D85ess-2 Sebm003002 PDF

‘SEBM003002 IMTANINTUZA\ IL KOMATSU DS5E-SS-2 MACHINE MODEL SERIAL No. D85E-SS-2 3001 and up + This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice. + D85E-SS-2 mount the S6D125-1 and $6D125-2 engine. For details of the engine, see the 6D125 Series and 125-2 Series Engine Shop Manual. + This shop manual combines DWT065-1A towing winch in one volume. © 2002 KOMATSU All Rights Reserved 00-1 Printed in Japan 04-02(02) 2CONTENTS No. of page 01 GENERAL eee Seen om sn om 10 STRUCTURE AND FUNCTION ........... 20 TESTING AND ADJUSTING . eee soe 204 30 DISASSEMBLY AND ASSEMBLY ..... se sevens B01 40 MAINTENANCE STANDARD a ee evssees 604 90 OTHERS ..... - ee eee erred sennnneeenns 91 00-2 o14u02o14u02 ‘The affected pages are indicated by the use of the following marks. It is requested that necessary | Mark | inclestiony Action required actions be taken to these pages according tothe | 6 |pagetobe newly added| Add table below. thas a @ Page to be replaced Replace () | Page to be doloted Discard Pages having no marks are those previously revised or made aditions. LIST OF REVISED PAGES Wark Page "="0°T prank Page FEMI") mark page PVR] wank page PSYC] wank Page Fevison 2 001 @ |) 106 10-45 | 202 @ 2034 @ 00-2 107 @ 10-48 2021 © 2035 © 0021 @| 108 10461 @ | 203 20-36 © 0022 @ 1081 @ 10.47 20-4 20-37 © 0023 @ 109 10-48 205 20-38 © 003 10-10 10.49 206 20-39 © 00-4 10-11 10-50 | 207 20-40 © 005 | 10-12 10-51 | 208 20-41 © 006 | 10-13 1052 20-9 20-42 © 007 | 1044 10.53, 20-10 20-43 © 00-8 10-15 1054 © 20-11 20-44 © 009 | 1017 @ 10541 @ | 20-12 20-46 © 00-10 ; 0171 @ 1055 | 20-13 20-47 © 00-11 10-18 10551 © | 20-14 20-48 © 00-12 10-19 1056 20-15 20-49 © 00-13, 10-20 1057 20-16 20-50 © 00-14 10-21 10571 @ 20-17 2051 © 00-15 10-22 10572 20.18 20-52 © 00-16 10-23 1058 | 2019 20-53 © 00-17 1024 @ 10581 20-20 20-54 © 00-18 10-25 1059 | 20-21 20-55 00-19 1025-1 10-60 20-211 20-58 00-20 10-252 10-61 20212 © 20-57 00-21 10-26 1062 @ 20-22 ® 20-57-41 > 00-22 10-27 10-63 20-23 20572 @ 10.28 10-631 2023-1 2057-3 @ O11 10-30 10-632 | 20232 @ 20574 @ 01-2 1031 10-64 | 20-24 20575 @ 01-3 1032 @ 10-65 | 20-25 2057-6 @ 014 10.33, 10-66 2026 @ 20-58 015, 10:34 10.67 20-27 20-59 016 10-35 10-68 20-28 20-60 01-7 10-36 10-69 2028-1 @ | 20-61 018 | 10.37 10-70 20.282 © 20-62 019 | 1038 10-71 20-283 0 20-63 | 10-39 10-72 20-28-4 20-64 101 © 10-40 10-73 20-29 i 20-65 102 10-41 10-74 2030 @ 20-66 103 10-42 10-78 20-31 20-67 04° 10.43, 20-32 20-68 05 ® 10-48 201 @ 20-33 20-69 00-2-1Mack Page an Mare Page Revision) pare Page Revision! rk Page REVtICM] mark Page Rewsion 20-70 | 3011 30-106-1 30-147-4 2071 | 3012 30-106-2 30-147-5 20-72 | 3013 30-106-3 30-148 20-73 30-14 O 30-107 30-149 20-74 30-141 @ | 30-108 30-150 20-75 30-15 30-108 30-151 20-76 30-16 30-110 30-152 20-77 } 30-17 | 3059 30-111 30-153 20.79 30-17-1 | 3060 30-112 30-184 20-80 30-18 | 3061 30-113 30-155 20:81 30-19 30-62 30-114 30-156 20-82 30-20 30-63 30-115 | 30-157 20-83 30-21 30-64 30-116 30-158 20-84 30-22 | 30-65 30-117 30-159 20-85 30-23 30-66 30-118 30-160 20-86 30-23-1 30-67 30-119 30-161 20-87 30-232 30-68 30-120 | 30-162 20-88 30-233, 30-69 30-121 30-163 20-89 30-23-4 | 30-70 30-122 30-164 20-80 30-24 | 30-71 30-123 30-165, 20-91 30-25 30-72 30-124 30-166 20-92 30-26 30-73 30-125 30-167 20-93 | 30.27 30-74 30-126 | 30-168 20-94 30-28 | 30-75 30-127 30-169 20-95 30-29 | 30-76 30-128 30-170 20-96 | 30-30 30-77 30-128 30-171 20-97 30-30-1 | 30-78 30-130 | 30-172 20-98 30-30-2 30-79 30-130-1 | 30-173 20-100 30-31 | 30-80 30-131 30-174 20-101 | 30-32 « 3081 @ 30-132 30-175 20-102 30-33 |e 3082 © 30-1321 30-176 20-103 3034 @ 30-83 30-132-2 30-177 20-104 @ 30-35 30-84 30-1323 30-178 20-105 30-36 30-85 30-132-4 30-179 20-108 @ 30-361 @ 30-86 30-133 30-180 20-1061 @ | 30362 @ 30-87 30-133-1 30-181 20-107 30-363 @ 30-88 30-134 30-182 20-108 30-37 30-89 30-135 30-183 20-109 30-38 30-90 30-136 30-184 30-39 30-91 30-137 30-185 30-1 30-40 30-92 30-138 @ 30-186 30-2 30-41 30-93 30-138-1 @ 30-186-1 @ 303 30-42 @ 30-94 30-139 30-186-2 @ 30-4 3043 @ 30-95 30-140 30-187 30-5 30-44 © 30-96 30-141 30-188 305-1 3045 @ 30-97 30-142, 30-189 30-5-2 30-45-1 © 30-98 30-143 30-190 306 30-46 30-99 30-144 30-191 30-7 30-47 30-100 30-145 30-192 30-8 30-48 @ 30-101 30-146 30-193 30-9 30-481 @ 30-102 30-147 @ 30-194 3010 @ 30-49 30-103 30-1471 @ 30-195 30-101 @ 30-50 | 30-104 30-147-2 @ 30-196 30102 @ 30-51 | 30108 © 30-1473 @ 30-197 0-2-2 014U02Fovision Revision] Revision Revision Revision 014U02 ark Pago S200] mare Page Fevitiorl wank Page S2vsiOnl neark Page ROMS ak Page Favicon 30-198 90-14 90-69 30-199 90-15 90-70 90-17 90-71 40-1 90-18 90-72 402 90-19 90-73 403 90-20 90-74 40-4 90-21 406 90-22 407 90-23 408 90-24 409 90-25 40-10 @ 90-26 40-101 @ 90-27 40-11 90-28 40-12 90-29 40-13 90-30 40-14 90-31 40-15 90-32 40-16 90-33 40-17 90-34 40-18 90-35 4019 @ 90-36 40191 © 90.37 40-20 90-38 40-21 90-39 40-22 90-40 40-24 90-41 40-25 90-42 | 40-26 90-43 | 40.27 90-44 4028 @ 90-45 40-29 90-46 4029-1 @ 90-47 40.292 @ 90-48 4030 © 90-49 4031 @ 90-50 40-32 90-51 40-33 90-52 | 40-34 90-53 | 40.36 90-54 | 4037 © 90-55 40:38 90-56 | 90-57 | 90-1 90-58 90-2 90-59 | 90-3 90-60 i 90-4 90-61 | 90-6 90-62 | 90-7 90-63 | 90:8 90-64 | 90-9 90-65 | 90-10 90-66 | 90-12 90-67 90-13 90-68 | 00-2-3SAFETY SAFETY SAFETY NOTICE SAFETY NOTICE IMPORTANT SAFETY NOTICE the specific purpose. to deal with the situation. Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for To prevent injury to workers, the symbol is used io mark safety precautions inthis manual The cautions accompanying these symbols should always be followed carefully. If any danger- cus situation ares or may possibly arse, fst consider sefety, and take the necessary actions 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 alll 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 leam 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 work ing. PREPARATIONS FOR WORK 7. 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 8. Bofore 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 controt 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 sate footing 00-3SAFETY SAFETY NOTICE PRECAUTIONS DURING WORK 11.When removing the oil filer cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oll from spurting out Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circutt. 12.The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned, Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 13.Before starting work, remove the leads from the battery. Always remove the lead from the negative (-) terminal fist 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 stil 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 cil from spilling out. If any fuel of oil drips onto the floor, wipe it up immediately. Fuel or oll on the floor can cause you to slip, or can even statt fires. 18.As @ general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts. 00-4 19.Be sure to assemble all parts again in their 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 install ing 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-lype machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.FOREWORD GENERAL FOREWORD GENERAL This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components. ‘STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an under standing of the structure, but also serves as reference material for troubleshooting In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards. TESTING AND ADJUSTING This section explains checks to be made before and after performing repaits, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating "Problems" with "Causes" are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them MAINTENANCE STANDARD This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION, OTHERS This section mainly gives hydraulic circuit diagrams and electric circuit diagrams, {In addition, this section may give the specifications of attachments and options together. 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. 00-5FOREWORD HOW TO READ THE SHOP MANUAL HOW TO READ THE SHOP MANUAL VOLUMES ‘Shop manuals are issued as a guide to carrying out repairs. They are divided as follows: Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Each issued as one volume to cover all models Electrical volume Attachments volume: These various volumes are designed to avoid dupli- cating the same information, Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-to- date information before you start any work. FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number, Example 1 (Chassis volume) 10-3 Item number (10. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume): 12- ——Unit number (1. Engine) item number (2. Testing and Adjust- ing) Consecutive page number for each item pte 3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example. Example: 10-4 12-2038 10-44 — — 12-203-1 Added pages —[ 49.503. 12-204 00-6 REVISED EDITION MARK When a manual is revised, an edition mark (©2®....)is recorded on the bottom of the pages. 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. Symbol | item A safely Remarks | Special safety precautions are necessary when performing the work Special technical precautions or other precautions for preserving standards are necessary when performing the work * Caution Weight of parts of eys- tems. Caution necessary when selecting hoisting wire, or when working posture Is important, et. tg Weight Places that require special attention for the tightening torque during assembly. Tightening torque Places to be coated with Os Coat | adhesives and lubricants, | ete | Places where oil, water or Oil, water | fuel must be added, and tne capacity : Places where oll or water way | Drain | must be drained, and quantity tobe drained,FOREWORD HOISTING INSTRUCTIONS HOISTING By Heavy paits (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 + Ia 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 Allowable load mm kN tons. 10 | 38 10 15 13.7 14 125 157 16 1 216 22 16 275 28 18 353 36 20 43. 4a 22.4 54.9 56 30 98.1 10.0 40 | 1765 18.0 50 | 2746 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. 3) 4) HOISTING INSTRUCTIONS. 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. J ip J) d dln dp dp @ CS WU W i 100% eR TOKTHT Do not sling a heavy joad with one rope alone, but sling with two or more ropes symmetrically wound onto the load. Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 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 {2000 kg} of total weight can be sus- pended. This weight becomes 9.8 kN (1000 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 {4000 kg) if they sling a 19.6 KN (2000 kg} load at a lifting angle of 150°. avacity KN Ks) Lose 3060 «6020180 Lifting angle (eearee) sa090880 00-7FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER A Before carrying out the following work, release Type t the residual pressure from the hydraulic tank For details, see TESTING AND ADJUSTING, Fiet Releasing residual pressure from hydraulic tank Aer it the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, | prepare an oll receiving container. Disconnection 1) Release the residual pressure from the hydraulic tank. For details, see TESTING AND Fie? ADJUSTING, Releasing residual pressure from 1 hydraulic tank 2) Hold adapter (1) and push hose joint (2) into mating adapter (3). (See Fig. 1) * The adapter can be pushed in about 3.5 mm, + Do not hold rubber cap portion (4). 3) Alter hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against (3) until it clicks. (See Fig. 2) Fie.3 4) Hold hose adapter (1) or hose (5) and pull it out (ee Fig. 3) I } 0 I % Since some hydraulic oil flows out, prepare + L- an oll receiving container. Connection 1) Hold hose adapter (1) or hose (5) and insert it in, mating adapter (3), aligning them with each other. (See Fig. 4) + Do not hold rubber cap portion (4). | Fie. 4 2) Alter inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (See Fig. 5) + When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5mm. This does not indicate abnormality, i however. Fie.6 00-8 cwe10701FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER Type 2 Type 3 Disassembly 1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end. 2) Hold in the condition in Step 1), and turn lever (4) to the right (clockwise). 3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it. 7) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end. 2) Hold in the condition in Step 1), and push until cover (8) contacts contact surface a of the hexagonal portion at the male end. i eveeeans 3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it. | T oe we ea 2 cuvoeass + Hold the mouthpiece of the tightening portion and push body (2) in straight until siding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to con- rect it + Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it. CL errFOREWORD COATING MATERIALS COATING MATERIALS The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below. For coating materials not listed below, use the equivalent of products shown in this list. Catogoy | Komatsu ode | Pato. | Gy | Conaner Main aplication, features * Used to prevent rubber gaskets, eran | 780-129-2000 | 1509 | Tube rubber cushions, and cock plug fom coming Su 1 > Usedin paces requiring an mmo- ately etecive, rong adheshs, rs - 20g | Polyethylene Used for piastics (except polyeth- ore 790-129-9050 | (25¢8,) | container ylene, polyprophyiene, tetrafluor- Sethigne'and nyt chloride), rubber etl sl non-metal 7 Features: Resistance wo eat ana , ’ Poiyettyiene |” Exomais cre oe 002 a ao ‘container’ | * Used for ant-loosening and seal- art pupose for Dols ad puge T acnesive > Used as aahosie or sealant for 790-128-6060 | Adhesi metal, glass and plastic. (Seto! | Hardehin ura | agate ana | Hard can nadenng | agdnt Adhesives aoa) Poyathyene [> Used a8 sealant for machined uta | 790-128-9040 | 2509 | Pelietylene |* psed _— > Used as neat resisting sealant or wild, | reo-t2e-e120 | 755 Tube (das wate Quick hardoning ype adhesive Three bond Paystiyine | > Sutin: wih Save to Sin 1735 tee ED 50g container * Used mainly for adhesion of met- ale rubere, places and woods ~ Gul nardening ype adhesive 2 Gutcttelype este strength at wropatora | rep-izeciao | 29 | Pauettylene |" reo sulntey + Geet aly for adhesion of rub- be, olasee and metas > Resistance to neat, chemoals toate | roataserto | sooo | Poyattyiene | > SSF ent penne subec o high temeratcres. Used as adhesive or sealant for ves | 790-129-8010 | 2009 | Tube Goskels Snd'pecking of ows . Faincase, ot > Used 28 sealant for_varous threads, po os, aes ves | re0-t2.8070 | 14g can + Used “ae sealant or tapered Gasket plugs, ecows, spies of hyeraur Scant eee ~ Features: Sllcon based, resist scot heat ood vos | roosessnco | zoog | tne | * Seeestpt or tage su + ab Usat-as sealant foro pan, that drive case at 00-10FOREWORD COATING MATERIALS: Category | Komatveose | Pana. | aw | Contaner | Nain appicatore eatwosr Fiures Silicon based quck hare eee ter | reorzsccr | 1g | tue [+ Saf PR? soaiat tor tute! Catt a Stato ores Adhesives thermostat housing, etc. maroa aed a hetresiang slater eepend | rso-25a000 | 100g | Tune |* weeds aire , ’ 7 Used asian for sling pow ax) Cd) 609 Ge tion (to prevent from squeaking). Monitor od pete pez or ison ed io pevert pee ooo ume | onesccoo.0 | 200g | Tube | — hnpctitatraeds Ce ree tor sokage, emanate SYG2-400LI | General purpose type ‘SYG2-350LI ' cou | USES | varous | vatous erica Sy¥Gx 80eNI wraeamncn Teed fer toma erporhire, oan fee Vahl bear at clad cor: G2-CA SYG2-400CA-A ‘Various ‘Various tact with water or steam. Sea iance Ser eon Wehrasenarn a Teed for plooas wih Pas oad toveconu™ | azaoom | Bee: | Betostype mae oa 00-11FOREWORD STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE ‘STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) + In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the table below. Teajgancer | wenegoes a tas Ge 8 ©... mm mm Nm kgm 6 10 132214 1.35 20.18 8 13 3123 32203 40 7 6627 67 207 2 19 113.210 1581 “4 22 17219 1822 16 24 279 = 30 28.523 1B 27 382 + 39 3924 20 30 549 2 59 56 =6 22. 82 748 = 83 7628.5 24 36 927 = 103 94.5 + 10.5 27 i a 1920 «140 105 = 15 30 { 6 1720 190 175 =20 33 50 2210 = 240 225 225 36 55 2750 = 290 280 = 30 39 60 3290 = 340 335 + 35 ‘Thread diameter Width across ‘of bolt flats mm mm Nm kgm 6 10 7.85 £1.95 08202 8 13 186 24.9 19205 10 14 40.2 25.9 41208 2 7 82.35 = 7.85 84208 ‘TABLE OF TIGHTENING TORQUES FOR FLARED NUTS. + In the case of flared nuts for which there is no LG special nec ighten tf torque ven LLL the table below. ‘SADoOSES: ie = ieee ed 00-12FOREWORD STANDARD TIGHTENING TORQUE TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS % In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the table below. Thread diameter ‘Width across flat Tightening torque mm mm Nm kom 10 14 657 +68 67207 12 7 11229.8 11521 16 22 279 229 285 +3 TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS + Uniess there are special instructions, tighten the O-ring boss piping joints to the torque below. ‘Thread diameter Width across flat Tightening torque Norninal No. mm mm Nm kgm 02 14 34.3249 35205 03, 04 20 Varies depending 93.1298 95=1 05, 06 24 on type of 142.1 2196 14522 10, 12 33 connector. 421.6 258.8 4326 14 42 877.4 2192.3 89.5 = 13.5 TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS % Unless there are special instructions, tighten the O-ting boss plugs to the torque below. Thread diameter | Width across flat Tightening torque Norminal No. mm mm Nm kom 08 08 14 7.95 £1.47 0.75 £0.15 10 10 7 1127 21.47 1.15 20.15 12 12 19 17.64 2 1.96 1.8202 4 1“ 22 22.54 = 1.96 2.3202 16 16 24 29.4 24.9 3205 18 18 27 so2249 4205 20 20 30 4924.9 5205 24 24 x2 68.6 +98 721 30 30 82 107.8 = 147 1215 33, 33 a 12742196 1922 36 36 36 151.9 £245 155225 42 42 a 2107 #294 21523 52 52 a 328.4 = 44.1 9324.5 00-13FOREWORD STANDARD TIGHTENING TORQUE TIGHTENING TORQUE FOR 102 ENGINE SERIES (BOLT AND NUTS) Use these torques for bolts and nuts (unit: mm) of Cummins Engine. Thread diameter | Tightening torque mm | Nm kom 6 1.02 £0.20 8 245 <0.41 10 4.98 =0.61 12 7.85 1.22 TIGHTENING TORQUE FOR 102 ENGINE SERIES (EYE JOINTS) Use these torques for eye joints (unit: mm) of Cummins Engine. Tightening torque mm Nm kgm 6 as 0.81 £0.20 8 1022 1.02 £0.20 10 1222 1.22 £0.20 R aes 2.45 £0.41 4 3625 3.67 £0.51 TIGHTENING TORQUE FOR 102 ENGINE SERIES (TAPERED SCREWS) Use these torques for tapered screws (unit: inch) of Cummins Engine. ‘Thread diameter Tightening torque mm Nm kam 1/16 Bet 0.31 £0.10 178 822 0.81 +0.20 4 1222 1.22 =0.20 3/8 1522 1.53 20.41 4/2 Dhad 2.45 20.41 asa 3625 367 20.51 1 6029 6.12 =0.92 00-14FOREWORD ELECTRIC WIRE CODE ELECTRIC WIRE CODE In the wiring diagrams, various cotors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS, Example: SWB indicates a cable having a nominal number 5 and white coating with black stripe. CLASSIFICATION BY THICKNESS Copper wire Curent Nomina Cebleo. err nese arcana ca) “a Applcable ccut tumerot | Binds | SBE (mm) (mm?) oes 1 on ve 2 | Stating gg. ona 2 26 oe 208 at 20 Lighting signal ee, 5 6 030 323 48 or Charging and signal 15 84 045 13.36 | 70 59 ‘Starting (Glow piug) 40 35 080 W278 14 198 stering 60 127 080 eae 136 178 Stang 100 217 080 toa.t 176 200 starting CLASSIFICATION BY COLOR AND CODE Circuits} | Prot |X| Charging [Groans] statiig | Loming | tnsiunent | Snet | other feston on (oo) ow |B 8 A Y @ L 1 | mary Go| white | Black | Black | Red | velow | Green | Bue coe] WA ow AW vA ow lw 2 Gor] white & Red] — [we & Black] Red & white [Relow & Rea|Green & Whi Blue & White coe] we | BY Re ve on LR 8 | Color |White & Black) — pick & Yellow, Red & Black \Yellow & Black Green & Red | Blue & Yellow t cow] we] | OBR RY ve ev wv a [Awe i seen | color | White & Blue Biacka& Red |Red& Yalow, Yelow® | Green ® Joie @ Yelow coef we | | RG YL ee iB 5 Cowrfntea Greed — | — [Red & Green| Yotow & Blue| Green & Blacl Bue & Black So = aL vw au — 6 Color = | = | Resse fetowa nid cron sue] — 00-15FOREWORD CONVERSION TABLE CONVERSION TABLE METHOD OF USING THE CONVERSION TABLE ‘The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. EXAMPLE + Method of using the Conversion Table to convert from milimeters to inches 1. Convert 85 mm into inches. (1) Locate the number 50 in the vertical column at the left side, take this as @, then draw a horizontal line from ®. (2) Locate the number 5 in the row across the top, take this as @, then draw a perpendicular line down from ®) (3) Take the point where the two lines cross as(©. This point ©) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. 2. Convert 50 mm into inches. (1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to convert itto 55 mm, (2) Carry out the same procedure as above to convert 85 mm to 2.165 inches. (3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point cone place to the right) to return to the original value. This gives 550 mm = 21.65 inches. Millimeters to inches 41mm = 0.09937 in 10 1 2 3 4 . + | 0 jo 0.039 | 0.079 | 0.118 | 0.157 10 | 0.994 | 0.433 | 0.472 | 0.512 | 0.551 20 | 0.787 | 0.827 | 0.866 | 0.906 | 0.945 30 | 1.181 | 1.220 | 1.260 | 1.299 | 1.339 40 | 1.575 | 1.614 | 1.654 | 1.693 | 1.732 6 7 8 9 0.236 | 0.276 | 0.315 | 0.354 0.630 | 0.669 | 0.709 | 0.748 1,024 | 1.063 | 1.102 | 1.142 1.417 | 1.457 | 1.496 | 1.536 1.811 | 1.850 | 1.890 | 1.929 4.969 | 2.008 | 2.047 | 2.087 | 2.126 "480 | 2.520 2.205 | 2.244 | 2.283 | 2.923 2.598 | 2638 | 2.677 | 2.717 | 2992 | 3.092 | 3.071 | 3.110 | 3.386 | 3.425 | 3.465 | 3.504 3.780 | 3819 | 3.858 | 3.898 2.362 "| “2.402 | 2.447 70 | 2.786 | 2795 | 2.835 | 2874 | 2.913, 80 | 3.150 | 3.189 | 3.228 | a268 3.307 90 | 3.543 | 3.583 | 3.622 | 3.661 | 3.701 00-16FOREWORD CONVERSION TABLE Millimeters to Inches 1 mm = 0.03937 in 7 1 o 1 2 3 | 4 5 6 7 8 es | o jo 0.039 | 0.079 | 0.118 | 0.157 | 0.197 | 0.236 | 0276 | 0.315 | 0.354 10 | 0.894 | 0.433 | 0472 | 0.512 | 0.651 | 0.591 | 0.630 | 0.669 | 0.709 | 0.748 20 | 0.787 | 0.827 | 0.866 | 0.906 | 0.945 | 0.984 | 1.024 | 1.063 | 1.102 | 1.142 30 | 1.181 | 1.220 | 1.260 | 1.299 | 1.939 | 1.978 | 1.417 | 1.457 | 1.496 | 1.596 40 | 1.575 | 1.614 | 1.654 | 1.698 | 1.732 | 1.72 | 1.811 | 1.850 | 1.890 | 1.929 50 1.969 | 2.008 | 2.047 | 2.087 | 2.126 | 2.165 | 2.205 | 2.244 | 2.283 | 2.323 60 | 2362 | 2402 | 2.441 | 2.480 2.520 | 2559 | 2598 | 2.698 | 2.677 | 2.717 70 | 2.756 | 2705 | 2835 | 2874 | 2913 | 2053 | 2092 | 3032 | 3071 | a.1t0 20 | 3.150 | 3.189 | 3228 | 3.268 | 3.07 | 3.946 | 3.986 | 3.425 | 3.465 | 3.504 90 | 3543 | ase | 3622 | 3061 | 3701 | 3.740 | 3760 | ae19 | aasa | acca Kilogram to Pound 4 kg = 2.2046 ib 0 1 2 3 4 5 6 7 | 8 o 0/0 220] 441] 661 | ee2 | 11.02 | 1323] 1543| 1764| 1984 10 |22.05 | 24.25 | 26.46 | 28.66 | 30.86 | 33.07 | 35.27| 37.48 | 39.68) 41.89 20 |4a.09 | 46.30 | 48.50 | 50.71 | 51.91 | 55.12 | 57.92) 59.63| 61.73) 63.99 30 |66.14 | 68.34 | 70.55 | 7275 | 74.96 | 7.16 | 79.97| 81.57 | 83.78) 85.98 40/8818 | 90.39 | 92,59 | 94.80 | 97.00 | 99.21 | 101.41 | 103.62 | 105.82 | 108.03, 50 11023 | 11244 114.64) 116.85 119.05 | 121.25 | 128.46 | 125.66 | 127.87 | 130.07 60 | 19228 | 194.48 | 196.69 | 138.89 141.10 | 149.90 | 145.51 | 147.71 | 149.91 | 152.12 70 —|154.92 | 196.53 | 158.73 | 160.94 | 163.14 | 165.95 | 167.55 | 169.76 | 171.96 | 174.17 80 |176.37 | 178.57 | 180.78 | 182.98 | 185.19 | 187.39 | 189.60 | 191.80 | 194.01 | 196.21 90 [198.42 | 200.62 | 202.88 | 205.03 | 207.24 | 209.44 | 211.64 | 213.85 | 216.05 | 21826 | 00-17FOREWORD Liter to U.S. Gallon CONVERSION TABLE 1f = 0.2642 US. Gal [0 1 2 3 4 6 6 7 8 9 o ° 0.264) 0528| 0793| 1.057] 1.921) 1.585] 1.849] 2113] 2378 10 2ed2| 2.906] 3.170] 3.434] 3.698| 3.963| 4.227| 4401 | 4.755] 5.019 20 s263| 5548| 5812] 6.076| 6.240] 6.604| seco| 7.133| 7.997] 7.661 30 7.925 | 819 e454] 2718 | s.9a2| 9.246] 9510) 9.774 | 10.039 | 10.303 40 | 10.567 | 10.831 | 11.095 | 11.959 | 11.624 | 11.888 | 12.152 | 12.416 | 12.680 | 12.944 | 50 | 13.209 | 13.473 | 13.737 | 14.001 | 14.265 | 14.529 | 14.795 | 15.058 | 15.922 | 15.586 60 | 15.850 | 16.115 | 16.379 | 16.643 | 16.907 | 17.171 | 17.495 | 17.700 | 17.964 | 18.228 70 | 18,492 | 18.756 | 19.020 | 19.285 | 19.549 | 19.813 | 20.077 | 20.341 | 20.605 | 20.870 go | 21.194 | 21.998 | 21.662 | 21.926 | 22.190 | 22.485 | 22.719 | 22.989 | 23.247 | 23.511 90 | 23.778 | 24.040 | 24.304 | 24.568 | 24.892 | 25.096 | 25.361 | 26.625 | 25.869 | 26.153 Liter to U.K. Gallon 1 = 021997 UK. Gal ° 1 2 3 4 5 6 7 8 9 ° 0 0.220 | 0.440] 0.660 0.880] 1.100| 1.220! 1.540| 1.760| 1.980 10 2.200| 2420] 2,640] 2.860 3.080] 3.200 3520] 3740) 3.950| 4.179 20 4309 4619] 4.899] 5.059 | 5.279/ 5.499) 5.719| 5939 6.159| 6.379 20 6509 6819| 7.099) 7.259) 7.479| 7.969) 7.019] 8.139 8359/8579 40 2709 9.019] 9299 9.459/ 9.679 | 9.899 | 10.119 | 10.339 | 10.559 | 10.778 50 | 10.998 | 11.281 | 11.438 | 11.658 | 11.878 | 12.098 | 12.918 | 12.528 | 12.758 | 12.978 60 | 13.198 | 13.418 | 18.638 | 19.858 | 14.078 | 14.298 | 14.518 | 14.798 | 14.958 | 15.178 70 15.998 | 15.618 | 15.898 | 16.058 | 16.278 | 16.498 | 16.718 | 16.998 | 17.158 | 17.978 | eo | 17.508 | 17.818 | 18.037 | 18.257 | 18.477 | 18.697 | 18.917 | 19.197 | 19.357 | 19.577 20 | 19.797 | 20.017 | 20.237 | 20.487 | 20.677 | 20.897 | 21.117 | 21.987 | 21.557 | 21.777 00-18FOREWORD CONVERSION TABLE kgm to ft. Ib 1 kgm = 7.238 ft. fo ° 1 2 3 4 | os 6 7 8 9 o 0 72; 145| 21.7 | 289] 362) 434 | 506] 57.9 | 65.1 10 723 | 796 | 868 | 940 | 101.3 | 1085 | 115.7 | 1230 | 130.2 | 137.4 20 1447 | 151.9 | 159.1 | 166.4 | 173.6 | 1808 | 188.1 | 195.3 | 2025 | 209.8 30 217.0 | 224.2 | 281.5 | 238.7 | 245.9 | 253.2 | 2604 | 267.6 | 274.9 | 262.1 40 209.8 | 2066 | 3038 | 911.0 | 918.9 | 3255 | 927 | 9400 | 947.2 | 9544 50 361.7 | 968.9 | 376.1 | 383.4 | 3906 | 3978 | 405.1 | 4123 | 4195 | 4268 60 434.0 | 444.2 | 448.5 | 455.7 | 4629 | 4702 | 477.4 | 484.6 | 491.8 | 499.1 70 506.3 | 513.5 | 520.8 | 528.0 | 535.2 | 5425 | 549.7 | 556.9 | 564.2 | 571.4 80 5786 | 585.9 | 5931 | 6003 | 607.6 | 6148 | 6220 | 629.9 | 696.6 | 643.7 90 651.0 | 658.2 | 665.4 | 672.7 | 679.9 | 687.1 | 694.4 | 701.6 | 708.8 | 716.1 | 100 | 7233 | 7305 | 737.8 | 745.0 | 7522 | 7595 | 766.7 | 773.9 | 781.2 | 788.4 110 | 798.6 | 8029 | 810.1 | 817.3 | e246 | 831.8 | 839.0 | 846.3 | 853.5 | 860.7 120 | 868.0 | 875.2 | 882.4 | 889.7 | 896.9 | 904.1 | 911.4 | 918.6 | 925.8 | 993.1 130 240.3 | 947.5 | 954.8 | 962.0 | 969.2 | 9765 | 983.7 | 990.9 | 998.2 | 1005.4 140 | 1012.6 | 1019.9 | 1027.1 | 1034.3 | 1041.5 | 1048.8 | 1056.0 | 1063.2 | 10705 | 1077.7 150 | 1084.9 | 1092.2 | 1099.4 | 1106.6 | 1113.9 | 1121.1 | 128. | 1195.6 | 11428 | 1150.0 1eo | 1157.3 | 1164.5 | 1171.7 | 1179.0 | 11862 1193.4 | 1200.7 | 1207.9 | 1215.1 | 1222.4 170 | 1129.6 | 1286.8 | 1244.1 | 1251.3 | 1258.5 | 1265.8 | 1273.0 | 1280.1 | 1287.5 | 1294.7 180 | 1301.9 | 1309.2 | 1316.4 | 1323.6 | 1330.9 | 1338.1 1945.3 | 1952.6 | 1259.8 | 1967.0 190 | 1374.3 | 1981.5 | 1388.7 | 1396.0 | 1403.2 | 1410.4 | 1417.7 | 1424.9 | 1492.1 | 1499.4 00-19FOREWORD kg/em? to Ib/in? CONVERSION TABLE tkglom? = 14.2239 tie? l o | 4 2]3f4fs5ife]7 ° o| 2] 204] 427] 569] 714/05.) 996 | 10 1422} 186.5] 1707) 184] 190.1] 2ta4] 207.6] 2418 20 2845) 298.7/ 312.9) 327.1) 341.4) 355.6) 369. 8) 384.0 30 426.7| 440.9| 455.1] 469.4) 483.6) 497.8) 512. o| 526.3) 40 56.9} 503.2| 597.4 6116] 6258] 640.1 0543) 668.5 50 7112, 725.4 7396] 753.8) 760.1] 762.3) 7965| 810.7 60 253.4} 967.6] 81.8) 996.1] 9103] 924.5) 9987] 9530 70 | 9952] 1010 | 1024 | 1038 | 1052 | 1067 | 1081 | 1095 80 | 1138 | 1152 1166 1181 1195 1209 1223 1237 | 90 | 1260 | 1294 | 1909 | 1923 | 1997 | 1251 | 1965 | 1380 | 110 1565 | 1579 1593 1607 1621 1636, 1650 1664 120 | 1707 | 1721 | 17a5 | 1749 | 1764 | 1778 | 1792 | 1806 130 | 1849 | 1863 | 1977 | 1892 | 1906 | 1920 | 1934 | 1949 140 | 1991 | 2005 | 2020 2034 | 204s | 2062 | 2077 | 2001 150 | 2104 | 2148 | 2162 | 2176 | 2190 | 2205 | 2a19 | 2298 160 | 2276 | 2290 | 2004 | 2318 | 2asa | 2047 | aaet | 2975 170 | 2618 | 242 | 244s | 2460 | 2475 | 249 | 2503 | asia 1eo | 2560 | 2574 | 2589 | 2603 | 2617 | 26a1 | 2646 | 2660 190 | 2702 | 2717 | 2731 | 274s | 2759 | 2773 | ares | 2802 | 200 | 224s | 2050 | 2873 | 2807 | 2001 | 2ore | 2090 | 2044 210 | 2967 | 3001 | 015 | a030 | aaa | sose | 072 | sos6 220 | si29 | staa | aise | a172 | sie6 | az00 | azis | s2e9 230 | se71 | 3286 | 3900 | sata | 328 | saaa | aa57 | 371 240 | 3414 | 3426 | saa2 | a4s6 | 3470 | s4a5 | a4o0 | 3513 00-20 8 113.8 256.0 398.3) 540.5) 682.7 825.0 967.2} 1109 1252 1394 1536 1678 1821 1963 2105 2287 | 2389 2532 2674 2816 2058 3101 3248 3385 3527 9 128.0 270.2 412.5| 554.7| 696.9] 839.2| 981.4] 1124 1266 1408 1550 1603 1885 1977 2119 2262 2404 2546 2688 2830 2973 3115 3257 3399 3542FOREWORD CONVERSION TABLE Temperature Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen- tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures. ‘These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If itis desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right. 10 =33.8'F °c + | +f | cc a | oF | a | uve | -37.2| -35 | -s10]-111 | 12 | 536] a3 | 47 | 1166] 278 | 82 | 1796 -34.4| -30 | -220]-106| 13 | 554] a9 | 48 | 1184] 283 | 93 | 1814 14 | s72| 94 | 49 | 1202] 289 | 84 | 183.2 | -31.7 | -25 | -130 | -100 15 | 500] 100 | so | 1220} 204 | a5 | 1850 | -28.9| -20 | -40] -94 -23| 19 | 22] -9| 16 | cos] ios | 51 | 1208] 300 | 26 | 1008 T i 404 | 40 | 400} -1.7} 41 | 518] 78 | 46 | 1148 | 272 -278| -18 | 04] -83| 17 | 626] 111 | 52 | 1256] 306 | 87 | 1886 | -272| -17 | 14] 78] 18 | 644] 117 | 53 | 1274] 31.1 | 88 | 190.4 -267| -16 | 32] -72] 19 | 662] 122 | 54 | 1292] 317 | 89 | 1922 261 | -15 | 50| -67| 20 | 680] 128 | 55 | 131.0] s22 | 90 | 1940 256 | -14 | 68| -61/ 21 | 698] 133 | 56 | 1328] s28 | 91 | 1958 -250| -13 | a6| -s6| 22 | 716] 139 | 57 | 1346] 333 | 92 | 1976 -244| -12 | 104] -50| 23 | 734] 144 | 58 | 1964] 33.9 | 93 | 1994 -239| -11 | 122] -44| 24 | 752] 150 | 59 | 1982] 344 | 94 | 2012 | -233| -10 | 140] -39| 25 | 770| 156 | 0 | 1400] 35.0 | 95 | 203.0 | | | -228| -9 | 138] -33| 26 | 7es| 161 | 61 | 1418] 956 | 96 | 2008 -222| -8 | 176| -28| 27 | 806] 167 | 62 | 1436] 961 | 97 | 2066 -217| -7 | 194] -22| 28 | 24] 172 | 63 | 1454] 967 | 98 | 2084 vat} 6 | 212] -17| 29 | 842] 178 | 64 | 1472] 97.2 | 99 | 2102 -206| -5 | 230] -11| 30 | 860] 183 | 65 | 1490] 37.8 | 100 | 2120 -20.0| -4 | 248] -06 | 31 | e78| 189 | 66 | 1508] 406 | 105 | 221.0 -194| -3 | 266] 0 | 32 | e96] 194 | 67 | 1526] 433 | 110 | 2900 -189| -2 | 224] 06] 33 | 914] 200 | 68 | 1544] 461 | 115 | 239.0 -1a3| -1 | 302] 11] 34 | 932] 206 | 69 | 1562] 489 | 120 | 248.0 178| 0 | 320} 17] 35 | 950] 211 | 70 | 1580] 51.7 | 125 | 257.0 -172| 1 | 338] 22] 36 | 968] 217 | 71 | 1598] 544 | 130 | 266.0 -167| 2 | 356] 28] 37 | 986] 222 | 72 | 1616] 57.2 | 135 | 275.0 16.41 3 | a74] 33] 38 | 1004] 228 | 73 | 1634] 60.0 | 140 | 2840 -156| 4 | 302] 39] 39 | 1022] 233 | 7a | 1652] 627 | 145 | 2930 -150| 5 | 410] 44/ 40 | 1040] 239 | 75 | 1670] 656 | 150 | 3020 -144| 6 | 428] 50) 41 | 1058] 244 | 76 | 1688] 683 | 185 | 311.0 | -139| 7 | 446] 56 | 42 | 1076] 250 | 77 | 1706] 71.1 | 160 | 320.0 | -133| 8 | 464] 61) 43 | 1094] 256 | 78 | 1724] 739 | 165 | 329.0 ~12.8 9 | 482 67) 44 111.2 | 26.1 79 | 1742] 76.7 | 170 | 338.0 -12.2| 10 50.0 72 | 45 | 113.0 | 26.7 80 | 176.0 | 79.4 | 175 | 347.0FOREWORD 7 UNITS UNITS In this manual, the measuring units are indicated with Intemnatinal System of units (SI) As for reference, conventionally used Gravitational System of units are indicated in parentheses { Example: N (kg) Nm (kgm) MPa {kgicm?} kPa {mmH:0) kPa (mmHg) kWirpm (HP/tpm} gikWh {g/HPh} 00-2201 GENERAL o14u02 General assembly drawing Specifications . Weight table Table of fuel, coolant and lubri icant OVD 01-3 016 018 01-1GENERAL ASSEMBLY DRAWING D85E-SS-2 Unit: mm, 30 01-2 o14u02o14u02 SPECIFICATIONS {To bottom of undercover) Machine model D85E-SS-2 Serial No. 3001 and up [Operating weight, | +Bare tractor kg 15,620 | + with angledozer kg 19,010 + With angledozer + towing winch "+ sweep guard kg * 20,970 Min, turning radius m 34 Gradeability deg 30 ‘Stability (front, rear, left, right) deg 38 Forward 1st kenih 39 |g |Forard ana kh 68 2 | | Forward ard kmh 106 gle 2 | 8 [Reverse ist kit 50 © | Reverse 2nd kev 86 Reverse 3rd env 134 2 | Bare tractor kPa tkglom*) 42.2 (0.43) & |With angledozer kPa tkg/em’) 51.0 (0.52) B | ih anleoze owing winch kPa {kgiem’y 56.9 (0.58) Bare tractor mm 4,138 with angledozer mm 5,930 Bare tractor mm 2,660 With angledozer mm 4370 To tip of exhaust pipe mm 2,980 8| 2 |r top of operator's compartment mm 2375 2 | § |wnon sweepguard installed mm 3.40 £ 6 Track gauge mm 2,050 Length of track on ground mm 2,980 |Width of track shoe (standard) mm 610 ‘ground clearance mm 400 Note: The values for the weight and ground pressure marked # are reference valus.Machine model DasE-SS-2 Serial No. 3001 ~ 3033 3034 and up Name 860125-1 $60125.2 A-cycle, water cooled, | 4-cycle, water cooled, inline vertical ype ditect |inline vertical type direct Type with injection, with turbocharger turbocharger No. of eylinder ~ bore x stroke mm = 125 x 150 6-125 « 150 Piston desplacement ftec} 11.04 {11,040} 11.04 (11,040) Rated horsepwer wirpm {HPipm) | 149/1,950 (200/1,950) | 149/1,950 (200/1,950) £ | 8 |max. torque ‘Nmitpm tkgmirpmi | 980/1,200 (100/1,200) | 980/1,200 {100/1,200) | € |aigh idling rpm. 2,100 2,100 3 |Low tating om 225 825 Min, fue! consumption ratio | ghtWh {g/MPh) 208 (155) 208 (185) Starting motor 24V, 7.5kw Alternator 24V, 138 Bottery 12V, 140Ah x2 Radiator core type D6 Torque converter, 3-element, 1-stage, 1-phase Toransmission Planetary gear type, multiple disc clutch, hydraulically actuated, lubrication gear pump, force feed, forward 3 speed, reverse 3 speed, manual mechanical type 5 55 sewn ce eB ya nek ® Boosted. Nona 01-4 3 014U02014U02 § [Face ror Gon each side 5 Track shoe (610mm) Assenbly type, single grouser, 42 on each side, Pitch: 203.2 mm. Power train, lubrication pump Gear type (SAL(2) ~ 045 + 045) Hydraulic pump Gear type (SAL(3) - 100) | Gear type (SAL(3) - 080) Theoretical discharge amount: 251.3 &/min/2,500 rpm Max. descharge pressure: 20.6 MPa (210 kg/m?) Ee SE BE sl Type 3/88) 1-spool type, mechanically operated 2 |§"| - For blade lift 3 2] [ive Reciprocal type 212 |g Joyinaer bore ne 96 3 | & [E5/outside diameter of piston rod | mm 6 213 [eelpiston stoke ‘mm 1.108 3 | 22] mae. destance between pins | mm 1.908 Min. destance between pins | -mm 200 Hydraulic tank Box type (externally installed control valve) Type Hydraulic angledozer Blade support method Brace type B]_Yaax sting neiont trom ground) | enm 1288 5] 8 |aax. towering depth (rom ground) | mm 495 BYE |ato. wt mm 400 2| 5 |Max. angle deg 25 =| |Range for blade curting angle dog - 2 § | Blade wiath mm 4370 § | Blade height mm 1.070 = & | tage cuting angle deg 56 01-5 @WEIGHT TABLE Ay This weight table is a guide for use when transporting or handling components. DasE-SS-2 Serial No. 3001 - 3033 3034 and up Engime, damper assembly 1.215 + Engine assembly 1,150 + Damper assembly 45 + Parts mounted to engine (wiring) 15 Radiator assembly (including oil cooler) 163, * Oil cooler assembly (for hydraulic oil) 6 Fuel tank assembly 183, Power train unit assembly 1,570 + Steering clutch, brake assembly 700 + Steering valve assembly 25 + Transmission assembly 485 + Torque converter, PTO assembly 290 + Transmission valve assembly 7 + Main relier valve assembly 6 Final drive assembly (each side} 815 790 Sprocket assembly (each side) a3x9 Hull frame assembly 2,032 Track group assembly (each side) 1,700 + Track frame 700 + Idler assembly (each side) 200 + Track roller assembly (single: 1) 54x6 + Track roller assembly (double: 1) 61x2 * Carrier roller assembly (1) 30x2 ‘Track shoe assembly (each side) (610 mm, wet type) 1,530 Pivot shaft (each side) 100 Equalizer bar us, Hydraulic tank assembly 55 Main control valve (lift) 37 01-6 o1auoz014U02 Machine model D85E-SS-2 Serial No. 3001 and up Engine underguerd | 105 Transmission underguard 30 Operator's seat " ‘Angledozer assembly 2,890 + Blade 13% * Ctrame 1.037 + Arm brace a6 Blade lift cylinder assembly 93x2 Hydraulic pump assembly 15 Power train pump assembly 20 Sweep gard assembly 610 01-7TABLE OF FUEL, COOLANT AND LUBRICANTS Serial No. : 3001 - 3033 "AMBIENT TEMPERATURE, CAPACITY (0) RESERVOIR ar 7 FLUID |-2 4 4 225 a9 86 106 | speetiea | nest om ow 9 me z Engine oll pan a4 Eo Power train case | al 2 Final drive case (each) 27 2 Towing winch Engine ol 66 66 Damper case 7 7 Pivot shaft case (each) E as | 45 Idler each) 01s | 015 Hydraulic tank E Meee 95 95 “Track roller (each) os | 0.2 Gear oil Se Carrier roller (each) 024 | 024 Fuel tank Diesel fuel = 410 - ci GEERT [oot | ade anton ae °F ASTM DATE Nos NOTE: (2) When staring the engine in and atmospheric (1) When fuel sulphur content is less than 0.5%, change oil in the oil pan every periodic maintenance hours described in this manual. Change oil according to the following table if fuel sulphur content is above 0.5%. Change interval of oil Fuel sulphur content | on cine oll pan 0.5 to 1.0% 1/2 of regular internal Above 1.0% 1/4 of regular interval ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers API: American Petroleum Institute temperature of lower than 0°C, be sure to use engine oil of SAE10W, SAE10W-30 and ‘SAE15W-40 even though an atmospheric tem- Perature goes up to 10°C more or less in the day time. (3) Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to half. (4) There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W- 40), but be sure to add single grade oil that matches the temperature in the table on the loft (5) We recommend Komatsu genuine oil which has been specifically formulated and ap- proved for use in engine and hydraulic work equipment applications. Specified capacity: Total amount of oil including oil for components and oil in piping. Refill capacity: Amont of oil needed to refill system during normal inspection and maintenance. 01-8 @ o1au02014U02 Serial No. 3034 and up "AMBIENT TEMPERATURE RESERVOIR oe Specified | Refill Engine oil pan “4 38 Poewr train case 78 50 Final drive case 27 27 Towing winch 65 65 Damper case 7 17 Pivot shaft case (each) 45 45 Idler (each) 0.25 0.25 Hydraulic tank 95 55 Trackroller (each) 032 032 Carrier roller (each) 0.24 0.24 Fuel tank : 410 - Gooling system - {including sub tank) kasd “= ASTM D975 No.1 01-9) o14u02 10 STRUCTURE AND FUNCTION Radiator, oil cooler Engine control... Power train system. Power train skeleto Power train unit . : Power train hydraulic piping diagram Power train hydraulic circuit diagram Power train hydraulic system diagram... Damper, universal joint Torque converter and PTO... Transmission control . Transmission wnnnennmnns Transmission control valve Main relief vaive .. Lubrication relief vaive. Steering, brake control.. Bevel gear shaft, steering clutch, steering brake Steering control valve ... Reducing valve Scavenging pump starainer. Power train oil strainer Power train oil filter Final drive .. Main frame. Track frame Recoil spring . Suspension Work equipment hydraulic piping diagrAM srvnenns Work epuipment contol ermnnnn Work equipment hydraulic circuit diagram Work equipment hydraulic system diagram : Hydraulic tank and filter Main control valve Operation of steering, work equipment control circuit. . Piston valve Work equipment Electrical circuit diagram .. Engine control Machine monitor system . Sensors 10-56 10- 70 10-1 ®RADIATOR, OIL COOLER ‘A. Power train oil cooler inlet port B. Power train oil cooler outlet port 10-2 sewearzoc2 . Hydraulic oil cooler . Radiator core assembly Fan guard Inlet port hose Reservoir tank Outlet port hose Lower tank (with built-in power train oil cooler) Fan Water filler cap Power train oil cooler Drain plug Boss Cushion o14u02o14u02 OUTLINE © A reservoir tank has been installed for the radiator to make it possible to check the radiator water level. © The power train oil cooler is built into the lower tank. saws 2008 Fadiator Power wa cole (ult ower aol 38 mots 20 at dispation Heat dsipatn 108000 20800 eat spat 5283 18 10-3ENGINE CONTROL Serial No. : 3001 - 3033 Decelerator pedal Throttle lever Clutch Cable Fuel injection pump peeps Lever positions @ STOP @® Low idling ® High idling 1 40F12008 OUTLINE ‘The engine speed is controlled by throttle lever (2) or decelerator pedal (1) o14u02o14u02 STRUCTURE AND FUNCTION Serial No. 3034 and up 1. Decelerator pedal 2. Throttle lever 3. Clutch 4, Cable 5. Fuel injection pump Lever positions @ STOP @ Low idling @ High idling ENGINE CONTROL 5 sxooests OUTLINE + The engine speed is controlled by throttle lever (2) or decelerator pedal (1). 10-5 ®POWER TRAIN SYSTEM OUTLINE * The twisting vibration of the motive force generated by engine (1) is reduced by damper (2). The motive force then passes through universal joint (3) and is transmitted to torque converter (6). * In accordance with the change in the load, the motive force from the engine is transmitted by means of oil from torque converter (6) to the transmission input shaft (turbine shaft). * In transmission (7), the speed is reduced and the speed range is selected (forward: 3 speeds, reverse: 3 speeds) by the combination of the planetary gear system and the hydraulic clutches. The pair of clutches selected according to the change in the loads are connected, and the motive force is transmitted from the bevel pinion at the rear end of the transmission to bevel gear (8). 10-6 9.10 na Forauao2 The motive force transmitted to the bevel gear is transmitted by engaging or disengag- ing steering clutch (9) and steering brake (10) to control the direction of travel. If the steering and directional lever is operated to steer the machine, the motive force at steering clutch (9) on the side to which the lever is operated is disengaged, and the direction of turn changes. The radius of the turn is controlled by using steering brake (10). Steer- ing clutch (9) and steering brake (10) use wet- type, spring-boosted multiple disc clutches. The power coming from steoring units (9) and (10) is transmitted to final drive (11). Final drive (11) consists of a single-stage spur gear and single-stage planetary gear. This reduces the speed and rotates sprocket (12) to drive track shoe (13) and move the machine. o1au02o14u02 POWER TRAIN SKELETON Serial No. 3001 - 3033: S6D125-1 ) Serial No. 3034 and up: S6D125-2 2. Damper 3. Universal joint 4. Hydaulic pump Serial No. 3001 - 3033: Satta) 100) Serial No. 3034 and up: SAL(3)-80 5. P.T.O 6. Torque converter 7. Transmission . Ste |. Final drive . Sprocket Forauons Bevel gear Steering clutch ring brake Track shoe 1. Power train pump (SAL(2)-045) ». Power train lubrication pump (SAL(2)-045) Scavenging pumpPOWER TRAIN UNIT Power train oil strainer Scavenging pump Power train lubrication pump (SAL(2)-045) Power train pump (SAL(2)-045) PTO, torque converter Main relief valve Transmission control valve Transmission Steering control valve Steering clutch, brake Beexomsenn 10-8 1 40F12012 OUTLINE The power train unit can be broadly divided into the following parts: torque converter (with PTO), transmission unit, and steering unit. Therefore, after the power train unit is removed, it can be divided into the torque converter, transmission unit, and steering unit. The steering unit consists of the transfer, bevel gear shaft, steering clutch, and steering brake. o1au02014U02 POWER TRAIN HYDRAULIC PIPNG DIAGRAM + Without central pressure detection PEN oman st002126 Power train oil filter Transmission control valve Steering control valve Main relief valve Power train pump (SAL(2)-045) Power train lubrication pump (SAL(2)-045) Scavenging pump Power train oil strainer Power train oil cooler (built into radiato lower tank) 10-8-1 @o14u02 With central pressure detection (Option) Central pressure detection port Power train oil filter Transmission control valve Steering control valve Main relief valve Power train pump (SAL(2)-045) Power train lubrication pump (SAL(2)-045) ‘Scavenging pump Power train oil strainer Power train oil cooler (built into radiator lower tank) ommo 9 @ Pp Forauone Fressure detection port for torque converter cutlet port Fressure detection port for torque converter inlet port . Transmission modulating pressure detection fort Fight clutch pressure detection port Left clutch pressure detection port Right brake pressure detection port . Left brake pressure detection portPOWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 0.23 MPa (34 kg/em 0.33 MPa 7 (34 kg/em’) Lye [32 ete 21 1 ie | deem i i +) ise : lg : oiler 18 Le) 25201 NPA! | | eons BY | ra (13 | ——{ 14 1 < B = aor 2019 1. Power train oil pan 10. 3rd clutch 22. Steering control valve 29. Clutch, brake lubrication A.{C): Pressure detection port for torque 1A. Torque converter case 11, 2nd clutch 22A. Parking brake valve 30. Strainer converter outlet port 1B. Transmission case 12. Directional valve 22B. Right clutch valve 31. Scavenging pump B. (B): Pressure detection port for torque 1C. Steering case 13. Reverse clutch 22C. Right brake valve 32. Lubrication velve converter inlet port 2. Oilstrainer 14. Forward clutch 22D. Left brake valve .(A): Transmission modulating pressure 3. Power train pump (SAL(2)-045) 18. Torque converter relief valve 22E. Left clutch valve detection port 4, Power train oil filter 16. Torque coverter 23, Right brake D. (RC): Right clutch pressure detection port 5. Main relief valve 17. Oil cooler (24, Right clutch E. (LC): Left clutch pressure detection port 6. Modulating valve 18, Transmission lubrication valve. 25. Left clutch F. (RB): Right brake pressure detection port 7. Quick return valve 19. Transmission lubrication 26. Left brake G. (LB): Left brake pressure detection port 8. Speed valve 20. PTO lubrication 27. Power train lubrication pump (SAL(2}-045) H. Power train oi! temperature sensor 9. 1st clutch 21. Reducing valve 28. Lubrication valve mount 10-10 o14u02o1au02 POWER TRAIN HYDRAULIC SYSTEM DIAGRAM {Engine started, steering and directional lever at neutral, gear shift lever at Ist speed) na 14012020 10-11DAMPER, UNIVERSAL JOINT 10-12 Foxavoos 014U02o14u02 12, 3. 14, 6. 16. v7. Songonsena Breather Oil filler plug Inspection plug |. Drain plug Damper case . Bearing Coupling Cross pin . Drive shaft 10. - Drive plate Shaft Torsion plate ‘Stopper pin Friction plate Friction spring Hub Cover OUTLINE ‘+ The damper is a wet type with a friction spring. The damper is set with a stopper angle of 4° and a stopper torque of 2667.4 Nm (272 kgm) (at a stopper angle of 4"). 10-13TORQUE CONVERTER AND PTO TCS38-5A ‘TCS38-6A (For towing winch with PTO) 10-14 140F12037-1%. o14u02o1auo2 14012038 OUTLINE * The torque converter is a S-element, 1-stage, ‘phase type and forms one unit with the transmission. © Pump (14) forms one unit with coupling (6), input shaft (7) and drive case (12), and is rotated by the power from the engine. © Turbine (13) forms one unit with transmission input shaft (17), and is rotated by the oil from. the pump. © Stator (15) forms one unit with stator shaft (16), and is fixed to PTO case (11) 20. 21. . Scavenging pump drive gear (No. of teeth: 23. 24. Hydraulic pump mount Power train pump, lubrication pump mount Scavenging pump mount PTO lubrication tube Coupling Input shaft PTO drive gear (No. of teeth: 62) Idler gear (No. of teeth: 63) Idler gear shaft PTO case Drive case Turbine Pump Stator Stator shaft . Transmission input shatt Power train pump, lubrication pump gear (No. of teeth: 53) Coupling (when PTO for towing winch is installed) Cover Hydraulic pump gear (No. of teeth 53) 56) ‘Scavenging pump strainer Power train pump strainer Torque converter oil inlet port To oil cooler 10-15o14u02 TRANSMISSION CONTROL Serial No. : 3001 - 3033, Lever positions ® NEUTRAL @ FORWARD ) REVERSE Ist ® 2nd © 3rd @ FREE ® Lock 1, Safety lever 2. Steering and directional lever 3. Gear shift lever 4, Transmission control valve Foeuo06 OUTLINE © The transmission is controlled by steering and directional lever (2), which changes the direction of travel, and gear shift lever (3), which selects the speed clutch, 10-17 @STRUCTURE AND FUNCTION Serial No. 3034 and up Lever positions 1. NEUTRAL 2 FORWARD 2nd 3rd FREE Lock @8@6@60680 10-17-1 ® REVERSE 3. Ist rs Safety lever Joystick (directional change, gear shift) Brake valve Transmission control valve TRANSMISSION CONTROL ‘sxoms17 OUTLINE The transmission controlled by joystick (2), which changes the direction of travel, and selects the gear shift. 014U02TRANSMISSION zonvio x9[ 10-18o14u02 Main relief valve Transmission case Lubrication relief valve Transmission control valve, valve cover assembly Input shaft REVERSE sun gear (No. cf teeth: 26) Pinion shaft REVERSE ring gear (No. of teeth: 75 (inside) Lf 90 (outside) uy 9. REVERSE planet pinion (No. of teeth: 22) 10. Disc : 4 11. Plate vr 12, Piston : 13. FORWARD planet pinion (No. of teeth: 23) a 14, 3rd planet pinion (No. of teeth: 30) 15. 3rd ring gear (No. of teeth: 76 (inside), 90 i E {outside)) ¢ 16. 2nd sun gear (No. of teeth: 33) ry 17. 1st planet pinion (No. of teeth: 18) id 18. 1st sun gear (No. of teeth: 39) 19. Output shaft (No. of teeth on 3rd sun gear - portion: 17), 419A. Bvel pinion (No. of teeth: 18) 20. Ist ring gear (No. of teeth: 75 (inside), 90 (outside)) 21. Ist carrier (No. of teeth: 75) 8, - 22. 1st clutch housing 23. 2nd clutch housing 4 24. 2nd planet pinion (No. of teeth: 21) 25. 2nd ring gear (No. of teeth: 75 inside), 90 | a F (outside)) it \ 26. 3rd clutch housing 27. 2nd, 3rd carrier aaa ; 28. FORWARD clutch housing iq ¥ 29. FORWARD sun gear (No. of teeth: 29) + 30. FORWARD ring gear (No. of teeth: 75 (inside), (7 90 (outside)) | \ \ 31. FORWARD carrier (No. of teeth: 70) BeNo 1 8 4 4 u ” W 4 15 16 W 18 19 194 exoe 32. REVERSE clutch housing 33. Return spring \ 34. REVERSE ring gear (No. cf teeth: 70) | \ 35. Pin 36. REVERSE carrier (No. of teeth: 75) ‘A. To FORWARD clutch B. To REVERSE clutch I ©. To 3rd clutch 6% 6M 6 OU] 0 | eB) le | lk Ot D. To 2nd clutch E F G H. To 1st clutch 2 No.3 No.5. =. Scavenging pump suction port —_ a = > Drain plug Reverse! Forward | 3rd | 2nd | 1st |. From torque converter case to drain port for w-w transmission case Power train oil suction port I J. Transmission lubrication inlet port K. Power train oil suction port Foauoos 10-19OUTLINE The transmission is equipped with a planetary type, "3forward and 3-reverse speed” transmission which is a combined structure of a planetary gear mechanism and disc cluthes. The rotational direction and the revolution of the transmission output shaft is selected by fixing two dise clutches out of five disc clutches by means of control valve operation. No.1 clutch is fixed in reverse, No.2 clutch in forward, No.3 clutch in third speed, No.4 clutch in second speed, and No.5 clutch in first speed. Any speed can by selected from three forward speeds and three reverse speeds by fixing either No.1 or No.2 clutch and one clutch amoung No.3, No.4, and No.5 clutches and by combining two of the above. Speeds and operating clutches Speed [Operating etch Reuval Tos clutch First speed No2 and No clutches Forward | second speed No.2 and Nod clutches ‘Third speed No.2 and No clutches Neutral No. clutch First speed No.1 and No clatches Reverse | second speed No.1 and No. clutches Third speed No.1 and No clutches Number of discs and plates on each clutch Thich No | Nomber of aises | Number of plates. Nest etutch a 3 No2 clutch 5 4 No clutch 3 2 Nod clutch 3 2 Nos-eluteh 3 2 10-20 o14u02o14u02 OPERATION 1. FUNCTION OF PISTON * To lock ring gear (8), the discs (10) and plates (11) are brought into close contact. The clutch consists of a clutch piston (12), clutch plates (11), clutch discs (10), pins (12) and piston return springs (33). The disc's internal teeth engage with the ring gear's external teeth. The plates, whose notch on the outside diameter engage with pins (35) on housing (32). © Clutch engaged (oil pressure is acting) Oil from the control valve flows under pressure through the port in housing (32) to the piston (12). The piston presses clutch plates (11) and clutch discs (10) together, and the frictional force developed stops clutch discs (10) revolution, thus ring gear (8) meshing with the dise’s internal teeth is locked. © Clutch disengaged (oil pressure is not acting) When the supply of pressure oil from the control valve is shut off, piston (12) returns to the initial position by the force of piston return spring (33), thus relieving the frictional force between plates (11) and disc (10) making the ring gear (8) free. Per) WoW ow Hf 1 a, 140F 12042 n® 2 ‘Wor 2043 no ao yn =) | | th 14012048 10-21. FORWARD 1st When FORWARD 1st is selected, No. 2 clutch and No. 5 clutch are engaged, and the motive force transmitted from the torque converter to input shaft (5) is transmitted to output shaft (19) No. 2 clutch is actuated by the oil pressure ‘applied to the clutch piston, and fixes ring gear (30) in position. No. § clutch is actuated by the oil pressure applied to the clutch piston, and engages ring gear (20), The motive force from the torque converter is transmitted to input shaft (5), and the rotation of the input shaft passes through sun gear (23) and is transmitted to planet pinion (13). 10-22 0 Forauoo9 Ring gear (30) is fixed in position by No. 2 clutch, 50 the rotation of planet pinion (13) rotates carrier (31), which is on the inside of ring gear (30) Carrier (31) and carrier (27) are meshed by the spline and rotate as one part, so the rotation of, carrier (31) passes through planet pinion (24) and is transmitted to ring gear (25). Carrier (21) is meshed with ring gear (25), so they rotate as one unit, and the rotation is transmitted to planet pinion (17). Ring gear (20) is fixed in position by No. 5 clutch, 50 the rotation of planet pinion (17) rotates sun gear (18) and this rotates output shaft (19) o14u02o14u02 oe | | No.1 | No.2 | No.3 No.4 | No.5 Reverse| Forward | 3rd 2nd) 1st REVERSE 1st When REVERSE ‘st is selected, No. 1 clutch and No. § clutch are engaged, and the motive force transmitted from the torque converter to input shaft (5) is transmitted to output shaft (19), No. 1 clutch is actuated by the oil pressure applied to the clutch piston, and fixes carrier (36) in position. No. § clutch is actuated by the il pressure applied to the clutch piston, and engages ring gear (20). The motive force from the torque converter is transmitted to input shaft (5), and the rotation of the input shaft passes through sun gear (6) and is transmitted to planet pinion (9). = rN \ aN \ U4 u 0 Fo.auoro Carrier (36) is fixed in position by No. 1 clutch, 0 the rotation of planet pinion (9) rotates ring gear (34). Ring gear (34) rotates in the opposite direction from the input shaft, and rotates carrier (31). Carrier (31) and carrier (27) are meshed by @ spline and rotate as one part, so the rotation of carrier (31) passes through planet pinion (24) and is transmitted to ring gear (25) Carrier (21) is meshed with ring gear (25), so they rotate as one unit, and the rotation is transmitted to planet pinion (17). Ring gear (20) is fixed in position by No. 5 clutch, so the rotation of planet pinion (17) rotates sun gear (18) and this rotates output shaft (19). 10-23TRANSMISSION CONTROL VALVE Serial No. 3001 - 3023 140812047 o14u02o1au02 Valve body Spacer Quick return valve sleeve Quick return valve Plug Valve body Stopper Speed valve spool Directional valve spool Collar Cover Stopper Piston . Piston spring Modulating valve spool Modulating valve sleeve ”. Modulating valve spring (Large) Modulating valve spring (Small) Modulating valve spring Stopper Cover 140612048 10-25Serial No. 3024 and up zonvto O Oc00. © OT 10-25-1 @014U02 lL Le 1. Valve body y 2. Spacer L 3. Quick return valve sleeve <= 101) 2 4 Quick return valve 5 Pg 7 3. Valve bod KOSS 6p 3, Stopper Lg > Sy 8. Speed valve spool 4 Zi 9. Directional valve spool ec yiren ee coe WLLL fo 4 12. Stopper CS 13. Baton 14, Piston spring 15, Modulating valve spool . 16. Modulating valve sleeve 17. Modulating valve spring (Large) 18. Modulating valve spring (Small) 19, Modulating valve spring 20. Stopper 21. Cover ies 8 9 wu 21 20 9 B71 «615 4 (13:12 a8 soca 10-25-2MODULATING VALVE OUTLINE '* The modulating valve consists of a modulating relief valve and a quick return valve, and acts to modulates the pressure. ‘© When the gear shift lever is operated to shift gear, the clutch is pushed into close contact by the piston. However, if high pressure is suddenly applied, the piston will suddenly engage the clutch. This will make the machine suddenly start, and it will receive an excessive shock. * To prevent this, the modulating valve is installed. When the gear shift lever is operated to shift gear, the pressure on the piston gradually rises to the set pressure and the clutch is engaged smoothly. This allows the machine to start without any shock, thereby improving the durability of the power train and at the same time providing a comfortable ride for the operator. © The figure shows the relationship between the time and the increase in the hydraulic pressure of the modulating valve. For example, when the gear is shifted from F1 and F2, the oil from the pump passes through the speed valve spool, flows to the second clutch and fills the circuit up to the clutch pis ton port. The time taken for the circuit to be filled up to the clutch piston port is called the “filling time”, and the oil pressure during this time is 0 — 0.5MPa (0 — 5kg/cm*,) When the circuit up to the clutch piston port is filled with oil, the oil pressure starts to rise. The time taken for the pressure to rise to the set pressure is called the “built-up time”. The filling time and built-up time together are called the “modulating time”. 10-26 pa tegen!) 32192) 29160) 20:20) Ou pressure roma Modulating ime frog ume —/” uitd-up ime iSet pressure) ° Os 70 Time (See) 140F12049 o1auo2o14u02 OPERATION 1. Immediately after shifting gear When the gear shift lever is operated and the clutch is engaged, the passage from the pump. to the clutch cylinder is opened and the oil flows into the clutch cylinder. Quick return valve (4) uses the force of this flow and moves to the left in the direction of the arrow. It connects port A to drain port B, and releases the back pressure of modulating valve sleeve (16). When this happens, modulating vaive (15) and modulating valve sleeve (16) are pushed back to the right in the direction of the arrow by the reaction force of springs (17), (18), and (19). 2. During rise in oil pressure When the oil sent under force by the pump fills the circuit up to the clutch cylinder, the pressure starts to rise. The oil passing through orifice a of quick return valve (4) moves quick return valve (4) to the right in the direction of the arrow and closes the passage between port A and drain port B. The oil also passes through orifice b in modulating valve (15), flows into port € and pushes piston (13). When this happens, the reaction force causes modulating valve (15) to compress springs (17) and (18), and moves to the left in the direction of the arrow. At ther same time, the oil passing through the port in the middle of quick return valve (4) passes through orifice ¢, flows to port A, and becomes the back pressure of valve sleeve (16). It then moves valve sleeve (16) to the left in the direction of the arrow and compresses spring (19). To.utoh eyinder 4 9 — Be ain [La = gq H ain From 14012080 Tootuchovindes gd / 9 = Be orain TLLN VA, pump won 140F12051 10-273. Completion of rise in pressure As the pressure in the circuit rises, the back pressure of valve sleeve (16) rises, and valve sleeve (16) moves to the left in the direction of, the arrow, ‘At the same time, as the pressure pushing piston (13) rises, modulating valve (15) is moved to the left in the direction of the arrow by the reaction force. The above operation is repeated intermittently to increase the load on springs (17), (18), and (19), and the oil pressure rises ‘gradually. Finally, valve sleeve (16) contacts stopper (20) and does not move any further, so this com- pletes the rise in the oil pressure. 10-28 To clutch eyinder 4 16 oroin From 1513 pump 140F12052 o14U02MAIN RELIEF VALVE Body Torque converter relief valve Valve spring Piston) Piston spring Main relief valve Valve spring Piston spring Piston Drain port (torque converter relief] Drain port From pump, Drain port To torque converter |. Main relief pressure pick-up port yzrooe> 10-30 1 40F12053 OUTLINE 1. Main relief valve Main relief valve (6) sets the specified press- ures for the transmission, steering clutch and brake. 2. Torque converter relief valve Torque converter relief valve (2) is used to protect the torque converter from any abnormally high pressure. It relieves the circuit when the Pressure at the torque converter inlet port goes above the set pressure. Unit: MPa (Kg/cm’) acne Specified pressure Main relief pressure 3.2 (33.0) Torque converter inlet port pressure 0.83 (8.5) o14u02o14u02 OPERATION OF MAIN RELIEF VALVE ‘© The oil from the power train pump passes through the oil filter, and enters port A of the main relief valve. It then passes through orifice a and enters port B. ‘When the oil from the pump fills the circuit, the pressure starts to rise. ‘© When the pressure in the circuit rises, the oil entering port B pushes piston (4). The reaction, force compresses spring (7), moves main relief valve (6) to the left in the direction of the arrow, and opens ports A and C. When this happens, the oil from the pump is relieved from port A to port C, and flows port C to the torque converter. The pressure of port A at this point is 3.2 MPa (33 kg/cm?) OPERATION OF TORQUE CONVERTER RELIEF VALVE * The oil relief from the main relief valve flows into the torque converter from port C, and at the same time passes through orifice b and enters port D. When the oil fills the torque converter, the pressure starts to rise. © If the pressure in the torque converter rises abnormally high, the oil entering port D pushes piston (9). The reaction force compresses spring (3), moves relief valve (2) to the right in the direction of the arrow, and opens ports C and E. When this happens, the oil and port © is relieved to port E, and is drained to the oil tank. The pressure of port C at this point is 0.83 MPa (8.5 kg/cm?) Totorque converter Toil tank tt: me eo on To torque converter To oil tank Tt; [Pak 140F 12084 From pump Totorque converter To oil tank From pump 140F12055 140F12056 10-31LUBRICATION RELIEF VALVE Piston Spring FORWARD clutch housing eyo A. From oil cooler 8. Drain C. Drain 10-32 5 Fovauons OUTLINE © The oil coming from the torque converter Passes through the oil cooler built into the radiator lower tank, passes through the lubrication relief valve, and lubricates the transmission and PTO. '* The lubrication relief valve is installed on the left side of the FORWARD clutch housing, and Prevents any abnormal pressure in the lubricating oil Unit: MPa tkg/cm*} eae pane Specified pressure Pressure during normal 0.05 — 0.15 operation 40.5 - 1.5) Cracking pressure 0.3 (3.0) o1au02o1auo2 STEERING, BRAKE CONTROL Lever, pedal positions ) NEUTRAL Left clutch disengaged Left clutch disengaged, left brake applied Right clutch disengaged Right clutch disengaged, right brake applied Brake released Brake applied FREE Lock Brake pedal Safety lever Steering and directional lever Rod (from brake pedal) Rod (from steering lever) Rod (steering) Rod (brake) Parking brake lever Steering control valve 1 2 3 4. 5. 6. 7 8 a 140F12058 OUTLINE © Steering and directional lever (3) operates the steering and brake through left and right rods 6) Brake pedal (1) operates only the brake through rod (7). ‘© Safety lever (2) is interconnected with parking brake lever (8) and acts also as the parking brake If steering and directional lever (3) is operated slightly to the left, the left steering clutch is Partially disengaged and the machine turns slowly to the left, * If steering and directional lever (3) is operated fully to the left, the left steering clutch is completely disengaged and the left steering brake is applied, so the machine turns sharply to the left 10-33BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE 1. Transmission 2. Steering unit 10-34 140812059 o14u02o1au02 NOgReNs Output shaft Brake spring (large) Brake spring (small) Stopper . Brake hub Brake cage Brake cylinder 10. 12. 13. 14. Brake cover Brake plate (each sid Brake disc (each si Brake drum| Brake inner drum Bevel gear shaft cage Bevel gear shaft nut 15, 16. 17. 18. 19, 20. 21. Bevel gear shaft Bevel pinion Bovel gear Bevel gear shaft bearing Clutch inner drum Clutch outer drum Spacer Clutch plate (each side: 6) . Clutch disc (each side: 5) Clutch support bearing Clutch piston Clutch spring Clutch cage Seal ring 14012060 10-35OUTLINE Bevel gear shaft © The power transmitted from the engine ~ torque converter (or main clutch) ~ transmission comes to the bevel pinion and bevel gear, ‘Which are meshed by the bevel gear shaft sys: tem. From here it is sent and right angles to the left and right by the bevel gear shaft, and the rotation speed is reduced at the same ime. * The bevel gear shaft system uses a spiral bevel gear for the bevel pinion and bevel gear, and lubrication is carried out by splash lubrication using oil from the power train scavenging pump. © The bevel gear shaft system consists of the following parts: bevel gear (17) which is meshed with the bevel pinion, bevel gear shaft (15), bevel gear shaft bearing (18) and bevel gear shaft cage (13) which support the bevel gear shaft. Steering clutch * The steering clutch is a interconnected by a spline with the left and right bevel gear shafts. It acts to engage and disengage the power from the bevel gear shaft to the final drive, and to change the direction in which the machine turns. * The steering clutches are a wet, multiple disc type, spring-boosted type. They are hydraulically operated by the steering valve which is actuated by operation of the steering lever, and they are interconnected with the brakes. Lubrication is carried out by a forced lubrication system in which the oil from the power train lubrication pump passes through a pas- ‘sage inside the steering case, enters the cover, hub, and cage, and is sent to the discs and plates. * The steering clutches consist of the follewing parts: inner drum (19) which is joined by a ine to the bevel gear shaft, disc (23) which meshed with the inner drum, plate (22) whose outside circumference is joined to the clutch drum by a spline, spacer (21), clutch outer drum (20), piston (25) ans spring (26) which press the discs and plates together, cage (27) which supports the parts, and bearing (24). Clutch outer drum (20) and cage (27) are joined to brake inner drum (12), and trans- mits the power from the bevel gear shaft through the brake hub to output shaft (1). 10-36 Steering brakes * The steering brakes are joined to the left and right steering clutches, and stop the machine ‘or change the direction of travel by applying braking force to the power from the steering clutches to the final drive. © The steering brakes are a wet, multiple disc type, spring-boosted type. They are hydraul cally operated by the steering valve which is actuated by operation of the brake pedal and steering lever, and they are interconnected with the clutches. Lubrication is carried out by a force lubrication. system in which the oil from the power train lubrication pump and scavenging pump lubrication circuit passes through a passage inside the steering case, enters the brake cover and cage, and is sent to the discs and plates. © When the engine is stopped, the steering brakes are applied without the brake pedal being pressed because the back pressure of the brake system drops and the brakes are applied. However, when the engine is started again, the pressure and the circuit rises and the brake is released, so the parking brake must always be locked * The steering brake consists of the following parts: clutch outer drum (20), clutch cage (27), inner drum (12) which is joined to brake hub {6), disc (10) which is meshed with the inner drum, plate (9) which is joined at the outside circumference to brake drum (11) by a spline, brake drum (11), piston (7) and springs (2) and 3) which press the discs and plates together, cage (6) which supports these parts, brake cover (8), and output shaft (1). Brake drum (11) and brake cover (8) are fixed to the steering case. Output shaft (1) is joined to the brake hub by a spline, and is stopped in the axial direction by stopper (4) o14U02o14u02 Operation of steering clutch 1. Steering clutch engaged When the steering lever is at the neutral position, the steering valve is also at the neutral position, so there is no back pressure applied to piston (25) In this condition, the piston is pushed to the right in the direction of the arrow by the tension of spring (26), ans pushes discs (23) and plates (22) against the stopper portion of cluteh drum (20). Therefore, the power from bevel gear shaft (18) passes from inner drum (19) through the discs and plates that are pushed together into tight contact, and is transmitted to clutch drum (20). From here it passes through brake inner drum (12) which forms one unit with the clutch drum, and brake hub (5), and is transmitted through output shaft (1) to the final drive 2. Steering clutch disengaged When the steering lever is pulled, the steering valve is switched, and oil enters the back portion of piston (25). When the oil pressure rises, the oil pushes the piston to the left in the direction of the arrow, compresses spring (26), and releases the pressure pushing discs (23) and plates (22) together. When this happens, the power from bevel gear shaft (15) rotates only inner drum (19) and the discs, so it is not transmitted beyond clutch drum (20). Therefore, it is not transmitted to the final drive When the steering lever is released, the steering valve opens the drain circuit, and piston (25) is returned to its original position by the pressure of spring (26). This returns the steering clutch to the condition in Section 1. “Steer- ing clutch engaged”, When the left steering clutch is disengaged, power is transmitted only to the right steering clutch, so the machine turns to the left. 1 § 12 2% 27 25 20 23 22 19 15 een ieee i Saws DBD y | a 140F1 2062 10-37Operation of steering brakes 1. Steering brake released When the steering lever and brake pedal are at the neutral position, the steering valve is also at the neutral position, so the steering clutch is, engaged and oil enters the back-pressure port of steering brake piston (7) When the oil pressure rises, the oil pushes the piston to the left in the direction of the arrow, compresses springs (2) and (3), and releases the pressure pushing discs (10) and plates (8) together. When this happens, the power transmitted from bevel gear shaft (15) through the steering clutches to brake inner drum (12) is transmitted from hub (6) to output shaft (1), and goes to the final drive. 2. Steering brake applied (steering lever oper ated) If the steering lever is operated fully, the steering valve switches and the steering clutch is disengaged. At the same time, the oil applying back pressure to piston (7) is connected to the drain circuit. In this condition, the piston is pushed out to the right in the direction of the arrow by the tension of springs (2) and (3), so discs (10) and plates (9) are pressed against the stopper portion of brake outer drum (11). The brake outer drum is joined to the steering case and is fixed in position. Therefore, even if the steering clutch is disengaged, the rotation of brake inner drum (12) that is still rotating under inertia, that is the rotation of output shaft (1), is stopped because the discs and plates are pushed into contact together. The hydraulic force applied to piston (7) can be controlled by the amount that the steering lever is operated, and the braking force can be adjusted, so the turning radius and time taken to turn can be controlled, 10-38 + 40F12063 1 40F 12064 o1au02o1au02 3. Brake applied (steering lever at nevtral, brake pedal depressed) When the brake pedal is depressed, the steering valve switches, and the oil applying back pressure to piston (7) is connected to the drain circuit. The steering clutch remains engaged, so only the brake is actuated to stop the rotation of output shaft (1). 1 40F12065 10-39STEERING CONTROL VALVE 10-40 1 40F12066 o14u02o14u02 x 1. Right steering lever 12. Valve spring 2. Brake lever (clutch valve) 3. Left steering lever 13. Piston (clutch valve) 4, Parking brake lever 14. Right clutch valve 5. Body 18. Bolt (clutch valve) 6 Cover 16. Modulating spring 7. Cover (clutch valve) 8. Parking brake valve 17. Guide (clutch valve) 9. Check valve 18. Roller (right steering) 10. Roller (parking brake) 19. Roller (brake) 11. Right brake valve 20. Roller (left steering) OUTLINE ‘* The steering control valve is in the circuit between the power train pump through the main relief valve and the steering clutch and brake piston. It consists of two sets of steering valves and brake valves. If the steering and directional lever is moved to the right or left, the steering clutch is disengaged. If the lever is moved further, the brake is applied. The machine can be turned gradually or sharply by adjusting the movement of the lever. If the brake pedal is depressed, left and right brakes are applied and the machine stops, The above operation is carried out by switch- ing the steering control valve, which is inter- ‘connected with the lever and pedal. The steering control valve sends oil from the power train pump to the steering clutch and brake, and operates the disc clutches. 2 22 23. 24. 2. 26. 27. 140612067 Guide (brake valve) A. To right clutch Modulating spring B. Port P (brake valve) C. To right brake Bolt brake valve). To left brake Left clutch valve E, Clutch valve drain Left brake valve F. Brake valve drain Piston (brake valve) G. To left clutch Valve spring (brake valve) Valve control The steering control valve is operated by left and right steering levers (1) and (3), which are interconnected with the steering and direc: tional lever, and brake lever (2), which is interconnected with the brake pedal, and parking brake lever (4). Left and right steering levers (1) and (3) are interconnected with the steering valve and brake valve inside the steering con’ trol valve by a cam to carry out the control. 10-41OPERATION 1. When steering and directional lever, brake pedal are at neutral (clutch engaged, brake released, parking brake OFF) Stearing F-Alever Brake pedal FY RM cluten To main role valve 4 F, hoy BH brake " == CG Reding valve : 8 A i LH brake E “<3 F \ Perking brake “ON 140 12068-1K * When the steering and directional lever is at neutral and the brake pedal is released, levers (1), (2), and (3) are also at the neutral powition, so the oil ports of each valve are opened or closed by the tension of the spring. The oil from the power train pump passes through main relief valve and enters port A of check valve (9). ‘+ Some of the oil entering port A goes through Port B of left and right steering valves (24) and (14), and stops. 10-42 * When this happens, the oil from the back pressure port of the clutch piston returns from port € to drain port H, and the clutch is engaged by the tension of the clutch spring The rest of the oil pushes open check valve (9), enters port E of left and right brake valves (25) and (11), and flows from port F to the back pressure port of the brake piston. The piston waits for the pressure in the circuit to rise, then it moves to the left in the direction of the arrow, compresses the brake spring, and releases the brake. o14u02o14u02 2. When steering and operated to left (left clutch disengaged, brake released, parking brake OFF) Steering F-Rlover: Hu LH. cluten disengaged of No mii ie 9 15, © If the steering and directional lever is operated to the left, roller (20) of lever (3) pushes bolt (15) to the left in the direction of the arrow, and compresses modulating spring (16). The reaction force moves steering valve (24) to the left in the direction of the arrow. When this happens, the circuit between port © and drain port H is closed, and the circuit between ports B and C is opened. ‘© The oil from the power train pump enters port € from port B. Some of the oil flows to the clutch piston port to become the back press: ure, and the rest of the oil passes through orifice b and enters port D. The oil entering port D pushes piston (13), and the reaction force compresses spring (16) and moves valve (24) to the right in the direction of the arrow. This closes the circuit between ports B and C, so the oil does not go beyond port C, The pressure is maintained but does not rise any further. © If the steering and directional lever is operated further, the above operation is repeated, and when roller (20) of lever (3) reaches a position where it contacts bolt (23) of the brake valve, the pressure beyond port C rises to the set LH. brake LM claten 140F1 2069) pressure 25 + 0.1 MPa (25 = 1 kg/cm’) of the reducing valve, and the clutch is completely disengaged. ‘The pressure beyond port C is determined by the tension of modulating spring (16), which changes the load in accordance with the amount that the steering and directional lever is moved. Therefore, if the steering and directional lever is moved only a short distance, the pressure beyond port C is set to a low level, and the clutch is partially disengaged: if the steering and directional lever is moved the full distance, the pressure beyond port C is set to a high level, and the clutch is completely engaged. Port J is connected to port C, and reduces the operating force of lever (3), which pushes out bolt (15) to the left in the direction of the arrow. However, the pressure of port J, (the booster pressure) follows the pressure of port C which changes in accordance with the amount that the steering and directional lever is moved, 50 the operating force of the steering and directional lever also changes 10-433. When steering and directional lever is operated further to left (left clutch disengaged, left brake applied, parking brake OFF) © If the steering and directional lever is operated further from the condition in Item 2, roller (20) of lever (3) pushes bolt (23) to the left in the direction of the arrow, and compresses modulating spring (22). The reaction force moves brake valve (25) to the left in the direction of the arrow. When this happens, the circuit between ports E and F is closed, and the circuit between port F and drain port H is opened. ‘© The oil from the power train pump flows from. Port A, pushes open check valve (9), enters port E and stops. Some of the oil flowing to the brake piston port and forming the back pressure is drained from port F to port H, and the rest of the oil passes from port F through orifice ¢ and enters port G However, if the oil beyond port F is drained to port H and the pressure drops, it enters port G and pushes piston (26). The reaction force pushing valve (25) to the left in the direction of the arrow becomes smaller, so valve (25) is moved to the right in the direction of the arrow 10-44 Ace g Ace aa B 4 CG a 7 \ co) Ba Li. brake 3 j n Stennge-Riewe — g i 7 - LW. clutch dsengoges = eee F ff oo Li brake Ju apnled a on Parking brake “OFF aoe 2070 by the tension of return spring (27). This closes the circuit between ports F and H, and the pressure beyond F is maintained to prevent it from dropping any further If the steering and directional lever is operated further, the above operation is repeated, and when it is operated fully, the brake is applied completely. The pressure beyond port F is determined by the tension of return spring (27), which changes the load in accordance with the amount that the steering and directional lever is moved, Therefore, if the steering and directional lever is moved only a short distance, the pressure beyond port F is set to a high level, and the brake is partially applied; if the steering and directional lever is moved the full distance, the pressure beyond port F is set to a low level, ‘and the brake is completely applied. Port K is connected to port E, and reduces the operating force of lever (3), which pushes out bolt (23) to the left in the direction of the arrow. 014U02o14u02 4, When brake pedal is depressed (clutch ‘engaged, brake applied, parking brake OFF) ‘Steering F-R lever Neutral \ Brake pedal Brake applied RH clutch » Pena LH brake ut a ue © When the brake pedal is depressed, the two rollers (19) of lever (2) push left and right bolts (23) to the left in the direction of the arrow, and left and right brake valves (25) and (11) are actuated in the same way as in Item 3. Therefore, the oil pressure is set according to the amount that the brake pedal is operated, and the braking force can be adjusted, The left and right steering levers are not being operated, so the clutch is still engaged. Parking brake “OFF 140F12071 10-455. When parking brake is ON (clutch engaged, brake applied, steering and directional lever, brake pedal at neutral) Steering F-Rlever Neutral Broke pedal \ © When the brake lock lever is moved to the LOCK position, roller (10) of lever (4) pushes parking brake valve (8) to the left in the direction of the arrow. Check valve (9) is pushed by parking brake valve (8), and moves to the left in the direction of the arrow in the same way, and the circuit between port A and port E is closed. The oil which flow to the brake piston ort and forms the back pressure passes from port F through port E, and is drained through 10-46 RH. claten LH brake on Parking brake “ON 140812072 check valve (9) and parking brake valve (8) Parking brake valve (8) is kept pushed in by lever (4) and roller (10), and is fixed in position, so the back pressure of the brake piston port continues to go down. The brake becomes completely applied, and it is kept in this condition. Even when the engine is started again, check valve (9) remains closed, so the brake is kept applied, o14u02014U02 REDUCING VALVE Orifice Plug Body Spring ‘Spool Spring Spool @NOMSeNs Outline '* The reducing valve is installed between the ‘main relief valve and the steering control valve, The set pressure of the main relief valve is a high 3.2 MPa (33 kg/cm’) at rated, so the reducing valve lowers the oil pressure to the set pressure for the steering to protect the steering Plug From main relief valve To steering control valve >> Unit: MPa (kg/em?) — Set pressure Cracking pressure 2.45 (25) 10-46-1 @o14u02 SCAVENGING PUMP STRAINER Noesena p> ‘Scavenging pump PTO drive gear (No. of teeth: 62) ‘Scavenging pump drive gear (No. of teeth: 56) Strainer PTO case Spring Cover To steering unit lubrication From transmission case 1 40F12088 OUTLINE * Scavenging pump (1) is driven by PTO drive gear (2). The oil sucked up from the trans~ mission case is sent to the steering unit lubrication circuit, — — Capacity Filtering particle size 100 mesh. Filtering area 1,520 cm? 10-47POWER TRAIN OIL STRAINER PTO case Magnet Strainer Spring . Cover | Magnet assembly >> To power train lubrication pump From power train oil tank 10-48 Filtering particle size Filtering area Pressure resistance 140F1 2009 Capacity 100 mesh 2,100 cm? 0.2 MPa (2.0 kg/em’) o14u02o1au02 POWER TRAIN OIL FILTER D> SNOMaoNa Power train oil filter Hydraulic tank oil filter Cover Body Element Valve Spring Drain plug To transmission case From power train pump rewF013 = ~ Capacity Cracking pressure Filtering particle si Filtering area Filtering oil flow 0.15 + 0.02 MPa (1.5 + 0.2 kg/em®) 30 um 5,400 cm? 10-49FINAL DRIVE OUTLINE The final drive uses a single-stage spur gear, single-stage planetary gear reduction system. Splash-type lubrication is carried out by the rotation of the gear. The final drive can be removed or installed as a unit. Floating seal (4) is installed to the rotating and sliding portion of the sprocket to prevent the entry of dirt or dust, or leakage of oil 10-50 140F12001 o14u02o14u02 SNOMBwNS Sun gear (No. of teeth: 13) Carrier Ring gear (No. of teeth: 68) Floating seal Cover Cover Final drive case Bearing cage 140F12092 No. 1 pinion (No. of teeth: 21) No. 1 gear (No. of teeth: 78) Sprocket hub Sprocket teeth Hub Planet pinion (No. of teeth: 27) Pinion shaft Pivot shaft 10-51POWER TRAIN ‘* The motive force from the bevel gear shaft and steering clutch is transmitted to No. 1 pinion (9), and is then transmitted to sun gear (1) through No. 1 gear (10), which is meshed with the No. 1 The rotation of sun gear (1) is transmitted to planet pinion (14), but ring gear (3), which is meshed with the planet pinion, is fixed to cover (5), so the planet pinion rotates and moves in orbit around the sun gear along the ring gear. 10-52 14062093, When this happens, the rotating force of sun gear (1) becomes the rotating force of carrier (2), which supports the planet pinion, and this is transmitted to sprocket hub (11) The direction of rotation of carrier (2) is the same as the direction of rotation of sun gear a, ‘The rotation force transmitted to sprocket hub (11) is transmitted to sprocket teeth (12). o14u02i MAIN FRAME 014u02 1. Engine mount 2. Power train unit mount 3. Main frame assembly sawrore OUTLINE © A hullrame structure is used in which the radiator guard, main frame, and transmission underguard form one unit. 10-53TRACK FRAME Serial No. : 3001 - 3033 1. Equalizer bar * Track roller raucagza Idler Carrier roller ary Flange type and arrangement Track frame pese-ss.2 | 8 Sprocket S.$.0.S.5.D.5.S Track roller guard Track roller Pivot shaft Pxomeen 10-54 oO o1auo2014U02 STRUCTURE AND FUNCTION Serial No. 3034 and up POM ReNS |. Equalizer bar Idler . Carrier roller, Track frame Sprocket Track roller guard Track roller . Pivot shaft + Track roller ‘TRACK FRAME «002127 ary Flange type and arrangement D85E-Ss-2 8 SSDSSDSS 10-54-1o14u02 RECOIL SPRING Serial No. : 3001 - 3033 140F1 2096 . Yoke OUTLINE Dust seal * The recoil spring adjusts the track shoe tension Rod by moving rod (3) backwards or forwards. The Recoil spring power of the recoil spring is adjusted by Piston releasing or adding grease through lubricator Wear ring (8). Recoil spring (4) also acts to absorb any Cab sudden impact shock that is brought to bear Lubricator on the idler. Nut Housing Cylinder Bushing Holder 10-55STRUCTURE AND FUNCTION Serial No. 3034 and up 1. Yoke 2. Dust seal 3, Rod . Recoil spring Piston . Wear ring . Cab Lubricator Nut Housing 11. Cylinder 12. Bushing 13. Holder 10-55-1 RECOIL SPRING OUTLINE The recoil spring adjusts the track shoe tension by moving rod (3) backwards or forwards. The power of the recoil-spring is adjusted by releasing or adding grease through lubricator (8). Recoil spring (4) also acts to absorb any sudden impact shock that is brought to bear on the idler. o1auo2SUSPENSION Serial No. : 3001 - 3033, 140F12097 o14U02o14u02 Pengnnens Center pin Equalizer bar Pivot shaft Side pin Seal Bushing Bushing Seal Plug (for adding oil to pivot shaft) Cover Bushing Seal i 6 ld, 1 OUTLINE 140F12098 © The front of the track frame moves up and down with pivot shaft (3) at the rear forming the center of the movement. The equalizer bar moves up and down with center pin (1) forming the center of movement, and is connected to the left and right track frames by side pin (4). * Amount of movement at center of equalizer bar side pin Unit: mm. Up Down D85E-SS-2 819 819 10-57STRUCTURE AND FUNCTION SUSPENSION Serial No. 3034 and up 10-57-1 @ 014U02014U02 STRUCTURE AND FUNCTION B28 epnogaeye |. Center pin . Equalizer bar Pivot shaft Side pin Seal Bust . Bushing Seal Plug (for adding oil to pivot shaft) Cover |. Bushing Seal VA, eaetaey SUSPENSION The front of the track frame moves up and down with pivot shaft (3) at the rear forming the center of the movement. The equalizer bar moves up and down with center pin (1) forming the center of movement, and is connected to the left and right track frames by side pin (4), + Amount of movement at center of equalizer bar side pin. Unit: mm. up Down D85E-SS-2 81.9 819 10-57-2 ®WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM ANGLEDOZER Serial No. 3001 ~ 3101 1002128, 1. Blade 2. Right brace 3. Right lift cylinder 4, Left lift cylinder 5. Hydraulic pump Serial No. 3001 ~ 3033 : SAL(3)-100 Serial No. 3034 and up : SAL(3)-080, 6. Oil filter 7. Main control valve 8. Hydraulic tank 9. Left brace 10. Oil cooler (Piping type) 11, Suction valve 10-58 ® o1auo2014U02 Serial No. 3102 and up suoo2i74 1. Blade 2. Right brace 3. Right lift cylinder 4, Left lift cylinder 5. Hydraulic pump (SAL(3)-080) 6. Oil filter 7. Main control valve 8. Hydraulic tank 9. Left brace 10. Oil cooler (Piping type) 11. Suction valve 10-58-1 ®o1au02 WORK EQUIPMENT CONTROL vewFor6 Lever positions 1. Safety lever ® HOLD ® Blade LOWER @® Blade FLOAT @ Blade RAISE © FREE ® Lock 2. Blade control lever 10-59WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM ANGLEDOZER 10-60 108:420 Kpa (1.05:+0.2 kgiem’) ob > Lower Float | PFs i ' ' ' qo aA ' ' Beha SST ' 38 15Kpe (2hoKgerm) = ' ; 0395018 ko/em’) ' 3 - - t > a ' > > 1awro17 Hydraulic tank 2. Hydraulic pump (SAL(3)-100) 3. Main control valve 3A. Load check valve 3B. Suction valve 3C. Blade lift valve 3D. Main relief valve Oil cooler Left blade lift cylinder Right blade lift cylinder Hydraulic filter Hydraulic tank breaker relief valve Prone o14u02o14u02 WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM (Engine running, hydraulic control lever in “HOLD") 10-61HYDRAULIC TANK AND FILTER Serial No. : 3001 ~ 3033 sew F018 o14u02014U02 Senouaenn Power train oil filter Hydraulic filter Hydraulic tank Cap Sight gauge Drain plug Strainer Hydraulic fiter body Cover Element Valve Spring Drain plug Hydraulic tank filler cap 14A. Key cylinder 148. Vacuum valve 14C. Pressure valve From control valve To hydraulic tank 14a saori2n3 Specified value Capacity of hydraulic tank 7e Pressure valve 38+ 15KPa Hydraulic | racking pressure {0.39 + 0.15 kg/em’) tank cap | Vacuum valve 0—45KPa actuation pressure |(0 — 0.046 kg/em”) Cracking pressure | 103 + 20 KPa (1.05 + 0.2 kg/em’) Hydraulic | Filtering filter | particle size 304m 10,026 cm? 230 ¢/min 10-63‘STRUCTURE AND FUNCTION Serial Nol 3034 and up 10-63-1 HYDRAULIC TANK AND FILTER 014U02o1auoz STRUCTURE AND FUNCTION HYDRAULIC TANK AND FILTER 10 MW 412 13 |. Power tr filter . Hydraulic filter . Hydraulic tank Cap . Sight gauge . Drain plug . Strainer . Hydraulic filter body . Cover Element |. Valve . Spring . Drain plug . Hydraulic tank filler cap 14A. Key cylinder 14B. Vacuum valve 14C. Pressure valve papeeeeieesaes A. From control valve B. To hydraulic tank ——— Specified value Capacity of hydraulic tank 730 Pressure valve 38 + 15 KPa Hydraulic [oracking pressure _|(0.39 + 0.15 kg/om” tank c@P | Vacuum valve 0 45 KPa actuation pressure | (0 - 0.046 kg/cm’) Cr 103 + 20 KPa Cracking pressure | 14 3055 20\K08 syarute [Eterna pariel 30am Filter Filtering area 10,026 em? Oil flow 230 w/min 10-63-2MAIN CONTROL VALVE rowF 020 Valve body Main relief valve Spool Lever Detent Check valve 10-64 o14u0201402 s4wraot 10-6510-66 OPERATION OF WORK EQUIPMENT CONTROL CIRCUIT ANGLEDOZER At blade RAISE OPERATION ‘© When blade control lever (1) is operated to the RAISE position, the spool (3) of lift valve (2) moves to the right. When this happens, the circuits between ports A, B, P, and T are connected. © The pressurized oil from pump (4) enters port P, pushes up check valve (5), passes through lift valve (2), then enters the head end of lift cylinder (6) to raise blade (7). At the same time, the oil at the cylinder bottom passes through lift valve (2), then flows from port T to oil cooler (8) and filter (9), and is drained to hydraulic tank (10) awroze o14u02o14U02 PISTON VALVE (BLADE LIFT CYLINDER) OUTLINE ‘© The piston valve is installed on the piston in the blade lift cylinder. When the piston reaches. its stroke end, the valve releases the oil from the hydraulic pump to reduce the oil pressure being exerted on the piston. In addition the piston valve relieves the shock which occurs when the piston comes into contact with the cylinder head or the bottom and serves to reduce the subsequent surge pressure in the cylinder by letting the oil escape from the cylinder before the piston reaches its stroke end. OPERATION 1. Piston valve CLOSED Pressurized oil from the hydraulic pump acts on piston (2) and piston valve (3). The piston valve is pushed in the direction of the arrow until piston valve seat (4) comes into snug contact with the tapered section, thereby, this causing the pressure in the cylinder to rise and moving piston (2) in the direction of the arrow. 2. Piston valve OPEN Just before piston rod (1) reaches its stroke end, the front end of piston valve (3) comes into contact with the cylinder bottom (or the cylinder head) and is prevented from moving any further while piston (2) alone keeps on moving ahead Then, the oil sealed within the piston valve on the cylinder head side will escape from piston valve seat (4), (5) so that the oil pressure in the cylinder is prevented from rising Laars298 contact 10-67WORK EQUIPMENT ANGLEDOZER End bit Cutting edge Blade Center shaft Joint Brace Arm Trunnion Came Ceyomeens 10-68 Forauors ss Angledozer Blade width Blade height Max. lifting height Max. lowering depth (mm) Max. tilt Cutting edge angle Max. blade angle (mm) (mm) (mm) (mm) 014U02ELECTRICAL CIRCUIT DIAGRAM tf starting recutator | Binetat sytem Tear iano TFcoot (anal Stet tina avi ton service ameter @ lj [Foaling water ‘Engine Stoo Ste" Sressbre 3 a i be: | lies inte St “Bape ester a Alternator | pevasa | tS voter temperature sensor Teh Tew Engine oil oressure ) sensor 50110K08 (0.540. thaven?) Head ‘amo RH GOW Head Lano cw 60W 014U02 -Tranemission safety lever limit switch Rear temp sow aatiery oh TY Fender GNO (Spi sviten sawcai2077 ) Pover train oi Temperature sensor 10-69ENGINE CONTROL SAFETY MECHANISM WHEN STARTING ENGINE FOR TRANSMISSION SAFETY LOCK LEVER FUNCTION ‘© There is a limit switch installed to the transmission safety lock lever, and if the lock lever is not placed at LOCK position, the starting circuit does not come ON, so the engine cannot be started. ‘© When the transmission safety lock lever is placed at the LOCK position, the steering and directional lever is automatically returned to the neutral position. 10-70 Starting switch © C Tele] EI (Power source) lever 1 teansmiasion safety lock Neutral Reverse Forward Ad steering FR lever Engine q 1 40F12208 o14U02o14u02 MACHINE MONITOR SYSTEM Sensor signal Each sensor ‘© The machine monitor system uses sensors installed at various parts of the machine to ‘observe the machine condition. It processes this information swiftly and displays it on the Panel to keep the operator informed of the machine condition. The information displayed on the panel can be broadly divided into the following categories. The monitor group, which informs the operator when there is any abnormality in the machine 2. The gauge group (coolant temperature, power train oil temperature), which always displays the condition of the machine. Power source! sow 028 The machine monitor system consists of the gauge panel, sensors, and power source. The gauge panel and sensors are connected with wiring harnesses, and the power supply for the gauge panel is taken from the battery. If any abnormality occurs in the machine (detected by the sensor), the monitor lights up to protect the machine. 10-71GAUGE PANEL 1 2 3 vawr02e OUTLINE ‘© The gauge panel consists of the monitor group, which gives a warning if any abnormality occurs in the machine, and the service meter and gauge group, which displays the condition of the machine. The items displayed on the indicator type gauges and monitor portion are as shown in the table in GAUGE PANEL DISPLAY. OPERATION ‘* These check the condition from the time the engine is started to the time the engine stops. If there is any abnormality, the lamp lights up to inform the operator. 10-72 oe eee Service meter Engine coolant temperature gauge Power train oil temperature gauge Heater signal Engine oil pressure caution lamp Battery charge caution lamp o14u02o14u02 ‘© Gauge panel display Category} Symbol Display item Display range Display method Displayed when engine is running, starting switch at ON’ bret ‘When charge is defective Display goes out when normal and lights up & when abnormal é Displayed when engine is running, starting when abnormal Displays when starting switch is at HEAT ‘Lights up curing preheating (glows red Preheating When preheating for 20 — 30 sec) * Goes out when starting switch is turned back from HEAT position 3 Engine cooling water Displays when starting switch is ON temparatare + indiates coolant temperature g sawFo28 é a ae Power tain oi Displays when stating switch is ON temperature indicates oll temperature sews ge : ‘operates nen engine ol pressure is normal BE] BL | parr 0 — 99999 hours Qveratas wnen en 10-73SENSORS ‘+The signal from the sensor is input directly to the machine gauge panel. + The engine oil pressure sensor signal is judged to be normal when the contacts are open and the signal wire is separated from the chassis ground. When When| Display category Type of sensor Sensor method | Jorma: | abnormal Caution Engine oil pressure Contact OFF (open) | ON (closed) Engine coolant temperature Resistance = - Gauge Power train oil temperature Resistance = - 10-74 o14U02o14u02 ENGINE OIL PRESSURE SENSOR Teese ee eeed seesSee = FUNCTION © The engine oil pressure sensor is installed at the front on the left side of the cylinder block. When the engine oil pressure is above the specified value, diaphragm (4) bends, so contact (3) and contact ring (2) are separated and the circuit is turned OFF. When the engine oil pressure goes below the specified pressure, the curve of the diaphragm becomes smaller, s0 the contact and contact link come into contact and the circuit is turned ON and gauge panel display. ENGINE COOLANT TEMPERATURE SENSOR POWER TRAIN OIL TEMPERATURE SENSOR FUNCTION ‘* The engine coolant temperature sensor is installed to the thermostat housing on the right side of the engine. It detects the tem: perature with thermistor (3) and sends a signal to the gauge panel. The monitor panel moves the gauge indicator to the range that corresponds to the signal, and if it is above the specified temperature, the gauge panel display. ‘© The power train oil temperature sensor is in stalled to the left side of the torque converter case, and operates in the same way as the engine coolant temperature sensor. Plug Contact ring Contact Diaphragm. Spring Thermistor Stucture of circuit oonene 1. Connector 2. Plug 3. Thermistor Structure of excuit vewra2s 10-75o1au02 20 TESTING AND ADJUSTING Standard value table for engine . Standard value table for chassis ...nnnnne20- 3 Standard value table for electrical system : Too! list for testing and adjusting 20-8 Adjusting valve clearance . Measuring compression pressure. Measuring blow-by .. Adjusting fuel injection timing Measuring exhaust color .... Measuring boost pressure Measuring exhaust temperature Measuring engine oil pressure Measuring engine speed Testing fan belt tension Measuring speed at torque converter stall. 19 fuel control linkage.. 20-20 1g steering and directional lever, gear shift lever, parking brake lever linkage ... 20-22 Adjusting brake pedal linkage Adjusting work equipment control linkage Measuring power train oil pressure . Measuring and adjusting blade control oil presure .. Bleeding air from hydraulic cylinder Releasing remaining pressure from hydraulic circuit 20-30 Procedure for simple test of steering brake performance 20-31 Procedure for testing SensOrS.n.nnnnnnan-20-32 Troubleshooting... 20-33 1 The following precautions are necessary when using the STANDARD VALUE TABLE for testing and adjusting, or for troubleshooting. Therefore, they should be used as target 1. The values in the table are for new machines, and are obtained for reference to values for new machines and the values when shipping from the fact values for judging the progress of wear, or when repairig the machine. 2 The values for judging failures are based on standards when shipping the machine from the factory, and on the results of various tests. These values should be used as reference together with the repair condition and operating record of the machine to make judgements on failures. the safety pins and block the tracks. machine. Pe ee. Be careful not to get caught in rotating parts. The values in the table should not be used for judging claims. ‘When carrying out testing, adjusting or troubleshooting, stop the machine on level ground, install When working in groups, use agreed signals and do not allow unauthorized persons near the When checking the water level in the radiator, wait for the water to cool. Do not remove the radiator cap while the water is hot. Boiling water may spurt out. 20-1 @STANDARD VALUE TABLE FOR ENGINE + FOR ENGINE ON CHASSIS Serial No. : 3001 - 3023 Machine mode! D8sE-SS-2 Engine $08125-1 Standard] Permissible Check item Conditions Unit ance foe High idling 2100260 | 2,100+50 Engine speed Low idling rom | 625225 | 625425 At rated speed 1,950 — z Wa in. 80 Intake pressure | At rated output temrig) | iain 600) Exhaust temperature] All speed : (Turbine inlet temp.) | (intake air temp. : 20°C) ce eananaee: ae Sudden aceleration Bosch | Max.5.0 60 Exhaust gas.color | ae high idling index | Max. 1.0 20 Intake valve (20°C) Ose Valve clearance | ehaust valve (20°C) mm on 7 Oil temperature : 40 — 60°C MPa | Min.3.1 22 Compression pressure Engine speed : 200 — 250 rpm {kglem?) | (Min. 32) 22) SAE30 oil (Water temperature inside operating eee : Blow-by pressure | range) ax. ot At high idling, SAE30 oil (rnmll,0}) Max. 50) a (Water temperature inside operating range) ‘At high idling (SAE3O, min. 80°C) | acl — en : Se es 7 Oil pressure At low idling (SAE30, min. 80°C) tkovemy | nO nal ce ae 0.25—0.45 0.18 At high idling (SAE10W, min. 80°C) etna ae : Min.0.1 0.07 At low idling (SAE10W, min. 80°C) mee aa Oiltemperature | Whole speed range (inside oil pan) 90110 120 Fuel injection timing | Compression B.T.D.C, degree | 2441 2aet Fan belttension | Sl2°k when pushed with finger force ee a 61 of 5B.8N (6 kg) 20-2 @ o14u02o14u02 Serial No. : 3034 and up Machine model D85E-SS-2 Engine $06125-2 ; Standard] Permissible Check item Conditions Unit nae es High idling 2100+80 | 2,100+60 Engine speed Low idling mm | ‘625425 | 825425 At ated speed 1,950 = Pa in Exhaust temperature] All speed « (Turbine inlet temp.) | (intake air temp. : 20°C) re peas ee Sudden aceleration Bosch | Max.5.0 60 Exhaust gas.color” | ae high idling index | Max.1.0 20 Valve clearance | Intake valve (20°C) a 0.33 = Exhaust valve (20°C) 071 = MPa | Min. 3.33 2:35 Compression pressure tigiem’} | (Min. 343 (24 (Water temperature inside operating ee Blow-by pressure | range) i x oe At high idling, SAE3O oil soot est arta 1 (Water temperature inside operating | range) | | : os—os | oz At high idling (SAE30, min. 80°C) era a MPa | Min. 0.18 0.07 Oil pressure At low idling (SAE30, min. 80°C) teaem | Minis) | on 025-04a | 0.18 At high idling (SAE10W, min, 80°C) ay : Min. 0.1 0.07 At low idling (SAE10W, min. 80°C) meas bah Oiltemperature | Whole speed range (inside oil pan) cc | 90—110 120 Fuel injection timing | Compression B.T.D.. degree | 134075 | 1320.75 Slack when pushed with finger force Fanbelttension | Sr saan ei) mm 10 —2 20-2-1 oOo14uoz STANDARD VALUE TABLE FOR CHASSIS D85E-SS-2 Check item f i Measurement conditions Unit F"Sangara | Permissible value value - + Engine oil pressure : within operating range 3 + Engine oil temperature : within operating 3 |Torque converter | range rpm = |etat'speed |» Power train oil temperature : 70 —80°C 1.70 100 1,850 2 + Hydraulic oil temperature : 45 — 55°C + No of speed range :F3 Engine : low idling : 0 ~full throttle [eee Fuol contol tever|+ Center offever knobs = gine : low idling - 0 soi 4320 | ar Decelerator pedal |+ Center of pedal 57210 | 57410 3 + Engine stopped Between each B [Gearshiftlever |. Center oflever knob speed range Eadie eet é + Engine stopped NoF 73+ 10 73+10 3 + Center of lever knob N+ R 65+10 | 65410 3 mm | Steering. FA lever + Engine low idling yt stroxe CERT U bela a 8 + Center of lever knob RIGHT turn a3215 | 63215 3 Until steering clutch 3 is fully disengaged 2 7 & | Engine low idling Brake pedal | Coton of podal Full stroke yot12 | 79212 + Engine low idling = » Ceoterotleverieeb HOLD RAISE 7ex12 | 7ex12 Blade control lever — + Hydraulic oil tempera- a tes45 65°C HOLD + LOWER We12 | 7212 7552294, 177 é full throttle 77230) (120) 3 Engine: full throttle 21.6491 ; S __|Fuet control lever |+ Center of ever knob + low idling (22210) | (49) z Engine : low idling 7262196) 1177 $3 * stop N | (7.4420) (12.0) 8B | decolerator peda |” ENGINE speed: low idling 625+ 25pm) | “9 | og.14 20.4 | 147.1 8 © [Decelerator pedal |. Center of pedal (za) | (15) = + Engine stopped ast + 2nd feede tes ees = (33+20) | (60) E _[Goarshitt lever - —S +} | (se2e106| 588 Center ofteverknob 2nd + 3rd LE ast20 eos 20-3| D8se $-2 Classi feeeeeneen eck iter i Uni Cleft) Check Measurement conditions fees eee value | value + Enginestopped sy vp za4t196| 49.0 2 |= Center of lever knob (3.0420) | (60) z zaaries| 490 NOR * (30220) | (60) B | Steering F-R lever — at 3 + Engine low idling Until steering clutch 127498 24.5 3 + Center of lever knob _ is fully disengaged «3+10) | (2s) | Until machine tums | N | 235498 | 49.0 3 when brake is applied | (kg) | (2.4% 1.0) (5.0) 8 + Engine low idling 451.0+78.5| 588.4 5 [Brake pedal. Center of pedal (46.0+8.0)| 60.0) 4 7 2 + Engine low idling ze2t98 | 588 5 Blade control |* Hydraulic oitterpera Hoenn (4.01.0) (6.0) & lever ure : 45 — go2t98 | 588 + Center ofleverknob HOLD» LOWER aoe | ea + Power train oil Es 02°37" Torque converter |” temperatures Engine :lowidling | os) relict pressure | 9 aye - . (inter) Engine :full throttle | fees qet | eee +15) | (75+ ae o2toa | o2t0a Torque converter eens (2041.0) | (2041.0) outlet pressure 0.45 40.15 | 0450.15 Engine : full throttle erin | asain Transmission main . 33401 | 30 «_ (telef pressure ballet (340210) (31.0) § Transmission mo- ae 3as01 | 30 3 | dulating pressure Engine:fullthrote | | @a0e1.0)| (10) = [Transmission lub- ngine igen) 0.12008 | 0.12005 8 [rication pressue beled eed (1.005) | (1.005) z : zezoa | 22 3 ‘Steering clutch Engine : low idling (25.0 + 1.0) (22.0) |operating pressure : 25201 | 2a Engine : full throttle wy) ay : 2sro1 | 22 Engine: low ili Vee ais eeuenianr (25021.0)| (22.0) pressure | 25201 | 22 | | Eons (25.0% 1.0) | (22.0) |) Min 15.7 | Min, 157 5 | Blade lift rliet aaa (Min. 160) | (Min. 160) pressure 206410 | 176 Engine : ull throttle ping (een 20-4 o1au02o14u02 | D8SE-SS-2 Classifi- a - unit ————J classi) Check item leasurement conditions nie eases eee value value Onlevelsurface —F tst 39 39 Engine at full throttle. 8 Engine watertempe- F 2nd 6a sa 5 rature : Inside operat- F 3rd 10.6 10.6 E | Travel speed ing range Spann kewh Saeenee £ Run up distance: Ist ee Be é 10 —30m R2nd 86 86 Measurement dis- = eons R3rd 134 13.4 20-5Dss€-ss.2 Classifi : it tation | Check item Conditions, Unk een eens value value Posture of work equipment £ tL g = mm) 2 Max. 100 | Max. 100 £ ve7F01851 15 min, z + Hydraulic oil temperature : 45 — 55°C | + Engine stopped + Center of blade cutting edge ; from height of 800 mm to ground Blade lift z Posture of work equipment § 8 02 | $ < 20:33 25 2 |z —x4 i i To7Foise7 =| + Hydraulic oil temperature : 45 — 55°C g 2 * Engine : full throttle Z| sec.) 15202 | 18 £ + Blade: no load 8 z + From ground to maximum height 3 + Engine : full throttle td + Hydraulic oil temperature : 45 — 55 °C Blade time __|+ Lower the blade from the maximum lag height, and measure the time taken from Max.1.7 | Max.2.0 the point when the blade touches the ‘ground to the point where the idler is raised from the ground 20-6 o14u02o1au02 STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM moot INSP jeasuremen Classifi] ——Chectitem —_|onnertor) "Sion Judgement table Messmer! lmethod 1) Turn starting eceaa aeaecce switch OFF and 50°C Approx. 153.0] | insert dummy erc Approx. 79.49 measure resist- Taz —[Aporox.2552]| nce of sensor. Coolant CNIS 135°C __[ Approx. 17.02] | 2) Turn starting temperature @-® ‘switch ON, and check dispiay. 3) Connect socket areas 1) Turn starting temperature ‘sensor switch OFF and 8 °C [Approx 15340] | insert dummy € 120°C Approx. 15.82 measure resist- 3 135¢ [Approx 11.02] | Sree of sensor. Power tin cuss | rare mperature: @O-®@ g fate oe tempera g switeh ON, and 3 check display. 2 3) Connect socket g 8 sawecas 2 The following results show that the 7 Starting sensor is normal switch OFF aE 2) Disconnect Coolant temperature | CNIS eembiont | When normal nts sensor (Male) (coolant (Coolant temperature er ‘Aopron, 2552 temperature gouge) " 1 sensor) eve Approx 5019 3) Disconnect Power train nse, " ' cNsa temperature sensor | (Male) sre Aoprox. 7340 (power tain (Power train : temperature temperature gauge) are: peeesieaee: sensor). 4. | The following results show that the 1) Start engine. 2 | sensor is normal Engine oil pressure z [Engine oil pressure over to continuit seer i 5 50 Kpa (0.6 kg/em*) feecetn 2 | [engine of pressure ar 8 Junder 50 Kpa (0S kg/em*)| Continuity 3 | wnen engine is running (1/2 throttle or pari Between | 3 | above): 27.5 — 295V ee Alternator alternator] | se. it the batory is od, or after starting in erica cold areas, the voltage may not rise for 3 some time. 2 20-7TOOL LIST FOR TESTING AND ADJUSTING Test measurement tem |Symbol] PartNo Part name Remarks 1:60 2,000 pm Engine speed A. | 799.209.8001 | Mutitachometer igital display 9-4 800s0m_ Waterers 799-101-1600 | Digital temperature gauge | -99.9to1,200°¢ oiltemperature, 8 eeu tenner. 799-201-1110 | Cable | Measure exhaust temperature iraulic tester ressure gauge : 2-5, 5.9, 39.2, 58.8 MPa 799-101-5001 | Hydraulic test Pressure gauge 25,58, 92; 588 MPa i ressure gauge: 49MPa Olt pressure © | 790-201-1203 | Digital hyerouictestor | Pressure gauge: S2MPA, MPa 789-401-2220 | Hydraulic gauge ee aa es 0-69 MPa (0-70 Kg/em® 1 795-502-1590] Gauge bly Kit part No. 795-502-1205 Compression pressure | D - 2 | 795-502-1360 | Adapter | a 1) 7992011511 | Toot 799-201-1541 | Gauge Bees ae Kit part No, 799-201-1508 799.201.1571 | Tube 4) 799.201.1450} Adapter | a | ¢ | Commercaty| pester gauge Intake valve 0.33 mim Metta 7 available Feeler gauge exhaust valve : 0.71 mm Discoloration: 0~ 70% 1} 799-201-9000 | Handy smoke checker | {with standard colon oo : (Discoloration x 110 = Bosch index) { a Commercially 2 Commercially! Smoke meter 2 Boost pressure H | 799-401-2310 | Pressure gauge 1,500 mm Hg s | | 79A-264-0090| Push-pull scale 0~ 490.3 Nm (0-50 kg) Operating force - 794-264-0020) Push-pull scale 0 204.21Ne (0-30 kg) Commercially Be Stroke, hydrautie dein | y | Commercialy| scajg = Work equipment spped | K | COMMELIY Stopwatch = 799-601-8000 | T-adapter kit | Troubleshooting of i fe wiring harness sensor 799-601-7320 | Adapter assembly Troubleshooting of | yy | Commercially] tase, a voltage, resistance value available 20-8 o14U02014U02 ADJUSTING VALVE CLEARANCE 1. Remove the cylinder head cover. 2. Rotate the crankshaft in the normal direction. While watching the movement of the intake valve of the No. 6 cylinder, bring the No. 1 cylinder into the top dead center position of the compression stroke and align the "1.6 TOP" mark on vibration damper (1) with pointer (2). + When the No. 1 cylinder comes near the top dead center of the compression | [ ) Th stroke, the No. 6 intake valve will start to saori227 ‘move (open). 3. Adjust the valve clearance for valves marked in the valve arrangement chart. 4, Rotate the crankshaft in the normal direction % Valve arrangement chart by one revolution and adjust the valve clear- ‘ance for the remaining valves marked © Crincero [7 1273 14] 5] @ fexmavevave | Je] fo] [el [ol del > invexe vave {el {e] fel [el [el fo To adjust the valve clearance, loosen lock nut (4) on adjustment screw (3), insert feeler gauge F corresponding to the specified clearance between crosshead (5) and rocker arm (6), and adjust the clearance with the adjustment screw until the thickness gauge can slide lightly. 6150F201 5. After the clearance is properly adjusted, tighten the lock nut to secure the adjustment screw. a Lock nut: 68.6 + 4.9 Nm (7+ 0.5 kgm) The engine firing order is 1—5~3-6~2~4 Intake and exhaust valve clearances may be adjusted for each cylinder in the firing order by rotating the crankshaft 120° at a time in the normal direction. % For details about valve clearance, see STAN- DARD VALUE TABLE FOR ENGINE ae 20-9MEASURING COMPRESSION PRESSURE MEASUREMENT PROCEDURE A, Wile measuring the compression pressure, take care not to burn yourself on the exhaust ‘manifold or muffler, and be careful not to get caught in any revolving part of the engine. %* Measure the compression pressure while the engine is warm. (Oil temperature: 40 ~ 60°C) 1. Adjust the valve clearance properly. For details, see ADJUSTING VALVE CLEARANCE. 2. Remove spill tube (1) and disconnect fuel injection pipe (2) 3. Remove nozzle holder assembly (3) for each cylinder. & Remove the nozzle holder assembly by prying it with two mounting bolts. % Take care not to let any dirt or foreign ‘matter get into the cylinder. 4. Install adapter D2 to the nozzle holder mounting section of the cylinder to be measured, and tighten the adapter to the specified torque. wm] Torque: 21.6 + 29 Nm (2.2 + 0.3kgm) 5. Connect compression gauge D1 to the adapter. 6. Place the fuel control lever in NO INJECTION position, crank the engine with the starting motor, and read the gauge when the pointer is stabilized. A, 110% do not put the fuel control lever in NO INJECTION position, fuel will blow out. % Most compression leakage can be prevented by applying a small amount of oil to the mounting section of the adapter. % For the reference values of the compression pressure, see STANDARD VALUE ‘TABLE FOR ENGINE, 20-10 140F 12274 140612276 o14u02o1au02 MEASURING BLOWBY + Raise the coolant temperature to the operating range before measuring. |. Install tools E4, E1 to the tip of engine breather hose (1), then connect it to tools E3, E2 . Run the engine at rated output, and measure the blow-by pressure. A, Wren measuring, be careful not to touch any hot parts or rotating parts. + The blow-by should be measured with the engine running at rated output. © When measuring in the field, a similar value can be obtained at stall speed. * If itis possible to check at rated output or stall speed, measure at high idling. In this case, the blow-by value will be ‘about 80% of the value at rated output. Blow-by varies greatly according to the condition of the engine. Therefore, if the blow-by value is considered abnormal, check for problems connected with defective blow-by, such as excessive oil consumption, defective exhaust gas color, and prematurely dirty or deteriorated oil 140F12276-3 20-11ADJUSTING FUEL INJECTION TIMING There are two methods for checking and adju: the fuel injection timing of an injection pump. © The "MATCH MARK ALIGNMENT” method, which is used when the injection pump is installed to the original engine and the pump is not being repaired. * The “DELIVERY VALVE” method, which is used when a repaired or replaced injection pump is installed to the engine. + Before inspecting and adjusting the fuel injection timing, bring the No. 1 cylinder piston to the top dead center of the compression stroke, For details, see ADJUSTING VALVE ‘CLEARANCE. CHECKING AND ADJUSTING BY THE MATCH MARK ALIGNMENT METHOD 1. With No. 1 cylinder piston at TOP position, rotate the crankshaft 30° to 40” in the reverse direction, 2. Align the injection timing stamp fine on crankshaft damper (1) with pointer (2) by slowly rotating the crankshaft in the normal direction. 3. Confirm that stamp line a on the injection pump js aligned with stamp line b on the coupling. % If the stamp fines are out of alignment, loosen nut (3), align the stamp lines by shifting the coupling, and tighten the nut. G5) Nut: 60.7 + 2.0 Nm (6.2 + 0.2 kam) CHECKING AND ADJUSTING BY THE DELIVERY VALVE METHOD 1. Disconnect fuel injection pipe (4) for the No. 1 cylinder. 2. Remove delivery valve holder (6). 20-12 140 12279| o14u02o14u02 Remove spring (6) and delivery valve (7) from the delivery valve holder, and reassemble the delivery valve holder. Place the fuel control lever in FULL position, slowly rotate the crankshaft in the normal direction while operating the priming pump, and observe the position when the fuel stops flowing out of the delivery vaive holder. In the position where the outflow of fuel stops, check the injection timing stamp line on the crankshaft damper to see if it is aligned with the pointer. 4 If the injection timing stamp line passed through the pointer The injection timing is late. 4% If the injection timing stamp line did not reach the pointe The injection timing is advanced. If the inspection shows that the injection timing is out of adjustment, adjust the fuel injection timing in the following manner. After the checking and adjusting, be sure to reassemble the spring and the delivery valve. 1) Rotate the crankshaft 30° to 40° in the reverse direction, starting from TOP position in No. 1 cylinder 2) Align the injection timing stamp line on damper (1) with pointer (2) by slowly rotating the crankshaft in the normal direction, 3) Loosen nut (3) on the injection pump. mounting flange slot, and rotate the flange on the pump side little by little by operating the priming pump until no fuel flows out of the delivery valve holder. 4) Tighten the nut on the injection pump mounting flange slot. Recheck the injection timing to see if it is properly adjusted. Som) Nut: 60.7 +2.0 Nm (6.2 + 0.2 kgm) 5) Align match mark a with mark b and stamp the marks. 140F12280 140Fi 2282 20-13MEASURING EXHAUST COLOR © When measuring in the field where there is no air or electric power supply, use tool G1; when recording formal data, use tool G2. % Raise the coolant temperature to the operating range before measuring. B. © <272Ful not to touch any hot parts when removing or installing the measuring tools. Measuring with G1 1) Install filter paper to tool G1. 2) Insert the exhaust gas suction port into the exhaust pipe, accelerate the engine suddenly, and operate the handle of tool G1 at the same time to collect the exhaust gas on the filter paper. 3) Remove, the filter paper and compare it with the scale supplied to judge the condition. Measuring with G2 1) Insert probe ( into the outlet port of the ex. haust pipe (1), and tighten the clip to secure it, to the exhaust pipe. 2) Connect the air hose and the socket of the probe hose accelerator switch to tool G2. Keep the pressure of the air supply below 1.47 MPa (15 kg/cm’), 3) Connect the power cord to the AC100V socket. ‘ When connecting the cord, check that the power switch of tool G2 is OFF. 4) Loosen the cap nut of the suction pump, and fit the filter paper. % Fit the filter paper securely so that the exhaust gas cannot leak. 5) Turn the power switch of tool G2 ON. 6) Accelerate the engine suddenly, and depress the accelerator pedal of tool G2 at the same time to collect the exhaust gas color on the filter 7) Place the filter paper used to catch the exhaust gas color on top of at least 10 sheets of, unused filter paper inside the filter paper holder, and read the value shown. 20-14 of 17MF 02146 ope s7Mro247 1702148 o14u02014U02 MEASURING BOOST PRESSURE B® arotul not to touch any hot parts when removing or installing the measuring tools. 1. Remove boost pressure measurement plug (1) (PT1/8), then install the coupler inside oil pressure gauge kit C. 2. Connect the oil pressure measurement hose to the coupler and pressure gauge H (1500 mmHg) When measuring the pressure, be careful not to touch the rotating parts or hot parts, Note: Operate the engine speed at midrange or above, and use the self-seal portion of the gauge to bleed the oil inside the hose. © Insert the gauge about half way, repeat the ‘action to open the self-seal portion, and bleed the oil, 4% If there is oil inside the hose, the gauge will ‘no work, so always bleed the oil 3. Run the engine at the rated speed and read the gauge indicator. 140F12369 20-15MEASURING EXHAUST TEMPERATURE By The temperature sensor is installed to the exhaust manifold, so if the machine is being operated, wait for the manifold temperature to drop before installing the sensor. ‘% Raise the coolant temperature to the operating range before measuring. 1. Remove plug (1) from the exhaust manifold, and install temperature sensor (2). © Temperature sensor: 6215-11-8180 {cable length 610mm) or 6215-11-8170 (cable length 490mm) 2. Connect to digital temperature gauge B with the wiring harness. Measurement procedure 1. When measuring with the torque converter stalled The conditions are only for torque converter stall, so when measuring to exhaust temperature, the core of the sensor will heat up and the torque converter will over- heat before a stable value is obtained 1) Raise the exhaust temperature by using full stall (torque converter stall + hydraulic pump relief) (standard value: Approx. 650°C) In the above condition, cancel the hydraulic relief, and carry out only torque converter stall. if the temperature starts to go down, or goes up without going down, repeat step 1) to raise the set temperature.) Note the stable temperature when the temperature starts to go down, 2 3) 2. When measuring the maximum value for the exhaust temperature Carry out actual work and measure the maximum value during operation. % Use the peak mode (it can store the maximum value in memory) of the temperature gauge function. Note The exhaust temperature varies greatly according to the ambient temperature (temperature of the engine intake air), so if any abnormal value is obtained, carry out temperature compensation, + Compensation — Measured value + 2 (converted ambient temperature — ambient temperature} The converted ambient temperature is taken as 20°C. 20-16 Pre Amalel ae X-type connector (2 pin) Herat 799:201-1110 Temperature} temperate L attorque Festa overeat. + Torque converters ‘Stabe wading possible TMF 02155, 140612371 ——_—_ ~ When measured only 1702157. o1au02o14u02 MEASURING ENGINE OIL PRESSURE + Raise the coolant temperature to the operating range before measuring. 1, Remove pressure measurement sensor (1), then install oil pressure gauge C [0.98 MPa (10 kg/cm’) 2. Start the engine, and measure the oil pressure at low idling and high idling, MEASURING ENGINE SPEED Be careful not to touch any hot parts when removing or installing the measuring tools. + Measure the engine speed under the following conditions: 1) Coolant temperature: Within operating range 2) Power train oil temperature: 70 — 90°C 3) Hydraulic temperature: 45 — 55°C 1. Remove cap (1) from the speed pick-up port, then install the adapter of tachometer A. 2. Connect tachometer A to the adapter with the cable. A Wien measuring the engine speed, be careful not to touch the rotating parts or hot parts. 3. Start the engine and measure the engine speed at high idling and low idling +k When measuring items other than above (torque converter stall), see the measurement procedure for each item. 140F 12367 140F12572 20-17TESTING FAN BELT TENSION 1. Testing fan belt tension ‘© Press the belt with a finger pressure of 58.8 N (6 kg) at a point midway between the fan pulley and alternator pulley, and measure the deflection. 4% Deflection of V-belt: Approx. 10 mm ing belt, 1) Loosen alternator mount bolt (1) and adjustment plate mounting bolt (2). 2) Loosen locknut (3), then tighten adjust- ‘ment nut (4) to adjust the belt tension. 3) After adjusting the belt tension to the standard value, tighten locknut (3), then tighten adjustment plate mounting bolt (2) and alternator mount bolt (1). 20-18 140F12263 aor r2204 o1au02o14u02 MEASURING SPEED AT TORQUE CONVERTER STALL Measure the stall speed under the following conditions. * Coolant temperature: Within operating range ‘© Power train oll temperature: 70 — 90°C ‘+ Hydraulic oll temperature: Min. 50°C Make sure that there is no one near the machine before starting measurements. 1. Remove cap (1) from the engine speed pick-up port, and install tachometer A. 2. Depress the brake pedal securely and place the gear shift lever at position F3. 3. Depress the decelerator pedal, then move the fuel control lever to the FULL position and run the engine at full throttle to stall the torque converter. 4. When the torque converter oil temperature gauge enters the red range, return the gear shift lever immediately to neutral and lower the oil temperature, 5, Repeat the above Steps 2 — 4 three times. 6. Repeat the procedure in Steps 2 — 4 to stall the torque converter. 7. Measure the engine speed at the moment the torque converter oil gauge enters the red range. % After completing the measurement, return the gear shift lever immediately to neutral and run the engine at full throttle to lower the oil temperature. By Meeautions when relieving torque converter: 1) Depress the decelerator pedal before moving the fuel control lever to the FULL position. 2) Release the decelerator pedal gradually and un the engine at full throttle. For safety reasons, always keep your right foot near the decelerator pedal until the measurement operation has been completed, l 140F12991 Gauge pane! Red =) 20-19ADJUSTING FUEL CONTROL LINKAGE Serial No. : 1001 - 3033 140F 2208 1. Adjust the length of rod (1) to dimension A, then connect throttle lever (2) and lever assembly (3). % Dimension A: 468.5 mm. 2. Set governor lever (4) of the fuel injection pump to the LOW IDLING position, align lever assembly (3) with the low idling detent position, then adjust rod (5) and connect cable (6). 3. Place governor lever (4) of the fuel injection pump at the FULL position, set clearance b between the lever of lever assembly (3) and stopper bolt (7) to 0, then turn stopper bolt (7), back two turns from this position and secure stopper bolt (7) in position. 4, Place governor lever (4) of the fuel injection Pump at the STOP position, set clearance ¢ between the lever of lever assembly (3) and stopper bolt (8) to 0, then secure stopper bolt (8) in position. 20-20 © o14u02o1auo2 Adjust the height of stopper bolt (10) of decelerator pedal (9) to dimension D. ¥ Stopper bolt height dimension D: 21 mm. . Set governor lever (4) of the fuel injection pump to the LOW IDLING position, depress decelerator pedal (9) until it contacts stopper bolt (10), then connect cable (11), yoke (12), and rod (13). + Standard installed length of rod (13): 88.1 mm. In the condition in Step 5, adjust with cable (11) and yoke (12) 50 that clearance e at the ‘oblong hole of yoke (12) is 0. + When doing this, check that governor lever (4) of the fuel injection pump does not move from the low idling position. 3. Start the engine, move throttle lever (2) to the FULL position, then depress decelerator pedal (9) until it contacts stopper bolt (10), and adjust the height of stopper bolt (10) so that the ‘engine speed is 900 + 25 rpm. 14012290 140F12291 20-21TESTING AND ADJUSTING Serial No. 3034 and up ADJUSTING FUEL CONTROL LINKAGE 2 " B 6 1 Adjust the length of yoke (1) to dimension A, then connect throttle lever (2) and lever assembly (3). Dimension A: 52.5 mm Set governor lever (4) of the fuel injection pump to the LOW IDLING position, align lever assembly (3) with the low idling detent position, then adjust rod (5) and connect cable (6). Place governor lever (4) of the fuel injection pump at the FULL position, set clearance b between the lever of the lever assembly (3) and stopper bolt (7) to 0, then turn stopper bolt (7) back two turns from this position and secure stopper bolt (7) in position. Place governor lever (4) of the fuel injection pump at the STOP position, set clearance ¢ between the lever of lever assembly (3) and stopper bolt (8) to 0, then secure stopper bolt (8) in position. 20-21-1 @ 014U02o14u02 Adjust the height of stopper bolt (10) of decelerator pedal (8) to dimension D. * Stopper bolt height dimension D: 21 mm. Set governor lever (4) of the fuel injection pump to the LOW IDLING position, depress decelerator pedal (9) until it contacts stopper bolt (10), then connect cable (11), yoke (12), and rod (13). %* Standard installed length of rod (13) 88.1 mm In the condition in Step 5, adjust with cable (11) and yoke (12) so that clearance e at the oblong hole of yoke (12) is 0. %* When doing this, check that governor lever (4) of the fuel injection pump does not move from the low idling position. Start the engine, move throttle lever (2) to the FULL position, then depress decelerator pedal (9) until it contacts stopper bolt (10), and adjust the height of stopper bolt (10) so that the engine speed is 900 rpm: 140612290 140F12291 20-21-2 @ADJUSTING STEERING AND DIRECTIONAL LEVER, GEAR SHIFT LEVER, PARKING BRAKE LEVER LINKAGE Serial No. : 3001 - 3033 % Tighten the locknut of the cable and rod securely, then bend the cotter pin securely. + Speed range selector lever (1) and directional selector lever (2) are installed to the transmission control valve, and the speed position and directional position are set by the detent inside the valve. 1. Adjusting steering linkage 1) Connect rods (3) and (4) 4% Standard length of rod (3): 380 mm Standard length of rod (4): 375.2 mm 2) Pull both rods (3) and rod (4) at 9.8 — 19.6N (1 — 2 kg) towards the front of the machine, and set lightly in contact with the clutch spool inside the steering valve. 3) In the condition in Step 2, the set clearance ‘@ at the oblong hole in the yoke of rod (4) to 0, then turn the turnbuckle of rod (3) to adjust clearance b of the oblong hole to 0.1 0.2mm, 4) Connect all the steering linkages. 5) With steering and directional lever (5) at the N position, turn turnbuckle (7) to adjust 0 that the distance between the top center ‘and the tip of handle (6) is dimension C. 4 Dimension C: 110 mm 2. Adjusting directional linkage 1) Connect all the directional linkages, 2) Set steering and directional lever (5) at the F position, then turn turnbuckle (8) to adjust so that the clearance from handle (6) is dimension D. % Dimension D: 40 mm 20-22 @ T= 14012306 140F12907 145F12309 o14U02o14u02 3. Adjusting gear shift linkage 1) Connect all the gear shift linkages. 2) Set gear shift lever (9) at the 1st and 3rd position, then turn turnbuckle (11) to adjust $0 that clearances e and f from the notch in slide cover (10) are equal. 1% Clearance dimension @ and: 15 mm 4. Adjusting parking brake lever 1) Set parking brake lever (12) at the FREE position, then connect the parking brake linkage, 2) With parking brake lever (12) at the LOCK position, turn turnbuckle (15) to adjust so that the clearance at the hole in bracket (14) and lever (13) is dimension g. % Clearance dimension g: 2— 3 mm 3) With lever (16) facing 45° down, loosen bolt (17) and adjust the mounting position of lever (16) so that the play in the forward and reverse direction of steering and directional lever (5) is within + 15 mm. 4) With parking brake lever (12) at the LOCK position, turn rod (18) and adjust so that lever (16) faces 45° downward. ‘® After adjusting, place parking brake lever (12) at the FREE position, place steering and directional lever (5) securely in the F or R position, and apply the lock. Check that the steering and directional lever moves from the F or R position, to the N position 5) With parking brake lever (12) at the LOCK position, adjust the installed height H of the switch so that lever (19) pushes safety switch (20) into the set mark groove. 4% Installed height H: 2.8 mm 140F12810 140F12012 140F2313 20-23TESTING AND ADJUSTING ADJUSTING STEERING AND DIRECTIONAL LEVER, Serial No. 3034 and up * * Tighten the locknut of the cable and rod securely, then bend the cotter pin securely. ‘Speed range selector lever (1) and directional selector lever (2) are installed to the transmission control valve, and the speed position and directional position are set by the detent inside the valve. |. Adjusting steering linkage 1) Connect rods (3) and (4). * Standard length of rod (3): 375.2 Standard legth of rod (4): 375.2 mm 2) Pull both rods (3) and rod (4) at 9.8 - 19.6 N (1 ~ 2 kg) towards the front of the machine, and set lightly in contact with the clutch spool inside the steering valve. 3) In the condition in Step 2, the set clearance ‘a at the oblong hole in the yoke of rod (4) to 0, then turn the turnbuckle of rod (3) to adjust clearance b of the oblong hole to 0.1 - 0.2 mm. 4) Connect all the steering linkages. 5) With steering and directional lever (5) at the N position, turn turnbuckle (7) to adjust so that the distance between the top center and the tip of handle (6) is dimension C. * Dimension C: 100 mm Adjusting directional linkage 1) Connect all the directional linkages. 2) Set steering and directional lever (5) at the F position, then turn turnbuckle (8) to adjust so that the clearance from handle (6) is dimension D. * Dimension D: 37 mm Adjusting speed lever linkage 1) Connect all the speed lever linkages, and adjust turnbuckle (10) so that the "2" display of display plate (9) is in the center of the hole in the “2nd" position. 2) Keep in the same condition as in Step 1) and install the knob so that the ‘2 display of knob (5) is at the front. 20-23:1 @ GEAR SHIFT LEVER, PARKING BRAKE LEVER LINKAGE 140F12307 o14uo2014U02 ADJUSTING STEERING AND DIRECTIONAL LEVER, TESTING AND ADJUSTING GEAR SHIFT LEVER, PARKING BRAKE LEVER LINKAGE 4. Adjusting parking brake lever 1) Connect the linkage and set parking brake lever (11) to the FREE condition, then adjust stopper bolt (12) to give dimension E. * Dimension E: 424 mm * After adjusting, set parking brake lever (11) to the FREE position and check thtat steering and directional lever (5) enters F and R positions securely. Then place the parking brake lever at the LOCK position and check that the steering and directional lever is returned from the F or B position to the N position. 2) With the parking brake lever at the LOCK position, adjust installed height H of the switch so that lever (13) pushes safety switch (14) into the set mark groove. Installed height H: 2.8 mmADJUSTING BRAKE PEDAL LINKAGE % Tighten the locknut of the rod and cable securely, and bend the cotter pin securely. 1. Adjust height B of bumper (2) so that the travel of brake pedal (1) is dimension A. + Brake pedal travel dimension A: 79 mm + Standard height B of bumper: 24 mm 2. Adjust length of rod (3) to dimension C, and install to lever (4). + Dimension C: 850 mm 3. Adjust length of rod (5) to dimension D, and install to lever (6) + Dimension D: 175 mm 4. Push rod (3) towards the back of the machine with a force of 9.8 — 19.6N (1 — 2 kg), and with it pushed lightly against the brake spool inside the steering valve, turn joint (7) only and connect rod (3) and rod (6). 5. With brake pedal (1) at the brake OFF posi tion, adjust the length of the rod so that the play of brake pedal (1) at the center of the pedal is 3 — 8 mm % Turn joint (7) and joint (8) at the same time in the same direction to adjust the length of the rod, 6. With brake pedal (1) at the brake OFF position, check that lever (6) is in contact with bumper (2). 20-24 140F12321 Unit: mm aor 2922 o1auo2oe ADJUSTING WORK EQUIPMENT CONTROL LINKAGE 1. Set length of rod (1) to dimension A, and connect. + Dimension A: 228.4 mm + Check the travel of the lever, and if it is not normal, adjust with rod (1). 01402 20-25MEASURING POWER TRAIN OIL PRESSURE With central pressure detection (Option) B 8208 the machine on level ground, lower the work equipment to the ground and apply the parking brake %* When measuring the hydraulic pressure, remove all the sand and dirt from around the nipple and plug % Raise the power train oil temperature to at 70 = 80°C before measuring, * Refer to the diagram and table below to install il pressure gauge C to the nipple for the circuit to be measured. Table of centralized pressure pick-up port positions and gauges to use when measuring hydraulic pressure Measuring torque converter inlet port and outlet pressure i) Install oil pressure gauge C to torque converter inlet pressure measurement nipple (7) and outlet pressure measurement nipple @). ii) Set the gearshift lever at neutral, and measure the torque converter inlet port Pressure and outlet port pressure with the engine at low idling and high idling, 2. Measuring transmission oil pressure 1) Measuring main relief pressure ’) Install oil pressure gauge C to main relief pressure measurement nipple (1). Set the F-R lever to the N position, and measure the main relief pressure with the ‘engine at low idling and high idling 20-26 No Measurementiocaton yp nn 2 | Left brake actuating pressure 5.9 (60) ssssssnsnannsionsnneeeeeeEEEE 1eort2sa7 False xia rare a o14u02o14u02 2) Measuring modulating pressure (clutch circuit pressure) ’) Install oil pressure gauge € to modulating pressure measurement nipple (6) Note: At the central pressure detection port, it is possible to measure the modulating pressure, but it is not possible to measure the modulating time. (The oil pressure pick-up hose is long and there is a time lag when measuring.) When measuring the modulating time, install the oil pressure measurement nipple directly to the control valve. * Measure the hydraulic pressure when the clutch is actuated with the engine at low idling and high idling when the gearshift lever is operated to all the positions given below. ii) With the FR lever at the N position, measure the modulating pressure at each speed position. ) Place the gearshift lever at F1. Measure the modulating pressure iv) Place the gearshift lever at F2. Measure the modulating pressure. v) Place the gearshift lever at F3. Measure the modulating pressure. % For the following measurements, place the speed lever at position 3, and depress the foot brake securely before measuring vi) * With the engine at low idling, place the FR lever at the F position, and measure the modulating pressure. ‘* Run the engine at high idling, and stall the torque converter, then measure the modulating pressure. Combination of speed range and clutches 7 Gluich] Not [No.2] No.3 [No.4] No 6 No. | cay | 6 | (Bra) | tana | (ist) Fr o o F2 ° ° FS o[° Rt ° ° Fa ° ° Fa oO ° 20-27vii) * With the engine at low idling, place the FR lever at the R position, and measure the modulating pressure. © Run the engine at high idling and stall the torque converter, then measure the modulating pressure. By Precautions when staling the torque converter 1) Depress the decelerator pedal before pulling the fuel contro! lever to the FULL position. 2) Release the decelerator pedal to run the engine at high idling. However, for safety reasons, always keep your right foot on the decelerator pedal until the completion of the measurement operation. 3) Measuring transmission lubricating oil pressure |) Remove lubricating oil pressure measurement plug (9) (PT1/8), and install oil pressure gauge C [1.0 MPa (10 kg/em?)} ii) Place the steering and directional lever at neutral, and measure the lubricating oil Pressure with the engine at low idling and high idling. Note: The oil pressure differs greatly between high temperature and low temperature, so warm up the oil throughly before measuring. For details, see MEASURING ENGINE ‘SPEED AT TORQUE CONVERTER STALL. 3. Measuring steering clutch pressure 1) Install oil pressure gauge C to left nipple (4) and right nipple (5) for measuring the steering clutch pressure. 2) Place the steering and directional lever at the N position for direction, then operate it in the direction of steering fully to the inside or outside, and measure the oil pressure with the engine at low idling and high idling. 20-28 140F12339 4. Measuring steering brake pressure 1) Install oil pressure gauge C to left nipple (2) and right nipple (3) for measuring the steering brake oil pressure. 2) Place the steering and directional lever at the N position for steering and direction, and measure the oil pressure with the engine at ow idling and high idling. % Check at the same time that the hydraulic pressure is 0 Pa (0 kg/cm) when the steering and directional lever is operated fully to the inside or outside, or the brake pedal is depressed, or the parking brake is placed at the LOCK position. 014u02014U02 TESTING AND ADJUSTING Without central pressure detection (STD) A Stop the machine on level ground, lower the work equipment to the ground and apply the parking brake. %* When measuring the hydraulic pressure, remove all the sand and dirt from around the plug. %* Raise the power train oil temperature to 70 — 80 °C before measuring. @ Remove the measurement plug from the circuit to be measured, and install the oil pressue gauge C referring to the diagram and table below. Table of pressure pick-up port positions and gauges to use when measuring hydraulic pressure No,| Measurement location | yp 29° 1 | Transmission main relief pressure | 5.9 (60) 2 | Left brake actuating pressure 59 (60) 3 | Right broke actuating pressure | 5.9 (60) 4 | Left clutch actuating pressure 59 (60) Right clutch actuating pressure | 6.9 (60) 6 | Transmission modulating pressure (#1) | 5.9 (60) 7 | Torque converter inlet pressure (#1)| 2.45 (25) 8 | Torque converter outlet pressure (#1)| 0.98 (10) 9 | Transmission lubricating oil pressure vet)| 0.98 (10), 1. Measuring torque converter oil pressure 1) Measuring torque converter inlet and outlet port pressure (31) i) Remove the torque converter inlet pressure measurement plug (7) and outlet pressure measurement plug (8), and install the oil pressure gauge c. ii) Set the gearshift lever at neutral, and measure the torque converter inlet port pressure and outlet port pressure with the engine at low idling and high idling. 2. Measuring transmission oil pressure 1) Measuring main relief pressure (#2) i) Remove the main relief pressure measurement plug (1), and install the oil pressure gauge C. ii) Set the F-R lever to the N position, ‘and measure the main relief pressure with the engine at low idling and high idling. MEASURING POWER TRAIN OIL PRESSURE ran0079! 20-28-1 @TESTING AND ADJUSTING MEASURING POWER TRAIN OIL PRESSURE 2) Measuring modulating pressure (#1) (clutch circuit pressure) i) Remove the modulating pressure measurement plug (6), and install the oil pressure gauge C. Measure the hydraulic pressure when the clutch is actuated with the engine at low idling and high idling when the gearshift lever is operated to all the positions given below. With the F-R lever at the N position, Combination of speed range and clutches measure the modulating pressure at 7 Clutch] No.1] No.2] No] Noa|Nos oe eee No. | (R) | (F) | (3rd)|(2nd)| (1st) Place the gearshift lever at F1. FI ° Measure the modulating pressure. 7 S S iv) Place the gearshift lever at F2. FS. 2 ° Measure the modulating pressure. eI : Ss v) Place the gearshift lever at F3. RZ ° ° Measure the modulating pressure. a e * For the following measurements, Place the speed lever at position 3, and depress the foot brake securely before measuring. vi) + With the engine at low idling, place the F-R lever at the F position, and measure the modulating pressure. + Run the engine at high idling, and stall the torque converter, then measure the modulating pressure. 20-28-2 5 ® 014u02014U02 TESTING AND ADJUSTING vii) + With the engine at low idling, place the 3) F-R lever at the R position, and measure the modulating pressure. + Run the engine at high idling and stall the torque converter, then measure the modulating pressure. A Precautions when stalling the torque converter + Depress the decelerator pedal before pulling the fuel control lever to the FULL Position. + Release the decelerator pedal to run the engine at high idling. However, for safety reasons, always keep your right foot on the decelerator pedal until the completion of the measurement operation. Measuring transmission lubricating oil pressure (#1) i) Remove lubricating oil pressure measurement plug (9) (PT1/8), and install oil pressure gauge C [0.98 MPa {10 kg/cm?) ii) Place the steering and directional lever at neutral, and measure the lubricating oil pressure with the engine at low idling and high idling. Note: The oil pressure differs greatly between high temperature and low temperature, so warm up the oil throughly before measuring. For details, see MEASURING ENGINE SPEED AT TORQUE CONVERTER STALL. Measuring steering clutch pressure (#3) 1) Remove the left plug (4) and the right plug (5) for measuring the steering clutch pressure, and install the oil pressure gauge C. 2) Place the steering and directional lever at the N position for direction, then operate it in the direction of steering fully to the inside or outside, and measure the oil pressure with the engine at low idling and high idling. MEASURING POWER TRAIN OIL PRESSURE Transaission Torsue converter valve Fron oi cooler 4 19000797 ‘rap00792 4. Measur 1g steering brake pressure (#3) 1) Remove the left plug (2) and the right plug (3) for measuring the steering brake oil pressure, and install the oil pressure gauge C. 2) Place the steering and directional lever at the N position for steering and direction, and measure the oil pressure with the engine at low idling and high idling. * Check at the same time that the hydraulic pressure is 0 MPa (0 kg/cm?) when the steering and directional lever is operated fully to the inside or outside, or the brake pedal is depressed, or the parking brake is placed at the LOCK position. 20-28-3TESTING AND ADJUSTING MEASURING POWER TRAIN OIL PRESSURE fen) tea 4 B dmH) Sika 9000703 Condition of machine when measuring hydraulic pressure Pressure pickup port No. Remarks Pressure can always are be checked 6 Pressure can be checked only when power train unit is being overhauled 7 89 "4: The pressure can be checked only when overhauling the power train unit. »2: The pressure can be checked when the right side cover is removed. 23: The pressure can be checked when the rear cover is removed. 20-28-4 0} o14u02o14u02 A. 3208 the machine on level ground, lower the work equipment completely to the ground, then apply the parking brake. ‘* When installing the oil pressure gauge, remove all the dirt and mud from around the plug. |. Measuring oil pressure 1) Remove plug (1a) for measuring work equipment main relief oil pressure, then install oll pressure gauge C (gauge: 39.2 MPa (400 kg/cm’). 2) Disconnect hoses (left and right: 1 each) at blade RAISE end (head end), and install blind plugs. Or put the blade in contact with a rock face with the RAISE circuit {head end) operated to the mid-point of the stroke, and relieve the RAISE circuit. % It is also possible to measure in the same way by removing measurement plug (1b) at the LOWER end. % Blind plug: 07222-00616 Sleeve nut for blind plug: 07221-20628 ‘© Remove the cap nut (4) from main relief valve (3), then loosen locknut (5) and turn. adjustment screw (6) to adjust. + Turn the adjustment screw to adjust the pressure as follows. ‘* To INCREASE pressure, turn CLOCK- WISE. ‘* To DECREASE pressure, turn COUNT- ERCLOCKWISE. % Amount of adjustment for one turn of adjustment screw: 3.5 MPa (35.7 kg/cm?) Fe Locknut: 30.9 + 3.4Nm (3.15 + 0.35 kgm) "97 Cap nut: 30.9 + 3.4Nm (3.15 + 0.35 kgm) + After adjusting, check the main relief valve oil pressure again 6 MEASURING AND ADJUSTING BLADE CONTROL OIL PRESSURE sen 20-29BLEEDING AIR FROM HYDRAULIC CYLINDER % When operating the hydraulic cylinders for the first time after replacing or reassembling the cylinders or piping, always bleed the air from the hydraulic cylinders as follows: 1) Start engine and run at low idling for approx. 5 minutes. 2) Run the engine at low idling, and raise and lower the blade 4 — 5 times. 3) Run the engine at high idling and repeat Step 2), then run the engine at low idling and operate the piston rod to relieve the circuit. RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT There is no accumulator installed, so the remaining pressure in the piping between the control valve and hydraulic cylinder cannot be released by operating the control levers. When the above piping is removed, be careful of the following points 1, Run the engine at low idling, operate the hydraulic cylinders as far as possible so that the pressure is not relieved at the end of the stroke, lower the work equipment to the ground, and stop the engine. % If the engine is stopped with the hydraulic circuit relieved and the hydraulic cylinder at the end of its stroke, do not carry out any work for 5 to 10 minutes. 2. When removing the piping, loosen the piping sleeve nut gradually to release the pressure remaining in the piping slowly, then remove the piping after the oil stops spurting out. 20-30 @o14u0z PROCEDURE FOR SIMPLE TEST OF STEERING BRAKE PERFORMANCE % Carry out the measurement under the follow: ing conditions. '* Coolant temperature: Within operating range Power train oil temperature: 70 — 90°C 1. Stop the machine on a fiat road surface with the blabe in the travel posture, 2. Run the engine at low idling, depress the brake pedal securely, and place the gearshift lever at Fa. 3. Depress the decelerator pedal and pull the fuel control lever to the FULL position. 4, Release the decelerator pedal gradually, raise the engine speed to high idling, and check that the machine does not move. By Duting the measurement, keep your right foot on the decelerator pedal, and if the machine starts to move, quickly depress the decelerator pedal and return the gearshift lever to neutral. Note: If this test is carried out in F1, an excessive load will be brought to bear on the brake. For this reason, never use F1; always use F2 ‘o00893 20-31PROCEDURE FOR TESTING SENSORS 1. Engine oil pressure sensor 1) Stop the engine and turn the starting ‘switch OFF (eg egeta sees 2) With the ‘sensor still installed to the engine, disconnect the wiring harness from the sensor. Measure the resistance between the terminal and the chassis with the engine stopped and with the engine running, 7 i} 3) % Judgement Structure of The following results show that the sensor 202F05175 is normal 1. Plug Engine oll pressure over ame 2. Contact rin 50 KPa (0.5 kglem?) " ou a Contacte Engine ol pressure under ontinut 4. Diaphragm 50KPa (08 tafe — 5. Spring 6. Terminal 2, Coolant temperature, Power train oil tem- erature sensor 1) Stop the engine, turn the starting switch OFF, and remove the sensor from the engine or torque converter. 2) Measure the resistance between terminals 1 and 2 with the sensor at about the same temperature as the ambient temperature. + Judgement The following results show that the sensor is normal * Coolant temperature sensor ‘Power train oil temperature sensor ‘Ambient temperature When normal “Ambient temperature When norm ‘Approx. 135°C ‘Approx 11.02 ‘Approx, 135% ‘Approx 11.08 i ' i 1 ‘Approx. 102°C ‘Approx. 25.69 ‘Approx. 120°C Approx. 1582 1 1 1 i Approx. 67°C Approx. 7842 Approx. 50% Approx. 153.4 7 i Approx. 50°C Approx. 153.49 1 el 1. Connector 7 2. Plug 3. Thermistor Structure of ceca ar 02s 20-32 o14u02014U02 TROUBLESHOOTING Points to remember when troubleshooting Sequence of events in troubleshooting Point to remember when carrying out maintenance Check before troubleshooting Method of using troubleshooting charts ... ‘Type of connector and position of installation Connector position drawing ‘ Connection table for connector pin number: Electrical circuit diagrams for each system Troubleshooting of engine system ($ mode! coe Troubleshooting of hydraulic, mechanical system (H mode) ... Troubleshooting of electrical system (E mode! Troubleshooting of machine monitor system (M mode). 20-107 20-33‘TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING A Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted. A Wren carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near. Ai If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for the engine to coo! down before starting troubleshooting. Be extremely careful not to touch any hot parts or to get caught in any rotating parts. A Wren disconnecting wiring, always disconnect the negative (-) terminal of the battery first. & When removing the plug or cap from a location which is under pressure from oil, water, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly. The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1. When carrying out troubleshooting, do not 2) Check for any external leakage of oil from hurry to disassemble the components. the piping or hydraulic equipment. If components are disassembled immediately 3) Check the travel of the control levers. any failure occurs: 4) Check the stroke of the control valve + Parts that have no connection with the fail- spool. ure or other unnecessary parts will be dis- 5) Other maintenance items can be checked assembled. externally, 80 check any item that is con- + Itwill become impossible to find the cause sidered to be necessary. of the failure. 4. Confirming failure It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out through prior investigation and to carry out troubleshooting in accordance with the fixed proce- Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. ‘* When operating the machine to reenact. the troubleshooting symptoms, do not carry out any investigation or measure- dure. ment that may make the problem worse. 2. Points to ask user or operator 5. Troubleshooting 1) Have any other problems occured apart Use the results of the investigation and in- from the problem that had been reported? spection in Items 2 - 4 to narrow down the 2) Was there anything strange about the ma- causes of failure, then use the troubleshoot- chine before tha failure occurred? ing flowchart to locate the position of the 3) Did the failure occur suddenly, or were failure exactly. there problems with the machine condition * The basic procedure for troubleshooting before this? is as follows. 4) Under what conditions did the failure oc- 1) Start from the simple points. cur? 2). Start from the most likely points. 5) Had any repairs been carried out before the 3) Investigate other related parts or in- failure? formation. ‘When were these repairs carried out? Measures to remove root cause of failure 6) Has the same kind of failure occurred be- Even if the dailure is repaired, if the root fore? 3. Check before troubleshooting cause of the failure is not repaired, the same failure will occur again. 1) Check the oil level. To prevent this, always investigate why the problem occureed. Then, remove the root cause. 20-34 ® o14u02014U02 ‘TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING Gob som ae 2 conan of falure 2 shop manual to find locations of po Work being cried out atthe time ofthe 1) Look at the troubleshooting sation ofthe ewoo1 90] 20-35 @‘TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and re- Pairs must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil). 1 ” POINTS TO REMEMBER WHEN HANDLING ELECTRIC EQUIPMENT Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting ‘one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are fre- quently removed and installed again, so they ly to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses. Main failures occurring in wiring harness © Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces. @® Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the pl ing at the joint will peel and cause improper connection or breakage. 20-36 Improper insertion Tewoot92 Tewoo193 o14u02014U02 ‘TROUBLESHOOTING @ Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken. ® High-pressure water entering connector The connector is designed to make it diffi cult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. As already said, the connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be short- circuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it. © Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a con- ing the mating portion of the connector, be careful not to use excessive force or deform the pins. + If there is oil or water in the compressed air, the contacts will become even dirtier, 0 remove the oil and water from the compressed air completely before cleaning with compressed air. POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE rewoorss 20-37‘TROUBLESHOOTING 2), Removing, installing, and drying connectors and wiring harnesses © Disconnecting connectors @ Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors and not the wires. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. * Never pull with one hand. ® When removing from clips When removing a connector from a clip, pull the connector in a parallel direction to the clip. Ifthe connector is twisted up and down or to the left or right, the housing may break. @® Aection to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. * If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector. 20-38 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE Press tientiy 0 Tev00197 Catches Tav00485 014U02o1au02 ‘TROUBLESHOOTING © Connecting connectors @ Check the connector visually. 1) Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). 2) Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. 3) Check that there is no damage or breakage to the outside of the connector. If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. ‘If there is any damage or breakage, replace the connector. Fix the connector securely. Align the position of the connector correctly, then insert it securely. For connectors with lock stopper, push in the connector until the stopper clicks into position. Correct any protrusion of the boot and any misalignment of the wiring harness For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp. is out of position, adjust it to its correct position. Ifthe connector cannot be corrected easily, remove the clamp and adjust the position. If the connector clamp has been removed, be sure to return it to its original po Check also that there are no loose clamps. POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE _-Cliks inte sosition Tewoo19s 20-39TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE. © Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure wa: ter or steam directly on the wiring harness. If water gets directly on the connector, do as follows. © Disconnect the connector and wipe off the water with a dry cloth. * If the connector is blown dry with compressed air, there is the risk that oil the air may cause defective contact, so remove all oil and water from the compressed air before blowing with air. rewonrs6 to dry the connector. ‘* Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector. Ss @ _Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer . rewouea © 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. %* After completely drying the connector, blow it with contact restorer and reassemble. Tevo0203 o1auo2o1au02 TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 3) Handling control box ® The control box contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the control box. ® Do not open the cover of the control box unless necessary. Tewonoe @ Do not place objects on top of the control box. @ Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. © During rainy weather, do not leave the control box in a place where it is exposed to rain. © Do not place the control box on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the control box. Fit an arc welding ground close to the welding point. 8 rewoues 2. Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connect connectors. 2) Before carrying out troubleshooting, check that all the related connectors are properly inserted. * Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. % If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated. 4), When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. If there is any change, there is probably defective contact in that circuit. 20-41TROUBLESHOOTING 3. POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT With the increase in pressure and precision of hy draulic equipment, the most common cause of fai ure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful. 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) 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, 80 it is desirable to use unit exchange. Disas- sembly and main-tenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be confirmed with special test equipment. 3) Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is 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. 4) Do not let any dirt or dust get in during refilling operations. Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method. 20-42 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE o1auo2014u02 ‘TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 5) 6) n Change hydraulic oil when the temperature is high. When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil, 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 sec- ondary flushing is carried out with the specified hydraulic oil. Cleaning operations After repairing the hydraulic equipment (pump, control valve, etc.) or when running the 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 effective device. Tewoo210 20-43CHECKS BEFORE TROUBLESHOOTING Judgement nen standard Remedy 1. Check fuel level = [Aad fuer 2. Check for dirt oF water in fuel = | Clean, drain | 3 Check hydraulic oi level = [add oi 2 § | 4 Check hydraulic oll strainer = | clean, dai 2 | § 2 | & check power tain ol level = |Add oi 8 | 5 | 6 check engine oil evel (level of ol in oil pan) - Add oil & | 38 | 7. check cooting water level = | add water g 8. Check condition of dust indicator = | lean or 3 replace 3 9. Check for loose or corroded battery terminals or wires - Tighten or bl ge replace £ E | 10. check for loose or corrode altornator terminals or wies — | Tahten or gs replace © & | 11, Check for loose or cooraded starting motor terminals or wires - Tighten or replace $B 2] 12. Check tor abnormal noise or smell - Repair 8B 8] 13. check for oil leakage - Repair S32 FE 8| 14. Bleed air rom system — | Bleed sir 15. Check battery voltage (engine stopped) 20—s0v | Replace 16. Check level of battery electrolyte = |Add or z replace 2 |, |17. Check for discolored, burt, or bare wiring — | Replace B | § | 18. check for missing wiring clamps, hanging wires — — | Repair | § | 19. checks for water leaking onto wiring (check carefully for water - Dry area s| 3 leakage at connectors and terminals) around &| § connector | 20. Check for broken or corroded fuses — | Replace | 21. check alternator voltage (engine running at over half throttle) After running | Replace 3 engine for a several minutes 275—295V 22. Noise when battery relay is operated. — | Replace (Turns starting switch ON — OFF) 20-44 o1auo2TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS 3. Using troubleshooting chart for engine-related failure This troubleshooting chart is divided into three sections: questions, check items, and troubleshooting. The questions and check items are used to pinpoint high probability causes that can be located from the failure symptoms or simple 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 B are items that can be obtained from the user, depending on the user's level. [Check items] The serviceman carries out simple inspection to narrow down the causes. The items under © in Causes the chart on the right correspond to this. The serviceman narrows down the causes from information @ that he has obtained from the user and the results of © that he has obtained from his own inspection. Troubleshooting] Troubleshooting is carried out in the order of [vyi2y{ay probability, starting with the causes that have been marked as having the highest probability from information gained from {Questions} and [Check items}. 2 @ | 2 (b) ° 3 (o) ° eS @ |o @ o g ©jls Pi : i e Ig i e 38 ii e Es 20-46 01402o14U02 ‘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 |, and of these, causes that have a high probability are marked with T. Check each of the [Questions] and [Check items] in turn, and marked the ! or T 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. 21. For [Confirm recent repair history] in the [causes {Questions} Section, ask the user, and mark the Cause column with # to use as reference / for locating the cause of the failure. How- F ever, do not use this when making calcula- £ tions to narrow down the causes. if #2, Use the # in the Cause column as reference é) |e for [Degree of use (Operated for long pe- S/=/_/%, ig riod)] in the [Questions] section as reference. /§/8/ 8/2 [# As a rule, do not use it when calculating the s/2/8/8/8/ 8 points for locating the cause, but it can be #/é/8/z/$/§ included if necessary to determine the order [$/2/2/8/8/&, for troubleshooting. 5/$/$/s/s/s 11 [Contvn recent repair history 12 [Degree of ure Operated or long patiod Al a[A| 20-47‘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 [Dust indicator is red]. If we look from these three symptoms to find the causes, we find that there is a relationship with five causes. Let us explain here the method of using this causal relationship to pinpoint the most probable cause. ‘S-7 Exhaust gas is black (incomplete combustion) General causes why exhaust gas is black omar + Insufficient intake of air + Improper condition of fuel injection + Excessive injection of fuel (3 Poae case song ton Oana en) © Mtoe ca on Om iS Stemeisconn ne cone “ere aaa js — char nl tn pga ugar asta fa bree ochre ond eed noe ‘Chak tome Wien eset rc db gpd 20-48 01402014U02 TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS — 11 Five causes i J 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. Three symptoms| Step 2 ‘Add up the total of Oand Omarks where the horizontal lines for the three symptoms and the vertical columns for the causes intersect. (1) Clogged air cleaner element: 000 (2) Air leakage between turbocharger and head: 00 (3) Clogged, seized injection nozzle: ° (4) Defective contact of valve, valve seat: © (5) Worn piston ring, cylinder: 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 @. The Remedy is given as [Clean], so carry out cleaning, and the exhaust gas color should return to normal. 20-49METHOD OF USING TROUBLESHOOTING CHARTS 1. Category of troubleshooting code number ‘Troubleshooting code No. ‘Component 5-00 Engine H-00 Power train, work equipment (Hydraulic, mechanicel system) £00 Eloctronic system M-00 Machine monitor 2. Method of using troubleshooting table @ Troubleshooting code number and problem The top left of the troubleshooting chart gives the troubleshooting code number and the problem with the machine. @ Distinguishing condition Even with the same problem, the method of troubleshooting may differ according to the model, component, or problem. In such cases, the troubleshooting chart 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. @ Method of following troubleshooting chart * Check or measure the item inside the box, and according to the answer follow either the YES line or the NO line to go to the next box. (Note: The number written at the top right corner of the box is an index number; it does not indicate the order to follow.) ‘* Following the YES or NO lines according to the results of the check or measurement will lead ally to the Cause column. Check the cause and take the action given in the Remedy column on the right. ‘* Below the box there are the methods for inspection or measurement, and the judgement values. If the judgement values below the box are correct or the answer to the question inside the box 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 box is given the preparatory work needed for inspection and measurement, and the judgement values. If this preparatory work is neglected, or the method of operation or handling is mistaken, there is 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). @ General precautions When using the troubleshooting chart, precautions that apply to all items are given at the top of the age and marked with %. The precautions marked % are not given in the box, but must always be followed when carrying out the check inside the box. © Troubleshooting tools When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For details, see TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING, @ Installation position, pin number A diagram or chart is given for the connector type, installation position, and connector pin number ‘connection table, so when carrying out troubleshooting, see this chart for details of the onnector pin number and location for details of the connector pin number and locations for inspection and measurement of wiring connector number OO appearing in the troubleshooting flow chart. 20-50 o14u02o14u02 Example 1 @_M-3. When starting switch is ON (engine stopped), CHECK items shown abnormality @® a) Abnormality in radiator water level * Radiator water level monitor flashes Cause Remedy ves petecrerateorwater | papace 4 See. yes 3 VES Defective monitor module. Replace as Ea 2p esitatien LY Oar contc con , Rabeitemaes Lp ween eros Saas NE NO} Sees etsy" | feerenace EIRSBE No] Siena ios = en Pha * breerest eno. Secs Seat | Aisa @ _& Before carrying out troubleshooting, check that all the related connectors are properly inserted, % Always connect any disconnected connectors before going on the next step. 20-51TYPE OF CONNECTOR AND POSITION OF INSTALLATION %& The ADDRESS column in this table shows the address in the connector position drawing (3-dimensional drawing) non [ type” |"Sne | Pecworese |RSS] Pest Pousc | Nec] race ore [ape eta 1 | Rear amp wa] fous [ — fap — H-3 om [ow far] — ra] | cnas iy 1 oe fom fal — ve] [cx [owes | 4 @-2 eN3 x H-9 | cna x 3 H-2 ows [x [+ [immomeemeror aa] Foxe | x | 2 | mmmedaicomee [ona NAb x 4 | Intermediate connector Je7 CN29 1 ~ G-3 os fom fal — exo [| x [af — Fo cme | M | 1 [hesttemttcanerigny [C-3] | onor | swe | x6 | iemeting somecior |g ene | nes | | tom c-3] | ens | swe | ao | intermediate connecor Tyg [cx | x | + | reodtomp vets c-o] Jom | x [oa] — 87 eves | x | 2 |smtermedotecomecr fe-1] [ens | — | 6 | — 8.7 cuss [x | 2 | Headtame eight 6-3] [ens [nes | 3 | eimotatsinor 87 ona | swe | o | — e-8{ [ow | Kes | 4 | Giowoniten D7 conte x 1 - Fat] | ener | kes | a | oteoa serten cr exis [x [2 | Sacantmpeawre 151 Pcwwe | nes | «| Ugitng ies 7 CNI6 x 2 | Starting motor e-8 CNS [a - 1a car? | swe | 6 | imermesisteconnector [e-2| | ones | x | 9 | neutatsatewswien [1a ewe [tf | atornator e-2] | cnse + | Horn switch 4-9 ons | swe fe | ra] [ onse [x [2 | Power wan oi na| enzo | swe | 6 | mermeciaw-conmecor |-a| | cxoo | swe | 0 | momedate conmector 5g cna + | Horn switch nea] | enzz | swe | | staring swicn be? ‘N23 x 2 | Intermediate connector 1-3 - 20-52 o14u02CONNECTOR POSITION DRAWING o Ea = 20-53TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS CONNECTION TABLE FOR CONNECTOR PIN NUMBERS. * The terms male and female refer to the pins, while the terms male housing and female housing refer to the mating portion of the housing, No. X type connector of pins Male (female housing) Female (male housing) 2 Wy} 7 2 ‘rewoo22 Tener? 1 3 3 [ a zZ 1 1 : (EGE 2 4 2 20-54 19ME0219ME02 TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS. No. ‘SWP type connector of pins Male (female housing) Female (male housing) 6 8 o o |) a= 0 2 7 1841 4 fg b 16 8 io‘TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS. No. M type connector of pins Male (female housing) Female (male housing) f e ae ei ‘BLPOONIS ‘2uP00039 2 3 : EG HE - - HE 3 ‘ case 4 & ut 7} aD 4 fas 5 ‘surccoat 20-56 19ME0219ME02 ‘TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS No. pins S type connector Male (female housing) Female (male housing) Tewomso 10 12 © gag) =e) Boy 2 5 rewo0rse 16 6 7 ewoors 20-57TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS No. MIC connector of pins Male (female housing) Female (male housing) 7 1 3 5 ‘ 5 eo 4 5 TT s xr 1 —> 5. _— 7 Sverre Eites 3 6 7 9 6 i 13 a a rewoonsa reworse 20-57-1 19ME0219ME02 TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS No. of pins AMPO40 type connector Male (female housing) Female (male housing) 4 a 12 16 rewoorse 20 20-57-2‘TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS: No. AMPO70 type connector of pins Male (female housing) Female (male housing) 8 2 20-57-3 19ME0219ME02 TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS. No. of pins L type connector Male (female housing) Female (male housing) 20-57-4‘TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS No. Automobile connector of pins Male (female housing) Female (male housing) 2 eee 2 19ME02TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ) No. Relay connector of pins Male (female housing) Female (male housing) _ ) pea eee eee ere ‘ ia} | 5 i C we 8 vos 6 = 2 ) 6 4 3 6 5 6 Q ° maven ; i om 20-57-6ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM MACHINE MONITOR Intake aie heater relay swe aif Power vain al iemperature \9=00e, - Engine ol pressure lamp i — CNSOOKS) 20-58 Lighting switch Ligting switch (Rearlamp) (Head lamp) Intake ai heater (ee Staring switch _—_Bimetal iz timer Giow switch ‘Starting motor Aliemator ed Tp g|'swrie cnaol” cnzeixar inisor le ewraos Head amp (LH) Head lam(R.H.) Engine oll pressure Coolant temperature gauge Powertrain ot temperature sensor Rear amp zonvLoo14u02 sa $2 83 s4 ss sé 87 88 so S10 sa $12 $13 S14 S15 S16 TROUBLESHOOTING OF ENGINE (S MODE) Starting performance is poor (Starting always takes time) en. eee O60 Engine does not start ® Engine dos not turn. 20-61 Engine turns but no exhaust gas comes out (Fuel is not being injected) . 20-62 3) Exhaust gas comes out but engine does not start (Fuel is being injected 20-63 Engine does not pick up smoothly (Follow-up is poor) . 20-64 Engine stops during operations... -. 20-65 Engine does not rotate smoothly thunting) 20-66 Engine lacks output (no power. 20-67 Exhaust gas is black (incomplete combustion)... 20-68 Oil consumption is excessive (or exhaust gas is blue). S200) Oil becomes contaminated quickly 20-70 Fuel consumption is @XCESSIVE xrnisnsrninmnsninennansnn eer oy] Oils in cooling water, or water spurts back, or water level go0s GOWN ..runsssnsnsesnsnee 20-72 Oil presure lamp lights up (drop in oil pressure) 20-73 Oil lovel rises... 20-74 Water temperature becomes too high (overheating) 20-75 Abnormal noise is made 20.76 Vibration is excessive nnnsnsnnnsninens ee : 20-77 + Whith the S mode, use the same matrix, regardless of whether a turbocharger is installed or not. 20-59S-1 Starting performance is poor (Starting always takes time) General causes why starting performance is poor * Defective electrical system Insutficient supply of fuel + Insufficient intake of air + Improper selection of fuel Legend i 1 of ~10°C or below, 1S Possible causes (ding fom Questions and check items) 40s sono femmes 21 eld csciawerany vee ‘3: Most probeble causes aging fom Questions and Check items ‘ASTM D975 No. 1, and ~10C or above, use ASTM. 1: Possible causes due to length of use used for 3 long period) D975 No. 2 diesel fuel) (© ame to confirm the use + Battery charging rate, om ‘Ampanr— 29°91 soox | gon | con | 25% | 70% vas [yar [vas Puze | 10 ity should exceed the valve for the charging rae hove table. the specie gravity must exceed the value for the fof 75% in he above table cena Sire ates | ats a = obo ened oA TO t t eae Nowe 20-60 o14u02o14u02 S-2 Engine does not start © Engine does not turn General causes why engine does not turn Internal parts of engine seized * internal parts of the engine are seized, carry ‘out troubleshooting for “Engine stops during operations”. + Failure in power train + Defective electrical system Caer Most probable causes judging om Questons and Check tems) 2 Possible causes due o length of use used for along period) (© heme to conf the ease Confirm recent apa Rory Degre of use ‘peraed Tor ong period af fe ‘Conaiton of hors when Haring Hor does no sound = © o Questions orang soeed is stow e || wen sarang suiten Makes grating noe ole ‘vened to START, non Soon eisengages again moves ou, but Makes rating noise and When saving swich turned to START. pion does notmave oat [OO When staring switch s turned to ON. here no heking sound © 2 Barer ermal loose = ‘Wen staring switch foned 9 ON, Inkage does not move Wien baiery checked, Datery westolye i found 0 e Om ‘onec item ‘Space gray of easly, vege ot batery om or te Totowing condivons 1) — 8), rn the starting switch OFF connect th cord, and carryout woublashooting at ON 1 When termina 8 and erminlC of starting switch ar connected, engine srs wren 3) wen terminal band terminal C of sae rely ae connaced imal and werminal of slang mater we connected, ‘& When terminal of savy sich and terminal Bot sarang molar are connected. engine starts ‘5 There i no 28V voltage between batery ‘aay Terminal terminal When sng geri nepacted dey oath surface ound 1 be ‘Does not move aven whan falc sano ka (Garry out woubieshooting for defective wing oF Doss not move even when engine slop motor Inkage is asconnecled Asor |e reniace| @ Remecy| — esiace Resin 20-61@ Engine turns but no exhaust gas comes out (Fuel is not being injected) General causes why engine turns but no exhaust gas comes out + Supply of fuel impossible + Supply of fuel is extremely small = Improper selection of fuel (particularly in winter) Standards fr use of ful am a "AMBIENT TEMPERATURE AUD | + «on 2 8 8 we 1 i ies ue i & 5 Lasers 2/3/3 est is cats uti tom Oeste ad check tra i 23/2/3)3 Ros probable causes judging from Guestione and Check tr é/é/z li i s/f iz e/é/ See ctan laos orton pea! i 3/8/3/3/ 8/8 3 Rtas ct econ S/8/8/8/ 8] §/8/é/4/8/# Toa aT TH Degree of ve [Operated for tong period apo = Se i Ton nao Mrenvaringeeaet TOOLS __ [hone aterinrinn con Sal | Eeewmaseren = Tee ea rom z Trg Sa eS ae STO ste ronan cae fates econo 5 E | “1 tection pup counting docs not coat | srasosconnos nomen tl tne sroeedacantomes [o[ [TOS 5 B | Bio iiigusonsosonermectoraoe ime mriseored[ 0 [01S andr oa and when oe tots t Sat nce = Tn cara nae puea teense tern oennt | Te cq | Check ews pump deci . : | [ett sew orca aR c When fuel cap inapected directv, itis found to be clogged | . T SN rerila needing somone a Sa nd esas ep Tar tne coated = MBB He wes 4] 419) 5 a2 ileigl8 alt 20-62 o14u02o14u02 ® Exhaust gas comes out but engine does not start (Fuel is being injected) General causes why exhaust gas comes out but engine does not start * Lack of rotating force due to defective electrical system, + Insufficient supply of fuel + Insufficient intake of air + Improper selection of fuel Legend (© Possible causes (judging trom Questions and check items) SS: Most probable causes udging tom Os na and Check ter) ©: Possible causes due to lagth of use (used for slong period) (© heme to confi the cause Coon Degree of use [[Spersed or tng poo afale a Sudeny ted aa Og Wen engin i erante abnormal noe herd om wean heed TO Engine ol moat be add more Hequeny 3 § | Novsoreieg Wet hes been ued 3 3 | renocement firs sna eon cacti ccvang Open usa Gand weg hel aaa Destinator ed Intron dos ot aR = ng or ranks eogine som = Md tek 0a ep 3 When fn eer laced ot FULL pain, dee wat one Hopeer | —[O When erg ranted wih saring motor 1 Lie ut comes ou even when ton pump sve ° i ii OR saw Br Bd Pw | one in coner oxen anon oe 5 5 & There eotge For on pone 2 [ Wen exavat mani i tuched medal aha waving ie engine, tmpartre of some evinde ow Wen fel ier dine. fu cones out 3 arava Pend cover an ack OaCHY = ‘Wen conolrck i puphe, tis foundiobe heavy. ordoeerovreum | | Wen cOmrebin pressure asd ound be ow . Wen fe er, aero napecied Seth they ae fund be ; clogged [in tac pa ain hapa ety Wan wb ped . 4 [men a element napectes deci found wo be copped [reser mount doesnot become worm . [einer seat gov of eco 0 vorpe oto . Wien feed pump is operated tare no responae or pum aw . ‘Speed af 0m cinders dost nochange when operating on edueed . ‘Wen el ab hapeied areca Tana ob Seago £/2/3ls|slslalz romeo] 2) 312/212) 8) 312 . zl#le{s|e/é|el 20-63S-3 Engine does not pick up smoothly (Follow-up is poor) General causes why engine does not pick up smoothly * Insufficient intake of air + Insufficient supply of fuel + Improper condition of fuel injection + Improper fuel used os (Possible ceuses vdging from Questions and check items) 1S: Moet probable cauees judging rom Questons and Chack items 2 Pouuble causes due to length of use fused or along period) ‘© heme to cont the cause operon [Toemaomemis fo fetet de 7 Tnapedied in bara wed apatste ae et ea nae Fa a arf eee a ond an oad EST 3 ee ia Ce eerie Black o e o ° g [eeariew coe ermine TTT S ae elo tmp cae gn ew Soe 3 ese a nad rn roar peed aoa TW od boca] | TS g.[Betamncinnr aaron sonra : 2 [nen contol atis pushes found be benn, or door ratreurn = | 3 [then compression presure measured, ti found Be ow . . nas abr Gass s cncnd derby te od eb wi ' e Wa nd sore aerwk speato Wins re ROT = 8|5/8]2] sls lel e|siel2 20-64 o1au02014U02 ‘$-4 Engine stops during operations Legend Possible caus Most probable ca Possible causes due to length of use (ved for along period) General causes why engine stops during operations ~ Seized parts inside engine + Insufficient supply of fuel Overheating + If there is overheating and insufficient output, carry out troubleshooting for overheating, Failure in power train + If the engine stops because of a failure in the power train, carry out troubleshooting for the chassis. judging rom Questions and check items) useing rom Questone and Check tem) operas Saad oa a m=O ee | [Fue gauge lamp ights up 3 eed Sg al 3} 3 i [Stat des ner = i ao op on eT oe i Remove head cover and check directly ° 4 [renee fed pump activ id z 8 ir oe ne NE TOE 7 perede le] e/e ig 1812/8] 8/21 2)8/3)- 20-65'S-5 Engine does not rotate smoothly (hunting) General causes why engine does not rotate smoothly ~ Air in fuel system + Defective governor mechanism + Defective engine throttle controller mechanism (engine throttle controller type) * If there is no hunting when the engine throttle controller rod is disconnected, carry out troubleshooting for the electrical system. Legend 1S povsvn caves Guin om Ovestons ane hac tems) moat posvie asses jg rom Guesons and Chee ts Poosbe eres de olga eased ors ona pros) tar to cone he cose Tan rea aT POT agen ou Soared Tria peed ate lOecursstcerain speed ange] © 3] OTS ‘Occur attow cing [TO ef foletols Condon ot hatin ‘cers even when speed . A raised as ma i Occurs on ope 3 8 [Reteaeeontope one 2 epoca ers has vot Geen Grieg oR TET ° praton mana Tt fund when hls Ged fe Teatepe Fon he! pha - 3 Wien eed pono open ve | _DLNO response, ight, return is quick " E. |__2 No reson. nah reten nom i 3 4. | Beane sone sonetnes reso ish a[e EB [ Enareis sometimes ctu to top els Selon icon pmo nas come of otts 1 Whar govror ever waved Ww Tondo be ze ‘han nection aun istered. governor und Be MBTOPETY eieaa me [whan contotracks pushed, fis ound tobe heavy, or docs nat elura . 2 [When fuel cap is inspected directly, i is found to be clogged . ° 3 Finer eed pm svar smocteddrocty, ound 0 De 2 ° ier oe wiped Tas, ey we Find Be S lremess] £) 2) 8/3] 3 32/8 2/212 fe ele 20-66 o14u02o14u02 $-6 Engine lacks output (no power) General causes why engine lacks output Insufficient intake of air Insutficient supply of fuel + Improper condition of fuel injection + Improper fuel used (if non-specified fuel is used, output drops) * Lack of output due to overheating * If there is overheating and insufficient ‘output, carry out troubleshooting for overheating Possible causes (judging trom Questions and check items) Most probable causes judging rom Questions and Check toms) 4 Posie causes due to len fur ord far aang pera! 8 heme to conta the case Degree ote Doennedtorirg pvtos [a] [aya = Sam Sedaey a eae oman Graduay St _efefete a § [Rhone atm oe aaed nore heey 2 J [Pesce testo aresoa ia eens | 5 = Non-peced oa abana weed 2 Dust instr red 2 me afe ceceten Bie under igh Toe = Ta of fiaerenca ad Wom Wound bhatt = Sowa gus excess 2 Engin cup spor and combat @ Wear 3 & 3 1p | Mahi seed under 0 oad normal Bu speed eden dope a = E | ster oad apie | [Wen extant manfod uched ne & | semoerature of some evinders is tow: = There ning tom engine otton 3 fe angg sound i head rom around cynder head z High ing speed fei = Lene rom fel ping = ‘When av semi i nepecied dreciy Wis fourd abe cooped Wen vobocargr aed by had, fond ob hear = When compression peur meurd found 1 be low . . When fe it, seme ar mapecied Get, hey are fond . - [tobe conned [ine tees burp avin epost dey, Wi ound wo be dogged 3 | Speed ot some crinders does ot cange when operating on reduced a E | cvindes 2 | When convlrack i pushed Wie found tebe hea, o” does rat aura When valve caranc is chested dest found o Be y out standard vale When lever plead at FUL polio doesnt conic Hopper . When ee bumps operated: opwration i t0 ht orto heavy . Wan flea is apected dct found tobe dogged . Tedlelsle Telals romeoy| 8] 3/3/38 3/318 8/3128 |8l2 3]2)2/8 20-67$-7 Exhaust gas is black (incomplete combustion) General causes why exhaust gas is black + Insufficient intake of air Improper condition of fuel injection Excessive injection of fuel tegen (6 Possible causes cdsing fom Questions and check items) 5 | Moat probable causes jiudeing ftom Questions and Check items 2 Possible causes due to length of use sed for 3 long period) © ame to confirm the ene Cue 20-68 Contr en ann RO Dears of we Speriedtorora pared | [a tata Sudaeniy care Baek [S| | [0 2 op | oer ot ena os Gras bea Bee slo 3 3 Blue under ight ose = [Roa ovruatbenaaed ae rea To or Susser z 3 3 en Gruul oe e Novspeaied Wot bing weed 3 a Nowe of rere eed om on WDE = /, (Dustndestr ise /— [Blow gos excessive = eal Engine pick poor and combanton 5 wea 3 T os ‘When estaus manifold atouched mmedatev afer saringrane | || | = 2. [tonnes of some cine iow 2 [Seaton ction ump nas cone of zs 8 Fianna sound ser Fom wend oie” Rad xu noe norma saaa[ol 3 har barr OT Ran Tor ae = When af deen hapeied det found wo be copped . ‘Wher compreson pressure mest 8 ound © bow . Seve cf sre eyindes does ot change when epersing on reduced 2 | tds : [When het dean ever mao neon isan = ‘ ance crea dey Hi foun 0 be ove | standard vale When controle pute sound tobeheavy.ordoesnaivewmm || . Jromesy 21 8/313) 5 3 sole zie 2 o14u02o14u02 + Do not run the engine at idling for more than’ 20 minutes continuously. (Both low and high idling) General causes why oil consumption is excessive ‘Abnormal combustion of oil + External leakage of cil + Wear of lubrication system Legend (0 Possible causes judging fom Questions and check te) Most probable causes judging from Questions and Check items) 2 Possbl causes due to length of we used fora long pertod! (© tems to confirm the cause consumption is excessive (or exhaust gas is blue) Degree of wae [ Speraed or ong pad [[Evoine oi becomes contaminated avciy /CEanais ges bun onder ightont There od engine cooing water on deh or TORGFLOW vranemiton darper chamber soe er evel inakage of 1 Wom engine Excessive lay of rbocharger shat ‘Chackrear ees ety [Titer inte mantels removed. de is fourd tobe diy wih OF 20-69‘$-9 Oil becomes contaminated quickly General causes why oil becomes contaminated quickly + Intake of exhaust gas due to internal wear = Clogging of lubrication passage + Improper combustion = Improper oil used + Operation under excessive load Caer Legend 0 Possible causes Gudging from Questions and check tems) 18 : Mos probeble causes judging trom Questions and Check tems) 2 Powsiblecouses due ta length of use (used fra long pei) (© : ome to confirm the cause Conf rcert ropa OT Deore of 5 [oeesea trina pened [= = = Engine oust be added more Heaven 2 Nor specied felis being used 3 Color exnaus gat Su wn omions a Tamomatyeceane [0 stele «| Amount of iw y 9 2 z None = : [omer cao arp say on even wen of rea ie = oi [when ot ers ispecad. metal pris ae fund a} [elo 2 © When exhaust pipe se removed, nse is found 10 be dirty with o¥ | 2 3 Engine of temperate ies qh = i Then compression rere ranered Ws aura Tobe ow = : 3 When breathe element mepaced ect fund 0 be clog9ed 2 7 2 | mit ayo nose is broken i |] [isso ented Sec nt Sed 7 4 [When ot coors specad recy. fond 9 e dogoed . 3 4 [enarger dan bes eoooed . g 2 [Races iy of wrbocharae sh Ie Wine softy ve ect nspected eng found Be 5 caver if se Jemecn] & al- 20-70 o14u02014u02 S-10 Fuel consumption is excessive General causes why fuel consumption is exces: Leakage of fuel + Improper condition of fuel injection + Excessive injection of fuel Levens © "Postiblecauses Gung rom Queson ang check tes) : Mow probbie causes (waging rom Questions snd Check tems) & Roeube caves due flog fue (osed fo aang pero) € hereto canfer the case Desree of ven Opera orang peed = : ‘More than fr other machine i ee eee ttsame rece! 3 eee eee eee ‘Gradually increased o ce ‘Suddenly increased ole ack 3 3 enna os ctor Sack - Teal on acon pono as came Tere ie regular conbuston 3 [enone mana «icin mad aa sin re . $ [Match mark on injection pump is misaligned os 5 here enteraientage of fn rom eine 3 {Engine ove res ne a fds 3 [ergs ow ing speed moh = TiS pr Hw Tat econ aroun eT Speed cf some eindes Gov ot Changs when opeaing an "duced [nen contol eputhed i ound wba heavy or dont rover . [rene mde ug dese meod nection ian urd = 2 [Renter over and io oe Remove feed pump on check Srey When engine seed i esured low ting Speed a TRG be ROM . nemeds| 2(3/2]2/2|2 20-71$-11 Oilis in cooling water, or water spurts back, or water level goes down General causes why oil is in cooling water ~ Internal leakage in lubrication system Internal leakage in cooling system Legend (© Possible causes iudging trom Questions and check items) Most probable causes judging frm Questions and Check toms! 12 Posse causes cue to length af use (used for along per) (© tems to cont the couse 1 Contr recent apa NAOT Desree of ‘peraied for long pero ae Bodden eveased Tiydule oi torave converte, transmission ol & cloudy whe Vihen hydraulic i, traue converter wansmission oll Gained \ enact tems \- Questions 20-72 o14u02o14U02 $-12 Oil pressure lamp lights up (drop in oil pressure) General causes why oil pressure lamp lights up * Leakage, clogging, wear of lubricating system Defective ol pressure control Improper oil used (improper viscosity) Deterioration of oil due to overheating + Standards for engine oil selection AMBIENT TEMPERATURE KIND OF FLUID SAE Engine oil —_—- | Leaena (0 Possible causes judging rom Questions and check items) Most probabie causes ljudging trom Questions and Check Kems) 12 Possible causes due to length of use (used for along period) (© tems to confem the couse one oe a ao [Teeuton tmp ighis ap © T Non-specitied fuel has been used ole / Tak wer ing = a enon whe peste a ter ah ig sfatsfeleleyo / | Semen Ft Tepes [Chaves coping ealage fom Rydaute ppg external T 4 [Wen o vel mo pani checked i found we ow I = t © Maal parices are stuck 1001 titer element ° o Tibor a Wr pared Seca an RD zs F [eemnearpenane cc ores oc E E [ossumoroitons enw, re =r . ; | Theres catching of reel valve or regulator valve, spring or ele ie 3 | save gute moter : 22 [en ote serra ropced St pataesnorn m a ihe pene eed un wiih Sanrd a renesy 218] 2/8) 2] #]e/ 3/81 3/2]8 eee zirielil? 20-73$-13 Oillevel rises 4 If there is oil in the cooling water, carry out troubleshooting for “Oil is in cooling water”. General causes why oil level rises + Water in oil (cloudy white) + Fuel in oil (diluted, and smells of diese! fuel + Entry of oil from other component om Looted S essle avsestsng fom Qvesons an check 3: tan mesos cms usa om Guesan ans Cnet tas &Poosbu coe auroral ons ony peed 3: iinee comme ae E [Degree of use [[Seeraied for tne period Cm EIENEY = | [ecanemenonree ast5 3 °/ ions se ae ap aa Ca TOT 3 / number of bubbles appear. or water spurts back ° iz ‘ioe nae bathe tls caus tid = { re = | [chs perremertomnow rome t shamber = | [teanasarnreemoe a Farts saa ror Fea stste Tes ATA ane OTT z T Tress Spirit dried shoe os WE = Win coeporan peouiva momar Fs oangur brie = [Renmei pone ad cee rear = [ee roo sea drecty . 4. Lar pone maioy egiparars noord wala fond obs Ee = 3 [Remove head cover and check rect . © [Ramos mencn seen mech rear = emacs ¢| 2) 4/2] 8/2 i sleet /E]3 i 20-74 o14uo2o14u02 S-14 Water temperature becomes too high (overh General causes why water temperature becomes too high ~ Lack of cooling water (deformation, damage of fan) Drop in heat dissipation efficiency * Defective cooling circulation system ~ Rise in oil temperature of power train + Carry out troubleshooting for chassis. ing) (© Possible causes (udging trom Questions and check items > Most probabia causes judging from Questions and Check tems) 22 Possible causes due to length of ut (used fr along period) (© teme to conf the cause egies ce Genie rig pw | [a fs aye ae Selemiy roman? —[S o/s i eerie aronriswonnen tet stot] te : fans ect eC te | ne ames ae Certo oe : Ta aT = arb nr oslo = iar i osng or ao aE = olny wat Tow ot Foran ose 2 Esch us nada OTST = igh rt a av cy oct = Thre py heron ur tae = [Rano oons new otargura im Goaped wm arormea [te 3 1 vnc ngrbaw sr oad nds ap or GO o [Weer nts brn cizner tora one donor Cote er ound So i = Tans GTA Tino TOR OTT —] > 7 Terme Srna Ts BB TT ew 3 oo y i op | innate poe Wend a ooo be Seed 2 3 [ [Rrertonseto cores eto mot Rao om e ; 9 [Breen tepeens senna wa erate boreme = 3 2 [ neval cori pected dcr on be Senped = i ‘Wr meee sade i er ey eo ESTE ss inn compro Sn mated Wa ob as 7 sles renee § 3) 3/3) 2/2) 2/4l- i 2]*]2/ 83/3 20-75$-15 Abnormal noise is made # Judge if the noise is an internal noise or an external noise. General causes why abnormal noise is made + Abnormality due to defective parts Abnormal combustion noise ‘Air sucked in from intake system Legens (6 Passile causes (voging fom Questions and check items) Most probable causes (vdging from Questions and Check items (2 Poosible causes due to longth of ue (sed for along period] (© rem to cont the ease Degree of use ‘perate torong pared [o> | condition a normal nose ae e 7 : Budseniy oeerre ate = | Ronspectied fel is bona wed ote || Color or exraust gas oy 2 | [Brown goss excessive > Tis of trerence ard Fam sound wrbosherge |) Engine pk poor and combustion 5 weg 7 t _[Hten esa mails nti ore als 2. | temoeratue of some evingers ow L [Rnormer no isto when aeewetna eae es leteteletet fet & [cionging sound heard ror ard eyinder nes [liter compression prenure io aatred Wound be ow = T When wabocharge rotated by hand ii found be heavy = Temove gar cove and EneEE Sec . . a | ereton inte rt eno = '& [When control rack pushed is ound to be heavy or does not return . t & [Tinjection pump teat shows that injection amount is incorrect | 2 [Fans detormed. or belt i loose Wen eh noe sen Tso oe ; ] Temove cyindr fead cover ond cheak recy = S/ 2/8) 8/2] sal als 5 “Ee elle 12/2 )2]2 2 20-76 014U02S-16 Vibration is excessive + If there is abnormal noise together with the vibration, carry out troubleshooting for “Abnor- mal noise is made” General causes why vibration is excessive * Defective parts (abnormal wear, breakage) + Improper alignment + Abnormal combustion om Legena 0" Possible causes iudging trom Questions and check tems) 1 Most probeble causes udaing trom Questions and Check items) 2 Poasble causes ave to length of ure used fr along period (© tems to confirm the eave 014u02 Conn recent apa Ratary Degree of ‘Oberaed for long paved Seddenyeveases a Gradually ncreasee Nor specibed fel har been used ofefelofo ofefefofo ‘il prernire low atiow ding 2 2] Vibration flows engine speed Sfofofels Eataust ones Back oe ‘Seal on ijecion pump hes come of © Remove side cover and check deci le "Check dvecty fr worn suppor Bt. ny Check directly or loose engine mounting Bat, broken curhion ie Grek inside of autut shalt (arp decoy ie ‘When racial runout, face runout ae measured, hay are found Be Remove tant cover snd check decty ie Remove head cover and eheck drecty le rere Repisce Repco Aaa [© epiace 20-77o14u02 Table of failure modes and causes (Hydraulic, mechanical systems) Ha He HS Ha HS He HT He Ho HA10 Ha H2 Hog Hota TROUBLESHOOTING OF HYDRAULIC MECHANICAL SYSTEM (H MODE) Brakes does not work .... Machine does not turn (can travel in s straight line) Overruns when turing .... Can turn in only one direction (when steering and directional lever is operated) . Excessive time lag ... Machine can travel in only one direction (forward or reverse) Machine does not move (when engine is started and lever is shifted to 2nd or 3rd) Machine does not move in any speed range Power train oil temperature rises too high. Drawbar pull is weak, travel speed is slow. Abnormal noise is generated from around hydraulic pump. Blade lifting speed is slow or lacks power..... Blade does not rise Hydraulic drift of brade lift is excessive 20:80 20-81 20-82 20-83 20-84 20-85 . 20-85 . 20-86 20-88 -. 20-90 .- 20-92 20-94 20-95 20-96 . 20-96 20-79TABLE OF FAILURE MODES AND CAUSES (Hydraulic, Mechanical System) o14u02 Hydraulic system Mechanical oyster [Foe Powertrain | Valve | Parts cousing failure | & | 2 lif there 3 lisany es 5 © sonor g|.|./2 3 |malty, in! B\2 3 |g0 to $|8/3/8 vesmo| Eglzls § |Troublet sl} | [sl 3)2)5/8) | |8lno- i) g\slo| 18 2/s/el2 5 [Table a s\e/é| |) |3| |s/2is)s) | §| eirox s\£/g)=/3/8|_|2] /3||2/B)a/al /&/s £)3/8\3/2/3|5/3|_|=\2/2|3\[s| o/ 2] = Feilure mode ls 2|8\3)2)2\s|£/8)s/2/ 2] 2 2lZig ela lelglele/e|e/els zig ielz/ 2/2) 88! 2)8/§|3/£|2|5|2|8/2/5|5/5) 2) 2/2) 8) 8 1 [Brakes doos not work alot | I ololo tet ‘Machine does not turn (can travel in a a | : 2 | straight line) ae eee) 2 3 | Overruns when turning o[o| [ ofofo He an turn in only one direction when ste 7 | 4 | ering and directional levers operated) |_| °° Jee en ee 5 | Excessive time lag ° o|9 oO HS ‘Machine can travel in only one direc | : 5 | tion onward or reverse) 2 a oO} | Mie Machine does not move jwhen engine | |] | 5 7 | started and lever is shifted to 2nd or 3rd}| © 2}9}0}0 ke 8 | Machine does not move in any speed range | © oo ofo &- | Powertrain oltemperature rises too high | © ° oo 10 | Drawbar pull is weak, travel speed is slow | O oo olo ‘Abnormal noise is generated from : 1 | ground hydrau! pump Hee ahs 72 | Blade ting speed is sow or lcks power o 1 [Blade does not aise a Eafe) Bale) 14 | Hydraulic drift of blade lifts excessive ofo 20-80o14u02 H-1 Brakes does not work. % Check the oil level in the power train before carrying out troubleshooting. yes ‘erating capscty || See Now 1) bow NO yes NO] 4 yes, YES] Dove soe ovate enn "GSpaaNStNG, NO Cause Remedy Woor of take dec and slate | mepace Detective seat of cuten piston | apace Note: 1) Depress the brake pedal fully and set to R2 to set to the stall condition, then depress the decelerator pedal gradually from the SLOW position to raise the engine speed to full throttle. The machine must not move off when this is done. Table 1 Unit: Ma (kg/em?) Hydraulic pressure a (ltt eight Cuten Brake Full o Min. 22 (22) Brake pedal not Ecce aepressed i Low idling ° Min. 22 (22) cae Full o ° rake pedal Engine speed essed oe Low iating ° ° 20-81H-2 Machine does not turn. (can tra in a straight line) 4 Check the oil level in the power train before carrying out troubleshooting. of Sons Note: 1) Travel in F1 (R1) with the engine at low idling, and operat No] Seized euch de, plate 4 YES] gtecive soa a euch ston YES] Doe: epoot ot vowe 3 [| fete “HOES ine NO slowly to the left or right. The machine must stop or turn slowly. Tobe 1 nt MP fem Hvac pressure convons cen rate | 7 Win 22 wring and rection (eto ‘toh lever not operated | Ensine spe 2 nase een Weft, right) Weft, right) a ane 0 Toh: Min. 22 23 Ue han 22 (2a tat warng | Opsrtes | Eoaine seed erin | telat ae aete| imatel ol Fight: Min. 22 (2) 9 al 8 | take hin 22 2 tate 0 teen ral Fight Min. 2.2 2) Fight 0 erated tote Uh tan. 22 2 Engine speed: ating | Right: Min. 22 22)| Right: 0 9 | iet: 0 Left: _Min_2.2 (221) 20-82 Aas the steering and directional lever o14u02o14u02 H-3 Overruns when turning 1 Yes Cause Remedy See Noe below. NO Note: 1) Travel in F1 (R1) with the engine at low idling, and operate the steering and directional lever slowly to the left or right. The machine must stop or turn slowly. 20-83H-4 Can turn in only one direction (when steering and directional lever is operated) ves YES] te cuscnand tate | | couse Remedy of suting of brake + ff some == 3 ves etc eo tn Saxicgtace Ogee soo no} Sone L eee No Table 1 Unit Ma kazer®) Hydro pressure Conditions latch Brake oar 3 Min 222) tering and directional : tet righ et right tow ising | et righ) ht ai Fight’ 0 Right: Min. 2.222) oe : Lett Min. 22 22)| Lett 0 ested | Engine speed Steering | Te aa Right: 0 Right: Min. 2.2 (22) mngae | et Low iating | Cate Min. 2.2 (22)| tafe 0 ee a Fight Min.22 22 Fah 0 oie i : ot 8 Late Min. 2.2 (22) operates | engine soos: ——T ght Min 222 gh owiaing | fer tet Min. 2.2 (22) 20-84 Replace Reps orale o14u02o1auo2 H-5 Excessive time lag Cause Remedy ves. Delete operation of spent | Repair or replace ayes, Tee 2 Drtectve power in pump | tice Berar sage NO] fatsgenorsl « Blaster NO] + Sot poo1 move ‘theortle ii Detective spring. clogged fad i ho] oa eso eeon “HORE Sn. No Note: 1) Stop the machine on level ground, run the engine at low idling, then shift to F2 and check if the machine moves (travels). H-6 Machine can travel in only one direction (forward or reverse) + Conditions: Oil pressure is normal (Min. 3.0 MPa (31 kg/cm’) cause Remedy 1 yes Detective pat inside van. “Seeresrna NO 20-85H-7 Machine does not move (when engine is started and lever is shifted to 2nd or 3rd) + Check the oil level in the power train before carrying out troubleshooting. Yes YES| ope yan ng 2 [| rar vest ons gash er vyes| sivnmowe sto” | | s\ temanraietoa [| —_righem NO wg] emcnomar F}« Eman ‘sparking bate “RR ERIS. a + Ete a H rete No}. "spo! Sore no + Free length of NO iiscvm on «— no Table 1 Unit: MPa (kg/cm?) Hyéraule pressure Conditions Cute Broke 7 ° Min 22) cane tet right tt righ) ievrnotaperatea "| Emin speed 0 Win. 22 21 ee Weft, right) Weft, right) a ight 0 Right Win. 2.2 a Let Min.22(22i| Left nerated | Engine speed Steering | tote Fight © Right) Min. 22 (22) and ; Hee Low idling | Left: Min. 2.2 (22)| Left: 0 Gitectional a Fight” Min. 22 (21] Right 0 porated teh 0 tof Min. 22 2) Engine speed: aing | Right: Min. 22 (22 Right: 0 ow ling | sn: 0 Left: Min, 2.2 (22) 20-86 o14u02o14u02 Remedy 7 Yes YES] hang nr ot || TET ig fen NO Drogen brake ie 1) Detect por imide Detecting sering ch be Detective port iid orue Detective ranamaton vee ‘oot dogged abet Detcineadment of inkoge Detecting odinet of {see TESTING AND ADNSTRG) ep or epace place apse ope, is 20-87H-8 Machine does not move in any speed range + Check the oil level in the power train before carrying out troubleshooting. ves ‘ ves 3 YES; main ett 04 * sesstesstent - + Engine a fut aa ves| nemex || * Seisae a 8 yes noamoismmus [| ROMS no ws H eevee aaa ~ tssironet NO en no no Table 1 Unis Pa hem) Vidrac pressure (eh ht Conditions cuch | Brake rat 0 | mnzzen Brake pedal not Engine speed epresed ia Low idling o ‘Min. 2.2 (22) cues ra ° ° rake ped rake Engine speed ie oa Low idling o 0 20-88 o14u02o14uo2 Cause Remedy Deena patie wera a. sace 6 fanemson| + Getecove sa! of seeing ‘st prcsue at "S00 Table 2 Seaman of *] su port moa NO} norma 9" rtcive susie! | gag > Erpie speed “SoS NO Ine" Detecwve prt inagetroue Repa or replace No eSovener etecwve wansmissionvaive | Repro veoiace Dejecive aiesment ot | Asst Detective spring, seuling of Detective bate 86H.) - Table 2 Unit: MPa {kg/em) Hydraulic pressure Conditions clutch Brake ee © Min, 22 22), ‘i bs (lot right) Ait ight) tevernotapeata "| Enaine sed 0 Min. 22 0) Low idling (ft ight) lef eight Right) 0 Fight: Min. 2.2 22) tin Left: Min. 22 (22)| Left: 0 Operated | Engine speed: Maes a Steering Right 0 Fight: Min, 22 ( and ae Low iting | Lett: Min. 22 (22)| Let 0 babii Right: Min. 22 (22)| Right: 0 mares Full Leno Left: Min. 2.2 (22) Spetaies | Operated | Engine speed! Fight: Min. 22 @22)| Right: 0 pi tow idling | Lett: 0 Left:_Min. 22 22) 20-89H-9 Power train oil temperature rises too high + Check the oil level in the power train before carrying out troubleshooting. ves. ves. Is rate sraning? ves, See Noe 1) blow : ree: no] eae Py el Ea ves Tieewenat 5B NO Note: 1) Stop the machine on level ground, run the engine at low idling, then shift to F2 and check if the machine moves. 20-90 Table 1 “Ambient temperature | When normal asc ‘Approx. 1100 noe Approx. 15800 soc Approx. 189.40 o14u02o14u02 Cause Remedy 6 yes YES Torque convert || J omamacionace [| 7 etme mele snatgn Gest prem (a5 prem NO Dropping brake (ae 1) (Bee Engine vou Sipping bate ase epics tohten epee 20-91H-10 Drawbar pull is weak, travel speed is slow + Check the oil level in the power train before carrying out troubleshooting. Yes. 7 See Nate bsow YES] mosaaing ot No} 5 YES ves. Soerpenne “Sen Tan No ibe NO. eee Spl eee |: oe No {fermi 138 mm target Note: 1) Stop the machine on level ground, run the machine moves (travels). NO) ‘engine at low idling, then shift to F2 and check if the Table 1 Uni MP afew lever not operate ngine spes z : aaa Low idling i ee ©; 7 = Left: Min. 2.2(22)) Left: 0 Steering ie a Right: 0 Right: Min, 2.2 (22) and pane Low idling Left: Min. 2.2 (22)| Left: 0 fever Fut ight’ Min. 22 @2)) Right” @ ‘operated ae ft Left: 0 Left: Min. 2.2 (22) na idling Left: 0 Left: Min. 2.2 (22), 20-92 o14u02o14u02, Cause Remedy nec stein ch Detecivesorng scuting of Shoot logged win aet Pepsi or vplace Resta ores 20-93H-11 Abnormal noise is generated from around hydraulic pump 4 Check the oil level in the hydraulic tank before carrying out troubleshooting, cause Remedy Yes (Gore we cme Toten 1 Damases Sina baie YES] tear bong sucked Detective pam Replace i xo sa no] ae] Operate fora time ana watch | aSeeraing to gangamaua | Se 20-94 o1au02zo14u02 H-12 Blade lifting speed is slow or lacks power % When hydraulic drift of blade is normal + Check the hydraulic tank oil level before carrying out troubleshooting. % Check for any modification of blade. Cause Remedy ves Detective opration of ade YES] Grim che wave Betecive sohstment tm | gus, + orpagure | | Derren, +] alan yb] seaside] cancyinaer sealed” * Shag SIE oo oa bette maineavane | Ree ee asin NO Terr st $$$ in creat Bed ai No 20-95H-13 Blade does not raise 4 Check the hydraulic tank oil level before carrying out troubleshooting. Cause Remedy 1 yes Detective hydaute pump | mepace ees conn | Sinentyerauie Detective nysauic me | possir or repace No he H-14 Hydraulic drift of blade li is excessive couse Remedy 1 SSSA SS | Roce > Bae gpl ee «Bae nyarute Sage Tse enage NO 2 sinonsan __ | MOMS 2 Rane owarng 20-96 o14u02o14u02 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) Table of failure modes and causes (Electrical system) E+ Starting motor is not cranked when starting switch is turned to ON ... 2 Lamps do no light Up sn a) Front lamps... b) Rear lamps. E-3 Automatic preheating is not carried out when glow switch is turned to AUTO .. 20- 98 20-100 20-102 sn 20-102 20-103 20-104 20-97TABLE OF FAILURE MODES AND CAUSES (Electrical System) Troubleshooting Parts causing failure Ie there is any abnormality, {9010 YES/NO Trouble- shooting Table E-OX 8] | 3] 2] | 2] sla fl | 2] 2] | 2) 4} 2 5 F] 2] 2) 2] | § 5| 5 | | 3] 2] e| 8] §] 8] = 3| | 2) 2) 3) §| 2| 2 eee &| 8| | 8) =| 5] 8| 2/2) Starting motor isnot eranked when : : starting switch is turned to ON O}9}0)0 a Lamps do not light up a (front lamps, rear lamps) ° O}Jo;o/o E2 ‘Automatic preheating isnot carried out 2 when glow switch is turned to AUTO ° ° ° ojo es 20-98 o14u02E-1 Starting motor is not cranked when starting switch is turned to ON + Before carrying out troubleshooting, check that fuse FB2 No. 5 is normal, Before carrying out troubleshooting, check that all the related connectors are properly inserted. + Always connect any disconnected connectors before going on the next step. Now) 4 ves ves] saauosaran “ee a| + Sane ves| pice male's 5 YES ) wer tag 9 ves toned ore? ves 8 | Setwoon taney tr “Note 1) eect ves| maar, frou? oe Sater 7 (noma “temecemt | Govan wo eae woe) _6 [| Boa? Er iets ° eae tine No] street No E-1 Related electrical circuit diagram © Limit switch ‘Switch ON when main clutch at OFF io} C= rn 20-100 orauozo1auo2 Cause Remedy Note: 1) If the lamps (front lamps, rear lamps) or horn circuit are normal, the lamps light up normally or if the horn sounds normally. Detective contact of wing mal) and sang Seiten termina © a {etween terminal 8 and C) Farest between sstary aac contacto Detective starting wich ‘Renee Bana Ba termina (3) on arg Set termina eps or place Repice Pepsi or elace Charge or lace is possible to check instead if 20-101E-2. Lamps do not light up + If the battery is normal % Before carrying out troubleshooting, check that fuse FB1 No. 6 is normal. + Before carrying out troubleshooting, check that all the related connectors are properly inserted. + Always connect any disconnected connectors before going on the next step. a) Front lamps Cause Remedy ayes! 3 [| Snecma ves, Setchioand 0° LY YES] 1s vottape between Sime ie one rake? NO 1 [] stems norer + Hier is inert i Lam wich doesnot ot up Gaeta Sieaet towing | Revver ertace nating contact Repsv of retace Detecwve wont amo switch | Replace decomecton in info Noe Detective baer clay Replace NO Table 1 E[t[™ orf [Oto on_[ototo E-2 a) Related electrical circuit diagram Front lamp switch eq] orF_|O4O} @ Battery @ Baty relay “oO th-4]t] pi f-4]t|}—- Check meres er inahadul sar NO YES| te otagebatwoon | | * Twn ssrinarwten OFF Ete aes LY Note 1) 3\ Ca er ee na No NO NO No Note: 1) If the lamps (front lamps, rear lamps) or horn circuit are normal, it is possible to check instead if the lamps light up normally or if the horn sounds normally. 20-104 oO o14u02Cause Remeay | 8 ves Deterrent ry | egace ves] seaigces [] ves] fe ang cuenta EF'shen gow sich’ © a0 ov No Ivneas between CNB |2} and | Repair or replace 6 [] Soma srauie oa satgsee.. || 7 Sagem, bo owteive sow wich —— | gnce J REESE Foratnatttons 5 oansenngemich Ney fer wech 8ean | Ropar etce + han amin ai ‘eee nti tit i | ec rte corto J irri, | rsirorrece Seetriain betas ae a BS sre tics | pace Serotonin | cay rca cen eee S| meee mses a J ort tater riay | tea E-3. Related electrical circuit diagram Ar intake heater Heater pilot amp oy vic Staxtng ‘of Bimetal mer Fuse a] Battery iow te (ETH) na of forelay 20-105TESTING AND ADJUSTING E3 Serial No. 3034 and up ‘* If the battery is normal. %* Before carrying out troubleshooting, check that all the related connector are properly inserted. %* Always connect any disconnected connectors before going on the next step. YES. ‘YEg| there continuity between CN3B imate) (1) and (27 is voltage Check bimetal YES] between CN38 2) and chassis Note 1 normal? Tern sar vyes|sthere continuity] +20-s0v between starting [] + Turn starting switch terminal |] switchON. NO Note 1) 2 | [ena ar? Is vohage of Tur starting YES| stating switch switch ON. terminal 8 + Remove terminal NO “Note 1, | [norma 8 Doss barery elo] | = Connect 1 pole make ascund 1)“ oftester to) fowitchisturned || terminalof NO jor? battery. +2030 Tura starting ‘switch ON > OFF. NO Note: 1) if the lamps (front lamps, rear lamps) or horn circuit are normal, it is possible to check instead if the lamps light up normally or if the horn sounds normally. 20-106 o14u02o14u02 TESTING AND ADJUSTING £3 Cause Remedy ; & NES Defective heater relay Replace svorone Yes|bewweesent7 || 17 taond chs owes seaet es ethers continu normal? Feel ena Repair or sete on nets baoa reac ae and {3} when, +20-30V ‘NO and CN17 (13) Slow Baas ape Erte a] | eset vFon || ene H Sea Defective glow switch Replace onditions below2| | _ individual par. *20- 30 + Turn starting Defective contact, or “Than starting Gacomeconnvsting _ | Repiror euch NO harmeas beeen CME | eae + inen ambient ond ene Temperature iesetnon “5°C — Ss _ortrctive bimetatrimer | Reptac Defective contact, of disconnection in wiring harness between staring switch torminal BF and [cna (2) Repair or replace “J rtoctive starting switch | Replace Defective contact, or Jisconnection in wing harness between starting |Repair or switch terminal B and | replace battery celay Detective batery Replace E-4 Related electrical circuit diagram Ar intake heater rS 8S Monitor pane! cnag Preheat signal cust on? 8 © Starting switch iB BEAR HEAT FF ‘ON. START] Bimetal timer ‘Starting motor Battery relay Glow switch 1/552] id io 20-106-1orau02 Mr M2 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE) Abnormality in engine coolant temperature GaUge wns Abnormality in power train oil temperature gauge 20-108 20-109 20-107M-1 Abnormal ity in engine coolant temperature gauge ‘© The engine coolant temperature gauge shows an abnormally low temperature. + Before carrying out troubleshooting, check that all the related connectors are properly inserted. + Always connect 1 yes any disconnected connectors before going on the next step. Cause Remedy ‘sperewre sae [] eet exes, Lara "cave, NO Bree g S| wre Sesser seas Sis esar ase eet shu oun M-1 Related electrical circuit diagram : Fei-2 fenper stare, fom front gauge lamp switcn cnt? Engine water a temperature S CNIS sensor ) 3 6 ae : 3 sawoasz0a2 : Connector Coolant temperature ish conn 8 shownin he able bow a sensor [Ambient temperature] When normal ‘eee a seeaaaee : > al 135 Anproy. 11.08 ds ore Anprox. 2500 orc ‘Approy. 78.49 f Forauo2t we Approx. 19349 20-108 o14u02o14u02 M-2 Abnormality in power train oil temperature gauge ‘* The power train oil temperature gauge shows an abnormally low temperature. + Before carrying out troubleshooting, check that all the related connectors are properly inserted. + Always connect any disconné jected connectors before going on the next step. Cause Remedy 1 YES Detective power tain oll ‘Sock betecon aaeae Marte Sis item | SERNA Durer sound? Iarnass between NO (1) — * Conect show | NO Se i | terrence hans rou Power train oi! temperature Fei-2 From tront saide te F DR CNSL temperature a a N28 _CNSB_ sensor t p ( 0 ( ais 5 B i SUS sewca12089 Connector Powor train oi ihe conn show nthe te below, nme fecocvanie serer itis norm I, ° ‘Ambient temperature | _ When norm Se fe eh Te ‘oproy. 11.09 ve Anproy. 1589 sae Anprow. 15340 Fovsuoze 20-10930 DISASSEMBLY AND ASSEMBLY o14u02 Method of using manual... Precautions when carrying out operation... 30-5-1 Special tool list 3 STARTING MOTOR Removal .. Installation... ALTERNATOR Removal Installation... ENGINE OIL COOLER CORE Removal .. Installation... on FUEL INJECTION PUMP Removal Installation WATER PUMP Removal .. Installation TURBOCHARGER Removal Installation... NOZZLE HOLDER Removal Installation... ‘THERMOSTAT Removal... Installation... CYLINDER HEAD Removal Installation... ENGINE FRONT SEAL Removal .. Installation ENGNE REAR SEAL Removal. Installation. FUEL TANK Removal ... Installation RADIATOR Removal Installation HYDRAULIC OIL COOLER Removal Installation ENGINE Removal Installation. DAMPER Removal Installation. POWER TRAIN UNIT Removal Installation Separation Conneetion TORQUE CONVERTER Disassembly .. Assembly. PTO Disassembly Assembly. ‘TORQFLOW TRANSMISSION Disassembly . Assembly... STEERING CASE Disassembly .. Assembly ‘TORQUE CONVERTER VALVE Removal Installation... Disassembly Assembly. ‘TRANSMISSION Removal Installation Disassembly Assembly... STEERING CONTROL VALVE Removal Installation Disassembly .. Assembly... 30- 33 30- 33, 30- 37 30- 39 30- 42 30- 46 30- 47 30-48-1 30- 51 seeeeeeeeseee 30-107REDUCING VALVE Removal Installation Disassembly Assembly. SCAVENGING PUMP Removal ... Installation POWER TRAIN PUMP Removal... Installation FINAL DRIVE Removal .... Installation. Disassembly Assembly . ‘TRACK FRAME Removal Installation RECOIL SPRING Removal Installation Disassembly... Assembly. IDLER Removal Install Disassembly .. Assembly. TRACK ROLLER Removal .. Installation... Disassembly. Assembly. CARRIER ROLLER, Removal Installation... Disassembly Assembly. TRACK SHOE Removal Installation... Overall disassembly .. Overall assembly .. Press-fitting jig dimension table for link press... 30-167 Field disassembly of one 30-168, Field assembly of one link 30-169 PIVOT SHAFT Removal .. Installation EQUALIZER BAR Removal .. Installation 30-2 o EQUALIZER BAR SIDE BUSHING Removal Installation .. SEGMENT TEETH Removal Installation... WORK EQUIPMENT PUMP Removal .. Installation. MAIN CONTROL VALVE Removal .. Installation Disassembly... Assembly. ‘SUCTION VALVE Removal Installation BLADE LIFT CYLINDER Removal Installation. Disassembly .. Assembly. BLADE Removal Installation ‘SWEEP, CANOPY Removal Installation . DASHBOARD Removal Installation . FLOOR FRAME. Removal Installation... 01402o14u02 DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL METHOD OF USING MANUAL 1. When removing or installing unit assemblies @® When removing or installing a unit assembly, the order of work and techniques used are given for the removal operation; the order of work for the installation operation is not given. ® Any special techniques applying only to the installation procedure are marked 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 O O O O ASSEMBLY.......... Title of operation . Precautions related to safety when carrying out the operation 1. XXXX(1).. Step in operation i ee - Technique or important point to remember when removing X X X X (1). 2 AMAA a: [1] Indicates that a technique is listed for use during installation 3. OOOO assembly (3) ‘ oe Quantity of oil or water drained INSTALLATION OF O © O O ASSEMBLY... Title of operation + Carry out installation in the reverse order to removal. Technique used during installation Technique or important point to remember when installing A A A A (2). Step in operation -Point to remember when adding water or oil + Adding water, oil Quantity when ing with oil and water 2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions when carrying out the operation. 3. Listing of special tools © For details of the description, part number, and quantity of any tools (A1, etc.) that appear the operation procedure, see the SPECIAL TOOLS LIST given in this manual.DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL 4, Standard tightening torques of bolts and nuts Use these torques for metric bolts and nuts. (Always use torque wrench). Thread diameter Width ® ie) of bolt across flats mm mm Nm kgm 6 10 132216 1,350.15 8 B 3123 32203 10 7 6627 67207 12 19 113210 11521 4 2 177219 1822 16 ray 279230 28523 18 27 382239 3924 20 30 549 59 5626 22 32 745 283 76285 24 36 9272 103 94.5105 a a 13202 140 135215, 30 6 1720 190 175320 33 50 2210 240 225225 36 55 2750: 290 2802 30 39 60 3290 340 335235 Thread diameter Width of bolt across flats mm mm Nm kgm 6 70 7.852195 08202 8 3 186249 19305 10 4 40.2259 41206 12 a 82.352 7.85 84x08 5. Tightening torque of hose nuts Use these torques for hose nuts. Nominal No. |_Thfead diameter | Width across flat Tightening torque mm mm Nm kgm 02 4 19 245249 25205 03 8 28 492196 522 04 22 27 7852196 822 05 24 32 137.3229.4 1433 06 30 36 1765+ 29.4 1823 10 33 ro 196.12 49 2025 2 36 6 245.2 49 2525 4 a2 55 294.2249 3025 6. Tightening torque of split flange bolts Use these torques for split flange bolts. Thread diameter | Width across flat Tightening torque mm mm Nm kom 10 14 657268 2 7 112298 11821 16 2 27928 28523 014U02o14u02 DISASSEMBLY AND ASSEMBLY 7. Tightening torque of O-ring boss connector Use these torques for O-ring boss connector METHOD OF USING MANUAL Thread diameter Width across flat Tightening torque Nominal No. mm mm Nm I kgm 02 4 343249 35205 03, 04 20 Varies depending on] 93.1298 9521 05, 06 24 lvpe of connector 14212196 14552 10, 12 33 421.42 588 4326 a 2 377331323 8952135 8. Tightening torque Use these torques for O-ring boss cont of O-ring boss connector inector Thread diameter Width across flat Tightening torque Nominal No. mm mm Nm kgm 08 8 14 7.352 147 07520.15 10 10 7 14272147 1.1820.18 2 12 19 17.643 1.96 18202 14 14 2 22.543 1.96 23202 6 16 24 29.4249 3205 18 18 27 39.2249 4205 20 20 30 49249 5205 24 2 32 63.6298 Te1 30 30 32 107.82 18.7 11215 33 33 = 127-42 196 1322 36 36 36 1519245 165225 2 2 = 210.7229.4 21523 82 52 = | 3234s 4a 33245 30-5 @DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION PRECAUTIONS WHEN CARRYING OUT OPERATION [When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] 1. Precautions when carrying out removal work + If the coolant contains antifreeze, dispose of it correctly. + After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering. + When draining oil, prepare a container of adequate size to catch the oil. + Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. + To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. + Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. + Check the number and thickness of the shims, and keep in a safe place. + When raising components, be sure to use lifting equipment of ample strength. + When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. + Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or from entering after removal. * Precautions when handling piping during disassembly Fit the following blind plugs into the piping after disconnecting it during disassembly operations. 1) Hoses and tubes using sleeve nuts a Plug (nut end) Sleeve nut (elbow end) Use the two items below as a set 7 (07376-50270 (07221-20270 (Nut), 07222-00210 (Plug) 03 (07376-50316 (07221-20315 (Nut), 07222-00312 (Plug) 08 (07376-50422 (07221-20422 (Nut), 07222-00414 (Plug) 05 (07376-50522 (07221-20522 (Nut), 07222-00516 (Plug) 06 (07376-50628 (07221-20628 (Nut), 07222-00616 (Plug) 10 (07376-51034 (07221-21034 (Nut), 07222-01018 (Plug) 2 (07376-51234 (07221-21234 (Nut), 07222-01219 (Plug) 2) Split flange type hoses and tubes led Flange (hose end) Sleeve head (tube end) Split flange oF (07378-00800 (07378-10800 (07371-30800 05 (07378-00500 (07378-10500 (07371-30500 3) If the part is not under hydraulic pressure, the following corks can be used. Nominal Dimensions Nominal Part Number Dimensiors 06 ‘07049-00608 e[sle 08 (07049-00811 [6s] 1 10 07049-01012 toes | 12 12 07049-01215 raf 0 [15 14 07049-01418 1a [in s| 18 | Taper v8 a 16 07049-01620 16 [13.5] 20 i ie 18 (07049-01822 ve 15 [22 20 07049-02025 20 [17 | 25 22 (07049-02228 22 ([18.5| 28 24 (07049-02430 241 20 [30 27 (07049-02734 27 [22.5] 34 ewes 30-5-1 ® o14u02014U02 DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pins and lock plates securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 ~ 3 drops of adhesive. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil When press fitting parts, coat the surface with anti-friction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eyebolts, check that ther align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side. is no deformation or deterioration, screw them in fully, and When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: 1. Start the engine and run at low idling. 2. Operate the work equipment control lever to operate the hydraulic cylinder 4 - 5 times, stopping the cylinder 100 mm from the end of its stroke. Next, operate the hydraulic cylinder 3 - 4 times to the end of its stroke. After doing this, run the engine at normal speed. When using the machine for the first time after repair or long storage, follow the same procedure, 4ee Precautions when completing the operation If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine to circulate the water through the system. Then check the water level again. If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. If the piping or hydraulic equipment have been removed, always bleed the air from the system after reassembling the parts. * For details, see TESTING AND ADJUSTING, Bleeding air. ‘Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts. 30-5-2 °DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST SPECIAL TOOL LIST Nature of work ‘Symbol Part No. Part Name Q'ty Remarks: Enaine A_| 780-381-1170 | Wrench 7 |For tgntning cylinder head aaa 1 | 790-102-2802 | Wrench assembly | 1 [pprcempyay and mstaation sosembly of ronor.ow | c [2 | 791-416-1300 | Puller assembly | 1 |For installation of snp ring transmission assembly For checking operation of 3 | 798-301-1600 | Oil leak tester 1 [fecgheetng Disassembly and 1 | 791-422-1310 | Hanger + [enema tat aeeacen Feet Ai © Ta} 790-100-1340 | wrench 1 [Faasing sea ape 790-887-1082 | Lifting tool 1 1 [rovazr 1000 | Pate 1 |SreaaraeyansJogauation oror0.si6a5 | Bot 2 7 ee 1 agrrnaton arate Disassambly and _ | [zerszr tao [Remover assembiy [1 | comme cee 3 | 790-101-2102 | Putter al Reurnarmcct sete 790-101-1102 | Pump 1 791-427-1200 | Installer assembly | 1 i earanisani eae 1 ]fscet tng ert nub 790-101-1102 | Pump 1 791-885-8008 | Compressor 8 1 791-695-3160 | Extension 1 Dea es aie zai 790-201-2790 | Spacer 1 780-101-1102 | Pump 1 790-101-1600 | Gylinder 1 2 | 796-230-1110 | Installer 1 [isha snang season 3 | 791-516-1520 | Installer 1 [heginstalletion of track roier Undercarriage 6 [71516-1820 | installer 1 [Faginstion afte toa 791-430-1200 | Installer assembly | 1 i aerate 1 Tages ting pot sat 790-101-1102 | Pump 1 791-480-1100 | Remover assembiy | 1 6 | 790-101-2102 | Puller 1. [For taragval ef equaltzar bor [ 79001-1102 | Pump 1 Fling wi a Yor Tr, Wank 7 | 791-601-1000 1 eee 30-6 o14u02Nature of work Symbol Parts No. Part name ay Remarks 790-802.2000 | Repair stand 1 ore For disassembly and assembly oy abe et tod2 nepal ent 1 | of hydraulic cylinder assembly 790-101-1102 | Pump [4 For removal and installation of 2 | 790-330-1100 | Multi-wrench | eoemone leap seen Paear 1 | Forzomoval and instalation of Disassembly and — assembly of hydraulic | 4 | 4 | 790-720-1000 | Expander 1 cylinder assembly + | 738-720-1650 | Ring 1_ | For installation of piston ring 07281-01029 | Clamp 1 6 | 790-201-1791 | Push tool 1__| For press fitting coll bushing 790-101-5021 | Grip 1 7 | For press fitting dust seal 7 | 01010-50816 | Bolt Kit Part No, 790-201-1500 o14u02 1 | 795-931-1100 | Oil seal puller ass'y 1. | For removal of rear seal | | 795-931-1210 | Oil seal ig [a Disossembiy and See esnerear| 1 | [oras0e2s | Bon 2 [oresoaneas | Bon 2| oroso 1625 | Bor 3 lubricated track link eee eee eee Et Cleaning opin of leaning of pin of x | 791-600-7460 | Brush 1 | Forwashing pin | 791-432-1110 | Push tool 1 | v [rerea67560 | Bor 1] Fortege aug 2 [rove 1] Forsmet pus ‘791-646-7590 | Guide. iz | i ‘Aictightness check of | | 790-701-3000 | Checker 1 lubricated track link Filling of ubricated track] Ke | 791.946.8002 Tink with oil | Lubricator 1 30-7Nature of work | Symbol | Parts No. PartName [Q'ty] Remarks 737-6953110_ [Frame 1 791-635-3160 [Extension 1 791-635-3170 [Nut 4 1 | 791-695-3180 [Screw 2 rack link ko 791-635-3190 | Screw 1 791-645-3510 [Adapter 1 791-646-3260 [Pusher 7 > |_220st0%-1102_| Pump 7 790-101-1300 | Cylinder 1 [980 KN (100 tons) 790-105-2300 | Jack 1 [196 KNV (20 tons) © | 790-101-1102 [Pump 1 —_ [731-846-9520 [Adapter 1 791-432-1210 | Spacer 1 791-432-1110 [Push tool 7 2 | 791-606-7550 [Bar 1 |For targe plug 791-646-7560 | Guide 7 3. | 791-432-1120 [installer 1 | F3 Type seal 4 | 7av-6as.540 [Guide 1 791-695.2110 [Frame 1 791-695-2160 [Extension 1 | [preveasa170 [Nut 4 791-695-3180 |Serew 2 Track lnk 5 | 701-635-3190 | Screw 1 | Pin installer ee « 791-645-3510 [Adapter 1 791-645-3520 [Adapter 1 791-645-2530 [Pusher 791-4321210 [Spacer 1 791-432-1220 |Spacer 1 731-635-3110 | Frame 1 791-635-3160 [Extension 1 791-635:3170 [Nut a 791-695-2190 [Screw 7 791-645-3520 [Adapter 7 791-645-3540 | Guide 1 791-645-3550 [Pusher 7 30-8 o14u02Nature of work Symbol | Parts No PartName —_[a'ty Remarks > | zetor-1102 [Pump 1 790-105-2300. | Jack 1_ [196 KN (20 tons) 8 | 791-646-2270 [Guide 1 [Pin installer 791-635-3110. [Frame 1 BiseeAllls ke 791-635-3160 | Extension 1 g {791696170 [Nut 4 | Pin installer 791-635-3180 | Screw 2 | | 791-635-3190 [Screw 1 791-645-3510 | Adapter 1 791-645-3500 [Remover & Installer | 1 790-101-1102 | Pump 1 ieoek tae 790-101-1300 | Cylinder 1 [980 KN (100 tons) remover & Ke installer 790-105-2300 | Jack 1. [196 KN (20 tons) 791-432-1210 | Spacer 1 791-432-1220 | Spacer 1 o14u02 30-9REMOVAL OF STARTING MOTOR ASSEMBLY By Disconnect the cable from the negative (-) terminal of the battery. 1. Open top right side cover and remove bottom side cover. 2. Disconnect wiring (1) and (2). 3. Disconnect connector (3). 4, Remove starting motor assembly (4). INSTALLATION OF STARTING MOTOR ASSEMBLY ‘© Carry out installation in the reverse order to removal 30-10 ® eS Serial No. 3001 ~ 3033 o14u02o1au02 REMOVAL OF ALTERNATOR ASSEMBLY Serial No. : 3001 ~ 3033 A Disconnect the cable trom the negative (-) terminal of the battery. - Open top right side cover and remove bottom side cover. Disconnect wiring (1). Remove cover (2). Remove locknut (3), then remove rod (4). Loosen mounting bolt and nut (5), and remove 2 fan belts (6). = Remove mounting bolt and nut, then remove alternator assembly (7). INSTALLATION OF ALTERNA- TOR ASSEMBLY Serial No. : 3001 - 3033 © Carry out installation in the reverse order to removal, Gn Adjusting tension of alternator belt % Adjust the tension of the alternator belt. For details, see TESTING AND ADJUST- ING, 30-10-1 @DISASSEMBLY AND ASSEMBLY REMOVAL OF ALTERNATOR ASSEMBLY Serial No. 3034 and up Ai Disconnect the cable from the negative (-) terminal of the battery. 1. Open top right side cover and remove bottom side cover. + On machines with cab specification, the washer tank is installed inside the bottom right side cover, so disconnect the hose and connector, then remove the bottom side cover. 2. Disconnect wiring (1). 3. Remove cover (2). 4. Remove locknut (3), then remove rod (4). 5. Loosen mounting bolt and nut (5), and remove 2 fan belts (6). 6. Remove mounting bolt and nut, then remove alternator assembly (7). INSTALLATION OF ALTERNATOR ASSEMBLY Serial No. 3034 and up Carry out installation in the reverse order to removal. ‘Adjusting tension of alternator belt * Adjust the tension of the alternator belt. For details, see TESTING AND ADJUSTING. 30-10-2 ® ALTERNATOR 014U02o14u02 REMOVAL OF ENGINE OIL COOLER CORE 1. Drain cooling water. 2. Open top right side cover and remove bottom, side cover. 3. Remove turbocharger outlet tube (1). (Only for machines equipped with turbocharger) 4, Disconnect 3 clamps of wiring (2) 5, Remove oil cooler assembly (3) 6. Remove nut (4), then remove cooler core (6) from cover (5). INSTALLATION OF ENGINE OIL COOLER CORE © Carry out installation in the reverse order to removal. oo G"3=) Cooler core mounting nut 43.1 + 15.7 Nm (4.4 = 1.6 kam) © Refilling with water Add water through water filler to the spe. cified lever. Run the engine to circulate the water through the system. Then check the water level again 140F12006 30-11REMOVAL OF FUEL INJECTION PUMP ASSEMBLY Close the fuel supply valve. |. Open top left side cover and remove bottom side cover. x . Disconnect fuel control rod (1). Disconnect fuel hoses (2, (3) and (4). rs |. Disconnect fuel supply tube (5) and fuel return tube (6). + Mark the position of the tube clamp. ok If the fuel tank is full, fuel will flow out when tube (6) is disconnected, so after disconnecting it, bend the fuel tank return hose and tie it with string i roo Remove lubrication tubes (7) and (8). [a . Disconnect 6 fuel injection tubes (9). [#5] i sawemne 7. Remove 2 lock bolts (10) of laminated coupling and cross coupling. + Before removing the bolt, mark the mounting position of the laminated coupling and cross coupling 8. Remove fuel injection assembly (11). 30-12 o14u02INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY © Carry out installation in the reverse order to removal oO * Connect the rod. For details, see TESTING AND ADJUST- ING, Adjusting fuel control linkage 1 Hose, tube mounting joint bolt: 172 +2.5Nm (1.75 + 0.25 kgm) Tube mounting joint bolt (large): 29.444.9Nm (3.0 + 0.5 kam) (small): 22.14 2.5Nm (2.25 + 0.25 kgm) Injection tube sleeve nut: 23.5 + 1.0 Nm (2.40.1 kgm) Laminated coupling mounting bolt: 61.2+2.5Nm (6.25 + 0.25 kgm) o14u02 4% Install the fuel injection pump. For details, see TESTING AND ADJUST- ING, Testing and adjusting of fuel injection timing. G>5=) Fuel injection pump mounting bolt: 29.4+49Nm {3.0 + 0.5 kgm) 30-13REMOVAL OF WATER PUMP ASSEMBLY Serial No. : 3001 ~ 3033 1. Drain cooling water. 2. Open top right side cover and remove bottom side cover. 3. Disconnect hose, and remove reserve tank (1) together with bracket, 4. Remove safety cover (2) 5. Remove muffler drain pipe (3) %* When removing the muffler drain pipe, loosen the mounting bolt of muffler (4), then lift up to remove. 6. Remove connectors (6) and (6). 7. Disconnect connector (7). 8. Remove bracket (8) 9. Remove water pump assembly (9) a INSTALLATION OF WATER PUMP ASSEMBLY Serial No. : 3001 - 3033 '* Carry out installation in the reverse order to removal, ao ==] Water pump mounting bolt: 66.2 + 7.4 Nm {6.75 + 0.75 kgm) Add water through water filler to the specified level. Run the engine to circulate the water through the system. Then check the water level again, 30-14 i) o14u02014U02 DISASSEMBLY AND ASSEMBLY REMOVAL OF WATER PUMP ASSEMBLY Ser 1 2 Penoane 10. ". 12. jal No. 3034 and up Drain cooling water. Open top right side cover and remove bottom side cover. + On machines with the cab specification, the washer tank is installed inside the bottom right side cover, so disconnect the hose and connector, then remove the bottom side cover. Disconnect hose, and remove reserve tank (1) together with bracket. J. Remove safety cover (2). . Remove bracket (3). . Remove muffler drain pipe (4). . Disconnect water pump outlet connector (5). . Remove thermostat housing (6). . Disconnect water pump inlet connector (7). Remove bracket (8). Remove connector (9). Remove water pump assembly (10). INSTALLATION OF WATER PUMP ASSEMBLY Serial No. 3034 and up Carry out installation in the reverse order to removal. G"H=] Water pump mounting bolt: 66.2 + 7.4.Nm (6.75 + 0.75 kgm) Refilling with water Add water through water filler to the specified level. Run the engine to circulate the water through the system. Then check the water level again. WATER PUMP. 30-14-1 @orauoz REMOVAL OF TURBOCHARGER ASSEMBLY 1. Open top right side cover and remove bottom side cover. .. Disconnect hoses (1) and (2) . Remove safety covers (3), (4), (5), and (6). 4. Disconnect turbocharger inlet tube (7) and outlet tube (8) Remove turbocharger assembly (9) together with connector (10) INSTALLATION OF TURBO- CHARGER ASSEMBLY ‘© Carry out installation in the reverse order to removal, 30-15DISASSEMBLY AND ASSEMBLY REMOVAL OF NOZZLE HOLDER ASSEMBLY 1. Remove left and right engine side covers. 2. Remove spill pipe (1). =D 3. Disconnect fuel injection pipe (2) of nozzle holder to be removed. 4. Remove nozzle holder assembly (3). * Be careful not to let any dirt or dust enter the nozzle holder assembly mount. INSTALLATION OF NOZZLE HOLDER ASSEMBLY + Carry out installation in the reverse order to removal. ey 321 Spill pipe mounting joint bolt: 24.5 + 4.9 Nm (2.5 + 0.5 kgm} G>==) Fuel injection mounting sleeve nut: 23.5 1.0 Nm (2.4 + 0.1 kgm) Tighten the mounting bolts of the nozzle holder uniformly in turn. J3=] Nozzle holder assembly mounting bolt: 21.6 + 2.9 Nm (2.2 + 0.3 kgm} 30-16 NOZZLE HOLDER ‘Serial No. 3001 - 3033 xo0s10 014U02014U02 REMOVAL OF THERMOSTAT ASSEMBLY Serial No. : 3001 - 3033 1. Drain cooling water. 2. Open top right side cover. 3. Remove water temperature sensor connector (1) from clip. > Disconnect radiator inlet hose (2). ;. Remove cover (3). 6. Remove thermostat assembly (4). INSTALLATION OF THERMOSTAT ASSEMBLY Serial No. : 3001 - 3033 © Carry out installation in the reverse order to removal. © Refilling with water o& Add water through water filler to the specified level. Run the engine to circulate the water through the system. Then check the water level again. 30-17 oODISASSEMBLY AND ASSEMBLY REMOVAL OF THERMOSTAT ASSEMBLY Serial No, 3034 and up 1, Remove thermostat housing (1). For details, see REMOVAL OF WATER PUMP ASSEMBLY. 2. Remove thermostat (2) from housing. INSTALLATION OF THERMOSTAT ASSEMBLY Serial No. 3034 and up + Carry out installation in the reverse order to removal. + Refilling with water * Add water through water filler to the specified level. Run the engine to circulate the water through the system. Then check the water level again. 30-17-1 @ ‘THERMOSTAT proms 01402DISASSEMBLY AND ASSEMBLY REMOVAL OF CYLINDER HEAD ASSEMBLY Serial No. 3001 - 3033 a connect the cable from the negative (-) ter- inal of the battery. 1. Drain cooling water. 2. Remove left and right engine side covers, then remove hood (1). Wren disconnecting the connecting pin of ‘the damper and side cover, use a lever block to support the rod portion of the damper, then remove the pin, taking care not to let it fly out. facran] Engine side cover (each): 25 kg (is) Hood: 55 kg 3. Remove bottom left and right engine side covers. + On machines with the cab specification, the washer tank is installed inside the bottom right side cover, so disconnect the hose and connector, then remove the bottom side cover. 4. Disconnect fuel return tube (2), and remove fuel filter assembly (3), then move it towards track shoe. tea * If the fuel tank is full, fuel will flow out when tube (2) is disconnected, so after disconnecting it, bend the hose and tie it with string 5. Disconnect electrical intake air heater wiring (4) and wiring connector (5). Iter assembly (6) together with pip- 8. Disconnect fuel return hose (8). CYLINDER HEAD 01402o1au02 10. 1". 12, 13. 14, 15. 16. 7. 18, Disconnect tube (9). Sling air cleaner and intake manifold (10), and remove mounting bolts, then remove together with tube (9). 4 Mark the mounting position of each spacer and tube clamp before removing Remove safety covers. Sling muffler and exhaust manifold assembly (11), and remove mounting bolts, remove assembly. Remove muffler drain pipe (12). Disconnect wiring connector (13) of water temperature sensor from clip. Disconnect aeration hose (14) and radiator inlet hose (15). Remove water manifold assembly (16). Remove spill pipe (17). Ga Remove bracket (18), then remove cylinds head cover (19). © Remove bracket (18) only for No. 1 cylinder head. 1 Te a 14073094 aor 13035 30-19 ©19. Remove nozzle holder assembly (20). 20. Remove rocker arm assembly (21). Ga % Loosen the locknut and turn the adjustment screw back 2 — 3 turns, 21, Remove rocker arm housing (22). Gs) 22. Remove push rod (23), 23, Remove crosshead (24). wz 24, Remove head bolt (25), then remove cylinder head (26) (10) 30-20 = 120F13037| o1auo2o1auo2 DISASSEMBLY AND ASSEMBLY CYLINDER HEAD INSTALLATION OF CYLINDER HEAD ASSEMBLY Serial No. 3001 - 3033 + Carry out installation in the reverse order to removal. Gr] Fuel return tube mounting joint bolt: 29.4 + 4.9 Nm (3.0 + 0.5 kgm} jection pipe mounting sleeve nut: 29.4 + 4.9 Nm (3.0 + 0.5 kgm) % Screw in the manifold mounting bolts 2 - 3 threads by hand, tighten bolts: () - @, and after that tighten the other bolts. =] Manifold mounting bolt: 66.2 + 7.4 Nm (6.8 + 0.8 kgm} G“w=] Spill pipe mounting joint bol 245 + 4.9 Nm (2.5 + 0.5 kgm} =] Graz) Head cover mounting bolt: 9.8 £ 1.0 Nm (1.0 + 0.1 kgm} kel “% Tighten the mounting bolts of the nozzle holder uniformly in turn. ‘>= Nozzle holder mounting bolt: 21.6 + 2.9 Nm (2.2 + 0.3 kgm} Check that the ball of the adjustment screw is fitted properly into the socket of the push rod. * Adjust the valve clearance. For details, see TESTING AND ADJUSTING, Adjusting valve clearance. Gyw=] Rocker arm assembly mounting bolt: 66.2 + 7.4 Nm (6.75 + 0.75 kam) GE Lock nut: 66.2 + 7.4 Nm {6.75 + 0.75 kgm) ‘G>H=I Rocker arm housing mounting bolt: 66.2 + 7.4Nm (6.75 + 0.75 kgm} 140F13040 | ex] %* Adjust the crosshead as follows. i) Loosen locknut, then turn adjustment screw back. ii) Press down lightly on top of crosshead, then tighten adjustment screw. ili) When adjustment screw contacts valve stem, tighten a further 20°. iv) Tighten locknut to hold in position. ==] Locknut: 66.2 + 7.4Nm {6.75 + 0.75 kgm} 30-21DISASSEMBLY AND ASSEMBLY CYLINDER HEAD If any rust is found that exceeds an area of 5 mm square on the shaft or thread of the bolt, replace the head bolts with new parts. % Check that there is no dirt or dust on the cylinder head mounting surface or inside the cylinder. %* When installing the gasket, check that the grommet has not come out of position. %* Coat the bolt thread, seat surface, and seat surface of the cylinder head hole with molybdenum disulphide (LM-P). * Screw in the cylinder head mounting bolts 2 — 3 turns by hand, then tighten in the order shown in the diagram. (ADX= Mounting bolt: Anti-friction compound (LM-P) Gyre] Cylinder head mounting bolt: eisoraie Jet Step: Tighten to 68.6 + 9.8 Nm {7 + 1 kgm) 2nd Step: Tighten to 107.9 + 4.9 Nm {11 + 0.5 kgm} 3rd Step: 1. When using tool A: + Using an angle tightening wrench, tighten the bolt a fur- 566063534. ther 90°°3°, ea ear rarr eer 2. When not using tool A: 1) Using the angle of the bolt head as the base, make a start mark on the cylinder head and ‘Start mark on cylinder head socket. 2) Make an end mark at a posi- | | Sttmark tion 90°% from the start ue = mark. 3) Tighten so that the start mark Socket > oO End mark on the socket is aligned with Ed man, the end mark made at 90°°9° Se esse un eck on the cylinder head. 21wr02229| %* After tightening, make one punch mark on the bolt head to indicate the number of times that the bolt has been used. Make mark with punch + If any bolt has five punch marks, do not reuse it. Replace it with a new bolt. ing with water ‘* Add water through water filler to the specified level. Run the engine to circulate the water through the system. Then check the water level again. 521201061, 30-22 ® 01402o1auoz DISASSEMBLY AND ASSEMBLY REMOVAL OF CYLINDER HEAD ASSEMBLY Serial No. 3034 and up A Disconnect the cable from the negative (-) terminal of the battery. 1. Drain cooling water. 2. Remove left and right engine remove hood (1). covers, then AWren disconnecting the connecting pin of ‘the damper and side cover, use a lever block to support the rod portion of the damper, then remove the pin, taking care not to let it fly out. (CGE Engine side cover (each): 25 kg [i] Hood: 55 kg 3. Remove bottom left and right engine side covers. + On machines with the cab specification, the washer tank is installed inside the bottom. right side cover, so disconnect the hose and connector, then remove the bottom side cover. 4. Disconnect fuel return tube (2), and remove fuel filter assembly (3), then move it towards track shoe. If the fuel tank is full, fuel will flow out when tube (2) is disconnected, so after disconnecting it, bend the hose and tie it with string. 5. Disconnect electrical intake air heater wiring (4) and wiring connector (5). 6. Remove oil filter assembly (6) together with piping. 7. Remove 6 fuel injection pipes (7). 8. Disconnect fuel return hose (8). CYLINDER HEAD 140613018 30-23 ®DISASSEMBLY AND ASSEMBLY CYLINDER HEAD 9. Disconnect tube (9). 10. Sling air cleaner and intake manifold (10), and remove mounting bolts, then remove together with tube (9). Mark the mounting position of each spacer and tube clamp before removing. 11. Remove safety covers. 12. Sling muffler and exhaust manifold assembly (11), and remove mounting bolts, then remove assembly. 13, Remove muffler drain pipe (12). 14, Remove aeration tube (13). 15. Remove spill pipe (14). 16. Remove bracket (15), then remove cylinder head cover (16). + Remove bracket (15) only for No. 1 cyl head. 30-23-1 © o14u02014U02 DISASSEMBLY AND ASSEMBLY CYLINDER HEAD 17. Remove nozzle holder assembly (17). [ze 18, Remove rocker arm assembly (18). Ea * Loosen the locknut and turn the adjustment screw back 2 - 3 turns. 19. Remove rocker arm housing (19). 20. Remove push rod (20). 21. Remove crosshead (21). 22. Remove head bolt (22), then remove cylinder head (23).DISASSEMBLY AND ASSEMBLY INSTALLATION OF CYLINDER HEAD ASSEMBLY Serial No. 3034 and up + Carry out installation in the reverse order to removal. ‘G>H=1 Fuel return tube mounting joint bolt: 29.4 + 4.9 Nm (3.0 + 0.5 kgm} =] Fuel injection pipe mounting sleeve nut: 29.4 + 4.9 Nm {3.0 + 0.5 kgm} Screw in the manifold mounting bolts 2-3 threads by hand, tighten bolts: © - @, and after that tighten the other bolts. =] Manifold mounting bolt: 66.2 + 7.4 Nm (6.8 + 0.8 kgm} =] Spill pipe mounting joint bolt: 245 + 4.9 Nm (25 + 0.5 kgm} a=] Head cover mounting bolt: 9.8 + 1.0 Nm (1.0 1 kgm} % Tighten the mounting bolts of the nozzle holder uniformly in turn. ==] Nozzle holder mounting bolt: 21.6 + 2.9 Nm {2.2 + 0.3 kgm) * Check that the ball of the adjustment screw is fitted properly into the socket of the push rod. * Adjust the valve clearance. For details, see TESTING AND ADJUSTING, Adjusting valve clearance. Gz] Rocker arm assembly mounting bolt: 66.2 + 7.4 Nm {6.75 + 0.75 kgm} GED Lock nut: 66.2 + 7.4 Nm (6.75 + 0.75 kgm} ‘m= Rocker arm housing mounting bolt: 66.2 + 7.4 Nm’ 16.75 + 0.75 kgm} 30-23-3 @® CYLINDER HEAD 140F 13040 Adjust the crosshead as follows. i) Loosen locknut, then turn adjustment screw back. ii) Press down lightly on top of crosshead, then tighten adjustment screw. When adjustment screw contacts valve stem, tighten a further 20°. iv) Tighten locknut to hold in position. w=] Locknut: 66.2 + 7.41Nm {6.75 + 0.75 kgm} o1au02014U02 DISASSEMBLY AND ASSEMBLY CYLINDER HEAD If any rust is found that exceeds an area of 5 ‘mm square on the shaft or thread of the bolt, replace the head bolts with new parts. ‘* Check that there is no dirt or dust on the cylinder head mounting surface or inside the cylinder. ‘* When installing the gasket, check that the grommet has not come out of position. ‘* Coat the bolt thread, seat surface, and seat surface of the cylinder head hole with molybdenum disulphide (LM-P). + Screw in the cylinder head mounting bolts 2 = 3 turns by hand, then tighten in the order shown in the diagram. Xs Mounting bolt: Anti-riction compound (LM-P) S3=1 Cylinder head mounting bolt: A 1st Step: Tighten to 68.6 + 9.8 Nm (71 kgm} _ a 2nd Step: Tighten to 107.9 + 4.9 Nm ie P| {11 0.5 kgm} 3rd Step: 1. When using tool + Using an angle tightening wrench, tighten the bolt a fur- s0orosassax ther 90°*37, 2. When not using tool A: 1) Using the angle of the bolt head as the base, make a start mark on the cylinder head and ‘Start mark on cylinder head socket. | 2)Make an end mark at a posi- aut a‘ tion 90°°3” from the start = a mark. 3) Tighten so that the start mark Socket => End mark ‘on the socket is aligned with eta. i} eninge hea the end mark made at 90°°3 ‘Start mark on socket on the cylinder head 2iwroz22e % After tightening, make one punch mark on the bolt head to indicate the number of times that the bolt has been used. Make mark with punch + If any bolt has five punch marks, do not reuse it. Replace it with a new bolt. + Refilling with water Add water through water filler to the specified level. Run the engine to circulate the water through the system. Then check the water level again. Fe2s201081 30-23-4 ®REMOVAL OF ENGINE FRONT SEAL 1. Remove radiator assembly. For details, see REMOVAL OF RADIATOR ASSEMBLY. 2. Remove fan (1). 3. Remove fan guard and shroud assembly (2). 4, Loosen mounting bolt of alternator assembly, adjustment plate mounting bolt, and adjustment bolt, and remove alternator and fan drive (3). 5. Loosen air conditioner compressor mounting bolts and adjustment bolt, then remove air conditioner drive belt (4). ez 6. Remove damper (5). # 7. Remove pulley (6). Ea) 8. Remove front oil seal (7). % When removing the front oil seal, be ex: tremely careful not to damage the crankshaft. worse 30-24 o14u02o14u02 INSTALLATION OF ENGINE FRONT SEAL © Carry out installation in the reverse order to removal, ao %& Adjust the fan belt tension, For details, see TESTING AND ADJUST- ING, Testing and adjusting fan belt tension % Adjust the air conditioner compressor belt tension, For details, see TESTING AND ADJUST- ING, Testing and adjusting air conditioner ‘compressor belt tension. S255) Damper mounting bolt: 110.25 + 12.25 Nm (11.25 + 1.25 kgm) 235) Pulley mounting bolt: 276.85 + 31.85 Nm (28.25 + 3.25 kgm) > Oil seal press-fiting tolerance a: 11*2 mm oe Lip of oil seal (fill 50 — 80% of space at lip): Grease (G2-LI) rE all orn 30-25REMOVAL OF ENGINE REAR SEAL 1. Remove damper assembly. For details, see REMOVAL OF DAMPER ASSEMBLY. 2. Using eyeboits, sling flywheel (1), and remove mounting bolts, then remove. [#1] A. The Hiywinee pilot is shallow and it may come off suddenly, so be careful not to get your fingers caught. 3. Hook puller tip of tool I1 to metal ring of seal (2), and use impact force of a slide hammer to pull out. Before pulling out, knock the oil seal in slightly. This separates the seal from the housing and make it easier to pull out the seal. + Be extremely careful not to damage the crankshaft. % Do not use a dril. The metal powder will get inside the engine. 30-26 Too! H4: Seal puller assembly ———— 014u02o14u02 INSTALLATION OF ENGINE REAR SEAL '* Carry out installation in the reverse order to removal ‘%& When tightening the flywheel mounting bolts, follow the order on the diagram and use the procedure below, “—. Flywheel mounting bolt thread: Lubricating oil (E030) Flywheel mounting bolt: 1st step: 147 + 19.6 Nm (15 + 2.0 kgm) 2nd step: 289.1 + 19.6 Nm (29.5 + 2.0 kam) © Using dial gauge ©, measure radial and face runout of flywheel. Face runout: 0.2 mm Radial runout: 0.15 mm %& With the Tefion seal (lay down lip seal), check the condition of the wear of the shaft, select either a standard seal or a seal with a sleeve, then assemble the seal. The condition of wear is judged by the smoothness (no deformation can be felt when touched with the flat of a finger, depth of wear less than 10um). If there are no scratches, assemble a standard seal; in all other case, as. semble a seal with a sleeve. ‘Procedure for assembling standard seal & Before assembling the seal, check that there are no scratches, burrs, flashes, or rust on the housing, lip sliding surface, or at the corner of the end face of the crankshaft + When assembling the seal, do not coat the shaft and seal lip with oil or grease, and wipe off all the oil from the shaft. % Do not remove the internal plastic tube from the standard seal until assembling the seal. ‘Standard seal (61521-4160) Seal wah steve (6151-20-4160) Lpat utch end Lpat engine end toma plastic tbe ‘and assembly guide| Large inside ameter end ‘Smal isi diameter end 30-271) Put large inside diameter end of internal plastic tube (3) in contact with end of crankshaft (4). % Be particularly careful to assemble facing in the correct direction, 3 4 or ane 2) Hold metal ring of seal (2) with both hands and push in with force. 3) After pushing seal in, remove internal 2 plastic cylinder (3). + When removing, be careful not to damage the seal lip. 4) Tighten bolts of too! I-2 uniformly until end face of tool 2 contacts end face of crank- 2 shaft (4) to press fit seal (2). % When press fitting the seal, be extremely careful not to damage the lip at the clutch end when setting the tool. W 12 % After press fitting the seal, remove all the remains of the red sealant on the outside circumference. Noreost o14u02 ‘* Assembly procedure for seal with sleeve %* Before assembling the seal, check that there are no scratches, burrs, flashes, or rust on the housing, lip sliding surface, or at the corner of the end face of the crank- Up at enn end Lp atten end shaft. + When assembling the seal, do not coat the shaft and the area between the sleeve and seal lip with oil or grease, and wipe off all the oil from the crankshaft. Always handle the seal and sleeve as a set. Never disassemble it. 30-28onrauo2 1) Set sleeve and seal (2) to tool 3. ATs Inside surface of sleeve 2) Put sleeve of seal in contact with end face of crankshaft, then tighten bolts of tool -3 uniformly until end face of tool I-3 contacts end face of crankshaft (4) to press fit sleeve and seal (2). 3) Remove tool I-3 and install tool 1-2. 4) Tighten bolts of tool -2 uniformly until end face of tool 1-2 contacts end face of crankshaft (4) to press fit sleeve and seal (2). * After press fitting the seal, remove all the remains of the red sealant on the outside circumference. Coat i he salant fod 30-29REMOVAL OF FUEL TANK ASSEMBLY Serial No. : 3001 - 3033 Ay Disconnect the cable from the negative (-) terminal of the battery. 1. Remove rear sweep guard assembly. For details, see REMOVAL OF SWEEP, CANOPY ASSEMBLY. Rear sweep guard assembly: 190 kg 2. Remove seal installed to operator's seat frame, 3. Remove cover, and disconnect fuel return hoses (1) and (2). % If the fuel tank is full, fuel will flow out when the hose is disconnected, so drain the fuel to 2 point where it will not flow out. 4. Open battery side cover, and disconnect wiring connector (3) and ground connection (4). 5. Remove chassis rear cover. 6. Closr fuel supply valve, and disconnect hose ©). 7. Open cover at fender side, then remove left and right fuel tank mount bolts (6).. fen 8. Adjust position of sling rope, and remove fuel tank assembly (7). (ig) Fuel tank assembly : Approx. 550 kg (when full) INSTALLATION OF FUEL TANK ASSEMBLY Serial No. : 3001 - 3033 ‘* Carry out installation in the reverse order to removal. %* Make the clearance uniform between the fuel tank and left and right covers, then tighten the mounting bolts. 30-30 oO 140F13053 140F13057 Fotauross 014U02014U02 DISASSEMBLY AND ASSEMBLY REMOVAL OF FUEL TANK ASSEMBLY Serial No. 3034 and up A Disconnect the cable from the negative (-) terminal of the battery. 1. Remove seal installed to operator's compartment frame. 2, Remove cover, then disconnect fuel return hoses (1) and (2). + Ifthe fuel tank is full, fuel will flow out when the hoses are disconnected, so drain the fuel to a point where the fuel will not flow out. 3. Open battery cover and remove wiring connector (3) (CNA). 4, Disconnect wiring, then remove rear lamp (4). 5. Remove cover at rear of machine. 6. Close fuel supply valve, then disconnect hose (5). 7. Remove bracket (6). a FUEL TANK DETERSDISASSEMBLY AND ASSEMBLY 8 Remove cover at fender side, then remo\ and right fuel tank mounting bolts (7). 9. Set lifting tool to rear lamp mounting bracket, then lift fuel tank assembly (8), and move to rear to remove. fac) Fuel tank assembly: Approx. 550 kg (when fuel tank is full) INSTALLATION OF FUEL TANK ASSEMBLY Serial No. 3034 and up + Carry out installation in the reverse order to removal. ‘Goma Bracket mounting bolt: 110 + 12.3 Nm {11.25 + 1.25 kgm} “Make the clearance between the fuel tank and the left and right covers uniform, and tighten the mounting bolts. 30-30-2 FUEL TANK ox003182 014U02014u02 REMOVAL OF RADIATOR ASSEMBLY A Lower the work equipment to the ground and stop the engine. Then loosen the oil fil ler cap slowly to release the pressure inside the hydraulic tank, By Disconnect the cable from the negative (—) terminal of the battery. 1. Remove sweep guard on top of engine. For details, see REMOVAL OF SWEEP, CANOPY ASSEMBLY. 2. Drain cooling water. 3. Lift off engine hood side cover assembly (1). Go [42x] Engine hood side cover assembly: 105 kg 4. Remove radiator under cover (2). 5. Disconnect left and right power train oil cooler hoses (3). + Fit blind plugs to prevent dirt or dust from getting into the piping. 6. Remove radiator outlet hose (4). 7. Open front mask. 8 Remove baffle (6). 9. Disconnect hydraulic oil cooler hose (6), and remove hydraulic oil cooler assembly (7). saws 4013062 30-3110. u. 12. 13. 14. 15. Remove radiator top cover (8). Disconnect hose (9) between radiator and reserve tank. Disconnect aeration hose (10). Ge Remove radiator inlet hose (11). fea Remove bracket (12) Remove 2 radiator bottom mount bolts, and raise radiator assembly (13) slowly, then remove. % When removing the radiator, be extremely careful not to damage the seal or radiator core. TEE Radiator assembly: 45 kg 30-32 o14u02INSTALLATION OF RADIATOR ASSEMBLY © Carry out installation in the reverse order to removal. 62) Hood mounting bolt: 276.9 + 31.9Nm (28.25 + 3.25 kgm) m1 Radiator outlet and inlet hose clamp: 5.9 + 0.5 Nm (60 + 5 kgem) =) Aeration hose clamp: 2.9 + 0.5 Nm (30 5 kgem) * Refilling with water Add water through water filler to the specified level. Run the engine to circulate the water through the system. Then check the water level again. * Refilling with oil (hydraulic tank, power train case) + Add engine oil through oil filler to the specified level Run the engine to circulate the oil through the system. Then check the oil level again. o1auo2 REMOVAL OF HYDRAULIC OIL COOLER ASSEMBLY A Lower the work equipment to the ground and stop the engine. Then release the pressure inside the circuit. For details, see TEST- ING AND ADJUSTING, removing remaining pressure from hydraulic circuit. 1. Open radiator grill 2. Disconnect hose (1) + Fit blind plugs to prevent dirt or dust from getting into the piping. 3. Remove hydraulic oil cooler assembly (2). INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY © Carry out installation in the reverse order to removal. ‘© Refilling with oil (hydraulic tank) % Add engine oil through oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. 30-33REMOVAL OF ENGINE ASSEMBLY Serial No. : 3001 - 3033 By Disconnect the cable from the negative (—) terminal of the battery. + Close the fuel supply valve of the fuel tank. 1. Remove sweep guard on top of engine. For details, see REMOVAL OF SWEEP GUARD, CANOPY ASSEMBLY. x Remove radiator assembly. For details, see REMOVAL OF RADIATOR ASSEMBLY. » Disconnect fuel supply hose (1), fuel return hose (2), and spill hose (3). ok If the fuel tank is full, fuel will flow out when hoses (2) and (3) are disconnected, so after disconnecting them, bend the hoses and tie them with string. Disconnect fuel control rods (4) and (5), cable (6), then remove bracket (7). ry Disconnect starting motor wiring (8). = Disconnect CN17, CN18, and CN20 of central wiring connector (9). 7. Disconnect engine ground connection (10). & Remove reserve tank (11) together with bracket (12). 30-34 oO o14u02° Remove fan (13). 10. Remove shroud (14), 11. Open chassis bottom cover, and disconnect universal joint (15) at damper end. A, The bottom cover weights 26 ks, so support it with a transmission jack before removing the mounting bolts. 014U02 12. Remove left and right engine mount bolts at front (16) and rear (17) ae 13. Use a lever block to raise engine assembly horizontally, then remove engine mount cap (18) at rear right. 140613183 30-35assembly (19) towards front of machine, and gradually lft it off. + When removing the engine assembly, be extremely careful not to damage the wiring or hoses. (ie} Engine assembly: 1,300 kg INSTALLATION OF ENGINE ASSEMBLY Serial No. : 3001 - 3033 * Carry out installation in the reverse order to removal. Adjust the rod and cable. For details, see TESTING AND ADJUSTING, Adjusting fuel control linkage. ~~ Universal joint mounting bolt thread: Thread tightener (LT-2) &5=)_ Universal joint mounting bolt: 110.5 + 12.3Nm {11.25 + 1.25 kgm} Ez) ==] Engine mounting bolt: 549.2 + 58.8 Nm {56+ 6 kgm} 30-36 140F3091 o14u02014U02 DISASSEMBLY AND ASSEMBLY REMOVAL OF ENGINE ASSEMBLY Serial No. 3034 and up A Disconnect the cable from the negative (-) ter- * minal of the battery. Close the fuel supply valve of the fuel tank. . Remove radiator assembly. For details, see REMOVAL OF RADIATOR AS- SEMBLY. . Disconnect fuel supply hose (1), fuel return hose (2), and spill hose (3). If the fuel tank is full, fuel will flow out when hoses (2) and (3) are disconnected, so after disconnecting them, bend the hoses and tie them with string. . Disconnect fuel control rods (4) and (5), and cable (6), then remove bracket (7). Disconnect starting motor wiring (8). ;- Disconnect wiring connector (9). Disconnect ground connection (10). . Remove reserve tank (11) together with bracket (12), ENGINE Siaoe13977DISASSEMBLY AND ASSEMBLY 8. Remove fan (13). 9, Remove shroud (14). 10. Open chassis bottom cover, and disconnect universal joint (15) at damper end. A{The bottom cover weight 26 kg, so support it with a transmission jack before removing the mounting bolts. 11. Remove left and right engine mount bolts at front (16) and rear (17). 12. Use a lever block to raise engine assembly horizontally, then remove engine mount cap (18) at rear right. 30-36-2 o ENGINE ui 18 s40F13090 140F13188 014U02DISASSEMBLY AND ASSEMBLY 13. Move engine assembly (19) towards front of machine, and gradually lift it off. ‘* When removing the engine assembly, be extremely careful not to damage the wiring or hoses. os Engine assembly: 1300 kg INSTALLATION OF ENGINE ASSEMBLY Serial No. 3034 and up + Carry out installation in the reverse order to removal. Em ‘* Adjust the rod and cable. For details, see TESTING AND ADJUSTING, Adjusting fuel control linkage. 014U02 Be) ‘X= Universal joint mounting bolt thread: Thread tightener (LT-2) =) Universal joint mounting bolt: 110.0 + 12.3 Nm (11.25 + 1.25 kgm) ENGINE \ 140F13097 30-36-3 @o14u02 REMOVAL OF DAMPER ASSEMBLY 1. Disconnect deceleration cable (1) at engine end. 2. Remove cover of plate (2), and disconnect brake rod (3) at turnbuckle portion, + Measure the installed dimension of the rod before disconnecting the turnbuckle. 3. Remove plate (2). 4, Remove chassis bottom cover. Ay The bottom cover weights 26 kg, 0 support it with a transmission jack before removing the mounting bolts. 5. Sling universal joint (4), and remove mount: ing bolts, then remove universal joint. 6. Remove coupling (5). 7. Remove drain plug of damper, and drain oil. Damper: Approx. 1.7 140F13095| Removing damper cover 1) Remove mounting bolts, then set guide bolt © in position, and use forcing screw @ to pull out pilot portion of damper cover assembly (6) to a point where it can be removed from flywheel housing. 2) Sling damper cover assembly (6), remove forcing screw @, then use guide bolt ® to move damper cover to center position, and remove from under chassis. [zx] Damper cover: 30 kg {14013096 140F13097 30-379. Remove damper (7). 10. Remove bearing (8) from fiywheel. © Disassembly of damper cover 1) Remove snap ring (10) from damper cover 9) 2) Turn over damper cover, and set on block, then knock out shaft assembly (11) with plastic hammer ©. 3) Remove oil seal (12) from damper cover. 4) Remove snap rings (14) and (15) from shaft (13), 30-38 7MF02246 Forauass 14013101 2 EO 140F13102 140F13108 o14u02o14uoz 5} Using push tool @, pull out bearing (16) from shaft (13) with press. Q @. & ‘14013104 140F 33165 INSTALLATION OF DAMPER om I J ASSEMBLY ‘* Assembly of damper cover 41) Install snap ring (16) to shaft (13) 2) Using push tool @, press fit bearing (16) with press. |) 14013106, 14013107, 3) Install snap ring (14) to shaft (13). * Check that the snap ring is fitted securely in the groove of the shaft. 4) Set damper cover (9) on block, and knock in shaft assembly (11) with plastic hammer ® 140F13108 5) Install snap ring (10) to damper cover (9). %& Check that the snap ring is fitted 4 ~__ securely in the groove. 6) Turn over damper cover, and install oil seal (12). 7° Lip of oil seal: Grease (G2-LI) " 140F13100 € 9 140F13109 30-391. Install bearing (8) to flywheel. X= Fill gap at shaded portion of with approx. 70g of grease (G2-LI). 2. Install damper (7) G25=] Mounting bolt: 110.4+13.3Nm. (11.3 + 1.3 kgm) 3. Installation of damper cover 1) Raise damper cover assembly (6), align with position of flywheel housing, then install guide bolt @) and align position of ‘mounting bolt holes. 2) Push in damper cover (6) and tighten mounting bolts. 4. Install coupling (5). 5. Refill damper with oil 4B Damper: Approx. 1.70 30-40 17M 02246 140F13111 140F13095| o1auo2o14u02 1. Raise universal joint (4) and install ’ Mounting bolt: Thread tightener (LT-2) 6-8 Mounting bolt: 110.4 + 12.3 Nm (11.3 + 1.3 kgm) {install plate (2) and connect turnbuckle of brake rod (3) % Adjust the rod. For details, see TESTING AND ADJUSTING, Adjusting brake pedal linkage. . Install deceleration cable (1). %* Adjust the cable. For details, see TESTING AND ADJUSTING, Adjusting fuel control linkage. }. Using transmission jack, install chassis bottom cover. 30-41REMOVAL OF POWER TRAIN UNIT ASSEMBLY 1. Draining oil wele Hydraulic tank: Approx. 554 2. Remove sweep guard and canopy assembly. For details, see REMOVAL OF SWEEP GUARD, CANOPY ASSEMBLY. 8. Remove floor frame assembly. For details, see REMOVAL OF FLOOR FRAME ASSEMBLY. 4. Disconnect fuel return hose (1) and fuel supply hose (2). ta) 5, Remove fuel tank mounting bolt cover (3), then remove 4 mounting bolts (4). Serial No. : 3001 - 3033 6. Remove bar (5). Serial No. : 3001 - 3033 7. Lift off fuel tank assembly (6). % Raise the rear of the tank slightly, then wind the sling rope around the body of the tank (2 places}, and lift up. (i) Fuel tank assembly: ‘Approx. 190 kg (empty) 550 kg (full) 30-42 o rordUoas o14u02DISASSEMBLY AND ASSEMBLY Serial No. 3034 and up 6. Lift off fuel tank assembly (6). oes Fuel tank assembly: 120 kg (when empty) Approx. 400 kg (when full) Serial No. 3034 and up 7. Remove bar (7). o14u02 8. Remove top cover of central pressure detection port, then remove bracket (8) from frame. 9. Disconnect 2 power train filter outlet and inlet hoses (9). 10. Disconnect work equipment pump outlet hose (10). 11. Disconnect hose (11) at tube end. 12. Remove pipe (12), power train oil supply pipe (13), and suction pipe (14). 13. Remove PPC hoses (15) (set of 3). POWER TRAIN UNIT No. 3034 and up 140F13130] 30-43 @DISASSEMBLY AND ASSEMBLY 14, Remove terminal wiring (16) and battery (17), then remove pedestal. 15. Remove fuel contro! cable clamp (18) and fuel hose clamp (19), then move to side so that cable and hose are not in the way. 16. Remove PPC charge relief valve assembly (20) together with mount, and move towards engine. 17. Disconnect power train cooler hose (21). POWER TRAIN UNIT 140613131 oF 13122 18, Remove universal joint (22). ma 30-44 140F 19122 014U02o1auo2 DISASSEMBLY AND ASSEMBLY 19. Remove final drive shaft cover (23), then use bolt (D to pull drive shaft (24) out to a position where spline portion at steering case end comes out. + If the shaft will not come out, move the sprocket (use a jack to push up the shoe grouser from the ground), and adjust to a Position where the shaft can be removed. Then pull the shaft out. 20. Remove mount caps (25) at both ends of steering case together with cover. 21. Loosen coupling clamp (26), then move seal (27) slightly towards outside (open). es 22. Remove front mount bolts (28). POWER TRAIN UNIT 14013129) 140F13124DISASSEMBLY AND ASSEMBLY 23. Lift off power train unit assembly (29). * Check that all wiring and piping has been disconnected before removing the power train unit assembly as Power train unit assembly: 1600 kg 30-45-1 @ POWER TRAIN UNIT 140F13135| o14u02INSTALLATION OF POWER TRAIN UNIT ASSEMBLY ‘© Carry out installation in the reverse order to removal. qo 2am] Fuel return hose (large) clamp: 3.3 + 0.49 Nm (34 + 5 kgem) 1 Fuel return hose (small) clamp: 0.2 + 0.049 Nm (2 + 0.5 kgem) -5=1 Bar mounting bolt: 926.1 + 102.9 Nm (94.5 + 10.5 kgm) === Towing winch drive shaft mounting bolt: 66.2 +7.4Nm (6.75 + 0.75 kgm) = Universal joint mounting bolt: Thread tightener (LT-2) Universal joint mounting bolt: 110.25 + 12.25 Nm (11.25 + 1.25 kgm) + Clamp the angled portion of the coupling seal securely, and assemble so that the clamp thread is parallel with the seat surface of the cap mount. == Coupling clamp nut: 6.615 41.715 Nm (0.675 + 0.175 kgm) + Add oil through oil filler to the specified level. Run the engine to circulate the oil through the system, Then check the oil level again. 30-46 o14u02o14u02 SEPARATION OF POWER TRAIN UNIT 1. Remove towing winch drive shaft. Esa) 2, Remove drain plugs of steering case and transmission case, and drain oil from case. ‘wie Power train case : Approx. 500 3. Remove hoses (1), (2) and (3). 4. Remove brake rods (4) and (6), and cables (6) and (7). 2] 5. Remove pressure detection hose (8) 6. Sling steering case assembly (9), then remove mounting bolts, and disconnect from transmission case. Steering case assembly : 800 kg 7. Remove suction tube (10), then remove hydraulic pump assembly (11). 8. Remove suction tube (12) and outlet hoses (13) and (14), then remove tandem pump assembly (5). 9. Remove hose (16), then remove scavenging pump. assembly (17). -— 140F13161 rt | 140612160 30-4710. Remove left and right mounts (20). 11. Disconnect tubes (21), and remove tubes (22) and (23) 140F12163, oa. Cd Bo a ie aor 13168 12, Set torque converter and transmission assembly with torque converter at top. 13. Remove bolt (24), then remove holder (25), O-ring (26), and coupling (27) 14, Remove sleeves (28) and (29). 30-48 © 014U02014U02 15. Sling PTO assembly (30), then remove mounting bolts, and disconnect from transmission assembly (31). CONNECTION OF POWER TRAIN UNIT '* Carry out connection in the reverse order to separation. fe) "== Drive shaft mounting bol 66.2 + 7.4 Nm (6.75 + 0.75 kam) % Bend the cotter pin securely. For details of adjusting the backlash and tooth contact between the bevel gear and bevel pinion, see ASSEMBLY OF TOROFLOW TRANSMISSION ASSEMBLY. xa ~~. Mounting bolt: Thread tightener (LT-2) 3=1 Mounting bolt: 276.05 + 31.85 Nm {28.25 + 3.25 kgm} 140F13166 30-48-1 ®o14u02 DISASSEMBLY OF TORQUE CONVERTER ASSEMBLY 1. Case, turbine assembly Remove 24 bolts from below, then remove eyebolts (@, and remove case and turbine assembly (1). . Gear, input shaft -— Remove gear (3) and input shaft (4). q ‘ 3. Case 1) Remove snap ring (8). 2) Remove spacer (9). 140F13188 140613189 140F13191 30-493) Using puller ®, disconnect case assembly (10) from turbine (11). 4. Stator Remove snap ring (14), then remove stator (15), 5. Pump assembly 1) Using forcing screws ® from stator shaft ‘end, remove pump assembly (16) from stator shaft (17). 2) Pull out cage (18) from pump (19). 30-50 140F13192| 140613194 140F13195) o14u02or4u02 ASSEMBLY OF TORQUE CONVERTER ASSEMBLY % Clean all parts, and check for dirt or damage before installing. % Put a drop of engine oil on the rotating portion of the bearing, then rotate it several times. % Check that the snap ring is fitted securely in the groove. % Coat the seal ring thinly with grease (G2-LI). 1. Pump assembly 1) Press fit bearing (21) to cage (20), and install snap ring (22), 2) Install cage (18) to pump (19). 3) Install pump assembly (16) to stator shaft (17). + Push the inner race side of the bearing to press fit. % After press fitting the bearing, put a small drop of engine oil on it and rotate it at least 10 times. 140F13196 140613195 1a0F13197 30-512. Stator 1) Install stator (15). 2) Install snap ring (14). 3. Case 1) Install bearing (13) to case (12) 2) Push inner race side of bearing, and install case assembly (10) to boss portion of turbine (11), 3) Install spacer (9) 4) Install snap ring (8). 30-52 140613198 140613199 oF 13191 14013190. o14u02o14u02 4G r, input shaft 1) Press fit inner race (7) to collar (6). 2) Install collar (6) to input shaft (5) 3) Install input shaft (4) and gear (3), = Mounting bolt: Thread tightener (LT-2) J Mounting bolt: 66.15 + 7.35 Nm (6.75 + 0.75 kgm) turbine assembly ing eyebolts (®, align groove of case with drain plug, and install case and turbine assembly (1) ~~ Mounting bolt: Thread tightener (LT-2) -3=) Mounting bolt: 53.9 + 4.9 Nm (5.5 + 0.5 kgm) 2) Install drain plug. 2351 Drain plug: 7.35 + 1.47 Nm (0.75 + 0.15 kgm) 140613200, Aa0F 13189] 14013188 30-53DISASSEMBLY OF PTO ASSEMBLY 1. Lubrication tubes Remove lubrication tubes (1) and (2). 2. Cover assembly (right) 1) Remove mounting bolts, then using forcing screws (0, remove cover assembly (3) 2) Knock out gear assembly (4) from cover (5) and remove. 3) Remove bearing (6) from gear (7). 3. Cover assembly (left) 1) Remove mounting bolts, then using fore ing screws @, remove cover assembly (8). 30-54 140F13209) 014u02o14u02 4 2) 3) Knock out gear assembly (9) from cover (10). Remove bearing (11) from gear (12). Idler gear » 2) Remove mounting bolts, then remove plate (13). Remove mounting bolts, and using forcing screws (3), remove shaft (14). 4 140F13210 ae sas fo PI 14013211 140F 13212 | 140F 13213 30-553) Remove bearing (16) and spacer (17) from gear (15). * If these parts are to be used again, do not change the sets. Put them in sets with the outer race and keep them in a safe place. 4) Remove outer race (18) from gear (15). 5. Cover Remove cover (20) 6. Scavenging pump drive gear 1) Remove snap ring (21) 2). Knock out gear (22) from snap ring side. 3) Remove bearing (23). 30-56 013214 Push) n E> IL aw 140F 15216 149F13217 o14u02014U02 7. Input shaft bearing Remove snap ring (24), then remove bearing (25). ASSEMBLY OF PTO ASSEMBLY * Clean all parts, and check for dirt or damage before installing. * Put a drop of engine oil on the rotating portion of the bearing, then rotate it several times. % Check that the snap ring is fitted securely in the groove, 1. Input shaft bearing Press fit bearing (25), and install snap ring (24) 2. Scavenging pump drive gear 1) Install bearing (23). 2) Support inner race end of bearing (23), and install gear (22) to beairng, a 2. 140F19217 Ice) 5 saortsa9 30-573) Install snap ring (21). 3. Idler gear 1) Install shaft (14). S35) Mounting bolt: 110.35 + 12.25 Nm (11.25 + 1.25 kam) 2) Install bearing (16). 3) Install spacer (17) 4) Install outer race (18) to gear (15). 5) Install gear (15). 6) Install bearing (16). 1 Press fit inner race side. 30-58 140F13220, 140F13222| 40F13224| AY 140F13226; o1au02o14u02 7) Fit plate (13) and tighten bolts. Mounting bolt: Thread tightener (LT-2) S3=] Mounting bolt: 176.5 +1 4. Cover assembly (left) 1) Install bearing (11) to gear (12). 2) Install gear assembly (9) to cover (10) 3) Mesh idler gear, and install cover assembly (8). 140613211 14013228] 30-595. Cover assembly (right) 1) Install bearing (6) to gear (7). 2) Install gear assembly (4) to cover (5). 3) Mesh idler gear, install cover assembly (3). 6. Cover Install cover (20). 7. Lubrication tubes Install lubrication tubes (2) and (1). 30-60 140613220 o14u02o14u02 DISASSEMBLY OF TOROFLOW TRANSMISSION ASSEMBLY %* After removing the discs and plates, keep them in a flat place to prevent them from being distorted. 1. Relief valve assembly Remove relief valve assembly (1). 2. Control valve assembly 1) Remove cover assembly (2) 2) Using forcing screws (D, remove sleeves (8) and (4) 3) Remove control vaive assembly (6) % Do not remove the bolts marked 140F 12318 30-613. Transmission cas¢ 1) Remove mounting bolts from both sides. 2) Using eyebolts @, remove transmission case (7). 4, Tie bolt Remove tie bolt (8). 5. Input shaft, front plate, No. 1 carrier assembly 1) Using eyebolts @, remove input shaft, front plate, and No. 1 carrier assembly (9). 2) Disassemble input shaft, front plate, and No. 1 carrier assembly as follows. i) Remove snap ring (10), then remove No. 2 sun gear (11) and snap ring (12) ii) Remove snap ring (13), then remove No. 1 sun gear (14) and collar (18). 30-62 140F13320 140F13321 Mor r3322 140F13923, o14u02o14u02 iti) Remove snap ring (17). iv) Knock out input shaft from torque con: verter end, and remove front cover (18), v) Remove snap ring (19), then knock out input shaft (20) to torque converter end and remove. vi) Remove snap ring (21), then remove No. 1 ring gear (22) vi) Pull out shaft (23), and remove thrust washer (24), gear (25), bearing (26), and ball (27). 1 Be careful not to lose the ball 6. No. 1 disc, plate, spring 1) Remove spring (35) 2) Remove disc (36) and plate (37) 140F13326 140F13377 Bon T ut 25 4 26 140813328 30-637. No.1 housing assembly 1) Using eyebolts @, remove No. 1 housing assembly (41) 2) Remove piston (42) from housing. 8. No. 2 piston Remove No. 2 piston (43). 9. Guide pin Remove guide pin (44) 10. No. 2 disc, plate, spring 1) Remove spring (46) for No. 2 and 3. 2) Remove disc (46) and plate (47). 11. No. 2 housing, No. 2 carrier assembly 1) Using tool C2, push up No. 3 carrier (48), then remove snap ring (49). 2) Using eyebolts @), remove No. 2 housing and No. 2 carrier assembly (50). 3) Disassemble No. 2 housing and No. 2 carrier assembly as follows. i) Remove snap ring (51), and pull out No. 2 carrier assembly (52) from No. 2 housing (53). 30-64 140F13330 140F12333) st o1au02o14u02 li) Remove spacer (54) from No. 2 carrier assembly (62). iii) Remove No. 2 ring gear (66). iv) Pull out shaft (57), and remove thrust washer (58), gear (59), bearing (60) and ball (61), v) Remove snap ring (49). vi) Remove snap ring (63), then remove ring gear (64). 12. No. 3 disc, plate Remove disc (68) and plate (69). 13. No. 3 ring gear Remove No. 3 ring gear (70) 14. No. 3, 4 carrier assembly 1) Remove No. 3 and 4 carrier assembly (71) 1 40F13298 140613339 ‘140F 13340 30-652) Disassemble No. 3 and 4 carrier assembly as follows. i) Remove seal ring (72) ii) Knock pin (73) into shaft (74). ii) Knock out shaft (74) from No. 3 carrier end. iv) Remove thrust_washer (76), No. 4 planetary gear (77), and bearing (78) ‘ Remove the pin from the shaft. 140F13342 v) Knock out shaft (79), and remove thrust washer (80), No. 3 planetary gear (81), bearing (82), and ball (83). + Be careful not to lose the ball 15. No. 3 housing 1) Remove No. 3 housing (86). 2) Remove No. 3 piston (87). 140F19348 16. No. 4 disc, plate, spring 1) Remove spring (88). 2) Remove disc (89) and plate (90). 140F13345 30-66 o14u02o1au02 17. No. § carrier, No. 4 ring gear assembly 1) Remove mounting bolts (91). 2) Remove No. 5 carrier and No. 4 ring gear assembly (92). 3) Disassemble No. § carrier and No. 4 ring gear assembly as follows. ') Knock out shaft (93), and remove thrust washer (94), gear (95), bearing (96), and ball (97) + Be careful not to lose the ball ii) Remove snap ring (98), then remove No. 4 ring gear (89) from carrier (100). 18. No. 4 housing assembly 1) Remove No. 4 housing assembly (101) 2) Remove No. 4 piston (102) 100 a1 140F 13340, 140F12350 30-6719. Guide pin Remove guide pin (103). 20. No. § disc, plate, spring 1) Remove spring (104). 2) Remove disc (105) and plate (106). 21. No. 5 ring g Remove No. 5 ring gear (107) 22. No. 5 piston Remove No. 5 piston (108). 23. Collar 1) Remove snap ring (109). 2) Remove collar (110). 24, No. 4 sun gear Remove No. 4 sun gear (111). 25. No. 5 sun gear Remove No. 5 sun gear (112). 26. Cage (for securing No. 5 cage) 1) Remove snap ring (113). 2) Using forcing screw ®, remove cage (114), 30-68 so 352 SS 14613954 ys ya 1 40F 13355 o14u0201402 27. Bevel pinion assembly 1) Using eyebolts @, remove bevel pinion assembly (115) from case (123). Check the number and thickness of the shims, and keep in a safe place. 2) Remove snap ring (120). 3) Press bevel pinion (117) with press, then using too! C-1, remove nut (119). 4) Support cage (116), and push end face of shaft, then remove bevel pinion (117) from cage 140F13356 10 / eB serum mr) if 14019350, 140F13969 30-69ASSEMBLY OF TORQFLOW TRANSMISSION ASSEMBLY ‘* Precautions when assembling ag Clean all parts, and check for dirt or damage before assembling, + Coat the sliding surfaces of all parts with ‘engine oil before installing. Seas ‘% Assemble the piston seal ring so that the side pressure receiving the pressure faces the housing as shown in the diagram. + When installing the metal seal ring, coat it with grease (G2-LI), and install it uniformly so that itis not offset to one side. 420420 1. Bevel pinion assembly 1) Assemble bevel pinion assembly as follows. ys i) Install bearing (118) to cage (116) ‘ The bearing is a bearing set, so be careful not to change the sets when assembling. 14013360 ii) Install bevel pinion (117) to inner race end of bearing z % Support the bevel pinion side, and le press fit the inner race side of the ae bearing. Fy A me ay 140813361 ii) Press bevel pinion assembly (115) with press, then using tool C-1, tighten nut (119) ‘ Tighten until the first nut is securely in contact with the inner race, then tighten the second nut to the specified tightening torque. 119 G2) Second nut: 4 367.7 + 24.52 Nm f (37.5 + 2.5 kgm) =e) 14013358 30-70 o14u02orau02 iv) Install snap ring (120) 2) Assemble removed shims (121) and (122), then using eyebolts ©, install bevel pinion assembly (115) to case (123). “= Mounting bolt: Thread tightener (LT-2) ‘% Adjust the thickness of shim (122) as follows. i) With the shim at the cover side removed, push the cover towards the case, and rotate the shaft several times to settle the bearing, ) Keep the cover pushed, and tap the cover several times with @ plastic hammer ii) Measure the clearance between the cover and cage at two places around the circumference. iv) Select a shim so that the thickness is clearance — 0.05 — 0.15 mm. 2. Cage (for securing No. 5 cartier) 1) Press fit bearing (124) to cage (125). 14013359) i I {thr aorta 140F12963 30-712) Fit seal ring to cage and case end, then install cage assembly (114). + Press fit the inner race of the bearing. 3) Install snap ring (113). 3. No. 5 sun gear 1) Install snap ring (126). 2) Install No. 5 sun gear (112). 4, No. 4 sun gear 1) Install No. 4 sun gear (111). 2) Install collar (110). 3) Install snap ring (109). 5. No. § ring gear Install No. 5 ring gear (107). 6. No. 5 piston Fit seal ring and install No. 5 piston (108). 7. Guide pin Install guide pin (103) 8. No. 5 discs, plates, spring 1) Install discs (105) and plates (106), + Discs: 3; Plates: 2 2) Install spring (104), + Free length of spring: 59 mm. 30-72 Heer na 126 140F13365 140F13381 or4u02o14u02 9. No. 4 housing assembly 1) Fit seal ring and install No. 4 piston (102) 2) Install No. 4 housing (101). * Check that the springs are fitted securely into the groove. 10. No. 5 carrier, No. 4 ring gear assembly 1) Assemble No. 5 carrier assembly as follows. i) Set No. 4 ring gear (99) to carrier (100), and install snap ring (98). ii) Assemble bearing (96) to gear (95), put thrust washer (94) in contact on both sides, and set to carrier. ii) Fit ball (97) and install shaft (93). 2) Using guide bolt ®, install No. 5 carrier and No. 4 ring gear assembly (92) 7-7 Mounting bolt: Thread tightener (LT-2) =] Mounting bolt: 66 + 7.4 Nm (6.75 + 0.75 kgm) 140F13350 7 s— J 93 140F13348 30-7311. No. 4 discs, plates, spring Install No. 4 discs (89), plates (90), and spring (8). % Discs: 3; plates: 2 Free length of spring: 59 mm 12, No. 3 housing assembly 1) Fit seal ring and install No. 3 piston (87). 2) Install No. 3 housing (86) % Check that the spring is fitted securely in the groove. 13. No. 3, 4 cas assembly 1) Assemble No. 3 and 4 carrier assembly as follows. i) Press fit bearing (85), and install snap ring (84), ii) Assemble bearing (82) to No. 3 pla- etary gear (81), put thrust washer (80) in contact on both sides, and set to carrier. ii) Fit ball (83) and install shaft (79). 30-74 140613345 140F133¢4 14013968 o14u02orauoz iv) Assemble bearing (78) to No. 4 planetary gear (77), put thrust washer (76) in contact on both sides, and set to carrier. v) Align pin hole of shaft with pin hole of carrier, and install shaft (74). Check that pin holes are aligned, then knock in pin (73). vi) Install seal ring (72). 2) Align sun gear and ring gear, and install No. 3 and 4 carrier assembly (71), % Be careful not to get your fingers caught. 14. No. 3 ring gear Install No, 3 ring gear (70). % Set the gear so that the side with a notch in the outside teeth faces down. Install No. 3 discs (68) and plates (69). Discs: 3; plates: 2 140F13342 140F13370 140F13371 30-7517. No. 2 housing, No. 2 carrier assembly 1) Assemble No, 2 housing as follows. i) Press fit bearing (68) to No. 2 housing (63), and install snap ring (70). ji) Set ring gear (64) to No. 3 cartier (55), and install snap ring (63). iil) Assemble bearing (60) to gear (59), put thrust washer (58) in contact on both sides, and set to carrier. iv) Fit ball (61) and install shaft (57) ‘& When two gears are assembled, assemble snap ring (49). ¥) Install seal ring vi) Install No. 2 ring gear (56). vi) Install spacer (54). % Install with the cut on the inside facing the carrier. 30-76 6 140F13373 S58 60 ZB ae + A — acess Be + A 30-935. Clutch, brake assembly ‘© Assembly of clutch, brake assembly 1) Assembly of clutch assembly i) Fit snap ring (30) in groove of clutch inner drum (29). ii) Using push tool, press fit bearing (45) to inner drum (28), then install snap ring (44) ili) Set inner drum (29) to clutch outer drum (27) + The cage is press fitted to the inner drum from the rear, so align with the height of the outer drum and mesh block 9. iv) Assemble discs (42), and plates (43) and (40) in the order shown in the diagram. + Number of disc and plate Disc (42): 5 Plate (43): 6 Plate (40): 1 30-94 140F 13416] 0 0 140F13481 140F13443 o14u02o1auo2 v) Install stopper (33) to hub (16). 140F12420, vi) Set brake hub (35) to hub (16), and tighten bolts (39). 16 vii) Using push tool, install bearing (38) to hub. vill) Turn over piston and hub assembly, and install spring (34) to brake hub (35). ix) Fit seal ring, then align clutch plate (32) with spring, and set in position. % Align the match marks when stalling. % Align the springs securely with the groove. 140813445 s40F 13448 x) Fit seal ring set piston (31) to hub, then tighten bolts uniformly. The bolt holes are aligned at only x one place. sor sae? sor 10480 30-95xi) Set brake hub assembly (28) in position fon clutch assembly, then tighten mounting bolts. % Align the match mark on the brake hub with the molded groove in the clutch outer drum. ‘The outer race of the bearing of inner drum (29) is press fitted to piston (31), 30-96 ‘Align ddl and tap 8 Tar 13449 is us fivted 14013451 Align tap B with molded groove. o14u02o14u02 xi) Turn over brake hub and clutch assembly, then install snap ring (30) to piston (31), % Remove snap ring (30) from the inner drum and install it to the piston, 2) Assembly of brake assembly i) Set brake drum (22) to drum and hub assembly (26) ii) Install discs (23), plates (24), and spring (25). % Discs: 5 Plates: 4 iii) Using push tool, install outer race (21) to cage (17). iv) Install seal ring (18) to hub (16) v) Fit seal ring and install cage (17) to hub. Align the oil holes in the cage vis- vally with the oil holes in the drum at 4 places. an 140F 19454 SA at aor 13455, 140613456 140F13458 uv 140F13459 30-97vi) Install seal ring to piston (15). vii) Align center of spot facing reference mark on piston (15) with “13.5 mm drill hole” on drum (opposite side from cil hole), and set in position. viii) Install spring (14). ix) Install guide bolts 6D and 42 to piston (15) and cage (17). % Guide bolt 2 is for alig brake release bolt hole. x) Install bearing (13) to cover (12). 19 the xi) Using eyebolts 8, align with guide bolt, then set cover (12) in position. % Check that the spring is fitted securely into both the piston and cover. xii) Compress spring with bolt (® and nut 4, and at the same time press fit inner race of bearing to hub (16) 30-98 140613460 140F13461 Reterence mark 135 dfilfole in nydraube crcut Spot facing o14u02014U02 xiii) Fit spacer (10) and install spacer (9) and snap ring (8). xiv) Install flange (7). xv) Remove bolt and nut used to com- ress spring, then install 4 bolts (11). 3) Using tool E-1, install clutch and brake assembly (6). 6. Cover 1) Install 10 sleeves (5) 140F13402 14013468 “ fl ea uJ z = si 140F13401 30-992) Using eyebolts ©, install cover (4). = Mating surface: Gasket sealant (LG-4) + Coat both surfaces. 7. Steering valve assembly Raise steering valve assembly (3) and install =] Mounting bolt: 49 ¢ 4.9 Nm (5 + 0.5 kgm) 8. Piping Install tubes (2) and (1) 30-100 oJ es dF ia o14u02o14u02 REMOVAL OF TORQUE CONVERTER VALVE ASSEMBLY 1. Remove floor frame assembly. For details, see REMOVAL OF FLOOR FRAME ASSEMBLY. x Disconnect 2 pressure dectection hoses (1) Remove torque converter main relief valve assembly (2) (#1) INSTALLATION OF TORQUE CONVERTER VALVE ASSEM- BLY © Carry out installation in the reverse order to removal Main relief valve mounting bolt: 49 + 4.9 Nm (5.0 + 0.5 kgm) “es SACD 7 VOL 30-101DISASSEMBLY OF TORQUE CONVERTER VALVE ASSEMBLY 1. Remove plug (1), then remove valve (2), spring (3), valve (4), valve (5), shim (6), and springs (7) and (8) from valve body (9). ‘Check the number and thickness of the shims, and keep in a safe place. 2. Remove plug (10), then remove washer (11). 3. Remove plug (13), then remove guide (14), spring (15), spool (16), valve (17), spring (18), and vaive (19). 4. Remove plug (20) ASSEMBLY OF TORQUE CON- VERTER VALVE ASSEMBLY * Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing, 1, Assemble spring (15) and guide (14) to spool (16) 2. Assemble valve (19), spring (18), and valve (17), then assemble in valve body (9), and install plugs (20) and (13) 3. Assemble washer (11) and springs (8) and (7) to plug (10), and install to valve body (9). 4, Assemble valve (2), spring (3), and vaive (4), the assemble in valve (6), and assemble shim (6) on opposite side. 4 Check the thickness and number of shims, then assemble them. ‘Standard shim thickness: 3 mm. 5. Assemble valve (6) to valve body (9), then install plug (1), 6. Tighten plugs (10) and (1). 30-102 o14u02014U02 REMOVAL OF TRANSMISSION CONTROL VALVE ASSEMBLY 1. Remove floor frame assembly. For details, see REMOVAL OF FLOOR FRAME ASSEMBLY, 2, Remove brake rod (1) and steering rod (2). 3. Disconnect pilot hose (3), and remove cable clamp (4), 4, Disconnect directional cable (5) and speed cable (6) 5. Remove mounting bolts, then using forcing screws, remove valve cover (7) (3) 6. Remove transmission control valve assembly (8). fa) 4 The length of the mounting bolts is difer ent, so mark them clearly INSTALLATION OF TRANS- MISSION CONTROL VALVE ‘© Carry out installation in the reverse order to removal, ao + Adjust the steering lever and brake pedal. For details, see TESTING AND ADJUST- ING (= % Adjust the directional lever and speed lever. For details, see TESTING AND ADJUST: ING, ws) % Look through the inspection hole in the ‘cover to check that the lever and yoke are meshed, then tighten the mounting bolts. % When installing the cover, tap it with a plastic hammer. If the dowel pin portion does not fit remove the cover, mesh the lever and yoke again, then install, ‘si 11 40F1 3598 140619539 30-103= & There are two types of mounting bolt, so Feroval and inatalion of Ware worvane check the mounting position when install 5 > ing them, % Mounting bolt: % = 4 bolts * = 4 bolts “55 Mounting bolt: 49.0 + 4.9 Nm (5.0 + 0.5 kgm) 30-104 o14u02014u02 DISASSEMBLY OF TRANSMIS- SION CONTROL VALVE ASSEMBLY 1. Disassembly of quick return valve 1) Remove cover (2) from valve body (1), 2) Pull out spacer (3), and remove ring (4). 3) Remove plug (5), pull out valve (6) and sleeve (7), then remove snap ring (8). 2. Disassembly of speed valve 1) Remove spool assembly (10) from valve body (9) 2) Loosen nut (11), and disconnect spool (12) and yoke (13), 3. Disassembly of directional valve, modulation valve 1) Remove snap ring (14), then remove stop: per (15). 2) Loosen nut (16), and remove yoke (17). 3) Remove cover (18), shim (19), and spacer (20), then remove spring (21), washer (22), and springs (23) and (24). 4) Remove cover (25). 5) Remove collar (26) and spool (27). 6) Remove valve assembly (28). 7) Remove snap ring (29), stopper (30), valve (31), spring (32), valve (33), and valve (34) from valve assembly (28) ASSEMBLY OF TRANSMIS- SION CONTROL VALVE ASSEMBLY % Clean all parts, and check for dirt or damage. Cost the sliding surfaces of all parts with engine oil before installing. 1. Assembly of directional valve, modulation valve 1) Assemble valves (34) and (33), spring (32), and valve (31) to valve (28), fit stopper (30), then install snap ring (29). 2) Assemble valve assembly (28) to body (9), then assemble springs (24) and (23), washer (22), and spring (21) from opposite side, and install spacer (20). 3) Install shim (19) and cover (18). % Standard shim thickness: 2.5 mm 4) Install spool (27) and collar (26) to body (9), then install cover (25). 5) Assemble stopper (15), and install snap ring (14). 6) Assemble nut (16) to yoke (17), and install to valve (27). SD Locknut: 30.9 + 3.4 Nm (3.2 + 0.35 kgm) 4% Dimension a for mounting yoke: 29.1 mm, 2. Assembly of speed vaive 1) Assemble nut (11) to yoke (13), and install to spool (12), Locknut: 30.9 + 3.4 Nm (3.2 + 0.35 kgm) 2) Assemble spool assembly (10) to body (9). 3. Assembly of quick return valve 1) Install plug (5) to body (1), assemble valve (6) and sleeve (7), then install snap ring @) 2) Assemble spacer (3) to body (1), then fit snap ring (4) and install cover (2) 30-105DISASSEMBLY OF TRANSMIS- SION CONTROL VALVE ASSEMBLY Serial No. : 3001 - 3023 1. Disassembly of quick return valve 1) Remove cover (2) from valve body (1). 2) Pull out spacer (3), and remove ring (4). 3) Remove plug (5), pull out valve (6) and sleeve (7), then remove snap ring (8). 2. Disassembly of speed valve 1) Remove spool assembly (10) from valve body (9). 2) Loosen nut (11), and disconnect spool (12) and yoke (13). 3. Disassembly of directional valve, modulation valve 1) Remove snap ring (14), then remove stopper (15). 2) Loosen nut (16), and remove yoke (17). 3) Remove cover (18), shim (19), and spacer (20), then remove spring (21), washer (22), and springs (23) and (24) 4) Remove cover (28). 5) Remove collar (26) and spool (27). 6) Remove valve assembly (28). 7) Remove snap ring (29), stopper (30), valve (31), spring (32), valve (33), and valve (34) from valve assembly (28). 30-106 ASSEMBLY OF TRANSMIS. SION CONTROL VALVE ASSEMBLY Serial No. : 3001 - 3023 ind check for dirt or damage. ing surfaces of all parts with ‘engine oil before installing. 1. Assembly of directional valve, modulation valve 1) Assemble valves (34) and (33), spring (32), and valve (31) to valve (28), fit stopper (30), then install snap ring (29). 2) Assemble valve assembly (28) to body (9), then assemble springs (24) and (23), washer (22), and spring (21) from opposite ide, and install spacer (20). 3) Install shim (19) and cover (18). ‘& Standard shim thickness: 2.5 mm 4) Install spool (27) and collar (26) to body (9), then install cover (25). 5) Assemble stopper (15), and install snap ring (14). 6) Assemble nut (16) to yoke (17), and install to valve (27). @3E) Locknut: 30.9 + 3.4 Nm (3.2 + 0.35 kgm) + Dimension a for mounting yoke: 29.1 mm 2. Assembly of speed valve 1) Assemble nut (11) to yoke (13), and install 10 spool (12). S321 Locknut: 30.9 + 3.4 Nm (3.2 + 0.35 kgm) 2) Assemble spool assembly (10) to body (9). 3. Assembly of quick return valve 1) Install plug (5) to body (1), assemble valve (6) and sleeve (7), then install snap ring 8) 2) Assemble spacer (3) to body (1), then fit snap ring (4) and install cover (2). o14u02140F 13541 aor 13542 zonvto 30-106-1DISASSEMBLY OF TRANSMISSION CONTROL VALVE ASSEMBLY Serial No. : 3024 and up 1. Disassembly of quick return valve 1) Remove snap ring (2) from valve body (1) 2) Pull out spacer (3), and remove snap ring (a) 3) Remove plug (5), pull out valve (6) and sleeve (7), then remove snap ring (8). isassembly of speed valve 1) Remove spool assembly (10) from valve body (9) 2) Loosen nut (11), and disconnect spool (12), and yoke (13). 3. Disassembly of directional valve, modulation valve 1) Remove snap ring (14), then remove stopper (15) 2) Loosen nut (16), and remove yoke (17). 3) Remove cover (18), shim (19), and spacer (20), then remove spring (21), washer (22), and springs (23) and (24). 4) Remove cover (25) 5) Remove collar (26) and spool (27) 6) Remove valve assembly (28). 7) Remove snap ring (29), stopper (30), valve {G1), spring (32), valve (33), and valve (34) from valve assembly (28). 30-106-2 ® ASSEMBLY OF TRANSMISSION CONTROL VALVE ASSEMBLY Serial No. : 3024 and up + Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing, 1. Assembly of directional valve, modu valve 1) Assemble valves (34) and (33), spring (32), and valve (31) to valve (28), fit stopper (30), then install snap ring (29). 2) Assemble valve assembly (28) to body (9), then assemble springs (24) and (23), washer (22), and spring (21) from opposite side, and install spacer (20) 3) Install shim (19) and cover (18). %* Standard shim thickness: 2.5 mm 4) Install spool (27) and collar (26) to body (9), then install cover (25) 5) Assemble stopper (15), and install snap ring (14) 6) Assemble nut (16) to yoke (17), and install to valve (27). 625") Locknut: 30.9 + 3.4 Nm (3.2 + 0.35 kgm) %& Dimension a for mounting yoke: 29.1 mm Assembly of speed valve 1) Assemble nut (11) to yoke (13), and install to spool (12) Locknut: 30.9 + 3.4 Nm (3.2 + 0.35 kgm) 2) Assemble spool assembly (10) to body (9) S 3. Assembly of quick return valve 1) Install plug (5) to body (1), assemble valve (6) and sleeve (7), then install snap ring (8) 2) Assemble spacer (3) to body (1), then fit snap rings (4) and (2) 014U02014U02 s, ag 20 ea 21 J fe i/* “ 2B 24 4013542 30-106-3 ®REMOVAL OF STEERING CONTROL VALVE ASSEMBLY 1. Remove fuel tank assembly, For details, see REMOVAL OF FUEL TANK ASSEMBLY. 2. Disconnect wire cable (1) and rods (2) and (3) ao 3. Remove rod (4) Esa} 4. Lift off valve assembly (5). Steering valve assembly: 27 kg * When removing the steering valve, remove the bolts marked @ in the diagram below. INSTALLATION OF STEERING CONTROL VALVE ASSEMBLY Carry out installation in the reverse order to removal. Gn. ‘ Adjust each rod. For details, see TESTING AND ADJUST- ING, Adjusting steering control linkage. © Refilling with oil (power train case) % Add oil through water filler to the specified level Run the engine to circulate the oil through the system, Then check the oil level again. >=] Mounting bolt: 49.1 + 5.0 Nm (5.0 + 0.5 kgm) Refilling with oil (power train case) Add oil through water filler to the specified level Run the engine to circulate the oil through the system, ‘Then check the oil level again. 14013549] aor 3544 140F 13545, 30-107DISASSEMBLY OF STEERING CONTROL VALVE ASSEMBLY Disconnect lever cases (2) and (3) from valve assembly (1). Disassembly of lever case (2) 1) Remove levers (4), (5) and (6). + Be careful not to lose the keys. 2) Remove lever assembly (7). 3) Remove bearing (8) from lever assembly 7). 4) Remove seal (9) from case (2), then remove bearing (10). Disassembly of lever case (3). 1) Remove lever (11). + Be careful not to lose the key. 2) Remove lever assembly (12), then remove pin (13) and roller (14), 3) Remove bearing (15) 4) Remove seal (16) and bearing (17) from case (3). Disassembly of valve assembly 1) Remove body (18), then remove valve (19), spring (20), and valve (21), 2) Remove nuts (22) and (23), then remove cover (48) 3) Remove plugs (24) and (25). 4) Disassembly of right clutch, left clutch valve ’) Push in valve from lever case mount end, and remove spring (26), piston (27), valve (28), and valve assembly (29 ji) Remove nut (31) from bolt (30), then remove guide (32), shim (33), spring (34), and guide (35). % Check the number and thickness of the shims, and keep in a safe place, iil) Remove cylinder (36) from body (1). 5) Disassembly of right brake, left brake valve i) Push in valve from lever case mounting end, and remove spring (37), valve (38), piston (39), and valve assembly (40). ii) Remove nut (42) from bolt (41), then remove guide (43), shim (44), spring (45), and guide (46) % Check the number and thickness of the shims, and keep in a safe place. iii) Remove cylinder (47) from body (1). 30-108 o14u02g zonvio 30-109ASSEMBLY OF STEERING CONTROL VALVE ASSEMBLY * Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. 1. Assembly of valve assembly 1) Assembly of right brake, left brake valve i) Assemble guide (46), spring (45), shim (44), and guide (43) to bolt (41), and install nut (42) ‘ Check the thickness and number of shims, then assemble them Standard shim thickness: 0.5 mm =) Nut: 13.3 £ 1.5 Nm (1.35 + 0.15 kgm) Install cylinder (47) to body (1), i) Assemble valve assembly (40), piston (39), valve (38), and spring (37) to body (1), and install iv) Fit O-ring to plug (24) and install to body. Sm Plug: 68.6 + 9.8 Nm (7 +1 kgm) 2) Assembly of right clutch, left clutch valve i) Assemble guide (35), spring (34), shim (33), and guide (32) to bolt (30), and install nut (31), + Check the thickness and number of shims, then assemble them. Standard shim thickness: 0.5 mm Some) Nut: 13.3 + 1.5 Nm (1.35 + 0.15 kgm) i) Install cylinder (36) to body (1). iil) Assemble valve assembly (29), valve (28), piston (27), and spring (26) to body (1), and install iv) Fit O-ring to plug (25) and install to body. 3) Install cover (48), then install nuts (23) and (22), = Nut 13.3 + 1.5 Nm (1.25 + 0.15 kgm) 4) Assemble valve (21), spring (20), and valve (19) to body (1), then fit O-ring to body (18) and install 2. Assembly of lever case (3) 1) Install case (3), bearing (17), and seal (16). 2) Assemble roller (14) to lever assembly (12), and install pin (13). 3) Install bearing (15) to lever assembly (12), then assemble lever (11) Assemble the keys securely. 30-110 3. Install lever case (3) to body (1) 4. Assembly of lever case (2) 1) Install bearing (10) and oil seal (9) to case (2). 2) Install bearing (8) to lever assembly (7), then install levers (6), (5), and (4) Install the keys securely in levers (6), (5), and (4), 3) Install lever case (2) to valve body (1). 014u02140F 19546 zonvio 30-111REMOVAL OF REDUCING VALVE ASSEMBLY 1. Remove chassis rear cover. 2. Disconnect hose (1) 3. Remove reducing valve (2). INSTALLATION OF REDUCING VALVE ASSEMBLY © Carry out installation in the reverse order to removal. Gy] ===) Mounting bolt: 30.9 + 3.5 Nm (3.2 + 0.4 kgm) 30-112 o14u02o14U02 DISASSEMBLY OF REDUCING VALVE 1. Remove plug (2) from body (1), then remove shim (3) and spring (4). % Check the number and thickness of the shims, and keep in a safe place. 2. Remove plug (6) from body (1), then remove sleeve (6), spring (7), valve (8), and spool (9). ASSEMBLY OF REDUCING VALVE % Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. 1. Assemble spool (9), valve (8), spring (7), and sleeve (6), and install in body (1) 2. Fit O-ring to plug (5) and install to body (1). 3. Assemble shim (3) and spring (4) to plug (2), then assemble to body (1). % Check the thickness and number of shims, then assemble them. Standard shim thickness: 3 mm ‘Amount of change in oil pressure for one shim (t- 0.5): 58.8 kPa (0.6 kg/cm?) % Assemble spring (4) securely to spool (9). 4, Tighten plugs (2) and (6) to standard torque. Goam] Plug: 68.6 + 9.8 Nm (7 +1 kgm) : kes 1 40F 13554 30-113REMOVAL OF SCAVENGING PUMP ASSEMBLY 1. Drain oil wey Power train: Approx. 70 ¢ 2. Remove undercover. A, The bottom cover weighs 26 ka, so support it with a transmission jack before removing the mounting bolts. 3. Disconnect hose (1). 4, Remove scavenging pump assembly (2). INSTALLATION OF SCAVENGING PUMP ASSEMBLY © Carry out installation in the reverse order to removal. Refilling with oil % Add oil through oil filler to the specified level. Run the engine to circulate the oil through the system, Then check the oil level again. 30-114 Zo 140F13557 o14u02o14u02 REMOVAL OF POWER TRAIN PUMP ASSEMBLY 1. Disconnect deceleration cable (1) at engine end. fesa 2. Remove cover of plate (2), and disconnect brake rod (3) at turnbuckle portion % Measure the installed length of the rod before disconnecting the turnbuckle. 3. Remove plate (2). 4. Disconnect hose (4). 5. Open chassis bottom cover, and disconnect tube (5). The bottom cover weights 26 kg, So support it with a transmission jack before removing the mounting bolts. 6. Lift off power train pump assembly (6) INSTALLATION OF POWER TRAIN PUMP ASSEMBLY * Carry out installation in the reverse order to removal. ao Adjust the cable. For details, see TESTING AND ADJUSTING, Adjusting fuel control linkage. Adjust the rod. For details, see TESTING AND ADJUSTING, Adjusting brake pedal linkage. © Refilling with oil (power train case) + Add oil through oil filer to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. 14012093, © 140F 13658 30-115REMOVAL OF FINAL DRIVE ASSEMBLY 1. Remove track shoe assembly. For details, REMOVAL OF TRACK SHOE ASSEMBLY, 2. Using jack (50 ton), jack up chassis, then set stands @® and @ (height: Approx. 900 mm) under front frame and steering case. A Set the stands in position securely. 3. Drain oil from final drive case. ipprox. 26 ¢ (each) we Final drive case: 4. Remove bracket (1) = 5. Remove cover (2). 6. Use bolt ® to pull drive shaft (3) out to a position where spline portion comes out % If the-shaft will not come out, move the sprocket (use a jack to push up the shoe grouser from the ground), and adjust to a Position where the shaft can be removed Then pull the shaft out. 7. Leave 2 or 3 of 11 inside mounting bolts (4) and 9 outside mounting bolts in position at top, and remove remaining mounting bolts. 8. Remove 2 cover mounting bolts from final drive case, then set tool F-1 and lever block (1/2 ton) in position, and sling final drive assembly (5). (aa) 9. Remove remaining bolts, then move case to outside to remove. %& Operate the lever block and use a bar to make a uniform gap at the mating face of the final drive case assembly and case, then remove. EP Final rive assembly: 800 kg 10. Remove drive shaft (3) 30-116 oF 13561 oq ° 140F 13568 o14U02,o14u02 INSTALLATION OF FINAL DRIVE ASSEMBLY © Carry out installation in the reverse order to removal. Go 7°. Thread of bracket mounting bolt: Thread tightener (LT-2) % Be careful not to damage the seal when installing. =) Cover mounting bolt: 110.3 + 12.3 Nm (11.25 + 1.25 kgm) a) "351 Final drive assembly mounting bolt: 549 + 59 Nm (56 + 6 kgm) =e S-5=1 Cover mounting bolt 277 + 32 Nm (28.25 + 3.25 kgm) 30-117DISASSEMBLY OF FINAL DRIVE ASSEMBLY 1. Carrier assembly 1) Remove cover. 2) Remove mounting bolts, and using eyebolts ®), remove carrier assembly (1) © Disassembly of carrier assembly 1) Remove lock plate (2). 2) Using forcing screws @, remove plate (3) together with gear assembly (4). 3) Remove gear assembly (4) from plate (3). + If gear assembly (4) remains in position, when the plate is removed, use puller ® to remove it. 4) Support gear (5), then push shaft (6) and remove bearing (7). 5) Remove bearing (7) from shaft (6). 6) Remove outer race (8) from gear (5). 30-118 140813566 140F19567 140F13668 14013569 Push Push A 140F13572 140F13573 o14u02o14u02 2. Using eyebolts @, remove shaft (9). 3. ing gear, housing assembly 1) Remove holder (10). 2) Using eyebolts ®, remove ring gear and hub assembly (11) 3) Remove snap ring (12), then remove ring gear (14) from hub (13). 4. Sprocket, hub assembly 1) Fit eyebolts, pull out sprocket and hub assembly (15) with tool F-3, and remove. + Bearing (19) will come out at the same time. 140F19570 140F13571 140F13579 30-1192) Remove floating seal (16). + If it is to be used again, be careful not to damage the seal surface and keep it in a safe place. 3) Remove outer race (18). 5. Cover assembly 1) Using forcing screws @, pull out cover assembly (21) from case (22), then replace with eyebolts @, and remove. 2) Remove floating seal (16) 1 If itis to be used again, be careful not to damage the seal surface and keep it ina safe place. 3) Using forcing screws ®, remove spacer (20) and bearing (19) from cover. 30-120 EY 140F13578 -0F13562 140F13563 o14u02o14u02 6. Gear assembly 1) Using eyebolts @, remove gear assembly (24) from case. 2) Using puller 48, remove be: gear assembly (25) 19 (26) from 7. Output shaft Remove output shaft (27) 8. Pinion assembly 1) Using forcing screws (i, remove cage (28). + Check the number and thickness of the shims, and keep in a safe place. 14013586 140619587 2) Remove pinion assembly (29). 3) Remove bearing (31) from pinion (30). » 3 sa0r13669_ 41 4) Remove outer race (32) and oil seal (33) from cage (28). 5) Remove outer race (34) from case. 140F13590 140F13591 30-121ASSEMBLY OF FINAL DRIVE ASSEMBLY + Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing 1. Pinion assembly 1) Using push tool 1, install oil seal (33) to cage (28), Lip of oil seal: Grease (G2-LI) 2) Install outer race (32) to cage (28). 3) Install outer race (34) to case. 4) Install bearing (31) to pinion (30). 5) Install pinion assembly (29). % Install so that the part with the small outside diameter is facing the outside. 6) Assemble shim, the install cage (28). 30-122 4013591] aH 3 140F13569 140F13594 o1auozo1au02 |. Cover % Select the shim thickness to be assembled as follows. i) Install pinion without fitting O-ring to cage. ii) Hold cage down by hand, and use a clearance gauge to measure clearance between gauge and case at 2 places on the circumference. ili) Select shim and install. Shim thickness: clearance a + (0 — 0.1 mm) % Ifthe clearance a is 0, check that the rotating torque of the pinion is at least 0.98 Nm (0.1 kgm). . Output shaft Install output shaft (27). |. Gear assembly 1) Install bearing (26) to gear (25) 2) Install thrust washer (35) to case. 3) Using eyebolts ®, install gear assembly (24), mbly 1) Install spacer (20) to cover (36) 2) Using tool F-4, press fit bearing (19). + A press can be used instead of the puller. 3) Using tool F-2, instal floating seal. % Remove all oil and grease from the O-ring and O-ring contact surface, and dry before installing. + After installing the floating seal, check that the angle of the seal is less than 1 mm. 14013595, 1 Jl, 140613596 140F13598 140F13599 30-1234) Using eyebolts ®, install cover assembly (21) to case, then tighten mounting bolts. 5. Sprocket, hub assembly 41) Install outer race (18) to hub (13). 2) Using too! F-2, install floating seal (16). % Remove ail oil and grease from the O-ring and O-ring contact surface, and dry before installing, % After installing the floating seal, check that the angle of the seal is less than 1 3) Check that there is no dirt or dust on slid ing surface of floating seal, then coat thinly with engine oi 4) Using eyebolts 8, set sprocket and hub assembly (15) in cover. 5) Using tool F-4, rotate sprocket and hub assembly, and press fit bearing (19). ‘ Press fit to a point which does not give any preload 30-124 o14u02o14u02 6) Set hub (13) to ring gear (14), and install snap ring (12). 7) Using eyeboits @, install ring gear and hub assembly (11). 8) Set holder (10) in position. oT bearings a ‘set right, so there is no need to adjust them, but in order to check that there are no defective parts, measure the preload as follows. ’) With no preload given to the bearings, measure the rotating torque of the sprock (kgm). ket hub, and take this as a Nm ‘ Measure the sliding resistance of the floating seal first. ii) Rotate the sprocket and tighten the plate holder bolt to 245.2 — 308.9 Nm (25 — 31.5 kgm). ill) After tightening the bolt, check that the rotating torque is a + (0 — 61.7) Nm [a+ (0 — 6.3) kgm). 6. Shaft Using eyebolts ®, install shaft (9). . Carrier assembly 1) Pre (5). 5s fit ‘outer race (8) to planetary gear ‘ The bearing is set right, so be careful not to change the combination when installing. 2) Assemble 2 bearings (7) to gear (5), and set to carrier (17) * Cente 3) Align wit =m r with the shaft hole. th dowel pin and install plate (3). Mounting bolts: 549.2 + 68.8 Nm (56 + 6 kgm) 140F13605 140F13606 140613607 140F13608 30-1254) Expand fit shaft (6). + Leave in dry ice for approx. 30 minutes. 5) Install lock plate (2), Gem Mout bolt: 110.4 + 12.3 Nm (11.25 + 1.25 kgm) 6) Using eyebolts (, install carrier assembly co} ==] Mounting bolts: 276.05 + 31.85 Nm (28.25 + 3.25 kgm) 7) Install cover. 30-126 14013609, 140F 13566 o14u02o14u02 REMOVAL OF TRACK FRAME ASSEMBLY a Remove track shoe assembly. For details, REMOVAL OF TRACK SHOE ASSEMBLY. Using jack (50 ton), jack up chassis, then set stands @ and @ (height: Approx. 900 mm) under front frame and steering case. Remove pivot shaft cover (1). a Remove equalizer bar side pin (2). %* Sling the track frame assembly, remove cover (3) and outside bushing (4), then knock out the pin and remove inside bushing (5). %* When knocking out the pin, catch the inside bushing and be careful not to drop it Remove pivot shaft bolt (6) and plate (7), then lift off track frame assembly (8). + Sling the carrier roller at its center. This makes it possible to balance it and raise it horizontally. + Oil will leak from the pivot chamber, so prepare a container to catch it. ‘Track frame assembly: 2,400 kg ‘=i = Pivot chamber: Approx. 4.5 & 30-127INSTALLATION OF TRACK FRAME ASSEMBLY © Carry out installation in the reverse order to removal. S321 Mounting bolt of pivot shaft cover: 549 + 56 Nm (56 + 6 kgm) Ge] = Inside cover: Fill with grease (G2-LI) % Do not forget to assemble the bushing. ‘ Coat track frame face a of the pivot shaft insertion portion with oil (EO-30CD). ) Plate mounting bolt: 549 + 69 Nm (56 + 6 kgm) 4m Pivotchamber: Approx. 4.5 ¢ % Fill the pivot chamber with oil up to a point 100 mm from the oil filer plug. 30-128 140F13617 o14u02o1auoz DISASSEMBLY AND ASSEMBLY RECOIL SPRING REMOVAL OF RECOIL SPRING ASSEMBLY 1. Remove idler assembly. For details, see REMOVAL OF IDLER ASSEM- BLY. 2. Lift off recoil spring assembly (1). zy eo Recoil spring assembly: 260 kg INSTALLATION OF RECOIL SPRING ASSEMBLY + Carry out installation in the reverse order to removal. % When assembling the recoil spring assembly inside the track frame, use lever block to sling the top and make it horizontal, then push in the recoil spring and set it in the frame. Serial No. 3001 - 3033 30-129 ®DISASSEMBLY AND ASSEMBLY RECOIL SPRING DISASSEMBLY OF RECOIL SPRING ASSEMBLY Serial No. 3001 - 3033 a ets 1. Remove yoke and piston assembly (2) from recoil spring assembly (1). 2. Disassembly of yoke, piston assembly 1) Remove snap ring (3), then remove ring (4), packing (5), and rings (6). 2) Remove bolt (7), then remove plate (8) and washer (9). 3) Using push tool @, remove piston (11) from yoke (10) with press. + If cylinder (20) has not been damaged, or nut (16) at the tip of the shaft has not fallen off, disassemble as follows. 3. Remove holder (13) from case (12) of recoil spring. X70 prevent danger, never stand in front of or behind the recoil spring assembly. 4. Disassembly of holder 1) Remove cover (14) from holder (13). 2) Remove seal (15) from holder (13). 5. Set recoil spring assembly (1) to tool G1. Ai The spring is under a high installed load, so be careful to set it correctly. Installed load of spring: 189.9 kN {19,370 kg} 6. Apply hydraulic pressure slowly, compress spring, and tighten nut (16) until spacer (17) ‘comes out, then take out spacers (17) and (18), and remove nut (16) 7. Gradually release hydraulic pressure to remove tension of spring. 8 Remove spring (19) and cylinder (20) from case (12), then remove bushing (21) from cylinder (20). 30-130 @ & ‘cuo01021 IA coun aes ®. n 10 16 20 | 014u02014U02 DISASSEMBLY AND ASSEMBLY Ai if cylinder (20) has been damaged, or nut (16) at the tip of the shaft has fallen off, there is danger that the recoil spring may fly off to the front when mounting bolts (22) of holder (13) are removed. For this reason, disassemble as follows. When disconnecting holder (13) and case (12), 2) 3) 4) do not stand in front of or behind the recoil spring assembly until safety has been confirmed and the recoil spring has been removed. 1) Set recoil spring assembly (1) to tool G1. Ai The spring is under a high installed load, so be careful to set it correctly. + Installed toad of sprin, 189.9 kN (19,370 kg) Apply hydraulic pressure slowly and secure recoil spring assembly. Maintain condition in Step 2), and remove mounting bolts (22) of holder (13). Gradually release hydraulic pressure to remove tension of spring. RECOIL SPRING 16 ral] 5 : 13 20 G1, 1 30-130-1 @o14u02 ASSEMBLY OF RECOIL SPRING ASSEMBLY Serial No. : 3001 - 3033 os . Install holder (13) to cal Press bushing (21) to cylinder (20), and assembly cab (12), spring (19), and cylinder {20) temporarily, then set to tool G-1. The spring is under a high installed load, so be careful to set all parts correctly. Apply hydraulic pressure slowly, compress spring, and set so that installed length of the spring is the standard value * When compressing the spring, be careful not to damage the thread. Use lever block ® and carry out centering before compressing the spring > Installed length of spring: 634 mm . Install nut (16), then install spacers (18) and (1). Gradually release hydraulic pressure to completely remove tension of spring, then remove recoil spring assemby (1) from tool GA. Assembly of holder ‘Assemble seal (15) to holder (13), then install cover (14). ~~ Lip of seal: Grease (G2-LI) (12) of recoil spring. ‘Assembly of yoke, piston assembly 1) Using push tool ®, press fit piston (11) to yoke (10), oa 1 me = : fj v7 rm 1 1 140F13626 10 Pa. an 30-131 ®DISASSEMBLY AND ASSEMBLY RECOIL SPRING 2) Assemble washer (9) and plate (8), and tighten bolt (7). % Bend the plate securely. 3) Fit ring (6), packing (5), and ring (4), and install snap ring (3) 8. Assemble yoke and piston assembly (2) to recoil spring assembly (1). © 9 2 so 7 cxoot02e exooro2s 30-132 o 014u02o14u02 DISASSEMBLY AND ASSEMBLY RECOIL SPRING DISASSEMBLY OF RECOIL SPRING ASSEMBLY serial No. 3034 and up 1. Remove yoke and piston assembly (2) from recoil spring assembly (1). 2. Disassembly of yoke, piston assembly 1) Remove snap ring (3), then remove ring (4), packing (5), rings (6). 2) Remove bolt (7), then remove plate (8) and washer (9). 3) Using push tool ®, remove piston (11) from yoke (10) with press. + If cylinder (19) has not been damaged, or nut (16) at the tip of the shaft has not fallen off, disassemble as follows. 3. Remove holder (13) from case (12) of recoil spring. B70 prevent danger, never stand in front of or behind the recoil spring assembly. 4. Disassembly of holder 1) Remove cover (14) from holder (13). 2) Remove seal (15) from holder (13). 5. Set recoil spring assembly (1) to tool G1 Ai The spring is under a high installed load, so be careful to set it correctly. Installed load of spring: 9 kN {19,370 kg} — a3 + ©, " 10 30-132-1 ®DISASSEMBLY AND ASSEMBLY 6. Apply hydraulic pressure slowly, compress spring, and tighten nut (16) until spacer (17) comes out, then take out spacer (17) and remove nut (16). 7. Gradually release hydraulic pressure to remove tension of spring. Remove spring (18) and cylinder (19) from case (12), then remove bushing (20) from cylinder (19), Ai ifcylinder (19) has been damaged, or nut (16) at the tip of the shaft has fallen off, there is danger that the recoil spring may fly off to the front when mounting bolts (21) of holder (13) are removed. For this reason, disassemble as follows. Wren disconnecting holder (13) and case (12), do not stand in front of or behind the recoil spring assembly until safety has been confirmed and the recoil spring has been removed. 1) Set recoil spring assembly (1) to tool G1. The spring is under a high installed load, 80 be careful to set it correctly. + Installed load of spring: 189.9 kN {19,370 kg} 2) Apply hydraulic pressure slowly and secure recoil spring assembly. 3) Maintain condition in Step 2), and remove mounting bolts (21) of holder (13). 4) Gradually release hydraulic pressure to remove tension of spring. 30-132-2 @ RECOIL SPRING Diverse 16 2 cxoo.0s2 exoor049 G1, ‘cuooroxe 014U02014U02 DISASSEMBLY AND ASSEMBLY ASSEMBLY OF RECOIL SPRING ASSEMBLY Serial No. 3034 and up 1. Press fit bushing (20) to cylinder (19), and assemble case (12), spring (18), and cylinder (19) temporarily, then set to tool G1. Qi The spring is under a high installed load, so. be careful to set all parts correctly. 2. Apply hydraulic pressure slowly, compress spring, and set so that installed length of the spring is the standard value. * When compressing the spring, be careful not to damage the thread. Use lever block @ and carry out centering while compressing the spring. Installed length of spring: 634 mm 3. Install nut (16), then install spacer (17). 4, Gradually release hydraulic pressure to completely remove tension of spring, then remove recoil spring assembly (1) from tool G1. 5. Assembly of holder Assemble seal (15) to holder (13), then install cover (14), Xs Lip of seal: Grease (G2-LI) Install holder (13) to case (12) of recoil spring. 7. Assembly of yoke, piston assembly 1) Using push tool @, press fit yoke (10). 2) Assemble washer (9) and plate (8), and tighten bolt (7). * Bend the plate securely. 3) Fit ring (6), packing (5), and ring (4), and install snap ring (3). fon (11) to RECOIL SPRING cupo%077 "14013630 | Dupo 30-132-3 oODISASSEMBLY AND ASSEMBLY 8. Assemble yoke and piston assembly (2) to recoil spring assembly (1). 30-132-4 ® RECOIL SPRING 14013539 o1auo2orauoz REMOVAL OF IDLER ASSEMBLY Serial No. : 3001 - 3033 1. Remove track shoe assembly. For details, see REMOVAL OF TRACK SHOE ASSEMBLY. 2. Remove lock plate (1), then remove lubricator 2. Ay 7° inside of the recoil spring cylinder is under negative pressure, so if the lubricator is not removed, the yoke will be pulled back into the cylinder when the yoke and idler support are discon nected. 3. Remove left and right guide plates (3). [#1] % Remove shim (4), check the number and thickness, and keep in a safe place. 4, Raise idler assembly and pull out, then remove mounting bolts of support (5) and yoke (6). 5. Lift off idler assembly (7). } Idler: Approx. 200 kg INSTALLATION OF IDLER ASSEMBLY Serial No. : 3001 - 3033 ‘© Carry out installation in the reverse order to removal. %& Standard shim thickness: 4 mm ‘% Adjust the shim thickness so that clearance A between the track frame and guide plate is 0.5 — 1.0 mm. ~~ Thread of guide plate mounting bolt: Thread tightener (LT-2) Guide plate s40F13922 30-133 ®DISASSEMBLY AND ASSEMBLY REMOVAL OF IDLER ASSEMBLY Serial No. 3034 and up 1. Remove track shoe assembly. For details, see REMOVAL OF TRACK SHOE ASSEMBLY. 2. Remove lock plate (1), then remove lubricator (2). AThe inside of the recoil spring cylinder is under negative pressure, so if the lubricator is not removed, the yoke will be pulled back into the cylinder when the yoke and idler support are disconnected. To prevent danger, never stand in front of or behind the recoil spring assembly. 3. Remove left and right guide plate (3). * Remove shim (4), check the number thickness, and keep in a safe place. 4. Raise idler assembly and pull out, then remove mounting bolts of support (5) and yoke (6). 5. Lift off idler assembly (7). (Ce) Idler: Approx. 200 kg INSTALLATION OF IDLER ASSEMBLY Serial No. 3034 and up + Carry out installation in the reverse order to removal. % Standard shim thickness: 4 mm * Adjust the shim thickness so that clearance ‘A between the track frame and guide plate is 0.5 - 1.0 mm. Xe Thread of guide plate mounting bolt: Thread tightener (LT-2) 30-133-1 ® IDLER oxo02955 014U02DISASSEMBLY OF IDLER ASSEMBLY 1. Remove nut (1), then knock out bolt (2) from nut end, 2. Using push-puller (D, pull out support (4) from idler (3) 3. Remove floating seals (5) from support (4). 4. Raise idler (3) and pull out shaft and support assembly (6). 5, Remove floating seals (7) and (8) from idler 8). 30-134 ~ Ta0r 13698 Kngek out SS 1 40F13699 a0 3640 Tar 13643 140F 13608 orau02o14u02 Tie with wire oF rope to prevent sing rope from ‘moving apart. 6. Remove floating seal (9) from shaft and sup- ’ port assembly (6). Remove nut (10), and knock out bolt (11) from | 8. Use push-puller © in the same way as in Step 2), and remove shaft (13) from support (12). Ee = oj 9. Remove 2 bushings (14) from idler (3). 140F13647 30-135ASSEMBLY OF IDLER ASSEMBLY 1. Using push too! ®, press fit bushing (14) to ler (3). 2. Fit O-ring to shaft (13), and assemble to support (12) ‘% When assembling the shaft, align the shaft and support groove. 3. Knock bolt (11), and tighten nut (10). - Bolt: Thread tightener (LT-2) 2 4. Using tool G-4, install floating seal (9) to shaft and support assembly (6), then assembly O-ring to shaft. ‘% When assembling the floating seal, clean the thick line portion (O-ring and O-ring contact surface), remove all oil and grease, and dry it. 5. Using tool G-4, assemble floating seal (8) to idler (3). ‘* When assembling the floating seal, clean the thick line portion (O-ring and O-ring contact surface), remove all oil and grease, and dry it, 30-136 M 140713648) 140F 13606 ea 140F13649) Ta0F 13645] 140F1 3652 o1au02o14u02 6. Raise idler (3) and assemble to shaft and support assembly (6). 7. Using tool G-4, assemble floating seal (7) to idler (3). % When assembling the floating seal, clean the thick line portion (O-ring and O-ring contact surface), remove all oil and grease, and dry it. Ce \ 1401365} Sting rope Tie with rope to prevent sling rope from moving apart. a Q view oris6a2 1 — oO 30-137DISASSEMBLY AND ASSEMBLY 8. Using tool G-4, assemble floating seal (5) to support (4). % When assembling the floating seal, clean the thick line portion (O-ring and O-ring contact surface), remove all oil and grease, and dry it. 9. Install support (4) to idler (3), knoc! then tighten nut (1), 7%. Bolt: Thread tightener (LT-2) bolt (2), For normal oll supply method 10. Remove plug (15) from support (4), then add specified amount of engine oil through oil filler port. Serial No. 3001 - 3033 4 ater: Approx. 150 cc (E030-CD) Serial No. 3034 and up 4 ater: Approx. 250 ec (E030-CD) 11. After adding oil, install plug (15) to support (4). 30-138 IDLER v 8003081 8003082 o14u0201402 DISASSEMBLY AND ASSEMBLY For vacuum oil supply method 10. Remove plug (15) from support (4). 11. Using tool G7, apply standard pressure to idler oil filler port and check for leakage of air from seal. * Standard air pressure: 1 kg/m? Method of checking Hold standard pr for 10 sec and check that gauge indicator does not go down. 12, Using tool G7, fill idler assembly with oil, then tighten plug (15). Serial No. 3001 ~ 3033, 4 ater: Approx. 150 ce (E030-CD) Serial No. 3034 and up 4H dter: Approx. 250 ce (E030-CD) IDLER 002081 GI oxnoa004 GI reott om To vacaue tank aoa 30-138-1 @REMOVAL OF TRACK ROLLER ASSEMBLY 1. Loosen track shoe tension. For details, see REMOVAL OF TRACK SHOE ASSEMBLY. 2. Remove mounting bolts of track roller guard (1). an 3. Remove track roller mounting bolts (2). 4. Start engine, and operate blade, ripper, and hydraulic jack to jack up machine. Ay Ate jacking up the machine, set blocks on top of the track shoes and lock the work equipment control levers and brake lock lever. 5. Remove track roller assembly (3). Track roller assembly: (W) 60 kg (8) 55kg INSTALLATION OF TRACK ROLLER ASSEMBLY ‘© Carry out installation in the reverse order to removal. Gn 0 Thread of roller guard mounting bolt: Thread tightener (LT-2) 1% Thread of track roller mounting bolt: ‘Thread tightener (LT-2) se Track roller mounting bolt: 385 + 42Nm (39.3 + 9.3 kam) + Install so that the oil plug is on the outside of the chassis. 140F12657| 30-139DISASSEMBLY OF TRACK ROLLER ASSEMBLY 1. Remove plug (2) from roller assembly (1) and drain oil. 2. Set roller assembly (1) on block (, then using push puller @, push in collar (3), pull out lock pin (4), and remove collar (3) 3. Remove floating seal (5) from collar (3). 4. Remove floating seal (6) from roller assembly M, 5. Raise roller (7) and pull out from shaft assembly (8). 6. Remove floating seal (9) from roller (7) 7. Remove floating seal (10) from shaft assembly (8). 8. Remove lock pin (11), then remove collar (13) from shaft (12) 9. Remove floating seal (14) from collar (13). 10. Remove bushing (15) from roller (7), then turn over, and remove bushing (16). 140F19665 40F19862| 140F 13663 Mn 13 140F13664 140F 19665; 140F13666 4013667] 30-140 o1au02014U02 ASSEMBLY OF TRACK ROLLER ASSEMBLY 1. Using push tool ®, press fit bushings (16) and (15) to roller (7). 2. Using tool G-3, install floating seal (14) to collar (13) %* When assembling the floating seal, clean the thick line portion (O-ring and O-ring contact surface), remove all oil and grease, and dry it. 2 3. Fit O-ring to shaft (12), assemble collar (13), then install lock pin (11). 4. Using tool G-3, install floating seal (10) to shaft assembly (8). ‘* When assembling the floating seal, clean the thick line portion (O-ring and O-ring contact surface), remove all oil and grease, and dry it. 2 5. Using tool G-3, install floating seal (9) to roller , %* When assembling the floating seal, clean the thick line portion (O-ring and O-ring contact surface), remove all oil and grease, and dry it. 16) 140F 366s] 140F13669| 13. u 140F13667 4 0. 140F19968 3 << wee) "CH Mor 9691 140612672 30-1416. Raise roller (7) and assemble to shaft assembly (8). 7. Using tool G-3, install floating seal (6) * When assembling the floating seal, clean the thick line portion (O-ring and O-ring contact surface), remove all oil and grease, and dry it, 8. Using tool G-3, install floating seal (5) to collar (3). %* When assembling the floating seal, clean the thick line portion (O-ring and O-ring contact surface), remove all oil and grease, and dry it. 4B Roller: 320 ec (G0140B) 10. Fit O-ring to shaft and assemble collar (3), then using push puller @, push in collar (3), and install lock pin (4). 11. Check oil level and tighten plug (2) to roller assembly (1). GF) Plug: 117.6 + 19.6 Nm (122 kgm) 30-142 1 40F 13662 140F13601] 2 40F 13669] 140F 13658 o14u02o14u02 REMOVAL OF CARRIER ROLLER ASSEMBLY 1. Remove top cover of track frame, and loosen lubricator (1) to loosen track shoe tension. Never loosen lubricator (1) more than one turn, % If the track tension is not relieved when the lubricator is loosened, move the machine backwards and forwards. 2. Using hydraulic jack ©, raise track shoe. 3. Remove mounting bolts (2). 4, Pass rope ® through hole in link, fit it around carrier roller (3) to support carrier, then loosen rope gradually, and pull out carrier (3) from support (4). (ai) [Cae] Carrier roller: 30 kg 140F13675| 140F13678) 140F13679| 140F 3680] 30-143INSTALLATION OF CARRIER ROLLER ASSEMBLY ‘© Carry out installation in the reverse order to removal. 1 Clearance TS mam ‘When installing the carrier roller to the support, leave the clearance shown in the diagram! 7° Support mounting bolt: { ‘Thread tightener (LT-2) 1 ‘* Adjust the tension of the track shoe assembly. For details, see TESTING AND ADJUSTING, ‘17M 02666 ‘Adjusting tension of track shoe assembly. 30-144 o1au0201402 DISASSEMBLY OF CARRIER ROLLER ASSEMBLY 1, Remove plug (1) and drain oil. 2. Remove snap ring (2), then remove cover (3). 4 5 3. Remove bolt (4), then remove spacer (5). 3 1 f 140613684 14013682 4. Set cartier roller on block ©, then using push tool @, pull out shaft assembly (6) with a press, and remove bearing (7). oo ee o~ 14013683 aor 13684 5. Disassembly of shaft assembly 1) Remove collar (8) from shaft assembly (6) 2) Remove floating seal (9). nw F9 3) Remove floating seal (10) from coller (8) = 10 4) Remove bearing (12) from shaft (11). _ 008 i 7 14013685 140613686) 6. Remove outer race (14) from roller (13), then turn over and remove outer race (15). " n [=}—| iS IS IS ‘S| 140F 13687 140F13688 30-145ASSEMBLY OF CARRIER ROLLER ASSEMBLY 1. Press fit outer races (15) and (14) to roller (3). 2. Assembly of shaft assembly 1) Using push tool @, press fit collar (8) to shaft (11). 2) Using tool G-2, assemble floating seal (10). % When assembling the floating seal, clean the thick line portion (O-ring and O-ring contact surface), remove all oil and grease, and dry it. 3) Assemble floating seal (9), then using push tool @, press fit bearing (12). % When assembling the floating seal, clean the thick line portion (O-ring and O-ring contact surface), remove all oil and grease, and dry it. 3. Set shaft assembly (6) on block @, and assemble roller (13). 4. Assemble bearing (7), then using push tool press fit + Rotate the roller when press fitting the bearing, and press fit until the rotation of the roller starts to become heavy. 5. Install spacer (5) with bolts (4). >=) Bolt: 277 + 32 Nm (28.3 + 3.3 kgm) 3. Refill carrier roller with oi WP Carrier roller: 240 e¢ (GO140B) 7. Fit O-ring to cover (3) and install to roller, then install snap ring (2) 8. Check oil level and tighten plug (1). 30-146 GE |_-D NS \ hs ‘ 13 \S ce SY | ED, ver 2e or 689 HA, Ete ) LT sorts ‘oss @ a eernea|| 2a | orn 45 Wf ee) { 2 ; at rien o14u02o14u02 DISASSEMBLY AND ASSEMBLY ‘TRACK SHOE CHECKING BEFORE REMOVAL OF TRACK SHOE ASSEMBLY Serial No. 3001 - 3033 Ai'1 some cases, it may be extremely dangerous to remove the track shoe assembly. To prevent danger, carry out the following checks before removing the track shoe assembly. + Checks before starting 1) Loosen the lubricator at the adjustment cylinder, remove the grease, move the machine backwards and forwards a short distance, and check that the track tension is relieved. If the track tension is not relieved and the track shoe assembly remains tense, there may be an abnormality inside the track frame (the recoil spring cylinder is broken, or the nut at the end of shaft has fallen off) Never loosen the lubricator more than one turn. 2) Check that there is no interference between the track frame and the guide shown in the diagram. if there is any interference (when progress of link pitch elongation is extreme), there are cases where it is impossible to know if there is any abnormality inside the track frame. Track “rane ox002956 REMOVAL OF TRACK SHOE ASSEMBLY (NORMAL) Serial No. 3001 - 3033 1. Set master link position. % To set the position of the master link, stop Oo the machine with the master link at the Oo front, approx. 500 mm from the ground, and set a block (height: 300 mm) under omy, the grouser. 2. Loosen track shoe frat] oe By Wher loosening tubricator (1), never loosen it more than one turn. % If the track tension is not relieved when the lubricator is loosened, move the machine backwards and forwards. 3. Remove track shoe (2) for master link. 4. Disconnect master link (3). + Sling the tip of the master link, then move the machine in reverse slowly, and lay out the track shoe assembly (4). & Track shoe length: Approx. 9.0 m 140F13696DISASSEMBLY AND ASSEMBLY TRACK SHOE REMOVAL OF TRACK SHOE ASSEMBLY (WHEN THERE IS ABNORMALITY INSIDE TRACK FRAME) 1 Serial No. 3001 - 3033 oO S * If CHECKING BEFORE REMOVAL OF TRACK SHOE ASSEMBLY shows that there is no abnor- ity, do as follows. 1. Remove work equipment assembly. For details, see REMOVAL OF WORK EQUIP- c1ooioe MENT ASSEMBLY. 2. Loosen lubricator (1) and relieve tension of track shoe assembly. Qi The recoil spring cylinder is under extremely jh internal pressure. Never loosen lubricator (1) more than one turn. If the track is not relieved by loosening the lubricator, move the machine backwards and forwards. 3. Drive slowly forward to put track shoe at idler end in contact with large block @ or a wall (if another large bulldozer of the same capacity as the machine being repaired is available, put in contact with the blade). Stop machine when recoil spring bends and track shoe also bends, then apply brake. When doing this, set so that master link is between idler and front carrier roller. For safety reasons, fit a lever block be- ‘tween carrier roller support and link. 4, Remove idler guide (2). Always remove the idler guide without fail at this point. If the track shoe is opened without removing idler guide (2), it will move to the front when it opens, and idler guide (2) will be pushed against the track frame. If the idler guide is removed in this condition, the idler yoke assembly will fly out to the front. 5. Remove shoe (4), then disconnect master link 5. AB extremely careful to ensure safety when disconnecting the track shoe. 6. Move machine towards rear slowly, and lay out track shoe assembly. cxpor04e 30-147-1 ® 014u02o14u02 DISASSEMBLY AND ASSEMBLY ‘TRACK SHOE INSTALLATION OF TRACK SHOE ASSEMBLY Serial No. 3001 - 3033 + Carry out installati moval. in the reverse order to re- When adjusting the track shoe tension, set dimension a to 25 + 5 mm. Tighten the shoe bolts in the order shown in the diagram. Xs Shoe bolt : Anti-friction compound (LM-P) Gz Shoe bolt (master link): am 17MF02689 Initial torque : 343.2 + 39.2 Nm (35 + 4 kgm) we) 0° ° Tightening angle : 180_y9. > f oe oh 1976308 30-147-2 @DISASSEMBLY AND ASSEMBLY CHECKING BEFORE REMOVAL OF TRACK SHOE ASSEMBLY Serial No. 3034 and up i'n some cases, it may be extremely dangerous to remove the track shoe assembly. To prevent danger, carry out the following checks before removing the track shoe assembly. + Checks before starting 1) Loosen the lubricator at the adjustment cylinder, remove the grease, move the machine backwards and forwards a short distance, and check that the track tension is relieved. If the track tension is not relieved and the track shoe assembly remains tense, there may be an abnormality inside the track frame (the recoil spring cylinder is broken, or the nut at the end of shaft has fallen off). Never loosen the lubricator more than one turn. REMOVAL OF TRACK SHOE ASSEMBLY (NORMAL) Serial No. 3034 and up * If CHECKING BEFORE REMOVAL OF TRACK SHOE ASSEMBLY shows that there is no abnormality, do as follows. 1. Set master link in position. Set a block (height: approx. 300 mm) so that the master link is approx. 500 mm from the ground at the front. 2. Relieve track shoe tension. Never loosen lubricator (1) more thai turn. + If the track is not relieved by loosening the lubricator, move the machine backwards and forwards. 3. Remove mounting bolts of track shoe (2) master link (3). 4. Raise tip of master link, move machine forwards slowly, and lay out track shoe assembly (4). 30-147-3 ® TRACK SHOE wot vxo02957 014u02014U02 DISASSEMBLY AND ASSEMBLY ‘TRACK SHOE REMOVAL OF TRACK SHOE ASSEMBLY (WHEN THERE IS ABNORMALITY INSIDE TRACK FRAME) Serial No. 3034 and up * When CHECKING BEFORE REMOVAL OF TRACK SHOE ASSEMBLY shows any abnormality, do as follows. If there is any abnormality inside the track frame, there is danger that the track shoe assembly may spring back when it is removed or that the idler may spring out when the track shoe assembly is removed. This may lead to serious injury, so remove the track shoe assembly as follows. Ay i there is any interference or abnormal catching around the idler assembly, examine carefully and remove the problem before starting. 1, Remove work equipment assembly. For details, see REMOVAL OF WORK EQUIP- MENT ASSEMBLY. 2. Loosen lubricator (1) of adjustment cylinder, then move machine backwards and forwards to release grease. En ‘Never loosen the lubricator more than one turn. cuporoe * Check that all the grease has been removed. 3. Drive slowly forward to put track shoe at idler end in contact with large block @ or a wall (if another large bulldozer of the same capacity as. the machine being repaired is available, put in contact with the blade). Stop machine when recoil spring bends and track shoe also bends, then apply brake. When doing this, set so that master link is between idler and front carrier roller. For safety reasons, fit a lever block between carrier roller support and link. + Remove shoe (2), then disconnect master link (3). —) Be extremely careful to ensure safety when disconnecting the track shoe. + Move machine towards rear slowly, and lay out track shoe assembly. 30-147-4 ®DISASSEMBLY AND ASSEMBLY ‘TRACK SHOE INSTALLATION OF TRACK SHOE ASSEMBLY Serial No. 3034 and up + Carry out installation in the reverse order to re- joval. * When adjusting the track shoe tension, set dimension a to 25 + 5 mm. 2) “%* Tighten the shoe bolts in the order shown in the diagram. AIXS Shoe bolt : Anti-friction compound (LM-P) =] Shoe bolt (master link): Initial torque : 343.2 + 39.2 Nm {35 + 4 kam} Tightening angle : 180_,9, one? 30-147-5 oO 014U02OVERALL DISASSEMBLY OF TRACK SHOE A. This section describes only for the lubricated track link. 1. Shoe (master link portion) Set the track assembly on a flat floor with the shoe facing up, then remove the shoe bolt at the master link, and remove the shoe. % Do not use an impact wrench when loosening the master link bolt. Fereso2s 2. Disassembly into 1/4 parts Because of the weight of the track assembly, if the 1/2 assembly is too large and there are problems with disassembly and assembly work, divide into 1/4 assem 3. Shoe (regular link portion) Raise the track assembly and set it on the floor with the shoe facing up, then use a shoe bolt impact wrench to remove the shoes. ‘ When moving the track assembly, be careful not to damage the master link portion. + If a gas cutter has to be used to remove the shoe nut, to prevent deterioration of the seal due to the heat, keep the temperature of the seal portion below 80°C, ‘and take action to prevent welding spatter from entering the gap between the links. 4. Draining oil Before disassembling the link assembly, drain the oil from inside the pin and take precautions so that the link press does not become dirty with ol. + Before disassembling, if itis judged that it is necessary to rebuild the track as a dry type track, the following work need not be carried out. 1) Set the link assembly on a flat floor with the large plug side facing up, then chamfer the burrs on the end face of the pin with a grinder. 4 If the track is disassembled with burrs still at the end face of the pin, the pin press fitting hole of the link will be scratched, and this will cause leakage from the pin press-fitting portion after rebuilding, 2) Using a drill (010mm), make a hole in the large plug, then remove the large plug % if any dirt or deteriorated oil is stuck to the pin hole, drill through with a longer dril to remove it. When doing this, be careful not to damage the oil hole. 30-148 19802241 o14u02o14u02 3) After removing the large plug, use a baby grinder (angle of grinder tip: 45° — 60°), and chamfer the pin hole so that the plug is not damaged when the plug is knocked in, 4) Turn over the link assembly so that the small plug side is facing up, remove the burrs at the end face of the pin with a grinder, then use tool W to knock the ‘small plug to the inside. % If the small plug hole is blocked with burrs, grind with a grinder until the hole can be seen completely. 5) Using a drill (010 mm), chamfer the small plug hole. 6) Blow with compressed air to remove the metal particles when draining the oil inside the pin or removing the burrs, then wash the link assembly with high-pressure water or steam. 5. Disassembly of link 1) Set the link assembly on a link press, then hit with a hammer so that the bushing and jaw are in tight contact. + If the link tread and outside diameter of the bushing are worn, adjust the height of the shoe or guide plate, and center the disassembly jig with the pin and bushing center to prevent damage to the link hole when disassembling. % If the centering is not carried out properly, the link hole may be damaged, the pin may break, or the bushing may crack during disassembly. 2) Operate the left cylinder and remove the left link and pin and bushing press-fitting portion at the same time. & Check the removal force of the pin and bushing, and use this value as reference to judge if it is possible to obtain the necessary pin and bushing press-fitting force when turning and reassembling, + Do not push the disassembly jig inside more than is necessary as the spacer may break, Left asassemby ng [rvesozza6! Ww | ‘ | F 198022440 | 19802286 oe eee ight disassembly 1, 30-1493) Return the left cylinder, then operate the right cylinder and remove the right link and pin and bushing press-fitting por at the same time. | 4) Return the right cylinder, remove the left and right links, pins, bushings, and spacers, then feed the following set for one link assembly into the jaw. + To decide if the seal can be used again, carry out inspection when the seal is still installed to the link, 50 do not remove the seal from the link. + If the oil is remaining, this can be used ‘as a guide line for reuse of the seal, so mark such links or seals. % If the end face of the bushing and seal surface are damaged, it will cause oil leakage, so be extremely careful when handling. 6. Inspection Check the following items to determine if the part can be reused as a lubricated track or as a grease-flled track. Carry out a comprehen sive check to determine if the link assembly can be rebuilt as a lubricated track or as a grease-flled track. Ay Wien making judgements about reuse of parts, see Shop manual “Guidance for Reusable Parts”. 1) Check the pins, bushing, links and spacers visually for damage, and carry out a color check or use a flaw detector to check parts that are suspected of being damaged. Any part that is cracked must not be used again, so scrap it. 2) Check the external appearance of the seal and the end face of the bushing visually to determine if they can be used again. If only the bushing is replaced with a new part, the worn or damaged part of the seal lip contacts the end face of the bushing directly, so it may not be able to carry out its sealing function. For t reason, always replace the seal together with the bushing, or rebuild as a grease-flled track. 30-150 014U02o14u02 3) 4) 5) Using calipers, measure spacer thickness a and overall length b of the sliding p tion of the bushing and spacer. Check if it is possible to obtain the specified seal mounting dimension when reassembling. + If the amount of wear of the spacer and bushing is greater than the specified amount, the assembly precision of the seal portion cannot be guaranteed, so replace with new parts, or rebuild as a grease-filled track Using @ micrometer, cylinder gauge, and calipers, measure the outside diameter of the pin and the inside diameter of the bushing at the worn portion, and judge if the parts can be used again. % If the amount of wear is greater than the specified amount, there will be play during travel, and it will also cause the oil to become dirty, so replace with new parts or rebuild as a grease-filled track. % For details of the dimensions when making judgement, see MAINTENANCE ‘STANDARDS. Using a measure the outside diameter of the pin and bushing press-fitting portion, and the inside diameter of the pin and. bushing press-fitting portion of the link to determine if the permitted interference can be ‘obtained. However, when rebuilding as a lubricated track, check the standard interference for the pin and link % Ifthe permitted interference can not be obtained, replace with new parts or replace with an oversize part. % For details of the dimensions when making judgement, see MAINTENANCE STANDARDS. F19802249 PROT 19802250, F19802251 30-151AY PRECAUTIONS FOR STORAGE 1) To prevent rust of the counterbore portion of the link, leave the seal installed to the link and be careful not to damage the seal lip during storage. 2) Coat the pin and bushing press-fitting portion, shoe mating surface, and master link ‘mating surface of the link with rust prevention oil to prevent rust. 3) Coat the whole circumference of the pins, bushings, and spacers with rust prevention oil to prevent rust, and be particularly careful not to damage the end face of the bushing during storage. 30-152 F19902253, 014u02o14u02 OVERALL ASSEMBLY OF TRACK SHOE 1. WHEN REBUILDING AS LUBRICATED TRACK A ese a Loading Seatring 1) Washing seal assembly ‘* Machines equipped with F3 type seals. Remove the seal assembly from the link, then separate into the seal ring and load ring, and clean the parts. > The seal ring and load ring deterior- ate easily when brought into contact | with cleaning agent (trichlene, etc), 50 wash the parts quickly. After cleaning, wipe the parts with a clean cloth to remove all the clean- rieoazae ing agent. 2) When reusing the pin, chamfer the corner of the end face smooth with a grinder. Remove any protruding parts stuck to the press-fitting portion with a grinder. % If the corner of the end face has become sharp due to wear, there will be scuffing when press fitting and this will cause oil leakage. 3) Make a mark on the end face at the small Pseeseeesesrecaeeeaeseraesaeranasiaeanranearait| plug end to show the direction of the si hole (hole in the radial direction) in the pin when assembling. % When rebuilding the pin, assemble in the same direction as when the part new (side hole on the link tread side). Make a mark to show ‘rection of hole 30-1534) If the link, pin, bushing, or spacer are dirty, wash them. Remove any protruding parts stuck to the link and bushing with grinder. These parts easily rust, so wash them immediately before assembly. 4 Use tool X to wash the pin hole. Do not polish or carry out any other treatment of the end face of the bush: ing as this causes the oil leakage. 5) Use tool ¥ to knock the large plug into the pin j) Insert plug into hole in guide through plug insertion window. (Coat the plug with oil.) ii) Push bar by hand and insert the plug as far as it will go. iii) Push plug with bar, and push guide itself against pin. iv) Hit in bar with a hammer. jimension “a” to knock in the plug from end face of pin: 6+ 2mm % If there is no more place to chamfer at the pin hole because of wear, use a baby grinder (angle of grinder tip: 45 — 60°) to carry out chamfering. % Coat the outside circumference of the plug with GO140B and knock in the smaller diameter part first. 6) Installation of seal assembly * Machines equipped with F3 type seal Clean the link counterbore, then use tool KA to push the seal in fully to the bottom, If there is oil stuck to the link counterbore and seal assembly, the seal will rotate and its sealing performance will drop, so do not coat with oil. In addition, be careful not to let oil get into the counterbore portion of the seal when pushing in. 30-154 19802287 rr 0280s Remove all oll and grease from the shaded area ~ Direction to push in Cesena] ka 198022598 Remove all oil and grease from shaded area 19802260 o14u02o14u02 7 8) In order to keep the protrusion of the pin and bushing constant and the installation dimensions of the steel within the specified value during assembly, adjust the press-fitting jig dimensions of the link press + For details of the standard dimensions, see PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS. % To leave a small space for the pin when assembling, ensure that the dimension (dimension a’) is greater than dimension “a” at the pin pushing portion of the left press-fiting jig. When assembling in order © left link press fitting, @ right link press fitting, provide the extra space for the pin on the right press-fitting jig. + If the end face of the pin (portion P) or the end face of the link (portion Q, R) are worn, add the amount of wear to the standard dimension when adjusting the dimension of the press-ftting jig so that the amount of protrusion of the left and right pin and bushing is uniform. Adjust the relief pressure of the link press to make sure that the pushing force of the press does not exceed the specified value. % If the pushing force is too strong, excessive force will be brought to bear on the spacer, and it will be pushed against the bushing. This will cause the spacer to break or will cause abnormal wear between the spacer and bushing end face. % If the interference at the press-ftting portion is different from when the part is new, as when reusing a pin or bushing, measure several of the press-fitting portions, and use the value below to determine the set pushing force according to the average interference. % Set pushing force of pin and bushing 588 KN (60 ton) Set pushing force = 1.8 X average pushing force {Adjust the relief pressure of link press to fix the set pushing force) F19802261 F19802262| 30-1552. Assembly of link 1) Use a clean brush to coat the area between the pin and bushing with oil (GO1408), set in position, then set in front of the jaw of the link press. + When reusing (turning) the bushing, set the worn surface on the outside cir cumference of the bushing facing the shoe mounting surface of the link (facing up on the link press). 2) Set the left and right bushing end master link with the shoe mounting surface facing up, then press fit to the bushing, + When doing this, use the pin end master link as a support. + Bushing press fitting force: 49 — 147 KN (5 — 15 ton) 3) Using shoe bolt hole pitch gauge, press fit until the distance between the shoe bolt holes of the left and right link is the specified value. Use compressed air to remove all metal particles from burrs while press fitting the bushing. 79002266 4) Turn over the master link, and check that the left and right master links have been press fitted in parallel 30-156 014U02o14u02 5) Measure the amount of protrusion of the left’ and right bushings with a depth gauge. % Adjust the press-fitting jig for the link press so that the protrusion of the left and right bushings is uniform. 6) Feed the master link portion, then set the pin and bushing in position. % When reusing the pin, assemble so that the side hole is on the link tread side in the same way as when the part is new. If the parts are not assembled facing the specified direction, the strength may drop, so mark the direction of the side hole clearly on the end face to prevent any mistake during assembly. % Align the large plugs so that they are on the left side facing the link press when assembling. 7) To prevent oil from leaking out from scuff marks on the pin press-fitting portion, coat the pin press-fitting hole in the link and the outside diameter of the pin press-fitting portion with gasket sealant (198-32-19890). 8) Set the right link in position and install the spacer to the pin. + Check that there is no dirt or dust stuck to the seal surface and bushing end face, then use a clean cloth or brush to coat with oil (GO1408). % Wipe the spacer with a clean cloth, then install it. crocs toe \ ) ae =F 19802268 F19802269 19802270 30-157it jig as the receiving end as the pushing end, press fit the pin and bushing at the same time. * * When press fitting, the seal may come off the link due to the play, so press fit smoothly. If the seal comes off the link, stop the press-fitting operation and fit the seal correctly on the link, then start the press-fitting operation again. Pin and bushing press fitting force: 196 — 392 KN (20 — 40 ton) 10) Using a fine adjustment spacer, press fit so that the end face of the pin is in tight contact with the bottom of the receiving jig. * ‘Adjust the depth of Ithe hole in the receiving jig so that the protrusion of the left and right pins is uniform. 11) Set the left link in position and install the spacer to the pit * Coat with oil in the same way as when installing the right link. 12) Using the left jig as the receiving end and the right jig as the pushing end, press fit the left link. * * * 30-158 When press fitting, be careful that the left and right seal and spacer do not ‘come out of position. Provide enough space on the left jig so that the end face of the pin does not contact the bottom of the jig. Link press fitting force: 196 — 392 KN (20 — 40 ton) 19902274 o1au02o1au0z 13) 14) 15) 16) Press fit the link, spacer, and bushing so that they are each in tight contact. It is impossible to check from outside if they are in tight contact, so control the hydraulic force of the link press and set the relief pressure to a constant value. Then apply hydraulic force and push in until this pressure is reached. For details of the setting for the relief pressure, see “Preparatory work". * Check that neighboring links rotate together. After assembling each link, use a dial gauge and pinch bar to measure the end play from the link previously assembled, to check that the link is assembled within the specified value, % If the end play does not come within 0—0.13mm even when applying the pushing force until the relief valve is actuated, raise the relief pressure setting gradually to adjust. % Adjust the relief pressure setting carefully and be sure not to raise the pushing force of the link press higher than necessary. Using a shoe bolt hole pitch gauge, check that the distance between the shoe bolt holes is within the standard value. % If the distance between the shoe bolt holes is greater than the specified value, disassemble and check for any abnormality, then press fit again. % If the distance between the shoe bolt holes is smaller than the specified value, and the shoe cannot be installed, the wear of the spacer or bushing end face is probably greater than the repair limit, so disassemble and replace with ‘a new part. 1 If the end play is too large, the sealing performance will drop, so set the end play to a small value. After assembling each link, use tool KB to remove the air from inside the pin, and check the sealing performance. Hold the space inside the pin at a vacuum of 695 + 15 mmHg for 5 sec- conds and check that there is no change in pressure. If the pressure changes, disassemble and check the seal for any abnormality, then assemble again. ‘Small space ‘tend of pin 30-15917) Assemble the pin end master link as the final link. % Check that the left and right master links are press fitted in parallel 3. Filling with oit After completion of assembly of the link assembly, fill the pin hole with oil. 1) Using tool KC, remove the air inside the pin from the small plug hole, set to a vacuum of 695 + 15 mmHg, then fill with oil (601408) until the pressure is 0.2 — 0.3 MPa (2 — 3 kg/cm’) % In cold or extremely cold areas, instead of GO140B, fill with Komatsu genuine oil (150-09-18270) which has excellent low temperature qualities. + Be careful not to raise the oil pressure too high as this will have an adverse effect on the seal. To determine the oil amount, set the small plug end at the top (stand the link assembly on its side), leave for 30 minutes, then charge with oil so that depth L of the space at the pin hole is within the specified value below. Specified value of L: 30 — 50 mm 2) After completion of filling with oil, use tool Z to knock in the small plug to the spe fied position. % Coat the outside circumference of the small plug with GO140B. % Knock in the plug to the depth given below. Depth to drive from end face: 254 1mm 30-160 01408 Oitievet Pin Large plas .901F001 o14u02014u02 4, Shoe (regular link portion) Set the link assembly on the bed, then use a shoe bolt impact wrench and torque wrench to install the shoe. S-5=1 Shoe bolt (regular link): Initial tightening torque 392.3 + 39.2. Nm (40 + 4 kgm) Tightening angle: 120 + 10° 5. Connecting to make 1/2 assembly Set two completely assembled portions of track on a fiat surface in a straight line with the shoes facing up. Pull master link (1) at the pin end to master link (2) at the bushing end, and set at the mating surfaces. Then put shoe (3) on top, check that shoe bolt (4) goes in easily by hand, and connect the two parts. Mounting bolt: Anti-friction compound (LM-P) G2HE1_ Shoe bolt (master link): initial tightening torque: 343.2 + 39.2 Nm (35 + 4 kgm) Tightening angle: 180 95. + When tightening, tighten in order © — @. * Do not use an impact wrench for the master link mounting bolt. Feres026 19802282 30-1612. WHEN REBUILDING AS GREASE-FILLED TRACK 1. Preparatory work 1) Washing seal assembly * Machines equipped with F3 type seals Remove the seal assembly from the link, then separate into the seal ring and load ring, and clean the parts. The seal ring and load ring deterior- ate easily when brought into contact with cleaning agent, so wash the parts quickly After cleaning, wipe the parts with a clean cloth to remove all the cleaning agent. 2) When reusing the pin, chamfer the corner of the end face smooth with a grinder so that press fitting can be carried out smoothly. 3) Make a mark on the end face at the small plug end to show the direction of the side hole (hole in the radial direction) in the pin when assembling, + When reusing the pin, assemble in the same direciton as when the part is new {side hole on the link tread side).. 30-162 Make 2 mark o show ‘rection of hole F19802256 o14u02o14u02 4) Use tools ¥ and Z to knock the large and small plug into the pin i) Insert plug into hole in guide through plug insertion window. (Coat the plug with oil.) ii) Push bar by hand and insert the plug as far as it will go. it Push plug with bar, and push guide itself against pin. iv) Hit in bar with a hammer. % Dimension “a” to knock in the plug from end face of pin: Small plug: 25+ 1mm Large plug: 6 + 2mm % If the plug is not removed from the pin during disassembly, it can be used as it is. 5) Clean any part where outside diameter of the pin, front face of the spacer, end face or inside diameter of the bushing are dirty. Coat the outside diameter of the pin and the front face of the spacer with grease. 6) ” Installation of seal assembly ‘Machines equipped with F3 type seal Clean the link counterbore, then use tool KA to push the seal in fully to the bottom. 4% If there is grease stuck to the link counterbore and seal assembly, the seal will rotate and its sealing performance will drop, so do not coat with grease. © Machines equipped with W7 type seal When reusing the link and replacing the seal with a new part, clean the link counterbore, then push the seal in fully to the bottom, % If there is grease stuck to the link ‘counterbore and seal assembly, the seal will rotate and its sealing performance wil drop, so do not coat with grease. 8) In order to keep the protrusion of the pin and bushing constant and the installation fensions of the steel within the specified value during assembly, adjust the press-fitting jig dimensions ‘of the link press. ‘ For details of the standard dimensions, see PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS. + If the end face of the pin (portion P) or the end face of the link (portions Q, R) are worn, add the amount of wear to the standard dimension when adjusting the dimension of the press-fiting jig so that the amount of protrusion of the left and right pin and bushi i form, ea efi 70280 Remove al oil ang greas from the shaded area 3 to push in a4 KA F 199022598, Remove al oil and grease {rom the shaded area F 19902260 = =%__F19802261 30-1632. Assembly of link 1) Coat the area between the pin and bushing with lithium grease (G2-L)), set in position, then set in front of the jaw of the link press When reusing (turning) the bushing, set the worn surface on the outside cir- ‘cumference of the bushing facing the shoe mounting surface of the link (facing up on the link press) 2) Set the left and right bushing end master link with the shoe mounting surface facing up, then press fit to the bushing + When doing this, use the pin end master link as a support. + Bushing press fitting force: 49 — 147 KN (5 — 15 ton) 3) Using a shoe bolt hole pitch gauge, press fit until the distance between the shoe bolt holes of the left and right link is the specified value. Use compressed air to remove all metal particles from burrs while press fitting the bushing. 4) Turn over the master link, and check that the left and right master links have been press fitted in parallel. 5) Measure the amount of protrusion of the left and right bushings with a depth gauge. % Adjust the press-ftting jig for the link press so that the protrusion of the left and right bushings is uniform. LF) FY 19802267 | 30-164 o1au02o14u02 6) Feed the master link portion, then set the pin and bushing in position. ‘% When reusing the pin, assemble so that the side hole is on the link tread side in the same way as when the part is new. If the parts are not assembled facing the specified direction, the strength may drop, so mark the direction of the side hole clearly on the end face to prevent any mistake during assembly. % If the outside diameter of the pin is worn, assemble so that the face that is not worn is on the pulling side, How- ever, in this case, also assemble so that the side hole faces the tread surface of the link, 7) Sot the left and right links in position, then operate the left and right pushing jigs to press fit the pin and bushing at the same time. + When press fitting, the seal may come off the link due to the play, so press fit smoothly. If the seal comes off the link, stop the press-ftting operation and fit the seal correctly on the link, then start the press-fitting operation again. + Set pushing force of pin and bushing: ‘588 KN (60 ton) Set pushing force = 1.8 X average pushing force {Adjust the relief pressure of link press to fix the set pushing force) 8) Using a shoe bolt hole pitch gauge, check that the distance between the shoe bolt holes is within the standard value. 9) Assemble the pin end master link as the final link. %* Check that the left and right master links are press fitted in parallel. |. Shoe (regular link portion) Set the link assembly on the bed, then use a shoe bolt impact wrench and torque wrench to install the shoe. 5) Shoe bolt (regular link): Initial tightening torque: 392.3 + 39.2 Nm (40 + 4 kgm) Tightening angle: 120 + 10° 19802240 30-1654. Connecting to make 1/2 assembly Set two completely assembled portions of track on a flat surface in a straight line with the shoes facing up. Pull master link (1) at the pin end to master link (2) at the bushing end, and set at the mating surfaces. Then put shoe (3) on top, check that shoe bolt (4) goes in easily by hand, and connect the two parts, ~~ Mounting bolt: ‘Anti-friction compound (LM-P) IEE) Shoe bolt (master link: Initial tightening torque: 343.2 + 39.2 (35 + 4 kgm) Tightening angle: 180 %y- +& When tightening, tighten in order © — @. + Do not use an impact wrench for the master link mounting bolt. Fer64026 30-166 19802281 19802282 o14u02o14u02 PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS sig dimension 19802261 Unit: mm » 30 305 + 0:3 30-167FIELD DISASSEMBLY OF ONE LINK 1. Positioning track shoe assembly Set track shoe assembly on block @ (height: approx. 300 mm). 140F13901 2. Pins Using tool KD-1 frame, extension, nut, screw, screw, adapter, pusher), and tool KD-2 (pump, cylinder), remove pins (1) and (2). % If the tip of the pin or the side of the link are unevenly worn, correct with a hand grinder to ensure that the partis at a right angle to tool KD-1. 3. Links 1) Put tool KD-3 and spacer @ of the dimensions given below in contact with the tread of links (3) and (4) + Sot tool KD-3 as close to the tip of the link as possible. 2) Apply hydraulic pressure slowly to the p ler until the tip of the link opens 6 — 8 mm, then disconnect the link. There is danger that the bushing will come out, so do not apply more hydraulic pressure than necessary + if an electric pump is used, there is danger that more hydraulic’ pressure will be applied than necessary, so always use a hand pump. 3) Disconnect links (5) and (6) in the same way. Dimensions of spacer @: 55 mm x 47 mm (Outside diameter x thickness) 30-168 014U02or4u02 FIELD ASSEMBLY OF ONE LINK 1. Bushing Put tool KE-1 in contact with the end face of link (4), and press fit bushing (7) % Always use a new bushing. + Bushing press fitting force: 49 — 147 KN (5 — 15 ton) 2. Pins 1) Using tool KE-2, knock a large plug into the oil hole of pin (1). +o Always use a new pin. 2) To determine the pushing pressure when carrying out the final assembly, measure the outside diameter of the pin with a micrometer, and note down the measurement, 3) Coat the press-fitting hole for the pin in link (4) with gasket sealant (198-32-19890) % If the link is used again, finish the press-ftting hole for the pin smoothly with sandpaper. Press (or remover) + ker F15421166 Kez, 198022588 19802259 Coat whole circumference 19802269] 30-1694) Put tool KE-1 in contact with the end face of link (4), and press fit pin (1). Press (or remover) 1 Press fit so that the side hole in the pin is Side note + on the same side as the link tread. press fitting force: 147 — 245 KN (15 — 25 ton) + Always use a new pin, * > F15«21167 3. Seal Install seal (8) with too! KE-3. + Check that there is no oil on the contact surface of the link and seal. Carry out steps 1 — 3 in the repair shop beforehand. cS 14013906 i atin Kes Unk 140F13905 4 \k sub-assembly 1) Install link sub-assembly (10) + Check that there is no dirt or dust stuck to the surface of the seal or the end face of the bushing, then coat with oil {G01408) using a clean cloth or small brush 140F 13907 30-170 o14u02o14u02 2) Install tool KE-4 (guide used when press fitting link) to bushing (7) 5. Link 1) To determine the pushing pressure when carrying out the final assembly, measure the dimensions of the press-fitting hole for the pin in link (3) with a cylinder gauge, and note down the measurement. 2) Coat the press-fitting hole for the pin in link (3) with gasket sealant (198-32-19890). ok If the link is used again, finish the press-fitting hole for the pin smoothly with sandpaper. 3) Install seal (8) with tool KE-3. % Check that there is no oil on the contact surface of the link and seal + Check that there is no dirt or dust stuck to the surface of the seal or the end face of the bushing, then coat with oil (GO1408) using a clean cloth or small brush Cae, 407135908 Coat whole circumference F 19802269] 14012910] 30-1714) Using tool KE-5, press fit pin portion of link (3) to link sub-assembly (10). + Pin press fitting force 294 — 490 KN (30 — 50 ton} 5) Using tool KE-6, press fit bushing portion of link (3) to link sub-assembly (10). * To prevent the use of any excessive force, press fit the pin portion and bushing portion gradually in turn. 4% Pin and bushing press fitting force: 196 — 392 KN (20 — 40 tun) 6. Connecting link 1) Finish the inside surface of the press-fiting hole for the pin in links (5) and (6) smoothly with sandpaper. 30-172 1 40F13908 14013913 01402014U02 2) Remove block @, and lower the track shoe assembly to the ground. 3) Set lever block to the left and right link assemblies as shown in the fig., then put tool KE-7 and spacer @ in contact with the tread of links (5) and (6). + Set tool KE-7 as close to the tip of the link as possible. 4) Using tool KE-3, install seals (13) and (14) to links (5) and (6). + Always use new seals. % Check that there is no oil on the contact surface of the link and seal. +k Check that there is no dirt or dust stuck to the surface of the seal or the end face of bushing (7), then coat with oil (G01408) using a clean cloth or small brush. 5) Apply hydraulic pressure slowly to the puller until the tips of links (5) and (6) open 6 —8mm. % There is danger that the bushing will come out, so do not apply more hydraulic pressure than necessary. If an electric pump is used, there is danger that more hydraulic’ pressure will be applied than necessary, so always use a hand pump. 6) Operate lever block ®, align the centers of the link hole and bushing hole, and con- nnect the links with tool KE-8 (guide pin). Operate the lever block @) slowly and be careful not to damage the seal or get sand stuck to the seal surface. Pin 1) Using tool KE-2, knock a large plug into the oil hole of pin (2). 2 Always use a new pin, 2) To determine the pushing pressure when carrying out the final assembly, measure the outside diameter of pin (2) with a micrometer, and note down the measure- ‘ment. 14083916 kez 198022588, 30-1733) Set the track shoe assembly on block © again. Using tool KE-9, press fit pin (2) to links (5) and (6) + Press fit so that the side hole in the pin is on the same side as the link tread. Bushing press fitting force: 49 — 147 KN (5 — 15 ton) 4 5) Temporarily stop press fitting when there is 15 — 20 mm left for press fitting pin (2). Coat the remaining press-fitting portion of pin (2) with gasket sealant (198-32-19890) 6) 7) Coat the press-fitting hole for the pin in link (6) with gasket sealant (198-32-19890), then continue to press fit pin (2). 8) Using tool KE-5, apply the specific press- Ure to links (3) and (4) and links (5) and (6). + Set pushing force of pin and bushing: 588 KN (60 ton) Set pushing force = 1.8 X average Pushing force (Adjust the relief pressure of link press to fix the set pushing force) 8. Vacuum test Using hand vacuum pump @, remove the air from the small plug hole at the end face of pins (1) and (2) and check the sealing performance. & Check that the airtightness is maintained for 5 seconds at @ negative pressure of 695 + 15 mmHg. > "40139920 30-174 014U02o14u02 9. Charging with oil 1) Using too! KC, charge with oil (GO140B) through the small plug hole in the pin. + Be careful not to raise the pressure too high when charging with oil. This will have an adverse effect on the seal + Take into consideration the expansion of the oil under heat, and be careful not to charge with too much oil 2) Using tool Z, knock in the small plug quickly. % Coat the outside circumference of the small plug with GO140B. % Knock in the plug to the depth given below. Depth to drive from end face: 2541mm 30-175REMOVAL OF PIVOT SHAFT ASSEMBLY 1. Remove track frame assembly. For details, see REMOVAL OF TRACK FRAME ASSEMBLY, 2. Sling pivot shaft assembly (1). 3. Remove mounting bolts, then using forcing screws (, raise pivot shaft assembly and pull out. (ai) (ia) Pivot shaft assembly : 100 kg 4, Remove seal (2) 5. Remove ring (3). INSTALLATION OF PIVOT SHAFT ASSEMBLY * Carry out installation in the reverse order to removal. eo -8=) Pivot shaft mounting bolt: 549 + 59 Nm (56 + 6 kgm) Gz] + Assemble the seal as follows (see diagram on right) 1) Turn over the seal so that the em: bossed letters on the seal are on the inside. 2) With the seal turned over, insert the seal on the shaft. + When inserting the seal, be careful not to damage the surface. + Press fit ring (3) using tool G-5. + Press fitting force: 18.6 KN (1.9 ton) 30-176 Ring Seal Pivot shaft ="t2) insert Embossed letters Awd (0) Turn over 140613700 o14u02o14u02 REMOVAL OF EQUALIZER BAR ASSEMBLY 1. Remove side pin top cover (1). 2. Set jack (50 ton) under bottom of radiator and jack up, then raise work equipment and set stand @ (approx. 800 mm) in position. % Set at a height where the center pin can be removed. 3. Remove cover (2) of equalizer bar side pin, take out outer bushing (3) and side pin (4), then remove inner bushing (5). be] % Use the jack to make fine adjustment of the height, and when the pin moves easily, tap the pin out and remove it. 4. Sling equalizer bar assembly (6) with crane and chain block. 5. Remove lock plate (7), then using tool G-6, pull out center pin (8). Ge] A Do not operate the hydraulic circuit from the front or under the puller. Stand as far away as possible when operating it. 6. Operate chain block and crane and remove equalizer bar assembly (6). [is] Equalizer bar assembly : 150 kg A After removing the equalizer bar assem bly, do not lower the machine. 140F13702 140F 13612 140F 13619 pea s40F 9614 14013703 30-177INSTALLATION OF EQUALIZER BAR ASSEMBLY © Carry out installation in the reverse order to removal. 77%. Inside cover: Fill with grease (G2-LI) Between bushing and seal of equalizer bar side pin: Fill with grease (G2-LI) Connection of pin and bushing: Coat with grease (G2-LI) 7 Frame boss: Coat with anti-friction compound (LM-P) 77. Between bushings: Coat with grease (G2-LI) 14013705 14013706 30-178 o14u02o14u02 REMOVAL OF EQUALIZER BAR SIDE BUSHING |. Remove equalizer bar assembly. For details, see REMOVAL OF EQUALIZER BAR ASSEMBLY. Remove seal (1). Remove ring (2) Remove spherical bushing (3). INSTALLATION OF EQUALIZER BAR SIDE BUSHING Install ring (2) to one side. Press fit spherical bushing (3) with a press. + Press fitting force: 15.7 KN (1.6 ton) . Install ring (2) to opposite side. Install seal (1) >= Between bushing and seal: Fill with grease (G2-LI) Install equalizer bar assembly. For details, see INSTALLATION OF EQUALIZER BAR ASSEMBLY. saoF13707 fT saorra708 30-179REMOVAL OF SEGMENT TEETH 1. Stop machine at position where it is easy to remove teeth (midway between shoe and track frame). 2. Remove mounting bolts, then remove teeth (1. Go INSTALLATION OF SEGMENT TEETH ‘© Carry out installation in the reverse order to removal. Bo % Install the teeth to give the following clear- lances around the circumference of the teeth hub. Position of bolt A, C: 0 mm Position of bolt B: 0 — 0.5 mm Thread of teeth mounting bolt: Thread tightener (LT-2) = Teeth mounting nut 931 + 98 Nm (95 + 10 kgm) 30-180 Segment tooth Clearance 140613710 All teeth clearances must be ,/ the same distance and must 2 be within 2 mm. o14u02o14u02 REMOVAL OF WORK EQUIPMENT PUMP ASSEMBLY By Lower the work equipment to the ground and stop the engine. Then loosen the oil fil ler cap slowly to release the pressure inside the hydraulic tank. 1. Drain oil wis Hydraulic tank: Approx. 55 & 2. Remove chassis bottom cover. Ay Tre bottom cover weights. 26 kg. so support it with a transmission jack before removing the mounting bolts. 3. Disconnect deceleration cable (1) at engine end. Go + Deceleration cable is an option. 4. Remove cover of plate (2), and disconnect brake rod (3) at turnbuckle. %* Measure the installed dimension of the rod before disconnecting the turnbuch 5. Remove plate (2) 6. Disconnect hose (4) and tube (5). 7. Lift off pump assembly (6). INSTALLATION OF WORK EQUIPMENT PUMP ASSEMBLY ‘© Carry out installation in the reverse order to removal. ao % Adjust the cable. For details, see TESTING AND ADJUST- ING, Adjusting fuel control linkage. e 4 Adjust the rod, For details, see TESTING AND ADJUST- ING, Adjusting brake pedal linkage © Refilling with oil (hydraulic tank) + Add oil through oil filler to the specified level Run the engine to circulate the oil through the system. Then check the oil level again. 140F13093 ‘ INE 140F13713 140rsa714 30-181REMOVAL OF MAIN CONTROL VALVE ASSEMBLY By Lower the work equipment to the ground and release the pressure inside the circuit. For details, see TESTING AND ADJUSTING, Releasing pressure from hydraulic circuit 1. Drain hydraulic oil. i Hydraulic tank: Approx. 55 ¢ 2. Remove operator's seat assembly, then remove inside cover. 3. Remove cover (1). 4. Remove tube (2), and disconnect 3 hoses (3), then lift off hydraulic oil filter case assembly 4). [ac] Hydraulic oil filter case: 32 kg % Drain the oil from the plug at the bottom of the filter case before removing the tube, hose, and hydraulic filter case, 5. Remove 2 covers at operator's seat end, then remove 4 hoses (5) and cooler hose (6). 6. Disconnect drain hose (7) and control rod (8), then lift off main control valve assembly (9) together with bracket. [ix] Main control vaive assembly: 60 kg INSTALLATION OF MAIN CONTROL VALVE ASSEMBLY '* Carry out installation in the reverse order to removal. ‘© Refilling with oil (hydraulic tank) % Add oil through oil filler to the specified level, Run the engine to circulate the oil through the system, Then check the oil level again. 30-182 o14u0zo14u02 DISASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY = |. Remove suction valve (11) and main relief valve (13). Remove plugs (12), (14), (16), and (17). Remove cover (2), then remove plate (3) together with seal (4) Loosen bolt (8), and remove shaft (6) together with key (7) from lever (9), then remove lever 9). Remove oil seal (5). % Check the oil seal when assembling, and replace it if it is damaged. Remove case (10) from body (1), Remove case (18) together with detent (19) and plug (20), then remove spool assembly (21), 30-18310. Remove plug (20) from case (18), then remove detent (19) and ball (30). Disassembly of spool assembly 1), Remove joint (23) from spool (22) Remove the plug with the spool still assembled inside the valve body. 2) Remove plug (31), then remove ball (29) and spring (28). % Remove the plug with the spool stil assembled inside the valve body. 3) Remove plug (27), then remove retainers (24) and (26), and spring (25). % Remove the plug with the spool stil assembled inside the valve body. Remove plug (32), then remove spring (33) and check valve (34). 30-184 o14u02o1auo2 ASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY Assemble of spool assembly 1) Fit spring (25) and retainers (24) and (26), and install plug (27). S23 Plug: 14.7 + 4.9Nm (1.5 + 0.5 kgm) + Tighten the plug with the spool assembled inside the valve body. 2) Assemble spring (28) and ball (29), and install plug (31). S=) Plug: 7.35 + 2.45 Nm (0.75 + 0.25 kgm) % Tighten the plug with the spool assembled inside the valve body. 30-1853) Install joint (23) to spool! (22). GE) Joint; 66.19 + 7.35 Nm (6.75 + 0.75 kgm) & Tighten the plug with the spool assembled inside the valve body. 2. Install case (18) to body (1). 3. Assemble ball (30) and detent (19), and install plug (20), Some) Plug: 107.9 + 14.7 Nm (111.5 kgm) 4. Install case (10) to body (1). 5. Align lever (9) with notched portion of spool, then assemble shaft (6) and key (7), and tighten bolt (8). 6. Fit oll seal (5), then fit seal (4) and plate (3) and install cover (2). 7. Install plugs (12), (14), (15), (16), and (17). GD) Plug (12), (14): 68.6 + 9.8 Nm (7+1 kgm) Gre) Plug (16): 225.6 + 9.8 Nm (23 + 1 kgm) & Plug (16): 152.6 + 24.5 Nm (15.5 + 2.5 kgm) ’ Plug (17): Loctite (LT-2) G25E] Plug (17): 367.7 + 24.5 Nm (37.5 + 2.5 kgm) 8. Install main relief valve assemble (13) and suction valve assembly (11). 2551 Main relief valve assembly: 152 + 24.5 Nm (15.5 + 2.5 kgm) "3E1 Suction valve assembly: 225.6 + 9.8Nm (23 +1 kam) 9. Assemble check valve (34) and spring (33), and install plug (32) 77% Plug: Loctite (LT-2) GoHE] Plug: 367.7 + 24.5 Nm (37.5 + 2.5 kgm) 30-186 o14u02o1auo2 DISASSEMBLY AND ASSEMBLY SUCTION VALVE REMOVAL OF SUCTION VALVE ASSEMBLY Serial No. 3001 - 3101 A Lower the work equipment completely to the ground, then release the remaining pressure inside the circuit For details, see TESTING AND ADJUSTING, Re- leasing remaining pressure in hydraulic circuit. 1. Open front mask. 2. Disconnect tubes (1), (2), and (3). 3, Remove suction valve assembly (4) together with bracket (6). INSTALLATION OF SUCTION VALVE ASSEMBLY Serial No. 3001 - 3101 + Carry out installation in the reverse order to removal. + Refilling with oil (hydraulic tank) * Add oil through oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. 30-186-1 @DISASSEMBLY AND ASSEMBLY SUCTION VALVE REMOVAL OF SUCTION VALVE ASSEMBLY Serial No. 3102 and up Ailower the work equipment completely to the ‘ground, then release the remaining pressure inside the circuit. For details, see TESTING AND ADJUSTING, Re- leasing remaining pressure in hydraulic circuit. 1. Open front mask. 0x003161 2. Disconnect tubes (1), (2), and (3). 3. Remove suction valve assembly (4) together with bracket (5). INSTALLATION OF SUCTION VALVE ASSEMBLY Serial No. 3102 and up + Carry out installation in the reverse order to removal. + Refilling with oil (hydraulic tank) %* Add oil through oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. 30-186-2 @® 014U02o1au02 REMOVAL OF BLADE LIFT CYLINDER ASSEMBLY A Lower the work equipment completely to the ground and stop the engine. 1. Sling head of lift cylinder assembly, and remove cap (1). Ga % Check the number and thickness of the shims, and keep in a safe place. A Si2tt the engine and retract the piston rod fully. Tie the rod with wire to prevent it from ‘coming out. 2. Install lift cylinder to lock bracket (, and disconnect hose (2). Release the remaining pressure from hydraulic circuit. For details, see TESTING AND ADJUSTING, Releasing pressure from hydraulic circuit. + Fit blind plugs to prevent dirt or dust from getting into the piping. 3. Sling cylinder assembly (3), and remove (4), then remove cylinder assembly. ap) Blade it yinder assembly: 100 kg INSTALLATION OF BLADE LIFT CYLINDER ASSEMBLY © Carry out installation in the reverse order to removal. eo + Adjust so that play a of the spherical portion in the axial direction is within 0.5 mm, but can still rotate smoothly. %& Standard shim thickness: 5 mm &) 7 Yoke: Grease (G2-LI) © Bleeding air Bleed the air from the cylinder. For details, see TESTING AND ADJUSTING. ©. Refilling with oil (hydraulic tank) Add cil through oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. 30-187DISASSEMBLY OF BLADE LIFT CYLINDER ASSEMBLY 1. Remove tube from cylinder assembly. 2. Set cylinder assembly (1) to too! H-1. 3. Piston rod assembly 1) Using tool H-2, disconnect cylinder head assembly (2). 2) Pull out piston rod assembly (3). % Place an oil container under the cylinder to catch the oil. 4. Piston, head assembly 1) Set piston rod assembly (6) to tool H-1. 2) Using too! H-3, remove nut (7) Lift cylinder Width across flats of nut: 50 mm. 3) Remove piston assembly (8) and slider (9) 4) Remove cylinder head assembly (4). 30-188 view 140F13754 sawrr2 o14u02o1au02 5. Disassembly of piston assembly 1) Remove piston ring (10) and wear rings (11) and (12). 2) Remove retainers (13) and (14) from piston assembly. %* Do not remove the piston valve and valve seat installed to the piston, 6. Disassembly of head assembly 1) Remove O-ring and backup ring (17). 2) Remove snap ring (18), then remove dust seal (19). 3) Remove rod packing (20). 4) Remove bushing (21). 14013760 140F13762 30-189ASSEMBLY OF BLADE LIFT CYLINDER ASSEMBLY * Be careful not to damage the packings, dust seals, or O-rings when assembling. 1. Assemble of head assembly 1) Using tool H-6, press fit bushing (21) to head (4). 2) Using tool H-7, assemble dust seal (19), and install snap ring (18). 3) Install rod packing (20), then install O-ring ‘and backup ring (17). 2. Assembly of piston assembly 1) Install retainers (14) and (13) to piston. 2) Using tool H-4, expand piston ring (10). + Set the piston ring on tool H-4 and turn the handle 8 — 10 times to expand the ring. 3) Remove piston ring (10) from tool H-4, and install to piston. 4) Using tool H-5, compress piston ring (10). 5) Install wear rings (12) and (11). 30-190 He an 4 100613766 i; a aw 0 18 1% 14013767 14013762 Woo ae 4 20205487 19769776| o14u02o14u02 3. Piston, head assembly 1) Set cylinder rod to too! H-1. 2) Assemble cylinder head (4) to rod. 3) Fit slider (9) and install piston assembly (8), then using tool H-3, tighten nut (7). + The slider (9) is installed only to the lift cylinder. oN Nut: Thread tightener (Loctite No. 262) See) Nut: Cynder Wath across] Tightening 140F19758 fats torque 1079 = 108m Littevinder | 50mm | Tiros 11 kam) 4. Piston rod assembly 1) Set cylinder to tool H-1 2) Assemble piston rod assembly (3) to cylinder. 3) Using tool H-2, install cylinder head (2). = Cylinder head: 735 + 73.5 Nm (75+ 7.5 kgm) 5. Tube Install tube to cylinder assembly. #2 14019756 30-191REMOVAL OF BLADE ASSEMBLY % Set the work equipment on the flat ground. |. Start engine, raise blade slightly, then shaft left and right ends of blade to remove arm pin (1). Raise arm and brace assembly (2), and remove brace pin (3). ‘* When pulling out the pin, brace (4) will fll, 0 fit block () between brace (4) and arm 6) . Raise arm and brace assembly (2) and pull out arm pin (6), then remove arm and brace assembly (2). [er] Arm and brace assembly: 230 kg ‘% Remove the opposite side in the same way. = Raise blade (7) and pull out pin (8), then remove blade (7). [Gc] Blade: 1,400 kg 30-192 o14u02o14u02 INSTALLATION OF BLADE ASSEMBLY '* Carry out installation in the reverse order to removal. savor? 30-193REMOVAL OF SWEEP, CANOPY ASSEMBLY 1. Remove left and right external covers. [=] Left right external cover: 45 kg 2. Disconnect front lamp wiring connectors CN6, CN7b and CN8b, then remove 15 clips, and remove wiring (1). 3. Sling front sweep assembly (2), then remove mounting bolts (3) and collar (4), and lift off front sweep assembly (2) [Front sweep assembly: 220 kg 4. Sling rear sweep assembly (5), then remove 2 bottom mounting bolts (6). Raise higher, set rear sweep assembly (5) horizontal, then remove top mounting bolts (7), and lift off rear sweep assembly (5). [Cis] Rear sweep assembly: 190 kg 5. Disconnect rear lamp wiring connector CN1a, then lift off canopy assembly (8). Canopy assembly: 200 kg INSTALLATION OF SWEEP, CANOPY ASSEMBLY ‘© Carry out installation in the reverse order to removal. 30-194 o14u02o14u02 REMOVAL OF DASHBOARD ASSEMBLY 1. Remove 9 mounting bolts, then remove dashboard assembly (1), and put on floor. 2. Disconnect connector CN6O (2), and remove dashboard assembly (1). . Remove 4 bolts, then remove panel (3). INSTALLATION OF DASHBOARD ASSEMBLY © Carry out installation in the reverse order to removal, 30-195REMOVAL OF FLOOR FRAME ASSEMBLY 1. Remove sweep and canopy assembly. For details, see REMOVAL OF SWEEP, CANOPY ASSEMBLY. 2. Remove side cover under right side of engine. 3. Remove operator's seat assembly (1). 4. Remove 3 operator's seat side covers (2). 5. Remove R.H. armrest (3). * The 2 bolts on the inside at the top of the right suspension are tightened from the top, so remove this armrest. The knob of the safety lock lever of the winch control lever also gets in the way, so remove it too. 6. Lift off dashboard assembly (4). (ig?) Dashboard assembly : 70 kg 7. Remove floor plate, then disconnect brake rod (6) and main clutch pedal rod (7). 8. Disconnect deceleration pedal linkage (9) (at engine end). 30-196 o14u02o14u02 9. Disconnect torque converter oil temperature sensor connector (10) (CN28). 10. Disconnect starting motor wiring (11), then disconnect connector (12) (CN18, CN17, CN13, CN20, (CN31, CN32 and CN33) * Remove connectors CN31, CN32 and CN33 from the clip. 11. Disconnect floor frame ground connection (13), ‘connector (14) (CN4) for rear lamp, and (+) terminal (15) of front battery, and neutral limit switch connector (16) (CN23). 12. Disconnect directional control cable (17) speed cable (18), 13. Disconnect fuel control cable (19) at lever end. 14. Disconnect parking lever (safety lock lever) control cable (20) at lever end, (#3) Eee TELE SSN 140F 13817 30-19715. Disconnect steering rod (21). 16. Disconnect winch control rods (22) and (23). (7 17. Lift off floor frame assembly (24). (a) %* For the rear right suspension portion, remove 4 bolts at top; for the rear left suspension portion, remove 4 bolts at bottom. * Be careful not to damage the control cable, rods, and wiring when removing, [iE] Floor frame assembly : 350 kg 30-198 Fovau0a8 o14u02o14u02 INSTALLATION OF FLOOR FRAME ASSEMBLY ‘© Carry out installation in the reverse order to removal. Ea] % Connect the rod and adjust it. For details, see TESTING AND ADJUSTING, Adjusting brake pedal linkage, Adjusting main clutch pedal linkage. Insert the stopper for the yoke connecting pin securely. * Connect the cable and adjust it For details, see TESTING AND ADJUSTING, Adjusting fuel control linkage. Insert the stopper for the yoke connecting pin securely. %* When connecting the rod, adjust the cable. For details, see TESTING AND ADJUSTING, Adjusting gear shift lever linkage. Insert the stopper for the yoke connecting pin securely. * Connect the cable and adjust it For details, see TESTING AND ADJUSTING, Adjusting fuel control linkage. ‘% Connect the rods and adjust them. For details, see TESTING AND ADJUSTING, Adjusting parking brake lever. ‘% Connect the rod and adjust it. For details, see TESTING AND ADJUSTING, Adjusting steering linkage. ‘When connecting the rod, adjust it. For details, see TESTING AND ADJUSTING, Adjusting winch control lever linkage. es) ‘S==1 Front mounting bolt: $49.2 + 68.8 Nm (86 + 6 kgm) ==) Suspension bolt: 110.25 + 12.25 Nm (11.25 + 1.25 kgm) 30-19940 MAINTENANCE STANDARD Engine mount Power train unit mount Damper, universal joint ... Torque converter, PTO Transmission Transmission control valve Main relief valve Bevel gear shaft, steering clutch, steering brake ‘Steering control valve Power train, lubrication pump ... Final drive Hull frame a Track frame, recoil spring Idler Track roller. Carrier roller Track shoe Suspension .. Hydraulic pump Main control vaive.. Work equipment cylinder .... ‘Work equipment Cutting edge, end bit... o14u02 40-1ENGINE MOUNT cam ; 4 = (0.62 14INe | Hoenn (a+iskem) [J : AA 8-2 ‘or i2016 Unit mm No Cheek tem criteria Remedy Totrance Standard standard | Clearance 1 | Clearance between bracket and cushion Sze ‘Shaft Hole ne: re =ar [soe | on = hea 03 o 0.346 ea ee evace Standed size Repair 2 | Free height of mount rubber 0 8 o14u02— POWER TRAIN UNIT MOUNT o14u02 7 8-8 Forauors Unit: mm No. Cheek item Criteria Remedy {— Tolerance Standard Standard | Clearance Interference between steering case ‘ize clearance | limit tga eaaes Shaft Hole 0096 | +0088 | 0096 — baal +0.050 ° = 0.004 | _Mex0 or +008 [on — 2 | clearance between bracket and cushion 6 ay 7 aaa 0.4 | Replace ‘Standard size Ropair limit 3 | Free height of front mount rubber 90 88 a: 4 | Free height of rear mount rubber a a 40-3DAMPER, UNIVERSAL JOINT GD 110.25 12.25Nm (N51, kem) o14u02TORQUE CONVERTER, PTO | 26.544.9Nm (2.50.5 kam) Gra 176, 4+ 19.6 (1822 kem) =] §3.94,9Nm (5,540.5 kem) 1 66.15+7.35Nm (6.75%0.75 kam) Zee] 66.15+7_35Nm (6,150.75 kem) Soe) 276+31.85Nm (28.253.25 kem) I i ] I vw { G2 66.1527.35Nm 1520.15) 140F12225 40-6 o1au02014U02 Gre) 24.544.9Nm (2,540.5 kem) fo He 156.8:+19.6Nm (162 kam) x 140812226 Unit: mm No (Check item Criteria Remedy Standard size Tolerance Repair limit 1 | Qursdeeiameter of sat contact Repoir hard surface of coupling o chrome au 0.087 = plating or Feplace Inside diameter of seal ring contact 0.035 - 2 | ssurtace of retainer 105 7 1055 Standard size Repair limit 3 | Wear of stator shat seal ring Replace ‘Wiath: 2 Width: 27 Hoight: 4 Height: 36TRANSMISSION 1a qo a) € iz / S : fol HI Na i ~ ae \ = - 66.157. 351Nm Se 166.6+9.8Nm / ‘ (6,750.75 kam) (171 kgm) / \ _ ~~ / D> \ a t Verte eee eee Veee bee Nce bie Fouauors 40-8 o14u02o14u02 Unit: em we Check em ctw remedy Stoner se epi it 1 No.1 etch srng 0) =, trated | oe | Tnaated so | 7s | ise | 8 | evn 2 | no. 2h ering v0) ws | = [an | os | ames 3 | No.3 atch srng 0) « | « [aay | = | ae 1 [No.4 eth png 10) = | 0s | 22% | ae | AN 6 | ne. & ech song 0) =» | «= | ey | we | Ban Sondra Tolerance Repo in | rout esembia teks o No 1 each Aeplace © 03 wa 7 [Tout erent wetness oN Zach | oo yea ws a | To arembie ticinns one 8acn | _—_ a0 02 me 2 Tot assembled tciness oN aetacn | 298 rea 78 10] Towraseentind hme atv beunen | 298 roa an 11 | etna oho. 1 — 8 cath en 30 zon 6 12 | Thats of No.1 — Sch ee 20 ror as 1a Wear tea ing on wanemison wana | OHO | wane 27 Monae raticese 23 | ricinnc Sg | Then 22TRANSMISSION CONTROL VALVE Serial No. : 3001 ~ 3023 140F12228 Serial No. : 3024 and up 1 1 40-10 oO 014U021402 a |e [7 [Re | ow [Eames [as | 8, | 7° | Cone | oe =| Sppstooneat ama | gaa] eo a [| Speonenmamoar | my] a Sa] s[Siacmmeteeree™ |» | eae [7 [aS om | « | Geaance Between modulating vate 5 =a [Fear | 002 T ooy ie 7 iste ccs ee) Fora | lad eau ee 3] mecuiaing va spring outer wx | ors | aah [| aneN 3 | Moding ve srng sax a | BN | oom | GON 10 | Module vwe piston spring am | = | aah | = | tity 40-10-1 ®o14u02 MAIN RELIEF VALVE aA 4924.9Nm 00.5 kgm) A fet pa- saori2229 Unit: men No Cheek item itera Remedy Tolerance Standard Standard. | clearance + | Slane beeen main a vave sz | oan | noe | eteorence | tim = | ae [Ba [ee 2 | fale vave and valve Coy | cao | “0 | es | 200 Standard size Repairimit | Replace 3 | Main relief valve spring (outer) lengua | atengmiee| ceive |e ion | ieee ve [| om9 | sro | 2 | doa 4 | Main ret valve sping inner) we | mo | HN [ms | EN 5 | Torque convertor rl valve spring Py a | sem | me | CSN 40-11BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE y2 a 5 3 — {any B 7 << 6eCL ff 4 fi oH Soe] 10£12Nm S30 10£12Nm GoH=)217432Nm Go) 1102 12Nm S71 110£12Nm (1L.2£1.2kgm) (28.343.3 kgm) (U.241.2 kgm) (.2£1.2 kgm) 140612220 (1.21.2 kgm) 40-12 o14u02o14u02 Unit: men No. Check tem citer Remedy Standard size Repair it Thickness of brake plate Replace 29 26 1 Tolerance Repair iit Distortion of brake pate one tess than 018 os Standard size Repair i Thickness of brake de Replace 52 as 2 Tolerance Repair mit an Distortion of brake die ae tess than 0.25 oa Standard size Repair iit 3 | Total assembled thickness of brake plates . tnd doce m8 wus Standard size Repair int Thickness of lth plate 26 23 ‘ Tolerance Repair Ht Distortion of eth plate Laeotal Tess than 0.18 0a Standard sie Repair tt Thickness of lth dee Replace a aa 5 Tolerance Repair iit Distortion of cute dise Lehotal less than 032 oa Standor size Repair imi Total assembled thickness of clutch ° Plots and coes Ps ae Replace Standard clearance Clearance it 7 | Backlash of brake cise and brake inner dram oa—07 10 « | Bactasn of cute cee o3—07 10 Adjust 2 | Bactash of bevel gear and pinion 020 — 028 oas Aca or Tolerance Standard standard | Clearance Searing coat eurtace of sal we i S| corres | “arae 10 | giameter portion of brake piston err - ncaiacs ae ‘0100 | 0.072 | 0100— i : corm | ‘0 base —7 | Seating coat wafoce of smal ge) 20.005] 0088} @08s — J dlomete portion of uch piston [al [So 7 | rake modulating eoing " ao | mee, | oo | aan @ [cuter ave ten eng ms [os | Sey] ee | BAN 9 | rake valve return spring 8 os | deme, | es | CaN 10 | Parking brake valve sping = (ie, | aa | aie, 40-14 o1au02o14u02 POWER TRAIN, LUBRICATION PUMP © SAL(2)-045 + 045 4 1 2 3 ( ate \ fet. = }—- i ne. : GSE gsi3Nm aE) eeinm 6520 110213m aap, amy wees, = = 12 = - «| Spine ane rottrg ora aa EN naa (oil: EO10-CD, (rpm), pressur amount limit. oe 40-15FINAL DRIVE Wie (eset aeaetantee bes Ee Gam) 548.8458, 8Nm (56:6 kam) =I 276,8531.85Nm (28.253.25 kam) om = 110.25 12.25Nm Ci212Kem) | oe 110.25412.25Nm (BSN KRM —g A === + 2 SESE 1 = } } 7 r i Sse 216.85231.ENm (28,255.25 kam) 7 noe AL _ eee ii ‘aes LoL | a J oJ i 2 | m= 9802 49m (1005 kam) 40-16 =) 216.8531. 85Nm (28. 253.25 kam) 3 110.25 12.25Nm (11.25 1,28 km) Ss 548.8458, 8Nm (5626 kam) 140F12239, o14u02o14u02 Unit: mm No Cheek tem criteria Remedy Standord clearance Clarence tnt Backlash benveen No, pinion and "| No. 1 gear 023-061 10 2 [ Bakam teen a aero as Saas ia | | Bactiash benveen planet pinion and aes is fing gear Standard aire Repair ii 4 | Outside ameter of i sea! contact Surface of No" pinion 7 80 799 Replace ‘Outside deter of al seal contack 5 | surface of No. 1 pinion ae a 6 | Heian of bat of sat and cover a 1s Tolerance Standard Standard 1 | Seatac bemeen rtm sat and tie | sron woe | snore yoosr | +0080 | aaa — be +0032 o 0.051 bt «| Gesrance of No. pinion in axial 0— 0. etndard shim tikes: 1.5) ‘ust Standard ize Tolerance Repair it 3 | Wear of diameter of sprocket teeth tp 2 220 80 +0 10 | Wear of ameter of sprocket teth root e017 ; 750 ae rreplace Standard sre Repair ii 5 of width of sprocket teeth tip cy 50 Wear of width of sprocket teeth root 37 n 40-17HULL FRAME a a poveie pai » [se ee Pepe | > [Seamimrrorrrrns [es [mee Paes [a | 40-18 o14u02o14u02 TRACK FRAME, RECOIL SPRING Serial No. : 3001 ~ 3033 14uca02020 saor12241 Units mm No. (Check item Criteria Remedy ‘tem Repair limit 1 | Deformation of ack frame Curvature 7 {for length of 3,000) Correct Twisting 3 (for length of 300) Opening of idler portion 5 Standard size Repair limit Free length | tnstalled | installed | Free | Installed 2 | Recoil spring X00. | length load length Toad _| Replace 79.89 KN 768.94 KN ras x 241 | 684. | rgsroxe) | 7 | 117.239 ko) Tolerance Standard Standard Clearance between adjustment eyinder | size clearance Replace 3 | and bushing fi nee bushing =o120 | +0270 | 0.181 — - =0207_| +0061 oa77 af 4 | Pressing force for idler yoke 382 KN (40 ton) ‘Adjust 40-19 @MAINTENANCE STANDARD Serial No. 3034 and up TRACK FRAME, RECOIL SPRING 3x002130 Unie mm No] Check item Criteria Remedy Tapa Deformation of wack Tor leat of 30007 1) frame ing 3 (for length of 300) cee Opening otiderporion | 8 Standard size Repair limit, Free length] Installed | tetated | Free | insaled ee POE anstyte [tong | ctenome | tiene | gga 189.5 KN ‘eae en Heel ol (19,370 kg) ae (17,239 kg) ‘Standard Tolerance Standard | Clearance Clearance beween uo” [Taaan [crete] seorece | Mirae | 3| Salamone eying : Renae and bushing 90 0.120 40.270, 0.181 — 10 9 tan | 2a | an 4 Press fitting force for 392 KN (40 ton) Adjust idler yoke 40-19-1 @® o1auo2IDLER vawrcen Unit: mn we Check item citer remedy Standard see Repair init 1 | Outside diameter of protruding portion ai ria 20 - 2 | outside aiometer of ler wood 20 570 ‘Add meta 3.| Width of protruding portion of idler 101 7 ov 2 | wai oer woo was 5 5 | Overs with oficter 120 186 Tolerance Standord Standors | clesrance 6 clearance beoweensnatana tuaning | [shan | woe | Suarance | tt | Rasiace xoxo | sox2 | oza— iad 0.350 0.008 0.492 = Standordcewrance earace lini 7| Pray in xia ection 026 — 068 18 Gearance between gue ple ond 8 | frame plate ie _ Clearance benveen support and Fame | Ste 20 50 10 | standard ticks of sie plate shi a0 ‘Adiust 40-20 o14u02o14u02 TRACK ROLLER 8. 65-41,65Nm (39.2544 .25k am)| | af 10 om 384,6541.65Nm (39,254.25 am) | bee ‘ 1 f Ny: ee 1 i 5 Prazwcnm 4 | i (ioazeem “7 | cosanem | ata Single fange Double flange 4012088 Unit en No. ‘check tem ceria Remedy ‘Standard size Repair init 1 | outside giameter of rack roller eed n0 14 2 ounsie ciereter of ange (outside) 200 Z Outside dareter of ange Gide) 7 3 | (double flange) a 4 | Width of track roller tread (single flange) a 2 ‘Add metal or replace 3 | with of wack oler tread (double lange) a7 8 6 | wiatn of ange (single ange) 195 135 7 wath of Range (outside of double flange) 195 138 8] with of ange inside of double ange) 195 138 9 | vera width of wack oer 285 7 Tolerance suandare standerd | clearance se clearance | init | Replace 10| clearance between shaft and bushing shat | Hote Replace Tez | sous | oma 7 0.350 —0.007 0.493 iad ‘Standare clearance ‘Clearance limit 11| Pray in axa direction Replace 026 — 066 18 40-21CARRIER ROLLER S “HL 276.85: 31.85N (28,253.25 k em) worse nt Ne chek ciara Reedy Standerd eo fpr nt 1 | outside diameter of ange 200 ~ 2 | ousie aamete of carr oer vod 168 6 td at 2 | wa of aris oter wou «5 5 «| wien of tage "9 8 Terence stander standard | clemance 5 | Clearance between shaft and support a Shatt Hole caeaiee 33 93% | on 7 =0.2 o os at Terence sundae standerainerrnce| poy, Interference between shaft and seal size interference | limit eer et sno | Hot ors | samme | or o | ae [8 ois | - 7 | Pray of roller in axial direction Standard clesrance Clearance limit o—os2 04 40-22 o1auo2TRACK SHOE DRY TYPE 40-24 014U02o14u02 Unit: mm No. Check item Criteria Remedy ‘Standard size Repair limit 7 1 |Link piten orreplace 203.45 206.45 2| Height of grouser ——_Singla 650 250 ‘Add metal 19 3 | Height of ink 1250 80 Sueeneeet States oan 25 (During heavy-duty work) | Turn hl oucreacnmmneneenena tee 67.5 (During light-duty work) _| oF replace Tolerance Standard Standara_|Interference 5 | Interference between bushing and link ied Shaft Hole interference) limit oaoa | +0078 | 0.20— 65 | +0304 ° 0.404 ae Fo20 | +0062 | 0.188 — 6 | Interference between master pin and ink | 4495 | {5789 : vee | 008 yoaes | +0062 | 0273— 7| Interference between regular pin and ink | 44.95 | {338° 7 a73 7, | 0.14 | Replace Tolerance ‘Standard Standard | Clearance Clearance between master pin and size clearance | — limit 8| gener Shaft Hole “e080 | +0890 | 0480 — 444 | “ors | +0430 0.980 = 9g | Clearance between regular pin and ma | 70485 | e1ais | o180— = bushing +0285 | +0815 0.830 10 | Protrusion of bushing 5.25 Adjust 11 | Protrusion of pin 42 Initial tightening torque Tightening angle Tighten Tightening torque for shoe bolt ie cial ett 3232 39.2Nm ae or replace (40 * 4 kgm) : 40-25LUBRICATED TYPE = ol ao 40-26 S S rors o14u02o1au02 Unit: mm No. ‘Check item rite Remedy ‘Standard size Repair limit 1 | Link teh aes 208.45 = 2| Height of grouser Single 650 250 ‘Add metal tolug 3 | Height of ink 1250 1150 peepee aaa a eal G75 (During heavy duty word | Ture i oueeereaerecnene oe {65.0 (during light duty work) _| or roplace Tolerance Standard Standard | Interference size interference | limit 5 | Interference between bushing and link Shett Hot yoaoa | +007a | 0.230— 665 | +0300 | 0 0.404 a Foaas | v0.08 | 0273 — 6 | Interference between pin and link aaa oo ¥ ea — | Replace Tolerance Standard Standard | Clearance 7 | Clearance between pin and bushing on Shaft Hole | “learance | mit ¥0235 | +0915 | o180— 4435 | +0005 | +0415 0.830 = 8 | Protusion of bushing 3.05 ‘Adjust | Prowusion of pin 30 Initial tightening torque ‘Tightening angle 10 } Tightening torque for regular shoe bolt pee * 8232 99.2Nm ce Tighten (a0 + 4 kgm) cor replace Tightening torque for master lnk 343.2 238.2 Nm e 17 | connecting bolt (35+ 4 kgm) 180-20 40-27SUSPENSION Serial No. : 3001 - 3033, S548, 8 +58.8Nm GST 548.8258.8Nm (5646 kgm) (566 k gm) 140F122485 40-28 o o14u02014U02 1G 48.8258. 8Nm 528 kam) / fea 140F1 2286 Unit: mm ‘check item Criteria Remedy Tolerance ‘Standard Standard | Clearance Clearance between pivot shatt and size clearance | limit ‘bushing (inside) Sha Hole —ora0 | +0125 | 0205 — ne =0176 | +0085 0.299 “a ‘Gearance between pivat shaft and a ~onas | ror07 | 0217 — 10 | Replace bushing (outside) 0208 | +0072 0315 bushing ‘Clearance between center pin and = =o100 | +025 | 0290— | gg bushing =o145_| +019 0.296 —o0as | 0002 | 0015 — Clearance between side pin and bushing | 60 epee (ean Nee | OS Clearance between side pin and 01 +03 02 a spherical surface of bushing =03 +01 06: Press fiting force of pivot shaft bushing 098 — 225KN (inside) (01 — 23 ton) Press fiting force of pivat shaft bushing 0.98 — 363KN (outside) (0.1 — 37 100), es 665 — 2352 KN Press fiting force of side pin bushing eau 40-29MAINTENANCE STANDARD Serial No. 3034 and up G7 1548.8258.8 Nm (56:6 kgm) F848. 8258.8 Nm (8626 kgrn} SUSPENSION 014U02014U02 MAINTENANCE STANDARD ‘SUSPENSION Unit: mm No, Criteria Remedy Standard Tolerance Standard | Clearance , | clearance between size Shaft Hole | clearance | limit Z shaft and bushing (inside) [= Saat atotae | oa . 0.208 | +0.085 0.333 2| Clearance between pivot | 19g, -0.120 | +0.107 | 0.192— aa shaft and bushing (outside) -o174 | 40.072 0.281 i topics 4| Clearance between center | 79 0.100 | +025 | 0.290— os | bustina pin and bushing aoa | 40.19 0.396 ; 1 | Clearance between side a 0.08 | -0.002 | 0.015— ae pin and bushing 0.078 | -0.033, 0.076 z Clearance between side Ce “01 +03 oe 5| Bin and spherical surt 66 ya a o2—06) 10 «5 | Press fitting force of pivot shaft bushing (inside) d 7 | Press fitting force of pivot 0.98 — 36.3 KN ie shaft bushing (outside) (0.1 — 3.7 ton) g | Press fitting force of side 68.6 — 235.2 KN pin bushing (7 — 24 ton} 40-29-2 @HYDRAULIC PUMP * SAL (3)-100 Serial No. : 3001 - 3033 277 £32Nm 28.5 + 3 kgm (28.54 3kgm) Unit: mm Ne Check tem cree emeay onder ewrerce Cheaance it 1 | Clearance bemeon gar case and sce ie ls 0.13 — 0.18 0.22 Gesance batwoon raise dame of 2 | plambeering ond cuide cores ot 1060 — 0148 020 ropiace Sear ana Stonderd ae] Tolerance Repair it 3 | Dept tor hing in sin 4 ° ae 11a 3 | Spline set rotting ore Bae ag : Siendard) Dachorae charge amu a ee =| “toi:tore-co, trom) reece | ‘ammre Timi - ‘Si emperatre: 45 — 55) ttmin) | twin 25 NPs asco | meme | aa aa 40-30 @ o1au02MAINTENANCE STANDARD HYDRAULIC PUMP + SAL(3)-080 Serial No. 3034 and up 4 3 1 2 ' 3277 + 32Nm {28.54 3 kgm} “40F12247 es Unit mm No. Check item Criteria Remedy Standard clearance Clearance limit ; | Clearance between gear case and side plate atk aa Glorance boqreen Inside 2 | diameter of plas besring ang 0.080 — 0.149 0.20 Replace 8rd earttar of gear shat Standard size Tolerance Repair imit 3 | Depth for hitting in pin a “ aoe = 4 | Sotne shot rotating toave 63-118 Nm anda isch speed | Oiscnarge | Siharve | “amount a Discharge amount (rpm) pressure lamount (¢imini| limit (e/min) fae (si £010-CD pyr ~ Oil temperature: 45 ~ 56°C 3 pe 2500 | «2aSMPa, | 14 170 40-31MAIN CONTROL VALVE 66.24 7 Nm (6.75 + 0.78 kgm) 2091 34 Nm (216-4035 tom) __- 29+ 5 Nm (20+ 05 kam) ais om — 39 10.Nm (621 kgm — c= os 108: 15 Nm (11 + 1.5 kgen) ——— 69. 10Nm (7 + 1 kgm rez znmisst26tam— © om {968 + 25 Nm (97.5 + 2.6 kam) — = 182: 28Nm 08828 49n)— 18+ 51Nm (1.5 +05 kgm) om 7.4 25 No (0.78 + 0.25 kgm) ee AA 106 £15 Nm (1 1.8 kom) 368+ 25Nem(375+25kgm) 3 sewFen0 40-32 o14u02o14u02 ke oe 152 25Nm 158425 kom) iru OQ sera Unit: ram No. Check item criteria Remedy Standard size Repair iit Free | lnsteled | Instoled | Free | Permi 1 | Retum spring of spool tength | tent | load | length_| load 103 N 37N ne fe (19) mn 2.9kq)_| Peplece “ON aan 2 | Detent of spring 158 125 ne - aaa “aa N 397 N 3 | Spring of iad check valve 26 meee Ss 40-33WORK EQUIPMENT CYLINDER © BLADE LIFT 7a 1.0787 + 1079Nm (78 + 7.5 kam) (11011 kgm) : i (Wieth across fats: 0 mm) + 0F12261 Unit: mn No. Check iter Criteria Remedy Tolerance Standard Standare | Clearance 1 | Clearance between piston rod size : clearance | limit | Replace ‘and bushing Soe hen bushing 030 | +o26r | o0s7— 6 0104 | +0067 0.66 | 2666 ‘Clearance between piston rod bushing 02 +03 02 ‘Adjust shim 2 | ana in = 03 0 os. 10 | orreplace 73 | Clearance between eylinder support 7 ‘a100 | +0116 | 0100 — to | Replace bushing and boss aia | “o 0.290 bushing 40-34 o14u02WORK EQUIPMENT * ANGLEDOZER 40-36 i Fo1auor7 014U02,o14u02 Fouuore Unit: nan Cheekitem crt remedy Tolerance Bese [eases Standard Standard | Clearance Clearance between tunnion and | sive | atvorance | © tnt spherical surface of cap ont bach “04 as | or ie: “05 ° 20 ie Clearance between arm pin and ae | a sherical surface of arm cap. 100 41.0, 1.8 iad Clearance between arm mounting | 40.3 06 — pin and bracket (large) i ° 13 = Clearance between arm mounting 703 | 06 pin and bracket (small) ® 0 13. i Clearance between brace mount sav | 03 ing pin and arm bracket = ° 13. : Clearance between brace mount me | 07— ing pn and brece 0 foe ve | 3 | Replece Cleerance between brace mount soz | 03— ing pin and joint ecnee ° 08 7 Clearance botwoen brace mount [0 fanaa roe | ing pin and bearing 50 -03 0 os 7 Clearance beween joint mounting] a1 vos | or : pinond brocket 23 8 os Clearance between joint mounting] gg “04 soz | or— i pinanaient ata ° os Ciearance bewoon entershat | 798Gha | 02 | 08 | 02— : Sn tame aot! | 08 | 08 as Clearance ween centershahl | gg core eeas a|o1 = : meuning pinangbracke | 33 ° as Clearance between center shaft 55 (Shaft) | = -0.1 +405 | 62— 7 ousting pivandcontershet | eolMol) | 03 | 01 | 88 40-37 ©CUTTING EDGE, END BIT 441.3 + 49.0Nm (a5 25 kgm) Go) 44195490. (45 = kgm) i” ® ® ® @ eo 8 & Foraunee Unit: mm No. Check item Criter Remedy Standard size Repair limit 1. | Height of outside of end bit a 292 254 2 | Width of end bit 440 400 Replace 3. | Height of inside of end bit 254 237 Height of cutting edge (from center of 4 | boit mounting hole to edge) ad aaa 40-38 o14u02o1au02 90 OTHERS TOWING WINCH DWT065-1A 1. General 1-1 Specification 1-2 Power train system 2. Structure and function 90-4 241 General view 90- 4 22 Winch section 90- 6 23 Hydraulic system 90- 8 2-31 Piping 90- 8 2-3-2 Hydraulic circuit diagram 90- 9 2-3-3 General view of control valve and function pean 90-10 2-3-4 Clutch structure and function {including lubrication valve) ............. 90-42 2-4 Control of winch 25 Fairlead eseeeaeeae eee 3. Testing and adjusting ...... veces 9047 3-1 Standard value table for towing winch ......... 90-17 32 Tool lst for testing and adjusting 90-18 33 Adjusting winch control lever ........ 90-19 3-4 Measuring and adjusting winch hydraulic pressure... serene 90-20 3-5 Table of failure modes and causes ............ 90-22 H-1. Winch does not rotate ee) H-2. Brake of winch does not work ........... 90-24 4, Disassembly and assembly «2... .6...c..c126, 90°25 Method of using manual : 90-25 Precautions when carving out operation 90-26 4-1 Special tool list 90-28 4-2 Towing winch assembly fe ooze Removal ....-..seeecccsssessstecesesees 90-29 Installation ss 0020 43 Towing winch pump assembly <0... 90-30 Removal erooee 90-30 Installation - fea e000) 4-4 Towing winch control valve assombiy vests 9031 Removal Installation sembly ee eeeeeeeseeee 90-32 Assembly eee 0004 45 Towing winch assembly on 90-36 Disassembly .......0cccscceseeeseseees 90-36; Assembly .. Repeee ce) 46 Assembling information... Lit 90-69 46-1 Bearing clearance and gear backlash... 90-69 5. Maintenance standard 5-1 Clutch 52 Brake 5-3 Valve 5-4 Towing winch pump.1. GENERAL 1-1 SPECIFICATION wT085 Winch mode! = 1A Applicable mod Dase-ss-2 Applicable serial number 3001 and up Operating weight (without cable) ) 1.380 Overall length (mm) 1,008 Overall with | (am) 1070 ‘Overall height (mm) ‘960 Drum diameter (mm) 254 Flange diameter (mm) 510 rum width (om) 320 Engine rated speed (opm) 1.980 Engine rated torque (Non (xg 659 672) Wire cable x Drum capacity (eam Xm) 26x73 Installed cable (em mi) 26x65 Cable weight 9) 195 Forward 72.576 Reduction ratio oT os Reverse 31.636 Bare drum 307,900 (31,400), Forward Line put Fall drum 178,100 (18,200), eee Bare drum = Reverse Full drum a Bare drum 28 Forward ie Full drum 8 een Bare drum 6 Reverse Full drum 10 Clutch type ‘Wet type, multiple disc, hydraulically actuated, adjustment free type Transmission Wet type, multiple disc clutch, 1 stage each for normal and reverse rotation Brake Wet type, multiple disc, hydraulically actuated, adjustment free type Free drum Not available Leasing arm Not exist ‘Attachment Fails Option Drawbar Mounted ‘Towing winch pump Gear type (S8R(1)021), discharge amount: 43 «/min 90-2 o14u02o14u02 1-2, POWER TRAIN SYSTEM 10. |. Steering brake 2 13. 14, 15, Oenorsens Engine Damper Universal joint Torque converter - PTO Control lever Transmission Drive shaft Bevel gear Winch control valve Steering clutch Drive winch Final drive Sprocket Truck shoe Fo1auoss The motive force produced by engine (1) has its twisting vibration reduced by damper (2), then passes through universal joint (3), and is transmitted to torque converter and PTO (4). The motive force is then transmitted from the torque converter, PTO to drive shaft (7) and then to drive winch (12). The towing winch is carried out using control lever (5) which is at the right side of the operator's seat. This control lever actuates control valve (9) of the winch, and this engages the winch clutches. 90-32. STRUCTURE AND FUNCTION 2-1 GENERAL VIEW s4WoAs2061 Coupling (input shaft) 2. Winch case 3. Winch drum 4. Drawbar 90-4 o14u022-2 WINCH SECTION ir Asus saweatzoc2 90-6 o14u02o14u02 Input shaft gear (18 teeth) No. 1 Counter shaft pinion (44 teeth) No. 2 Driven pinion (25 teeth) Bevel pinion (18 teeth) Bevel gear (41 teeth) No. 3 Forward pinion (18 teeth) . No. 3 Reverse pinion (18 teeth) No.4 Counter gear (39 teeth) No. 4 Counter gear (17 teeth) No. § Counter gear (54 teeth) No. 5 Counter pinion (15 teeth) Drum shaft gear (50 teeth) PASH rommonwp> 1 4WoAr2068 Clutch (pay in) Clutch (pay out) Shaft (winch drum) Winch drum Brake Coupling {input shaft) oraena POWER TRAIN eae Input shaft ~A~+B-C-D-E] ¢ + J+ K +L winch drum OIL QUANTITY (E030-CD) Gear case: 66 « 90-72-3 HYDRAULIC SYSTEM 2-3-1 PIPING zonvto fh pump (SBR(1)021) 90-8o14u02 2-3-2 HYDRAULIC CIRCUIT DIAGRAM A ld be BAL i orF —~ it Cai AGE ed + 27k ee 2 a EEE Ee ete eet eer sewrcas Winch case (functions as hydraulic tank) ‘A. Tap for main relief pressure and inching Strainer pressure Towing winch pump (SBR(1)021) B. Tap for brake case pilot pressure Inching valve . Tap for clutch pressure (Pay out) Relief valve D. Tap for clutch pressure (Pay in) Clutch valve E. Tap for brake pressure Brake valve Clutch piston (Pay out) Clutch piston (Pay in) Brake piston Lubrication of transfer 90-92-3-3 GENERAL VIEW OF CONTROL VALVE AND FUNCTION GENERAL VIEW ha EXPLANATION OF FUNCTION Relief valve ‘After both the clutch circuit and brake circuit have been filled with oil from the control valve, oil pressure in main relief valve (6) rises and oil is drained to the case. By this operation of the relief valve, the set pressure in the whole circuit is maintained in the range of 1.81 MPa (18.5 kg/em’). Operation of the clutch/brake valve Winch control lever — NEUTRAL, (Clutch OFF, brake ON) Oil from the pump passes through the relief valve and enters the clutch circuit and brake circuit. As the winch control lever is kept at the NEUTRAL position, the circuit is closed. However, @ part of the oil can flow into the ‘clutch to lubricate the clutch interior. ‘© Winch control lever — ON (Clutch ON, brake OFF) When the winch control lever is placed in the ON position, spool of clutch valve (6) is moved to close the drain circuit, and oil flows into the clutch circuit. The clutch lubricating circuit nearly closes, and the oil pushes the piston to engage the clutch. After the clutch 90-10 sewoar2066 circuit has been filled with oil, the oil flows from brake valve (7) to the brake cylinder to release the brake. Winch control lever in position “Float” (Clutch OFF, brake OFF) ‘As the spool of inching valve (4) closes the cir cuit from the pressure relief vaive (5) to the clutch valve (6), the regulated pressure flows to brake valve (7) and into the brake piston (10) to release the brake. This position is used for the free of drum as both brake and winding clutches are free. Winch contro! lever — INCHING (Clutch OFF, brake partially applied) When the winch lever is in this position, winch spool (A) is half open, and the brake is partially applied. Winch control lever — SLOW PAY OUT (Clutch partially engaged, brake OFF) When the winch lever is in this position, clutch spool (6) is half open, and the pay out clutch is partially engaged. this position is used when it is needed to use @ slow pay out speed. o14u022-3-4 CLUTCH STRUCTURE AND FUNCTION (INCL. LUBRICATION VALVE) Fram control vaive = 14WCA12067 1. Spring 6 Spring 41. Drum 2 Gear 7. Housing 12, Bolt 3. Pusher plate & Spool 4. Disc 9. Housing 5. Plate 10. Piston 90-12 o1auo2o14u02 FUNCTION When the winch control lever is at the NEUTRAL position, piston (10) is pushed by clutch spring (6) in the direction “© *. Therefore, disc (4) and plate (8) are free of compressive force, so the clutch is, disengaged and no power is transmitted to the drum. When the winch control lever is placed in the ON position, oil from the control valve flows through the inside of the shaft into gap “A” between housing (9) and piston (10). After filling in the gap, Pressurized oil pushes through piston (10) in the direction * ©" to compress disc (4) against plate (8). Power is transmitted to the drum by friction force between plate and disc. Cooling and lubrication of latch Clutch Lubrication When the clutch circuit oil pressure is low (when the clutch is disengaged), oil from the control valve passes through gap “A” between housing (7) and spool (8) and enters the orifice at the front end of the housing to lubricate the inside of the housing to lubricate the inside of the clutch. When the clutch circuit oil pressure rises (with the clutch engaged), the hydraulic pressure acts on spool (8) and pushes it to the left in the direction of the arrow. Spool (8) pushes spring (1), and when it comes into contact with housing (7), the clutch lubrication oil is restricted by clearance “a” between the spool and housing. The oil then starts to flow into clutch piston gap A From contol valve To clutch piston Forowros8 90-132-4 CONTROL OF WINCH Lever position © Winch contro! lever Neutral Pay in Pay out Inching Float Slow pay out Lock lever Free Lock @9*SO5e88 90-14 4098 1. Winch control lever 2. Lock lever 3. Control valve OUTLINE '* It is possible to lock the operation of the winch control lever by placing the lock lever at the LOCK position. (When the winch control lever is at the NEU- TRAL position) 014U022-5 FAIRLEAD vewrea7 1. Flame 2. Shaft 3. Roller 4. Roller 5. Shaft 90-15014U02 3. TESTING AND ADJUSTING 3-1 STANDARD VALUE TABLE FOR TOWING WINCH ce DWTO65-14 cass) Check tom Measurement condkions Unit Standard | Permissible value value | Inching contrat | * Engine stopped Hold ~ Inching o-1s | 0-15 g Center of lever knob : Hold -- Float vis+20 | 115420 B | clutch control} * Engine stopped Hota - Nownal sors | sorts = Center of lever knob . 6 Hola Reverse a oo oid Reverse 80418 0+ 15 mate | 588 g = | etincontol | + Center oflever knob Inching mate me 83 N 5884196 88.3 22 Exceeds detent | ikg) | (60+ 2.0) eo) £3 2 Normal SS | clutch controt ocean Neutral ~ OF eae ae ‘utch control Reverse (4.0 + 2.0) (7.0) rotation Towing wien | © Towing winch ol ote relief pressure | temperature: 45 — 55°C Neutral oe ~ Engi ot fl howe (019) Normal or 180. 16 reverse rotation as+10 | 160) Towing winen_| «Towing winch oi o*e clutch pressure | "temperature: 45 — 56°C Neutral oT - 2 Engine at ful throtle (#29) 2 Normal or Mpa | 1840.1 16 5 reverse rotation |(kg/em®)| (185410) | (160) 6 18+0. 16 Towing winch | * Towing winch oi! Float 7 brake pressure temperature: 45 — 55°C (18.5 + 1.0) (16.0) Engine at full throttle aie Jnching nate 2 Selector pilot ei ceeal Fi yatoa 16 precwrevor” | yoneainehl Mest cebeto | 60) towing seta Engine at full throttle 0-18 brake valve Inching ate ae 90-173-2 TOOL LIST FOR TESTING AND ADJUSTING Testmensurementitom | Symbol | PartNo. | Partname Remarks ed ee eee Disa hyarovte <0 NPo Oil pressure | re02ei-r203 | ata Pres gage: SNE “hip 7e04o1-22z0 | warauic couse | MPR, 7anze10090 | rushpu sate | 0— 49031 (0 — 20%) Operating ore 8 remzesanze | rusnpul see | 0— 23421 0 — 30%) Stroke ce | Commercially | seaie 7 available 90-18 o14u02o14u02 3-3 ADJUSTING TOWING WINCH CONTROL LEVER 1. Assemble so that the distance between the pins of rod (1) is dimension a. Dimension a: 76 mm. 2. Set lever (2) to the HOLD position and lock lever (3) to the LOCK position, then install guide (4) so that clearance b = 1 mm. 3. Connect cables (5) and (6) to the levers, set the lock lever to the LOCK position, then connect cables (5) and (6) to the towing winch valve. & When doing this, be careful not to pull the valve spool. 4. When installing plate (7), run the engine at low idling, and install so that it guides the lever at the lever position so that the start of the winch drum rotation is gentle (0 — 15 rpm) Standard dimensions ¢: 25+ 3mm d:21£3mm aA sawros2 90-193-4 MEASURING AND ADJUSTING TOWING WINCH OIL PRESSURE By S208 the machine on level ground, tower the ‘& When installing the work equipment completely to the ground, then apply the parking brake. Pressure gauge, remove all the dirt and mud from around the plug. ief pressure 1) Remove relief pressure measurement plug (1), then install oil pressure gauge A (gauge: 5.9 MPa (60 kg/cm?) 2) Operate the control lever in the normal and reverse rotation directions. 3) Run the engine at full throttle and measure the oil pressure, Measuring clutch pressure 1) Remove oil pressure measurement plug (2) at clutch normal rotation side and oil Pressure measurement plug (3) at clutch reverse rotation side, then install oil pressure gauge A (gauge: 5.9 MPa (60 kg/cm’). 2) Operate the control lever in the normal and reverse rotation directions. 3) Run the engine at full throttle and measure the clutch pressure for normal and reverse rotation. Measuring brake pressure 1) Remove brake pressure measurement plug (4), then install oil pressure gauge A (gauge: 5.9 MPa (60 kg/cm?) 2) Operate the control lever to the INCHING and FLOAT positions. 3) Run the engine at full throttle and measure the inching pressure at INCHING and the brake pressure at FLOAT. Measuring brake valve selector pilot pressure 1) Remove pilot pressure measurement plug (©), then install oil pressure gauge A (gauge: 5.9 MPa (60 kg/cm’). 2) Operate the control lever to the INCHING and FLOAT positions. 3) Run the engine at full throttle and measure the pilot pressure at INCHING and FLOAT. 90-20 F065 o14u02014u02 5. Adjusting relief pressure Remove plug (6) and springs (7) and (8), and adjust by changing the thickness of shim (9). o& Standard shim thickness: 2.5 mm. (6 shims) ‘4 Amount of adjustment for each shim: 50 + 10 KPa (0.5 + 0.1 kg/cm?) fos s4wcatzo7e 90-213-5 TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC, MECHANICAL SYSTEMS) Hydraulic system Pars causing fire = 2|¢ z ele 5 Failure mode fls)3| 8/2 al zl¢ 2/3)/3|/2/8 2/3] 2 Bl) s/e)3e|s 8| 2) + | Towing winch does not urn ofofo o fo 9 2 ner 0 o fo ° 90-22 014U02o14u02 H-1 Towing winch does not turn Cause Remedy 2 YES Worn clutch ise or plat, oc reskage msde tng] RAPA ot eo repace ves| 's brake released? H] Detective operation of | Repair of 1 |v sem NO brake piston replace 4 ves Is itch and a Repair oF brake ol pressure L Detective ret valve | Renal rma? ves} Does outeh 7 valve spoo! move LH + See Table 3 || Precmnve Defective operation of | Repair or 's adjustment of No clutch vatve spo reploce U controtiever LY NO} linkage norma? + Sea TESTING AND ADJUSTING Defective adhsiment of | agiuat NO contro fever linkage i 31: Check that the winch drum rotates freely when the control lever is at FLOAT. Unit: MPa (kg/er Neva A o fatwonte | Normaloreevererotaton | agerenoy | «ae t0) thing | on Float © | vest 90-23H-2. Towing winch brake does not work Yes ta brake ait Dressure normal? 7 DMPa (0 am |g aajustmont of Engine ata” [| asiustment throttle NO] fntage normal? + Control over ">| Hnkage normal atrLoaT position Cause Remedy Worn winch bake die _ ‘or detective Replace ‘Speratn of brake piston — Defective inching valve | Repair or p00! replace Defective adjustment of a no control lever linkage ai 90-24 014U02o14u02 4. DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL 1. When removing or installing unit assemblies (1) When removing or installing a unit assembly, the order of work and techniques used are given for the removal operation; the order of work for the installation operation is not given. (2) Any special techniques applying only to the installation procedure are marked [ai], and the same mark is placed after the relevant step in the removal procedure to indicate which step in the installa. tion procedure it applies to. (Example) REMOVAL OF © 0 O ASSEMBLY A 1. XXXX (1) * 2 AAA QQ) 3. DOOD assembly (3) _ INSTALLATION OF ©.0 0 ASSEMBLY .. Title of operation Precautions related to safety when carrying out the operation Step in operation Technique or important point to remember when removing XXXX (1) during installation - See Lubricant and Coolant Table Title of operation ‘* Carry out installation in the reverse order to removal 1g water, oil... Technique used during installation Technique or important point to remember when installing A A A (2) ‘Step in operation = Point to remember when adding water or oil Quantity of filling oil and water 2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given together as PRECAUTION WHEN CARRYING OUT OPERATION, so be sure to follow these precautions when carrying out the operation. 3. Listing of special tools (1) For details of the description, part number, and quantity of any tools (A,, etc.) that appear in the operation procedure, see the SPECIAL TOOLS LIST given in this manual. 90-25PRECAUTIONS WHEN CARRYING OUT OPERATION [When carrying out removal or installation (disassembly or assembly} of units, be sure to follow the general precautions given below when carrying out the operation] 1. Precautions when carrying out removal work ‘If the coolant contains antifreeze, dispose of it correctly. * After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering, ¢ When draining oil, prepare a container of adequate size to catch the oil. © Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. * To prevent any excessive force from being applied to the wiring, always hold the connectors when dis connecting the connectors. * Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. ‘Check the number and thickness of the shims, and keep in a safe place. ‘© When raising components, be sure to use lifting equipment of ample strength. ‘¢ When using forcing screws to remove any components, tighten the forcing screws alternately. Befor removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. Precautions when handling piping during disassembling Fit the following blind plugs into the piping after disconnecting it during disassembly operations. 1) Hoses and tubes using sleeve nuts tromber | P19 tout ond) | ys te wo ers below aba set 02 | o7a76.s0210 [07221-20010 wut) 07222-00210 (Pus) 03 | o7s76-soa15 [07221-20316 wu, 07222-00512 (Plug) 04 | ovare-soaza_|oranv-20az2 wu) 07222-00814 (tug) 05 | o7sre-sosze_ [07271-20622 wu) 07222-00515 (Pus) 06 | 07376-50628 [07221-20628 (Nut) 07222-00616 (lua) 70_| 0737651034 [07221-71034 (Nuv, 07222-01016 (Plug) v2 | o7avesiaaa [or22i-21234 (Nun, 0722201219 (Pua) 2) Split flange type hoses and tubes Nominal ‘Sleeve head Nominal | Flange those end) | Sleeve hea Split flange a ‘07379-00400 | 07378-10400 _| 07371-30800 oe ‘07379-00500 | _o7a7@-10500__| 07377-20500 3) If the part is not under hydraulic pressure, the following corks can be used. Nariel pan number | _inersions of eye os _[ emo |e [5 8 oe [onseaoen | [oe | n 10 [onsoanor [wo [a5 | ve [omswoise | v4 [8 | 16 16 | orworee [16 [a5 | 2 29 | omwwanes | [17 | 2s z2_|onsoanea | m [105 | 28 2 [oman] 2« | 0 | a 2 lonsoarra| a7 [as | a 90-26 o14u02o14u02 Precautions for installation operations Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pin or lock plate securely. ‘When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 — 3 drops of adhesive ‘When coating with gasket sealant, clean the surface and remove ail oil and grease, check that there is no. dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil ‘When press fitting parts, coat the surface with antifriction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eyebolts, check that there is no deformation or deterioration, screw them fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side. When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follow: 1. Start the engine and run at low idling. 2. Operate the work equipment control lever to operate the hydraulic cylinder 4 — 5 times, stopping 100 mmm from the end of its stroke. 3. Next, operate the hydraulic cylinder 3 — 4 times to the end of its stroke. 4. After doing this, run the engine at normal speed. * When using the machine for the first time after repair or long storage, follow the same procedure. . Precautions when completing the operations If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine to circulate the water through the system. Then check the water level again. If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again, If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been removed for repair, always bleed the air from the system after reassembling the parts. + For details, see TESTING AND ADJUSTING, Bleeding air ‘Add the specified amount of grease (molybdenum disulphide grease) to the work equipment related parts. 90-274-1 SPECIAL TOOL LIST Name of work ‘Symbol Part No. Part Name ary Remarks 1 | 796-760-9110} Push tool 1 2 | 791-875.1210 | Wrench 1 Disassembly, assembly | | 3 | 791.463.1120 | Push tool 1 (of towing winch assembly 4 | 790-101-8401 | Push tool kit 1 8 | 791-875-1220 | Push toot 1 90-28 o1au02o14uo2 4-2 TOWING WINCH ASSEMBLY REMOVAL OF TOWING WINCH ASSEMBLY |. Remove 4 covers (1). Ri . Disconnect drive shaft (2). iii] » . Disconnect winch control cables (3) and (4). 4, Sling towing winch assembly (6), remove 6 bolts and 4 nuts, then remove assembly. + Using a lever block, make the clearance uniform at the top and bottom between the steering case and the winch assembly, then remove the assembly. [=] Towing winch assembly: 1,300 kg INSTALLATION OF TOWING WINCH ASSEMBLY © Carry out installation in the reverse order to removal. Go S232) Drive shaft mounting bolt: 66.2 + 7.4Nm (6.75 + 0.75 kgm) ‘ Connect the cable. For details, see TESTING AND ADJUST- ING, Adjusting winch control linkage. % After completing installation of the towing winch assembly, run the engine, rotate the winch drum, and check the cil level. 90-294-3 TOWING WINCH PUMP ASSEMBLY REMOVAL OF TOWING WINCH PUMP ASSEMBLY 1. Remove cover (1). 2. Disconnect tubes (2) and (3), and remove winch pump assembly (4). INSTALLATION OF TOWING WINCH PUMP ASSEMBLY © Carry out installation in the reverse order to removal. saweort 90-30 o14u02o1au02 4-4 TOWING WINCH CONTROL VALVE ASSEMBLY REMOVAL OF TOWING WINCH CONTROL VALVE ASSEMBLY 1. Remove 3 covers (1) 2. Remove tubes (2) and (3). Go 3. Disconnect cables (4) and (5). 4. Remove 9 mounting bolts, then remove winch control valve assembly (6). INSTALLATION OF TOWING WINCH CONTROL VALVE ASSEMBLY * Carry out installation in the reverse order to removal. 1 Mounting bolt of tube at valve end: 49+49Nm (5.0 + 0.5 kgm) + Connect the cable. For details, see TESTING AND ADJUST- ING, Adjusting winch control linkage. Control valve mounting bolt: 49+ 4.9Nm {5.0 + 0.5 kgm) 4073 90-31DISASSEMBLY OF TOWING WINCH CONTROL VALVE ASSEMBLY 1. Relief valve 1) Remove plug (2a), then remove springs (3) and (4). 2) Remove plug (2b), then remove valve (5), spring (6), valve (7), shim (8) together with spool (9) + Check the number and thickness of the shims, and keep in a safe place. 2. Brake valve 1) Remove cover (10). 2) Using bolt, remove stopper (11). 3) Remove spring (12) and spool (13). 4) Remove cover (14). + This cover is also used for the clutch valve. 5) Using bolt, remove stopper (15) and piston. (16). 3. Clutch spool 1) Remove cover (14). Already removed in Step 2-4). 2) Remove bolt (17), then remove washers (18) and (19), collar (20), spring (21), and collar (22), 3) Loosen locknut (23) and remove yoke (24). 4) Remove spool (25) 4, Inching spool 1) Remove plug (26), then remove spring (27), guide (28), and ball (29). 2) Remove cover (30). 3) Remove bolt (31), then remove washer (32), detent (33), stopper (34), spring (35), and collar (36). 4) Loosen locknut (37) and remove yoke (38). 5) Remove spool (39). il seal Remove oil seal (40). 90-32 o14u0zTOWING WINCH CONTROL VALVE ASSEMBLY zonvio 90-33ASSEMBLY OF TOWING WINCH CONTROL VALVE ASSEMBLY 1. Oil seal 4. Brake valve Install oil seal (40) to body (1). , Outside circumference of oil seal: Gasket sealant (LG-5) Coat thinly and wipe off all the gasket sealant that is squeezed out. ’ Lip of oil seal: Grease (G2-L!) . Inching spool 1) Assemble spool (39) to body (1). 2) Screw yoke (38) to specified dimension, and tighten locknut (37). % For details of the specified dimensions, see the diagram on the right. 3) Fit collar (36), spring (35), stopper (34), detent (33), and washer (32), and tighten bolt (31). ’ Bolt: Thread tightener (LT-2) =] Bolt: 30.89 + 3.43 Nm (3.15 + 0.35 kgm) 4) Install cover (30) 5) Assemble ball (28), guide (28), and spring (27), and tighten plug (26). G2) Plug: 39.2 +4.9Nm (440.5 kgm) & Clutch spool 1) Assemble spool (25) to body (1). 2) Screw yoke (24) to specified dimension, and tighten locknut (23) + For details of the specified dimensions, see the diagram on the right. 3) Fit collar (22), spring (21), collar (20), and washers (19) and (18), and tighten bolt 7, ’ Bolt: Thread tightener (LT-2) -3m Bolt: 30.89 + 3.43 Nm (3.15 + 0.35 kam) 4) Install cover (14). % Install the cover after installing the brake valve, 90-34 1) Assemble piston (16) to stopper (15), and install to body (1). 2) Install cover (14). + This cover is also used for the clutch spool. 3) Assemble spool (13) and spring (12), and install stopper (11). 4) Install cover (10). valve 1) Assemble valve (7), spring (6), and valve (5) to spool (9). 2) Fit removed shim (8), and assemble spool (9) in body (1). 3) Tighten plug (2b) 5-55) Plug: 68.6 + 9.8 Nm (7+ 1 kgm) 4) Assemble springs (4) and (3), and tighten plug (2a) 5S Plug: 68.6 +9.8Nm (721 kgm) o14u02o14u02 TOWING WINCH CONTROL VALVE ASSEMBLY sowro7e 55mm. _ ry t ‘ram 10 mm Hold Inching 14075 Bmmeémm FUN OR 40076 90-354-5 TOWING WINCH ASSEMBLY DISASSEMBLY OF TOWING WINCH ASSEMBLY ° |. Draining oil Remove drain plug and drain oil from case. wy case: Approx. 66 ¢ Setting towing winch Set towing winch assembly (1) horizontally with top surface facing up. Piping Remove pipes (2), (3), and (4). ‘Towing winch pump assembly Remove towing winch pump assembly (6). Remove the coupling at the same time. Control valve assembly 1) Remove control valve assembly (7). 2) Remove valve seat (8). Covers, suction tube 1) Remove suction tube (9). 2) Remove covers (10) and (11). Bar Remove bar (12). 90-36 o14u02o14u02 8. Brake assembly 1) Using forcing screws, pull out a little, then sling with shackle ©, and remove brake assembly (13). © Disassemble brake assembly as follows. 2) Loosen mounting bolts uniformly, and remove plate (15). 3) Remove disc (16) and plate (17). 4) Pull out snap ring (18) from groove of housing (19). 5) Twist from piston end and remove drum (20), + Be careful not to damage the piston. 6) Remove housing and piston assembly (21), and pull out piston (22) from housing (23). 7) Remove housing (26). 4085 s4wF 096 n n EL veweos7 90-378) Remove spring (27). 9) Remove spacer (28). 2 Sleeve, oil tube 1) Remove sleeve (14). 2) Remove plate (32), then remove oil tube (31), ‘© Disassembly of transfer group assembly cover (34), and using forcing screws ©, remove bevel pinion gear assembly (35) % Loosen the center bolts at both the bevel pinion gear and input shaft ends. 90-38 aweone © _sawross o14u02o14U02 ‘© Disassemble bevel pinion gear assembly as follows. 2) Remove bolt (36) and plate (37). 3) Support gear (40), then push shaft portion of bevel pinion gear (41) to remove bevel pinion gear (41), 4) Separate into cage (42), spacer (43), gear (40), spacer (44), and pinion gear (41). 11, Idler gear cover Remove idler gear cover (47). 12, Input shaft assembly 1) Remove bolt (48), then remove plate (49) and coupling (50). 2) Remove spacer (52). 3) Remove cage (53). 40 140054) Remove input shaft assembly (55). 13. Cage at pump mounting end Remove cage (57) at pump mounting end. 14. Transfer cover Using forcing screws @, remove cover (58). 15. Idler gear assembly Remove idler gear assembly (62) embly of clutch group 16. Covers Remove covers (forward clutch end) (64) and (reverse clutch end) (65). % The shaft will go down at the forward clutch end, so support it lightly. Check the number and thickness of the shims, and keep in a safe place. 17. Snap ring 1) Remove snap ring (forward clutch end) (66). 2) Using tool A-2, remove nut (reverse clutch end) (67), then remove spacer. 90-40 tawer00 o14u02o14u02 18. Bearing (reverse clutch end) Using gear puller ®, remove bearing (69) and spacer (70) ‘Tap the drum with a copper hammer, make a clearance between the gear and the spacer, then fit the puller. Nyt | YU tat 19. Snap ring (needle bearing at reverse clutch end) Remove snap ring (71). “MC Le LU ¢ a 20. Bearing (forward clutch end) 1) Using puller @, push shaft (72) towards a reverse clutch. % For the reverse clutch, the outer race ‘end of the needle bearing is pushed out by the shaft. 2) Remove bearing (73) and spacer (74). sewers 90-4121. Forward clutch assembly Push shaft further and remove forward clutch assembly (75). % For details of the disassembly procedure, see from Step 23-2) 22. Collar, bevel gear Push shaft further and remove spacer (76a), bevel gear (77), and spacer (76b).. 23. Reverse clutch assembly, bearing assembly 1) Pull out shaft (72) completely, and remove reverse clutch assembly (80). 2) Remove bearing assembly (81) from case. sssemble reverse and forward clutch semblies as follows. 3) Sling housing and remove housing and drum assembly (87) from gear (86) 4) Housing i) Remove screw (88). ii) Remove 2 drum mounting bolts (100), and install bolt © and nut ©. iil) Remove remaining bolts. iv) Loosen nut @ slowly, and remove plate (89). v) Remove drum (90). 5) Remove spring (91), disc (92), and plate (93). 90-42 5 | lo | E 7 raweste Tea hy ei IO} O} sewer at sowens7 s9wer18 014U02014U02 24, 25. 26. 27. 6) Remove plate (94). 7) Remove piston (96) from housing (95). % There is spring (97) in the reverse clutch, Nut (drum shaft) Remove nut (101) and washer (102). Drum mounting bolts Loosen drum mounting bolts (126). Disassembly of intermediate shaft group Cover 1) Set the case with the brake end facing down, 2) Using forcing screws @, remove cover (103) %& Check the number and thickness of the shims, and keep in a safe place. Intermediate shaft, gears, bearing 1) Using puller ®, pull out intermediate shaft (108). + Fit a block between gear (107) and the case, 5 420 102 vawetat @ sewerze2) Remove gears (107) and (109), and bearing (110). * Carry out this operation after Step 28. ‘* Disassembly of drum group 28. Cover Using forcing screws ®, pull out cover (112), then sling with eyebolts 18, and remove. * Check the number and thickness of the shims, and keep in a safe place. 29. Gear, bearing (intermediate shaft) Remove gears (107) and (109), and bearing (10). + For gear (107), see the diagram for Step 27-2) 30. Shaft 1) Remove dowel pin (117). 2) Remove plate (113). 3) Using puller 42, pull out shaft (116). 90-44 17 sewri24 IK m2 far sewerar sowei29 o14u02o14u02 4) When the bearing at the gear end comes out completely, lift off with a crane. 31. Drum 1) Remove drum mounting bolts (126). (See Step 25.) 2) Sling gear (114) and drum (115) as one unit, and make a clearance a. 3) Insert thin steel plate ( between drum (121) and case. 4) Pull out drum (121), then fit eyebolts (, and remove. 5) Remove spacer (125) from drum, seweras 90-4532. Drum, gear 1) Fit eyebotts, sling drum (115), then remove lifting tool ds. 2) Lower drum (115) to drum side to remove. 3) Lift off gear (114) © Disassembly of countershaft group 33. Cover Using forcing screws 8, remove cover (129). % Check the number and thickness of the shims, and keep in a safe place. 34. Shaft 1) Using puller 8, pull out shaft (135) from bearing, % Put block # in contact between gear (137) and the case. 2) Sling with eyebolts ‘8, and remove shaft (135), 35. Gear, bearing 1) Remove spacer (136) and gear (137). 2) Remove bearing (138). 90-46 115 vaweta7 ar o14u02o14u02 3) Remove cover (140). 36. Gear, bearing Using gear puller 08, remove bearing (131), gear (133), and spacer (134). et sawrr4s ‘© When using the bearing again, remove as follows. 1) Bearing of drum shaft 2) Bearing of transfer input shaft i) Put bearing race puller 2 in contact with inner race and remove. sewers 3) Bearing of transfer idle gear 4) Bearing of brake housing i) Put gear puller @ in contact with outer race of bearing and remove. vewera7 90-4790-48 ii) Put gear puller @ in contact with outer race of bearing and remove. o14u02o1au02 ASSEMBLY OF TOWING WINCH ASSEMBLY © Precautions when assembling Clean all parts, and check for dirt or damage. + Put drops of engine oil on the rotating part of the bearing, and rotate it several times. %* Coat the sliding surfaces of all parts with engine oil before installing, %& Set the piston seal ring so that the side receiving the pressure faces the housing, coat it with grease (G2-LI), then install it evenly. Make sure that it is not to one side. = Rotating seal ring: Fix with grease (G2-LI) and be careful that it does not get caught when assembling it. %& Check that the snap ring is fitted securely in the groove. % Do not change the combination of the taper roller bearing and outer race. ‘* Assembly of countershaft group 1. Bearing, plate 1) Set case with brake facing down. 2) Press fit outer race (139) to case. 3) Install plate (140). 4) Assemble bearing (138). 2. Gear, spacer Assemble gear (137) and spacer (136). towF 90-493. Shaft 1) Assemble spacer (134) and gear (133) to shaft (135), and press fit bearing (131), 2) Align shaft (135) with spline of previously assembled collar and gear, and set in po: tion, 3) Using puller (©, press fit shaft (135) to previously assembled bearing. 4. Adjusting preload, cage 1) Press fit outer race (132) to cover (128). 2) Install cage, and tighten 3 bolts lightly and uniformly by hand, 3) Measure clearance a between cage and case with thickness gauge 2. + Measure at several places and take the average. + Selection of shim clearance a + 0.2 mm 4) Assemble selected shim (130), and install cover (129). 5) Put dial gauge @ in contact with gear, move shaft up and down, and measure clearance b in axial direction. 4 Clearance b in axial direction 0.1 — 0.3mm % Ifthe clearance in the axial direction is not within the standard value, adjust with shims again. 90-50 ssw i56 o1au02o14u02 Assembly of drum group Intermediate shaft bearing (inside case) 1) Press fit outer race (106) to case. 2) Assemble bearing (105). . Oil seal Using too! A-4, install oil seal (120). 7 Lip of oil seal: Grease (G2-LI) Drum, gear 1) Assemble gear (114). 2) Sling drum (115), then align with spline of gear (114) and install, then keep raised with lifting tool @ |. Drum 1) Install outer race (123a), spacer (128), and outer race (123b) to drum (121). 2) Assemble bearing (122) 3) Using tool A-5, press fit oil seal (124) 7 Lip of oil seal: Grease (G2-L!) 4) Install spacer (125) 1 + Install so that the spacer protrudes only slightly from the end face of the drum. ‘* When installed as specified, the collar protrudes approx. 3 mm from the end face of the drum. La C) = vawri62 123 tay ii24 125 12 Wa june sewr6s 90-515) Set thin steel plate ® so that shaft hole in case is hidden + This is to prevent the spacer from falling out when the drum is pushed in. 6) Sling drum (121) with lifting too! ®, lower it on to steel plate ®,, and push into case. + Be careful not to drop the spacer. 7) Tighten drum mounting bolts (126) temporarily. (See Disassembly Step 25.) % Remove the lifting tool used to sling the drum and gear. 8) Raise drum (121) approx. 3 mm from case, fit washer, then push from outer race (123) end, and ‘return outer race, bearing, and spacer (125) to specified position. + Do not forget to remove the washer used above. % After installing the shaft, it is also Approx. 3 mm Possible to tighten the nut to return the 25 aWFI68 parts. 9. Shaft 41) Press fit bearing (118) to shaft (116). 2) Sling shaft (116) with eyebolts @, then align with bearing of drum and set in posi- 18 *) tion. ial I . 4 16 Eee 3) Using puller @, press fit shaft (116) to bearing (122). a 1 If the outer race was not knocked into Ne place in Step 8-8), tighten the nut of the yy shaft, and return to the specified posi rease| tion. 16. 4) Tighten nuts of shaft temporarily. 5) Fill inside of drum with grease (G2-LD. ea Inside drum: Grease (G2-LI) ia + Amount of grease: Approx. 2.5 & ewer s9wF173 90-52 014u02o14u02 1) Using puller ®, press fit bearing (118a). 2) Using puller (9, press fit outer race (119a), spacer (128), and outer race (119b) to gear end. 3) Using puller ‘2, press fit bearing (118b). 4) Install plate (113). == Mounting bolt: 176.5 + 19.6 Nm (18 +2 kgm) 11, Adjusting preload, cat 1) Press fit outer race (119) to cover (112). 2) Install cover (112), tighten nut (101) of shaft lightly by hand. 3) Measure clearance a between cover (112) and case with thickness gauge @. ‘& Measure at several places and take the average, sawer76 118 1182 119] sewer77 sawei7e sawes79 11 90-5312, 13. + Selection of shim: clearance a + 0.2mm + Remove the cover. 4) Install intermediate shaft gears (107) and (109) If cover (112) is installed, gear (107) will not go in, 50 set it in position first. 5) Install dowel pin (117) to shaft 6) Assemble selected shim (127), and install cover (112). 7) Fit washer (102), and tighten nut (101) 75m] Nut: 490.3 + 98.1 Nm (50 + 10 kgm) % Tighten the nut first to 392.3. Nm (40 kgm), then turn in the direction of tightening and align the cotter pin hole. 8) Tighten drum mounting bolts. "5=] Mounting bolt: 549 + 58.8 Nm (56 + 6 kgm) 9) Put dial gauge 8 in contact with drum, then move drum up and down cud measure clearance b in the axial direction. ‘ Clearance b in the axial direction: 0.1—0.3mm % If clearance b in the axial direction is not within the standard value, adjust with shims again Assembly of intermediate shaft group Bearing, gear Already assembled. (See Steps 5 and 11-4)) Shaft 1) Press fit bearing (105) to shaft. 2) Align with spline of gear, and set shaft (108) in position. 3) Using puller #8, press fit shaft (108) to bearing, % Press fit to the bearing installed in Step 51). 90-54 14056 195 aweras ard 108 o14u02o14u02 14. 15, Adjusting preload, cage 1) Press fit outer race (106) to cover (103). 2) Install cage, and tighten 3 bolts lightly and uniformly by hand, 3) Measure clearance between cover and case with thickness gauge (2. ‘ Measure at several places and take the average. Selection of shim ‘measured value + 0.2 mm 4) Assemble selected shim (104), and install cover (103) 5) Put dial gauge @ in contact with gear (107), then move gear up and down and measure clearance ¢ in the axial direction ‘%& Clearance ¢ in the axial direction: 0.1 —0.3mm 1 If clearance ¢ in the axial direction is not within the standard value, adjust with shims again, Assembly of clutch group Reverse clutch assembly * Assemble reverse and forward clutch assemblies as follows. 1) Set drum (90) to plate (89). % Align the bolt holes. 2) Assemble disc (92) and plate (93). % Align the notched portion in the outside circumference of the discs. % Assemble the discs and plates in turn so that a plate is at the top. Discs: 7, plates : 7 3) Assemble spring (91). 4) Assemble plate (94) A M4 103 acd 140191 40F 19 sawF194 90-555) Housing, piston assembly i) Assemble O-ring to piston (96). ’ Orring: Grease (G2-LI) ji) Assemble piston (96) to housing (95). iil) Assemble spring (97). %& This spring is not used for the forward clutch, Coat with grease to prevent it from falling off when it faces down. 6) Align bolt hole, then place housing and piston assembly (87) on top of plate. 7) Tighten bolt (100) temporarily from below. Insert the clutch shaft, align with the spline of the housing and drum, then tighten fully G3) Bolt: 132.4 + 14.7 Nm (13.5 + 1.5 kgm) 8) Install screw (88) from opposite side of housing. ===) Bolt: 132.4 + 14.7 Nm (13.5 + 1.5 kgm) 9) Install needle bearing to forward clutch. i) Press fit bearing (82) to drum. ii) Install snap ring (71). i) Install race (99). 10) Support gear end, align outside teeth of disc (92), and install to gear (86). 90-56 7 t4wF 120 140195 140196 2 s4wFI97 o1au02o14u02 16. 7. 18. 19. 11) Raise reverse clutch assembly (80), and sot inside case. ‘& Make marks so that the oil hole can be recognized from both sides. Clutch shaft 1) Install seal (84) to shaft (72. + Install at 2 places on each side. 2) Align oil hole in clutch and oil hole in shaft (position of gasket), then assemble shaft (72), Make a mark at the end face of the spline so that the position of the oil hole can be recognized from the end face of the shaft. Bearing assembly 1) Install bearing (78) to spacer (79) 2) Install bearing assembly (81) to case, and push in shaft (72) Forward clutch assembly Raise forward clutch assembly (75), set inside case, and leave raised. + Make marks so that the oil hole can be recognized from both sides, Collar, bevel gear Assemble spacer (76a), bevel gear (77), and spacer (76b), and push in shaft. % Set the notch in the collar at the position of the oil hole in the clutch, confirm the position of the oil hole, then push in. & Ifthe center of the inner race of the needle bearing is not obtained, it is stif, so tap the opposite end of the shaft. |. Bearing (forward clutch end) 1) Push end face of shaft at reverse clutch end with puller 43. 2) Assemble spacer (70). 19, s4wr201 5 if Toa vewr209 Tewr204 90-573) Using puller i, press fit bearing (73) % Push the inner race with tool A-3. 4) Install snap ring (66). 5) Install sleeve (74) % Set with the small hole facing the outside. 21. Cover (forward clutch end) 1) Press fit outer race (85) to cover (64) 2) Assemble seal ring to shaft. ’ Seal ring: Grease (G2-L!) 3) Assemble shim, then install cover (64). % Standard shim thickness: 2mm % The preload is adjusted with the shim on the opposite side, but change the shim thickness in accordance with the tooth contact and backlash of the bevel gear. 22. Needle bearing (reverse clutch end) 1) Press fit bearing (82) + Press fit the outer race end, 2) Intall snap ring (71). 90-58 Clutch group awe2t0 seweess o14u02o14u02 23. Bearing (reverse clutch end) 1) Install spacer (70). 2) Using puller {, press fit bearing (69). + Using tool A-3, push the inner race. 3) Assemble washer (68) and lock washer (83) 4) Using tool A-2, tighten nut (67). Goa=) Nut: 156.5 + 39.5 Nm (16 + 4 kgm) 5) Bend lock washer (83) 24. Oil tube Assemble oil tube (31) and install plate (32). 25. Adjusting preload, cover (reverse clutch end) 1) Press fit outer race (82) to cover (65). sweat 82 sewers 90-5926. 2) Tighten 3 mounting bolts lightly and uniformly by hand to fit cover. 3) Measure clearance between cover and case with thickness gauge (2. * Measure at several places and take the average. + Selection of shim measured value + 0.2 mm 4) Install seal ring to shaft. ’ Seal ring: Grease (G2-LI) 5) Assemble selected shim (75), and install cover (65) 6) Put dial gauge ‘8 in contact with end face of clutch hub, then move bevel gear and measure clearance d in the axial direction. + Clearance d in the axial direction: 0.1 — 0.2mm % If clearance d in the axial direction is not within the standard value, adjust with shims again. Assembly. of transfer group Idler gear assembly 1) Press fit bearing (63) to idler gear (62). 2) Install idler gear assembly (62) 90-60 o1auo2o14u02 27. Transfer cover Install transfer cover (68). ’ Cover: Gasket sealant (LG-4) 28. Cage at pump end 1) Install outer race (61) to cage (57). 2) Install cage (57) at pump end. 29. Input shaft assembly 1) Press fit bearings (56) and (54) to input shaft (59). + Use tool A-1 at bearing (56) end. 2) Install input shaft assembly (55). 3) Install outer race (60). 4) Adjusting preload, cage {Install oil seal (56) to cage. , Lip of oil seal: Grease (G2-LI) ii) Install cage, and tighten 4 bolts lightly and uniformly by hand. iil) Measure clearance between cage and case with thickness gauge (2. * Measure at several places and take the average. + Selection of shim measured value + 0.2 mm. 8 51 sowr22 avr22s sawr226 sawr229 90-61iv) Assemble selected shim and install cage (53) v) Put dial gauge {9 in contact with end face of shaft, then move shaft and measure clearance e in the axial direction. + Clearance e in the axial direction: 0.1 — 0.3mm & If clearance e in the axial direction is not within the standard value, adjust with shims again, 5) Install spacer (52). 6) Assemble coupling (50), then fit O-ring and plate (49) and tighten bolts (48). S Mounting bolt: 176 + 19.6 Nm (18 + 2 kgm) 30. Idler gear cover Install idler gear cover (47). 31. Bevel pinion gear assembly 1) Assemble to bevel pinion gear as follows. i) Press fit bearing (46) to bevel pinion gear (a1), ii) Assemble spacer (44), gear (40), and spacer (43). sewezas sawrese ili) Press fit bearing (45) to cage (42) iv) Press fit inner race end of bearing installed to cage (42) to bevel pinion gear (a1), 90-62 o14u02o14u02 v) Fit plate (37) and tighten bolt (36) G>5=) Bolt: 176 + 19.6 Nm (18 +2 kgm) Press fit outer race (38) to transfer case, and install snap ring (38). Assemble removed shim, and install bevel pinion gear assembly (35). Install cover (34), 90-6332. Adjusting tooth contact, backlash 1) Adjusting backlash % Itis difficult to completely fix the gear in position, so use a fuse wire, Put fuse wire (® between the gears, rotate the gears to crush the fuse wire, then measure the fuse wire with a micrometer. Put the fuse wire at right angles to the gear from the root of the gear tooth Standard value for backlash: 0.15 — 0.2mm 6 Measure at 2 — 3 places. {f the result of the measurement shows that the backlash is not correct, adjust as follows. Forward % Adjust the number of the shim at both ‘ends of the clutch shaft. When doing t this, to avoid changing the preload that_has already been adjusted, \ remove shims from one side and add all of them to the other side. + OF > ‘4 Backlash is too small 140F13439) '* When backlash is too small Remove the shim from the reverse clutch side and add it to the forward t Clutch side to move the bevel gear in direction A. ax ‘* When backlash is too large Remove the shim from the forward oe clutch side and add it to the reverse clutch side to move the bevel gear in direction B. Forward Backlash is too large 140F13440] 90-64 o14u02o14u02 2) Checking tooth contact Testing i) Coat the tooth face of the bevel pinion lightly with red lead (minimum). Rotate the bevel gear forward and backward and inspect the pattern left on the teeth. ii) Tooth contact should be checked with ‘no load on the bevel pinion. It should be in the center of the tooth height. The tooth contact pattern should be located 25 to 40% from the small end “d", and should cover 30 to 50% of the length of the tooth. In addition, there should be no strong contact at the addendum “a” or dedendum "b" (tip or root of the gear teeth) or at the big end “c” and small end “d’. % If the gears are adjusted to this pattern, the tooth contact will be correct when load is applied. ‘a: Addendum — d: Small end b: Dedendum —_e: Width contact €: Big end f: Center of tooth contact Adjustment If the result of the inspection shows that the correct tooth contact is not being obtained, adjust again as follows: i) If Bevel pinion is too far from center line of bevel gear Contact is at the small end of the convex tooth face of the bevel gear and at the big end of the concave tooth face. © Correct as follows. Adjust the shim thickness at the bevel pinion end, and move the bevel pinion in direction A. Or, move the bevel gear in direction B and check the tooth contact pattern and backlash again. ii) If bevel pinion is too close to center line of bevel gear Contact is at the small end of the concave tooth face of the bevel gear and the big end of the convex tooth face. ‘© Procedure for adjustment Adjust the thickness of the shims at the bevel pinion to move the bevel pinion in direction A. Adjust the shim thickness at the bearing cage of the bevel gear shaft to move the bevel gear in direction B. Check the tooth contact pattern and backlash again. ‘* When adjusting the amount that the bevel gear moves in or out, do not change the preload of the bearing. Adjust by removing the shim on one side and adding the same shim to the other side. - {| ac t A Be a + A 90-65* Assembly of brake group 33. Brake assembly Assembly of brake assembly 41) Adjusting overall height of brake disc, plate i) Without assembling spring, assemble housing and piston assembly (21), hous~ ing (26), and discs and plates. ii) Measure clearance f between housing and top face of disc. 4 When measuring, hold the disc down lightly, measure at 4 places around the circumference, and take the average value. Standard clearance f: 0.9 + 0.1 mm Select a spacer of thickness equal to clearance f. ‘ There are 5 types of spacer: 0.4 mm, 0.6 mm, 0.8 mm, 1.0mm, 1.2mm 2) Install spring (27) to cover (29). ‘ Assemble the spring so that the inside “opens”, 3) Housing, piston assembly i) Assemble seal ring (30) to housing (23). ’ Seal ring: Grease (G2-LI) Assemble piston (22) to housing, i) Assemble spacer (28) selected in Item 1p) to end face of piston. & Stick with engine oil iv) Install housing and piston assembly (21). % Be careful that the spacer does not get caught between the housing and shim. 4) Drum assembly i) Set snap ring (18) in groove of drum (20). % The snap ring is installed to the hub side. ji) Press fit bearing (25). iil) Install snap ring (24). 90-66 sowF240 o14u02o14u02 34, 35. iv) Push inner race end of bearing of drum (20), and install to housing (19). v) Install snap ring (18) (assembled in Step 4}i)) to housing (19). 5) Install housing (26). 6) Assemble discs (16) and plates (17). % Discs: 6, plates: 6 7) Assemble plate (15), and tighten bolts uni formly. 8) Install sleeve (14). 9) Sling brake assembly (13) with shackle 19 and install ’ Case mounting surface: Gasket sealant (LG-6) Bar Install bar (12) Refilling with oil Tighten drain plug and add engine oil ‘mw Case: 66 . Covers, suction tube 1) Install covers (10) and (11). , Cover: Gasket sealant (LG-4) 2) Install suction tube (3). s4wr08t 90-6737. Control valve assembly 1) Install valve seat (8) 2) Install control valve assembly (7), 38. Hydraulic pump assembly Fit coupling and install pump assembly (6). 39. Piping Install pipes (4), (3), and (2). 90-68 o14u02o14u02 4-6 ASSEMBLING INFORMATION 4-6-1 BEARING CLEARANCE AND GEAR BACKLASH 0..201-0.525mm 0. 15-0. 20mm 0. 195-0. 493mm 7 248-0. 20nm pate 0.2 01-0. 525mm for input snatt gear 0, 201-0. 825mm, 0. 253-0. 635mm s4weAs2079 90-695. MAINTENANCE STANDARD 5-1 CLUTCH rewcarzoro Unit: mm No. Cheek item Criteria Remedy Standard size Repaie limit Thickness of dise 38 34 Warp of dise 02 os Thickness of pate 22 20 2 Warp of plate 02 os 3 | Assembled thickness of disc and plate 2 39 Replace Standard size Repair limit Free | Installed | Installed | Free | Installed ae length | tength load length load 4 | clutch spring aN 358.4N 4a Payin | 765 sss | uy eee 4a3N 3766N 4b, Payout | 63.1 5 | atin | 2 | aeey 18N T6N 5 | Spoo! eeturn spring 5 * | cist | 72 | oiety teh piston spring (Pay oun) a sean 6 | Clutch piston spring Pay out) a oe eS 90-70 014u02o14u02 5-2 BRAKE v4wcas2071 Unit: mm No Ccheck item Criteria Remedy Standard sie Repair limit ‘Thickness of aise ar 43 1 warp of dise 032 os Replace ‘Thickness of plat 26 24 2 Warp of plate 015 03 2 | Assembled thickness of disc and plate 38 a 90-715-3 VALVE 90-72 7 saweaszo72 o14u02o14u02 Unit: mm Wo heck tom cite femedy Standard size | Standard clerance | _ Clearance nt 1 | tenance pemeen plunger and ree abe poo! 6 002 — 0088 008 Gearance between tet vate wpa 2 | Gasrance 2 0.05 — 058 008 Cieorance betwen dich valve Sod 3 | lemrace 2 00s — ase 08 Replace ‘earancebetwsen brake valve soo «| Seance 7” 0.035 — 0058 a0 G | Gesrenco ponroon bak vava spo re amas ry snd longer ‘earance brwean rang valve ooo = «| learance 7” 0.038 ase 008 Standard se eps nit Free | Tonaled | tated | — Free] Toatatod venoty | “engi | “ood” | torotm | "tooo 27 er valve sin . “me 7a. Large 62 425 ae 60.1 oe einen Z (17.8 kg) (16.9 kg) 7001.8 o51N 7. Smet sa | as | amNY | coe | BIN voaN aN 6 | utc vate return soring 7 a | amet, [oro | aaN, | Renin 2 | tating valve ering 0 oe | ay | oe | aN Tarn TaN 10 | Brake valve spring 49 45 (1.91 kg). ae 1.8 kg) ca2N sa N 11 neking va detent spring as | 7 | ez | = | a S68N San 12 | Relief valve piston spring bad - (0.58 ka) eal (0.55 ka) 90-735-4 TOWING WINCH PUMP ‘SBR(1)-021 1127 98Nm (1521 kom se2roaees Unit: mm No. Check item Criteria Remedy Standard clearance Clearance limit 1 | Side clearance 0.10018 019 Clearance between inside diameter 2 | of plain bearing and outside diameter 0.06—o119 020 Replace of Bear shatt Standard size Tolerance Repair imit 3 | Depth to drive in pin 10 @ = -05 4 | Rotating torque of spline shaft 2.0—49Nm (0.2 —05 kom) Standard | Permissible Discharge amount Speed Discharge | gisenarge | discharge =| “eit eoroco, om) pressure | “mount ‘mount 7 oil temperature: 46 — 56°C) MPa tkafem?) | (uimin} (min) 3.500 29 (30) n 2 90-74 o14u02

D85ess-2 Sebm003002 PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

D85ess-2 Sebm003002 PDF

Uploaded by

Copyright:

Available Formats

You might also like