP (female) (8) . or disconnection in wiring harness between CNALZ (female) (8) . or between CNAF7 (female) (2) . 3) Load bucket. NO NO Defective controller leplace Defective contact.CNSAS (7) CNAF7 (female) (1). 3) Load bucket.CNAF7 (female) (1) Hter inspectior epair or replac Defective controller leolace Defective chassis hydraulic system bucket is empty but not when ‘ES g Remedy Defective pressure switch or defective chassis hydraulic system 1) Turn starting switch OFF.CNSAS (7) . 2) Empty bucket. 3) Empty bucket. (3) Works 3 YES Is there continuity L between CNALZ NO (female) (8) and chassis ground? Does controller k zl 1) Turn starting switch ON. 2) Disconnect CNAF7. 2) Disconnect CNAF7. loaded (8) and chassis ground normal? l)O-3v 2) Turn starting switch ON. 2) Load bucket.CNSAS (8) . Does controller LED display 55? 1) Turn starting switch ON.TROUBLESHOOTING (21 Works when D-l bucket is loaded but not when empty YES ” I Is there continuity YES between CNA!? (male) (1) and (2)? . NO when Cause Defective chassis hydraulic system 1 2 Is there continuity between CNAF7 _ NO (male) (1) and (2)7 1) Turn starting switch ON.CNAL4 (4) -chassis ground dter inspectior epair or replac Defective pressure switch or defective chassis hydraulic system 20-457 0 .

(cl Related Solenoid electric circuit diagram system CNALI CNSAS 3 @ ----a 3 @ @ 3 ---a r-hi CNAFG CNAF5 I CNAF4 I Solenoid 1 (relief) t CNTLI D-l (d) Related CNCLI ’ I I Solenoid 3 (low pressure) Solenoid 2 (high pressure) I electric circuit diagram Speed sensor system CNSAS CNALB CNTL2 Speed (+) Speed t-1 CNTOG 3 3 3 -3 Speed sensor TDwuo350 D-l (e) Related electric circuit diagram Model selection system TOW00904 20-458 0 .D-l TROUBLESHOOTING D-l (a). (b).

(f-13)) Related electric Pressure switch system circuit CNAL2 diagram CNSAS CNAF7 c 3 @ 3 Pressure switch CNAL4 20-459 0 .TROUBLESHOOTING D-l D-l (f-(111 Related electric circuit diagram ECSS operation switch and network CNDP2 CNALI CNL08 Network (+) .a I 1 3 CNAL2 I Network 6) -3 CNLOG I ECSS operation switch TDW00352 D-l (f-1211.

check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. Cause YES Is voltage between CNALZ (15) and chassis ground normal? 1)20-30V 2) Turn starting switch ON. CNDP2 CNALI Network (+) 3 I a CNAL2 i Network a \ (4 3 a:- CNLOG @ ECSS operation switch 7 ( TDW00352 20-460 a . Remedy Replace Defective controller 1 Contact of chassis ground with wiring harness between CNALZ (female) (15) . 3) Turn main monitor ECSS switch OFF.CNDPP (1) . inserted.D-2 TROUBLESHOOTING D-2 ECSS cannot be canceled Ir + f t Before carrying out troubleshooting. Check that the ECSS switch on the main monitor is Off. 2) Disconnect CNLOG. repair Or rep’ace Go to troubleshooting of main monitor Defective main monitor NO 1) Disconnect CNALZ. Carry out troubleshooting with the starting switch ON.CNLOG (female) (7) 2 YES _ Is there continuity L between CNAL2 NO (female) (15)‘and chassis ground? After inspection.

Defective speed sensor. NO inserted. or defective mount of speedsensor Replace or adjust Defective controller Replace Go to Troubleshooting D-l (e) No D-4 Output is turned ON when transmission is in 1st 1 1 YES Replace (female) (14) and chassisground normal? Defective contact. check that all the related connectors are properly Always connect any disconnected connectors before going on the nex-t step.s 3 Directional. speed switch To solenoid TDW00355 20-46 1 0 .soeed solenoid NO I) Disconnect CNALZ. Carry out troubleshooting with the starting switch ON. I) Start engine. D-4 D-3 Output is turned ON (travel speed does not become (deviates around 5 km/h) * * * * 5 km/h) Before carrying out troubleshooting. Check that the ECSS switch on the main monitor is OFF.B 3 .TROUBLESHOOTING D-3.CNSAS (3) . Remedy Cause 2 YES YES Is monitor speed Idisplay incorrect? Is machine model code normal? 1) Check LED display code. @ Hi/Lo Speed e a CNTLI 3 h After inspection repair or replacf I CNL04 . 2)50-70R I CNSAS CNAL2 @. or disconnection in wiring harness between CNALP (female) (14) . 2) See STRUCTURE AND FUNCTION for details of the codes.

Cause 1 YES between (female) 1) Disconnect CNAL2. After inspection repair Or rep’acf CNL04 3 %. speed switch 1 1 To solenoid TDWDO355 20-462 0 .CNSAS (2) -Hi/Lo solenoid NO @ Remedy Defective controller CNALZ (13) and CNSAS Hi/Lo Speed @ @ CNTLI 0 _ inserted. 2) 50-70R CNAL2 @ Replace Defective contact. or disconnection in wiring harness between CNAL2 (female) (13) . Carry out troubleshooting with-the starting switch ON.TROUBLESHOOTING D-5 Output * * * * D-5 is turned ON when transmission is in 4th Before carrying out troubleshooting. Check that the ECSS switch on the main monitor is OFF. $J 3 Directional. check that all the related connectors are properly Always connect any disconnected connectors before going on the next step.

(19). Remedy Cause 1 3 YES 1)20-30V 2) Measure voltage between CNALl h (8). Check that the ECSS switch on the main monitor is OFF. inserted. or disconnection in wiring harness between CNALl (female) (8). repair or replace Abnormality Repair in fuse box NO Defective contact. So to troubleshooting main monitor of 20-463 0 . (18) . 1) Disconnect CNALl. Defective controller Replace Defective contact.1)20-30V (female) (9).CNTLl (8) .CNCLl (12) -chassis ground NO After inspection. Is voltage between YES CNDPl (male) (1) and chassis 2 ground normal? Is there continuity between CNALl . Always connect any disconnected connectors before going on the next step. (19) 2) Disconnect CNDPl. Carry out troubleshooting with the starting switch ON. (13) .(9). (19) .D-6.CNDPl (female) (1) After inspection. or disconnection in wiring harness between CNALl (female) (9). repair or replace 8 Ei CNALI I CNDPI +24V Fuse box a E 0 CNTLI CNCLI @ TDW00359 D-7 ECSS is abnormal display but main monitor does not give abnormality Remedy Cause Check that the ECSS controller is displaying an error code. D-7 TROUBLESHOOTING D-6 Controller * * * * LED code is not displayed check that all the related connectors are properly Before carrying out troubleshooting.CNSAS (1) .

. ...... .. ... ........ .. ..... 20-504 Short circuit in power source when w- 20-503 .. . ... .... .... . . ....... ......... .. ............. .. . .. ........ .... ....... . .. .. . . 2..... ......... ... ... . ..... .... ....... ........ ..... . .. .. ...... .... .. ... .. ......... ..... .. ... . . . .... ... ... . (b) Auto-leveler LED system . ........... .. . ..... ....... ... ...... .. . . .. .. ... ... ... 20-516 Failure code 1541 Abnormality in model selection w-14 Sensor cannot be adjusted w-15 Does not carry out auto-leveling wiring harness. ............ ... .. . . ....... . ...... ........... .. ... .. .. . ... ...... .. . . .. ..... . 20-518 20-519 20-520 20-520 20-521 20-522 . . ....... Failure code 1491 Abnormality w-12 system. ...... . ..... ..... ..... .... . (a) Auto-leveler switch system . ...... ...... .... .... ............... ... .. ...... ....... Table of troubleshooting w- 7 out troubleshooting 2 w- 3 in bucket dump solenoid w- 5 6 7 9 in damping 20-508 solenoid system ........ ...... . ...... in bucket lever kick-out Disconnection w-11 20-507 Failure code [481 Abnormality W-IO are OFF.......... ........ .. .......... ........... ..... . .... . ........ ... . .. ....... ... . ... ..... . ........ .. ..... ..... ....... ....... . . .. .. .. .......... ... ....... ....... ...... ... . . .. . ... . .. .... ... (c) Bucket lever neutral switch system .. ...... . . .. . ... ... .... ... ................ . .. ... ......... .. ..... Failure code [411 Abnormality 4 20-503 and causes .. . .... . ... . .. . ........ . .... ....... .. ...... ... . .... ..... Failure code table . .. ............ ... ....... ... ......20-515 Failure code 1521 in boom angle potentiometer system ....... ...... ............. ... ......... . ...... ........... .. . .. . .......... ... ........ .... ..... ........... .... .... .. ... ...... ..... 4. 1....... ....... . ......... ...... ...... .. ...... ........ ...8 DUMP. ... .. . . . ... . .. ...... .......... .. . . . .... .... .20-517 in boom lever kick-out relay system.............. .... ...... .. ... . . .TROUBLESHOOTING OF WORK EQUIPMENT CONTROLLER SYSTEM (W MODE) OUTLINE .. . ........... .. .. . ..... . . ....... . . . .. .. . .... . ............ ....... ..... .... When carrying 3.............. . 20-509 source at hot end of damping solenoid....... ... ..................... . ........ .. . ... ... ... .. . ... ...... .... ... .. .. ... .... Function .. ......... LOWER detection pressure switch.. ..... .20-506 Failure code 1421 Abnormality : z system . .. .. .. ... .. . . ... ..... . ... .... . ..... ..... .. .... .. ..... 20-503 Failure code [401 Abnormality w- modes 20-503 in bucket angle potentiometer system .... ... ...................... . ...... .. .... ...... .. ... . .....20-516 Failure code 1531 Abnormality w-13 ..... ..... .... ................... .. ..............._.. 20-513 Failure code [501 in auto-leveler relay system .... .._.. . ........ . ... ..... .....20-510 relay system . .......... . (d) Engine speed signal system ...... .... ..... .............. ....... .... .. . ... . ..... .... ..... ... ...... .... ... .. ......... . ....... . ... . ...... .. ... .. ............ ..... . ....... ....... .....I . .......... ... ...20-510 source at return end of damping solenoid ........ ..... .. . Failure code [431 Short circuit in power w- bucket in bucket tilt solenoid Short circuit in power w- ............ .. .. Failure code 1451 Abnormality w- TILT solenoids Failure code [441 Abnormality W....... ... .. ... .. . . .. . . ... ....... . ...... ........... . . ... ..._...... ....... ........ ..... ..... ......... ... .. . .... .... .... 20-514 Failure code 1511 in boom RAISE. . . ..... .... ... ......... ....... .. . . .. ......... .... . ......

. .. . .. . . .. ._... ._. . . . . ... .. .. . . . . . . .. . .. . . .._. . .. . . .. . . . . . . . 20-532 check . . . . .. . . . . . . . . . . . . . . . . .. . . . . . .. . . .. . . . . . . . . . .. .. . . . ... . . . . .... .. . . . . . . . . . . . . . . .. ... . . ... . . . . . . . . . . . . . .. . . . .. . . . . . . . . . . . .. . .. .. . . .. . .. . . . .. ..... . . . . .. . . . . . ... ... .. . . .. . . . .. .. . . . 20-523 (a) Auto-leveler (a) Remote W-18 cannot Buzzer for switch Bucket correction.. . . . . . ... . . . .. . . . .. . . . . . . . .. . . . . . . .. . . . . . . . . . .. . .. . .. . . .... . . . . . . . .. . . .. . . . . . 20-525 Bucket does not tilt immediately RAISE and auto mode w-20 ... . . . .. . . ... . . . . . . .. . . .. . . . .. . . . . . . . . ... . . . . . . .. .. . . . . . . . . .. . . . . . . . . . .. . . .. . .. . . . . .. . . . . . .. . . . . . . . . . . . . ... .. . . . . . . .. 20-529 (b) Lever is not held by detent .W-16 w-17 Auto-leveler w-19 be set set switch system (b) Auto-leveler set LED system . . . . . . . . . .. . . . . . . .. . . . . . . . . . .. . 20-526 operation w-21 at boom does not sound . . . . . . . . . . .. . .. . . . . . . . .. . . . . .. . . . .. . . . . .. 20-523 Remote positioner RAISE. . . . . . .. . . . . . . . . .. .. . . . . . . .. . . . . . . . . .. .. . . .. . . ... . . . . .. 20-533 : $ . . . . . . . . . . . . . .. 20-530 code is not displayed W-23 Failure W-24 Maintenance 20-502 0 monitor on main monitor . . .. . .. .. . . . .. . .. . . . 20-527 boom stop response are slow . . . . . . .. . . .. .. . . . . . . . . . . . .....positioner LED system . . . 20-528 Bucket kick-out does not work even when bucket is at maximum tilt .. . . . . . .. . . .. . . 20-524 Remote positioner set LEDs do not flash (a1 Remote positioner switch (b) Remote positioner LED system . . .LOWER LEDs do not light up positioner switch system . . .. . ... . . .. . . . . . . . 20-525 system . .. .. . . . .. .. . . .. . . . . . . . . . . . . .. . . ... . ... . . . . . . . .... . . . . . . . . . .. . .. . . . . .... . . . . 20-524 (b) Remote ... . . . . .. . . . . . . . . . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . ... . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . .. . .. . . ... . . .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .. . . .. .. . . . . . . . . . . . . .. . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . ... . .. . . . . . . .. . .. . . . . . . . . . .. . . . . .. . .. . . . .. .. . . . ... . . . .. . . . . w-22 Bucket (lever) control (a) FLOAT detent when remote positioner is at is ON .. . . . . . . . . . . . . . .. . ... . .. . . . . . . ..

However. boom stop response are slow 51 Disconnection in boom RAISE. the failure code is displayed on the main monitor to inform the operator that there has been a failure (trouble data mode). and buzzer output. failure codes number W-14 to W23 do not have any detection function and are for use when there is an abnormality in the movement of the work equipment. tion. TILT solenoids are OFF 42 Abnormality in bucket tilt solenoid system w-4 43 Abnormality in damping solenoid system w-5 44 Short circuit in power source at hot end of damping solenoid w-3 Failure Failure code Sensor cannot be adjusted w-14 - w-15 - Does not carry auto-leveling W-16 - Auto-leveler w-17 - Remote LOWER up positioner RAISE. Failure code Failure No. The controller receives the data from the potentiometer. and Failure code table No. Fupction The control mechanism of the work equipment controller consists of the controller. W-l 40 Abnormality in bucket dump solenoid system w-z 41 Short circuit in power source when bucket DUMP. When carrying out troubleshooting The has controller a troubleshooting func- when a failure from failure code W-l to W-13 is detected. processes it according to the input signal for each switch and carries out control of the solenoid. potentiometer input. LOWER detection pressure switch w-22 - Bucket N-II 52 Abnormality in boom angle potentiometer system W-23 - Failure code is not displayed on main monitor N-12 53 Abnormality in bucket angle potentiometer system W-24 - Maintenance N-13 54 Abnormality in model wiring harness W-8 49 Abnormality in boom kick-out relay system w-9 50 N-10 lever (lever) operation control monitor check selection 20-503 0 . 2.TROUBLESHOOTING OUTLINE OUTLINE 1. LEDs do not flash out cannot be set Bucket does not tilt immediatelv at boom FLOAT detent when remote positioner is at RAISE and auto mode is ON w-20 - Buzzer for switch does not sound Abnormality in auto-leveler relay system w-21 - Bucket correction. soienoid output. LEDs do not light W-18 - Remote LOWER positioner RAISE. 3. It is used mainly for control of auto-leveling. input switches.

Table of troubleshooting modes and causes Cause of failure Failure mode Main monitor display failure code stopping boom when remote is being actuated 20-504 0 positioner .TROUBLESHOOTING OUTLINE 4.

0 1 0 1 10101 0 1 1 1 1 1 0 0 set switch system & Remote positioner & Remote positioner $ g 2 1 I I I I I I 1 I 0 0 I LED system G Remote positioner I 0 I 1 switch system CJ Remote positioner I 0 (~1 Proximity switch system Boom pressure sensor signal system Buzzer signal system Boom lever detent switch system set LED system Leveler set LED system $ I 1 00 0 Leveler set switch system 0 z 041903 !I 2 l-b E! -. ? . K iit 9.

Always connect any disconnected connectors before going on the next step.7-ton Replace Wiring harness CNL26 (female) CNF25 (female) short circuiting chassis ground Repair or replace wiring harness between (6). always turn the starting switch OFF. or short circuit Repair or replace wiring harness Defective dump solenoid Replace CNF25. 2) 7 . 1 MR 1) Disconnect Defective controller NO Work equipment controller CNL26 I I 1 CNLR12 I I I CNFR4 I i I CNF26 1 i 1 Damping solenoid Damping solenoid (4 Damping solenoid (+) DUMP solenoid (+I noid Bucket TILT solenoid TAWO0494 20-506 0 .10 R N 4 YES Is resistance between CNF25 (male) (1) and (2) normal? 1) Disconnect CNF25.CNF25 (female) (1). (16) (1).W-l TROUBLESHOOTING W-l * * * Failure code [40] Abnormality in bucket dump solenoid system Before carrying out troubleshooting. 1 MR between CNLX (female) (6) and 1)Disconnect r CNL26. (2) with Defective dump solenoid Replace Defective contact. No 2) Min. When disconnecting connectors to connect the T-adapter (or socket adapter). check that all the related connectors are properly inserted. (2). Remedy Cause YES 2 I II n0rrlXJ? 2) Min. (16) . or disconnection in wiring harness between CNL26 (female) (6). 2.

Always connect any disconnected connectors before going on the next step. Is voltage i- 1) Disconnect CNF25. When disconnecting connectors to connect the T-adapter (or socket adapter). NO Wiring harness between CNL26 (female) (16) and CNF24 (female) (2) short circuiting at power sourcf end Repair or replace wiring harness Wiring harness between CNL26 (female) (7) and CNF24 (female) (1) short circuiting at power sourcf end Repair or replace wiring larness Wiring harness between CNL26 (female) (16) and CNF25 (female) (2) short circuiting at power source end qepair or -eplace wiring larness Wiring harness between CNL26 (female) (6) and CNF25 (female) (1) short circuiting at power source end ?epair or .TROUBLESHOOTING w-2 W-2 Failure code 1411 Short circuit in power source when DUMP.I I DUMP solenoid (+) TILTsolenoid Damping solenoid @ s\ . 3) Turn auto mode OFF. TILT solenoids are OFF * * * bucket Before carrying out troubleshooting. always turn the starting switch OFF. 1 V 2) Turn starting switch ON. 2) Max. Is voltage between CNL26 (7) and chassis normal? p Is voltage _ between CNL26 1) Max.a ?-. CNF24. 3) Turn auto mode 1) Disconnect NO OFF. Cause YES Remedy Defective controller 2 Is voltage between CNL26 (6) and chassis normal? m. 1 V 3) Turn starting switch ON.z 1) Max. (+) DUMP/TlLTsolenoid (-) CNF24 BucketTILT solenoid TAWOO494 20-507 0 . 1 V 3) Turn starting switch ON. 2) Max. check that all the related connectors are properly inserted.eplace wiring iarness Work equipment controller CNL26 I CNLR12 CNFR4 CNF26 Damping solenoid H @ 3 Damping solenoid (+_) a . z T . 4) Turn auto mode OFF. 1 V ND (7) and chassis 2) Turn starting switch ON. 4) Turn auto mode OFF.

check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.E Remedy Replace ‘ Is insulation between CNL26 (female) (7) and .w-3 TROUBLESHOOTING W-3 Failure code [42] * * * Abnormality in bucket tilt solenoid system Before carrying out troubleshooting. or disconnection in wiring 1) Disconnect CNL26. When disconnecting connectors to connect the T-adapter (or socket adapter). always turn the starting switch OFF.10 R Repair or replace wiring harness Repair or replace wiring harness Replace CNF24. 1 MD Wiring harness CNL26 (female) CNF24 (female) short circuiting chassis ground 3 YES p Is insulation between CNF24 NO (male) (1) and chassis normal? between (7). _. (2) with Replace Defective tilt solenoid 1) Disconnect CNF24. (16) (1). 2)7-10R Work equipment controller CNL26 CNLR12 Damping solenoid (-1 @ d @ Damping solenoid (c) a 3 g DUMP solenoid (+) @ 3 @ TILT solenoid (+I c 3 @ @ a 3 a 3 a- DUMP/TILT solenoid f-j -3 CNF25 (?$ - CNF24 20-508 0 Bucket DUMP solenoid Bucket TILT solenoid . 1 MR Defective contact.26 (female) (7) and I16) normal? 1) Disconnect CNL26. chassis normal? I Is resistance between CNL. 2) Min. 2) 7 . No 2) Min..

TROUBLESHOOTING w-4 W-4 Failure code 1431 Abnormality * f + in damping solenoid system Before carrying out troubleshooting. or short ircuit Is resistance between CNF26 (male) (1) and (2) normal? 1) Disconnect jefective controller defective damping olenoid I) Disconnect CNF26. or lisconnection in wiring rarness between CNL26 female) (5). Always connect anv disconnected connectors before going on the next step. Cause YES s I Is insulation YESlbetween CNL26 11 Replace Viring harness ZNL26 (female) :NF26 (female) hart circuiting hassis ground Repair or replace wiring harness between (5). (2) with Replace jefective contact. (2). No 2) Min. 2) 18-22R Work equipment controller CNL26 CNLR12 CNFR4 Damping solenoid (-) @ &yJ @ a @I- Damping solenoid (4 ($ $) @ 3 @ DUMP solenoid I+) @ 3 3 CNF26 Damping solenoid TILT solenoid (+) DUMP/TILT solenoid (4 CNF24 Bucket TILT solenoid TAWOO494 20-509 0 . check that all the related connectors are properly inserted. When disconnecting connectors to connect the T-adapter (or socket adapter). always turn the starting switch OFF.CNF26 female) (1). (15) (l). (15) . 2) 18-22R I defective damping olenoid NO I I Repair or ~a~~~saswiring Replace CNF26. 1 MR R Remedy il between CNL26 (female) (5) and 1) Disconnect CNL26.

When disconnecting connectors to connect the T-adapter (or socket adapter). 2) Turn starting switch ON. 3) Max.CNF26 (female) circuiting with source Remedy between (15) and (2) short power Repair or replace wiring harness Work equipment controller Damping solenoid (+) DUMP solenoid (c) Tl LT solenoid (+) Bucket TILT solenoid TAWOO494 20-5 10 0 . 1 V Defective controller Replace Wiring harness between CNL26 (female) (5) and 1CNF26 (female) (I) short circuiting with power ~source Repair or replace wiring harness W-6 Failure code 1451 Short circuit in power source at return end of damping solenoid I 1 YES Is voltage between CNL26 (female) (15) and chassis normal? I) Disconnect CNF26.TROUBLESHOOTING W-5. 3) Max. W-6 W-5 Failure code 1441 Short circuit in power source at hot end of damping solenoid * * * Before carrying out troubleshooting. 1 V NO Cause I Replace Defective controller Wiring harness CNL26 (female) . check that all the related connectors are properly inserted. 1 YES Is voltage between CNL26 (female) (5) and chassis normal? NO 1) Disconnect CNF26. Always connect any disconnected connectors before going on the next step. 2) Turn starting switch ON. always turn the starting switch OFF.

or disconnection in wiring harness between CNL48 (female) (2) and chassis NC 20-511 0 .CNL48 [female) (11 short circuiting with +24V Xepair or .s Defective controller %splace Defective CNLSI auto leveler relay. 3NL51 (female) (3) 3NL48 (female) (1) Xepair or .eplace wiring 7arnes. CNL26. 2) Max. NO 2) 50-110R when auto mode is switched 7 ON? Is insulation YES_ between CNL51 (female) (3) and 6 chassis normal? 1) Turn auto mode OFF. or disconnection n wiring harness cetween CNL26 (female) :21) . 1) Disconnect 4) Turn auto mode CNL51 and ON.betweenCNL51 3) Turn starting NO (female) (5) and switch OFF.TROUBLESHOOTING w-7 W-7 Failure code 1481 Abnormality system * * * in bucket lever kick-out relay Before carrying out troubleshooting. 1 MR NO 3efective contact. 1 R L N( 1)Disconnect 3 A- Remedy Does failure code appear immediately CNL48. 2) Min. CNL51 [female) (3) . or defective :ontact. 3)20-30V 4) Turn auto mode ON. always turn the starting switch OFF.CNL51 (female) (5). dump. . Always connect any disconnected connectors before going on the next step. Cause switch ON. When disconnecting connectors to connect the T-adapter (or socket adapter). chassis normal? then turn it on again. 2) Min. 1 MR - YE! Repair or replace wiring harness Defective CNL48 bucket relay Replace Defective controller Replace Wiring harness between CNL51 (female) (3) and CNL48 (female) (1) short circuiting with chassis ground Repair or replace wiring harness Wiring harness between CNL51 (female) (5) and CNL26 (female) (21) short circuiting with chassis ground Repair or *eplace wiring 7arness _ 1) Disconnect CNL51 and CNL48.eplace wiring tarness NO YE: 5r Is resistance YES_ between CNL48 (female) (2) and chassis normal? 4 Is resistance YES_ between CNL48 (male) (1) and (2) normal? - _ I) Disconnect CNL48. check that all the related connectors are properly inserted. wiring harness between CNL26 (female) (21) CNL51 (female) (5). 2) Set bucket to Is insulation max.

w-7 TROUBLESHOOTING CNDIODE Bucket relay CNL48 r ! 1 CNL32 Work equipment controller CNL26 Proximity switch :i Auto leveler relay output Bucket lever kick-out output To battery t- Proximity switch relay CNL50 Power GND - I I- CNL33 I I Auto leveler relay CNL51 CNFR2 CNF05 To proximity switch for bucket TDW00364 20-512 0 .

Always connect any disconnected connectors before going on the next step. I YES I 1 is resistance between CNL26 (female) (20) and chassis normal? 1) Disconnect CNL26.a +24V - 1 20-513 0 . 1 MR NO Cause Remedy Defective controller Replace Disconnection in wiring harness between CNL26 (female) (20) and CNL49 (female) (1) Repair or replace wiring harness Wiring harness between CNL26 (female) (20) and CNL49 (female) (1) short circuiting with chassis ground Repair or replace wiring harness Q Work equipment controller CNL26 Boom relay CNL49 CNL33 . 2) 50.1lOR _ Is insulation _ between CNL26 NO (female) (20) and chassis normal? _ 1) Disconnect CNL49.TROUBLESHOOTING W-B W-8 Failure code [491 Abnormality * * * in boom lever kick-out relay system Before carrying out troubleshooting. When disconnecting connectors to connect the T-adapter (or socket adapter). 2) Min. check that all the related connectors are properly inserted. always turn the starting switch OFF.

Remedy Cause YES 1 Is resistance between CNL26 (female) (11) and chassis normal? 1) Disconnect CNL26. 1 R _ _ NO NO Defective controller Replace Defective contact. or short circuit with ground Repair or replace wiring harness Defective contact. Always connect any disconnected connectors before going on the next step. always turn the starting switch OFF. or disconnection in wiring harness between CNL26 [female) (11) and CNL51 [female) (11. check that all the related connectors are properly inserted. 2)50-110R YES _ 3 Is resistance _ between CNL51 NO (male) (1) and (2) normal? 1) Disconnect CNLBI. When disconnecting connectors to connect the T-adapter (or socket adapter). 2) Max. or disconnection in wiring harness between CNL51 (female) (2) and chassis Repair or replace wiring harness Defective CNL51 auto leveler relay Replace Q % Bucket relay CNDIODE I CNL48 I 1 CNL32 2 3 5 Auto leveler relay output a- 6 a:- Bucket lever kick-out output i I t- To battery s Proximity I Power GND 1 switch CNL50 -i 1 4 2 3 5 CNL33 6 1 To proximity for bucket 20-5 0 I 4 switch To bucket solenoid Auto leveler positioner J relay relay .w-9 TROUBLESHOOTING W-9 Failure code [SO] Abnormality * * * in auto-leveler relay system Before carrying out troubleshooting. 2)50-110R Is continuity YES between CNL51 2 (female) (2) and chassis normal? - 1) Disconnect CNL51.

CNF21 (female) fl). 2) Max. NO controller CNL27 CNSLIP Boom RAISE pressure switch ~~LOWER pressure Signal GND output TAWO0495 20-5 15 0 . 2) Max. (9) . 1 R \ Work equipment Defective controller Replace Defective contact. always turn the starting switch OFF. check that all the related connectors are properly inserted. (2) Repair or replace wiring harness Defective boom LOWER switch Replace Defective contact. or disconnection in wiring harness between CNL27 (female) (5).CNF22 (female) (l). Remedy YES 2 Is continuity YES between CNL27 (female) (6) and Is continuity between CNL27 (female) (5) and (9) normal? 1) Disconnect CNL27. 1 R 2) Max. (9) . (2) Repair or replace wiring harness Defective boom RAISE switch Replace . or disconnection in wiring harness between CNL27 (female) (6). 1 R 4 YES Is continuity between CNF21 NO (male) (1) and (2) normal? 1) Disconnect CNF21.TROUBLESHOOTING W-IO * * * W-IO Failure code 1511 Disconnection detection pressure switch in boom RAISE. Always connect any disconnected connectors before going on the next step. LOWER Before carrying out troubleshooting. When disconnecting connectors to connect the T-adapter (or socket adapter).

3 YES Is resistance between CNF29 [male) (1) .(3) normal? 1) Between (1) and (2):0.(3) normal? 1) Between (1) and (2): 0. Always connect any disconnected connectors before going on the next step.(21. or short circuit with ground Repair or replace wiring harness Defective boom angle potentiometer Replace in bucket angle potentiometer Cause r Isfailure YE between CNL27 1)0. always turn the starting switch OFF.2 7 5 lu2 2) Between (21 and (3): 4 .2-5kQ 2) Between (2) and (3):4-5kQ 3) Disconnect CNF29.5 kD 3) Disconnect CNF28. (2) . 2 YES Iefective controller Remedy leplace code 5.(2). Cause YES Is failure code 52 YES displayed in condition for measuring Item l? 1 Is voltage between CNL27 (9) and (19) normal? - 1)0. 3 YES Is resistance between CNF28 (male) (1) .3 displayed in condition for measuring Item l? NO 1) Turn starting switch ON (after resetting). 20-516 a Remedy No Uready reset Iefective contact.w-11.7v 2) Turn starting switch ON.3-4. or disconnection in wiring harness between CNF28 (female) (1) and CNL27 (female) (19). ~~~c.“$n” ~0 3) Insert T-adapter. When disconnecting connectors to connect the T-adapter (or socket adapter). or fisconnection in wiring tarness between CNF29 female) (1) and CNL27 female) (20). TROUBLESHOOTING W-11 * * * Failure code [52] system Abnormality w-12 in boom angle potentiometer Before carrying out troubleshooting. NO I) Turn starting switch ON (after resetting). check that all the related connectors are properly inserted. W-12 No Failure code [531 Abnormality system Replace Already reset Defective contact. N 3) Insert T-adapter.3-4. (2) .7v 2. or short :ircuit with ground tepair or eplace wiring larness Defective boom angle aotentiometer teplace .

CNSLIP NO Cause w-12 Remedy Defective contact. TROUBLESHOOTING sr When 1521 and 1531 are displayed at the same time YES (male) (1). 3) Disconnect CNL27. or short circuit with ground Repair or replace wiring harness Defective bucket angle potentiometer Replace Defective boom angle potentiometer Replace Defective controller Replace CNF29 Bucketangle potentiometer Work equipment controlle Bucketangle potentiomete iometer Boom angle potentiometer TAWO0496 20-5 17 0 . CNF29 (female) (2). 1 MR I NO 1) 4-6V 2) Turn starting switch ON. (3). (3) chassis normal? I YE 1) Disconnect CNF29. (3). 2) Min. 1 MR 1 Is voltage between CNL27 (male) (9) and (IO) normal? I I 1) Disconnect CNF28. 2) Min.w-11. 4) Insert T-adapter. (10) .CNF28 (female) (2). or disconnection in wiring harness between CNL27 (female) (9).

or disconnection in wiring Tarness between CNL26 :female) (13) . 1 20- Between CNL27 (14) and (9) WA420 1 / 20-30 30 Max. When disconnecting connectors to connect the T-adapter (or socket adapter). check that all the related connectors are properly inserted. 1 20 . Between CN L27 (13) and (9) Max. always turn the starting switch OFF.CNL27 [female) (13). 1 Model selectic CNL27 I I CNHYD2 I I I Model selection 1 @ (ij@ Model selection 2 @ @Q Model selection 3 @ @@ GND @ @ @ CNL26 Power source 24V for sensor TAWO0497 20-5 0 18 . 1 Max. CNHYD2 (3) . Cause YE YE 2 YE l-l Is voltage between CNL27 (9) and (12) as shown in Table l? NO between CNL26 (13) and CNL27 NO 1)20-30V Table Remedy >efective controller 3eplace Iefective contact. or disconnection in wiring harness between CNL26 [female) (13) -CNHYD2 (4). or short circuit Repair or replace wiring harness Defective controller Replace 1 WA320 I WA380 Between CNL27 (12) and (9) Max. then turn the starting switch ON.CNHYDZ (41.CNL27 :female) (14). or short :ircuit qepair or . CNHYDZ 12) .CNHYDZ :4). Before carrying out troubleshooting. or short circuit qepair or *eplace wiring larness Defective contact.CNL27 (female) (121.w-13 TROUBLESHOOTING W-13 Failure code [54] Abnormality in model selection wiring harness Check that the model selection connector has been properly selected (see STRUCTURE AND FUNCTION) Insert a T-adapter. Always connect any disconnected connectors before going on the next step. WA470 120-30 1 20 -30 1 Work equipment controller I Max. CNHYD2 (1) .eplace wiring iarness Defective contact.30 20 -30 Max. or disconnection in wiring harness between CNL26 [female) (13) .

W-l 4 TROUBLESHOOTING W-14 * * * * Sensor cannot be adjusted For details of the method of operation. Is remote positioner set signal system normal? 1) See Troubleshooting W-18. 2) Auto leveler set LED and remote positioner set LED light up or flash. No NO Cause 1 Remedy Defective controller Replace Defective remote positioner set switch or LED system Repair or replace wiring harness Defective auto leveler set switch or LED system Repair or replace wiring harness 20-5 19 0 . always turn the starting switch OFF. I 3 YES YES 2 1 Corresponding LED lights up and does not flash. Is auto leveler set signal system 1) See Troubleshootina W-16. Before carrying out troubleshooting. Always connect any disconnected connectors before going on the next step. see STRUCTURE AND FUNCTION. check that all the related connectors are properly inserted. When disconnecting connectors to connect the T-adapter (or socket adapter). 1) Turn auto leveler set switch and remote positioner set switch ON simultaneously.

always turn the starting switch OFF. 2) Maintenance monitor auto mode switch ON: Max. 1 MR 1) Disconnect CNL28 and CNLZO. 1 R OFF: Min. Always connect any disconnected connectors before going on the next step. When disconnecting connectors to connect the T-adapter (or socket adapter). or disconnection in wiring ?arness between CNL28 ifemale) (8) and CNL20 Ifemale) (17 t Repair or replace wiring harness airing harness between CNL28 (fernate) (8) and CNL20 (female) (11) short circuiting with chassis ground Repair or replace wiring harness Defective contact. check that all the related connectors are properly inserted. 2) Short circuit of CNL20 (femalet (11) with ground 3) Max. 1 R _ NC NO UO Work equipment controller >efective controller Replace Iefective contact. or short circuit with ground Repair or replace wiring harness Maintenance CNL27 monitor CNL20 Auto leveler set switch Auto leveler switch Auto leveler set display Auto mode display IV TDW00370 20-520 a Remedy . or disconnection in wiring harness between CNL27 (female) (18) and CNLZO (female) (6). (a) Auto-leveler (b) Auto-leveler switch system LED system Cause 3 YEI Is insulation YES between CNL28 (female) (8) and chassis normal? 2 YE 1 1) Disconnect CNL27.w-15 TROUBLESHOOTING W-15 Ir Ir Ir Ir Does not carry out auto-leveling Check that the maintenance monitor works properly in Troubleshooting W-24 [Maintenance monitor check]. 1 MD . 2) Min. Before carrying out troubleshooting. Is insulation between CNL28 (female) (8) and chassis normal? 1) Disconnect CNL28 and CNL20.

CNFZO (female) (l). (2) with Defective bucket lever neutral switch NO CNFR3 Remedy CNMO Replace Bucket neutral switch (3 CNL26 Power source of sensor TAW00498 20-52 1 0 .CNL27 (female) (11). 2) Lever at neutral: Max. or disconnection in wiring harness between CNL26 (female) (13) . 1 MD CNLRII Is insulation between CNL27 (female) (11) and chassis normal? I) Disconnect CNL27 and CNL26. l switch ON. (21. and check that the voltage Cause YES 1 Bucket lever neutral switch signal Is continuity between CNL27 - ffemale) (11) and 3 - CNL26 Ifemale) (13) normal? 1)Disconnect CNL27 and CNL26. turn the starting between CNL26 (I I) and (9) is 20 .TROUBLESHOOTING w-15 ICI Bucket lever neutral switch system Insert the T-adapter into CNL26. or short circuit Repair or replace wiring harness Wiring harness CNL26 (female) CNF20 (female) short circuiting chassis ground Repair or replace wiring harness between 113) and (I). 1 MR Work equipment controller YES 2 I Is continuity between CNFZO NO (male) (11 and (2) normal? 1) Disconnect CNFZO.30 V. 2) Min. 1 R 3) Lever at other than neutral: Min. 1 R 3) Lever at other than neutral: Min. 2) Lever at neutral: Max. 1 MR YES - _ No Defective controller Replace Defective contact.

TROUBLESHOOTING (d) Engine w-15 speed signal system Cause Y ‘ES 4 YEI 1 El Remedy Engine speed signal is normal Go to other system 3efective controller Replace 3efective contact. 1 MR 1) Disconnect CNE04. 2) Min. CNLOi Ifemale) (3) short circuitin Gth chassis ground Repair or replace wiring harness Defective speed sensor Replace Is voltage between CNL26 (7 1) and (9) normal? 1) Insert T-adapter. and CNLG’. 3) Max. 212-3kR H CNEO4. and CNL07. CNL28.CNL28. 1 R NO NC Work equipment controller TDWOO372 20-522 0 . 3)20-30V IIs insulation 11 Disconnect 4-l NO Is resistance between CNE04 (male) (2) and (3) normal? 2 (female) (4) and chassis normal? I 1) Disconnect CNE04. or jisconnection in wiring iarness between CNL28 ifemale) (4) and CNE04 Ifemale) (2) Repair or replace wiring harness airing harness between ZNL28 (female) (4) ZNE04 (female) 12). 21 Turn auto mode ON. 2) Short circuit CNEOI (2) with ground.

2) Min. 1 MR _ _ 1) Disconnect CNL28 and CNL20. (al Auto-leveler set switch system Remedy (b) Auto-leveler set LED system 3 YES Is continuity YES between CNU~ (female1 (7) and chassis normal? 2 Is insulation YES between CNL28 (female) (7) and 1 Auto leveler set signal system 2 0 is continuity between CNL27 (female) (3) and chassis normal? 1) Disconnect CNL27. check that all the related connectors are properly inserted. always turn the starting switch OFF. 1) Disconnect No CNL28 and CNLPO. 2) Maintenance monitor auto mode switch ON: Max. or disconnection in wiring harness between CNL27 (female) (3) and CNL20 (female) (4). 1 Ma - . 1 R NO NO Defective controller Defective contact. 2) Short circuit CNL20 (female) (9) with ground. 1 $2 OFF: Min. Always connect any disconnected connectors before going on the next step. 3) Max. Before carrying out troubleshooting. or short circuit with ground Repair or replace wiring narness I Work equipment controller Maintenance CNL27 monitor CNL20 Auto leveler set switch Auto leveler switch Auto mode display i@P TDWOO370 20-523 0 . When disconnecting connectors to connect the T-adapter (or socket adapter).W-16 TROUBLESHOOTING W-16 Auto-leveler cannot be set Check that the maintenance monitor works properly in Troubleshooting W-24 [Maintenance monitor check]. or disconnection in wiring harness between CNL28 (female) (7) and CNL20 (female) (9) Repair or replace wiring harness Wiring harness between CNL28 (female) (7) and CNL20 (female) (9) short circuiting with chassis ground Repair or replace wiring harness Defective contact.

Before carrying out troubleshooting. or disconnection in wiring larness between CNL27 [female) (4) and CNL20 [female) (7). (13) :epair or aplace wiring arness Niring harness :NL28 (female) :NL20 (female) short circuiting :hassis ground lepair or eplace wiring iarness YE FH NC (female) (6). 1 Q IO 1) Disconnect CNL27. 1 R OFF: Min. 2) Maintenance monitor remote positioner switch ON: Max. or short circuit with ground 1 No Work equipment between (6). Always connect any disconnected connectors before going on the next step. always turn the starting switch OFF. 2) Short circuit CNL20 (female) (12). LOWER LEDs do not light up Check that the maintenance monitor works properly in Troubleshooting W-24 [Maintenance monitor check]. 1 MR Iefective contact.CNLZO female) (12). (a) Remote (b) Remote positioner positioner switch system LED system Cause 3 YE! Remedy Iefective controller eplace Iefective contact. or iisconnection in wiring tarness between CNL28 female) (6). check that all the related connectors are properly inserted. TDW00375 repair or eplace wiring rarness . 3) Max.w-17 TROUBLESHOOTING W-17 * * f * Remote positioner RAISE. When disconnecting connectors to connect the T-adapter (or socket adapter). (14) (121. (13) with controller CNL26 Maintenance display monitor CNL20 CNL27 Remote switch positioner Positioner selector set switch CNL28 1 I 20-524 0 Fib&& positioner LOWER/ 4. (14) . (14) - 1) Disconnect CNL28 and CNL20. (13) with ground.

2) Maintenance monitor remote positioner set switch ON: Max. Rlepair or rreplace wiring harness Wiring harness between CNL26 (female) (IO) CNL20 (female) (IO) short circuiting with chassis ground Rlepair or rleplace wiring hlarness Defective contact. 2) Min. or disconnection in wiring harness between CNL26 (female) (10) . 1 MD 1 _ 1) Disconnect CNL26 and CNLZO. or disconnection in wiring harness between CNL27 (female) (2) and CNL20 (female) (51. Before carrying out troubleshooting.20 (female) (10) with ground. Always connect any disconnected connectors before going on the next step. 1 Q OFF: Min. 2) Short circuit CNl.CNL20 (female) (10) . 1 MR _ NO 1I Disconnect CNL26 and CNLZO.arness controller CNL26 Remote display positioner set @ .eplace Defective contact. 3) Max. or short circuit with ground Flepair or eplace wiring c:. starting switch OFF. always turn the When disconnecting connectors to connect the T-adapter (or socket adapter).Maintenance monitor CNL20 CNL27 Remote switch positioner Positioner selector set switch 20-525 0 . check that all the related connectors are properly inserted.W-l 8 TROUBLESHOOTING W-18 t * Ir + Remote positioner set LEDs do not flash Check that the maintenance monitor works properly in Troubleshooting W-24 [Maintenance monitor check]. (a) Remote (b) Remote positioner positioner switch system LED system Cause 3 YES Is continuity YES between CNL26 (female) (10) chassis normal? 2 Is insulation YES between CNL26 (female) (10) chassis normal? Remote positioner set signal system - Is continuity between CNL27 (female) (2) and chassis normal? 1) Disconnect CNL27. 1 R NO NO Work equipment r Remedy Defective controller R.

1 Q 3) Boom lever detent: Min. check that all the related connectors are properly inserted. 1 R 3) Boom lever detent: Min. 2) Boom fever at NO 1 Cause Remedy Defective controller Replace Defective contact. 1 MR Work equipment controller CNL27 CNLRI 1 CNFR3 CNF23 Boom lever detent switch Signal GND output TAW00439 20-526 0 1 . or short circuit Repair or replace wiring harness Defective boom lever detent switch Replace neutral: Max. I YES 1 I Boom lever As+an+ -witch Is continuity between CNL27 (female) (8) and 2 YES l-l 1) Disconnect NO CNL27.w-19 TROUBLESHOOTING W-19 Ir * f Bucket does not tilt immediately at boom FLOAT detent remote positioner is at RAISE and auto mode is ON when Before carrying out troubleshooting. Always connect any disconnected connectors before going on the next step. (9) . I2) Boom lever at neutral: Max. When disconnecting connectors to connect the T-adapter (or socket adapter). 1 MD oenween t (female) (1) and (2) norma 1) Disconnect CNF23. or disconnection in wiring harness between CNL27 (female) (81. always turn the starting switch OFF. (2).CNF23 (1).

Always connect any disconnected connectors before going on the next step. When disconnecting connectors to connect the T-adapter (or socket adapter). 2) 5-6R Work equipment NO 1) Disconnect CNL28 and CNLOI. always turn the starting switch OFF. 1 R VO Remedy Defective controller leplace Defective contact.w-20 TROUBLESHOOTING W-20 f *. Before carrying out troubleshooting. Cause 2 YES pHG iEH-- 1 1) Disconnect CNL28 and CNLOS.resistor CNL34 (8) -chassis Wiring harness between CNL28 (female) (161 and CNLOB (female) (6) short circuiting with chassis ground lepair or eplace wiring rarness l Main monitor controller CNL34 CNL28 3 Buzzer output CNL08 $J -8 Resistor 20-527 0 . check that all the related connectors are properly inserted. or disconnection in wiring harness between CNL28 (female) (16) and CNLOB (female) (6) tepair or eplace wiring ramess * Defective contact. 3) Max. * * Buzzer for switch operation does not sound Check that the main monitor and alarm buzzer work properly. 2) Short circuit between CNL08 (female) (6) and chassis. or disconnection in wiring harness between CNL28 (female) (16) .

3)1-5v between CNL28 (female) (9) and 2 R between CNF30 (female) (11 and 1) Disconnect CNFBO. boom stop response are slow Check that the boom cylinder bottom pressure sensor works properly. or disconnection in wiring harness between CNL26 (female) (13) and CNF30 (female) (2). 2) Min. check that all the related connectors are properly inserted. or disconnection in wiring 7arness between CNL28 Ifemale) (9) and CNF30 [female) (3) Repair or replace wiring harness 8Wiring harness between CNL28 (female) (9) and CNF30 (female) (3) short circuiting with chassis ground *Wiring harness between CNL28 (female) (9) and CNM13 (1) short circuiting with chassis ground Repair or replace wiring harness Defective contact. Before carrying out troubleshooting. Always connect any disconnected connectors before going on the next step. 2) Turn starting switch ON.w-21 TROUBLESHOOTING W-21 * * * Ir Bucket correction. always turn the starting switch OFF. 2) Turn starting switch ON. 1 MR IO qeplace controller 3efective contact. 3)20-30V CNL28 and CNF30. When disconnecting connectors to connect the T-adapter (or socket adapter). or short circuit Repair or replace wiring harness CNM13 Work equipment c Oil pressure sensor for boom cylinder bottom Power GND 20-528 0 TAW00501 . Remedy Cause ES Iefective YE! YE 1) Insert T-adapter.

1 R 5 YES Is continuity between CNLSO (male) (3) and (6) normal? (Al NO 1) Disconnect CNLSO. When disconnecting connectors to connect the T-adapter (or socket adapter). 1) Disconnect CNLBO. 2) Max. (2). or short circuit lepair or aplace wiring arness Defective bucket positioner solenoid leplace IDefective contact. Does lever kickout work? % 11 Short circuit CNL48 (female) (3). CNL17. 3) Max. Auto mode: OFF tilt l Cause Defective proximity switch Go to CNF05. (a) Bucket kick-out does not work even when bucket is at maximum Check that failure code [481 is not being output. or disconnection in wiring harness between CNL50 (female) (3) and +24V.(female) (2) and chassis epair or splace wiring arness IDefective Irelay eplace CNL48 bucket Defective CNLSO proximity switch relay Ieplace Defective contact. always turn the starting switch OFF. Always connect any disconnected connectors before going on the next step. 2) Max. . check that all the related connectors are properly inserted. 2)20-30V Y‘ES 7 Is continuity between CNL48 (female) (3) and chassis normal? I 1) Disconnect CNL17 and CNL48.[female) (5). or short Icircuit I Remedy epair or aplace wiring arness IDisconnection in wiring Iharness between CNL17 . or disconnection in wiring harness between CNL51 (female) (6) and CNL50 (female) (6). RIO 2) Short circuit CNL17 (female) 1) Disconnect (1).[female) (1) and CNL48 . 1 Q 2) Max. Tilt the -bucket fully. . or short circuit Iepair or eplace wiring rarness Defective CNL51 auto leveler relay teplace 20-529 0 . 1 R NO NO NO leplace (A) Defective contact. 1 R - 6 YES I Is continuity between CNL51 (male) (3) and (61 normal? II 1) Disconnect CNLSl. (5).w-22 TROUBLESHOOTING W-22 + * * Bucket (lever) control Before carrying out troubleshooting. NO 3) Check that voltage between CNL48 (female) (3) and chassis is20-30V. 2) Turn starting L switch ON. or fdisconnection in wiring Iharness between CNL17 .

3) Turn starting switch ON. 2) Turn starting switch ON. 4) Max. (b) Lever is not held by detent (I) l Lever is not held by detent regardless of position Check that failure code t481 is not being detected. 1 V 3) Turn starting switch ON.witch relay leplace Wring harness between ZNL51 (female) (6) and :NL50 (female) (6) short :ircuiting with +24 V lepair or eplace wiring arness (2) Lever is not held by detent only when auto mode switch is OFF . 3) Max. YES 1 Is voltage between CNL51 (female) (6) and chassis normal? I) Disconnect CNL51 and CNFOS. 1 V + 1) Disconnect CNL50. 2) Min. 2)50-110R NO . or lisconnection in wiring rarness between CNL50 female) (2) and CNF05 female) (2) lepair or eplace wiring arness lefective proximity . 1 MR L NO 1) Disconnect CNL48. Tilt the bucket fully. epair or aplace Viring harness between :NL48 (female) (51 and bucket positioner olenoid short circuiting vith +24V epair or splace wiring amess )efective proximity iwitch leplace lefective contact. 2) Short circuit CNFOS (2) and (3). 1 V 20-530 0 3 YES Is resistance YES between CNL50 (male) (2) and (1) between CNL51 NO (female) (61 and chassis normal? 1) Disconnect CNL51 and CNL50. of auto mode switch Cause 2 YES Is voltage between CNL48 ‘(female) (5) and chassis normal? A Iefective function of bucket lever detent Is insulation YES between CNL48 1(male) (3) and (5) normal? - defective CNL48 bucket clay NO 1) Disconnect CNL48.w-22 TROUBLESHOOTING. 2) Max.

TROUBLESHOOTING w-22 CNDIODE Bucket relay CNL48 1 m CNL32 Work equipment controller CNL26 a:- Proximityswitch @ Auto leveler relay output c r Bucketlever kick-out output @ - I @ To battery I-- Proximity switch relay CNL50 Power GND e CNL33 1 1 Auto leveler relay CNL51 17 c To battery ~~.c$gsitioner Power GND 4 CNLR2 CNFR2 a @ 3 (I$ @ 3 CNF05 To proximity switch for bucket 8 TOW00364 20-531 0 .

3) Max. (3). always turn the starting switch OFF. When disconnecting connectors to connect the T-adapter (or socket adapter). (3) with Work equipment controller CNL26 CNL34 CNDP2 ECSS CNLO6 I 20-532 0 Main monitor Repair or replace wiring harness . Always connect any disconnected connectors before going on the next step. (12) (l). 1 R 1) Disconnect CNLOS and CNDP2 2) Min.W-23 TROUBLESHOOTING W-23 * * * Failure code is not displayed on main monitor Before carrying out troubleshooting. 1 MR Wiring harness CNL26 (female) CNL08 (female) short circuiting chassis ground I NO between (l). check that all the related connectors are properly inserted. Remedy Replace Repair or replace wiring harness 2) Short circuit CNL08 (11.

3 YE: io to (A) between CNLZO 2 . LOWER switch: ON: Max. io to IB) I NOI NC NO Iefective maintenance nonitor qeplace 6YE: YESDoes LOWER LED .ED system is normal light up? 1) Connect CNLSO (13) to GND (3). 1 MR I NO NC jefective maintenance nonitor YES ?eplace _. - r . 4 W Does RAISE LED light up? 1) Connect CNLZO (12) to GND (3). 1 MD between CNL20 (male) (6) and chassis normal? 1) Auto mode switch: ON: Max.position set LED light up? 2 YES Does level set LED light up? 1 Check switch system . (2). NC No refective maintenance 70nitor system 20-533 0 . 1 Q OFF: Min. 1 R OFF: Min. I) Connect CNUO (10) to power source (1). (2). iwitch system is normal Is resistance I) RAISE. Voltage between CNL20 (I). When disconnecting connectors to connect the T-adapter (or socket adapter). (2).30V 3 YES DoesRAISE . 1 R OFF: Min. (2) and chassis: 20 . always turn the starting switch OFF. . check that all the related connectors are properly inserted. 1 R OFF: Min. 1 MR 1 ichassis normal? Is resistance 1) RAISE position set switch: ON: Max. _ 1) Connect CNLZO (9) to power source (1). Does auto mode LED light up? 1) Connect CNL20 (11) to power source (11. Cause Remedy Check maintenance monitor (CNL20). Check switch system I) Level set switch: ON: Max. 1 MR .A.TROUBLESHOOTING W-24 * * * * W-24 Maintenance monitor check Before carrying out troubleshooting. Always connect any disconnected connectors before going on the next step. jefective maintenance nonitor NO qeplace insert T-adapter and turn starting switch ON.

............................................................................................................................................................. 30............33 30... 30-106 Installation ............................. 30-I 13 DIFFERENTIAL Disassembly ..... TURBOCHARGER Removal and Installation ............................. 30-137 CENTER HINGE PIN Removal ......................................................................................................34 30-35 30.................. 30-I 47 Installation .. 30-156 Disassembly ...................... 30-154 Installation ..................................................................... STARTING MOTOR Removal and Installation .......................... TORQUE CONVERTER CHARGING PUMP Removal ............................... 30-104 FRONT AXLE Removal ...................... Installation ...40 30.................. 30-130 Assembly ... 30-161 ORBIT-ROLL VALVE Removal ......... 30...........24 30-27 30............... RADIATOR Removal .............................................. THERMOSTAT Removal and Installation .............17 30-22 30..................................15 30........................ TORQUE CONVERTER......................... 30................................... 30-l 69 30-l 0 ...... 30-101 Assembly ..92 Assembly .36 30................................... 30..................................................... TORQUE CONVERTER Disassembly .............. . NOZZLE HOLDER Removal and Installation ................... 30....................................................................... Installation ....... 30-151 STEERING VALVE Removal ...................88 Installation ...............................................76 TRANSMISSION CONTROL VALVE Removal .....................................................................30 DISASSEMBLY AND ASSEMBLY g 2 ................................ FUEL INJECTION PUMP Removal .. 30......... installation . METHOD OF USING MANUAL .................................13 30................................................ 30..................56 TRANSMISSION CLUTCH PACK Disassembly ................ 30-109 Installation .............. ENGINE Removal .................... 30...................................... ENGINE OIL COOLER Removal and Installation ..................................................................... Installation ........ 30-I 20 AXLE HOUSING Disassembly ........................................................... 30-166 Assembly ..16 30.................................... Installation ........................................94 TRANSMISSION ACCUMULATOR VALVE Disassembly ................97 Assembly ....................................................................28 30-........................ Installation ...................................90 Disassembly ...................... ALTERNATOR Removal and installation ..........................................10 30................................... Assembly ............. 30............98 TRANSMISSION MODULATING VALVE Disassembly ............... SPECIAL TOOL LIST..................... PRECAUTIONS WHEN CARRYING OUT OPERATION ......... 30-100 DRIVE SHAFT Disassembly .........................................11 30......... 30-l 15 Assembly ........................................... WATER PUMP Removal and Installation ..................41 30-43 30-46 30..........70 Assembly ....... TRANSMISSION Disassembly .........12 30................................ TRANSMISSION Removal ... CYLINDER HEAD Removal ............14 30.......... 30- 3 3030- 4 6 30- 8 30- 9 30............................................................................. Assembly ..................................... 30-165 Disassembly .................................99 Assembly ............... 30-157 Assembly ....... 30-108 REAR AXLE Removal .............................. 30-164 Installation ..............................................................

........................ ..... ... ........... 30-226 Installation ..... ............ .................. . ......... .. 30-222 FUEL TANK Removal ... 30-241 Installation . ... .......... 30-214 WORK EQUIPMENT Removal ....... ... ........... .. 30-193 Installation .. ....... ......... ... . .... ....... 30-185 Installation ............... 30-182 Installation ........... .................... .. . ..................... . .... ..... 30-243 AIR CONDITIONER CONDENSER COMPRESSOR Removal and Installation ....... .. . .. ........... 30-177 RIGHT BRAKE VALVE (TANDEM) Disassembly ........... 30-181 PARKING BRAKE DISC Removal ........... ... .... 30-176 Installation . .... . ....... ....... ......................... .......... 30-211 Assembly .......... .. ........ . ............. 30-192 MAIN CONTROL VALVE Removal ............................. ............................... ............. .. ..... ....... ........ ..... 30-175 BRAKE VALVE Removal .................. ..... .... . ..... .... .. ....... 30-201 Installation .. ... ..... 30-244 ......... ........ . ............. ......... ..... ..... ............................___..................... ....... ............... 30-230 Installation ...._. ...._... ... .... .......................... .... ........... ................. 30-184 HYDRAULIC TANK Removal . .. ................ ..... ... .............. 30-180 Assembly ..... .. ............... ...... ............... .. 30-210 HYDRAULIC CYLINDER Disassembly ... ......... ................... .......... ...................... .............. .. ....... ..... ...... ... .......... .................. 30-209 Installation .................... 30-189 Installation ... _............... 30-240 AIR CONDITIONER CONDENSER Removal ...... ................. .... FLOOR FRAME Removal ........... ...... ... 30-178 Assembly ......... . .... ....STEERING CYLINDER Removal .. 30-242 DRY RECEIVER Removal and Installation ..... 30-223 Installation ... ... . .....30-188 HYDRAULIC....... ..... .. .................... 30-229 30-2 0 CAB Removal ... .. ....... .... 30-196 Assembly ... .. 30-208 BOOM CYLINDER Removal ............. ............... ......... ... . 30-198 PPC VALVE Removal .... .. ..... ........ ..................... 30-203 Disassembly ........... ... STEERING....... ........ . .................... 30-231 MAIN MONITOR Removal .... ............ . ....... ..... SWITCH............. ................ .. .............. .. ...... .... . ..... ........................... .......... ..._........ 30-233 MAINTENANCE MONITOR Removal and Installation ... ............... 30-217 installation ............ 30-204 Assembly .. ............ 30-206 Installation ............... ........ ........... .. ............ . . . ....... 30-220 COUNTERWEIGHT Removal and Installation .. .. 30-187 HYDRAULIC FILTER Removal and Installation ............. ..... . ....... ... 30-205 BUCKET CYLINDER Removal ... ....... ...... ... .. ............... .... .... ..... ....... ........... .................... ..... . ........... ... ...... .... ...... ... ............. . .... .... .......... ...... ................................... . ..... ...._..... ..... 30-225 CAB.... ........... ..... PPC PUMP Removal .. . ....... ........... 30-234 AIR CONDITIONER UNIT Removal .. ..._.. .. 30-232 Installation .... ........... 30-235 Installation .... 30-195 Disassembly . 30-179 LEFT BRAKE VALVE (SINGLE) Disassembly . 30-174 installation ....... .................. ................ .. . ...... ....... .......... ... ... ..... . . ....................... ... ..... . ........ .... ...... .

. . or assembly) of units so be sure to follow For details of the description.. . . Title of operation l Carry out installation in the reverse order to removal.. ... ..-. . .. . .. Step in operation * . see the SPECIAL TOOLS LIST given in this manual. the order of work and techniques used are given for the removal operation.. . . XXXX (I) . A A A (2): .. . .. .. ... and the same mark is placed after the relevant step in the removal procedure to indicate which step in the installation procedure it applies to. . ... (Example) REMOVAL OF 0 0 0 ASSEMBLY . . .. . .. . .. .. . . . ... . ... . ..... . . ... . . ... . .. and quantity of any tools (Al. . . . Technique or important installing DA A (2). . . . . . .... the order of work for the installation operation is not given. . . .. .. . Indicates that a technique is listed for use 2.. . ..... . . . . . . . .. OF USING MANUAL When removing or installing unit assemblies (Ii When removing or installing a unit assembly. . ..... . .. . . oil . . . . . . . ... .. . ..METHOD OF USING MANUAL DISASSEMBLY AND ASSEMBLY METHOD 1. . . .. . . .. 0 0 0 0 assembly (3) : . . .. . . . ... .. . . . . . .. ... ... .. .... in 30-3 0 . ... .... . . . ... ... . (2) Any special techniques applying only to the installation procedure are marked m.. . . .... . . . . . . . m during installation 3.. ... . . .. . . Title of operation . .. . . . . . . .. . . . . ..... . .. Technique used during installation point to remember when . . .. . .. ... ... ... . ... . . . .... .. . Step in operation * . . . . . Quantity of filling 2. . .. .. . . .. . .. . .. . . . . .. General precautions when carrying out installation or removal are given together as PRECAUTION WHEN CARRYING OUT these precautions when carrying out the operation. . . . .. . . . etc. . .. . .... . . .. part number. . . .) that appear the operation procedure.... . .. . . . ... . Precautions related to safety when carrying out A the operation 1.. .... . . . . . .. .. . . . . .. . .. ... .. ... . . .. ..... . . .... .. .. . . . . See Lubricant and Coolant Table INSTALLATION OF 0 0 0 ASSEMBLY . .. .... . . . ... .. . ....... ... . . .. . Technique or important point to remember when removing XXXX (I).. Point to remember when adding water or oil QI . . .... . . . .... . . 3.. . .. . . . Listing of special tools (I) oil and water (disassembly OPERATION.. . . . ... . ..... . l Adding water. . .. . .. . .. . . . . . . .... . . . . . . ._. .. . .. .. . p . . .. . .

Check the number and thicknessof the shims.] of units. dispose of it correctly. prepare a container of adequate size to catch the oil.07222-01219 (Plug) Split flange type hoses and tubes ~~~~e~' 3) it during Flange (hose end) Sleeve head (tube end) Splitflange 04 07379-00400 07376-10400 07371-30400 05 07379-00500 07378-10500 07371-30500 If the part is not under hydraulic 14 07049-01418 14 1 11. and keep in a safe place. When draining oil. tighten the forcing screws alternately.07222-00414 (Plug) 05 0737650522 07221-20522 (Nut). When raising components. DEW00401 operations. be sure to follow the Precautions when carrying out removal work If the coolant contains antifreeze.07222-00312 (Plug) 04 07376-50422 07221-20422 (Nut). After disconnecting hoses or tubes. .DISASSEMBLY AND ASSEMBLY PRECAUTIONS PRECAUTIONS WHEN CARRYING OUT OPERATION WHEN CARRYING OUT OPERATION [When carrying out removal or installation (disassembly or assembly) general precautions given below when carrying out the operation.07222-00515 (Plug) 06 07376-50628 07221-20628 (Nut).5 28 24 07049-02430 24 20 30 27 07049-02734 27 22. Confirm the match marks showing the installation position. Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. Precautions when handling piping during disassembling Fit the following blind plugs into the piping after disconnecting 1) Hoses and tubes using sleeve nuts ~~~~e~' 2) 30-4 0 disassembly Sleeve nut (elbow end) Plug (nut end) Use the two items below as a set 02 07376-50210 07221-20210 (Nut).07222-01018 (Plug) 12 07376-51234 07221-21234 (Nut). To prevent any excessive force from being applied to the wiring. Before removing any unit. When using forcing screws to remove any components.07222-00210 (Plug) 03 0737650315 07221-20315 (Nut).5 18 16 07049-01620 16 13.07222-00616 (Plug) 10 07376-51034 07221-21034 (Nut). clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. the following corks can be used.5 20 18 07049-01822 18 15 22 20 07049-02025 20 17 25 22 07049-02228 22 18. always hold the connectors when disconnecting the connectors. cover them or fit blind plugs to prevent dirt or dust from entering.5 34 pressure. be sure to use lifting equipment of ample strength. and make match marks in the necessary places before removal to prevent any mistake when assembling.

check that the snap ring is fitted securely in the ring groove. or motors. O-rings. Then check the water level again. After bleeding the air. pumps. After fitting snap rings. see TESTING AND ADJUSTING. clean the surface and remove all oil and grease. tighten the drain valve. or rust. follow the same procedure.’ I) Start the engine‘and control lever to operate the hydraulic cylinder 4 . When operating the hydraulic cylinders for the first time after reassembling cylinders. If the piping or hydraulic equipment. cotter pins. tighten plug (I). check that there is no dirt or damage. raise the engine speed. run at low idling. add engine oil to the specified level. Precautions when completing the operations \ If the coolant has been drained. then coat uniformly with gasket sealant.15 kgm) 5) After doing this. When coating with adhesive. always bleed the air from the system after reassembling the parts. Then check the oil level again. and align the direction of the hook. then coat the threaded portion with 2 . and add water to the specified level. and lock plates with new parts. dents. clean the part and remove all oil and grease. operate the steering. w Plug : 11. Replace all gaskets. bucket. When coating with gasket sealant. When tightening split flanges. coat the surface with antifriction compound (LM-P). Repeat this operation until no more air comes out from the plug hole. Clean all parts. then stop the engine and loosen air bleed plug (1) to bleed the air from the hydraulic tank. have been removed for repair. dirt.3 + 1.DISASSEMBLY Precautions AND ASSEMBLY for installation PRECAUTIONS WHEN CARRYING OUT OPERATION operations Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Run the engine to circulate the oil through the system.15 k 0. clean the connector to remove all oil. screw them fully. then connect securely. burrs. * When using the machine for the first time after repair or long storage. Coat rotating parts and sliding parts with engine oil. When press fitting parts.5 Nm (1. When connecting wiring connectors. 30-5 0 . Add the specified amount of grease (molybdenum disulphide grease) to the work equipment related parts. 2) Operate the work equipment stopping 100 mm from the end of its stroke. 4 Following this. Bend the cotter pin or lock plate securely.5 times. Bleeding air. 3) Next. and boom cylinders 3 . check that there is no deformation or deterioration. Install the hoses without twisting or interference. run the engine at normal speed. pumps and other hydraulic equipment removed for repair. and correct any damage. or water. such as hydraulic cylinders. If the hydraulic equipment has been removed and installed again.4 times to the end of their strokes.3 drops of adhesive. repeat the procedure in Step 3) to bleed the air. + For details. Run the engine to circulate the water through the system. alwavs bleed the air as follows: . When using eyebolts. tighten uniformly in turn to prevent excessive tightening on one side.

3rd 4th clutch A assembly 4 1 01010-51075 Removal.DISASSEMBLY SPECIAL TOOL LIST AND ASSEMBLY SPECIAL TOOL LIST Nature of work iymbol Disassembly. assembly axle housing assembly of 1 790-101-2910 Puller 2 790-101-2920 Bolt assembly: 2 790-101-2900 Removal D 3 790-101-2930 Nut 4 793-422-l Seal support 2-l - 30-6 0 1 set Puller 51 140 010 16-30840 793-422-~1~lder l Adjustment 2 2 bolt 6 1 1 of axle shaft bearing Holder for oil seal when press fitting oil seal IFor adjusting shim . Part t 1 793-305-I I 2 I 793-415-1210 3 793-415-l 793-415-I I Lifting tool 2 I Lifting tool 1 1 220 Lifting tool 1 150 Plate 1 Bolt 4 600 Remarks O’ty Name I Rear housing IFor F . differential assembly of assembly 130 C 120 Jig for settling Ist _ 4th piston seal I I 793-422-l F-R Mandrel 1 01011-01010 l Bolt 5 01643-32060 l Washer 5 l Joint 4 5 I mo-sol-1720 I III - Disassembly.R clutch For 1st 2nd. transmission assembly of Part No. parking 01580-11008 Nut 1 1 793-310-1300 Disassembly. assembly transmission clutch lifting tool installation brake 4 1 Stand i 11 ~1~~~::: of of disc installation of B pack assembly - 6 793-415-1250 Seal holder 1 7 793-415-I Seal holder ? I 1 Disassembly.

DISASSEMBLY Nature AND ASSEMBLY symbol of work SPECIAL TOOL LIST I Part No. 1 1 1 793-840-1310 I4 Installation hinge pin 792-103-0400 Part Name I Grip Remarks O’ty i 1 Push tool I I 7 I 1 of center Press fitting 1 6 1 793-520-2370 17 1 793520-2350 1 Push tool I ’ 1 Push tool I 1 8 783-520-2540 Guide 1 9 793-520-2360 Bar 2 790-502-I 003 Cylinder F of bearing repair stand 1 790-5~. assembly hydraulic cylinder Installation of of piston ring 1 Boom cylinder J 796-720-1690 Ring 1 07281-01919 Clamp 1 2 I ~ 796-720-1640 I Ring Bucket cylinder I 1 07281-00909 Clamp 1 790-101-5021 Grip 1 01010-50816 Bolt 1 790-201-1650 Plate 1 790-201-1560 I Plate I ’ Insertion of dust seal Kit Part No.: 790-201-1500 K I 30-7 0 .-2000 I 790-101-1102 G 1 790-330-1100 H Commercially available 790-101-5027 I 1 I Pump 1 Wrench ass’y I 1 Socket (width across flats: 46) ’ Grip 1 s Steering Removal. installation Steermg Removal.: 790-201-1702 B&j Disassembly. mstallatton Press fitting of coil bushing Kit Part No.

m INSTALLATION OF STARTING MOTOR ASSEMBLY l Carry out removal. 4. Disconnect wiring connector 5. Remove engine (-1 ter- hood side cover and lock in posi- starting motor (3). Disconnect hose (I 1.DISASSEMBLY AND ASSEMBLY STARTING MOTOR REMOVAL OF STARTING MOTOR ASSEMBLY ADisconnect the cable from the negative minal of the battery. . Disconnect wiring (2). Open tion. install ground connection (5) securely. assembly (4). 1. 2. 3. * 30-8 0 installation in the reverse order to When installing the starting motor assembly.

ING AND ADJUSTING. and adjustment plate mounting bolt (31. INSTALLATION OF ALTERNATOR ASSEMBLY l Carry out removal. a 5. J. 30-9 0 . in the reverse order to For details. and adjustment plate mounting bolt (3). 2. Mark the wiring with tags takes when assembling. the negative (-1 ter- hood side cover and lock in posi- Disconnect 3 set of wiring (I). Loosen mounting bolt and nut (2). installation Adjust the belt tension. m 4. see TESTTesting and adjusting To prevent interference with the fan belt. then remove alternator assembly (5). 1. set with the mount bolt and nut facing in the direction shown in the diagram on the right when installing. to prevent misDEW01348 3. Remove mount bolt and nut (Z). then remove fan belt (4) from alternator assembly (5). fan belt tension. Move alternator assembly (5) towards engine. Open engine tion.DISASSEMBLY AND ASSEMBLY ALTERNATOR REMOVAL OF ALTERNATOR ASSEMBLY ADisconnect the cable from minal of the battery.

Remove 4 nuts (6) from oil cooler cover assembly (51. Carry out removal. 30-l 0 0 . Remove oil filter and head assembly with tube (3). Disconnect 4. For details. Remove cooler cover assembly 6. Run the engine to circulate the water through the system. . Lift off engine hood assembly. 5. oil cooler XD DEW00010 INSTALLATION OF ENGINE COOLER ASSEMBLY . oil pressure sensor wiring (1). see REMOVAL OF FUEL INJECTION PUMP ASSEMBLY. (2) together pipe (41.DISASSEMBLY ENGINE AND ASSEMBLY OIL COOLER REMOVAL OF ENGINE OIL COOLER ASSEMBLY 1. then remove cooler (7). installation in the reverse OIL order to Refilling with water Add water through the water filler to the specified level. 3. Remove fuel injection pump assembly. then remove (5). 2. Then check the water level again.

DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP REMOVAL OF FUEL INJECTION PUMP ASSEMBLY 1. Remove mounting bracket (14) at rear of fuel injection pump assembly (13). Disconnect stop motor cable (2) and remove gether with mounting bracket (3). Disconnect * cable (4) and remove bracket (5). Disconnect accelerator gether with mounting to- 4. 6. to- 3. and rea D&VOX07 30-l 1 0 . bend it and tie with wire to prevent fuel from leaking m out. 2. Disconnect 6 fuel injection move lubrication tube (12). remove front mounting bolts. then remove fuel injection pump B assembly (13). 5. After disconnecting hose (IO). (6) tom fuel hoses (9) and (10). Remove fuel filter and head assembly gether with hoses (7) and (8). pipes (II). 7. Remove boost compensation tube (1).

3 kgm) -w w .6 f 2.8 Nm (6.9 Nm (3.9 Nm (3.4 + 4. ing and adjusting fuel injection timing.7 + 7. Carry out removal installation in the reverse order to m w Joint bolt : 29. 30-12 0 Test- .9 Nm (2.3 f 0.5 kgm) m Fuel injection pipe sleeve nut : 22.DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY . For details. Mounting bolt of fuel injection pump assembly : 66.8 f 0.0 f 0.4 + 4.5 kgm) w Joint bolt : 29.0 F 0.8 kgm) Adjust the injection timing. see TESTING AND ADJUSTING.

Remove radiator fan guard (2). 5. fan belt tension. installation in the reverse order DBhWOl3 to a Adjust the belt tension.WATER PUMP DISASSEMBLY AND ASSEMBLY REMOVAL OF WATER PUMP ASSEMBLY Serial No.52999 1. ING AND ADJUSTING. 30-l 3 0 . 8. upper tube (I). 50001 . 3. Loosen adjustment bolt (7) and mount bolt (8) of alternator assembly (61. Drain engine 2. l For details. then remove sensor connector housing assembly (31 (5). 4. I INSTALLATION OF WATER PUMP ASSEMBLY l Carry out removal. and remove water pump assembly 7. then remove mounting bolts. Remove fan (IO) and spacer (11). see TESTTesting and adjusting Refilling with water Add water through the water filler to the specified level.Run the engine to circulate the water through the system. Loosen clamp of hose (12). Remove water temperature from clip and disconnect. Remove thermostat 6. (13). Remove spill hose (4). Then check the water level again. then move alternator assembly (6) towards a frame. remove adjustment bolt. coolant.

Testing and adjusting fan belt tension. in the reverse order to m . 2. Drain engine coolant. then move alternator assembly (6) towards a frame. INSTALLATION OF WATER PUMP ASSEMBLY . 6. 5.DISASSEMBLY WATER PUMP AND ASSEMBLY REMOVAL OF WATER PUMP ASSEMBLY Serial No. Then check the water level again. Remove thermostat housing assembly (5). remove adjustment bolt. For details. Remove spill hose (4). 7. Remove fan (10) and spacer (III. 8. see TESTING AND ADJUSTING. and remove water pump assembly (13). Adjust the belt tension. Loosen clamp of hose (12). 3. Remove water temperature sensor connector (3) from clip and disconnect. 30-l 3-l 0 w DBWOCO14 . Carry out installation removal.Run the engine to circulate the water through the system. 53001 and up 1. Refilling with water Add water through the water filler to the specified level. Loosen adjustment bolt (7) and mount bolt (8) of alternator assembly (6). then remove mounting bolts. Remove radiator upper tube (I). then remove fan guard (2). 4.

4. Remove muffler assembly (21. 3. Carry out installation removal. Remove intake hose (I).9 + 0. and rea move turbocharger assembly (5). m m 30-14 0 Turbocharger mounting bolt : 37.8 kgm) .DISASSEMBLY TURBOCHARGER AND ASSEMBLY REMOVAL OF TURBOCHARGER ASSEMBLY 1. m INSTALLATION OF TURBOCHARGER ASSEMBLY .8 Nm (3.8 t 0. Disconnect lubrication return tube (4). then remove lubrication inlet tube (3). 2.3 + 7.05 kgm) Insert hose (I) until it contacts the turbocharger flange. in the reverse order to ‘m m * Intake hose clamp : 8. Lift off engine hood assembly.43 Nm (0.8 f 0.

9 Nm (2. Lift off engine hood assembly. Remove intake connector. 4 .5 kgm) 30-l 5 0 .3 5 0. Remove spill holder (5).15 f 0. then remove nozzle J -1 ) %3 4 DEW01374 INSTALLATION OF NOZZLE HOLDER ASSEMBLY .5 Nm (0. w w installation in the reverse order to Fuel injection pipe sleeve nut : 22. 3. Remove fuel injection 4.5 ? 0.DISASSEMBLY NOZZLE HOLDER AND ASSEMBLY REMOVAL OF NOZZLE HOLDER ASSEMBLY 1.05 kgm) /12 w Holder mounting bolt : 44.9 Nm (4. 11 m (3). * Remove the intake connector only when removing the No. Carry out removal.nozzle holder assembly. hoses (41.1 + 4.5 f 0. 2.6 f 2. pipes (I) and lead (2). Remove holder 5.3 kgm) Lead mounting nut : 1.

Drain engine coolant. Open engine hood side cover. Remove 4. spill hose (4) securely. * Do not disconnect 5. Then check the water level again. Run the engine to circulate the water through the system. Remove cover (2). Carry out removal.DISASSEMBLY THERMOSTAT AND ASSEMBLY REMOVAL OF THERMOSTAT ASSEMBLY 1. thermostat INSTALLATION THERMOSTAT . installation the hose. OF ASSEMBLY in the reverse order to m Clamp . 3. m (3). 30-l 6 0 . Refilling with water Add water through the water filler to the specified level. Remove connector (1) from clip and disconnect. 2.

Remove radiator upper tube (1). so after removing the connector. 7. Serial No.DISASSEMBLY CYLINDER HEAD AND ASSEMBLY REMOVAL OF CYLINDER HEAD. and remove air cleaner assembly (I 1) together with mounting bracket. loosen clamp of hose (41.53001 Lift off engine hood assembly. Remove muffler assembly (8) together with bracket.52999 I Serial No. L DBW00023 DBWOOOZO DBWOO021 DBWOOO22 . 8. DUW0507' 4. then remove thermostat connector (5). a Remove intake hose (9). 5. 3. and up J DBWOOOt9 Remove mounting bracket (7) at top of water pump assembly.50001 . secure hanger (6) with the bolts. 6. DUW05072 I . * Thermostat connector (5) is tightened together with the cylinder head hanger. ASSEMBLY 1. * There are 4 spacers between the mounting bracket and the exhaust manifold. so be careful not to lose them. 9. Disconnect dust indicator connector (IO). Remove water temperature sensor connector (2) from clip and disconnect. 2. Drain engine coolant. Disconnect spill hose (31.

12. Remove air supply connector (12). Loosen clamp of turbocharger lubrication tube joint hose (141.DISASSEMBLY AND ASSEMBLY CYLINDER HEAD 10. Disconnect oil pressure sensor wiring (17) and relay wiring (181. and remove turbocharger lubrication inlet tube (13). 0. and 0. Disconnect wiring harness clamps 0. then remove turbocharger and exhaust manifold assembly (16). 13. DBWOOOX 14. 11. pull out the tube from the turbocharger and exhaust manifold assembly. then disconnect heater relay connector (19) from clip. and disconnect lubrication return tube (15) from turbocharger. m +r After removing together with the lubrication return tube. 30-l 8 0 . Remove mounting bolts.

Loosen nut of No.DISASSEMBLY AND ASSEMBLY CYLINDER HEAD 15. 5 and 6 fuel injection (251. 17. clamps (28) and (29) of No. Disconnect heater relay wiring (23). and move it towards frame. and remove boost compensation tube (21). I w DBWOOO31 . Disconnect clamp of wiring harness (20) from intake manifold. 16. 1 . 19. and remove 20. (24).3 fuel pipes (27). Remove mounting bolts of fuel filter assembly (221. Remove injection pipes clamp (26). Remove oil filter and tube assembly 18.

* Spill hoses: 25.. 25. . m (29). Remove spill hoses (30) and nozzles (31).DISASSEMBLY AND CYLINDER ASSEMBLY HEAD 21. 24. then remove intake m manifold (31).’ 22. 5 and 6 fuel injection pipe from intake manifold. Remove holders -I DBW00032 pipes (25) and (27). Remove clamp (30) of No. Remove fuel injection 23. Remove 5 leads (28). nozzles: 6 \ \ ‘I DBW0003b DBW00035 30-20 .

Remove rocker arm assembly (33).3 turns. DBW00039 29. m * Loosen the locknut and turn the adjustment screw back 2 . 28.DISASSEMBLY AND ASSEMBLY CYLINDER 26. m 30-2 1 0 . a HEAD 32 27. Remove 12 push rods (34). Remove cylinder head assembly (35). Remove head cover (32).

9 f 0.8 -+ 4.5 k 1. in the reverse order to w * Hose clamp : 8.8 Nm (2.) Fuel injection pipe Sleeve nut : 22.7 + 9..0) 63.9 Nm (2.15 + 0.1 kgm) m m 30-22 0 I DEW01399 .0) Mounting bolt of after-cooler assembly: 24.8 (6. the length of the other bolts is 80 mm.3 i 0. Tightening torque: m w Tightening 1st step O-0 2nd step 0-Q 3rd step O-0 m m w order Tightening torque DEW01398 1 (Nm (kgm)) 14.@ shown in the diagram on the right.3 kgm) m w Lead mounting nut : 1.5 f 9. Carry out installation removal.0 Nm (0.5 + 0.7 I 9.5 _+ 0.9 Nm (4.DISASSEMBLY AND ASSEMBLY CYLINDER HEAD INSTALLATION OF CYLINDER HEAD ASSEMBLY . * Tighten the bolts in the order 0 .1 f 4.8 + 1.8+ 0. The length of the bolts marked ‘.9 f 0.5 kgm) B Mounting bolt of cylinder head cover : 8. is 60 mm.05 kgm) w Mounting bolt of nozzle holder : 44.0 kgm) (Only the bolts marked ‘:: in the diagram on the right.6 f 2.05 kgm) Insert the hose until it contacts the turbocharger flange.5) 63.5 + 1.5 Nm (0.9 (1.5 + 0.5 i 1.8 (6.5 Nm (0.

0) After tightening.DISASSEMBLY m * * * m m a m AND ASSEMBLY * HEAD Tighten the mounting bolts and nuts in turn. Check that the ball of the adjustment screw is fitted securely in the socket of the push rod. For details. see TESTING AND ADJUSTING.5 + 0. Mounting bolt: Anti-friction compound (LM-P) Cylinder head mounting bolt: Tightening 1st CYLINDER steo torque Order tightening head bolts Intake side Front Rear flj Exhaust side DEW01 400 @Jr-n (kgm)) 98 f 9. When installing the gasket.5 kgm) Locknut : 44.9 Nm (2.5 + 4.5 + 0.5 kgm) If any rust of more than 5 mm square is found on the shaft or the thread of the bolt. Rocker arm mounting bolt. nut : 24.8 (IO + 1. r DEW01401 30-23 0 .9 Nm (4. Adjust the valve clearance. Tighten the cylinder head mounting bolts 2 . starting from the center and working to the outside. Then check the water level again. check that the grommets have not come out. then tighten in the order given in the diagram.3 turns by hand. Be careful to check that there is no dirt or dust on the mounting surface of the cylinder head or inside the cylinder. Refilling with water Add water through the water filler to the specified level.1 + 4. Run the engine to circulate the water through the system. do not reuse it. Replace it with a new bolt. make one punch mark on the bolt head to indicate the number of times it has been tightened. Adjusting valve clearance. If any bolt already has five punch marks. replace the head bolt with a new bolt.

g Release the remaining pressure in the piping. then stop the engine. 1. A Disconnect the cable from the negative (-)terminal of the battery. check that the whole bottom surface of the bucket (both portion a and portion b) are in contact with the ground. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. it correctly. After operating the levers. bolts. then remove I DEW00447 in- Loosen plugs (2) at top of hydraulic tank filter and plugs (3) of pump piping to prevent oil inside tank from flowing out. I 2. Ir If the colant contains antifreeze. _ mWOlE65 - u Drainmg water Loosen drain valve (4) and drain coolant. Then operate the control levers several times to release the . Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. Cover 1) Remove spection 2) mounting cover (I). When operating the levers. dispose . raise portion a of the bucket 30 . remaining pressure in the hydraulic piping.50 mm and lower portion b to the ground. Lower the bucket to the ground and stop the engine.DISASSEMBLY AND ASSEMBLY RADIATOR REMOVAL OF RADIATOR ASSEMBLY AStop the machine on level ground and install the safety bar on the frame. ti . & Coolant : 53 e of DLWOlS6 30-24 0 .

then fit grill to engine hood (6) temporarily. then connect to lifting chain and lift at 4 points. Engine hood 1) Remove radiator left and right plates (9) and bottom cover (IO). * To prevent the water from leaking out of the sub-tank. 2) Pass nylon rope @ through left and right hinge portions of side panel (81.DISASSEMBLY 3. * Remove the sub-tank hose and wirings (14) from the radiator clip. DLWO1868 3) Remove the front. Hood assembly : 200 kg (without rear fender) Hood assembly : Lelkg 260 kg (with rear fender) * Thread size when using eyebolts for removal : 12 mm &I kg 5. and remove grill (5). MWO1870 . * Open left and right side panels (8) to make it possible to fit the lifting tool. rear. and remove light wiring from clip portion of engine hood (6). AND ASSEMBLY RADIATOR Grill 1) Loosen mounting bolts of grill (51. 2) Disconnect wiring connector (71. * Be careful that the lifting tool does not come off. left. 4. Disconnect hose (13) between radiator and sub-tank at radiator end. bend the tip of the hose and fix it with a band. and right mounting bolts and top front mounting bolts of engine hood (6). Wiring 1) 2) Disconnect wiring connector (12) for radiator water level sensor. * Fit the lifting tool with the exhaust pipe still installed.

_ 2) Remove fan guard (16). (211% I (22) at connection portion of tube at bottom of radiator. 2) Disconnect radiator lower hose (18) at radiator end. * Loosen the hose clamp of the connection portion at the radiator end. el kg * 30-26 0 Radiator : 166 kg Be careful not to damage when removing. stay m I) Remove mounting bolts of radiator stay (15) at radiator end. 8.DISASSEMBLY AND ASSEMBLY RADIATOR 6. f Be careful not to damage the radiator fins when removing. 9. the radiator fins . * Mask the openings to prevent water or dust from entering. Radiator Remove a mounting bolts of radiator (23) and lift Off. 7. Hydraulic piping Disconnect oil cooler hoses (19) I (20) . Fan guard. Radiator hoses m 1) Disconnect radiator upper hose (17) at engine end.

25 kgm) Install the fan guard so that the clearance between the fan and fan guard is uniform. -1 Tighten plug at top of hydraulic tank filter and plug of pump piping. Refilling with oil 1) Tighten drain valve and add transmission oil through oil filler to the specified level.0 + 5. Then check the oil level again. f B Temporarily install the radiator stays.6 Nm (18.3 Nm (11. 30-27 0 .0 kgm) m4 Ir m (width across flats: 41 mm) 115 f * * w * .6 + 0. 2) %a Transmission : 35 .Q. Install so that the clearance from the fan is uniform. Be careful not to damage the radiator fins.3 f 12. Radiator mounting bolt : 176 f 19. Joint nut : 196 + 49 Nm (20. Install the radiator from the counterweight slowly.25 f 1. m * 113 w Hose clamp : 5.05 kgml * Fit the O-ring securely into the groove and be careful that it does not get caught when assembling. then add hydraulic oil through oil filler to specified level. Then check the water level again. k Run the engine to circulate the oil through the system.0 kgm) Tighten the mounting bolts of the radiator stay fully.5 Nm (0.DISASSEMBLY INSTALLATION ASSEMBLY l Carry out removal. RADIATOR AND ASSEMBLY OF RADIATOR installation in the reverse order to m * Run the engine to circulate the water through the system. Mounting bolt : 110.9 + 0.0 + 2. Install the hoses without twisting or interference.

DISASSEMBLY AND ENGINE ASSEMBLY REMOVAL OF ENGINE ASSEMBLY AStop the machine on level ground and install the safety bar on the frame.50 mm and lower portion b to the ground. 3. * Fit a blind plug in the heater hose to prevent antifreeze from flowing out. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. After operating the levers. see REMOVAL OF RADIATOR ASSEMBLY. 2. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. then disconnect. 3) Remove rubber (9) at bottom of bulkhead. see REMOVAL OF AIR CONDITIONER COMPRESSOR. (6) installed to radia- 2) Disconnect heater hose (8) from right side of engine assembly (7). Lower the bucket to the ground and stop the engine. t Loosen connecting hose clamp (5) of radiator lower tube (4) at engine end. For details. then remove mounting bolts (3) and put the compressor assembly on top of the fuel tank. raise portion a of the bucket 30 . ARelease * * * the remaining pressure in the piping. ADisconnect the cable from the negative minal of the battery.hose tor lower tube (4). When operating the levers. then stop the engine. (-1 ter- m Air conditioner compressor assembly * Remove air conditioner compressor. Heater hoses 1) Leave left heater. Ir Leave air conditioner hoses (I) installed to compressor (2). check that the whole bottom surface of the bucket (both portion a and portion b) are in contact with the ground. Then operate the control levers several times to release the remaining pressure in the hydraulic piping. For details. II 30-28 0 C&O1678 . 1. Radiator assembly m + Remove radiator assembly.

and (19) from fuel tank end. I) Disconnect slow blow fuse wirings (I 0) from slow blow fuse (II). * Disconnect from the connectors at the bottom right side of the bulkhead. . f When disconnecting the wiring. * When disconnecting the hoses. (18). Electric wiring ENGINE m Disconnect the following electric wiring. Ir Disconnect the hose clamps and bands. fit tags to distinguish them.DISASSEMBLY AND ASSEMBLY 4. Fuel hoses a Disconnect fuel hoses (17). DBWOlE81 5. Starting DEW01879 2) Disconnect engine wiring (12) from connectors (13) and (14). * Disconnect the connectors of the fuel tank level sensor wiring. * Remove the bracket for the transmission valve wiring from the engine housing portion. 3) Disconnect cable (15) between starting motor and battery relay from starting motor end. 4) Disconnect ground connection wiring (16). fit tags to distinguish them.

7. AND ENGINE ASSEMBLY a Fuel control cable Remove locknut of fuel control cable (20). * Loosen the hose lock U-bolt. oil cooler a the mounting Transmission support stand Set. make match marks to act as a guide when assembling.support stand @ under transmission. 30-30 0 . Drive shaft Remove rear drive shaft (27). * Use a stand with adjustable height and fix it securely so that it does not slip.. 8. 9. * Adjust to the correct height. Ir Before removing the locknut. then remove hose bracket (26) from engine.DISASSEMBLY 6. * Make match marks to show position. then remove. Oil cooler hose bracket Remove mounting bolts.

and disconnect hose from air cleaner.DISASSEMBLY AND ASSEMBLY ENGINE 10. then lift off muffler together with bracket (36). remove left and right mounting bolts. Air cleaner assembly 1) Disconnect electric wiring of dust indicator (28) from connecting portion. Ir Fit a cover to prevent water or dust from entering. so be extremely careful when removing the air cleaner assembly. DEW01888 3) Loosen clamp (32) of air cleaner hose (31). * Disconnect the hose at the turbocharger end. + It is difficult to stand. * It is difficult to stand. * Remove the hose at the turbocharger end to make it possible to fit the lifting tool to hook a. * When removing the muffler. 2) Remove clip (30) from electric wiring (29). DEW01890 11 Muffler assembly Sling muffler (35). r”llkg Muffler assembly (with bracket) : 30 kg . and lift off air cleaner assembly (34). be careful not to damage drain tubes (37). I 4) 32 DEW01889 Remove mounting bolts of air cleaner bracket (33). so be extremely careful when removing the muffler.

so when raising the engine.DISASSEMBLY AND ASSEMBLY ENGINE 12. i To prevent the drain valve from catching on any other part when the engine assembly is removed. be sure to keep it horizontal. and remove left and right mounting bolts (39) of engine. 30 mm to rear. raise it and tie it in position with wire. keep horizontal. 2) Remove connecting bolts (41) of engine and torque converter assembly (40). * When slinging the engine. * When raising the engine assembly. 30-32 0 A-7 I DBWO169S . Engine assembly m 1) Sling engine assembly (71. t Check the way that the cushion and spacer are installed and use for reference when installing. &I kg Engine assembly F : 730 kg . * The engine flywheel ring gear and torque converter ring gear and shaft are meshed. Engine oil drain valve Remove engine oil drain valve assembly (38) from fuel tank. I DBWOl893 13. check that there is no interference. be sure to keep it horizontal. coil’the hose. then lift off engine assembly (7). 3) After removing all connecting bolts (411. move approx.

B Filter top plug : 11.1 kgm) Washer Cushion Cushion .3 Nm (11.8 f 1. Ir Fit the rubber cushion securely into the groove of the bracket. see INSTALLATION TOR ASSEMBLY.0 * 6. Never use force to connect them.0 Nm (1. Connect curely.0kgm) (width across flats: 32 mm) Refilling with hydraulic oil Tighten the plug at top of the hydraulic tank filter and add hydraulic oil through the oil filler.3 f 12. & Outside circumference of O-ring : Soapy water Jr Be careful of the direction of assembly of the rubber cushion. * When connecting the engine to the torque converter. adjust the height so that the torque converter pilot can enter smoothly. mesh the pilot securely.2 f 0. Install radiator assembly.Washer DRW”lRq7 -’ DEW01898 L 30-33 0 . installation ENGINE OF ENGINE in the reverse order to Install air conditioner compressor. the electric wiring Match the distinguishing the hoses. clean the mating surface of the spider and the coupling. For details.25 kgm) I%7 * l Check that there is an O-ring at the torque converter mating surface. for details When connecting the drive shaft. Mounting bolt : 110.DISASSEMBLY AND ASSEMBLY INSTALLATION ASSEMBLY l Carry out removal.25 f 1. see INSTALLATION OF AIR CONDITIONER COMPRESSOR. m Mounting bolt : 549 f 58 Nm (56. and install. For details. t Position the engine properly. z 2 3 B OF RADIA- connectors se- tags and connect See TESTING AND ADJUSTING of adjusting the cable length.

Hydraulic piping Disconnect the following hydraulic . Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. transmission inspection cover (2). fuel control cable 2. DLWOlEB 3. Lower the bucket to the ground and stop the engine. Cover Remove cover (1) at bottom of cab. . and side inspection cover (3). strainer and Hose (7) between charging pump and torque converter oil filter Hose (8) between charging pump and top of transmission t Disconnect the tubes and hoses from the pump end. * Open the left inspection cover and apply the lock. 1. Air conditioner Remove clamp of air conditioner hose (4). hose.DISASSEMBLY TORQUE AND ASSEMBLY REMOVAL OF TORQUE CONVERTER CHARGING ASSEMBLY CONVERTER CHARGING PUMP PUMP AStop the machine on level ground and install the safety bar on the frame. and raise air conditioner hose and fuel control cable (5) with wire. 8 7 . 30-34 0 piping. Tube (6) between transmission charging pump .

DISASSEMBLY 4. + Carry out the removal operation with two workers. and pull out torque converter charging pump (9) from cover removal portion. AND ASSEMBLY TORQUE CONVERTER CHARGING Torque converter charging pump PUMP m Remove mounting bolts. and fit lifting tool @ to prevent the pump from falling. installation in the reverse order 7 / - DLWOlW2 DLWO1903 to Check that there is an O-ring at the mating surface with the housing. Fit the O-ring securely in the groove and be careful not to get it caught when assembling. so be careful not to crush your hands or fingers. 30-35 0 . el kg Torque converter charging pump : 10 kg INSTALLATION OF TORQUE CONVERTER CHARGING PUMP ASSEMBLY l Carry out removal. * The working space is confined.

. 2 FLOOR I 1 DBWO1904 Remove bulkhead assembly as follows. 2. 3. OF CAB. ADisconnect the cable from the minal of the battery. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. negative (-) ter- Loosen plugs (I) at top of hydraulic tank filter and plugs (2) of pump piping to prevent oil inside tank from flowing out. m 1) Disconnect air conditioner connector (3).DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER. 2) Disconnect air conditioner hose (4). Drain transmission oil. TRANSMISSION REMOVAL OF TORQUE CONVERTER. ALoosen the oil filler cap slowly to release the pressure inside the hydraulic tank. 3) Disconnect 2 reservoir tank hoses (5). see REMOVAL FRAME ASSEMBLY. 1. Then operate the control levers several times to release the remaining pressure in the hydraulic piping. assembly. Remove cab and floor frame For details. 3 I DBWO1905 5 30-36 0 4 I DBW01406 . TRANSMISSION ASSEMBLY AStop the machine on level ground and install the safety bar on the frame. 4) Disconnect breather hose (6).

TRANSMISSION mounting bolt. transmission cooler hose (13). m * The hose flange and spacer are tightened together. 5. (141. DBWO1908 4. remove then remove bulkhead. I . Sling hydraulic and steering pump assembly remove mounting bolts.DISASSEMBLY AND ASSEMBLY 5) Sling bulkhead (71. 6. TORQUE CONVERTER. Disconnect hoses (11) and (12) mounted at bottom of hydraulic and steering pump. then lift off. Remove hose clamp (81. then remove pipes (9) and (IO) at top of hydraulic and steering pump. so be careful not to lose them when disconnecting hoses (11). Disconnect 7.

Remove nect. Remove + 30-38 0 front drive shaft (20). Disconnect 13.DISASSEMBLY TORQUE CONVERTER. Disconnect (17) from DBwo1912 clip and discon- hoses (18) and (19). 3 connectors valve and cooler (16) from clip and discon- I 10. TRANSMISSION AND ASSEMBLY 8. 9. DBWO1913 12. Disconnect tube (15) between at transmission valve end. Remove nect. connector 11. Be careful not to let the coupling m fall out. . rear drive shaft (21).

* When raising. * Make match marks on the mount bracket and rear frame mount. Set block @ between flywheel. remove jeft and right mounting bolts (251. jl E: z 3 I I-’ 24 28 27 DBWo1917 17. m &I kg Torque converter. * Measure the clearances of clearance adjustment bolt (28). then measure the protrusion of the positioning bolt. and use it as a guide when assembling. taking care not to hit rear frame. Sling torque converter and transmission lXWO1916 I assembly.DISASSEMBLY AND ASSEMBLY 14. Lift off torque converter and transmission assembly (29). TRANSMISSION rear axle (22) and engine engine (23). and support TORQUE CONVERTER. Remove oil filler tube (24). 2i 15. then remove spacer (26) and cushion (27). transmission assembly: 700 kg 30-39 0 . 16. be extremely careful of the meshing of the engine and torque converter gear.

DISASSEMBLY TORQUE AND ASSEMBLY CONVERTER. Drive shaft mounting bolt : 110. Mounting bolt (25) : 549 k 59 Nm (56. F/PI w m .0 f 6. J.1 f 2. I h’ 24 28 27 DBWO1917 28 DEW01919 30-40 0 .5 Nm (2.0 + 6. Then check the oil level again. installation in the reverse order to Air conditioner hose sleeve nut : 22. Run the engine to circulate the oil through the system.25 kgm) m pKJ * When connecting the 3 hoses at the bottom of the hydraulic and steering pump. Carry out removal. Ir Assemble the cushion so that the chamfered surface is on the spacer side. When assembling the cushion. then align the tooth groove of the ring gear and connect to the engine.level. check the hose and spacer mount O-rings for damage and deterioration before installing. TRANSMISSION INSTALLATION OF TORQUE CONVERTER. TRANSMISSION ASSEMBLY . fit securely in the groove. do not use oil or soapy water under any circumstances.3 + 12.25 + 1. 4) Adjust clearance of clearance adjustment bolt (28).2 mm w Clearance adjustment nut : 549 + 59 Nm (56. I) Replace the O-ring at the mating surface of the engine and transmission with a new part. 3) Tighten mounting bolt (25) temporarily.0 kgm) m w .25 kgm) Position torque converter and transmission assembly as follows.0 kgm) Refilling with oil Add transmission oil to the specified . 2) Assemble cushion (27) and spacer (26).3 Nm (11.25 fr 0. (4 places) Ir Standard value for clearance a of clearance adjustment bolt : 1 .

-2 DEW00529 2) Disassemble follows.DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER DISASSEMBLY OF TORQUE CONVERTER ASSEMBLY 1. case assembly 1) Remove stator shaft and pump assembly from turbine and case assembly (2) (3). snap ring (51. i) Remove ii) Remove turbine and case assembly as 4 pilot (4). VI Remove bearing (8) from case. 6 18 DEW00534 . DEW00530 iii) Push boss portion of turbine move from case (7). Turbine. then remove plate (1). (6) and re- iv) Remove mounting bolts and disconnect ttirbine (6) and boss (18).

Bearing Remove bearing (15) from gear (13). Stator shaft Using forcing screws 0. 5. 4. Gear Remove gear (13) from pump (14). (11) end and disconnect push from stator shaft from pump assembly (121. AND Stator 1) Remove 2) Remove ASSEMBLY TORQUE CONVERTER snap ring (9).DISASSEMBLY 2. DEW00535 3. stator (IO). DEW00538 30-42 0 .

75 + 0. Stator shaft 1) 6 * 2) Install seal ring (16) to stator Seal ring: Grease (G2-LI) Make the protrusion of the form. seal ring uni- Push inner race of bearing and install pump assembly (12) to shaft (II). DEW00533 2.DISASSEMBLY TORQUE CONVERTER AND ASSEMBLY ASSEMBLY OF TORQUE CONVERTER ASSEMBLY 1. 13\ Bearing install bearing (15) to gear (13).4 Nm (6.2 f 7. DEW00541 . Gear Install gear (13) to pump (141. Mounting bolt: 66.75 kgm) m 3. shaft (II).

* Press fit the bearing until it contacts the case. 8 DEW00543 ii) Install boss (18) to turbine (6). Mounting bolt: Thread tightener (LT-2) Mounting bolt: 66. case assembly 1) Assemble turbine and case assembly as follows. and install I 30-44 0 DEW00545 .2 k 7.75 + 0. TORQUE CONVERTER Stator I) 2) 5.4 Nm (6. Turbine.DISASSEMBLY 4. AND ASSEMBLY Install stator (10).75 kgm) 6 18 DEW00533 iii) Push inner race of bearing turbine (6) to case (7). i) Install bearing (8) to case. Install snap ring (9).

35 kgm) DEW00529 30-45 0 .15 + 0.DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER iv) Fit plate (I) and install snap ring (5).9 k 3.4 Nm (3.4 Nm (3.9 ?I 3. a Mounting bolt: VI Thread tightener w (LT-21 Mounting bolt: 30.15 +_0. a Mounting bolt: (3) to stator Thread tightener w DEW00530 (LT-2) Mounting bolt: 30. Install pilot (4).35 kgm1 DEW00531 2) Install turbine and case assembly shaft and pump assembly (2).

2) Remove charging pump (IO). rear coupling Remove oil filler (I) and rear coupling (2). 3. &I kg Transmission DBWW172 control valve assembly: 45 kg -6 DBwoo173 4. 2) Remove tube hose (4) between verter filter and transmission transmission valve. Hydraulic piping I) Remove. 3) Lift off transmission control valve (7). Oil filler. * Remove the tube clamps. strainer and torque convalve from Transmission control valve 1) Remove modulation valve (5). Charging pump I)’ Remove hoses and flanges (8) and (9) from charging pump (IO) and housing. 2) Remove accumulator valve (6).tube hose (3) between charging pump. TRANSMISSION OF ASSEMBLY Remove the left and right mount brackets from the transmission assembly first. DLww170 2.DISASSEMBLY AND ASSEMBLY DISASSEMBLY TRANSMISSION . 1. * Lower the transmission assembly and install it to the assembly stand. * Leave the upper valve and lower valve assembly set bolts installed. DBWOO174 30-46 0 .

+ Remove slowly and be careful not to damage the seal ring. Ir Be careful not to crush the tube during the operation. * Install tool Al securely so that it does not come off. 2) Install tool Al to rear housing (14) and sling. Oil filter 1) Remove mounting bracket of oil filter (121. Al 14 DBWO0177 3) Using forcing screws. raise rear housing (141.DISASSEMBLY 5. Remove clamp of hose (9). filter. DEWCOY 6. * When removing. Rear housing 1) Remove torque converter pilot cap (13). I+ kg Rear housing. and hose. torque converter assembly : 190 kg _. then use tool Al to lift it off. install a guide bolt to front housing (151. then remove together with bracket. * After removing the tube.-A1 15 DBwm178 30-47 0 . then lift off horizontally. 176 7. TRANSMISSION AND ASSEMBLY Hydraulic piping I) 2) Remove PTO lubrication tube (11). fit a cover to protect the thread.

18 22’ DLWWlF3 17 3) 30-48 0 Insert screwdriver between rear housing (14) and shaft (221. Pump (torque converter. Lift off torque converter (16) from rear housing (14). remove snap ring (19) of pump gear (181. rel kg Torque converter Rear housing assembly : 55 kg : 135 kg \ / 9. * i3efore removing.DISASSEMBLY 8. AND ASSEMBLY TRANSMISSION Torque converter . use a felt pen to make match marks on the mating surface of the housing and torque converter. then remove ring washer (20) and split spacer (21). 16 ’ DEW00179 converter DEW@3180 2) Turn over rear housing (141. loader) I) Remove snap ring (17) at torque pump mount. then lever shaft and push down to remove. DBWOO182 .

then move towards 2nd. 4th. 3rd clutch (26) together from housing bearing. and 1st. 4th clutch output shaft. 2nd. * Remove lst. 25 2) Using tool A3. 3rd clutch (26). REVERSE side. Seal ring Remove seal rings (24) from each clutch shaft. 23 10. 3rd clutch : 47 kg DBW00185 . * Carry out the same procedure at the loader pump end.DISASSEMBLY 4) AND ASSEMBLY TRANSMISSION Remove bearing (23) from shaft (22). 4th clutch (25) and Ist. & kg Ist. then move towards FORWARD. f Remove slowly and take care not to hit any other gear. lift off lst. 3rd clutch 1) Remove 2nd. I 24 DBW00165 11. 3rd clutch from bearing.

3rd outer bearing (29). 14. Bearing I) Remove FORWARD. REVERSE clutch : 44. REVERSE clutch (27). Idler gear 1) Remove snap ring (31). REVERSE outer bearing (28). lift off 2nd. FORWARD. REVERSE clutch 1) Using tool A2.1 kg 13. LL Be careful not to get your fingers caught between gear (32) and the housing. 4th clutch (25). pull out FORWARD. . lst. then gear (32) from housing.DISASSEMBLY 3) TRANSMISSION AND ASSEMBLY Using tool A3. &I kg 2nd. 2) 30-50 0 remove idler Remove snap ring from idler gear (32). then remove bearings (33). and 2nd. 4th outer bearing (30) from housing. &I kg FORWARD. 4th clutch : 54 kg 25 DBW00188 12.

oil seal Remove dust seal (34) and oil seal (35). 3) 40 front lock Remove mounting bolts. 6) Tighten tool A4 with coupling mounting bolts. * Bolt length of tool A4: 64 mm 7) Remove snap ring (44). 2) Remove 39- mounting bolts. then remove cover (40) and gasket (40-I). remove tool A4. then remove plate (38) and manual cancel bolt (39).DISASSEMBLY AND ASSEMBLY TRANSMISSION 15. Parking brake assembly * Turn over the front housing. then remove end plate (45). 16. 4) Remove dust seal (41) and oil seal (42) from cover (40). 5) Install manual brake housing condition. 38 40-I DBWoo193 cancel bolt (39) to parking (43). and O-ring. holder (37). * There is a dowel pin.unting bolts. then remove coupling (36). Rear dust seal. I) Remove mo. and set piston in FREE DBWW194 44 45 Df3WWlSS 30-5 1 0 . so use forcing screws to remove.

I 30-52 0 DLWM199 . 46 I 9) Set guide bolts (43-I) to parking brake housing (431.75 mm. (12 mm.75 mm) el kg Parking brake housing : 21 IO) Turn over parking brake housing remove O-rings (51) and (52). * Guide bolt : (12 mm. * Loosen the mounting bolts uniformly a little at a time. and discs (48). pitch 1.DISASSEMBLY 8) AND ASSEMBLY TRANSMISSION Remove separate plates (46). pitch: 1. then remove hub (49) and spacer (50). then remove mounting bolts. ’ kg I‘i DEW00197 (43) and 52 DBW00199 11) Remove piston (53) and snap ring (54) from parking brake housing (43). -ir Remove the manual cancei bolt. wave springs (47). length: 130 mm) * Install the lifting tool. and lift off.

DISASSEMBLY 12) Remove piston AND ASSEMBLY piston (53). * Remove guide bolts (43-l). * Check the number and thickness of the shims (61) and use for reference when assembling. then remove parking brake retainer (60). seal rings TRANSMISSION (55) and (56) from 53 13) Remove springs (57) and (58) from brake retainer. Parking brake retainer I) Remove mounting bolts (59) from front housing. cup (62) from parking brake DBWW202 . 56 parking I 5758 17. 60 62 DLWCU205 2) Remove retainer bearing (60).

Output I) TRANSMISSION shaft gear Support remove * AND ASSEMBLY output shroud shaft (63) from outside. hand on the 64 3) 30-54 0 Remove towards position snap ring (65) from groove. * Be careful not to cut your edge of the shroud. move center. and (64). Fit a cover to the shaft spline to prevent damage to the oil seal.DISASSEMBLY 18. then move gear (66) to same as snap ring. . Cover DBWCO207 2) Remove shroud (64).

Covers 1) Remove covers (70) and (71). gear (66). 19. * Be careful not to damage the spline groove of the shaft. and bearing cone (69) from shaft (63). * Remove both the O-rings. A Be careful not to get your fingers caught between gear and the housing. 7 DBWW212 30-55 0 . DLWOQ210 6) Remove bearing cone (68). snap ring (65). then pass shaft through front housing and remove. 2) Remove O-ring (72).DISASSEMBLY TRANSMISSION AND ASSEMBLY 4) Push in shaft (63) towards rear. 5) Remove bearing cup (67).

. 67 4) Support output shaft (63) from outside. Covers Assemble O-rings and assemble covers (70) and (71) to front housing. * Press fit the bearing cup fully to the stepped portion of the housing. * To prevent defective adjustment of the end play. * Install O-ring (72) to the mating surface of the parking brake housing. Or carry out the work with two workers and support it by hand. press fit the cone as far as the shoulder of the shaft. 30-56 0 . assemble gear (66) and snap ring (651. * Be careful not to the O-rings fall out. Move it to the center.DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION TRANSMISSION ASSEMBLY 72. then remove gear (66) from the spline groove. 6 Outside circumference of O-ring : Grease 2. * Set the shaft at an angle and insert DLWDo211 it. then press fit bearing cone (68). * Temporarily assemble the bolt and secure with wire. 2) Press fit bearing cup (67) to front housing. and check that there is no clearance. 3) Assemble shaft (63) to front housing. * Do not insert snap ring (65) into the groove. and put it in the same position as the snap ring. (G2-LI) Output shaft gear 1) Press fit bearing cone (69) to output shaft (63). 1.

portion.DISASSEMBLY AND ASSEMBLY TRANSMISSION 5) insert gear (66) in shaft spline secure with snap ring (65). Insert the shroud from immediately above the gear.25 kgm) 6 Mounting bolt : Thread tightener (LT-21 64 3. Check that the gear does not interfere with the shroud.3 * 12. and 6) Coat mounting bolts with thread tightener. Wash and remove all oil and grease from the mounting bolt hole and mounting bolt. 15 . * Set a stand under the top of the front housing. + Press fit the bearing cup fully to the stepped portion of the retainer. 60 I 2) 62 MWW214 Turn over front housing (15).3 Nm (11. and check that there is no clearance. w Mounting bolt : 110. Ir When turning over. then turn over and assemble. and install shroud (64). Parking brake retainer 1) Press fit bearing cup (62) to parking brake retainer (60). hold the output shaft * bearing cone in the bottom bearing cup. be careful that the output shaft does not become at an angle. After turning over.25 + 1.

1 . * Rotating torque : 0.DISASSEMBLY 3) 4) ASSEMBLY Assemble desired shims (61) to parking brake retainer assembly (601.: 100 mm . do not measure at the point where movement begins. w Mounting bolt : 110.25 kgm) DLWCO2C-S 30-58 0 . If the rotating torque is not within the standard value. then install pushpull scale to tip of plate (63-l) and measure. Measure while it is rotating. Install measurement plate (63-I) and retainer plate to shaft (631. f Assemble so that the casting holes (3 places) are at the bottom. * Assemble the thinnest shim on the inside and the thickest shim on the outside.25 L.0 kgm) When measuring the rotating torque.25 kgm) * To settle the bearing. then tighten 3 mounting bolts (59) to specified torque.0 .3 Nm (11.95mm I II II III II DBWOO216 Tighten coupling mounting bolts to shaft (631 and measure rotating torque. rotate the shaft while tightening.1 Nm (0. If the rotating torque is within the standard value. w Mounting bolt (59): 110.25 f 1.3 Nm (11.25 kgm) TRANSMISSION 59 60 \ \ d c!uass: . * Standard shim thickness: 0.1. then assemble to front housing. change the shim thickness to adjust again.25 L.9. check that the end play is “0”.8 Nm (0. Plate length I?.1.1 * * * * * 5) AND kgm) If a small torque wrench is not available. tighten coupling mounting bolts.0.3 It 12.95 mm a Bearing: Transmission oil m Mounting bolt : 110. After tightening.01 . tap the end face of the shaft several times with a plastic hammer to settle the bearing again. it is possible to measure as follows.1.3 + 12. .3 + 12. Assemble selected shims (61) to parking brake retainer (60).3 Nm (11. * Coat the bearing well with oil.1 . Reading of push-pull scale : 1.

6 Outside circumference of O-ring : Grease (G2-LI) 52 DBWOO198 . * Coat the O-rings thinly with grease and stick them on to prevent them from falling out. 6 Outside circumference of seal ring. * Fit the O-rings securely in the grooves. * Knock in the piston uniformly a little at a time with a plastic hammer. Guide bolt : (12 mm. P * 53 56 I 3) DLW00201 Assemble snap ring (54) to parking brake housing (431.DISASSEMBLY 4. * Keep the inner and outer springs in sets. AND ASSEMBLY Parking brake assembly 1) Assemble springs (57) and (58) to parking brake retainer. f Set guide bolts (43-I) in position. and install piston (53). * Check that the snap ring is fitted securely in the groove. pitch: 1. * Be sure to assemble the piston seal facing in the correct direction and without twisting. length: 130 mm) 2) TRANSMISSION I 43-l Install seal rings (55) and (56) to piston (53). sliding surface : Transmission oil I 4) DLWW159 Assemble O-rings (51) and (52) to parking brake housing (43).75 mm.

J. length: 60 mm * * m 7) 11 DEW00197 Springs (57) and (58) are strong.75 I 6) Tighten parking brake housing (43) with 3 temporary tightening bolts (43-2) uniformly and screw in approx.3 Nm (11. Be careful not to let the spring and plate rest on top of each other.3 + 12. 9) Assemble separate plates (46).25 kgm) Install manual brake housing position. Lifting bolt : 12 mm. pitch: 1. and discs (48). Then replace one at a time with standard bolts (43-3) and tighten uniformly. 30-60 0 output . pitch: 1.25 + 1. and set in position. then assemble. wave springs (471. cancel bolt (39) to parking (431. Align the separate plate with the parking brake housing spline when assembling. 30 mm.DISASSEMBLY 5) AND ASSEMBLY TRANSMISSION Turn over parking brake housing (43).75. Be careful not to let the plate or spring get caught in the housing ring groove. Mounting bait (43-3) : 110. Be careful not to let the O-ring fall out or get caught. Ir Temporary tightening bolt : 12 mm. align with guide bolts (43-11. so be careful to tighten uniformly. and set piston to FREE 58 DLWOOZZO 8) Align spacer (50) and hub (49) with shaft spline. then assemble. Align the disc with the hub spline.

75 + 0.4 Nm (6.3 f 12. Check that the shaft turns.0 t 6.5 + 1 mm & Lip of oil seal : Grease (G2-LI) Coat lip of oil seal with G2-LI 13) Install gasket (40-I) to parking brake housing (43). Bolt length of tool A4 : 64 mm * A4 11) Install snap ring (441. * + Check that the snap ring is fitted securely in the groove.5 + 1 mm Press-fitting dimension II : 17. then install tool A4. w Mounting bolt : 66.3 Nm (11. * Be careful not to damage the oil seal. * & Outside circumference of coupling : Transmission oil w Coupling mounting bolt : 549 + 59 Nm (56. Knock the cover in uniformly with a plas* tic hammer. Press-fitting dimension a : 28. Be careful not to let the oil seal contact * the shalt.75 kgm) 15) Tighten coupling (361. align with dowel pi. then tighten lock plate (38) with mounting bolts.0 kgm) DLWWZZZ 40-l DBWO’J193 . 44 45 DBWCO195 12) Press fit oil seal (42) and dust seal (41) to cover (40). then remove manual cancel bolt (39).2 + 7.25 + 1. w Mounting bolt : 110.~. O-ring and holder (37) with mounting bolts.DISASSEMBLY AND ASSEMBLY TRANSMISSION IO) Assemble end plate (45). Push the O-ring into the shaft groove. then install cover (40). and tighten with coupling mounting bolts. and remove tool A4. lock at position of lock plate (38).25 kgm) DLWOOPl 14) Tighten manual cancel bolt (39) by hand.

0 _+ 1.0 t 1. and install snap ring (31). Bearing 1) Assemble FORWARD.0 mm & Lip of oil seal : Grease (G2-LI) 6.0 mm & Lip of oil seal : Grease (G2-LB f Prass fitting dimension b : 36. and press fit oil seal (35) and dust seal (34). 3rd outer bearing (291. 2) Press fit idler gear (32) to shaft. +r If the shaft has been removed.5 f: 0. 33 7.5 mm TRANSMISSION . then press fit it to dimension g. 4th outer bearing (30) to housing.DISASSEMBLY AND ASSEMBLY 5. 30-62 0 DBWOD191 . and 2nd. REVERSE outer bearing (281. Rear oil seal. Jr Press fitting dimension a : 28. Idler gear I) Press fit bearings (33) to idler gear (32). t Shaft dimension g : 46. dust seal 1) Turn over front housing. Ist. cool the shaft to -7O”C.

DISASSEMBLY AND ASSEMBLY 8. 2nd. assemble Ist. * Do not fit the bearing at the bottom of the clutch completely. A Be careful not to get your fingers caught in the gears. 3rd clutch I) Using tool A3. insert beari’ng of 2nd. insert 2nd. TRANSMISSION FORWARD. 226 9. and move it towards output shaft end. REVERSE clutch (27) in housing. REVERSE clutch 1) Using tool AZ. 4th. 2) Using tool A3. and 1st. then align REVERSE gear and idler gear (32) and assemble. insert FORWARD. 4th clutch gear (74). 3rd clutch (26) to housing. 4th clutch (25) in housing. 30-63 0 . 4th clutch into housing. 3) When 1st gear (73) passes 2nd.

then assemble and check that the rotation is smooth. &Seal ring : Transmission oil I 11. and snap ring (19) to inside of rear housing (14). Pump (torque converter. 8 22 30-64 0 DLWW232 . + Coat the seal rings well with oil. Seal rings Install seal rings (24) to each clutch shaft. 3rd clutch (26) into bearing assembly portion. * Press fit so that there is no clearance the rear of the shaft. loader) I) Press fit bearing (23) to shaft (22). AND ASSEMBLY TRANSMISSION insert Ist. then insert shaft (22) from pump mount end. ring washer (201. 24 DBWO3185 Press c at 23 I 2) DLWW321 Assemble gear (18). Rotate slightly to assemble. do not use force.DISASSEMBLY 4) IO. + If the gears are not properly meshed. * Check that each gear is corrkctly meshed when inserting into the bearing.

and install snap ring (17) at pump mount. and install snap ring (19). raise rear housing (14). then assemble ring washer (20) to split spacer. be careful of the meshing with the pump accessory gear. then set to mounting position of torque converter.DISASSEMBLY 3) 4) AND ASSEMBLY TRANSMISSION Assemble split spacer (21) to stepped portion of shaft. Ir Blow in air to check if the oil holes are correctly aligned. Turn over rear housing.8 +9. Ir Align the mounting bolt holes properly. and tighten mounting bolts (16-I).5 f 1. * Carry out the same procedure at the loader pump end.8 Nm (11. DEW00180 12. and install. m Mounting bolt : 112. Torque converter Using eyebolts.0 kgm) - \ DBW00234 .

3 f 12.DISASSEMBLY AND ASSEMBLY TRANSMISSION 13.3 Nm (II. pitch: 1.3 Nm (Il. w Mounting bolt : 110. and assemble to front housing (15). * Remove all oil and grease from the bolt hole before installing the mounting bolt. Mating surface of housing : Gasket sealant (Three Bond 1207B) Housing mounting bolt : 110. & Cap mounting bolt : Thread tightener (LT-2) m Cap mounting bolt : 66.2 + 7. + Screw guide pins into the front housing. Mesh the input shaft spline correctly.75 kgm) * Remove tool AI from rear housing (14). (12 mm. length: 55 mm) * Make sure that the gasket sealant is not squeezed out inside-the case.25 + I.4 Nm (6.75 + 0.3 + 12. Be careful not to damage the seal ring of each shaft. Rear housing 1) Using tool Al. Al 14 14. Oil filter Assemble oil filter(12) with bracket assembly.75 mm. * * * & w 2) See the right for details of the procedure for coating with gasket sealant.25 kgm) 30-66 0 DBwco177 .25 kgm) Outside I Assemble pilot cap (13). raise rear housing (141. Be careful also not to coat with too much gasket sealant.25 f I.

so be careful when using them. then fit control valve (7) temporarily.75 + 0. 2) Align with guide bolt and assemble gasket.35 kgm) w Hose.15 + 0. Ir Be careful not to get the O-ring caught.3 +4. * Tighten the mounting bolts in turn on diametrically opposite sides and be careful not to tighten too much. 3) Coat mounting bolts of control valve (7) with thread tightener and tighten. Ir Wash and remove all oil and grease from the control valve mounting bolt hole and mounting bolt thread.75 kgm) w Hose joint : 177 + 29 Nm (18.5 f 0.5 kgm) DBW00175 -6 DBW00173 .9 Nm (3. 2) Assemble clamp to hose (9) between torque converter oil filter and torque converter charging pump.9 + 3. & Mounting bolt : Thread tightener (LT-21 m Mounting bolt : 34.2 k 7.0 kgm) 17. * w Hose. flange (pump end) : 30. Be careful not to get the O-ring caught.0 * 3. w Mounting bolt : 110.DISASSEMBLY AND ASSEMBLY TRANSMISSION 15.3 + 12.4 Nm (6. Charging pump 1) Assemble O-ring to charging pump (IO).25 kgm) 2) Install hose and flange (8) and (9) to charging pump (10) and rear housing.3 Nm (11. * Be careful not to crush the tube during the operation. 16. * The length of the mounting bolts is different. Transmission control valve 1) Install guide bolt to mount portion of transmission control valve (7). flange (housing end) : 66. and install to transmission.25 f 1.4 Nm (3. Hydraulic piping I) Install PTO lubrication tube (II).

rear coupling I) 2) Sling transmission assembly and lift off from assembly stand.9 Nm (3. 6 Mounting bolt : Thread tightener (LT-2) w Mounting bolt : 34.DISASSEMBLY AND ASSEMBLY 4) 5) Assemble O-ring to accumulator valve (6).5 + 0.25 kgm) m Mounting bolt (strainer end) : 66. w Mounting bolt : 66. Hydraulic piping 1) Install tube and hose (4) between torque converter filter and transmission valve to transmission valve. & Mounting bolt : Thread tightener (LT-2) w Mounting bolt : 34.45 f 0.5 kgm) 2) Install tube hose (3) between strainer and charging pump.3 Nm (11.3 + 4.5 kgm) 18.4 Nm (6.9 Nm (3.75 f 0.2 ? 7.3 f 12.3 + 4.25 f 1.3 f 4.75 kgm) DLWO0170 30-68 0 .4 + 0. & Mounting bolt : Thread tightener (LT-2) w Mounting bolt : 34. * Be careful not to get the O-ring caught. and lift off slowly. * Wash and remove all oil and grease from the mounting bolt hole and mounting bolt.75 kgm) w Hose clamp : 4.2 + 7. and install to transmission. * Wash and remove all oil and grease from the mounting bolt hole and mounting bolt.5 kgm) Align gasket with modulation valve (5) and assemble to transmission valve. be careful of the center of gravity.5 Nm (0. Oil filler. * Wash and remove all oil and grease from the mounting bolt hole and mounting bolt. Ir Install the tube clamps. Assemble O-ring and install oil filler (1).5 + 0.9 Nm (3. 1: When standing the transmission assembly up.75 _+0.4 Nm (6. w Mounting bolt (pump end) : 110.5 f 0.05 kgm) TRANSMISSION DLWW238 Dl3WOX72 19.

Ir When screwing in the sensor with a wrench. and secure it in position with locknut (77). and finally tighten by hand until it is lightly in contact.8 Nm (6.8 f 9.0 * 1. stop before it contacts the gear. After sensor (75) contacts gear (76). & Sensor thread portion : Gasket sealant (LG-51 m Sensor locknut : 58.1 turn DLWWZ40 30-69 0 .1 turn. 20.DISASSEMBLY 3) AND ASSEMBLY TRANSMISSION Assemble so that rear coupling (2) and front coupling face in same direction. Adjusting speedometer sensor II Screw in sensor (75) until it contacts outermost surface of gear (76). hold the nut with a wrench when tightening. Transmission case 3 76 75 c I/Z .0 kgm) * Install the transmission bracket. * Before installing the sensor. check that the gear is at the outermost circumference in relation to the mounting surface. turn it back l/2 . t When securing with the locknut.

REVERSE clutch pack AThe clutch pack is oily. Ir After removing the ring. . then tighten tool B4. thrust bearing (71. 1. Spacer. FORWARD gear Remove spacer (21. remove tool B3. thrust washer (61. so be careful not to let it slip when setting the clutch pack on the stand. Be careful also not to get your fingers caught between the stand and the clutch pack. Bl bearing (I). and washer (8). 6 5 3 DEW00244 2) 30-70 0 Remove end plate (IO). FORWARD gear (5). 4 DEW00241 DBWBJ242 Bearing Using puller and remove 2. End plate I) Install tools B3 and B5. needle bearing (4).DISASSEMBLY AND ASSEMBLY DISASSEMBLY TRANSMISSION ASSEMBLY TRANSMISSION CLUTCH PACK OF CLUTCH PACK Disassembly of FORWARD. and remove ring (9). thrust washer (31. 8 3. * Set on tool Bl with the FORWARD clutch side at the top.

TRANSMISSION CLUTCH PACK Clutch plate Remove plate from housing. Remove snap ring (28). then remove housing (27). cylinder 1) 2) Remove snap ring (26) from shaft and housing (25). and spring (13) DBWOO245 5. 22 23 24 Shaft. 27 28 26 DLWW249 30-71 0 . REVERSE gear Using puller. * Do not use force to remove it. Snap ring * Set on tool Bl with the REVERSE at the top. push the piston in and try to remove it again. disc (12). Ill). Piston Blow air in FORWARD oil hole of shaft and remove piston (14). 8. thrust bearing (23). The inside circumference of the cylinder will be damaged.DISASSEMBLY AND ASSEMBLY 4. and washer (24). 7. spacer (19). * If the piston is at an angle and cannot be removed. remove spacer (16). clutch side Bearing.5 for the FORWARD clutch to disassemble the other parts. gear (17). thrust washer (22). DEWLW247 6. inner bearing (18). thrust washer (20). then remove housing (27). Repeat Steps 3 . needle bearing (21). Remove snap ring (15).

2) Remove end plate (39). * After removing the ring. then tighten tool B4. DEW03254 30-72 0 . then using puller. remove tool B3. 32 2. 3rd clutch Ir Set on tool Bl with the 1st clutch side at the top. remove spacer (30). idler gear I) Remove snap ring (291. and remove ring (38).DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK Disassembly of lst. 2) Remove 1st gear (35). 37 36 DBWCO252 3. inner bearing (31). and needle bearings (36) and (37). End plate I) Install tool B3 and B5. then remove thrust washer (34). 1st gear 1) Remove snap ring (331. 1. and idler gear (32).

CLUTCH PACK . 2) Remove thrust washer (43). Piston Blow air in REVERSE oil hole of shaft. disc (411. * Use the same procedure as in Steps 3 . Using puller. * If the piston is at an angle and cannot be removed. thrust washer (471. push the piston in and try to remove it again. and remove piston (44). Bearing Set on tool Bl with the 3rd clutch top.DISASSEMBLY TRANSMISSION AND ASSEMBLY 4. 7. 5. 6. remove bearing (45). * Do not use force to remove it.5 for the 1st gear to continue disassembly. and spring (42) from housing. side at the 3rd gear Remove spacer (461. The inside circumference of the cylinder will be damaged. Clutch plate 1. and 3rd gear (49).) Remove plate (401. needle bearing (481.

then tighten tool B4. CLUTCH PACK 51 50 1 2. 56 I 57 58 53 DLW02260 85 B3 DEW@263 30-74 0 . 2) Remove end plate (60). and thrust washer (55). 4th clutch pack * Set on tool Bl with the 4th clutch side at the top. and remove ring (59). 55 53 54 52 DEW00261 3. then remove bearing (51) together with idler gear. 4th gear 1) Remove thrust washer (521. 4th gear (531.DISASSEMBLY TRANSMISSION AND ASSEMBLY Disassembly of 2nd. needle bearing (541. 2) Remove snap ring (561. End plate 1) Install tools B3 and B5. and needle bearing (58) from 4th gear (53). Idler gear Fit puller to idler gear (501. remove tool B3. t After removing the ring. 1. spacer (57).

Idler gear * Set on tool BI with the 2nd clutch side at the top. 2nd gear Remove thrust washer (69). needle bearing (70). put the plate in contact with the center first. I) Remove snap ring (65). 2) Using puller. and remove piston (64). Clutch plate Remove plate from housing. inner bearing (671. 5. * When fitting the puller. 2nd gear (71). 8 cc) 2 2 6. and idler gear (68). 69 70 7. push the piston in and try to remove it again. I 72 71 70 69 30-75 Q . remove spacer (66). * If the piston is at an angle and cannot be removed. and thrust washer (72). The inside circumference of the cylinder will be damaged. disc (62). Ir Use the same procedure as in Steps 3 .5 for the 2nd gear to continue disassembly.TRANSMISSION DISASSEMBLY AND ASSEMBLY 4. and spring (63) Piston Blow air in 4th oil hole of shaft. * Do not use force to remove it. CLUTCH PACK (61).

k Be careful that the plate or spring are not caught in the clutch housing ring groove when assembling. t If the seal is assembled to the cylinder without making it fit first. housing I) Put housing (27) and snap ring (28) assembly on tool Bl. 2) Assemble shaft and housing to housing (271.3 minutes). Be careful to assemble so that disc (75) and spring (76) are not resting on each other. disc (751. * When assembling a new piston seal. and install snap ring (26). 30-76 0 . use tool B6 to make the seal fit well (time: approx. so be careful not to let it slip when setting the clutch pack on the stand. the seal will be damaged. 2 . TRANSMISSION -47 73 73-l Piston seal before using tool B6 73 (F-R) DLWOO268 REVERSE piston Install REVERSE piston (73).DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION ASSEMBLY CLUTCH PACK CLUTCH PACK Assembly of FORWARD. then assemble the seal. 3. Shaft. REVERSE clutch pack AThe clutch pack is oily. and spring (76) in turn. Clutch plate Insert tool B2 into housing. & Sliding surface of piston seal : Transmission oil DEW00269 5. Housing Assemble snap ring (28) to one side of housing 127). * Be careful not to damage the piston seal. Be careful also not to get your fingers caught between the stand and the clutch pack. & Inside surface of tool B6 : Transmission oil 4. 2. t Soak disc (75) in clean transmission oil for at least 2 minutes before assembling. J. then assemble plate (741. 1. Piston seal Assemble piston seal (73-I) to piston (73). * Check that the spring pin does not extend from the circumference of the shaft.

+ Check that the disc rotates smoothly by hand. bearing (231.106 . 8. and REVERSE gear Align spline groove on inside of plate with a screwdriver to assemble gear (17). thrust thrust washer (22).991 mm 1 .0. check that clearance “a” between thrust washer and spacer is within standard value. Never use force to push 21 17 22 23 m ij k 5 9. then tighten tool 84 to push in end plate (77). turn lightly when assembling. and remove tooi B3. 3) After press fitting bearing. AND ASSEMBLY TRANSMISSION End plate I) Install tools B3 and B5. 24 DLW02269 1 10.DISASSEMBLY 6. a Thrust washer : Transmission oil 2) Assemble snap ring (15). CLUTCH PACK I 85 78 DEW’00271 7. Needle bearing Assemble needle bearing (21) and thrust washer (20). * Press fit completely so that there is no clearance. * If the gear spline does not match. Bearing 1) Assemble spacer (191. + Check that the end face of the thrust washer is below the surface of the stepped portion of the shaft. then press fit inner bearing (18) and spacer (IS). + a = 0. 2) Assemble ring (781. Thrust washer Assemble washer (241.

& Sliding surface of piston seal : Transmission oil CLUTCH PACK DEW00272 12. + Assemble in the same way as for the REVERSE clutch plate. FORWARD piston 1) Turn over clutch pack. B5 DBWCO274 14. 16. thrust bearing (71. then tighten tool B4 to push in end plate (IO). and thrust washer (6). piston (14) in the same way as 3) Assemble REVERSE piston. 2) Assemble ring (91. g When turning over the clutch pack. * Assemble in the same way as for the REVERSE gear. and assemble plate (II). Needle bearing Assemble needle 30-78 0 bearing (4). disc (121. 2) In the same way as with REVERSE piston. make sure that piston seal fits well before assembling it to piston (14). be careful not to get your fingers caught between the stand and clutch pack. D&V00275 DLWW276 . Clutch plate Insert tool B2 in housing. End plate I) Install tools B3 and 85. FORWARD gear Assemble FORWARD gear (5). Thrust washer Assemble washer (8). 15. DBWW273 13.DISASSEMBLY AND ASSEMBLY TRANSMISSION 11. & Thrust washer : Transmission oil. * Assemble in the same way as for the REVERSE end plate. and spring (13) in turn. and remove tool B3.

* Press fit completely so that the spacer is in tight contact with bearing (I) at the stepped portion of the shaft. check that clearance “b” between the thrust washer and the spacer is within the standard value. f Check that the end face of the thrust race of the thrust washer is below the surface of the stepped portion of the shaft. FORWARD. Spacer Assemble thrust washer (3). Clutch pack operation test Blow in compressed air through oil hole in shaft and check that each clutch works properly. * b = 0. Bearing Press fit bearing (1). 6 Thrust washer : Transmission oil 18. * If the gear where the air is blown in is held in position. then assemble spacer (2). the clutch is working properly.106 .DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK 17.991 mm DLW02271 19. Ir After press fitting bearing (I). REVERSEclutch assembly DBWW279 .0.

Clutch plate Assemble plate (801. * Check that the spring pin does not extend from the circumference of the shaft. * Be careful to assemble so that disc (81) and spring (82) are not resting on each other. * Be careful not to damage the piston seal. * Soak disc (81) in clean transmission oil for at least 2 minutes before assembling.3 minutes). Piston seal Assemble piston seal (79-l) to piston (79). * Set the shaft housing on tool Bl with the 3rd clutch side at the top.DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK Assembly of lst. disc (81). * Be careful that plate (80) or spring (82) are not caught in the clutch housing ring groove when assembling. * When assembling a new piston seal. 87 2. then assemble the seal. 3rd piston Install 3rd piston (79). I 82 81 I 80 DBwal282 30-80 0 . Be careful also not to get your fingers caught between the stand and the clutch pack. a 1. use tool B7 to make the seal fit well (time: approx. 2 . 3rd clutch pack The clutch pack is oily. & Inside surface of tool B7 : Transmission oil Piston seal before 79. and spring (82) in turn to housing. so be careful not to let it slip when setting the clutch pack on the stand. * If the seal is assembled to the cylinder without making it fit first. the seal will be damaged. 6 Sliding surface of piston seal : Transmission oil 3.

then assemble needle bearing (48). Never use force to push it in. 5: 3rd gear Assemble 3rd gear (491. 2) Assemble ring (84). Ir If the gear spline does not match. 3) Assemble thrust washer (85).1 . then tighten tool B4 to push in end plate (83). Bearing Assemble thrust washer (47) and spacer (461. * Press fit completely so that the spacer is in tight contact with bearing (45) at the stepped portion of the shaft. AND ASSEMBLY TRANSMISSION CLUTCH PACK End plate I) install tools B3 and B5. then press fit bearing (45). * Check that the end face of the thrust washer is below the surface of the stepped portion of the shaft. and remove tool B3. n49 8 46 DBW00286 * After press fitting bearing. check that clearance “d” between thrust washer (47) and spacer (46) is within standard value.0.9 mm DiWO2272 30-81 0 . * Check that the disc rotates smoothly by hand. 6. turn lightly when assembling. * Assemble the needle bearing at the bottom first.DISASSEMBLY 4. * d = 0. * Check that ring (84) is fitted securely in the groove.

1st gear I) Assemble thrust washer (43). 4 85 39 38 3) Assemble 10.piston seal fits well before assembling it to piston (44). or Assemble in the same way as for the 3rd clutch plate. * Assemble 3rd gear. 3) Assemble piston (44) in the same way as 3rd piston. 42 CLUTCH PACK 41 8 DLWWZES 9. & Sliding surface of piston seal : Transmission oil 8. then tighten tool 84 to push in end plate (39). End plate I) Install tools 83 and B5. g When turning over the clutch pack.DISASSEMBLY AND ASSEMBLY TRANSMISSION 7. * Assemble in the same way as for the 3rd end plate. and remove tools 83 and B4. be careful not to get your fingers caught between the stand and clutch pack. 2) Assemble ring (381. 1st gear (35) and needle (37). 2) In the same way as with 3rd piston. disc (41). in the same way bearing as for the DBWWZ90 30-82 0 DBWOaZ91 c: 4 . 1st piston 1) Turn over clutch pack. and spring (42) in turn to housing. Clutch plate Assemble plate (401. make sure that.

11.DISASSEMBLY AND ASSEMBLY 2) 3) TRANSMISSION Assemble needle bearing (36) and thrust washer (34). the clutch is working properly.58 mm 13. Bearing 1) Press fit inner bearing (31) and spacer (30). * c = 0. + Fit the snap ring securely in the groove of the shaft. check that clearance “c” between the thrust washer and the gear is within the standard value. a Thrust washer : Transmission oil Assemble snap ring (33). * If the gear where the air is blown in is held in position. Clutch pack operation tesi Blow in compressed air through oil hole in shaft and check that each clutch works properly. 1st 3nd clutch assembly 30-83 0 . * Fit the snap ring securely in the shaft groove. * After press fitting the bearing. 2) Assemble snap ring (29). 12.02 .1. Idler gear 1) Assemble CLUTCH PACK 36 29 idler gear (32).

the seal will be damaged. Piston seal Assemble piston seal (86-I) to piston (86). 2nd piston Install 2nd piston 186).3 minutes). 3. use tool B7 to make the seal fit well (time: approx. disc (881. 2 . and spring (89) in turn to. then assemble the seal. 30-84 0 DLW01926 1 . * If the seal is assembled to the cylinder without making it fit first. Check that the spring pin does not extend from the circumference of the shaft. t Be careful to assemble so that disc (88) and spring (89) are not resting on each other. housing. & Inside surface of tool B7 : Transmission oil -n 86 seai Piston before using tool B7 86-l I 2. * Soak disc (88) in clean transmission oil for at least 2 minutes before assembling. f Be careful that the plate or spring are not caught in the clutch housing ring groove when assembling. Ir Set the shaft housing on tool Bl with the 2nd clutch side at the top. 1.DISASSEMBLY AND TRANSMISSION ASSEMBLY CLUTCH PACK Assembly of 2nd. J. 4th clutch pack &The clutch pack is oily. Clutch plate Assemble plate (87). * Be careful not to damage the piston seal. so be careful not to let it slip when setting the clutch pack on the stand. * When assembling a new piston seal. Be careful also not to get your fingers caught between the stand and the clutch pack.

7. turn lightly when assembling. then tighten tool B4 to push in end plate (90). 2nd gear Assemble 2nd gear (71). & Thrust washer : Transmission oil Bearing 1) Press fit inner bearing (67) and spacer (66). 6. check that clearance “e” between the thrust washer and the idler gear is within the standard value. * Check that the disc rotates smoothly by hand. * If the gear spline does not match.34 . 2) Assemble snap ring (65). then assemble needle bearing (70).66 mm . Thrust washer Assemble thrust washer (72). 21 Assembie ring (911. AND ASSEMBLY TRANSMISSION CLUTCH PACK End plate I) Install tools B3 and B5. 8. * Check that the end face of the thrust washer is below the surface of the stepped portion of the shaft. DEW03298 5. Never use force to push it in. * Fit the snap ring securely in the shaft groove. c c DBWW390 69 DLW02267 67 66 . Idler gear Assemble thrust washer (69) and idler gear (68).1. * After press fitting the bearing.DISASSEMBLY 4. * e = 0. and remove tool B3.

AND ASSEMBLY TRANSMISSION CLUTCH PACK 4th piston I) iurn over clutch pack. Clutch plate Assemble plate (611. 85 DBWW3U4 3) 30-86 0 Assemble thrust washer (55). Ir Assemble in the same way as for the 2nd end plate. 2) Assemble ring (591. disc (62). piston (64) in the same way as 3) Assemble 2nd piston. 2) In the same way as with 1st piston. be careful not to get your fingers caught between the stand and clutch pack. & Sliding surface of piston seal : DBWCGQ2 10. * Assemble in the same way as for the 2nd clutch plate. and spring (63) in turn to housing. DBWW303 11. g When turning over the clutch pack. then tighten tool B4 to push in end plate (60). and remove tool B3. make sure that piston seal fits well before assembling it to piston (64).DISASSEMBLY 9. End plate I) Install tools 83 and B5. .

then assemble 4th gear (53).DISASSEMBLY AND ASSEMBLY TRANSMISSION 12. After press fitting the bearing. 2) Assemble needle bearing (581.1. spacer (57). 4th clutch assembly 30-87 0 .17 . the clutch is working properly. * Check that the end face of the thrust washer is below the surface of the stepped portion of the shaft. Bearing Assemble idler gear (501. Clutch pack operation test Blow in compressed air through oil hole in shaft and check that each clutch works properly.43 mm 53 DBWOEC6 50 51 DLW02274 DBWW3a7 14. * * Press fit completely so that the idler gear is in tight contact with bearing (51) at the stepped portion of the shaft. 4th gear 1) Assemble in same way as for 2nd gear. then press fit bearing 52 (51). * If the gear where the air is blown in is held in position. 4) Assemble thrust washer (52). * f = 0. 2nd. 3) Assemble top needle bearing (54). and snap ring (56) to 4th gear (531. check that clearance “f” between the thrust washer and the idler gear is within the standard value. 56 57 58 CLUTCH PACK 53 DLWO2260 13.

Remove accumulator & kg 4. elbow (5). Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. Remove covers (I). and disconnect torque converter cooler tube (8). brake hose (41. I 2. Lower the bucket to the ground and stop the engine.5 kg m Torque converter cooler tube I) Remove mounting bolts. (21. Accumulator r 2 I \ dBWOO312 DBWOO310 . 30-88 0 I / DBWCCQ84 valve (7). and valve : 8. 3. m 2) Remove lock bracket (9) of torque converter cooler tube (8) from engine. Remove parking nipple 6).DISASSEMBLY AND ASSEMBLY REMOVAL CONTROL TRANSMISSION CONTROL VALVE OF TRANSMISSION VALVE ASSEMBLY AStop the machine on level ground and install the safety bar on the frame. and (3). 1. * Move the tube up.

7. and lower assembly under chassis. Sling transmission valve assembly (191. a valve : 46 kg DBWCO315 . Disconnect transmission wirings (II). f 6. AND ASSEMBLY TRANSMISSION CONTROL VALVE Electric wiring I) 2) Disconnect clamp of transmission wiring (IO) from transmission valve. Remove 8. avoid the connectors. The working space is confined. then remove mounting bolts. * When fitting the lifting tool. and be careful to maintain the balance. (131. * Remove together with the wiring bracket. * Remove the valve mounting bolts. (121. m * Leave upper and lower valve mounting bolts (20) installed.DISASSEMBLY 5. r+ kg modulating Transmission 11 (TO51 valve (18). fit securely to the valve body. (141. then remove clamp (17). and (15) from transmission valve. so be exA treme!y careful when carrying out this operation. m Fit tags to distinguish the wiring. Disconnect tube (16) between transmission film ters from transmission valve.

5 kgm) ? 4.9 Nm (3. so be extremely careful when carrying out this operation. Wash and remove all oil and grease from the mounting bolts and bolt holes. Use guide bolts to prevent the part from falling out during installation. Use a new part for the gasket. Wash and remove all oil and grease from the mounting bolts and bolt holes. a Ir * Use a new part for the gasket.9 Nm (3.5 kgm) Connect the wiring connector securely.3 + 4. : Thread tightener (LT-2) : + 4. AI& Mounting bolt: Thread tightener (LT-2) w Mounting bolt : 34.9 Nm (5.0 + 0.5 kgm) e115 DBWOO317 .3 49 Set bolt : all oil and grease from bolts and bolt holes. 480 Carry out removal.5 + 0.DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE INSTALLATION OF TRANSMISSION CONTROL VALVE ASSEMBLY .5 i 0.9 Nm (3. * t 6 m installation in the reverse order e90 to Use a new part for the O-ring. Lock with upper and lower valve set bolts (20). Mounting bolt : Thread tightener (LT-21 Mounting bolt : 34.3 + 4. + jr 6 m w 30-90 0 The working space is confined.5 f 0. Wash and remove the valve mounting Mounting bolt Mounting bolt 34.5 kgm) 116 g * *.

DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE DISASSEMBLY OF TRANSMISSION CONTROL VALVE ASSEMBLY 57 a \ \ 43 60 20 bl 42 10 51 21 / ‘f$P@ Al/ Modulating valve DBWOl929 30-92 0 .

F return spring (43). and plugs (62) and (63) from lower valve (I). O-ring (6) and orifice (7) from 2) Remove manual valve (5). 30-93 0 . and priority spring (50). gasket (24). 3. Disassembly of lower valve 1) Remove mounting bolts. pilot valve (131. main relief valve (181. cover (II). spring (16). remove valve plug (28) from dump valve (271. and sleeve (44). then remove cover (48). Disconnection Remove mounting bolts. them remove pilot filter (33) and O-ring (34). and torque converter out valve (22). then remove parking brake solenoid (351. remove cover (231. mounting bolts. then remove manual valve (5). valve (17). then remove check spring (29) and ball (30). Remove mounting bolts. gasket (421. remove lock plate (41. Disassembly of upper valve I) Remove mounting bolts. then remove gasket (3). ‘3) Remove dummy spool (20).DISASSEMBLY AND ASSEMBLY 1. Remove F return spring (51) and sleeve (52). then remove F-R valve (53). and (61). (60). Remove return spring (55) and spring spacer (56). 3) Remove plug (8) and O-ring (9). then remove speed valve (57) and ii-L valve (58). Remove plug (54) from F-R valve (53). and pilot spring (14). torque converter out spring (211. and O-rings (36) and z! N” 4 3) 4) 5) 6) 7) 8) 9) IO) 11) TRANSMISSION CONTROL VALVE (37). gasket (491. 8) Remove orifice plug (26) from dump valve assembly (641. then remove solenoid valve (381. 77) Remove mounting bolts.and dump spring (25). and mode spring (19). Remove priority valve (45). 2. Remove brake valve (46) and return spring (47). and disconnect upper valve (2) from lower valve (I). 5) Remove valve (151. then remove dump valve assembly (64). Remove orifices (591. gasket (121. Remove mounting bolts. 9) Remove orifice (31) and plug (32) from upper valve (2). f Record the shim thickness. 2) Remove mounting bolts. then remove cover (41). Remove mounting bolts. and O-rings (39) and (401. then remove 4) Remove bracket (IO).

DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE ASSEMBLY OF TRANSMISSION CONTROL VALVE ASSEMBLY 57 _a Gasket valve DEW01923 30-94 0 .

and (59) (01. Install plug (54) to F-R valve (53).015 kgm) 11) Assemble O-ring (34) to pilot filter (33). * Set the mounting angle of reverse solenoid valve (38) to 45”. then assemble F-R valve.9). then instatl parking brake solenoid (35). spring spacer (561. then install cover (41). then install pilot filter (33).62 + 0. * Check that there are no scratches.DISASSEMBLY 1. and set gasket (42) in position. m Mounting bolt : 66. set gasket (49) in position. or any other deterioration in the O-rings.165 + 0. or any other deterioration in the O-rings.475 kgml IO) Fit O-rings (37) and (36) to parking brake solenoid (351. * 30-95 0 . TRANSMISSION AND ASSEMBLY Assembly of lower valve 1) Install plug (63) to lower valve (I).35 kgml Ir Install guide bolts.275 f 0. then install cover (48).75 kgm) 9) Guide 48 DSWOO320 w 6) 7) 8) Mounting bolt : 30. Ir Check that there are no scratches.4 Nm (3.5 + 4.35 kgm) * Install guide bolts.15 + 0. then tighten the nut. deformation. and return spring (55) ((L=48).62 f 0. * Check that there are no scratches.31. CONTROL VALVE Assemble O-rings (40) and (39) to solenoid valve (38).9 ? 3.2 f 7.15 f 0. and install sleeve (52) and F return spring (51) (L=42).1) to lower valve (1). then install solenoid valve (38).75 + 0.4 Nm (6. Install priority spring (50) (L=150). w Mounting bolt : 1. Install priority valve (45). Install H-L valve (58).165 f 0. w Mounting bolt : 1. cracks. & Plug : Sealant (LG-1 or LG-51 f3-7mm DLWal319 2) Install plug (62) and orifices (61) (01. or any other deterioration in the O-rings.15 Nm (0.4 Nm (3. Install sleeve (44) and F return spring (43) (L=42). Replace the gasket with a new part.7 Nm (1. Replace the gasket with a new part.9 + 3. (60) 3) 4) f: 5) 2 3 (oO.15 Nm (0.015 kgm) w Solenoid nut : 12. * Install return spring (47) (L=46) and brake valve (46). cracks. w Mounting bolt : 30. deformation. deformation. cracks. speed valve (571.

and set with the mode spring. w Mouriting bolt : 30. m Mounting bolts : 53. * Install guide bolts.5 + 0. + Install guide bolts.5 F 2.3 f 4. then install lock plate (4).35 kgm) 8) Fit O-ring (9) to plug (8).0 f 0. AND ASSEMBLY TRANSMISSION Assembly of upper valve 1) Install plug i32) to upper valve (2). then install cover (23). and set gasket (12) in position. and dummy spool (20). and assemble upper valve (2) with set bolts (2-I). * Install guide bolts. check spring (29) (L=40).5).DISASSEMBLY 2.35 kgm) 5) Install torque converter out valve (22)..9 Nm (5.15 5 0. * Replace the gasket with a new part. Ir Replace the gasket with a new part.0 kgml 2) 3) 30-96 0 8 k 5 . 7) Install pilot spring (14) (L=74. a O-ring : Grease /62-L!) IO) Install manual valve (5) to upper valve (21. spring (16) (L=26) and valve (15).9 f 19.5).31.4 Nm (3. and main relief valve (181.15 & 0.9 + 3.n install dump valve assembly (64). set gasket (24) in position.9 f 3. CONTROL VALVE Connection Set gasket (3) to lower valve (I). pilot valve (131.5) to upper valve (2). then install cover (11) and bracket (IO).5 kgm) Coat with sealant &7mm 2-3mm DLWW319 Install orifice (31) (07.5 kgm) 41 Install dump spring (25) (L=31. then install plug. 6) Install mode spring (19) (L=163.2). Ir Install the recorded shim thickness to the main relief valve. 9) It&tall orifice (7) and O-ring (6) to manual valve (5). * Replace the gasket with a new part.4 Nm (3. m Mounting bolt : 30. valve (17). & Plug : Sealant (LG-1 or LG-5) 3. Install ball (301. torque converter out spring (21) (L=65). install orifice (26) (01. th. and valve plug (28) to dump valve (271. w Valve plug : 34.6 Nm (5.9 Nm (3. w Set bolt : 49 * 4.

TRANSMISSION DISASSEMBLY AND ASSEMBLY ACCUMULATOR VALVE DISASSEMBLY OF TRANSMISSION ACCUMULATOR UALVE ASSEMBLY 1. Remove bolts (7) and (81. spacer. il DBWW323 Pull out valves (II). set accumulator valve body (9) in vice. stoppers (13) and (15). and use for reference when assembling.5 e=iio e = 50 2ND e = 157.8 e = 135. P = 1. L = Approx. 2. 4. 3. M = 10. Using pads. then remove cover (IO) together with guide bolts. Remove mounting bolts (5) and (61.5 e=110 e = 50 DEW03324 12 14 16 16 DLWoo325 30-97 0 . Remove accumulator valve (4) from transmission assembly (3). or Fit tags to each spring. Spring Stopper Spacer FWD e = 184. . ii I 6. springs (12) and (141. * Reference . * The internal parts will come off together with the cover. stopper. and spacers (16) and (17) from cover (IO). so be extremely careful not to damage them when removing.5. Remove O-rings (I) and (2) from accumulator valve (4). 40 mm 5.8 e=10 IST e = 157. and assemble guide bolts.

* Be careful not to tighten the vice on the cover with excessive force.0 kgm) . VALVE Using pads. stoppers (13). and springs (12). TRANSMISSiON ACCUMULATOR VALVE AND ASSEMBLY Remove plugs (78) and (19) from cover (10). Assemble accumulator valve body (9) perpendicularly from above cover (IO).5 f 2. and remove guide bolts. Push in accumulator valve body (9). (14). and (13). (17). Plug : 5 mm (width across flats) * Do not remove the plugs unless necessary. 4. then secure with standard bolt. set accumulator valve cover (10) in vice. (15). a Plug : Thread tightener (LG-1) 18 I 19 10 DEW00326 6-jmm 2-3mm DAW00327 ASSEMBLY OF TRANSMISSION ACCUMULATOR ASSEMBLY 1.DISASSEMBLY 7. Ir Be careful not to let the thread tightener drip on to the hatched portion when coating with thread tightener. 3. . coat the thread with thread tightener as shown in the diagram below. Assemble spacers (18). * Assemble the body carefully and be sure that the O-ring does not fall out. Ir If plugs (18) and (19) have been removed. then tighten the plugs. then insert valves (11) from top of each spring. and (16).6 Nm (5. Ir Assemble the O-ring securely in the body groove. 5. then temporarily install with guide bolts. 2. Fit O-rings (20) and (21) in each groove of accumulator valve body (9). m Mounting bolt : 54 k 19. Mounting bolt : 8 mm (width across flats) 30-98 0 16 . and (12) to accumulator valve cover (lo).

and sleeve (15) from fill valve (7 1). stopper (7). Remove mounting bolts. 2. and spring (8). then remove fill valve assembly (17). Remove plugs (16) from modulating valve assembly (1). then remove ACC valve (41. fill spring (131. 4. Remove plug (121. remove cover (9) and O-ring (lo). 3. 30-99 0 . O-rings (141. remove cover (2) and O-ring (31.DISASSEMBLY AND ASSEMBLY TRANSMISSION MODULATING VALVE DISASSEMBLY OF TRANSMISSION MODULATING VALVE ASSEMBLY DLww3i9 1. Remove mounting bolts from modulating valve assembly (I). outer spring (51. inner spring (61.

Install O-ring (IO) and cover (9). stopper (7). Assemble sembly a f plugs (16) to modulating Be careful (LG-1 or LG-51 not to let the sealant drip.DISASSEMBLY AND ASSEMBLY TRANSMISSION MODULATING VALVE ASSEMBLY OF TRANSMISSION MODULATING VALVE ASSEMBLY 6 1.35 kgm) 30-100 0 4. and plug (12) to fill valve (111.15 + 0.4 Nm (3. O-rings (14). a O-ring : Transmission oil 3. then assemble filter assembly (17) to modulating valve assembly (I). Assemble sleeve (151. m Mounting bolt : 30. fill spring (13).35 kgm) .9 k 3.4 Nm (3. Assemble spring (8) (L=22). and ACC valve (4) to modulating valve assembly (I). outer spring (5) (L=49).9 + 3.15 ? 0. Plug : Sealant Coat with / sealant Z-3mm DLwm319 2. I &7mm valve as- (1). m Mounting bolt : 30. inner spring (6) (L=88). then assemble O-ring (3) and cover (2).

oil seal (5) and washer (6). Using press. pull out flange bearing 8 I DBW01332 I DLWO1933 (9). use a screwdriver to raise the caulked portion. and remove coupling (8) and retainer. t When removing cover (21. 30-101 0 . Ir Make match marks to prevent the coupling from being installed in the opposite direction. so do not remove it unless necessary. be careful not to damage cover (2) or tube (3). Front drive shaft I) Remove coupling and tube (1). Cover (2) is caulked at 2 places with a punch. ii) Remove washer (4). Make match marks a to prevent the coupling from being installed in the opposite direction. * When removing the caulking. * * .DISASSEMBLY AND ASSEMBLY DRIVE SHAFT DISASSEMBLY OF DRIVE SHAFT ASSEMBLY a 1. DEWOOBO! Caulking \ 5 \ 4 I DBW01931 2) 3) Loosen bolt (71. i) Remove cover (2). If cover (2) was removed and the oil seal was replaced.

Ir Be careful not to lose the bearing inside bearing cap (IO). I) DEW01939 Rear drive shaft DEW01997 30-102 0 . (12). 5) Remove ring (11) and bearing move spider (131. then re- r Center drive shaft 2.DISASSEMBLY DRIVE SHAFT AND ASSEMBLY 4) Remove bearing cap (IO) from spider. rear drive shaft 1) Carry out the same operation as in Step for the front drive shaft. Center drive shaft.

DISASSEMBLY DRIVE SHAFl- AND ASSEMBLY Center drive shaft 2) 3) Remove bearing cap (14). t inside (161. Ir Be careful not to lose the bearing seal bearing cap (14). Remove ring (15) and bearing move spider (17). then re- Rear drive shaft DSWO1940 30-l 03 0 .

assemble ring (II). then assemble cover (2) and caulk with a punch at points on diametrically opposite sides. replace the spider and bearing as a set. * Check that the bearing and washer are inside the bearing cap. * If cover (21 has been removed. bearing I) Set bearing (12) of spider (13) in mounting position. 2) 2. do as follows. bearing 18 Caulking 4 in di- I 30. I) Insert seal (5) and washers (4) and (6) in cover (2) and tube (3). * Use the same procedure for the front. & Bearing cap: Grease (G2-LI) * If the spider and bearing cap is worn. and rear drive shafts. be careful not to damage the bearing with the heat.DISASSEMBLY AND ASSEMBLY ASSEMBLY 1. * When welding strap (18) of the cap. and after assembling spider (13). * Assemble so that the grease nipples are facing in the same direction. center. DRIVE SHAFT Assemble seal bearing cap (IO). OF DRIVE SHAFT Spider. Ir Do not knock the flange rectly with a hammer. then install. Front drive shaft I) Press fit flange bearing (9).104 0 5 DBW01942 .

& Spiine portion: Grease (G2-LI) m Mounting bolt: 276 + 29 Nm (28. as in Step 3) D&V01936 Rear drive shaft .DISASSEMBLY 2) AND ASSEMBLY DRIVE SHAFf Align match marks. t Tighten the bolt to the specified tightening torque after installing to the machine.0 kgm) 19 I 8 3) Align match marks. & Spline portion: Grease (G2-LI) DEW00819 Center drive shaft 3. * If the spline is worn. * Check that the couplings are facing in the same direction. replace the whole drive shaft assembly. and tighten coupling (8) and retainer (19) with mounting bolt (7). and install coupling and tube (I).2 + 3. rear drive shaft * Carry out the same operation for the front drive shaft. Center.

Tire. 2. Jacking up chassis Jack up chassis and insert block 0 under front frame. mounting m : 317 kg Drive shaft Disconnect front drive shaft (2). Tire. A DLW01946 . and set block @ in position when the tires are slightly off the ground. set support 0 under the lift arm. 4. wheel Put sling around tire (I).DISASSEMBLY AND FRONT ASSEMBLY AXLE REMOVAL OF FRONT AXLE ASSEMBLY AStop the machine on level ground and install the safety bar on the frame. 6 kg 3. When removing the front frame inspection cover and disconnecting the brake tube to carry out the operation. then remove bolts and lift off. 113 pzJ Axle 1) Disconnect brake tube (3). wheel DLWO1944 I . 1. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. m + Jack up the front frame with the bucket.

+I kg 3) AND ASSEMBLY Axle : 1. * Adjust the height of the jack. m Awhen installing the nylon lifting tool. tighten the nylon rope fully. After removing the axle assembly. 30.107 0 . sling axle (41. make sure that it does not fall.060 kg (including oil 37&l Pull out axle from chassis in direction of arrow.DISASSEMBLY 2) FRONT AXLE Using jack and hoist. and remove mounting bolts (5). Ir Use a hoist and jack for the operation. then remove the mounting bolts. then lift off.

m a pJ * w Be careful not to tighten the tube nut too far.252 1.3 + 12. see TESTING AND ADJUSTING.9 & 12. Bleeding air.5 kgm) (Width across flats : 36 mm) m Drive shaft mounting bolt : 110.3 Nm (11.4 + 14.3 Nm (8.7 Nm (13. installation in the reverse order to m Ir Raise the front frame with the bucket.5 kgm) (Width across fiats : 41 mm) Bleed ttie air from the brake system and carry out an actuation check. Mounting bolt : 132. w Mounting bolt : 927 f 103 Nm (94.25 kgm) a Ir m . Tube nut : 80. Carry out removal. and remove block @ when the frame is slightly raised.25 kgm) . Use the bolt as a guide to align the mounting position.5 C 1.25 f 1. 30-108 0 .5 + 10. * For details.DISASSEMBLY FRONT AXLE AND ASSEMBLY INSTALLATION OF FRONT AXLE ASSEMBLY .

see REMOVAL SEMBLY. Ir Set the support securely so that it does not come out when the tire assembly is removed. 2. Lower the bucket to the ground and stop the engine. 1. Fuel tank Remove fuel tank (1). For details.DISASSEMBLY REAR AXLE AND ASSEMBLY REMOVAL OF REAR AXLE ASSEMBLY AStop the machine on level ground and install the safety bar on the frame. Jr Jack up the rear frame with a garage jack. and set block @ in position when the tires are slightly off the ground. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. OF FUEL TANK AS- Jacking up chassis 1) Set blocks @ between left and right rear axles and rear frame. * Set the blocks so that the angle of the tire angle on the opposite side does not change when the tire assembly is removed. 30-109 0 . I 2) DLW01952 Jack up chassis and insert block @ under rear frame. DLW01953 3) Set support @ under counterweight (2).

Tire. * Disconnect this brake hose from the connection with the tube at the left side of the engine compartment. wheel Put sling around tire (31. grease tubes 113 1) Disconnect brake hose (5). then remove bolts and lift off. 30-110 0 DLWO1958 . DLWO1957 2) Remove grease tubes (6) and (7). Brake. the m2/ mounting DLWU1956 5. * Make match marks to show position.DISASSEMBLY 3. REAR AXLE AND ASSEMBLY Tire. wheel mounting m : 317 kg Drive shaft Remove rear drive shaft (4). &I kg 4. * Remove the clamps of the grease tubes from the inside right of the engine compartment at the rear frame.

It is lowered too far. there is danger that it will damage the dust seal and bushing at the front pivot. then remove mounting bolts.100 kg 8 k 5 3) Lower rear pivot (8) a little at a time. fit a cover to the coupling to prevent damage to the dust seal and bushing at the front pivot. 4) Pull out axle and pivot assembly (13) from under chassis. &I kg Rear axle. taking care not to let it hit engine oil drain tube (IO). pivot : 1. m * Adjust the height of the garage jack and remove the axle. * Be careful not to lower the rear pivot too far. / 2) MWO1960 Sling one side of axle (9) and set a garage jack under axle housing on opposite side. the pivot will go down. AND ASSEMBLY REAR AXLE Axle 1) Secure rear pivot (8) to axle with chain @or wire. move to the rear. then remove from front pivot (12). * When removing the axle. remove chain @ or the wire used to hold it. so support it with a garage jack.DISASSEMBLY 6. * When removing the axle assembly. * Use a hoist and jack for the operation. DEW01964 . t After pulling the assembly out from the chassis. Ir Fix the pivot securely so that it does not move.

and remove thrust washer (18). DBW01965 DLW01966 Rear pivot : 120 kg 8 DBW01367 DLWO1970 8. It Be careful to fit the lifting tool so that it will not come off. 1) Remove trunnion * 2) Remove mounting bolts. then lift off carefully. 5) Remove retainer (19) from rear pivot. jL retainer from front pivot (221. Sling the rear pivot.DISASSEMBLY 7. m 30-112 0 DBWOlStXI . m 3) Remove 4) Lift off rear pivot (81. then remove packing (20) from retainer. & kg plate (17). then remove dust seal (25). a 6) Remove bushing Front pivot 1) Remove remove 2) (21) from rear pivot (8). then packing (23) from retainer. front pivot. AND ASSEMBLY REAR AXLE Rear Divot cap (14). /1 Remove bushing (24) from. them remove thrust plate (151 and thrust washer (16).

5 + 10.3 Nm (11.0 + 15. Divide the torque and tighten in three steps. Mounting bolt : 1.3 Nm (8. After installing the axle assembly. Coat the mounting bolts with thread tightener.25 kgm) Be careful not to tighten the tube nut too far.25 * 1.324 + 147 Nm (135.25 rf:1.3 + 12. do not tighten in one step. Mounting bolt : 110. Align the pilot portion securely and take care to assemble with the yoke facing in the correct direction. When tightening the mounting bolts. and take care to assemble the coupling facing in the correct direction.0 * 1. Mounting bolt : Thread tightener (LT-21 @qz-pg t & Check the assembly direction of the packing and dust seal. remove the chain or wire.7 Nm (11.25 kgml a + * * w Use the bolt as a guide to set to the mounting position. Tube nut : 80.5 kgm) Wash and remove all oil and grease from the mounting bolts and bolt hole.DISASSEMBLY INSTALLATION ASSEMBLY Carry out removal.5 kgm) (Width across flats: 36 mm) a * Ir m * m 8 : 5 Align the match marks.9 f 12.0 kgm) (Width across flats : 41 mm) D * t & Mounting bolt : 108 rt 14. dust seal : Grease (G2-LI) Front of front pivot Rear pivot c Dust seal side Rear of front pivot + Retainer Grease side Grease side Bushing 1 Dust seal side DBW01972 J 30-l 13 0 . Packing. REAR AXLE AND ASSEMBLY installation OF REAR AXLE in the reverse order to Mounting bolt : 927 5 103 Nm (94.

.DISASSEMBLY & AND Bushing : Grease (G2-LI) . * Wipe off any grease 30-l 14 0 REAR AXLE ASSEMBLY that is squeezed out. Bleeding air from brake system For details. Greasing Grease each pivot well. . see TESTING AND ADJUSTING.

then remove ential cover (5). 2) Lift off axle housing assembly DBW01975 (6). Differential cover Remove bleeder screws (4).021 kg (front) Axle assembly : 971 kg (rear) brake tubes (3).DISASSEMBLY DISASSEMBLY DIFFERENTIAL 1. * Set blocks to prevent the assembly from tilting when the housing assembly on one side is removed. differ- Axle housing 1) Sling axle housing assembly (6). & kg Axle housing assembly : 280 kg (front) kg C5?I Axle housing assembly : 270 kg (rear) I DBW01976 30-l 15 0 . OF ASSEMBLY oil drain plugs (I). Axle assembly 2) DIFFERENTIAL AND ASSEMBLY el R:iove : 1. * Make match marks on the housings to prevent mistakes between the left and right axle housings. and remove housing mounting bolts. Draining Remove %#I 2. 4. and drain oil. Axle oil : 37 e Axle assembly 1) Set axle assembly (2) on pallet. m 3.

* Loosen the mounting bolts of the coupling. Differential carrier assembly 1) Lift off differential carrier assembly (I I) from differential housing (13). 8.DISASSEMBLY 5. blow in compressed air from portion a. L=50mm). Make marks to distinguish between the left and right bearing carriers. be careful not to * damage the housing and piston surface. Use a puller to remove the bearing cone from the bearing carrier. Fit the sling around the flange half. raise evenly. AND 8 Cage assembly : 46 kg &I kg Remove O-ring (9) from cage. DIFFERENTIAL ASSEMBLY Cage I) Screw in forcing screws. and using guide bolts (7) (16 mm. and fit temporarily. and screw in forcing screws. and remove. 2) Remove square ring and D-ring. When removing the piston. and remove bearing carrier (12). raise housing and piston (IO). blow in air suddenly to make a gap between the housing and piston. P=2. Use a puller to remove the bearing cone from the bearing carrier. Ir Check the number of shims and use as reference when assembling. r+lkg Differential carrier assembly : 120 kg DBW01980 30-116 0 . 2) 6. remove cage assembly (81. * Be extremely careful not to let the lifting tool come off when removing. Bearing carrier assembly 1) Sling differential carrier assembly (II). Check the number of shims and use as reference when assembling. Brake piston Install bleeder screw. * If the D-ring is damaged. then raise. DEW01979 7. then use a screwdriver to lever it out and remove it.

car- carrier DEW01991 3) Remove thrust washer (16) from bevel gear and flange half assembly (151. washers (18). / 16 17 15 DEW01992 4) Remove spherical spider shaft.DISASSEMBLY AND ASSEMBLY DIFFERENTIAL 2) Remove plain half (74) from differential rier assembly (11). I DBWO1984 30-l 17 0 . and 18 DEW01983 5) Remove spherical washers (20) and pinion gears (21) from spider shaft (19). * Check the match marks on the assembly and flange half. pinion shaft. then remove side gear (17).

9. 25 Bevel gear.DISASSEMBLY 6) Remove AND side DIFFERENTIAL ASSEMBLY gear (22) and thrust washer (23). Coupling I) Remove mounting bolt (281._ and (27) from plain half (14) and flange half 15 DBWO1986 (25). r 26 25’ 14 DEW01987 31 28 29 28 30-118 0 . 23 7) Turn over bevel gear and flange half assembly (151. 2) Remove oil seal (32). then remove mounting bolts (241. and remove flange half (25). and O-ring (31). * Do not remove the protector press fitted to the coupling unless necessary. coupling (301. flange half assembly : 50 kg Bevel gear : 24 kg Flange 8) half : 25 kg Use a puller to pull out bearing cups (26) . then remove holder (291.

* 2) 11. pull out pinion gear (33) from cage assembly (81.DISASSEMBLY AND ASSEMBLY DIFFERENTIAL 10. Remove spacer (35) and bearing cone (36) from pinion gear (33). Pinion gear 1) Using press. Cage Remove bearing cups (38) and (39) from cage (37). ‘39 DEW01991 30-l 19 0 . then remove bearing cone Press 4 stand DLWcQ3m Be careful not to let the bearing catch on the press stand when removing.

Check that there is no clearance at the mating surface of each part. Pinion gear 1) Press fit bearing cone (36) to pinion gear (33). then check again. Ir Press fit so that the oil seal is level with the surface of portion b.120 0 . Coat seal press-fitting portion of cage (37) with gasket sealant. check that it can be rotated smoothly by hand. Ir Use a press to apply pressure at the specified load to the bearing. J.187 mm * When the case has been rotated at the specified load. Cage Press fit bearing cups (39) and (38) to Sr After press fitting the cup. 62 N DBW019!3 (6.DISASSEMBLY DIFFERENTIAL AND ASSEMBLY ASSEMBLY ASSEMBLY OF DIFFERENTIAL 1. Starting turning force @: Max. * Coat the cup press-fitting portion & Cup press-fitting portion : Oil cage (37). Sr Press load : 145 KN (14. check is no clearance at portion a.8 ton) & Bearing : Oil (axle oil) * Reference . and press fit bearing cone (34). 2) Assemble pinion gear (33) to cage (371. and assemble spacer (35).3 kg) End play : 0 . (axle oil) DLWOQ34 2. that there with oil. 3) (32). replace the bearing and spacer. Ir If the rotation is heavy. then press fit oil seal . 6 Oil press-fitting portion : Gasket sealant (Seal end 2421 6 Lip of oil seal : Grease (G2-Ll) ‘145 KN (14.8 ton) 33 ‘275rnm \\ * /J DEWOlS94 30. and rotate the case to settle the bearing.0.

Length = 55mm). * Tighten the mounting bolts on diametrically opposite sides. * When inserting the coupling. Ir Wash and remove all oil and grease from the threaded hole of the bevel gear. Differential carrier assembly I) Press fit bearing cups (27) and (26) to plain half (14) and flange half (25). and tighten fully after assembling. Pitch = 2mm. and holder (29) to pinion gear (33).94 Set bevel gear (40) on block @ with gear side at bottom. check that there is no clearance at portions c and d. then install guide bolts @ (Thread dia. * Check that there is no clearance at mating portion e of flange half (25) and bevel gear (40). be extremely careful not to damage the seal. Coupling Install coupling (30).0 + 2.5 f 19. and tighten mounting bolts.0 kgm) 4.0 kgm) 40 I DBW01996 25 I e\ e e 40 D&v01997 . O-ring (31). & Mounting bolt : Thread tightener (LT-2) B Mounting bolt : 176.0 t 6. * After press fitting the cups. 6 Bearing cup press-fitting portion : Oil (axle oil) 27 8 k f u C C 25 DLWOO393 d 2) DLWC03. * Tighten the mounting bolts temporarily. = 14mm.DISASSEMBLY AND ASSEMBLY DIFFERENTIAL 3.6 Nm (18. & Mounting bolt : Thread tightener (LT-2) (When tightening fully) m Mounting bolt : 549 f 59 Nm (56.

& Spider shaft : Oil (axle oil) & Spherical washer : Oil (axle oil1 Assemble spider shaft. align with dowel pin of plain half (141. &Thrust washer : Grease (G2-LII * Be careful not to coat with too much grease. & 4) AND ASSEMBLY Thrust washer 23 sliding surface : Oil (axle oil) Coat spider shaft (19) with oil. pinion gear. then assemble spherical washers (201. and be careful that it does not fall out when assembling. assemble pinion gears (21). then assemble side gear (22). and spherical washer (18). align. + When assembling the thrust washer. * When assembling the thrust washer. I DBW01993 18 DLWOO339 6) Assemble side gear (17) to bevel flange half assembly (15). be careful not to assemble it upside down. 7) Coat thrust washer (16) with grease.with dowel pins (411. then assemble to bevel gear and flange half assembly (15). coat with thrust washer oil. then stick thrust washer (16) in position. be careful not to assemble it upside down.DISASSEMBLY 3) 5) DIFFERENTIAL Turn over bevel gear and flange half assembly (151. install thrust washer (23). 30-122 0 gear and 6 .

P = 2. Ir Adjust so that shim thickness “t” is within a range of 0.0 kgm) 5.DISASSEMBLY AND ASSEMBLY DIFFERENTIAL 8) Align match mark on plain half (14) with bevel gear and flange half assemble (151.10 (. and install. Ir When inserting tool Cl in the differential housing. pinion gear and with the same 30.0. coat with oil thinly.5 f 19.6 Nm (18. !z 2 5 Adjusting shim of cage I) Assemble guide bolt @ (16 mm. MD + 0. then measure distance L between bevel pinion gear end face and tool Cl with inside micrometer or cylinder gauge. 3) Selection of shims t = C . * Mark the end face of the pinion gear with an electric pen as follows. w Mounting bolt : 176. * Tighten the mounting bolts on diagonally opposite sides.0 + 2. then assemble cage assembly (8) to differential housing (13) without shims. Ir Align the match marks securely.3 a : Deviation from dimension A b : Deviation from dimension B * Use the actual measured value for dimension D.(B + b) L : Actual measured value D: Diameter of tool Cl A: 212 + 0. m Mounting bolt : 277 + 32 Nm (28. and insert uniformly so that it is not twisted.1.25 kgm) 2) Insert measurement tool Cl to differential housing (131.123 0 .3 B : 64 f 0.25 f 3.(L + D/2) t : Shim thickness C: (A + a) . L = 55mm).91 .61 mm.01) i f L Dimension DBW02002 b (unit: mm) Dimension a (unit: mm) Always use the bevel bevel gear in pairs number.

3. 11 2) Using guide bolt @I (14 mm. 42 43 f a 7.25 mm 30. Standard shim thickness on one side: 0. IL DBWOZ'XJE I) 12’ 3) Tighten mounting bolts of bearing carrier assemblies (12) and (12-I). * Reference value . * Reference value .6 Nm (18.75 mm .3 . & Bearing cup press-fitting portion : Oil (axle oil) * After press fitting the bearing.3 . * Starting turning force: 13 . Shim thickness (bevel gear side): 0. and assembly the diifferential carrier assembly to defferential housing. then set to mounting position on differential housing. adjust the shim thickness. assemble a shim to bearing carrier assembly (12-I) at plain half end and a shim to bearing carrier assembly (12) at bevel gear end.DISASSEMBLY 6. and adjust. -Bearing oil : Oil (axle oil) * To settle all the parts. * Assemble the bearing carrier assembly without the square ring and D-ring.7 24 0 I Spring balance DBWO2WB . P-2. * Rotate the bevel gear and coat the bearing with oil.Measure preioad of bevel gear with a spring balance and check that it is within standard range. Shim thickness (plain half side): 0.1. AND DIFFERENTIAL ASSEMBLY Bearing carrier Press fit bearing cones (42) and (43) to bearing carrier assemblies (12) and (12-l).0 kgm) 4) .95 mm * Assemble the differential carrier assembly so that the bevel gear is on the right side as seen from the cage mount end. Adjusting shim of bearing carrier 1) Raise differential carrier assembly (1 I). rotate the bevel gear when tightening.5 -t 19. w Mounting bolt : 176. L=55mm). check that there is no 4243 clearance at portion f.0 + 2.36 N (1.7 kg) * If the starting turning force is not within the standard value.

DIFFERENTIAL (8). assemble shim (44) selected in Step 5. do not change the total for the left and right shim thickness. f Assemble the shims with the thinner shim on the inside and the thicker shim on the outside. AND ASSEMBLY Cage 1) Fit O-ring (9) in groove of cage assembly & O-ring : Oil (axle oil) * Coat thinly with oil. then install cage assembly (8). 2) To get backlash within standard value.46 mm * t Measure the backlash at three places around the circumference of the bevel gear.25 + 3. I 2) 9. Backlash standard value: 0. and check that the variation between each measurement is less than 0.30 .9 Nm (28. * If the backlash is too small: Move part of shim a to shim b. * When moving the shim. move part of shim on bevel gear side to opposite side. / b 30-125 0 . * If the backlash is too large: Move part of shim b to shim a.25 kgm) Adjusting backlash backlash of bevel gear with dial I) Measure gauge. m Mounting bolt : 277 + 31.0.DISASSEMBLY 8.1 mm. - 0Ewo2010 Install guide bolts @ to differential carrier assembly (II).

Reduce shims at pinion gear to bring closer to bevel gear. Move bevel gear closer to pinion gear and adjust backlash correctly. from at pinion away bevel gear. DEW00908 DEW00904 Bevel pinion gear is too 1. from at pinion away bevel gear. do not change the left and right. 2. DEW00908 Bevel gear is too far fron n pinion 1. Adjusting tooth contact Coat face of 7 or 8 teeth of bevel gear lightly with red lead (minimum). DEW00909 Bevel gear is too close to pinion 1. Reduce shims gear to bring gear.DISASSEMBLY DIFFERENTIAL AND ASSEMBLY 10. Adjust 3 by moving DEW00909 shims between . of shims. Move bevel gear to pinion adjust closer gear and backlash correctly. gear is too bevel 1. increase shims gear to move gear. Hold the bevel gear by hand to act as a brake. 2. gear. increase shims gear to move close to bevel gear. It should be in the center the tooth Bevel pinion far from of height. ? * When adjusting the bevel gear. at pinion closer to bevel gear. Move away bevel gear further from pinion gear and adjust backlash correctly. Move away bevel gear further from pinion gear and adjust backlash correctly. Always 30-126 0 keep the same the preload total thickness of the bearing. Tooth contact Procedure Cause The tooth contact pattern Adjust should about the cage. 2. Adjust start from when 5 mm from the toe of the pinion adjusting gear for adiustment by adjusting the shims the bevel gear in the same at way as backlash. the bevel gear and cover about 50% of the length of the tooth. rotate the pinion gear forward and backward and inspect the pantern left on the teeth. 2.

Put a pad under tool C3 to prevent damage to the piston surface. 6 Piston and piston mounting surface : Grease (G2-U) 2) Install piston press-fitting tool C2 to differential housing.0 f 2.6 kgm (18. Brake piston 1) Assemble D-ring (46-l) in groove of brake piston (10). & Square ring. install tool C2 to make sure that the center of the piston is pushed. Coat the brake piston and piston mount * thinly with grease to prevent the O-ring from being twisted or cut. and tighten tool C3 uniformly to press fit. When pushing the piston with the end face of tool C3. / DEW02015 DBWOZO16 Adjustment washer Differential housing DBWJ2019 -- DBWO’iUlS . * When assembling bearing carrier assembly (12-11. Bearing carrier assembly Remove bearing carrier assembly (12-11. so do not hit with a hammer when assembling. Do not hit with a plastic hammer to insert. If a hammer is used. D-ring : Grease (G2-Ll) m Mounting bolt : 176. the D-ring and piston will be damaged. Press fit completely until the piston contacts the housing.5 It 19.DISASSEMBLY AND ASSEMBLY DIFFERENTIAL 11. * Coat the square ring with grease and be careful not to let it drop out when assembling. then assemble again using adjusted shims.0 kgm) 12. there is danger that the square ring may fall out. assemble square ring (45) and D-ring (46).

Checking for brake oil leakage 1) Install bleeder screw.. The shape of the differential cover at portion * is different. 3) Install tools C5 and C6 to brake tube mount (47). 30. Coat continuously with a bead diameter of 2 . then bleed air inside cylinder.. remove the brake piston. f After raising pressure to 1. the right for details of coating. . Differential 1) Wash and remove all oil and grease from mounting surface of differential cover (5) and differential housing (13).128 0 DEW02022 \ Bead diameter of 2-3mm ‘5 DLW01587 ..9 MPa (50 kg/ cm*). * See the diagram on.35 MPa (3. J. leave for 5 minutes and check that the drop in pressure is less than 0.4 MPa (14 kg/ cm*). DIFFERENTIAL .. screw the mounting bolts into the forcing screw holes. turn back one turn. * If there is oil leakage. 5) If the result of the inspection shows that there is no oil leakage. so coat and take care that the bead does not come off.O kg/cm*). and raise. Guide bolt : 14 mm.DISASSEMBLY AND ASSEMBLY 13. insert the piston fully.9 MPa (50 kg/cm*)..0 kgm) cover 15.5 kg/cm*). Coupling Tighten mounting bolts of coupling (30) fully. then assemble again. * After raising pressure to 4..0 + 6. P = 2.1 MPa (1 . . 4) Operate tool C7.. A 47 y@& ‘c5 A6 yi. Ir Temporarily assemble the bleeder screw so that gasket sealant does not get into the mounting hole of the bleeder screw.3 mm.1 Differential housing DLwo202c DEW02021 14. & Mounting bolt : Thread tightener (LT-2) w Mounting bolt : 549 + 59 Nm (56. 2) After screwing in tool C3 of each piston press-fitting tool C2 fully. * After checking for brake oil leakage. L = 40 mm * When installing the differential cover.. raise the pressure further to 4.4 MPa (14 kg/cm2). then coat with gasket sealant. check the O-ring and other parts for damage. and raise pressure to 1. leave for 5 minutes and check that the drop in pressure is less than 0.

see Step 13 in ASSEMBLY AXLE HOUSING ASSEMBLY.6 Nm (18. then tighten bleeder screw (4) fully. & Cover mating surface : Gasket sealant (Loctite 515) w Cover mating surface : 176.0 kgm) 3) Check that there is no gasket sealant stuck to the bolt hole. I 16. Refilling with oil t For details.DISASSEMBLY AND ASSEMBLY DIFFERENTIAL 21 Install differential cover (5) to differential housing. OF 30. Coat carefully with gasket sealant so that * there is no break in the gasket sealant.129 0 .5 * 19.0 + 2. Axle housing DEW02023 1 assembly 17.

DISASSEMBLY AND ASSEMBLY AXLE HOUSING DISASSEMBLY OF AXLE HOUSING ASSEMBLY 1. Axle assembly : 1. Draining oil Remove drain plugs (I) and drain oil. Sr Make match marks on the housings to prevent mistakes between the left and right axle housings. and remove housing mounting bolts. eJ ks 3. and use eyebolts to lift at 4 points and move. * Do not remove the differential cover unless necessary. be careful not to damage the bleeder screw.021 kg (front) Axle assembly : 971 kg (rear) Differential cover Using forcing screws. * Set blocks to prevent the assembly from tilting when the housing assembly on one side is removed. remove differential cover (3). I %k * Set axle assembly &I kg 2. DLWO2026 30-130 0 . remove the 4 cover mounting bolts. (F) Differential assembly : 300 kg (RI Differential assembly : 320 kg Axle housing 1) Sling axle housing assembly (4). * When moving the differential assembly. Axle oil : 37 f? (2) on pallet. * When removing the differential cover.

plate 1) Remove lock bolts (7) of plate (6) and brake 7 6 DBWOi!028 - DLW01599 5. Brake disc.DISASSEMBLY 2) AND ASSEMBLY Lift off axle housing &I kg Axle housing assembly assembly AXLE HOUSING (4). DBWOZ027 4. 2) Remove outer ring (IO). and stand the axle housing assembly upright. * Be careful not to damage the front face of the disc. outer ring 1) Remove shaft (9). Sun gear shaft. : 280 kg (front) Axle housing assembly : 270 kg (rear) l+l kg Ir Change the place for the axle housing lifting tool. 3) Remove wave spring (8). face in contact 8 . * Be careful not to damage with the brake disc. 2) Remove plate (6) and brake disc (5).

+ When pulling up with the puller. Remove shims (14). * The planetary carrier assembly is heavy. HOUSING brake O-ring IiF Detail P ei kg 7. l+l kg * Planetary carrier assembly 8 N” DBWOZOU 4 : 48 kg Lifting tool @ 5 \lb I DBWO2033 2) 8. Jr Record the shim thickness reference when assembling. &?Ikg DLWOlKJZ 15 Ring gear : 15 kg . * Remove the O-ring. then lift off planetary carrier assembly (13) with lifting tool 0. * Assemble spacer @ to the end face of the puller bolt to adjust the height. be extremely careful that the teeth of the puller do not come off the ring gear. and 30-132 0 I DEQV02034 I use for Ring gear Use puller 13 and pull up uniformly to remove ring gear (15) from axle housing (16).DISASSEMBLY 6. so be extremely careful when removing it. AND AXLE ASSEMBLY Brake housing Remove mounting bolts (1 I). Brake housing I DBW02032 : 25 kg Planetary carrier assembly 1) Remove axle shaft mounting bolts. then remove housing (12).

f. t the bearing as follows. Copper hammer 16 D&V02036 16 DLW01609 16 el Axle shaft assembly el kg Axle housing : 85 kg kg : 90 kg DE. Install the puller so that the teeth the whole circumference of portion bearing (18). If the shaft is heated.DISASSEMBLY 9. DBW02033 * Remove 4) When removing bearing (18) of axle shaft (171. AXLE HOUSING AND ASSEMBLY Axle shaft 1) Stand housing and shaft assembly.‘02037 3) Pull out bearing (18) from axle shaft (171.Do not use a gas cutter or heat to remove the bearing under any circumstances. then raise 2) housing (16). be careful not to let adjustment bolt of puller contact outside circumference a of oil seal and sleeve (19). Put a copper hammer in contact with end face of axle shaft (171. the hardening of the shaft will be reduced and the strength will drop.%‘. . grip b of a / / DBWOZ039 30. then knock in shaft and rotate housing (16) to remove shaft.133 0 .

turn bolt (21) to loosen it. so be extremely careful that the puller does not come off from the bearing. Insert washer between bolt (21) and flange surface. and remove bearing (18). . t When installing tool Dl. fix the bearing puller securely in place so that there is no play. Ir The puller has little grip on the bearing. 30-l 34 0 I DBW02042 . add a washer to the flange surface to adjust the height of bolt (21) when removing bearing (18). Bolt (21) : l-14UNF DLWOI611 6) Insert tool Dl under bearing (181. * If the thread of bolt (21) is too short. be careful not to deform portion e of oil seal sleeve It 7) (19). + Replace the oil seal and sleeve assembly with a new part. f Screw the bolt fully into the thread. When doing this.DISASSEMBLY 5) AXLE HOUSING AND ASSEMBLY Install bolt (21) in portion d of tool Dl. and assemble tools D2 and D3.

I DEW02044 carrier pin in 27 17 2) DLWO1614 Using press. Axle housing oil seal (22) from axle housing 1) Remove (16).AXLE HOUSING DISASSEMBLY AND ASSEMBLY 10. 27 . Be careful not to knock the spring + too far. 16 24 zz k 4 I 11. or When removing the shaft. use a block at the end face of the shaft. remove shaft (27). Planetary carrier 1) Knock in spring pin (26) of planetary (25). 2) Remove bearing cups (23) and (24) from axle housing (16).

.\. el kg Planetary carrier : 30 kg 28.DISASSEMBLY 3) Remove AND ASSEMBLY spring AXLE pin (26) from HOUSING shaft (27). \ 30-136 0 29 . then remove bearing cone (29) and spacer (30).I DEW02045 4) Remove pinion gear (28) from planetary carrier (251.

AXLE HOUSING OF AXLE HOUSING Axle housing Press fit bearing cups (24) and (23) to axle housing (16). I b OBW02049 8 DBWOaOl t / DBW02050 . * After press fitting the cup. a DBWO2047 DBWO2051 6 2. & Sleeve contact surface of shaft : Oil (axle oil) * After press fitting the oil seal sleeve. check that surface c is level with the surrounding surface. * Coat the sleeve contact surface portion b of the oil seal thinly with axle oil. Be careful not to deform the parts when * hitting with a hammer. * Coat the bearing cup press-fitting portion of the axle housing with oil. check that * there is no clearance at portion d. check that there is no clearance at portion a.DISASSEMBLY AND ASSEMBLY ASSEMBLY ASSEMBLY 1. * Be careful not to fit the bearing at an angle. & Bearing press-fitting portion : Oil (axle oil) After press fitting the bearing. 2) Press fit bearing (18) to axle shaft (17). Bearing cup press-fitting portion : Oil (axle oil) Axle shaft I) Press fit axle shaft (17) and oil seal sleeve I (19).

* Adjust the height of the seal support with the adjustment bolts. shaft I) 2) Stand shaft (17) upright and install tool D4. coat the oil seal press-fitting portion of the housing with oil. * Use the weight of the axle housing to insert it. then insert to shaft carefully. f Set tool D4 securely so that it does not come off.DISASSEMBLY 3. then set so that the clearance is uniform. put the top surface of tool D4 in light contact with seal (22). AND ASSEMBLY AXLE HOUSING Housing. Assemble oil seal (22) to oil seal sleeve (19). * When assembling the oil seal. DEW02053 DEW02054 Oil (axle oil) 3) 4) Raise axle housing (16) to a horizontal position. Align axle housing (16) with oil seal pressfitting portion. & Lip of oil seal : Grease (G2-LI) D4 D4 DEW02052 Flange surface * & When raising axle housing (161. Oil seal press-fitting portion :. be extremely careful not to damage the lip surface. then lower housing slowly. * Stop axle housing (16) before press fitting the oil seal. 16 DBWO2055 30-138 0 .

..DISAS.2 mm Be careful not to install the seal at an angle. Flange sur&e DEW02058 Adjusting end play I) Stand axle shaft and housing assembly (4) upright. Flange surface * Ir After press fitting the bearing to the shaft.6 KN (2 ton) DBW02056 6) Pull out tool D4 horizontally. and press fit until end play is 0. DEW02057 / . check that there is no stepped portion between the seal and the sleeve and that surface e is level with the surrounding surface. portion : Oil (axle oil) 19.. &Bearing * Press-fitting cone press-fitting force : Approx. DBWO2059 .1 mm. then rotate axle housing by hand. * Reference Clearance (f) : 10. I / I/ A//‘/O//A//// e 4. * Secure flange g so that the axle shaft and housing assembly does not fall over. Ir Do not press fit so that there is no end play.SEMBLY AND ASSEMBLY 5) AXLE HOUSING Press fit bearing (30) to shaft (171../..5 + 0.

. then assemble shim adjustment tool D5 to portion j of planetary carrier.2 kg). Repeat Steps 3) and 4) to bring the starting turning force within the standard value. \ h 20 . turning force is less than 44. press fit the bearing again and repeat the operation from Step 3). sling at two points and raise 20 . At the same time as assembling axle shaft and housing assembly (4) to the axle housing. .1 . Rotate axle shaft (17) and hit the fiange portion with a copper hammer several times in the direction of the arrow to remove axle shaft (17). . * Install planetary carrier (25) without the gears.70.DISASSEMBLY AND ASSEMBLY AXLE HOUSING 2) install planetary carrier (25) to spline of axle 3) 4) shaft (171.5 kg).6 N (7.30 mm.1 N (4.5 . adjust again as fol- lows. w Bolt : 43 Nm (4.6 N (4. If the starting turning force is more than 70. Starting turning force X : 44.4 kgm) Make sure that bearings (18) and (30) are fully settled. 7t Remove all adhesive from the mounting bolts and mounting bolt holes of the axle shaft before using.2 turns. Rotate axle housing (16) and tighten retainer mounting bolt (31). then measure starting turning force “X” at drill hole h of axle housing (16). and install mounting bolts.30mm DLWOlK30 30-140 0 .2 kg) f 25 31 rl l-l If the starting turning force is not within the standard value. If the starting . loosen mounting bolt (31) of the shim adjustment tool 1 . .7. .

Assemble bearing cone (29) to gear (281.DISASSEMBLY AND ASSEMBLY AXLE HOUSING 5) Using depth micrometer. Subtract thickness t of the jig from H to give the value (H -t).t)z io5 6) After deciding shim. measure distance H from tool D5 to axle shaft end face. . and press fit shaft. DEW02070 27 27 DLWO1637 * Align the holes of shaft (27) and spring pin (26). and knock in the spring pin so that it is level with the surface of the carrier. Shim thickness = (H . and set gear (28) in position. DBW02060 53) 29 DLW01636 Align shaft (27) and spring pin hole (33). loosen bolt and remove planetary carrier (25). & Shaft : Oil (axle oil) Make surface level I 1 28. * Assemble the spacer from the brake housing side. lift up spacer (321. Planetary carrier 1) 2) Assemble spacer (32) inside planetary carrier (25). DBWOlE34 DBW02071 . 5.

Planetary carrier assembly 1) Assemble shim (14) selected in Step 5) to end face of axle shaft. Press fit horizontally and make sure that the ring gear is not at an angle. Mounting DBW02075 30-142 0 .0 kgml Clean the end face of the shaft and the planetary carrier spline before assembling. Ring gear Press fit ring gear (15) to axle housing insert pins (34). DEW02072 I 6. When assembling the planetary carrier.5 i 10. t Check that the gear rotates smoothly. be extremely careful not to get your fingers caught in the gear. * Wash and remove all oil and grease from mounting bolts and mounting bolt holes of axle shaft. then install planetary carrier assembly (13) and install mounting bolts. DBW02076 6 m t a bolt : Thread tightener (LT-2) Mounting bolt : 927 i 98 Nm (94. then assemble.DISASSEMBLY 4) AND AXLE ASSEMBLY HOUSING Tap differential side of gear (28) and end face of shaft (271. and push back bearing (29) so that the gear can rotate smoothly. 16 34 DBWO2073 7. t + (161. then Align the pin holes of the ring gear and the housing.

+ Coat the O-ring thinly with grease.143 0 . Starting turning force X: 44 . * Reference value . End play of planetary carrier : 0 .5 . Front (left) Oil filler . & O-ring : Grease (G2-LI) 2) Align axle housing (4) and portion i. Rear (left) v DEbW2f178 30. AND ASSEMBLY AXLE HOUSING 1 Make sure that bearing is fully settled. Axle housing . and measure end play of planetary carrier at end face of planetary carrier.gauge to axle housing (41.0. Plug for measuring the brake disc wear Dswozcvs Mounting bolt f f Assemble the axle housing so that the plug for measuring the brake disc wear is facing the rear. then check turning force “X” at axle housing assembly (4) and drill hole (h).2 kg) install stand of dial.71 N (4. + Reference value . Front (right) No oil filler .7.1 mm B:ake housing 1) Assemble O-ring (35) in groove of axle housing (4). Ir Be careful that the O-ring is not twisted or caught when installing. and install brake housing (12).DISASSEMBLY 2) 3) 8. Rear (right) .

2082 8 2) Assemble shaft (9). then assemble both to range (h). plate 1) Align end gap of wave spring (81. and plate (6) in order.DISASSEMBLY 9. wave spring (8). and is also within range (h). J.liog boss hole for measuring brake dii wear DEW02081 Assemble brake disc (5). * Always install the shaft before assembling the brake disc. brake disc (51. or Always use 2 wave springs together. * Always align the match mark with the spline portion when assembling. plate (6). * Be careful not to damage the surface in contact with the brake disc. embly of spring en 1 2) DBW02030 0.144 0 DEW02029 . then assemble. * Check that there is no damage to the front face of the plate when assembling. Be careful not to damage the front face of the brake disc. AXLE HOUSING AND ASSEMBLY Sun gear shaft. and plate. Match marks DEW02080 DBWO. outer ring 1) Align match mark of outer ring (IO) with spline portion at bottom of brake housing (121. Ir Assemble so that the end gap of the wave spring is on the O-ring boss hole side for measuring the disc wear. Brake disc. wave spring (8). L----w 30. I IO.

The shape at portion f is different at the differential housing end. and tighten. . + When assembling. then align spline groove and guide bolts 3 (20 mm.0 i 6. and assemble carefully. Wash and remove all oil and grease from * the axle housing and differential housing mounting surface.5. Coat so that the bead does not come off.0 kgm) - Bead diameter : 2-3mm 4 DBWO2302 DEW02083 . then 7 6 - 11. Axle housing DBWo2084 assembly 11 Wash and remove all oil and grease 2) 3) from mounting surface of axle housing (4) and differential housing (361. then coat with gasket sealant. L=230mm).DISASSEMBLY 3) AND ASSEMBLY AXLE HOUSING Assemble brake disc (5) and plate install lock bolt (7). See the diagram on the right for the coat* ing procedure. Install mounting bolfs (37) on diagonally opposite sides. * When assembling the axle housing.3 mm. w Housing mounting bolt : 549 + 59 Nm (56. (61. then coat with a continuous line of gasket sealant so that there is no break. Coat with a continuous bead diameter of 2 . . be careful not to damage the plate surface. a Mating surface of housing : Gasket sealant (Loctite 515) Raise axle housing (4) horizontally. be careful not to cut the gasket bead. P=2.

Differential cover If differential cover (3) was removed. * Set the axle horizontal and add a small amount of oil.DISASSEMBLY AND AXLE ASSEMBLY 12. (Before installing to chassis) * After installing to the chassis. 30-146 0 position when checking OBWO2243 l . see DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY. add oil and check the oil level again. I HO”SlNG 3 P”“^n / 13. oil level) * Set to a horizontal the oil level. Refilling with oil Tighten drain plugs (1) and add oil through oil filler (38) to specified level.

see REMOVAL OF CAB AND FLOOR FRAME ASSEMBLY. ADisconnect the cable from minal of the battery. ALoosen the oil filler cap slowly to release the pressure inside the hydraulic tank. check the number and thickness of the shims. and keep in a safe place. 4. * If there are shims. Lower the bucket to the ground and stop the engine. Remove cab and floor frame assembly.DISASSEMBLY REMOVAL PIN AND ASSEMBLY CENTER HINGE PIN OF CENTER HINGE AStop the machine on level ground and install the safety bar on the frame. Disconnect center drive shaft (4). the negative (4 ter- 1. DEW01904 . Loosen plugs (I) at top of hydraulic tank filter and plugs (2) of pump piping to prevent oil inside tank from flowing out. a . Then operate the control levers several times to release the remaining pressure in the hydraulic piping. Remove lock bolt at rod end of steering cylinder. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. For details. a B z 1 5 3. then remove pin (3). 2. Do the same for both left and right steering cylinders.

Disconnect stop valves as follows. I) Adjust height of rear frame (IO) and set block @ in position. * Disconnect hose (5) at the connecting portion at the rear frame end. Ir Set block @ and rollers @ under the frame on the left and right sides. Disconnect hoses (5) and (61. * Set block @ under the frame on the left and right sides. Then put them aside on the right side of the frame. and assemble rollers @ between frame (11) and block 0. + Block the left and right rear tires securely to prevent them from moving.DISASSEMBLY AND ASSEMBLY 5. f Remove the left side stop valve (5) and under spacer. * Adjust the height of the frame carefully. 30-148 0 CENTER HINGE PIN . f Choose a support with adjustable height for support 0. then disconnect hose (6) at the valve end. and cable (7). 6. (I) and (2) from the steer1) Disconnect-hoses ing valve. 7. Remove safety bar. 2) Remove blocks (3) on the front and rear frame sides. a Disconnect frame as foiiows. 3) 4) Set support @ under counterweight (12). adjustment brackets (4) for stop 3) Remove @-Y-J valves on the left and right sides. 2) Adjust height of front frame (111. 4) Remove left and right stop valves (5). then set block @ in position.

and remove pin (14) from bottom. and remove pin (13) from top. and pull out front frame towards front. DEW02094 9) Jack up front differential. 6) Remove upper hinge pin mounting bolts. then remove retainer (15) at rear frame end. * Be extremely careful to maintain the balance during the operation. After disconnecting. 16 \ MWO3805 / 8) 16 Pull out spacer (16).without using force.DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN 5) Remove lower hinge pin mounting bolts. remove the spacer. * Be careful not to let the pin fall. DEW02091 7) DLWO2092 Remove mounting bolts. * Be careful not to get the spacer at the bottom of the upper hinge caught in the rear frame. * There are shims. so check the number and thickness of the shims. and keep in a safe place. - Front frame Rear frame 30-l 49 0 . * Adjust the height of the front frame and rear frame carefully and set so that the pin can be removed.

DLWO2100 . * There are shims between the retainer and the front frame.. 2) Remove bottom spacer from front frame. 25 I 30. 2) Remove snap rings (18) and (19). so check the number and thickness of the shims and keep in a safe place.DISASSEMBLY 8. remove retainer (211. \ DBW02095 DLWO2101 9. Upper hinge bearing m I) Remove mounting bolts. AND ASSEMBLY CENTER HINGE PIN Lower hinge bearing m 1) Remove both top and bottom dust seals (17). and pull out bearing (20). then remove dust seal (22) from retainer.150 0 . 24 (23) and seal (24) 23 DBW02039 DAW02102 3) Remove bearing (25)..

2 mm. FLOOR m * f Be careful not to forget to assemble the shim.5 mm.0. then move front frame towards rear frame end. installation CENTER HINGE PIN OF CENTER in the Install cab and floor assembly.DISASSEMBLY AND ASSEMBLY INSTALLATION HINGE PIN l Carry out removal. reverse order to OF CAB. 5 mm from the surface of retainer (15). * Be careful not to damage the dust seal lip. always use a bar. see INSTALLATION FRAME ASSEMBLY. For details. I) Jack up front differential. m Pin mounting bolt : 19. Adjust the shims so that the clearance between the cylinder and frame is 0 .6 _+2 Nm (2. then select shims so that clearance b between hinge and retainer is below 0. 4) Tighten retainer (15) to upper hinge pin with 3 mounting bolts (27). and assemble. 2) Assemble spacer (16) to upper hinge. Never insert your fingers in the pin hole.2 kgm) (When adjusting shims) Temporarily tighten mounting bolts (28). Ir Be careful that the spacer at the bottom of the upper hinge does not interfere with the rear frame. /f Connect the frame as follows. * Assemble spacer (16) from the top so that the large chamfered side is on the bearing side. When aligning the position of the pin g hole.0 f 0. * leaving a clearance of approx. m Adjust the clearance between the front and rear frames. -15 DLW02104 30-151 0 . * Align the pin holes securely. and align pin holes. For details. & Outside circumference of hinge : Grease (G2-LI) & Inside circumference of spacer : Grease (G2-LI) 3) Assemble upper hinge pin (14) from bottom. see TESTING AND ADJUSTING STEERING CONTROL.

6 Nm (21. & Retainer mounting bolt : Thread tightener (LT-2) w Retainer mounting bolt : 206 + 19.8 Nm (21.5 f 1.0 kgm) Inset-t lower hinge pin (13) and secure lock bolt. then tighten pin mounting bolt (27) fully. 15 28 HINGE PIN 27 Clearance b with pin : Grease (G2-LI) counterweight.0 kgm) & Pin mounting bolt : Thread tightener (LT-2) m Pin mounting bolt : 206 + 9. and press fit so that the lip surface is facing the outside. f Press fit so that the bearing is level with the surface of snap ring (19). Ir Replace the dust seal with a new part. then use tools El and E2 to press fit bearing (201.8 f 9.0 kgm) m Retainer mounting bolt : 112. & Lip of dust seal : Grease (G2-LI) 30-152 0 18 . Lower hinge bearing 1) Assemble snap ring (19) to front frame lower hinge. and secure with snap ring (18).8 Nm (11.0 + 1. Install safety bar.DISASSEMBLY 5) 6) 7) 8) AND ASSEMBLY CENTER After adjusting shims. tighten retainer mounting bolt (28) to specified torque.0 f 2. 2) After assembling snap ring (181. a Outside circumference of hinge Remove support from front and rear frames. press fit dust seals (17) to top and bottom of pin portion. and DEW02107 1.

use tool E8 as a guide.8 Nm (11.l Mounting bolt : 19.6 + 2. 2) Press fit dust seal (22) to retainer (21). a Lip of dust seal : Grease (G2-LI) 6 Inside circumference of spacer : Grease (G2-LI) * Replace the dust seal with a new part.0 Nm (2. E8. always replace the parts as a set. E4 E9 E6 E8 25 25 A DBWO2111 DLWO21l. w 4) r- 24- 23 DLW02113 . and E9 to top of front frame upper hinge.2 kgm) (When adjusting shims) m Mounting bolt : 112.1 mm.0 f 0. Be careful that the bearing is not at an angle. set bearing (25) in tool E6.DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN m 2. E5. * Assemble spacer (23) from the bottom so that the large chamfered side is on the bearing side. so do not change the combination with spacer (26). E7. :: z 5 Upper hinge bearing I) Assemble tools E3. Fill the inside of bearing (25) with an ample amount of grease. The clearance of bearing (25) is adjusted. * Replace the dust seal with a new part. E4. When press fitting.5 + 1.0 kgm) Install dust seal (24) and spacer (23) from under front frame. When replacing. then set to press-fitting portion from above and Dress fit. and press fit so that the lip surface is facing the outside. When assembling the bearing. then assemble. and press fit so that the lip surface is facing the outside. do not forget to assemble spacer (26). and select shims so that maximum clearance a between retainer and hinge is below 0.8 rt 9. & Lip of seal : Grease (G2-LI) 3) Tighten retainer (21) with 3 mounting bolts.

* Remove the covers on the front and right side at the bottom of the cab. 1. (gSet support @ in position securely. 30-154 0 stop . * Remove clamps and brackets. set a support under the boom. 2)‘ 2. * Raise the boom. Lower the bucket to the ground and stop the engine. * Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. machine from moving. Then operate the control levers several times to release the remaining pressure in the hydraulic piping. then remove inspection cover (2).DISASSEMBLY AND ASSEMBLY STEERING VALVE REMOVAL OF STEERING VALVE ASSEMBLY AStop the machine on level ground and install the safety bar on the frame. Cover 1) Remove mounting bolts. Then apply the parking brake and put blocks under the wheels to prevent the. Loosen plugs (3) at top of hydraulic tank filter and plugs (4) of pump piping to prevent oil inside tank from flowing out. then remove front frame inspection cover (1). Hydraulic piping Disconnect hoses (6) and (6A) between valves from steering valve (5).

and remove bolts (141. then lift off steering valve. so be careful not to let it slip. m mounting Steering valve : 24 kg & kg * Carry out the removal operation with two workers. Steering valve Sling steering valve (61. Tube (8) between switch pump and steering valve Tube (9) between steering pump and steering valve Tube (10) between steering valve and main control valve Tubes (II) and (12) between steering valve and steering cylinder Tube (13) between steering valve and hydraulic tank l l l l l 4.155 0 .DISASSEMBLY 3. AThe steering valve is oily. AND ASSEMBLY Hydraulic piping STEERING VALVE m Disconnect following hydraulic piping from steering valve. 30.

2 + 0. Carry out removal.8 k 1. installation in the reverse order to m * * .1 kgm) 30-156 VALVE . force Refilling with oil Tighten the plug at the top of the hydraulic tank filter and add hydraulic oil through oil filler to the specified level. Replace the O-ring with a new part.DISASSEMBLY STEERING AND ASSEMBLY INSTALLATION OF STEERING VALVE ASSEMBLY . m Plug at top of filter : 11.0 Nm (1. Remove the clamp to avoid applying when installing the tube.

The set pressure of the main relief valve fixed. DKW03811 . so do not disassemble it. Remove * STEERING VALVE OF STEERING safety valve assembly (I). DKWO3808 2. sm is I/ cu 5 3.DISASSEMBLY AND ASSEMBLY DISASSEMBLY VALVE 1. j DKW03809 Removal of demand spool I) Remove plug (3). The set pressure of the safety valve is fixed. so do not disassemble it. Remove * main relief valve assembly (2). DKW03810 2) Remove spring (4).

DISASSEMBLY

3)

AND ASSEMBLY

STEERING VALVE

Remove demand spool (5).
*
Remove slowly, taking care not to damage the spool.
*
If shims are fitted, check the number and
thickness of the shims, and keep in a
safe place.

DKW03812

4)

Remove

plag (6).

Removal of steering spool
I)

Remove 2 bolts (7).
*
Remove on the opposite side in the same
way.

DKW03814

2) Remove
*

case (8) and spring (9).
Remove on the opposite side in the same
way.

I
30-l 58
0

DKWO3815

DISASSEMBLY

3)

AND

ASSEMBLY

Remove spring seat (IO).
Remove slowly, taking care not to dam*
age the spool.
Remove on the opposite side in the same
f
way.

STEERING

VALVE

I

DKW03616

41

Remove steering spool assembly (13).
*
Remove slowly, and be careful not to
bend or damage the spool assembly.
*
To prevent it from falling into the valve
body, remove the poppets at both ends.

DKW03617

5.

Disassembly
I)

Remove

of steering

spool assembly

cap screw (14).

*

2)

The cap screw is coated with adhesive
(Loctite #271), so use an industrial dryer,
and heat (200 - 250°C) before removing.
Remove spring (15) and poppet (16).
Remove on the opposite side in the same
*
way.

16

DKW03816

DKW03819

30- 159

DISASSEMBLY

6.

AND ASSEMBLY

Disassembly
I)

Remove

STEERING

VALVE

of check valve
plug (17).

DKW03821

2)

Remove

spring (18) and poppet

(19).

DKW03822

7.

Remove

30-l 60
0

plug (20).

DISASSEMBLY

AND ASSEMBLY

ASSEMBLY
VALVE
1.

STEERING

OF STEERING
I

Fit O-ring to plug (20) and install to valve
m

body.

plug: 93.2 + 4.9 Nm (9.5 ? 0.5 kgm)

I
2.

Assembly
1)

VALVE

DKW03823

of check valve

Install poppet (19) and spring (18).

DKW03822

2)

Fit O-ring (17) and install to valve body.
w
plug: 63.7 + 4.9 Nm (6.5 + 0.5 kgm)

DKW03821

3.

Assembly
I)
2)

of steering

spool

Install poppet (16) and spring‘(l5)

to spool.

Fit O-ring to cap screw (14) and install to spool.
&

Spool thread: Adhesive (Lo&e

# 271)

w

Cap screw: 8.8 +I 1.0 Nm (0.9 + 0.1 kgm)

16

bd

DKW03811

DKW0381E

30-l 61
0

DISASSEMBLY

4.

Installation

AND

ASSEMBLY

of demand

STEERING

VALVE

spool

1) Fit O-ring to plug (6) and install to valve body.
w

Plug: 137.3 rl: 2.0 Nm (14.0 f 0.2 kgm)

OKWO3824

2)

install demand spool (5) to valve body.
*
If shims were fitted, assemble shims.
*
Install slowly, taking care not to damage
the spool.

DKW03825

3)

Install

spring

(4).

DKW03826

4)

Fit O-ring and backup ring to plug (31, and
install to valve body..
w
Plug: 137.3 + 2.0 Nm (14.0 + 0.2 kgm)

DKW03827

30-162
0

DISASSEMBLY

AND

5.

of steering

Installation

ASSEMBLY

STEERING

VALVE

spool assembly

I)

install steering spool assembly (13) to valve
body.
Ir Be careful to install portion A of the spool
facing in to the correct direction.

2)
3)

Install spring seat (IO).
Install spring (9).
Ir Install on the opposite
way.

side in the same

8

5

DKW03829

5

4)
5)

6.

Install
body.
w

DKW03830

Fit O-ring to case (8) and install to valve
body.
Tighten bolt (7).
w
Bolt: 41.2 f 2.ONm (4.2 + 0.2 kgm)
Ir install on the opposite side in the same
way.
main
Main

relief valve

assembly

(2) to valve

relief valve assembly:
73.5 F 4.9 Nm (7.5 + 0.5 kgm)

7.
m

Install safety valve assembly

(I) to valve body.
DKW03831

Safety valve assembly:
73.5 + 4.9 Nm (7.5 + 0.5 kgm)
1

DKW03808

(

/

/

DKW03809

30- 163

DISASSEMBLY

ORBIT-ROLL VALVE

AND ASSEMBLY

REMOVAL OF ORBIT-ROLL
VALVE ASSEMBLY

A

Stop the machine on level ground
the safety bar on the frame.
Lower
to the ground and stop the engine.
the parking brake and put blocks
wheels to prevent the machine from

Loosen the oil
A pressure
inside

filler cap slowly to
the hydraulic tank.
ate the steering wheel and control
eral times to release the remaining
the hydraulic piping.

and install
the bucket
Then apply
under the
moving.

release the
Then operlevers sevpressure in

.

Loosen the plug at the top of the hydraulic tank
filter to prevent the oil inside the tank from flowing out.

1.

Remove

steering

2.

Remove

plug, and lift boot (2) up.

*
3.

Remove

Remove

post cover (I).

the floor mat.

column

connecting

bolt (3). a
DEW01696

4.

Remove

covers

(4), (5)‘ and (6) under floor.

DLWOB32

5.

Piping
Disconnect
valve.
I)
2)

the following

piping

from

orbit-roll

Disconnect hose (8) between orbit-roll valve
and accumlator, then remove nipple (9).
Disconnect hose (IO) between orbit-roll valve
and hydraulic tank.

30-164
0

DISASSEMBLY

6.

AND ASSEMBLY

ORBIT-ROLL

3)

Disconnect hose (11) between orbit-roll valve
and stop valve (R.H.), then remove nipples
(12) and (13).

4)

Disconnect hose (14) between orbit-roll valve
and stop valve (L.H.), then remove nipple.

Steering

VALVE

valve

Remove bracket (15) mounting
bolts, then rem
move together with orbit-roll valve (16).
6 kg

Orbit-roll

valve : 8 kg

INSTALLATION OF ORBIT-ROLL
VALVE ASSEMBLY
.

Carry out installation
removal.

in the

reverse

order

to

m
QZEI

Column

m

Orbit-roll

8
z
4

connecting bolt:
55.9 + 7.8 Nm (5.7 & 0.8 kgm)

m

m
Ir

.

valve bolt:
52 + 6.8 Nm (5.3 2 0.7 kgm)
Bracket bolt:
88.3 f 34.3 Nm (9.0 2 3.5 kgm)
Align the spline at the steering column end
and the spline at the orbit-roll valve end.

Refilling with oil (hydraulic
Add oil through
level.
J,

tank)

the oil filler to the

specified

Run the engine to circulate the oil through
the system. Then check the oil level again.

30- 165
0

DISASSEMBLY

ORBIT-ROLL VALVE

AND ASSEMBLY

DISASSEMBLY
VALVE

OF ORBIT-ROLL

*

Use a wire brush to remove all the dirt and dust
stuck to the joint around the outside circumference of the unit.

*

Carry out the operation in a clean place to prevent dirt or dust from sticking to the valve.

*

As far as’possible,
disassembling.

DISASSEMBLY

hold the valve in a vice when

OF ROTOR

1.

Set rotor side facing up, and
flange lightly in vice 0.

*

Put a copper plate in contact with the vice and
be careful not to tighten the vice too hard.

2.

Remove

screw

3.

Remove

O-ring

4.

Pull out rotor set (41, then remove
Ir

5.

Be careful
rotor set.

Remove

spacer

(I), then remove

hold

mounting

end cap (2).

(3) from end cap (2).

not.to

drop the

O-ring

star

(5).

inside

the

(6).

6
DLW01702

30- 166
0

DISASSEMBLY

AND ASSEMBLY

ORBIT-ROLL VALVE

6.

Remove

drive shaft (7).

7.

Remove

spacer

plate (8).

8.

Remove

O-ring

(9) from housing

I

(10).

I
DISASSEMBLY
9.

DLWU1703

OF CONTROL SIDE

Remove housing (10) from vice, and place on a
clean cloth. Be careful not to damage the finished surface.

10. Raise tip of snap ring (1 I) with screwdriver,
remove

from

and

housing.

DLWO1704

11. Turn spool and sleeve to place pin in a horizontal position, then push in spool and sleeve with
your thumb, and remove bushing (12) from housing.

DLW01705

12. Remove

X-ring

seal (13) from bushing

13. Remove dust seal (14) from
screwdriver.
*

Be careful

not to damage

bushing

(12).

(12) with
12
\

the bushing.

14

\
Q
Q

bQ

3
DLWO1706

DISASSEMBLY

AND ASSEMBLY

ORBIT-ROLL

14. Remove 2 bearing races (15) and thrust
(16) from spool and sleeve.

VALVE

needle

DLW01707

15. Pull out spool and sleeve assembly
117) from
housing (IO) in the direction of the arrow.
*

To prevent the spool and sleeve assembly
from catching in the housing, rotate the spool
and sleeve assembly slowly to the left and
right when pulling out from the housing.

16. Pull out pin (18) from spool and sleeve
bly (17).

assem-

DLWOl-KB

17. Push spool (20) inside sleeve (19) slightly to
front, and remove 6 centering springs (21) from
spool (20) carefully by hand.

18. Turn spool (20) slowly and pull out from rear of
sleeve (19) (in the direction of the arrow).

19. IRemove

O-ring

20. IRemove

set screw (23) from housing.

(22) from housing.

21. Screw a threaded bar into check sheet (241, and
pull out check sheet (24).

22. IRemove

O-rings

(25) and (26) from

check sheet

(24).
28
23. Tap housing,
(28).

30-168
0

and remove

ball (27) and retainer

DLW01710

DISASSEMBLY

AND ASSEMBLY

ASSEMBLY
VALVE

ORBIT-ROLL

OF ORBIT-ROLL

*

Check all parts for damage

*

Wash all metal
dry with air.

+r

Do not use a file or polish any part with
sandpaper.

*

Coat the O-rings with clean grease.
put grease on new X-ring seals)

+

Coat the O-ring for the rotor
amount of grease.

ASSEMBLY
1.

*

or burrs.

parts in clean solvent

OF CONTROL

Insert retainer

and blow
rough

(No need to

set with

a small

SIDE

(28) in housing’ with tweezers.

Check that the retainer
angle.

is not inserted

Insert ball (27).

3.

Fit O-rings (26) and (25) in check sheet (24), and
push check sheet (24) into housing.

4.

Be careful to set the top and bottom of the
check sheet facing in the correct direction.

DLW01711

Install set screw (23).
*
B
&

5.

e-23

at an

2.

*

VALVE

Check that the set screw is set in slightly
from the end face of the housing.
Set screw : 11.8 Nm (1.2 kgm)
Set screw : Loctite

Assemble
spool (20) and sleeve (19) so that
spring groove is on same side.
t
Rotate the spool and slide it in.
Ir Grip the splined portion of the spool lightly
and check that the spool rotates smoothly
inside the sleeve.
*
If there are match marks, check that the
match marks are aligned.

SP

DLW01712

DISASSEMBLY

ORBIT-ROLL VALVE

AND ASSEMBLY

6. Align spring groove positions
sleeve
spring
Sr Set
the

of spool (20) and
(191, and set on flat plate, then insert
(21) in spring groove.
so that the notches at both ends are at
bottom.

I
7. Insert pin (18) in spool and sleeve assembly

DLwO1713

(17).

DLW01714

8. Inset-t spool and sleeve assembly
ing (IO) in the direction
1)

2)
*
3)

r

Keep pin horizontal and rotate to left and
right a little at a time to insert.
or Be extremely careful not to get it caught.
Make the spool and sleeve assembly flush
with the rear end face of the housing.
If it is inserted beyond the end face, the pin
will fall out.
Check that spool and sleeve rotate smoothly
inside housing.

9. Install
IO.

(17) in housof the arrow.

O-ring

Fit 2 bearing
case (IO).

(22) to housing

(IO).

races (15) and thrust needle

(16) in

DLWO1716

30-170
0

DISASSEMBLY

AND ASSEMBLY

ORBIT-ROLL

11. Insert dust seal (14) in bushing

12. Insert X-ring

13. Insert
stall.
l

.

(12).

seal (13) in bushing

bushing

(12) in spool,

VALVE

and

(fzlD--ll

(12).

rotate

eQ

12

to in-

14

_A

@

Tap with a plastic hammer to assemble to
the specified position.
It must be in contact horizontally
with the
bearing race.

\”

G
e
/

10

/,

e=-.

DLwo1717

14. Fit snap ring (11) in housing.
Screw-

2
F+?

-

DLWO1718

5

ASSEMBLY OF ROTOR
15. Hold flange of housing lightly
*
*

in vice.

Be careful not to tighten the vice too hard.
Check that the spool and sleeve are set in
slightly from the housing surface with fourteen holes.

DLW01719

16. Insert O-ring

I

(9) in housing.

17. Put on spacer plate (8), and align
bolt hole and tap hole of housing.

positions

of

DLW01720

DISASSEMBLY

18.

AND

ORBIT-ROLL

ASSEMBLY

VALVE

Turn spool and sleeve assembly to make pin
(18) and port surface of housing parallel, then
mesh pin and yoke of drive shaft (7).
Ir

To position accurately, draw a line on the
end face of the drive shaft spline.

DLW01721

19. Insert

O-ring

(5) in rotor

set (4).

I

5
DLW01722

20. Make O-ring (5) end of rotor set to spacer plate
end, then align insert portion of star of rotor (4)
with drive.
1)
2)
J,

Check that lines A,B,C, and D are all parallel.
Without
removing
joint of drive shaft (71,
position bolt holes of rotor set.
This procedure is very important for determining the valve timing of unit.

Inset portion of star

Make line

Pin

Port Surface

DLW01723

21. Insert spacer (6) inside rotor set.

22. Set end cap (2) on rotor set, and align bolt hole.

DLW01724

30- 172
0

DISASSEMBLY

23. Coat thread
end cap.
*

AND ASSEMBLY

of screw with

ORBIT-ROLL

grease,

VALVE

and tighten

install the handle to the spool, and check
that the spool rotates.
m
End cap mounting screw
First step : 14.7 Nm (1.5 kgm)
Second step :
27.0 ? 1.5 Nm (2.75 + 0.15 kgm)

DLW01725

30-173
0

2. 1. * After removing the hoses. Then apply the parking brake and put blocks under the wheels to. fit plugs to prevent the entry of dirt or dust. ARelease the remaining pressure in the piping. DEW00965 2) 3). then remove m pin (3). Steering cylinder I) Remove rod bolt. 25 kg DEW01083 30-174 0 . Remove bottom bolt. see REMOVAL OF RADIATOR ASSEMBLY. 4) Disconnect bottom grease tube (4). Hydraulic piping Discoqnect steering cylinder rod and bottom hoses (I) and (2) at cylinder end.prevent the machine from moving. * Carry out the removal operation with people. then remove pin * Check the shim thickness and use guide when assembling. Remove steering cylinder (6). i Be careful not to scratch the cylinder r&lkg Steering cylinder: (5). For details. Lower the bucket to the ground and stop the engine.DISASSEMBLY REMOVAL CYLINDER STEERING AND ASSEMBLY CYLINDER OF STEERING ASSEMBLY AStop the machine on level ground and install the safety bar on the frame. as a two rod.

and wipe off the grease that is pushed out. * * * the pin holes. a DEW01084 30.STEERING CYLINDER DISASSEMBLY AND ASSEMBLY INSTALLATION OF STEERING CYLINDER ASSEMBLY Carry out removal.5 mm Remove all grease and oil from the cylinder pin. l installation in the reverse order to a AAlways use a bar when aligning Never insert your fingers. 0. Clearance a = Max. Adjust theshims so that clearance a is the standard value.175 0 .

DISASSEMBLY AND ASSEMBLY REMOVAL OF BRAKE VALVE ASSEMBLY AStop the machine on level ground and install the safety bar on the frame. Piping (left brake valve) 1) Disconnect tube (IO) and hose from accumulator to left brake valve at brake valve a end. I. ALoosen the oil filler cap slowly to release the pressure inside the hydraulic tank.176 0 BRAKE VALVE . a 1) Disconnect 2) 3) 4) 3. 3) Remove brake valve drain tube (12) and hose at valve end. 2) Disconnect left and right brake valve hoses m and elbow (11) at brake valve end. Covers Remove Piping covers (I) under cab. Wiring Disconnect connector of brake valve switch sensor (13). * After disconnecting the piping. Disconnect brake valve drain hose and tube (6) at valve end. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. 30. ARelease the pressure inside the accumulator by depressing the brake pedal slowly and repeatedly (at least 17 times) until there is no more reaction when the brake pedal is depressed. Lower the bucket to the ground and stop the engine. 2. Then operate the steering wheel and control levers several times to release the remaining pressure in the hydraulic piping. (right brake valve) hoses (2) and (3) between accumulator and brake valve. 4. and adaptm ers (4) and (5) at valve end. make marks and fit plugs to prevent the entry of dirt or dust. Disconnect hose (7) going to left brake valve at valve end. Disconnect tube (8) which goes to front brake and tube (9) going to rear brake at valve end.

2 * 7. then pull out cap (20).75 + 0.75 kgm) w Mounting bolt : 66. then pull out pin. ~\fiqz-q~4( * Replace the O-ring with a new part. and remove pedal. a w Mounting bolt : 66. 6.177 0 .4 Nm (6. 30. Carry out installation in the reverse order to removal.75 ? 0. f+GJ Brake valve 1) Remove brake valve mounting bolts (171. then remove mount flange from floor portion. see TESTING AND ADJUSTING. and disconnect mount flange (18) and body (191.2 + 7.DISASSEMBLY 5. bleed the air. AND ASSEMBLY BRAKE VALVE Pedal Pull out cotter pin (16) of pin (15) of brake pedal (141. 2) Remove mount flange mounting bolts. * Carry out the same procedure for both the left and right brake pedals. INSTALLATION OF BRAKE VALVE ASSEMBLY . Bleeding air from brake system.75 kgm) * After completion of assembly. For details.4 Nm (6.

then remove P cylinder assembly (8). * Make match marks before disassembling the valve. and be careful not to damage the cylinders or flange assembly. Bracket assembly I) 2) 3) Remove seat (I 1. Remove spring (11) and O-ring (121. DEW01092 3) 4) Remove plug (13) of S cylinder assembly. and boot (3) from brake valve.178 0 DDWO1096 . and secure jig in vice. Remove valve mounting bolts (IO). and (19) and O-ring (20) from T flange assembly (9). springs (171. (18).DISASSEMBLY AND ASSEMBLY RIGHT BRAKE VALVE DISASSEMBLY OF RIGHT BRAKE VALVE ASSEMBLY (TANDEM) 1. then remove bracket assembly. * Remove spring (15) inside the plunger of the P cylinder assembly. Remove mounting bolts (5) of bracket assembly (41. DEW01093 5) Remove holder (16). Remove oil seal (6) from upper portion of brake valve. plungers. then remove spring (14) and O-ring. Valve I) 21 Install valve to jig @ with bolts (5). and spools inside the T flange assembly and the S and P cylinders form sets. DEW01091 2. Jr * The cylinders. so be careful not to mix the parts for any set. Fit seals to prevent dirt or dust from entering. then remove S cylinder assembly (7). DEW01095 30. pedal stopper (21.

6 Nm (6.0 .5 Nm (15. pedal stopper (2). and install oil seal (6). Ir Use a new part for the oil seal. 1) Set T flange assembly facing up.lnstall seat (I). When setting in position. and hold jig % in vice. 1) Install springs (19).5 + 2.5 kgml 7) Install spring (14) and O-ring to S cylinder assembly (7).6 Nm (6. Use a new part for the O-ring. Use a new part for the O-ring. align the match marks. m Mounting bolt: 58. and tighten with plug (13). 2) Install O-ring (20) to T flange assembly (9).5 kgm) 3) .0 . Valve Install T flange assembly (9) to jig (iJ with bolts (5). and tighten with mounting bolts (10). and tighten with mounting bolts (5). 4) Install spring (11) and spring (15) inside plunger of P cylinder assembly to P cylinder assembly (8).8 . then install holder (16) on top of spring. * 6 O-ring: Lithium grease (7) to P cylinder 6) Set S cylinder assembly assembly (S). align the match * marks.7. 2. w Mounting bolt: 58.DISASSEMBLY AND ASSEMBLY RIGHT BRAKE VALVE ASSEMBLY OF RIGHT BRAKE VALVE ASSEMBLY (TANDEM) 1.7. (IS). * a Thread of plug: Thread tightener (Thread lock 1303B) w Plug: 152. & Lip of oil seal: Lithium grease 2) Install bracket assembly (4). and (17) to T flange assembly (9) in order.8 . + & O-ring: Lithium grease 3) Set P cylinder assembly (8) to T flange assembly (9). 5) Install O-ring (12) to P cylinder assembly (8). Use a new part for the O-ring.73. and boot (3) to valve.73. When setting the S cylinder assembly in * position.5 kgm) DEW01095 DDW01096 DEW01093 DDWO1094 Bracket assembly Remove valve from jig 0.0 f 24. 30-179 0 .

then remove bracket assembly. then re- The cylinders. and spools inside the S flange and the S cylinder form sets. 16 8 DDW01107 30. (21. 3) Remove plug (IO) of S cylinder assembly. and O-ring (16) from S flange:assembly (8). so be careful not to mix the parts for any set. and boot mounting bolts (5) of bracket as(4). plungers. Fit seals to prevent dirt or dust from entering. (3) from 2) Remove sembly 3) 2. 4) Remove holder (131. and secure jig in vice. * Make match marks before disassembling the valve.180 0 . Bracket assembly 1) Remove seat(l).DISASSEMBLY LEFT BRAKE VALVE AND ASSEMBLY DISASSEMBLY OF LEFT BRAKE VALVE ASSEMBLY (SINGLE) 1. and be careful not to damage the cylinders or flange assembly. 2) Remove valve mounting bolts move S cylinder assembly (7). pedal stopper brake valve. Remove oil seal (6) from brake valve. springs (14) and (15). * Ir (9). upper portion of 6 Valve 1) Install valve to jig @ with bolts (51. then remove spring (11) and O-ring (12).

and tighten with plug (IO). and install oil seal (6). m Mounting bolt: 58. f Use a new part for the oil seal.8 .0 .DISASSEMBLY AND ASSEMBLY LEFT BRAKE VALVE ASSEMBLY OF LEFT BRAKE VALVE ASSEMBLY (SINGLE) 1.7. 2) Install O-ring (IS) to S flange assembly (8).5 kgm) Install spring (11) and O-ring (12) to S cylinder assembly (71.8 .0 + 24. and hold jig @ in vice. Valve Install S flange assembly (8) to jig @ with bolts (51.5 kgm) 3) Install seat (I). 6 O-ring: Lithium grease & Thread of plug: Thread tightener (Thread lock 1303B) m Plug: 152. and boot (3) to valve.7. 1) Install springs (74) and (15) to S flange assembly (81. & Lip of oil seal: Lithium grease 2) Install bracket assembly (41. * Use a new part for the O-ring.5 f 2. w Mounting bolt: 58. DEW01090 Set S cylinder assembly (7) to S flange assembly (81.6 Nm 16. and tighten with mounting bolts (5).73.0 . align the match marks. 6 O-ring: Lithium grease 3) 4) 2. * Use a new part for the O-ring. then install holder (13) on top of spring. * When setting the S cylinder assembly in position.5 Nm (15.6 Nm (6. I) Set S flange assembly facing up. and tighten with mounting bolts (9). pedal stopper (21.5 kgm) Bracket assembly Remove valve from jig 0. 16 8 DDW01107 DEW01106 I DEW01104 u DDWOl105 30-181 0 .73.

182 0 . Loosen oil. lower the work equipment to the ground. move it to the right end. Remove lock plate (7) and 3 mounting bolts (8) of parking brake manual cancel bolt (6). 1. DBWO213. apply the parking brake. (5) of from @J 4. DBWO1732 30. : drain plug Transmission (1) and drain transmission I oil : 40 J? DEW01729 Drive shaft Remove protectpr (2-1) of drive shaft. - 2.DISASSEMBLY PARKING AND ASSEMBLY REMOVAL DISC OF PARKING BRAKE DISC BRAKE AStop the machine on level ground. -k After disconnecting the drive shaft. and put blocks under the wheels to prevent the machine from moving.2 3. Remove mounting bolt (4) and washer coupling (3) at front end of transmission coupling. * Release the parking brake. and disconnect center drive shaft (2) at transmission a end. * Remove together with the O-ring.

Install 3 parking brake manual cancel bolts (61. then tighten. Remove snap ring (12). then using guide bolt (9) and forcing screws (IO). PARKING BRAKE DISC AND ASSEMBLY Remove cover mounting bolts. 7. or get dirt on the 30. &I kg Cover assembly or get dirt on the : 6. Remove end plate (13).2 kg 6. and release parking brake. 0 DEW01735 9. DBW01734 8. and disc (16) in turn. then remove tool A4.183 0 . then remove Separator plate (14).DISASSEMBLY 5. Tighten tool A4 with coupling mounting f Bolt length of tool : 56 mm bolt (4). Sr Be careful not to damage oil seal lip surface. rt Be careful not to damage discs and plates. wave spring (15). remove cover Jf (11).

Refilling with oil Tighten the drain plug and add transmission through oil filler to the specified level.3 Nm (11. bolt : facing 549 + 59 Nm (56.DISASSEMBLY INSTALLATION BRAKE DISC .184 0 Transmission oil : 40 f? oil d .3 Nm (11. securely in the groove.0 kgm) m Ir w & Be careful not to damage or get dirt on the oil seal lip surface. Carry out removal.25 kgml Lip of oil seal : Grease (G2-LI) 8 m Ig 2 * .3 + 12. Assemble the ring securely in the ring groove of the housing.0 + 6.25 F 1. I&1 30.25 kgm) Be careful to in the correct Fit the O-ring Mounting assemble the coupling direction. PARKING BRAKE DISC AND ASSEMBLY OF PARKING installation in the reverse order to w * w * * w Be careful to connect the coupling facing in the correct direction. Mounting bolt : 110. Mounting bolt : 110.3 +_ 12.25 i 1.

Ladder Sling ladder (21. 1. 30-185 0 .DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK REMOVAL OF HYDRAULIC TANK ASSEMBLY AStop the machine on level ground and install the safety bar on the frame. C-Y z 5 2. AOperate the steering wheel and control levers several times to release the remaining pressure in the hydraulic piping. Cover Remove covers (I) on right side of floor. * Use the lifting tool to lift at two places. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. then remove mounting bolts. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. and lift off. 3. Hydraulic piping I) m Loosen plugs (3) at top of hydraulic tank filter and plugs (4) of pump piping to prevent oil inside tank from flowing out. Lower the bucket to the ground and stop the engine.

After removing the tubes. and bottom mounting bolts (13). Tube (9) between main control valves . . tank : 365 kg (including oil 190 I?) .(l2). tie them wire and move them to the side. * 4. with Hydraulic tank 1) Sling hydraulic tank. Oil cooler tube (6) . Tubes (IO) and (11) between hydraulic pump. Disconnect PPC valve (7) and hose (8) from valve end. and remove front. rear. . 2) Lift off hydraulic el kg 30-186 0 Hydraulic tank (12).DISASSEMBLY HYDRAULIC TANK AND ASSEMBLY 2) Disconnect following hoses and remove each tube. Brake oil return tube (5) .

For details. in the reverse order to Fit the O-ring securely in the groove and be careful not to get it caught when assembling. see the precautions given for the installation procedure. bleed the air. Then check the oil level again. and add hydraulic oil through oil filler (14) to the specified level. * After installing the piping. * * . Install the hoses without twisting or interference. * Run the engine to circulate the oil through the system. Refilling with oil Tighten the plugs at the top of the hydraulic tank filter and the plugs of the pump piping. 30-187 0 .DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK INSTALLATION OF HYDRAULIC TANK ASSEMBLY l a Carry out installation removal.

then I-1. Fit the O-ring securely in the groove and be careful not to get it caught when assembling. the Cover Remove mountina bolts. DBWO2140 2. Carry out removal. 0 0 3oooor I DEwoZl41 INSTALLATION OF HYDRAULIC FILTER ASSEMBLY . bypass valve (31. then remove covers (1-l and (l-1).DISASSEMBLY HYDRAULIC FILTER AND ASSEMBLY REMOVAL OF HYDRAULIC FILTER ASSEMBLY a 1. installation in the reverse order to $GJ f * Replace the O-ring with a new part. so be careful when removing. * Be careful not to damage the O-ring at the mating surface of cover (l-1) and the tank. ” ~~. 30-188 0 o”oooc DEW22162 . AThe tension of the spring is applied to cover (l-l). Filter Remove spring (2) and remove filter (4). Loosen the oil filler cap slowly to release pressure inside the hydraulic tank.

Ladder Sling ladder (21. I I II II Lxwo2133 OLwo2135 30-189 0 . STEERING. Loosen plugs (3) at top of hydraulic tank filter and plugs (4) of pump piping to prevent oil ina side tank from flowing out. SWITCH. PPC PUMP REMOVAL OF HYDRAULIC. I 2. and lift off. SWITCH. then remove mounting bolts. STEERING. Lower the bucket to the ground and stop the engine. PPC PUMP ASSEMBLY Astop the machine on level ground and install the safety bar on the frame. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Aoperate the control levers several times to release the remaining pressure in the hydraulic piping.DISASSEMBLY AND ASSEMBLY HYDRAULIC. 1. Cover Remove covers (I) on right side of floor. 3. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. * Use the lifting tool to lift at two places.

Support nylon liftbolts and : 19 kg I 5. and (14) at bottom of hydraulic pump (IO). then move to rear. DBwO2106 Hydraulic piping I) Remove clamps of air conditioner hose (8) and hydraulic hoses (91. 2) Sling right floor support (7) with ing tool 0. SWITCH. AND ASSEMBLY \ HYDRAULIC. fit plugs to prevent dirt or dust from entering. I I\+ 11 I\\/ 1 \ IO 12 13 - 30-190 0 oBwo2148 . * After disconnecting the hoses. a * After disconnecting the hoses. 8 (9 2) O&V02147 Remove hydraulic hoses (111. (121. PPC PUMP Floor support j?g I) Remove inspection covers (5) and (6) on right side. (13). mark them with tags to distinguish them.DISASSEMBLY 4. STEERING. then remove mounting lift off.

STEERING. Sling hydraulic pump with nylon lifting tool 0. so be extremely careful when carrying out this operation. * Carry out the removal operation with two workers. SWITCH. E2lk9 Hydraulic pump : 46 kg 30491 0 . I 6.DISASSEMBLY AND ASSEMBLY 3) 4) HYDRAULIC. After disconnecting the tubes. and take care to maintain balance when lifting off hydraulic pump (IO). mark them with tags to distinguish them. * * After disconnecting the tubes. DBWl2149 Hydraulic pump Remove mounting bolts. fit plugs to prevent dirt or dust from entering. m * The working space is confined. PPC PUMP Remove hydraulic tubes (15) and (16) from hydraulic pump (IO).

and add hydraulic oil through the oil filler to the specified level. 30-192 0 . Refilling with oil Tighten the plugs at the top of the hydraulic tank filter and the plugs of the pump piping. * After installing the piping. * Fit the O-ring securely in the groove and be careful not to get it caught when assembling. For details.25 + 3.25 kgm) Fit the O-ring securely in the groove and be careful not to get it caught when assembling. bleed the air. m . Thread of plug : Gasket sealant (LG-4) Tighten the floor support mounting bolts fully after installing the floor. Install the hoses without twisting or interference. Carry out removal. see the precautions given for the installation procedure. SWITCH. PPC PUMP AND ASSEMBLY INSTALLATION OF HYDRAULIC. Mounting bolt : 277 +.DISASSEMBLY HYDRAULIC. STEERING. * Run the engine to circulate the oil through the system. SWITCH. Then check the oil level again.31. f & * m installation in the reverse order to Wash and remove all oil and grease from the plug thread and piping thread. STEERING. PPC PUMP ASSEMBLY .9 Nm (28.

Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. . move them towards the rear of the machine. Set the support securely.DISASSEMBLY REMOVAL OF MAIN VALVE ASSEMBLY A MAIN CONTROL VALVE AND ASSEMBLY CONTROL Stop the machine on level ground and install the safety bar on the frame. then remove front cover (2). . a PPC hoses Disconnect following hoses from main control valve. Raise the boom. A the control A Operate lease the remaining Ir . Remove the cover at the front of the hydraulic tank. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. DEW02753 m Hydraulic hoses Disconnect following hydraulic piping. Hose (9) between steering valve and main control valve 30-193 0 . Lower the bucket to the ground and stop the engine. levers several times to repressure in the hydraulic piping. 2. 1. mark them with tags to distinguish them. * After removing each hose and tube. After disconnecting the hoses. and set support @ under boom (I). Loosen plugs (3) at top of hydraulic tank filter and plugs (4) of pump piping to prevent oil inside tank from flowing out. move them to the side. Hose (5) for bucket spool between PPC valve (P4) and main control valve (J) Hose (6) for boom spool between PPC valve (P2) and main control valve K) Hose (7) for bucket spool between PPC valve (PI) and main control valve (H) Hose (8) for boom spool between PPC valve (P3) and main control valve (I) After disconnecting the hoses.

be careful to fit the lifting equipment securely. 30. Main control valve : 75 kg r5 kg Jr When raising the main control valve. After disconnecting the tubes.DISASSEMBLY MAIN CONTROL VALVE AND ASSEMBLY Hose (IO) between hydraulic pump and hydraulic tank Tube (11) between hydraulic pump and main control valve .r Tubes (14) and (15) between valve and boom cylinder main control main control Remove the tube clamps.194 0 . * When lifting off the main control valve. Main control valve them /zJ Sling main control valve (16). Tubes (12) and (13) between valve and bucket cylinde. move towards the rear of the machine. then remove mounting bolts and lift off main control valve. be careful not to let it hit the horn. * * 3.

install the hoses without twisting or interference.0 Nm (1. Tighten the mounting bolts on diametrically opposite sides. Refilling with oil Tighten the plugs at the top of the hydraulic tank filter and the plugs of the pump piping. and add hydraulic oil through the oil filler to the specified level. Be careful of the angle of the tube when tightening the clamp.DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE INSTALLATION OF MAIN CONTROL VALVE ASSEMBLY l Carry out installation removal.8 + 1.195 0 . pTJ * * Fit the O-ring securely in the groove and be careful not to get it caught when assembling. Be careful that the tube does not interfere with any other part.1 kgm) I Hydraulic oil : 138 f? ti (Replacement amount) 30. Install the hoses without twisting or interference. in the reverse order to jf * * Check the tags on the hoses.2 + 0. and be careful not to deform the valve when tightening. pJ * * * . then connect the hoses. w Plug at top of filter : 11.

DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE DISASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY ’? n 27- @ g 28 -= c@ Q\ i 29-q 26 24 DOW01547 30-196 0 .

flange. then remove spring and valve (29). 2) Remove screen (32). retainer (16). so do not disassemble it. 2) Remove case (13). and valve (36). then remove retainer (4) and spring (5). collar (II). (28) Cut-off valve assembly 1) Remove pilot valve (31). 6 2. Safety valve assembly with suction Remove safety valve (25). spring (17). spring (17). retainer (lo). 6. and (43). 8. then remove seat (38). 5. Spool assembly (boom) 1) Remove case (3). 4. Check valve assembly.. Remove AND ASSEMBLY MAIN cut-off valve (2) from valve CONTROL VALVE body (1).DISASSEMBLY 1. Remove case (13). and retainer (18). (To prevent damage to the spool) Remove bolt (6). spring (9). then remove piston (34). spring (35). spring (39). (26). . then remove washer (7). then remove retainer (14). Remove spool (19) from body (1). * Check the correct direction for assembling spool (19) to the body. and retainer (12). plugs 1) Remove plug (27). 3) Remove spool (23) from body (1). 2) Remove flange (30). 3) Remove plugs (44) and (45). * The safety valve cannot be adjusted when it is installed to the machine. * 3) 4) 5) Loosen bolt (6) with spool (19) assembled to body (1). Main relief valve assembly Remove main relief valve assembly (24). 30. Suction valve assembly Remove suction valve assembly 7.-. retainer (16). 5) Remove plugs (41). then remove retainer (14). retainer (8). I DEW01548 Spool assembly (bucket) 1) Remove case (20). 4) Remove bar (37).197 0 . 3) Remove flange (33). spring (15). then remove spring (21) and retainer (22). spring (15). and retainer (18). 2) Hold spool (19) in position with a wrench (width across flats: 14 mm) at position a shown in diagram on right and loosen bolt (6). and valve (40). (42).

DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE ASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY DDW01547 30-198 0 .

w Plug : 466 + 24. m Plug (41) : 275 + 29. (42).8 + 0.8 Nm (23.8 Nm (23.8 Nm (6.5 Nm (15. Safety valve assembly with suction Install safety valve assembly (25).8 kgm) 4) Install screen (32) and pilot valve (31).1.8 kgm) Assemble valve (29) and spring (28) to body (I). Main relief valve assembly Install main relief valve assembly (24).8 Nm (15.5 f 2.7 f 7. spring (35).5 Nm (47.0 f 1.8 Nm (6. Cut-off valve assembly 1) Fit O-rings to plugs (43). spring (39).5 kgm) 3.0 kgml 4.0 kgml 2) Assemble valve (40).5 f 2. w Mounting bolt : 66.5 kgm) 30-199 0 . Suction valve assembly Install suction valve (26). plugs 1) Install plugs (45) and (44) and install to body (1). then fit O-ring to plug (27) and install. and (41) and install.4 Nm (28. flange.8 Nm (6.8 + 0.0 kgm) 5.5 m (15.0 f 1. m w 2. 147 + 9. w Mounting bolt : 66. m Safety valve assembly : 226 f 9.8 + 0. m Main relief valve assembly : 152 rt 24.0 i.0 kgm) Check valve assembly. then install O-ring to bar (37) and install. w Suction valve assembly : 226 f 9. QEl 8 c: 3 2) 3) Plug (44) : 152 + 24. then fit O-ring to flange (33) and install.7 f 7. MAIN CONTROL VALVE Screen3i3&49Nm (35+05kgmI Pilot valve : ’ .0 f 3.5 + 2. and seat (38) to valve body (2). B Mounting bolt : 66.8 kgm) 3) Assemble valve (36).DISASSEMBLY AND ASSEMBLY 1.7 f 7.5 kgm) Install flange (30). and piston (34) to valve body (2).

3) Assemble washer (7).0 + 1. retainer (181. spring (151.15 kgm) 4) Assemble spring (5) and retainer (41. 2) Assemble retainer (12) to spool (19).0 kgm) * Tighten the bolts in the order shown in the diagram on the right. then fit Oring to case (13) and install.7 f 1.5 Nm (1.DISASSEMBLY 6. 3) Assemble retainer (22) and spring (21) to spool (231. and retainer (141. DEW01551 30-200 0 . spring (9). and tighten bolt (6). then fit O-ring to case (3) and install. MAIN AND ASSEMBLY CONTROL VALVE 6 11 19 DEW01548 Install cut-off valve (2) to valve body (I). retainer (81. Ir Check that spool (19) is facing the correct direction when assembling it to the body. spring (171.8 Nm (11. 7. retainer (IO). then fit O-ring to case (20) and install. then hold spool in position with a wrench (width across flats: 14 mm) at position @ shown in diagram on right. w Mounting bolt : 108 + 9. retainer (161. Spool assembly (bucket) 1) Assemble spool (23) to body (I). retainer 5) Assemble (161.4 f 0. and collar (II) to bolt (61. then fit Oring to case (13) and install. 2) Assemble retainer (181. and retainer (141. spring (17). w Bolt (6) : 13. 8. spring (151. Spool assembly (boom) 1) Assemble spool (19) to body (I).

Hose (7) between PPC valve and hydraulic tank .REMOVAL a AND ASSEMBLY PPC VALVE OF PPC VALVE Stop the machine on level ground and install the safety bar on the frame. Hoses P4 (IO) and PI (11) for bucket spool J. remove the hoses from the outside. When removing the 4 hoses at the bottom of the PPC valve. 50001 .=I 0 o 0 0 -20 0 0 0 I 2 I 3 m2153 Serial No. covers (1). Hydraulic piping Disconnect following hydraulic piping from PPC valve. Serial No. Hose (6) between PPC valve and PPC valve . . . 0 0 0 c) 0 oT-- 0 4 .DISASSEMBLY . Hoses P2 (8) and P3 (9) for boom spool .. Cover 1) Remove 0 0 floor inspection cover (4).52999 2. a Operate the control levers several times to release the remaining pressure in the hydraulic piping. 53001 and up 30-20 1 0 . Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. +a 0 1. Loosen plugs (2) and (3) at top of hydraulic tank filter to prevent oil inside tank from flowing out. Remove . Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Lower the bucket to the ground and stop the engine. then remove the nipple and disconnect the hoses.

then remove PPC valve (14) from under floor. linkage \ DEW02161 D&W2162 PPC valve Remove mounting bolts. so be extremely careful when carrying out this operation. * The working space is confined.DISASSEMBLY * PPC VALVE AND ASSEMBLY After disconnecting the hoses. and disconnect (13) from PPC valve. 2) Loosen locknut (121. mark them Front of machine m Linkage 1) Remove console box side face cover (71). with tags to distinguish them. 30-202 @ .

see TESTING AND ADJUSTING. Refilling with oil Tighten the plugs at the top of the hydraulic tank filter.0 Nm (1. 30-203 0 . Then check the oil level again. and add hydraulic oil through oil filler to the specified level.DISASSEMBLY AND ASSEMBLY INSTALLATION ASSEMBLY l Carry out removal.2 f 0. installation PPC VALVE OF PPC VALVE in the reverse order to m * .8 f 1. For details.1 kgm) *_ Run the engine to circulate the oil through the system. w Plug at top of filter : 11. Adjust the linkage.

(6) from body (7).DISASSEMBLY AND ASSEMBLY DISASSEMBLY ASSEMBLY PPC VALVE OF PPC VALVE 1. * Check the number and thickness of the shims. Remove collar (5) from spool (4). so check the mounting position of each spring and make distinguishing marks. spring (IO). Remove valve assembly 6. then remove retainer (91. 7. 5. then remove spool (4). * The number of coils of spring (13) differs for each hydraulic port. 4. Remove seal (31. make a distinguishing mark on the boom LOWER spool and check the mounting position. and shim (II) from valve (12). 7 DEW01221 DEW01222 30-204 0 . * Of the 4 spools (41. Remove spring (13) from body (7). Remove plate (2). 2. Remove bolt (1). and keep in a safe place. 3. Remove collar (81.

* For spools (41. Fit O-ring to collar (5). + The number of coils of spring (13) differs for each hydraulic port as shown in the chart below. Assemble shim (111. on the 2. PPC VALVE OF PPC VALVE r Assemble spring (13) to body (7). B Bolt: 44. of coils of spring PI Bucket TILT 11 P2 Boom RAISE P3 Boom LOWER 14 P4 Bucket DUMP * 8 zi The position of each port is stamped valve body. 3 valve assembly (9) (6) to body (7). and assemble to spool (4).9 Nm (4. 6. Fit seal (3) and install plate (2).5 zt 0. spring (IO). so check each spring and be sure to install in the correct position. 5.1 f 4. Assemble 4. and retainer to valve (121. then install spool (4). Port position No.DISASSEMBLY AND ASSEMBLY ASSEMBLY ASSEMBLY 1. 3.5 kgm) 7 DEW01221 DEW01222 30-205 . then install the spools. and install collar (8). Install bolt (1). check the mounting position of the boom LOWER spool which was marked with a distinguishing mark.

Then loosen release the pressure 1. Bucket positioner 1) Disconnect connector (1). 2) Remove wiring clamps positioner. Hydraulic piping 1) Disconnect hose (3) at rod end from der. then remove pin (2). Lower the bucket to the ground and stop the engine. and keep in a safe place. 30-206 0 a cylin- CYLINDER . jl (1-I) for bucket 2. and lift at two places. f Be careful of the center of gravity when slinging. m Rod pin Sling cylinder. AOperate the control lease the remaining piping. t Check the number and thickness of the shims. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving.DISASSEMBLY REMOVAL CYLINDER a AND OF BUCKET ASSEMBLY Stop the machine on level ground and install the safety bar on the frame. BUCKET ASSEMBLY levers several times to repressure in the hydraulic the oil filler cap slowly to inside the hydraulic tank. and remove lock bolt. 3.

Serial No. Lift off bucket cylinder (7). 53001 and up) Remove lock bolt. J. then remove bottom pin (6). (Serial No.52999 I Bucket cylinder 1) 2) 3) Disconnect grease tube (8). check the number and thickness of the shims. and keep in a safe place.DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER 2) Disconnect tube (4) and hose (5) at bottom end from connecting portion. * If there are shims. 50001 . Be careful not to damage the cylinder rod portion. &I kg Bucket cylinder : 170 kg (with tube) Serial No. 53001 and up 30-207 0 . 4.

* Adjust the bucket positioner. Never insert your fingers in the pin hole. Install the hoses without twisting or interference. BUCKET CYLINDER OF BUCKET in the reverse order to Awhen aligning the position of the pin hole. 1. DBW02172 30-208 0 . * Clearance b : Max. use a bar. see TESTING AND ADJUSTING. For details.5 mm + Coat each pin with grease. * Clearance a : Max.DISASSEMBLY AND ASSEMBLY INSTALLATION CYLINDER l Carry out installation removal.5 mm m DBW02171 * * Fit the O-ring securely in the groove. 1.

check the number and thickness of the shims. the parking brake and put blocks wheels to prevent the machine from and install the bucket Then apply under the moving. Sr Set a support under the boom. a Operate the control levers several times to release the remaining pressure in the hydraulic piping. and remove slowly. Lower to the ground and stop the engine. 1. then remove pin (2). Boom cylinder I) Remove lock bolt. * Set the pin at a higher position than the top face of the tire. 2) Start engine. (I). and keep in a safe place. 2) Disconnect tube (5) and hose (6) at bottom end from connection. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Rod pin js I) Sling boom cylinder (I). 2. check the number and thickness of the shims. t If there are shims. / I I DEW02176 30-209 0 . 3. t If there are shims. then DBWO217b a remove bottom pin (7).DISASSEMBLY AND ASSEMBLY BOOM CYLINDER REMOVAL OF BOOM CYLINDER AStop the machine on level ground the safety bar on the frame. and operate control lever to retract cylinder rod of cylinder which has been removed. * Be careful not to damage the cylinder rod portion. * Be careful of the center of gravity. Hydraulic piping m I) Disconnect tube (3) and hose (4) at rod end from disconnection. 2) Remove boom cylinder. Boom cylinder assembly : r+ kg 170 kg (with tube) r . and keep in a safe place. and remove lock bolt.

m (a) : Max. Coat each pin with grease. + Sr Clearance (e) : Max. Never insert your fingers in the pin hole.0 mm Remove the support.DISASSEMBLY AND ASSEMBLY INSTALLATION OF BOOM CYLINDER ASSEMBLY a Carry out installation in the reverse order to removal. 1. 30-210 0 BOOM CYLINDER . When aligning the position of the pin hole. Install the hoses without twisting or interference. 1. 2.5 mm t Clearance * f Fit the O-ring securely in the groove. use a bar.

* Oil will flow out when the piston rod assembly is removed from the cylinder.DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY (STEERING. Bucketcylinder 1 27 DBWO1795 2) Pull out cylinder head and piston rod assembly (6) from cylinder (71. so place a container under the cylinder to catch the oil. Cylinder head. Set cylinder 2. and lift off. l 2) Pull out cylinder head and piston rod assembly (3) from cylinder (41. so place a container under the cylinder to catch the oil. Steering cylinder DEW01246 . remove cylinder head (2) from cylinder. 1. Boom. SEMBLY) BOOM. bucket cylinder assembly Remove mounting bolts of cylinder Bucket cylinder head (2). piston rod assembly Steering cylinder assembly I) Using tool G. t Oil will flow out when the piston rod assembly is removed from the cylinder. BUCKET assembly CYLINDER AS- Steering cylinder (1) to tool F. and lift off. . 1) Boom.

Remove piston mounting bolt (IO). 2) Using tool H.DISASSEMBLY 3. -f Width across fiats of nut: 46 mm piston (9). bucket cylinder only. * DEW01797 pis- I DEW01251 5. then remove cylinder 3) Remove head (2). bucket cylinder assembly Set cylinder head and piston rod assembly (6) to tool F. Rod of boom. remove nut (8). I 4. Disassembly of piston assembly Remove wear ring (15) and piston ring (16) from pistons (9) and (12). Remove O-ring and backup ring (14) from ton rod (13). 1) 2) Boom. piston (12). and cylinder head (5). then remove spacer (II). AND ASSEMBLY BOOM CYLINDER Cylinder head . . Steering cylinder assembly 1) Set cylinder head and piston rod assembly (3) to tool F. 30-212 0 .

1) 2) 3) 8 k f Boom.DISASSEMBLY 6. bucket cylinder assembly Remove snap ring (221. Remove O-ring and backup ring (26). I 2 20 21 19 DEW01253 . then remove bushing (25) from cylinder head (2). then remove dust seal (23). 3) Remove O-ring and backup ring (21). then remove dust seal (18). 2) Remove rod packing (19). 22 ‘23 24 30-2 13 0 . AND ASSEMBLY Disassembly of cylinder head assembly . BOOM I I CYLINDER 17 I. Remove rod packing (241. then remove bushing (20) from cylinder head (2). Steering cylinder assembly 1) Remove snap ring (17).

fit dust seal (231. BUCKET CYLINDER ASSEMBLY) * Clean all parts. bucket cylinder assembly 1) Using tool I. install dust seal (18) to cylinder head. press fit bushing (20) to cylinder head (2). . 3) Using tool K. Steering assembly 1) Using tool I. Boom. Assembly of cylinder head assembly . * Do not try to force the backup ring into position. Be careful not to damage the rod packing. Warm it in warm water (50 60°C) before fitting it. 1. 2) Install rod packing (19). BOOM. 2) Install rod packing (24). 30-214 0 I I v DEW01799 . dust seals or O-rings when assembling. 3) Using tool K. press fit bushing (25) to cylinder head (2). then install snap ring (22). and check for dir& or damage. Coat the sliding surfaces of all parts with engine oil before installing. DEW01793 24 264 DEW01257 4) Install O-ring and backup ring (26).DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY (STEERING.

then tighten mounting bolt (IO). Warm it in warm water (50 60°C) before fitting it. 2) Remove piston ring (16) from tool Jl.3+1. 16 J2 9. 4) Assemble wear ring (15). 9.DISASSEMBLY 4) 5) AND ASSEMBLY HYDRAULIC CYLINDER Install snap ring (17). DEW01260 2. 12 16 DEW01252 4. 3) Using tool J2. Sr Do not try to force the backup ring into position. expand piston ring (16).3) 30-215 0 . Warm it in warm water (50 . then assemble to pistons (12) and (9). 2) Assemble cylinder head (2). Boom. piston (121. + Do not try to force the backup ring into position. and spacer (I 1) to piston rod. Assemble O-ring and backup ring ( 14) to piston rod (13).8(11. + Set the piston ring on the expander and turn the handle 8 . Assembly of piston assembly 1) Using tool Jl. bucket cylinder assembly 1) Set piston rod assembly (6) to tool F.8+ 12. DEW01251 Cylinder head. & Mounting bolt: Thread tightener (LT-2) B Mounting bolt: Cylinder Boom cylinder Bucket cylinder NmOw-4 110. Install O-ring and backup ring (21).?2 8 G 3 3. compress piston ring (16).60°C) before fitting it. piston rod assembly .10 times to expand the ring.

2) Raise cylinder head and piston rod assembly (6) and assemble to cylinder (7).324f 147 (135f 15) 343 + 34 (35 z!z3. Boom. a Thread of piston rod: Thread tightener (LT-2) w Nut: Width 5. and using tool H. bucket cylinder 1) Set cylinder (7) to tool F. 1) 2) 3) 4) 5) cylinder assembly from tool F. Steering cylinder assembly 1) Set piston rod assembly (3) to tool F. install cylinder head (2) to cylinder (4). Using tool G. Remove cylinder assembly (I) From tool F. HYDRAULIC CYLINDER AND ASSEMBLY across flats1 46 I Nm(kgm) 785 f 78 (80 f 8) Cylinder head . tighten nut (8). 3) Assemble nut (81. Steering cylinder assembly Set cylinder (4) to tool F. 3) Install cylinder head (2) to cylinder (7).5) I I Remove . w Mounting bolt: Cylinder Boom cylinder Bucket cylinder Nm(kgm) 1. w Cylinder head: 588 +_ 59 Nm (60 t_ 6 kgm) Bend lock of cylinder head (2) into notch at cylinder end. Raise cylinder head and piston rod assembly (3) and assemble to cylinder (4). 4) DBW01853 Steering cylinder DEW01246 30-216 0 . 2) Assemble cylinder head (2) and piston (9) to piston rod.DISASSEMBLY .

3) Bucket Move machine towards nect bucket (2-I). * If there are shims. then disconnect cylinder rod and bellcrank. r+lkg Boom cylinder : 164 kg (each) . and remove mounting pin (6). I 2) Remove left and right bucket hinge mounta ing pins (2). and keep in a safe place. Lower to the ground and stop the engine. el kg Bucket cylinder : 166 kg DBWO2183 3. rear. * Set blocks @ on the top of the axle and lower the cylinder. Bucket link I) Remove bucket link mounting pin (I). * Set block @ between the cylinder bottom and the frame. check the number and thickness of the shims. g When aligning the position of the pin hole. then Bucket : 1. 1. * Set a support under the end of the boom. the parking brake and put blocks wheels to prevent the machine from and install the bucket Then apply under the moving. Boom cylinder pin m Sling boom cylinder (51.583 kg (with DElwo2179 DBWO21SU discon- edge) m Bucket cylinder mounting pin Sling bucket cylinder (3) and pull out pin (4). & kg 2.DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT REMOVAL OF WORK EQUIPMENT ASSEMBLY A I Stop the machine on level ground the safety bar on the frame. never insert your fingers in the pin hole. m Ir Secure the bucket link to the bellcrank with wire.

bucket link Sling boom. and keep in a safe place. bellcrank. and disconnect bellcrank (11) and bucket link (12).380 kg If there are shims. DEW02186 2) Sling bellcrank (II). and lift off boom. and bucket link assembly (71. AND ASSEMBLY Boom. a bucket link assembly : 1. m (76) from ‘16 DLWo2190 DfJWO2189 30-218 0 . WORK EQUIPMENT Boom. then pull out mounting pin (131. I. & kg 6. DBW02187 Bellcrank : 310 kg Dust seal. check the number and thickness of the shims. Bellcrank. and lift off. bellcrank.DISASSEMBLY 4.&lkg * 5. bushing 1) Pull out dust seal (15) and bushing boom (14). bellcrank. bucket link I) Remove pin (IO) from bellcrank and bucket link assembly (91. then pull out boom mounting pin (81.

DISASSEMBLY WORK EQUIPMENT AND ASSEMBLY 2) Pull out dust seal (17) and bushing bellcrank (11). (20) from I .l” 30-219 0 . (18) from 3) Pull out dust seal (19) and bushing bucket link (12).

remove DBWO2396 + 30-220 0 Clearance d : Max.5 mm (bucket DBWOZ195 hinge DEW02196 m * * After assembling the mounting block 0.5 mm (bucket link portion) * Clearance portion) b : Max. use a bar.5 mm DBWO2197 pin. 2. When aligning the position of the pin hole. then assemble the mounting pin and lock with the bolt.0 mm . install cord rings (211. 1. Be careful not to get the cord ring caught. insert shims so that clearances a and b on the left and right are uniform. Clearance c : Max. Clearance a : Max. * * * a Operate the control levers. align the mounting pin holes for the bucket and bucket link. Never insert your fingers in the pin hole. 1. 1.DISASSEMBLY WORK EQUIPMENT AND ASSEMBLY INSTALLATION OF WORK EQUIPMENT ASSEMBLY a m Carry out installation in the reverse order to removal.

set the support to the tip of the boom.5 mm After assembling the pin. and boom with press. 1 Press fit bushing (16) to each of bucket link. bellcrank. install boom kickout switch. Bushing : Grease (G2-LI) : 16 15 DBWO2199 Sr Greasing Coat each pin with grease. 30-22 1 0 . 1.WORK EQUIPMENT DISASSEMBLY AND ASSEMBLY J. then assemble dust seal (15). Ir * * & After installing the boom. Clearance e : Max.

Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. Lower the bucket to the ground and stop the engine.170 kg INSTALLATION OF COUNTERWEIGHT . Carry out removal. Counterweight m Sling counterweight (51.5 kgm) _. I 1.DISASSEMBLY AND COUNTERWEIGHT ASSEMBLY REMOVAL OF COUNTERWEIGHT AStop the machine on level ground and instail the safety bar on the frame. then remove mounting bolts (4) and lift off. and remove from engine hood (Z). (Width across fiats: 36 mm) I . w DEWOPOZ D6WO2203 & kg Counterweight: 1. installation in the reverse order to u DEW02204 m 30-222 0 Mounting bolt : 927 + 103 Nm (94. then make a clearance. 2) Disconnect wiring connector (31. 2. * Be careful to maintain the balance when lifting off. then lift off grill (1).5 i 10. Grill I) Sling grill (I).

DISASSEMBLY AND ASSEMBLY FUEL TANK REMOVAL OF FUEL TANK ASSEMBLY AStop the machine on level ground and install the safety bar on the frame. then tie with wire and move to the side. * Remove the drain valve. I 3. Drain valve Remove engine oil drain valve (5) from fuel tank. Lower the bucket to the ground and stop the engine. then fit grill to engine hood (2) temporarily. and remove grill (1). bolts of grill (I). and remove light wiring from engine hood (3-I) clip portion. Open the inspection cover and apply the lock. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. Disconnect wiring connector (31. Grill 1) Loosen mounting 2) 2. a 1. DBWOZZOE I 30-223 . DLWOZ339 Draining fuel Loosen drain valve (4) and drain fuel.

* Use two nylon ropes of a length of approx. 2) Disconnect spill hose (8) from fuel tank. m Fuel tank 1) Sling fuel tank (IO). AND FUEL TANK ASSEMBLY Fuel tubes.DISASSEMBLY 4. 5. wiring I) Disconnect fuel hoses (6) and (7) from fuel tank. When pulling the fuel tank out from under the chassis. 5 m to sling the tank. then slowly tower the fuel tank on to the pallet. 3) Disconnect wiring connector (9) for fuel unit. I3 kg Fuel tank : 179 kg (emptYI 2) Pull out fuel tank (IO) from under machine. remove it from the right side. \ DBWOZZ12 . t Set a pallet under the tank. then remove mounting bolts and lift off. taking care to maintain the balance. * Ir 30-224 0 m Tilt breather tube (11) to the side to prevent it from hitting the chassis.

and add fuel through oil 30-225 0 .5 * 10. then lift the fuel tank. Refilling with oil Tighten drain valve filler (12).5 kgm) (Width across flats: 36 mm) When raising the tank. tube under the chassis be- DEW02215 . right Mounting bolt : in the fol- 927 f 103 Nm (94. rear. keep it horizontal and set it in the mounting position. Pull the breather fore connecting. tighten lowing order: left. Raise the palleter fully.DISASSEMBLY AND ASSEMBLY INSTALLATION ASSEMBLY l Carry out installation removal. FUEL TANK OF FUEL TANK in the reverse order to Bolt a + m * * a * When tightening the bolts.

* Disconnect the intermediate hose clamp of hose (6). mark them with tags. t To distinguish the hoses. connection (3) between cab DBWO2218 4. Lift off left and right ladders (1). (51. 1.DISASSEMBLY AND ASSEMBLY CAB. Disconnect brake hoses (8). 3. (9). Remove 8 connectors (2) from clip and disconnect. and (II). mark them with tags. FLOOR FRAME REMOVAL OF CAB. * To distinguish the hoses. tie them securely with wire to the bottom of the cab. (IO). fit the connectors at the cab end to the clip. FLOOR FRAME ASSEMBLY ADisconnect the cable from the negative minal of the battery. DLWM842 5. kg E!?l Ladder (-1 ter- : 60 kg 2. mark them with tags. * To distinguish the connectors. and take steps to prevent oil or mud from getting on the connectors at the chassis end. 30-226 0 . Disconnect hoses (41. * After disconnecting the hoses. Disconnect ground and chassis. and (6). Ir After disconnecting.

H. mark them with tags. remove the hoses from the outside. then remove nipple (40). FLOOR FRAME AND ASSEMBLY Orbit-roll valve piping . CAB. and (15).DISASSEMBLY 6. Disconnect hose (39) between orbit-roll valve and accumulator from orbit-roil valve end. . then remove the nipple and disconnect the hoses.) then remove nipple (44). -k To distinguish the hoses. Disconnect hose (45) between orbit-roll valve and stop valve (L. Disconnect hose (43) between orbit-roll valve and stop valve (R. then remove nipple (42).H. Disconnect work equipment PPC valve hoses (121. Disconnect hose (41) between orbit-roil valve and hydraulic tank from orbit-roll valve end. . cable (16) at fuel injecm .) from orbit-roll valve end. 7. Disconnect accelerator ti-on pump end. (131. . I DEW02221 8. lr When removing the 4 hoses at the bottom of the PPC valve. (141.

then coil the tubes and secure them to the cab. FLOOR FRAME . then remove mount bolts. or dirt from entering. * After disconnecting the tubes. m f Loosen the sleeve nut of the air conditioner hose and gradually drain the refrigerant (R134a). + To prevent coolant from leaking out from the heater hose. * Fit blind plugs to prevent the water inside the washer tank from leaking out. mud. t Put the air conditioner hoses in a vinyl bag to prevent oil. 11. m 30-228 0 CAB. and lift off cab and floor frame assembly (22). and heater hoses (20) and (21). 10. bend the tip of the hose and tie it with wire. Disconnect 2 window washer tubes (17) at washer tank end. check the position for inserting them into the tank. Disconnect air conditioner hoses (18) and (191.DISASSEMBLY AND ASSEMBLY 9. Sling cab and floor frame assembly (22).

a * Check that there is no damage to the air conditioner hose.11. Align the position of the flange of plate (25) so that it is easy to prevent rotation during the tightening operation.8 (0. Sleeve nut: w Thread size Tigh.9 . FLOOR FRAME ASSEMBLY l w Carry out removal. floor frame assembly : 700 kg Align the hole of plate (25) with dowel pin (24) of viscous mount (23) and assemble.9 (0. Charge with refrigerant (R-134a).2) rel Ir ks * Cab. . then connect.que R M6 bolt at receiver portion 3.B to. DEW02227 30-229 0 . installation in the reverse order to Adjust the accelerator cable.i.1.4 .7) Other M6 bolts 7. FLOOR FRAME INSTALLATION OF CAB. For details.8 ..6. see TESTING AND ADJUSTING.0.8 .DISASSEMBLY AND ASSEMBLY CAB. sleeve nut. or O-ring.. Measuring accelerator pedal.

DBWOle33 2. Make marks to distinguish the hoses. * Remove the ashtray from cover (5).DISASSEMBLY CAB AND ASSEMBLY REMOVAL OF CAB ASSEMBLY A Stop the machine on level ground and install the safety bar on the frame. m + Fit tags to distinguish the connectors. Electric wiring 1) 3. 1. Remove cover (6). f Pull the steering post to tip it down. (Connectors CLI. and (3) from under 2) Remove 3) cover mounting bolts. Cover 1) Remove floor. Cab 1) Remove steering post and cab mounting bolts (9). 30-230 0 . CL31 Hoses 1) Disconnect Ir Sr 4. Disconnect cab wiring connectors (7). 2 window washer hoses (8). Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. Drain the washer fluid. (2). covers (11. then remove covers (4) and (5). CL2. Lower the bucket to the ground and stop the engine.

Carry out removal. 30-231 0 . t Remove 4 plugs (13) from the cab roof. bolts “. DBWOlm 3) Lift off cab 114).L ( IUI.._-/ DBW0183 INSTALLATION ASSEMBLY . Raise horizontally and lift off slowly. and (12) on left and right. then install eyebolts. * & kg Cab : 295 kg 13 / l--_.DISASSEMBLY 2) AND ASSEMBLY CAB Remove floor and cab mounting (ll). * Connect installation the wiring DBWOl840 OF CAB in the reverse connectors order to securely.

Remove dashboards (I) and (2). Remove mounting bolt caps from steering post cover (81. * Tip the steering post cover to the front. 4. steering post cover mounting 3. ADisconnect the cable from the negative minal of the battery. bolts (3) post DLW01841 5. 6. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving.DISASSEMBLY AND ASSEMBLY REMOVAL OF MAIN ASSEMBLY MAIN MONITOR MONITOR Astop the machine on level ground and install the safety bar on the frame. Remove and (4). 2. then remove mounting bolts (9). Lower the bucket to the ground and stop the engine. DEW01307 30-232 0 . Remove mounting bolt caps (7) of steering cover (61. Remove bracket (IO) at back of main monitor. Remove steering post cover (5). then remove bolts. (-) ter- 1.

and remove main monitor (II). and (16) from main monitor. 8. m k INSTALLATION OF MAIN MONITOR ASSEMBLY l Carry out installation removal.DISASSEMBLY AND ASSEMBLY MAIN 7. in the reverse I order MONITOR DEW01309 15 14 13 to @lJ Ir Fit the connector lock securely. 30-233 . * When removing the main monitor. Remove 8 mounting bolts (12) of main monitor (11). be careful not to subject it to any strong shock. (15). (141. Disconnect wiring connectors (131.

* Remove the cover and leave the bolts loosened. Remove monitor cover (3). Remove cover (2). INSTALLATION OF MAINTENANCE MONITOR ASSEMBLY . L22. 1. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. . Llg. Maintenance I) 3. order to MONITOR . * Remove the boot.DISASSEMBLY REMOVAL MONITOR AND ASSEMBLY MAINTENANCE OF MAINTENANCE ASSEMBLY AStop the machine on level ground and install the safety bar on the frame. Disconnect * * monitor Remove mounting bolts. a Disconnect the cable from the negative@terminal of the battery. Cover 1) 2) 3) 2. * Remove pad assembly (4) and mounting bolt cap (5). Lower the bucket to the ground and stop the engine. then remove maintenance monitor (6). electrical wiring (7) from connector. Carry out installation in the reverse removal. m f 30-234 0 Connect the connectors securely. * Open the fuse box cover and leave the bolts loosened. Remove cover (I) from cab. a Electrical wiring (7): L18.L20 Fit tags to distinguish the wiring. * Move the maintenance monitor to the side. * Turn the cover to the outside.

1. Carry out the oil return operation for the compressor. Remove the cover under the cab. DBW02230 cover (I) under floor. tip it over. . set the fan switch to the maximum position. Remove inspection 2. then remove seat support cover (5). l l A If the refrigerant gets in your eyes. so always wear protective goggles. f Slide the operator’s seat to the front. Remove clamps of heater hoses (1-1) and (I-2).negative@terminal of the battery. 3. +r Remove 2 bolts and loosen 6 bolts. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. then use a gauge manifold and release the refrigerant slowly from the core of the compressor high-pressure and lowpressure valves. and operate the air conditioner for 5 minutes. remove cover. ground and install Lower the bucket to the ground and stop the engine.DISASSEMBLY AIR CONDITIONER AND ASSEMBLY UNIT REMOVAL OF AIR CONDITIONER UNIT ASSEMBLY Stop the machine on level A the safety bar on the frame. Remove covers (2) and (3) at rear of cab. then Remove 5 mounting bolts of cover (41. there is danger of losing your sight. * Remove blind cap (3-I). I III DEiV01316 \ / ’ DEW01318 DEW01317 30-235 0 . run the engine at low idling. z? 2 f 4. A Disconnect the cable from the . When carrying out the oil return operation.

(161. Remove connectors (91. 8. (13). then remove cool and hot box assembly. and (17) from air conditioner unit wiring. DEW01319 6. (12). and (14) from fuse box assembly bracket. and put fuse box assembly on right console box temporarily. Remove console 7. (IO). (II). Disconnect floor wiring connectors (151.DISASSEMBLY 5. bracket (8) from right . Ir Mark the connectors with a tag to distinguish when installing. AIR CONDITIONER AND ASSEMBLY UNIT Remove cool and hot box assembly (6) and mounting bolts (71. then disconnect air conditioner relay wiring connector (18). 30-236 0 fuse box assembly box.

21 I 11. Remove left console box mounting bolts (20) and (211. Ir Loosen mounting bolt (27). Remove AND ASSEMBLY left console AIR CONDITIONER UNIT box cover (19). I 26 DEW01327 30-237 0 . then remove left console box (22).DISASSEMBLY 9. DEW01323 10. J. DEW01326 12. Remove mounting bolts (26) of air conditioner unit (23) and air conditioner damper (25). . Remove mounting II DEW01325 bolts (24) of air conditioner unit (23). Loosen the 4 mounting bolts at the cab end.

30-238 0 - /25_ DEW01331 k . Remove cover (30) at rear right of cab. m * Check that the pressure has been reduced.DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT 13. Remove connecting bolts (33) of air conditioner unit (23) and air conditioner damper (25). Disconnect air conditioner tubes (28) and (29) from air conditioner unit. Remove air conditioner filter (311. 14. then remove duct mounting bolts (32). 32 I 16. I- DEW01329 15.

6 kg UNIT \ DEWO? 333 heater hoses (35) and (36) from air unit. take steps the entry of dust or water. then remove air conditioner damper (25). Disconnect air conditioner damper wiring connector (37) from floor wiring. wir- / 18. to prevent II II DEW01336 30-239 0 . * After disconnecting. Disconnect conditioner (23).DISASSEMBLY AND ASSEMBLY 17. Remove AIR CONDITIONER clamp bolt (34) of air conditioner ing connector (16). then remove air conditioner unit 112 Air conditioner unit assembly: 38 kg 19.

AIR CONDITIONER ASSEMBLY Carry out installation OF AIR UNIT in the reverse order to removal. 750 mmHg. hose through Fill the air conditioner with new refrigerant. m Jr . (Attainment of vacuum: Min. (Specified oil level: 150 +‘i cc ND-OIL81 30-240 0 UNIT .2 kgm) Coat the O-ring with compressor oil ND-OlL8. (If the temperature is below 3”C. * Check the oil level in the compressor.0 + 0. w * Tube mounting bolt: 9. the system will not work. * Precautions when filIing air conditioner line with new refrigerant inside the room at I) Keep the temperature above 3°C. 6) Do not operate the compressor before charging with refrigerant. always use the repeat vacuum method to completely evacuate.) 2) Use R134a as the refrigerant.5 .1.1 4) Charge with 1.6 kg of refrigerant. upside5) Do not use the can of refrigerant down or use any other mistaken method. 3) When filling with refrigerant.8 + 2 Nm (1. Be careful not to let liquid freon get into the refrigerating system.DISASSEMBLY AND INSTALLATION CONDITIONER ASSEMBLY . Pass the air conditioner drain the floor support grommet.

DEW02232 2. a Disconnect hoses (4) and (5). (81. Sling condenser and bracket assembly (IO). or water from entering the joint. (71. Lower the bucket to the ground and stop the engine. I 30-241 0 . 3. and open left and right engine hood inspection covers (21. 1. then use a gauge manifold and release the refrigerant slowly from the compressor high-pressure valve. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. 4.DISASSEMBLY AND ASSEMBLY CONDITIONER ASSEMBLY AIR CONDITIONER CONDENSER CONDENSER AStop the machine on level ground and install the safety bar on the frame. or * I \ D&V02231 Open inspection cover (3) on top of the bulkhead. * Leave 1 mounting bolt each installed temporarily on the left and right sides at the top. * After disconnecting the hoses and tubes. Remove left and right covers (I) under bulkhead. Disconnect electric wiring connectors (6). and (9). fit covers to prevent dirt. dust. and remove mounting bolts of condenser and bracket assembly. then apply lock. Carry out the air return operation for the compressor.

6.8 . AIR CONDITIONER CONDENSER Remove mounting bolts of condenser and bracket assembly.8 .2) Filling with gas Fill the air conditioner with gas. always use the repeat vacuum method to completely evacuate.5) d M6 bolt at receiver portion 3.6.4 . dust. then remove condenser (12) together with bracket assembly from inside of bulkhead (1 I).DISASSEMBLY AND ASSEMBLY 5. even if there are bubbles.8 (0.3 (3.8 .5) b M22 x 1. or water from entering the joint.1. then add refrigerant until condition becomes normal .1. bracket assembly : 20 kg &I kg (including dry receiver) Remove condenser piping. * After disconnecting the hoses and tubes.34. Hose joint.11. thread : Compressor oil The tightening torques for the air conditioner piping are as follows. Check the oil level in the compressor.0. + Leave dry receiver (13) installed to the bracket when removing. - size Other M6 bolts CompF 7.2.2 . /-EJfi] * * 6 * Do not reinove the covers from the hoses until immediately before installing. use two wrenches to hold the hoses securely in position when tightening. Carry out installation in the reverse order to removal.9 (0. Check that the refrigerant level is correct. Condenser. Condenser (each) : 5.5 11.6 .3. (R134a) Before filling with refrigerant. Thread a Ml6 x 1.7) e .0 .7 (1.5 (2. then remove cona denser (12) from brackets (14) and (15).4 .24. (Specified oil level: 150 +‘i cc ND-OIL8) 30-242 0 a I DBLWQ233 * Checks after assembly Amount of bubbles in receiver sight glass Correct Low Remedyi Almost completely transparent.5) C M24 x 1.9 . fit covers to prevent dirt.5 29.0 . Be careful not to let liquid freon get into the refrigerating system.14. To prevent the hoses from twisting.4 kg &I kg INSTALLATION OF AIR CONDITIONER CONDENSER ASSEMBLY . Do not operate the compressor before charging with refrigerant. becomes transparent when engine speed is raised or lowered Continuous stream of bubbles passes Connect charging hose to compressor.5 19. Do not use the can of refrigerant upsidedown or use any other mistaken method.

6 + 7. run engine at low idling. then use a gauge manifold and release’ refrigerant slowly from compressor high-pressure and low-pressure valves.mounting bolt : 5. Check the oil level in the compressor. Remove mounting U-bolts (31.4 i 1.9 f 0. + After disconnecting the hoses. even if there are bubbles.55 & 0. Check that the refrigerant level is correct.15 kgm) f To prevent dirt. 3. installation in the reverse order to Hose. Do not use the can of refrigerant upsidedown or use any other mistaken method. . Filling with gas Fill the air conditioner with gas.DISASSEMBLY AND ASSEMBLY DRY RECEIVER REMOVAL OF DRY RECEIVER ASSEMBLY AStop the machine on level ground and install the safety bar on the frame. (R134a) Before filling with refrigerant. a Hose joint : Compressor oil w m U-bolt : 18. and operate air conditioner for 5 minutes. 8 2 f DBW02232 INSTALLATION OF DRY RECEIVER ASSEMBLY l Carry out removal. fit covers to the joint. do not remove the covers from the air conditioner hoses until immediately before installing. then add refrigerant until condition becomes normal 30-243 0 . Disconnect hoses (I) and (2).8 Nm (1. (Specified oil level: 150+‘04 cc ND-OIL81 Amount of bubbles in receiver sight glass Correct Almost completely transparent. becomes transparent when engine speed is raised or lowered Low Continuous stream of bubbles passes Remedy Connect charging hose to compressor. a 2. * Open inspection cover (1-l) on top of the bulkhead.8 kgm) * Be careful not to tighten the U-bolts too far.5 Nm (0. 1. Lower the bucket to the ground and stop the engine. Carry out oil return operation for compressor. always use the repeat vacuum method to completely evacuate. m . dust. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. Do not operate the compressor before charging with refrigerant. or water from entering. then remove dry m receiver (4) from bracket. Procedure for oil return operation Set fan switch to maximum position. Be careful not to let liquid freon get into the refrigerating system.

electric wiring INSTALLATION CONDITIONER COMPRESSOR . fit covers to prevent dirt. Carry out oil return operation for compressor. Filling with gas Fill the air conditioner with gas. the negative (-1 ter- 1. then use a gauge manifold and release refrigerant slowly from compressor high-pressure valve. -k V-belt deflection at approx. 2. or water from entering the joint. 4.8 . then remove m compressor (6). Remove hose mounting bolts (2). remove V-belt. installation from connector (I). Check the oil level in the compressor. 6 OF AIR CONDENSER ASSEMBLY in the reverse order V-belt adjustment procedure to Adjust belt with adjustment m Hose mounting bolt : 7.15 mm . always use the repeat vacuum method to completely evacuate.8 Nm (0.2 kgm) w 112 +r Adjust the V-belt as follows. ADisconnect the cable from minal of the battery. m Ir After disconnecting the hoses. (Specified oil level: 150”: cc ND-OIL81 30244 0 I DBW038M . 98 N (10 kg): II. Do not operate the compressor before charging with refrigerant. dust.DISASSEMBLY AND ASSEMBLY AIR CONDITIONER CONDENSER COMPRESSOR REMOVAL OF AIR CONDlTlONER CONDENSER COMPRESSOR ASSEMBLY AOpen the hood and apply the lock. Check that the refrigerant level is correct. Remove bolts (51. and disconnect hoses (3) and (4). Carry out removal.1. Disconnect 3.11. (R134a) Before filling with refrigerant.8 . Be careful not to let liquid freon get into the refrigerating system. Do not use the can of refrigerant upsidedown or use any other mistaken method.

...................... Steering cylinder mount ....................... 40.............................................. Brake valve ........................... Brake.......................5 40-14 40-18 40-19 40-20 40-21 40-24 40-26 40-28 40-30 40-31 40-32 40-33 40-34 40-38 40-39 40-40 40-44 40-45 40-46 40-48 40-49 40-l ........ Drive shaft...... Final drive ............ transmission mount......................................2 40......................................... Parking brake .................. PPC valve ................. Work equipment linkage ................................................ Bucket.... ........................................................................................ Steering valve....................................... Torque converter_........................ Bucket positioner and boom kick-out .......4 40......................... Transmission Modulation valve assembly ..... .................................... Transmission control valve ........................................................................3 40..... .... ... ...................................................................... Hydraulic cylinder ............... .......................... .......... .............................................. Main control valve ........................... Steering column ...................................................... Hydraulic pump ... Differential...................... Axle mount ........40 MAINTENANCE STANDARD Engine mount.......... Accumulator valve ................................ . Center hinge pin.. Torque converter charging pump ...............................

TRANSMISSION TRANSMISSION MOUNT ZNm MOUNT (B6kgm) (5&6kgm) J !I m II 113tlONm (lE&l.5kgm) r-i n w 549t59Nm (56*6kgm) SLwoo639 Unit: mm I No.MAINTENANCE ENGINE ENGINE MOUNT.Okgm) ii I w 27%34Nm (28.523.1 1 40-2 I I Check item Crearance between transmission bracket and adjustment bolt I Criteria l-2 I Remedy Adjust . STANDARD MOUNT.

10 .55°C SAL (2) 20 3.1.7 Nm (0.13. Criteria Check item 1Standard Model 1 Remedy clearance 0.125 Replace SAL (2) 20 Standard Model 3 SAL (2) 45 Tolerance size 0 .hl.9 .19 0.Okgm) Unit: mm No.5 12 SAL (2) 20 4 - Rotating torque spline shaft limit SAL (2) 45 Side clearance SAL (2) 20 2 1 Clearance of 5.6 .15 Clearance between inside diameter of plain bearing and outside of diameter of gear shaft / SAL (2) 45 Depth for knocking in pin 0.000 rpm .4 kgm) Discharge amount Oil: EOlO-CD Oil temperature: 45 .20 0.MAINTENANCE TORQUE CONVERTER CHARGING PUMP STANDARD TORQUE CONVERTER CHARGING PUMP (SAL(2)45+20) A-A w 113+10Nm (ll.3~~g~cp~*j 59 Umin 53 elmin 40-3 .0.060 .0.0.

227.75_9.2z7.49 51.75kgm) (3.35kgm) SAWW64l I No. Check Standard Outside 2 Inside diameter of retainer seal ring contact surface 3 4 diameter size Tolerance Repair limit 52 .4Nm 30.4Nm (6.75 Repair chrome plating of replace Replace .0.15-9.0.3 + 0.7 Thickness 4.5 Width 3 .035 0 110.4Nm (6.35kgm) w w 66.9 of pilot Wear of stator shaft seal ring Backlash between PTO drive gear and drive gear 40-4 Remedy Criteria item 1 Unit: mm I 0.0.0.03 2.MAINTENANCE TORQUE STANDARD TORQUE CONVERTER CONVERTER m w 66.040 110 + 0.9*3.150.01 .0.4Nm 30.18 .75kgm) (3.75+0.%3.1 3.010 .

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045 output and housmg between 20 (F) output oil seal and housing 40-7 .0.045 - 0.Oll +0.025 - 60 +0.030 0 o.Oll +0.005 Replace lo Clearance between idler gear and bearing Clearance 11 between ward/reverse bearing and housing clutch Clearance between - 110 -Lo15 -0.015 -0.015 +0.015 +0.015 16 Clearance between 2nd and 4th clutch bearing and housing (F) 140 +0.Oll 4.037 - 90 -0.030 0 o- 4.Oll 0 -0.0.048 - 0.015 0 -0.096-0.MAINTENANCE TRANSMISSION STANDARD Unit: mm No.011 -0.040 o.g Clearance shaft and bearing between (F) output 65 +O.015 -0.015 o.045 13 Clearance between 1st and 3rd clutch bearing and housing (R) 110 +0.011 -0.015 100 +0.011 0.0.054 0 -0.@ft 100 -0.038 - -0.015 120 i.Oll -0.014 -0.018 I7 Clearance between output shaft and bearing (RI 65 io.037 - 50 +0.030 J.between beanng Clearance sF”.023 +O.35 +0.0130.‘%I.$ft Clearance - 0.015 0 -0. / - 47 -Z.015 +0.013 -0.030 +O.040 -0.045 - 110 4.030 0 o- l.045 - - for(RI for- 12 ward/reverse bearing and housing clutch 90 -EL01 5 +0.045 - -0.0130.042 -0.013 -0.040 - +0.015 0 +0. ’ 2 3 Check Criteria item Clearance between pump drive shaft and bearing Clearance between drive shaft bearing housing pump and Clearance between 5 Clearance between pump drive shaft and bearing Clearance and between drive housing shaft bearing Hole Standard clearance Clearance limit 60 co.013 0.030 0 o- -Lo15 14 Clearance between 1st and 3rd clutch bearing and housing (F) 130 +0.011 -0.022 -0.35 - output and housing between 0.“ft bearing 21 .015 -0.030 0 o- -:.030 +O.011 -0.022 -0.: 1 :::i.022 -0.020 100 4.OlS 15 Clearance between 2nd and 4th clutch bearing and housing (RI 110 +0.037 - pump and Clearance between pump drive shaft and bearing g Shaft pump drive housing shaft bearing 8 Standard size Clearance between pump drive shaft and bearing 4 6 Tolerance Remedy Clearance between drive shaft bearing housing pump and Clearance between shaft and bearing idler 1 35 / 2::..009 -0.040 - .“i ) ‘.15 Clearance .0.037 - 85 4.030 0 o.009 Jo12 -0.011 -0.048 - -0.042 -0.025 +0.013 -0.045 - 18 .

01 . .1 .lOkgm) Adjust shim.O. - Check item Criteria Remedy 22 23 24 Inner diameter of housing seal ring contact surface 25 26 Replace pling oil seal slide part (R) 27 28 Clearance between output retainer and case Width of shaft seal rin 29 Thickness of seal ring 30 40-8 Free rotation torque of output shaft 0.ONm(O.MAINTENANCE TRANSMISSION STANDARD Unit: mm No.l.

05 I I I Reoair limit 1.074 I I Tolerance kO.7 Separator plate distortion - 0.25 I .08 1.020 -0.021 50 1 Friction plate distortion Standard clearance Replace Clearance at forward/ reverse clutch shaft bearina end spacer press-fitted:ection 7 Remedy Criteria Check item 0.20 -0.045 -0.MAINTENANCE TRANSMISSION STANDARD FORWARD/REVERSE Clutch 6 .02 0.040 +0.06 -0.034 +0.38 0.“?Oi6 8 k f - / - Friction plate thickness 2.43 1 -“.1 I 0.43 0.041 -0.1 0.6 0.38 0.32 +0.15 +0.012 I Separator plate thickness I Standard size 1.030 +O.07 140 -0.13 0 4.95 8 40-10 Clearance limit -0.015 55 I +0. 3 1 5 10 4 2 SA’A’OWS NO Tolerance Standard size 1 2 3 4 5 6 Clearance between IinnerI piston and cylinder (forward/reverse) - Clearance at forward/ reverse clutch shati~bearinn Dress-fitted section (R) Clearance at forward/ reverse clutch shaft bearing press-fitted section (F) Clearance at forward/ reverse clutch shaft spacer press-fitted section (R) Clearance at forward/ reverse clutch shaft spacer Dress-fitted section (F) Shaft 1 Hole 110 -0.‘: / 1.02 0.25 +0.2 1 -0.011 -0.27 -0.Oll 50 / %i.

o Thickness of forward/reverse clutch thrust washer 3.0 *o.2 mm Tolerance Remedy Repair limit (103 kg) (k10.MAINTENANCE STANDARD TRANSMISSION Unit: mm No. Thickness of forward clutch spacer 5.0.0 +0. Criteria Check item Standard size 9 Wave spring load at height of 2. 1 .991 Replace 40-11 .7 1.05 - Thickness of reverse I2 clutch spacer 13 End play of forward gear 0.5 kO..106 .106 .05 - 5.010 N +I01 N .0.991 14 End play of reverse gear 0.3 kg) 804 N (82 kg) 2.

Oll -:.Oll 1.0 kO.015 -0.7 7 Thickness of 3rd clutch side spacer 5.06 - 2 - Standard size Tolerance Repair limit 6 Thickness of gear end thrust washer 3.045 - 4 Clearance at 1st and 3rd clutch shaft spacer pressfitted section (F) 60 +0.054 +0.1 .38 0.030 +O.011 -0.06 -0.20 0.02 -0.05 - 8 End play of 1st gear 9 End play of 3rd gear - 40-l 2 0.1.064 -0.58 I 0. Remedy Criteria Check item 8 z s I Clearance between piston and cylinder (inner) 110 -0.32 +0.069 - 3 Clearance at 1st and 3rd clutch shaft bearing pressfitted section (F) Clearance at 1st and 3rd clutch shaft bearing pressfitted section (RI 60 +0.27 -0.43 0.015 -0.43 60 io.044 -0.044 -0.MAINTENANCE TRANSMISSION STANDARD 1st and 3rd Clutch 1 1 8 7 9 Unit: mm No.02 .06 -0.030 +O.07 0.044 4.0 +0.03 -0.04 -0.07 0.20 - (outer) 165 -0.38 0.1 2.27 -0.011 -0.094 - 5 Clearance at 1st and 3rd pressclutch section fitted shaft spacer (RI 61 +0.0.9 Replace .32 +0.054 +0.

32 +0.059 +0.17 .34 .074 - Clearance ‘at 2nd and 4th clutch shaft pressfitted section spacer (F) 65 +0.MAINTENANCE STANDARD TRANSMISSION 2nd and 4th Clutch 6 4_ Unit: mm No lCheck item Criteria I Remedy Clearance limit 1 Clearance between piston and cylinder (inner) I 110 -0.1.048 - Clearance at 2nd and 4th clutch shaft bearing press-fitted section outer diameter (F) 65 +0.017 -0.059 qo.049 0 -0.015 -0.0 Tolerance size I kO.049 -0.43 2 Clearance at 2nd and 4th clutch shaft bearing press-fitted section outer diameter (R) 60 -I-o.27 -0.049 -0.07 0.021 -0.43 0.38 0.1.1 Repair limit 2.070 -0.06 -0.033 +0.017 1.43 II Standard 7 Thickness of thrust washer Replace 3.66 0.20 0.041 -0.100 - 5 End play of 2nd gear 6 End play of 4th gear 0.7 40-l 3 .015 -0.

4Nm (3.15e0.&4.MAINTENANCE STANDARD TRANSMISSION TRASMISSION CONTROL VALVE CONTROL VALVE UPPER VALVE 30.923.35kgm) 8 39.9Nm 13 40-14 A-A .

013 0 +0.25 N (0.2 .013 0 +0.1 N (0.03 +O.013 0 +0.065 5 Clearance at main relief valve load piston 15 -0.020 -0.035 +0.044 4 Clearance between main relief valve spool and hod) 25 -0.2 valve spring I I 10 Quick return valve return spring 11 Main relief valve load piston spring 12 Main 73 0.5 kg) 49 71.3 N (0.3 315.045 +0.048 Replace I I I Standard size 8 Pilot vaive spring 74.02 -0.013 0 +0.058 0.7kO. 4.5 27 26 19 5.2 I converter regulator valve spring Torque - 40-15 .03 kg) 25.5 131.050 2 Clearance between pilot valve spool and body 25 -0.044 0.4 kg) 417 N (42.045 +0.058 0.035 -0.065 3 Clearance between quick return valve spool and body 25 -0.045 +0. 9 Quick return Free length Repair limit Installed length Installed load Free length Installed load 463+23 N (47.2k2.8 N (32.020 to.020 +0.058 0.035 +0.0 5.0 kg) 30.035 -0.03 +0.0 284.41 N (0.58ti.020 to.4 N (29.041 0.2i1.61 kg) 157.8k15.02 -0.5+0.025 kg) I I I 4.MAINTENANCE STANDARD TRASMISSION CONTROL VALVE Unit: mm No.02 -0.020 i-o.Oll 0 +0.035 +0.055 6 Clearance between torque converter regulator valve SDOOIand bodv 25 -0.45 kg) 31.9+0.018 0 +0.013 0 +0. 1 Check item Clearance between emergency manual valve spool and body Criteria Standard size Remedy Tolerance _ Shaft Standard clearance Hole Clearance limit 14 -0.52 kg) 163.048 0.028 +0.035 -0. I .065 7 Clearance between dummy spool and body 25 -0.03 +0.055 I relief valve spring I .

15d35kgm) (1.15Nm (0.15dl.4Nm (3.275_9.015kgm) 12.165e0.62-9.015kgm) 30.62d.15z0.4Nm (3.35kgm) 1 B-B 7 2 3 7 4 8 A-A 40-16 ‘9 .MAINTENANCE STANDARD TRASMISSION CONTROL VALVE LOWER VALVE w m 1.35kgm) m 1.S4.9&3.%3.9d3.15Nm (0.4Nm (3.66Nm w 30.35kgm) m 30.15*0.4Nm (3.475kgm) 30.9z3.165=0.

02 -0. +i.043 0.3 46.2 1 Replace I 62.4 kg) 757 N (77.8 N (6.5 kg) 40-l 7 .058 Clearance between parking brake valve spool and hod) 19 between selector Standard size spool Clearance between H-L selector spool and body 1 -J$ Standard 6 9 Remedy Shaft Clearance directional and body 1 Criteria Directional spring I Parking selector spool brake valve spring Free length 1.05+0.5 N (7.12kO.2 kg) 42 32 48 36.050 Clearance between priority valve spool and body 19 -0.3 kg) 81.02 +0.045 +0.MAINTENANCE STANDARD TRASMISSION CONTROL VALVE Unit: mm Check item No.013 0 +0.9 N (8.5 N (7.013 0 +0.03 +0.2 N (85.035 -0.2 kg) 73.3kO.050 limit Installed length Installed load Free length Installed load 78.9f3.4f3.043 0.4 kg) 70.065 1 Reoair 0.B4.013 - / +:$):.02 +0.36 kg) 841 A42.4 N kg) 40.1 144 44.7 150 111 46 37 69.050 Clearance between range selector spool and body 19 -0.035 +0.02 -0.3 I size 0.9 (8.8k3.013 0 +0.03 +0. 2 Tolerance Hole Standard clearance Clearance limit 19 -0.6 N (7.

075 0.030 -0.025 I +0.041 +0.5 607? 30.o.025 -0.MAINTENANCE STANDARD MODULATION MODULATION VALVE ASSEMBLY VALVE ASSEMBLY 3 8 4 9 2 6 .040 -0.030 Clearance between accumulator valve spool and body 1 +op / o.ti3.030 Clearance between fil.100 I 0.yo~3 1 0.l valve and sleeve 25 -0.067 I 4 Clearance between fill valve and sleeve 27 -0.025 0.020 -0.050 0.025 0 0.053 0.013 0 0.063 +0.040 0.091 +0.060 Clearance between fill valve and body 25 -0.065 0.040 +0.050 5 Clearance between sleeve and body 6 Accumulator spring 38 -0. 0.030 0.4 Unit: mm No Check item Criteria Standard size Remedy Tolerance Shaft Hole Standard clearance Clearance limit 25 -0.080 Free length InstalledlengthInstalled load Free length installed loac ~ 7 Accumulator spring 8 Accumulator spring 9 Fill valve spring 40-18 100 78.050 .4 N (61.020 0.l 7 A-A sAbvx65.020 -0.7 kg) Replace % k f .1 kg) g6 546 N (55.033 +0.

0kgm) c Unit: No. Check item Forward clutch tor spring accumula- Criteria Remedy mm .6Nm (5.MAINTENANCE STANDARD ACCUMULATOR \ ACCUMULATOR VALVE VALVE c J A-A &9?79.5&.

.A w / 277t32Nm (28.25kgm) \ _.25 kgm) .25 kgm) 40-20 110+12Nm (1125+1.MAINTENANCE STANDARD DRIVE SHAFT DRIVE SHAFT m m 110zlZNm (11.252 1.25~ 1.5 -c10.25kgm) \ w 927 -c103 Nm (94.25 + 3.5 kgm) w I --- llOk12Nm (Il.

86 I diameter of bevel gear) Unit: mm Remedy I Adjust I 40-2 1 .0kgm) 152&!5Nm (15.5=3.%2.5kgm) (5t0.5kgm) I No.4+1.7 kg) (outer 2 Differential side bearing carrier shim thickness (one side) 0.5&.0 3 Differential housing and gauge assembly shim thickness 0.7 .66 .4 .3 .1.5kgm) w 4. - Criteria Check item Bevel gear starting rota- 1 tional force I I 12.5Nm (0.MAINTENANCE DIFFERENTIAL STANDARD DIFFERENTIAL (l/2) w w w 177dONm (18dZkgm) 177s2ONm (18dkgm) 17L20Nm (18dkgm) 1 w \ w / 152z25Nm (15.3.45+0.36.3 N (1.15kgm) w 549+59Nm (56Skgm) 177dONm (18dkgm) & / ‘5=m 279d9Nm (28.1.

MAINTENANCE STANDARD DIFFERENTIAL 1 40-22 DIFFERENTIAL (Z/2) 11 4- 8. 7 5 .

35 - IO Bevel gear backlash 11 Differential 12 End play of pinion gear 66.018 -0.46 gear backlash I I 0.020- - differential bearing side Outer - 2 3 4 Clearance between gear and spider lace Replace pinion 5 I 6 Bearing carrier piston mount (piston carrier) 7 Thickness washer of side gear 8 Thickness washer of pinion gear 9 Height of spacer between pinion shaft bearings -0.079 -0.027 - Inner lace 100 +0.039 +0.0.015 0 -0.081 0 0.085 -0.037 -Lo20 -0.025 0 -0.013 0 -0.045 -0.025 I - 0.45 +0.MAJNTENANCE DIFFERENTIAL STANDARD Unit: mm I No - Check Tolerance Standard / size Clearance 1 Remedy Criteria item Shaft 1 Hole at Standard clearance Clearance limit lace 150 -:.10 .61 kO.110 0.037 - Clearance at pinion shaft gear side Outer 171.01 1.Ola -0.088 -0.05 3.088 -0.30 .020 -0.030- - Clearance at pinion shaft coupling side Outer lace 140 -:.093 -0.028 - bearing Inner lace 76.8 1.110 -0.028 -0.25 Adjust less than 0.068 -0.18 40-23 .054 -0.062 +0.09 -0.272 - Standard size Tolerance Repair limit 4 20.2 +0.085 -0.048 -0.062 -0.030 - bearing Inner lace 65 +0.043 +0.191 304 +0.0.059 +0.5 +0.

5S.5kgm) 40-24 1 .5+10.5kgm) 927k103Nm (94.MAINTENANCE STANDARD FINAL DRIVE FINAL DRIVE w w w 549d9Nm (%6kgm) 152d4Nm (15.5kgm) 927+103Nm (94.5~10.

120 0.025 -0.013 +0.1 - I Adjust 0.065 -0.085 -0.020 120 +0.207 +0.072 0 - - Shaft 180 1.045 +0.012 o-o.085 -0.045 -0.063 - - - 40 +0.9 40-25 .055 -0.025 0 -0.002 -0.020 -0.1 .007 +0.1.145 0.002 - Outer lace Clearance at axle housing bearing pressfitted section Axle shaft seal press-fitted section inner lace Clearance between gear bearing 7 pinion and shaft End play of axle shaft Clearance between oil seal I 4.035 +0.10 0 12 +0.025 -0.MAINTENANCE FINAL DRIVE STANDARD Unit: mm No.085 -0.03 374 2 Remedy Criteria Check item Replace 4 180 -:.023 0 -0. .lO +0.013 - Clearance at guide pin axle Clearance at housing bearing pressfitted section Tolerance +O.023 - Housing 215 - +0.045 -0.020 - 105 +0.10 0.085 -0.07 - io. Standard size Clearance between axle housing and ring gear 3 Shaft Hole Standard clearance Clearance limit -0.200 - Outer lace 160 -0.025 co.013 Jo20 Inner lace -0.

122 +0.050 0.050 0.594 - 170 -0.5 kgm) 4 Unit: mm Standard size Tolerance 22 iO.522 +0.055 0.1 Thickness of thrust plate 2 Thickness of wear plate Clearance between hole and shaft at front support end Clearance between hole and shaft at rear support end 40-26 Remedy Criteria Check item Standard size Tolerance Shaft Hole Repair limit - Standard clearance Clearance limit 190 -0.124 +0.646 - Replace .472 0 0.MAINTENANCE AXLE MOUNT STANDARD AXLE MOUNT w 1324 e 147 Nm (11 + 1.050 -0.005 -0.3 -0.5 5 +0.

0kgm) (finalvalue) w 112.5Q9.2kgml (when adjusting with shim) 279.2kgm) (when adjusting with shim) 112.0=0.6Q.5~l.8?9.4Nm (28.8Nm (11.010.ONm (2.5=l.Okgm) (final value) 1 40-28 7 19.5*3.2kgm) (when adjusting with shim) 112.&0.5zl.6z2.8Nm (11.ONm (2.0=0.Okgm) (final value) 19.8Nm (11.Okgm) 12 IO II 3 6 8 6 (2.8=9.2kgm) (when adjustingwith shim) 112.ONm (2.MAINTENANCE STANDARD CENTER HINGE PIN CENTER HINGE PIN w w 19.8*9.8&.Okgm) (finalvalue) SBWCC663 .6G?.8Nm (11.5tl.

060 +0.030 -0..036 +0.1 .1 - f0.130 - Clearance between upper hinge pin and spacer (small) 80 -0.049 +0.060 0. 12 I Value for shim between upper hinge and retarner Value for shim between I upper hinge and retarner I 56 I 1 Standard size Standard clearance Clearance limit 2.1 2.030 -0.130 Tolerance Standard size Height of upper hinge spacer (small) 9 Remedy Criteria Check item - / - Repair limit f0.023 1 o’“:50.1 - t 1o Height of upper hinge I spacer (large) I .5 Replace - 0.072 0.030 0.049 - Clearance between upper hinge pin and spacer (large 80 -0.030 -0.015 -0.142 - 130 4.015 0.071 +0.030 0.2 I Adjust I 40-29 .036 0. E : 2 STANDARD CENTER HINGE PIN 3 4 5 Tolerance Standard size Shaft Hole Standard clearance Clearance limit 80 -0.5 I 0.088 -0.079 - frame Clearance and between rear spacer (large) 95 -0.049 +0.s 25.066 0.030 0.109 - Clearance between.lower hinge pin and beanng 8o / %%! 1 j.036 0.MAINTENANCE NO.upper hinge pin and bearing 80 -0.5 0.030 -0.054 0 Clearance between upper hinge pin and rear frame 2 Clearance between.049 -EL015 0.1 0.076 +0.030 -0.025 -0.049 +0.030 0 0.071 +0.071 -0.088 80 -0.048 -0.05 0.

1 Criteria Check item Clearance between steering shaft and column bearing Standard size Hole Standard clearance Clearance limit Replace 19 40-30 Tolerance Shaft Remedy Jo* to.4Q.0.23 0.3kgm) No.&0.15 -0.MAINTENANCE STEERING STEERING COLUMN STANDARD COLUMN w 29.05 .9Nm (3.05 0.4 .

18 kg) Replace 40-31 .1 N (4.8 kg) 136.8 kg) - 47.2 32.23 kg) - 1.7 kg) 2 Load check valve spring 3 Demand spool return spring 75.9 N (5.0 56.3 N (0.5 4 Relief valve spring 24.3k4.8 kg) 5 Check valve return spring 21.9 N (0.8 N (0.MAINTENANCE STEERING VALVE STANDARD STEERING VALVE SLwo1253 Unit: mm No.6 17.8 N (0.1 68.95kO.0 2.7 N (11.1 N (13.0 22.8 kg) 20.88 kg) - 114.2 9.1 N (14.19 182.9 13.4 N (18.6 kg) - 145. Remedy Criteria Check item Repair limit Standard size 1 Steering spool return spring Free length Installed length Installed load Free length Installed load 37.5 kg) - 7.

+0.025 +0.10 0.5 (after adjusting with shim) Replace .225 - 50 l.025 +0.050 0.8 0 - 632~1 Standard clearance I (clearance a + b) - I 4 Connection between steering cylinder and rear frame 40-32 6.050 0.MAINTENANCE STEERING STANDARD STEERING CYLINDER MOUNT CYLINDER MOUNT 3.lO 0.8 0 66fl Max.150 +0.20 +O.4 Unit: mm No - 1 Check item Clearance between mounting pin and bushing at connection of steering cylinder rod and frame - Clearance between mounting pin and bushing at connection of steering cvlinder bottom and frame Connection between 3 steering cylinder front frame and Tolerance Standard size Shaft Hole Standard clearance Clearance limit 50 0 -0. 0.175 - _ 2 Remedy Criteria I Width of boss Width of hinge 60+0.

) - I I Lining thickness 1.) 0.0 Replace 3 Wear of brake outer ring disc contact surface kO.3 1 Reoair limit Installed length Installed load Installed load 7.5 7.15 I I i 5.2 0.l I - 2 Repair limit Tolerance Standard size 1 Remedy +0.9 (min.9 _+O.8 682 N (69.1 Standard size A Spring load 0.4 0.5 kg) 549 N (56 kg) 1 40-33 .MAINTENANCE STANDARD BRAKE BRAKE 3 2 sAwooEa3 Unit: mm No - Criteria Check item Inner ring thickness 6 Brake disc thickness 8 Depth of lining grooves 0.8 (min.

2 / 58 / 4 Return spring 31.2 I Repair limit 29.8G’Nm (0.2 Replace .8=0.2+7.3Nm w 7.5 5 Clearance between pedal mount hole and bracket hole 6 Clearance and pin - 33 Fg) j 45.75kgm) w 15&24.&73Nm (6.5 - 28 29.8 2 Control spring 46.025 -0.2kgm) 3 w 66.5 kg) 21.175 0.5Nm (155&.2 N (9. item Criteria Standard Free length 1 Control Remedy size Repair limit Installed length Installed load Free length Installed loac I spring 34 93.3 j - 78 1 - - roller -0.l 0 I 1.MAINTENANCE STANDARD BRAKEVALVE BRAKE VALVE BRAKE VALVE (LEFT) 6 m 5 66.7550.7 kg) - between :8k.) size I Tolerance I 0.3 j 34.075 IO - i I Standard 7 Outside diameter of roller 30 - 40-34 / 16.3 j (&g 3 Return spring 86.5kgm) sAwc&e69 5 Unit: mm No Check I.025 +O.7 N (1.

MAINTENANCE STANDARD BRAKE VALVE BRAKE VALVE (RIGHT) 8 w 66.8dNm (0.5Nm (15.Z7.Zkgm) 66.3Nm (6.75kgm) w 40-36 152d4.3Nm (6.5t2.&7.8dJ.75t0. 7.75kgm) .5kgm) / .75=0.

l 0 0.5 Tolerance limit installed load I - 0.075 I - I 10 Standard - I Clearance limit Standard clearance Hole Shaft roller I diameter 34 Standard size pedal 1 8 Repair size Installedlength installed load Free length spring Return spring Return Remedy Criteria item 0.7 kg) 28 17 I 31.175 0.3 34.2 I Repair limit I 1 of roller 30 j.MAINTENANCE BRAKE VALVE STANDARD z Unit: mm 7 3 No.025 -0.025 -0.2 40-37 .25 29.1 kg) 16.2 kg1 78 15 69.8 93.2 19.5 29.2 58 60.6 N (7.8 N (6.2 N (9.075 +O.025 Replace - I +O. Check Standard Free length 1 2 3 5 Control I I I Control I I spring I I spring Clearance Clearance 7 I and pin I between between Outside 21.025 -0.3 86.3 459 N (46.8 kg) 45.l 0 size I I -0.175 - 10 / I 1 Tolerance I 0.5 16.5 kg) 33 46.7 N (1.

2 kg) I 5 0.MAINTENANCE STANDARD PARKING BRAKE PARKING BRAKE 5 4 6 SAWCCE71 Unit: mm No Check item Criteria Tolerance Standard size 1 Clearance between piston Inner side and cylinder Shaft I 215 I.6 N 44. Outer side Remedy I I Tolerance Repair limit Separator plate Thickness Brake disc Distortion - Thickness 3.049+52.05 o- I I 1 0.375 I kO.7 53.08 2.2 Depth of lining groove 0.2 mm) I 0.15 Clearance limit 1 +0.7 1.97 +0.8 kg) (Height: 3.23 0.10 0.10 -0.2 kg) 66.05 0.9 N (k5.4 kg) 68.13 0 Standard size 2 3 6 Repair limit Parking brake spring 68.3 kg) 76.33 %ee length InstalledlengthInstalled load Free length Installed loac Parking brake spring I Standard size 4 0.106 N (112.9 394 N (40.13 0 .8 kg) I 892 N (91 kg) (Height: 3.7f2.2 mm) .075 k56.7 Wave spring load 40-38 I 0.0 944 N (96.28 +0.175 0 1 1.7 438f21.6 kO.9 N (107f5.5 53.18 I 1 I -0. I 250 - Standard clearance Hole 2.45 Lining thickness 0.

0.13 .060 .0.0.2 Nm (2.119 SAL (3) 100 Rotating speed Delivery pressure Standard deliDelivery very amount amount limii 231 l/min 214 B/min 45 . steering.6 .10 .5Alkgm) s6vVrn572 Unit: 8 2 5 No - Standard Model SAL (3) 100 1 Remedy Criteria Check item mm Clearance clearance 0.3 .4.40.22 0.MAINTENANCE HYDRAULIC STANDARD HYDRAULIC PUMP (Hydraulic.060 .53kgm) 279Q9Nm (28&3kgm) 279Q9Nm (28&3kgm) 113&8Nm (11. switch.19 limit SAL (3) 50 Side clearance SAL (3) 36 SAL (1) 25 SAL (3) 100 2 Clearance between inside diameter of plain bearing and outside of diameter of gear shaft SAL (3) 50 0.149 0. PUMP PPC pump) (SAL(3)100+50+36+(1)25) &a * c+ w 279iBNm (28.0.55°C SAL (1) 25 40-39 .1 kgm) Model - Replace 0.18 0.20 SAL (3) 36 SAL (1) 25 Model 3 Depth for knocking 4 Rotating torque shaft Discharge of spline amount Oil: EOIO-CD Oil temperature: 1 Standard size / Tolerance in pin 22.15 0.

15dL35kgm) w 466+25Nm (47.4Nm (3.5kgm) 6 U 0 SAW@3673 40-40 .5kgmJ .15*0. 31+3Nm (3.35kgm) w 15295Nm (15.M.5dL5kgm) w 22GlONm (23rlkgm) m w 152&?5Nm (15. 0 0 - 3 3 &z3.5z2.MAINTENANCE MAIN CONTROL VALVE STANDARD MAIN CONTROL VALVE 2-SPOOL VALVE 13.3AMNm w UG+lONm (23=1 kgm) I’.

5 208 N (21.7 kg) 53.) / - - 40 233 N (23.9 1 ‘9 / j - &t$ I .2 kg) / - 1 40-41 .8 83.y.MAINTENANCE MAIN CONTROL VALVE STANDARD Unit: mm Standard 1 Spool Remedy Criteria Check item Free length return spring (for bucket) Spool return spring (for bucket and boom) 3 Spool return spring (for bucket and boom) 1 54.3 N (3.5 23.4 kg) - Relief valve poppet 49.3 41.5 54.k.) / - 9 Suction 1 27.4 kg) 8 valve spring - 208 N (21.2 kg) - Main relief spring valve main valve 39.3 - - 235 N (24 kg) 30.2 / g5k.8 259 N (26.8 55.6 / 24.8 2 Repair size / 52.8 kg) - 86.2 33.7 Installed load j - 4 Spool Spool return spring (for boom) return spring (for boom) spring Check valve spring 1 32.9 26.I Replace - 47.5 1 (.8 limit Installed length Installed load Free length 125 N (12.

MAINTENANCE STANDARD MAIN CONTROL VALVE 3-SPOOL VALVE w 13.5kgm) / 2’ w 226elONm (2351 kgm) w 226elONm 3tlkgm) w 275GONm (28*3kgm) 40-42 (47.8 .‘5kgm_\ E (JQJ. (23+lkgm) fB+lONm -I I L - m 1’ 152+25Nm (15.5LEkgm) . 4 7 226zlONm .3+1.5z2.5Nm a.

1 N (4.8 53.2 kg) 24.5 23.4 kg) 47.3 41.MAINTENANCE No.2 235 N (24 kg) - 3 Spool return spring (for bucket and boom) 30.8 235 N (24 kg) - 4 Spool return spring (for boom) 55.2 33.3 N (3. - 1 MAIN CONTROL VALVE STANDARD Criteria Check item I Spool return spring (for bucket and attachment) I I Standard size Remedy Reoair limit Free length Installedlengthinstalled load Free length Installed load 54.3 40 233 kg) N (23.6 27.7 kg) - - 2 Spool return spring (for bucket and boom) 54.9 8 Check valve spring 32.8 - 5 Spool return spring (for boom) 86.9 - I Replace 259 N (26.8 208 N (21.8 52.4 kg) - - 7 Relief valve poppet spring 49.5 44.7 kg) - - 40-43 .7 26.5 125 N (12.8 83.5 kg) - - 19 6.5 208 N (21.2 kg) - - 6 Main relief valve springvalve main 39.9 N (0.

2 kg) - j - j (:347k.3 36.2 N (4.5 N (2.4 1 39.D.) or deformed 1 .0 2g.78 ’ I*3 31.if damaged Centering spring (bucket TILT. boom LOWER) 1 Repair limit Free length x O.4 N (3.4 N (3. installed length Installed load Free length installed load 52.73 x 1.4 / (:677k.MAINTENANCE STANDARD PPC VALVE PPC VALVE Unit: mm No. boom RAISE) 2 3 I Metering spring 40-44 52.) 31.4 x 7.4 kg) Replace spring .0 kg) - 23.0 29. Check item Criteria Remedy Standard size Centering spring (bucket DUMP.0 kg) 36.

239 0. :78!%78Nm (80+8kgm) Standard size Tolerance SBWOW76 Remedy Criteria I SBwcom Shaft Hole Standard clearance Clearance go -0.097 0.061 0.036 -0.025 -0.5kgm) w :588*59Nm w Boom Bucket :110+12Nm (11.5kgm) :343*34Nm (35.061 0.MAINTENANCE STANDARD HYDRAULIC HYDRAULIC CYLINDER CYLINDER Bucket m Steering :1152=123Nm (117.0t3.393 Bucket 90 -0.032 0.152 +0. I Check item.097 0.25kgm) Steering (6&6kgm) No.693 Replace bushing 40-45 .270 +0.270 +0.036 -0.539 limit 0.25*_1.123 +0.123 +0.087 +0.25kgm) :110=12Nm (11.693 Steering 45 -0.007 0.5=12.393 0.25~1.

MAINTENANCE STANDARD WORK EQUIPMENT WORK EQUIPMENT LINKAGE J a’ / a ‘b A-A LINKAGE B-B ! a b c-c b 16 6 a a b D-D b F-F 17 a 40-46 G-G b a’ H-H ‘b a J-J b SAWCC677 .

cufZngon pin 1 Connection of bucket cylinder and frame i I I I / I I of boss 110+0.5 106i1.297 1. 5.5 .0 0.5 I Replace IO 11 12 13 14 15 - 16 Connection frame of boom and Connection bucket of boom and Connection and bucket of bucket link 122k1. llo+"-8 0 117fl.156 0.5 223h0..297 1.5 O-6 insert shims on both sides so that clearance is less than 1.5 0.2.5’.2 .5+.6.7 . 120 4 Clearance between pin and bushing at connection of bucket cylinder bottom and frame 5 Clearance between pin and bushing at connection of bucket cylinder rod and bellcrank 6 Clearance between pin and bushing at connection of bellcrank and boom 7 Clearance between pin and bushing at connection of boom cylinder bottom and frame 8 Clearance between pin and bushing at connection of boom cylinder rod and boom Remedy - - - - - 5 .090 +0.5 2.5 .7 .036 -0.5 I I 116 +I.156 0.7 .207 co.090 +0.0 Replace replace if there is s.5 . I 0.0 im on both left nd t-k& 40-47 .5 117k1.5 Replace Connection of bucket cylinder and bellcrank 220+.z 3 Width 9 0.5 129+.5 112..icmn of bellcrank 106f1.5 0. +0.5 4.5 I 1.6. lessthan 2.036 -0.5 mm on both left and right rdjustwith shims o that clearance .5_ +2.7 .8 o.5.8.ne.207 +0.5 mm on both left and right Connection of boom and boom cylinder 103kl..MAINTENANCE STANDARD WORK EQUIPMENT LINKAGE Unit: mm No Check Criteria item 1 Clearance between pin and bushing at both ends of bucket link 2 Clearance between pin and bushing at connection of boom and bucket 85 -0.5 17 insert shims on bath sides so that clearance is less than 1.8 0 - Width I I Standard clearance (Clearance a + b) of hinge 114kl.5 0.8 0 go 112.5.120 3 Clearance between pin and bushing at connection of boom and frame 95 -0.11.5 o 93.5 I Connection of boom cylinder and frame Connection and bucket of bellcrank link g.

5 50 I Max.MAINTENANCE BUCKET STANDARD BUCKET (76+11kgm) & 3 A-A w m 902a39Nm (92+4kgm) 902=39Nm l92+4kgm) N 902239Nm (9?. t I Standard 1 2 I Bucket tooth Clearance wear of bucket base I tooth mountinq 3 Cutting 40-48 edge wear Repair limit size 18.5 I - - I Adjust or replace Reverse replace or .4kgm) A-A SAW00676 Unit: mm Remedy Criteria Check item No. 93 I 0.

1 2 Check item Criteria Clearance at bucket positioner switch 3-7 Clearance at boom kickout switch 3-7 Remedy Adjust 40-49 . I i ==? :: .7QONm (1. 2 w 53..6Nm (5..5Qkgm) w 17. : ~. ‘. =+I..%19.MAINTENANCE STANDARD BUCKET POSITIONER BUCKET POSITIONER AND BOOM KICK-OUT AND BOOM KICK-OUT -. .8-92kgm) A-A Unit: mm No. . 1 ..

1 FOR INTERNAL USE ONLY CORRECTIVE ACTION: PFMRl 081696 LOCATION: DATE: . (847) 970-4186 PROPOSAL 1 FOR MANUAL REVlslON FOR INTERNAL USE ONLY -. IL 66061-8112 U. Attn: Technical Publications Fax No.A. PMR 2 NAME OF COMPANY: : PHONE NO: : S DEPARTMENT: E R NAME: MANUAL NAME: MANUAL NO: MACHINE MODEL: S/N IF APPLICABLE: PAGE NO: PROBLEM: Attach photo or sketch. If more space is needed. use another sheet.S.Komatsu America international Company 440 North Fairwav Drive I Vernon Hills.No.