SEBMWO0300 SHO WP IMLANINTOA\ILs KOMATSU WD500-3 MACHINE MODEL SERIAL No. WD500-3 §0001 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. + WD500-3 mounts the $60140-2 engine. For details of the engine, see the 6D140-2 Series Engine Shop Manual. This Shop Manual includes only the portions exclusive to the WASOO-3. Use this manual together with Shop Manual for the WASOO-3. KOMATSU01 10 20 40 90 CONTENTS GENERAL .... STRUCTURE AND FUNCTION..........cscssssssseseeesecsteesesee TESTING AND ADJUSTING........ccsssssssssessseesseessntserseeses MAINTENANCE STANDARD.. No. of page 1 01-1 10-1 20-1 ee 40-1 ++ 90-1SAFETY SAFETY SAFETY NOTICE SAFETY NOTICE IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol iy is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed care- fully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals. which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. « Always wear safety glasses when hitting parts with a hammer. « Always wear safety glasses when grind- ing 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, al- ways wear welding gloves, apron, hand shield, cap and other clothes suited for weld- ing work. When carrying out any operation with two or more workers, always agree on the oper- ating procedure before starting. Always in- form your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them. 6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. ‘Smoke only in the areas provided for smok- ing. Never smoke while working. 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, Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. in addition, be sure to lock all the control levers and hang warn- ing 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 ma- chine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. 00-3SAFETY PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing compo- nents of the oil, water or air circuits, first remove the pressure completely from the circuit. 12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 13. Before starting work, remove the leads from the battery. Always remove the lead from the negative (-) terminal first. 14. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hit- ting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under in- ternal pressure or under pressure from a spring, always leave two bolts in position ‘on opposite sides. Slowly release the pres- sure, then slowly loosen the bolts to remove. 16, When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18. As a general rule, do not use gasoline to wash parts. In particular, use only the min mum of gasoline when washing electrical parts. 00-4 19, 20. 24 22, 23. 24, SAFETY NOTICE 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 be- ing operated. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely care- ful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. |. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. ‘When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. When measuring hydraulic pressure, check that the measuring tool is correctly assem- bled before taking any measurements. Take care when removing or installing the tracks of track-type machines. When removing the track, the track sepa- rates 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 understanding of the structure, but also serves as reference material for troubleshooting. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating "Problems" to “Causes” are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. MAINTENANCE STANDARD This section gives the judgement standards when inspecting disassembled parts. NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Use the specifications given in the book with the latest daFOREWORD HOW TO READ THE SHOP MANUAL VOLUMES Shop manuals are issued as a guide to carrying out repairs. They are divided as follows: Issued for every machine model Issued for each engine series Electrical volume: Each issued as one Attachments volume: | volume to cover all models These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is neces- sary that chassis, engine, electrical and attach- ment volumes be available. DISTRIBUTION AND UPDATING Any additions, amendments or other changes 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 tem number (10. Structure and Function} Consecutive page number for each item. Example 2 (Engine volume): 12-5 tee Unit number (1. Engine) Item number (2. Testing and Adjusting) |____Consecutive page number for each item. 3. Additional pages: Additional pages are indi- cated by a hyphen (-) and number after the page number. File as in the example. Example: 10-4 12-203 10-4-1 42-2081 10.4.2 1 ~ Added pages —l12-293.2 105 12-204 00-6 HOW TO READ THE SHOP MANUAL REVISED EDITION MARK When a manual is revised, an edition mark (Q@O....) is recorded on the bottom of the pages. REVISIONS Revised pages are shown in the LIST OF RE- VISED PAGES next to the CONTENTS page. SYMBOLS So that the shop manual can be of ample prac- tical use, important safety and quality portions are marked with the following symbols. Symbol | item Remarks | Special safety precautions are Safety | necessary when performing the work, Special technical precautions fr other precautions for pre- serving standards are neces sary when performing the work, Caution Weight of parts of systems. Caution necessary when se- lecting hoisting wire, or when working posture is important, ete, | Weight Places that require special at- tention for the tightening torque during assembly. [Tightening] torque Places to be coated with ad- Coat | hesives and lubricants, etc. Places where oil, water or fuel must be added, and the ca- pacity. Oil, water Places where oil or water must be drained, and quan- tity to be drained, Drain f-\e[d| 8 | 8 |FOREWORD HOISTING INSTRUCTIONS HOISTING Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISAS- SEMBLY AND ASSEMBLY section, every part weighing 25 kg or more, is indicated clearly with the symbol « If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existence of another part caus- ing interference with the part to be re- moved. WIRE ROPES 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table belo Wire ropes (Standard "Z" or “S* twist ropes without galvanizing) Rope diameter Allowable load mm kw tons 10 98 10 2 13.7 14 125 187 16 1“ | 218 22 16 ms | 28 18 e598 |e o.0) 20 41 | 4d 224 549 56 30 98.1 10.0 40 1765 18.0 50 2786 28.0 60 392.2 40.0 ‘* The allowable load value is estimated to be one-sixth or one-seventh of the break- ing strength of the rope used. 2) Sling wire ropes from the middle portion of the hook. 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 re- sult. Hooks have maximum strength at the middle portion. G44 100% 88% «79% «= 71% 41% sx00079 3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. B Singing 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 re- sult in a dangerous accident. 4) Do not sling a heavy load with ropes form- ing 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 allow- able 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 suspended. 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 2 19.6 KN (2000 kg) load at a lifting angle of 150°, 3 a ig 2 eA shop04so 00-7FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER ‘There are 2 types of push-pull type coupler. The method of disassembling and connecting is differ- cent, so see the table below when disassembling and connecting the coupler. ‘Type Type 2 Disassembly 1) Hold the mouthpiece of the tightening por- tion and push body (2) in straight until ing prevention ring (1) contacts contact sur- face a of the hexagonal portion at the male end. ce0638i \2 Hold in the condition in Step 1), and push until cover (3) contacts contact surface a of the hexagonal portion at the male end. exposes Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it. 3) | -> t cwrosaas Ie | - | - z= 1) Hold the mouthpiece of the tightening por- tion and push body (2) in straight until slid- ing prevention ring (1) contacts contact sur- face a of the hexagonal portion at the male end. < 1 enrossee 2) Hold in the condition in Step 1), and turn lever (4) to the right (clockwise). cwross96 3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it. exposes 00-8FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER. Type 1 ‘Type2 Connection Hold the mouthpiece of the tightening por- tion and push body (2) in straight until slid- ing prevention ring (1) contacts contact sur- face a of the hexagonal portion at the male end to connect it. cxossst + Hold the mouthpiece of the tightening por- tion and push body (2) in straight until slid- ing prevention ring (1) contacts contact sur- face a of the hexagonal portion at the male ‘end to connect it. 1 cvrosnaeFOREWORD COATING MATERIALS COATING MATERIALS x The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below. % For coating materials not listed below, use the equivalent of products shown in this list. Category | Komatsu code} PartNo. | ity | Container Main applications, features * Used to prevent rubber gaskets, rubber UT-1A__}780-129-9030) 1509 | Tube | cushions, and cock plug from coming out. * Used in places requiring an immediately effective, strong adhesive, Used for plas- Lr-18 |790-128-8050| 20.9 | |Polvethvene| tics except polyethylene, polyprophylene, pea tetrafluoroethlene and vinyl chloride), rub- ber, metal and non-metal. | + Features: Resistance to heat and chemi- Potato aaa ee a) 9 container |+ loosening and sealant pur- pase bo a eb 7o0-19- 4060 [adhesive Use aes or usa or mata dae eae alt sharon tra | SETIE™ Iuatieg] can vatean [spent vem? | e's Aaharves . Potvatvone|- Used a salon for machined hoes. [tre [pooze-s010| 220 9 Paver won] [sed oe heating teaan for rea rot macau! 70 | tune | Vann > Quick nrdocing ype eaheave Three bond otrene|* Catena wit Sco in 1735, 790-128-9140) 60.9 container |* Used mainly for adhesion of metals, rub- Sees ~aulec erdening woe adhesive | no ae ee ee eh ater 30 | Aromtone | pop raesrs0) 29 |Poattoe|” tat | . BSS nin fr adhesion of abbers le tel and nae 7 \ | |+ Features: Resistance to heat, chemicals Loctite |79a-129-8110| 50.cc Polvethylene|. Used at joint portions subject to high tem- coe container peratures. I Used ex ache or oreo for peas ict eae ize 010 eg) uw and packing of power train case, etc. + Features: Resistance to heat | GRRE SSS Re aurtcos and cata | | aks a High tmporte lenders, weed Soe | ica fro-tzo-soro| 18a | can | toorevnt ania, | + Used as sealant for heat resistance gasket for high temperature locations such as en- gine precombustion chamber, exhaust pipe, ete.FOREWORD COATING MATERIALS Category | Komatsu code] PartNo. | arty | Container Main applications, features + Features: Resistance to water, cil + Used as sealant for flange surface, thread. tes | 90-129-9020| 200 | Tube |* Also possible to use as sealant for flanges with large clearance. J+ Used as sealant for mating surfaces of fi nal drive case, transmission case. + Used as sealant for various threads, pipe J Polyethylene} joints, flanges. 46-5 [790-129-9080) 1k |" container |+ Used as sealant for tapered plugs, elbows, nipples of hydraulic piping. + Features: Silicon based, resistance to heat, Gasket | cold sealant Lc-6 | 09940-00011] 250g | Tube + Used as sealant for flange surface, tread. | + Used as sealant for oll pan, Final drive case, | [ete |+ Features: Sticon based, quick hardening type Lc-7 | 09920-00150 150g | Tube |. Used as sealant for flywheel housing, in- | take manifold, ol an, thermostat housing, ete. | Used as heat-resisting sealant for repairin Thee bond | 55 129.0050] 1009 | Tube |* Us8d88heat-rosatng sealant for repairing ra I engine * Used as lubricant for sliding portion (to pre- Molybde- LMG (09940-00051 809 Can vent from squeaking), disulphide + Used to prevent seizure or scuffling of the lubricant imp — | 09940-00040} 200g | Tube | thread when press fitting or shrink fitting. + Used as lubricant for linkage, bearings, etc. | [syc2-400u + General purpose type IsyG2.3s0L! G2ut — |s¥G2-4001LA | Various | Various 'syG2-1601_ | | 'Syca-160cNU { + Used for normal temperature, light load Grease (ooo bearing at places in contact with water or 'S¥G2-350CA aaa G2ca [S¥G2-400CAA| Various | Various 'S¥G2-160CA | |SYGAt60cNCA| | Molybdenum | 400g | + Used for places with heavy load disulphide | SYG2-400M | (10 per [Belows type lubricant | case) | 00-11FOREWORD 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. ‘Thread diameter Width of bolt across flats mm mm 6 10 13.2214 8 13 3123 10 a 66:7 2 19 113210 4 2 17419 16 | 24 279230 18 2 382239 20 30 549259 | 22 32 745283 24 36 927103 94.54 105 2 “a 13202 140, | 135215 30 48 1720+ 190 37520 33 50 22104240 225225 36 55 2750290 28030 39 60 3290+340 335235 Thread diameter Width of bolt across flats mm mm Nm kgm 6 70 7.8521.95 oBt02 8 13 186449 | 19205 10 4 402259 41206 2 2 82.3517.85 84208 Sealing surface TABLE OF TIGHTENING TORQUES FOR FLARED NUTS ++ In the case of flared nuts for which there is no special of BUI: instruction, tighten to the torque given in the table below. QLAU[ LEE Thread diameter | Width across flat Tightening torque mm mm Nm kgm 1% 19 265249 T 25405 8 24 49% 19.6 542 2 2 7854196 B42 24 32 137.3429.4 1423, 30 36 176.5429.4 1823 33 “1 196.14 49 2045 36 46 265.24 49 2525 42 | 55, 294.2449 3025 00-12FOREWORD ‘TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS STANDARD TIGHTENING TORQUE 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 kgm 10 4 657468 67207 2 a 112498 11541 16 2 279429 28.543 TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS * Unless there are special instructions, tighten the O-ring boss piping joints to the torque below. Nominal No. | thfead diameter | Width across flat ightening torque mm mm Nm kgm, 02 1% 343449 35405 03, 04 20 \Varies depending on| 93.1498 sit 05, 06 24 type of connector. 142.14 196 14542 10, 12 33 421.42 58.8 4346 14 2 877.14 132.3 89.54 13.5 ‘TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS ‘* Unless there are special instructions, tighten the O-ring boss plugs to the torque below. Nominal No, | Thread diameter | Width across flat Tightening torque mm mm’ [ Nm kgm 08 8 Ty 7354147 0.75£0.15 10 10 7 14.274 1.47 1.1820.18 2 2 19 17.644 1.96 jaz02 4 4 2 22.54% 1.96 23402 16 16 24 29.4449 3405 18 18 2 4405 20 20 30 5208 24 26 32 Tt 30 30 32 107.84 14.7 1218 33 33 = 127.44 19.6 1382 36 36 36 15194245 15.5225 a2 2 = 2072294 =| 21.543 52 52 = sz4e4ey | 33445FOREWORD 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 I Tightening torque mm) I Nm kgm 6 we? 4.02 + 0.20 8 meh 2.45 £0.41 10 6 438 + 0.61 2 Te 795 + 1.22 TIGHTENING TORQUE FOR 102 ENGINE SERIIES (EYE JOINTS) Use these torques for eye joints (unit: mm) of Cummins Engine. Thread diameter Tightening torque mm Nm| kgm) 6 as2 0.81 +0.20 8 1042 1.02 + 0.20 10 1242 1.22 £0.20 2 med 245 + 0.41 4 365 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 inch Nm kom 116 321 O31 = 0.10 18 es2 081 £0.20 4 1242 1.22 £0.20 3/8 1522 153 £0.41 412 mse 245 +041 ara 36 +5 367 £051 1 I +9 | 612 +082 00-14FOREWORD ELECTRIC WIRE CODE ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe. CLASSIFICATION BY THICKNESS pena [pean coer ee Renee eet oe ees |e eee "mb! | Names ar ef reas sein] mi |“ pliable cru oss | oa | os | 20 2 _ | Staring toning signal ot 2 2% | ow | 20 | an 20 _| Liahing signal et 5 | om | sa | ss a7] charging and signal 7s uae amos rae |r 38 _| Staring (Gtow pug) 40 85 oso | 4273 Tana 135 Starting co || om | ose | ras | ve | snug wo | a7 | os | war | 6 | 20 | Stoning CLASSIFICATION BY COLOR AND CODE Prior ba ~ Charging | Ground | starting | Lighting | instrument | signal Other cation pr. [code] 8 8 R Y s u 1 ry Color} White Black Black Red Yellow Green Blue code] WR = aw AW YR ow LW ; Color] White & Red) = [Black & White| Red & White |Yellow & Red|Green & White/Blue & White code] WB BY RB Ye GR a : Color} White & Black} - jlack & Yellow] Red & Black |Yellow & Black|Green & Red/ Blue & Red Code] WL = BR RY YG cy Ly © |ltecy |Color| White & Blue} Black & Red [Red & Yellow/Yellow & Green|Green & Yellow/Blue & Yellow [Code] WG - - RG Yu GB 1B 7 {cote |White & Green} - Red & Green [Yellow & Blue|Green & Black|Blue & Black code] — = = aL ww cL : |Color| _ - Red & Blue [Yellow & White|Green & Blue} -FOREWORD CONVERSION TABLE CONVERSION TABLE METHOD OF USING THE CONVERSION TABLE The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. EXAMPLE ‘+ Method of using the Conversion Table to convert from millimeters to inches 1. Convert 55 mm into inches. (1) Locate the number 50 in the vertical column at the left side, take this as @, then draw a horizontal line from @. (2) Locate the number 5 in the row across the top, take this as @, 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 550 mm into inches. (1) The number 550 does not appear in the table, so divide by 10 (move the dé to the left) to convert it to 55 mm. (2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. (3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches. imal point one place 1mm = 0.03937 in 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 2205 | 2.244| 2.283 | 2323 2.598 | 2.638 | 2.677 | 2.717 2.992 | 3.032 | 3.071) 3.110 3.386 | 3.425 | 3.465 | 3.504 3.780 | 3.819 | 3.858 | 3.898 | 3.1e9 | 3.228 | 3.268 3589 | 3.622 | 3.661 00-16FOREWORD Millimeters to Inches CONVERSION TABLE 11mm = 0.03937 in ° 1 2 3 4 5 6 7 8 9 o 0 — | 0.039 | 0.079 | 0.118 | 0.157 | 0.197 | 0.236 | 0.276 | 0.318 | 0.354 10 0.394 | 0.433 | 0.472 | 0.512 | 0.551 | 0.691 | 0.630 | 0.669 | 0.709 | 0.748 2 0.787 | 0.827 | 0.866 | 0.906 | 0.945 | 0.984 | 1.024 | 1.063 | 1.102 | 1.142 30 ati | 1.220 | 1.260 | 1.299 | 1.339 | 1.378 | 1.417 | 1.457 | 1.496 | 1.536 40 1.575 | 1.614 | 1.654 | 1.693 | 1.732 | 1.772 | 1.811 | 1.850 | 1.890 | 1.929 50 1.969 | 2.008 | 2.047 | 2.087 | 2.126 | 2.165 | 2.205 | 2.244 | 2.283 | 2.923 60 2.362 | 2.402 | 2.441 | 2.480 | 2.520 | 2559 | 2.598 | 2.638 | 2.677 | 2.717 70 2.786 | 2.795 | 2.835 | 2.874 | 2.913 | 2953 | 2.992 | 3.032 | 3.071 | 3.110 80 3.150 | 3.189 | 3.228 | 3.268 | 3.307 | 3.246 | 3.386 | 3.425 | 3.465 | 3.504 90 3.543 | 3583 | 3.622 | 3.661 | 3.701 | 3.740 | 3780 | 3819 | 3.888 | 3.898 Kilogram to Pound ‘kg = 2.2046 Ib ] ° 1 2 3 4 5 | 6 7 8 8 o ° 220| 441| 661| 882] 11.02] 13.23] 15.43] 17.64] 19.84 10 22.08 | 24.25| 26.46| 28.68| 30.86] 33.07| 35.27| 37.48| 39.68| 41.89 20 44.09 46.30] 48.50] 50.71/ 51.91) 55.12| 57.92| 59.53| 61.73| 63.93 30 66.14| 68.34| 7055| 72.75| 7496] 77.16] 79.37| 81.57| 23.78| 85.98 40 88.18 | 90.39] 9259} 94.80| 97.00| 99.21| 101.41 | 103.62 | 105.82 | 108.03 50 | 110.23 | 112.44 | 114.64) 116.85 | 119.05 | 121.25 | 123.46 | 125.66 | 127.87 | 130.07 60 132.28 | 134.48 | 136.69 | 138.89 | 141.10 | 143.0 | 145.51 | 147.71 | 149.91 | 152.12 70 | 154.32 | 156.53 | 158.73 | 160.94 | 163.14 | 165.35 | 167.55 | 169.76 | 171.96 | 174.17 80 | 176.37 | 178.57 | 180.78 | 182.98 | 185.19 | 187.39 | 189.60 | 191.80 | 194.01 | 196.21 90 | 198.42 | 200.62 | 202.83 | 208.03 | 207.24 | 209.44 | 211.64 | 213.85 | 216.05 | 218.26 00-17FOREWORD CONVERSION TABLE Liter to U.S. Gallon 1 = 0.2642 U.S. Gal 0 | 1 2 3 4 5 6 7 8 9 | | 0 0 0.264 | 0.528 | 0.793 | 1.057 | 1.321 | 1.585 | 1.849 | 2.113 | 2.378 10 2.642 | 2.906 | 3.170 | 3.434 | 3.698 | 3.963 | 4,227 | 4.491 | 4.755 | 5.019 20 5.283 | 5.548 | 5.812 | 6.076 | 6.340 | 6.604 | 6.869 | 7.133 | 7.397 | 7.661 30 7.925 | 8.169 | 2.456 | 8.718 | 8.982 | 9.246 | 9.510 | 9.774 | 10.039 | 10.303 40 10.567 | 10.831 | 11.095 | 11.359 | 11.624 | 11.888 | 12.152 | 12.416 | 12.680 | 12.944 | 50 13.209 | 13.473 | 13.737 | 14.001 | 14.265 | 14.529 | 14.795 | 15.058 | 15.322 | 15.586 60 15.850 | 16.115 | 16.379 | 16.643 | 16.907 | 17.171 | 17.435 | 17.700 | 17.964 | 18.228 70 18.492 | 18.756 | 19.020 | 19.285 | 19.549 | 19.813 | 20.077 | 20.341 | 20.605 | 20.870 80 21.134 | 21.398 | 21.662 | 21.926 | 22.190 | 22.455 | 22.719 |} 22.989 | 23.247 | 23.511 90 23.775 | 24.040 | 24.304 | 24.568 | 24.832 | 25.096 | 25.361 | 25.625 | 25.889 | 26.153 Liter to U.K. Gallon 16 = 0.21997 U.K. Gal T ° 1 2 afa|s |e] 7 a | 9 | ] ° © — | 0.220 | 0.440 | 0.660 | 0.880 | 1.100 | 1.320 | 1.540 1.760 | 1.980 10 2.200} 2.420| 2640| 2860| 2.080 | 3.300} 3520| 3.740 | 3.950) 4.179 20 4399 | 4619 | 4839 | 5.059) 5.279| 5.499] 5.719 | 5.939 | 6.159| 6.379 30 e599 | 6819) 7.039 | 7.259 | 7.479 | 7.969| 7.919 | 8.139 | 8.359 | 8.579 40 8.799 | 9.019 | 9.239 | 9.459 | 9.679 | 9.899 | 10.119 | 10.339 | 10.569 | 10.778 so | 10.998 | 19.281 | 11.438 | 17.688 | 11.878 | 12.098 | 12.378 | 12.528 | 12.758 | 12.978 60 | 12.198 | 12.418 | 13.638 | 13.858 | 14.078 | 14.298 | 14.518 | 14.798 | 14.958 | 15.178 70 | 18.298 | 18.618 | 15.838 | 16.058 | 16.278 | 16.498 | 16.718 | 16.938 | 17.158 | 17.378 80 17.598 | 17.818 | 18.037 | 18.257 | 18.477 | 18.697 | 18.917 | 19.197 | 19.357 | 19.577 90 | 19.797 | 20.017 | 20.237 | 20.457 | 20.677 | 20.897 | 21.117 | 21.337 | 21.557 | 21.777 | 00-18FOREWORD CONVERSION TABLE kgm to ft. Ib 11 kgm = 7.233 ft Ib ° 1 2 3 4 5 | 6 7 8 9 | o ° 72) 145| 217] 289] 362] 434] 506] 579] 65.1 10 723| 796| 868} 940| 101.3| 1085 | 1187 | 1230| 190.2 | 1374 20 1447 | 151.9 | 159.1 | 166.4] 1736 | 1808 | 188.1 | 1953 | 2025 | 2098 30 217.0 | 2242 | 2315 | 298.7 | 245.9 | 253.2 | 260.4 | 267.6 | 274.9 | 282.1 40 289.3 | 296.6 | 3038 | 311.0 | 3183 | 325.6 | 332.7 | 340.0 | 347.2 | 954.6 50 361.7 | 368.9 | 376.1 | 383.4 | 390.6 | 397.8 | 405.1 | 4123 | 4195 | 4268 60 434.0 | 4412 | 4485 | 455.7 | 4629 | 470.2) 477.4| 4946 | 491.8 | 499.1 70 5063 | 5135 | 5208 | 5280 | 535.2 | 5425 | 549.7 | 586.9 | 564.2 | 571.4 80 578.6 | 585.9 | 593.1 | 600.3 | 607.6 | 6148 | 622.0 | 629.3 | 6365 | 643.7 90 651.0 | 6582 | 665.4 | 672.7 | 679.9 | 687.1) 6944 | 701.6 | 7088 | 716.1 Aree feeral treo) trera freroy eee) evecare eect 110 796.6 | 802.9] 810.1 | 817.3 | 824.6 | 831.8 | 830.0 | 846.3 | 853.5 | 860.7 120 968.0 | 875.2 | 882.4 | 889.7 | 996.9 | 904.1 | 911.6 | 9186 | 926.8 | 933.1 130 | 9403 9475 | 9548 | 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 | 1070.5 | 1077.7 150 | 1084.9 | 1092.2 | 1099.4 | 1108.6 | 1113.9 | 1121.1 | 1128.3 | 1195.6 | 1142.8 | 1150.0 160 | 1157.3 | 1168.5 | 1171.7 | 1179.0 | 1186.2 | 1193.4 | 1200.7 | 1207.9 | 1215.1 | 1222.4 170 | 1129.6 | 1236.8 | 1244.1 | 1251.3 | 12585 | 1265.8 | 1273.0 | 1280.1 | 1287.5 | 1294.7 180 | 1301.9 | 1309.2 | 1316.4 | 1323.6 | 1330.9 | 1338.1 | 1345.3 | 1352.6 | 1359.8 | 1367.0 190 | 1374.2 | 1981.5 | 1388.7 | 1396.0 | 1403.2 | 1410.4 | 1417.7 | 1424.9 | 1432.1 | 1439.4 00-19FOREWORD CONVERSION TABLE kg/em? to Ibfin? tkglem? = 14.2233 Ibvin? ° 1 2 3 4 5 6 7 8 9 ° o | 142] 284] 427} 569] 71.1] 953] 996| 1138 | 1280 10 1422 | 1965 | 170.7 | 1849} 199.1] 2134 | 227.6 | 2418 | 256.0 | 2702 20 | 2045) 298.7 \ 3129] 327.1) 341.4| 3556 | 3698 | 384.0) 3983 | 4125 30 | 4267| 4409} 455.1 | 469.4) 483.6 | 497.8 | 5120 | 5263 | 5405 | 554.7 40 | 56a.9 503.2 | s97.4| 611.6 | 6258 | 6401} 6543 | 6685 | 682.7 | 6969 so | 711.2| 725.4) 7396 | 7538) 768.1 | 7823 | 7965 | 810.7 | 925.0 | 839.2 60 863.4 | 867.6 | 881.8 | 896.1 | 910.3 | 9245 | 938.7 | 953.0 | 967.2 | 981.4 70 | 9956 | 1010 | 1024 | 1038 | 1083 | 1067 | 1081 | 1095 | 1109 | 1124 eo [113g [1152 | 1166 | 1481 [1195 | 1209 | 1223 [1237 | 1252 | 1266 90 |1280 | 1294 | 1309 | 1323 [1337 | 1351 | 1365 | 1380 | 1394 | 1408 yoo |razz [1437 | 1451 | 1465 | 1479 | 1493 | 1508 | 1522 | 1836 | 1550 110 |1s65 |1579 | 1593 | 1607 1621 | 1636 | 1650 | 1664 | 1678 | 1693 yao |a707 Java. [1735 | 1749 [1764 1778 | 1792 | 1806 | 1821 | 1895 130 |1849 1863 | 1877 | 1992 | 1906 | 1920 | 1934 | 1949 | 1963 | 197 140 |1991 |2008 | 2020 | 2034 | 2048 | 2082 | 2077 | 2091 | 2105 | 2119 150 |2i3s [2148 ater | 2176 | 2190 | 2205 | 2219 | 2293 | 2247 | 2262 160 |2276 | 2290 | 2304 | 2318 | 2333 | 2347 | 2361 | 2375 | 2389 | 2404 170 |241e [2432 | 2446 | 2460 | 2475 | 2489 | 2503 | 2518 | 2592 | 2546 180 | 2560 | 2574 | 2589 | 2603 | 2617 | 2631 | 2646 | 2660 | 2674 | 2688 190 |2702 |2717 Ja7a1 |274s 2759 | 2773 | 2788 | 2802 | 2816 | 2830 200 | 2645 | 2859 | 2873 | 2887 | 2901 |2916 | 2930 | 2944 | 2958 | 2973 210 | 2987 | 3001 | 3015 | 3030 | 3044 | 3058 | 3072 | 3086 | 3101 | 3115 220 |3129 |3143 |a158 |3172 |3186 |3200 | 3214 |3229 | 3243 | 3257 230 |3271 |3286 |3300 | 3314 | 3328 | 3343 | 3357 | 3371 | 3385 | 3399 240 [3414 | 3428 [3442 [3456 | 3470 | 3485 | 3499 | 3513 | 3527 | 3542 00-20FOREWORD CONVERSION TABLE ‘Temperature Fahrenhelt-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into @ Centigrade tempera- reading or vice versa is to enter the accompanying table in the canter or boldface column of figures. figures refer to the temperature in either Fahrenheit or Centigrade degrees. If itis desired to convert from Fahrenheit to Centigrade degraes, consider the canter column as a table of Fahrenheit ‘temperatures and read the corresponding Centigrade temperature in the column at the let. is desired to convert from Centigrade to Fahrenheit degrees, consider the center column asa table of Centigrade values, ‘and read the corresponding Fahrenheit temperature on the right. 1° = 33.8% | ‘1 eee lero oF -404 | 40 | 00 | 117] 1 | sre] 78 | as | ie | 272] a1 | r78 72 | 35 | 310 | -11] 2 s36 | 83 | 47 | 1166 | 278 | 82 | 1796 -364 | a0 | -220 | -t05 | 13 | ssa} 29 | a | t1e4 | 203 | 93 | tera a7 | 25 | 130 | -100 | | 572 | 94 | 49 | 102 | 229 | a | 1032 -209 | -20 | -40 | -04| 1 | s90 | 100 | so | 1220} 204 | a5 | te50 -283 | 9 | 22] 29] 1 | oa] ws] si | 138] 300] 6 | 1868 -278 | 18 | «| 23] a7 | e26 | 111 | sz | 1256] 306 | 97 | 1386 a2 |-7 | x4 | a] we | ose] rz | sa | rare | arr | a8 | t904 -287 | 16 | 32 | -72| 1 | o62 | 122 | se | 1292] a17| a9 | 1922 -261 | 15 | 50 | -67| 2 | eo] v8 | 55 | 131.0 | 322 | 90 | 1940 -26|-4 | 68 | -61| 21 | oa] 133 | s6 | 1228} 328 | or | 1958 -0|-13 | a6 | -56| 2 | m6] 139 | 67 | 16 | 23a | 92 | t976 -204 | 12 | toa | 50 | 23 | 734] t4a | so | 1264] 339 | 93 | 1904 -23g.|-11 | 122 | +44] 2 | 752] 150 | so | 1202] a¢4| 96 | 2002 -233 | 10 | «0 | -39| 2 | 770] 156 | 60 | r400 | 350 | 95 | 2030 -2e| 2 | 18} -33| 2 | 78] 161 | 6 | v8 | a56| 96 | 2048 -22| 8 | we} -28| 2 | a6 | ir | o2 | vas} 961 | 97 | 2066 -217 | 7 | wa] -22| 2 | e2a| iz2| os | ra54 | 367 | 98 | 2084 saa | © | 22] 47] 29 | e42 | ize | 64 | te72 | 372} a9 | 2102 -2s | 6 | 230] 11] 30 | aso] v3 | 65 | v0 | 378 | 100 | 2120 -200 | «4 | 28 | 06] a1 | a8] 129 | 66 | 1508 | 406 | 105 | 2210 -i94| 2 | 266] 0 | a2 | e96] 194 | 67 | 1526] 433 | 110 | 2300 wa | 2 | 24 | 06) 33 | si] 200 asa | 451 | 118 | 239.0 sa3.| a | 202] 11] a4 | saz] 206 | 69 | 1562} 489 | 120 | 2480 -78| 0 | 320] 17 | 35 | 950] 211 | 70 | 1580] 517 | 126 | 2570 -72| 4 | a38 | 22| a6 | 968] a7 | m | 1598 | sea | 130 | 2560 -167 | 2 | 356 | 28] a7 | 986] 222 | 72 | r6r6 | 572 | 135 | 2750 ai | 3 | ara | 33| 38 | ros] 228 | 73 | 1624 | 600 | 140 | 2040 -156 | 4 | 392 | 39 39 | 122] 233 | 7 | 1652 | 627 | 15 | 2030 -150 | 5 | 4.0 | 46] 40 | 140] 239 | 7 | 1670 | 656 | 150 | 202.0 44] 6 | aa] so] 4 | 1058] 204 | 76 | 1038 | as | 155 | ai10 39 | 7 | ae | s6| 42 | wore] 250 | 77 | vos} 711 | 160 | 3200 -133| 8 | a4] 61 | 43 | 1094] 256 | 73 | 1724 | 739 | 165 | 3290 a8 | 9 | a2] 67) 4 | az] 261 | 79 | 42] 767 | 170 | 3380 122 | w | soo] 72 | 45 | 1130 | 267 | 30 | 1760] 794 | 175 | 347.0 00-21FOREWORD UNITS UNITS In this manual, the measuring units are indicated with Internatinal System of units (Si). As for reference, conventionally used Gravitational System of units are indicated in parentheses { }. Example: N {kg} Nm {kgm} MPa kg/cm’) kPa (mmH:0) kPa (mmHg) kwirpm {HP/ppm} g/kwh {g/HPh) 00-22O1 GENERAL ge List of lubricant and waterGENERAL GENERAL ASSEMBLY DRAWING GENERAL ASSEMBLY DRAWING 01-2GENERAL SPECIFICATIONS SPECIFICATIONS Machine model WDS500-3 Serial No. 50001 and up Operating weight kg 26,900 8 [Distribution (front) ke 12,700 = (Distribution (rear) kg. 14,200 Blade capacity m3 5 Travel speed FORWARD 1st km/h W FORWARD 2nd km/h 126 8 FORWARD 3rd km/h 212 5 FORWARD 4th km/h 348 E REVERSE 1st km/h 79 5 REVERSE 2nd km/h 144 . REVERSE 3rd km/h 23.5 REVERSE 4th km/h 38.1 Max. rimpull KN {kg} 259.9 {26,500} Gradeability deg 25 Min Center of outside wheel mm 6,160 Turning radius | Outsideconner of blade mm 7,485 Overall length mm 7,930 8 Overall width w/o blade mm 3,190 B| | blade width mm 4,550 2 Q Overall height (top of ROPS | mm 3,860 ale (Blade) mm 1,260 ‘S| Wheelbase mm 3,600 *) Tread mm 2,400 Min.ground clearance mm 455 Digging depth rom 440 Model S6D140E Type 4-cycle,water-cooled.6-cylinder direct injection.with turbocharger INo.of cylinders-bore x stroke mm 6-140 x 165 Piston displacement Kec} 15.2(15,200} g [Flywheel horsepower kW/rpm{HP/rpm) 235/2,100(315/2,100} [Maximum torpue Nm/rpm{kgm/rpm}} —_1,372/1,400(140/1,400} “Fuel consumption ratio &/KW-h{[@/HP-h} 226{ 168} High iding speed rpm 2,300 Low iding speed rom 725 [Starting motor 24V 11kW lAlternator 24V 35A battery 12V 170Ah x 2 O1-3GENERAL SPECIFICATIONS Machine model Serial No. WD500-3, 5000 1and up Torque converter Transmission Power train Reduction grar Srelement, 1-stage.single-phase (TCA40-10) Planetary gear,constant-mesh multiple-dise,hydraulically actuated modulation type Spiral bevel gear e Differential Straight bevel gear Final drive Planetary gear,single reduction.il bath Drive type Front/rear-wheel dribe Bl Front axle Fixed-frame,full-floating = Rear axle Center pin support type,full-floating Bi Tire 29.5-25-22PR{L3) <|Wheel rim 22.00 x 25WTB Inflation pressure Mpa {kg/enf} 0.34(35) Main brake Front/rear wheel braking, separate $ Front/rear wheel,wet disc, = hydraulically actuated © IParking brake Drive shaft,wet type disc brake = hydraulically released spring type = Sitype Articulated type & | structure Fully hydraulically power steering fo» |Work equipment pump | ¢/min 172 HYDRAULIC TANK |. Filter bypass valve Hydraulic filter . Oil level sight gauge Breather Hydraulic tank Drain valve - PPC, orbit-rolll return port in return port . Hydraulic cooler return port Main suction port Emergency steering suction port Emergency steering return port 10-3‘STRUCTURE AND FUNCTION OPERATION OF OIL FILTER BYPASS VALVE When the filter is clogged. Bypass valve (1) opens and the oil returns directly to the tank without passing through the filter. Bypass valve set pressure: 125 kPa {1.27 kg/cm’) When negative pressure is formed in the return circuit. Vaive (2) moves up and acts a check valve. Check vaive set pressure: 25.5 kPa (0.26 kg/cm} 10-4 RUE, tank HYDRAULIC TANK in control sovozst2 cont sovo2313‘STRUCTURE AND FUNCTION HYDRAULIC TANK BREATHER 1. Body 2. Filter element 3. Poppet 4, Sleeve sewoor41 FUNCTION Preventing negative pressure inside the tank ‘The tank is a pressurized, sealed type, so nega- tive pressure is formed inside the hydraulic tank when the oil level drops during operations. When this happens, the difference in pressure between the tank and the outside atmospheric pressure opens the poppet (3), and air from the outside is let into the tank to prevent negative pressure.” Preventing rise in pressure inside the tank ‘When the hydraulic cylinder are being used, the cil level in the hydraulic circuit changes and the temperature rises. If the hydraulic pressure rises above the set pressure, sleeve (4) is actuated to release the hydraulic pressure inside the tank. 10-5STRUCTURE AND FUNCTION PPC VALVE PPC VALVE sevooiae P. From PPC pump P1.To RIGHT TILT end of main control valve tilt spool P2.To LOWER end of main control vaive lift spool P3. To PAISE end of main control valve lift spool P4. To LEFT TILT end of main control valve tilt spool T. Drain 10-6‘STRUCTURE AND FUNCTION PPC VALVE sevoot4s Bolt Piston Plate Collar Retainer Centering spring Metering spring Valve Body PEIOMAwns 10-7STRUCTURE AND FUNCTION PPC VALVE OPERATION OF PPC VALVE [At neutral] To erlinder To tank To evtineer PAL tt t Pat y tH iy U Charee valve ' a ee Of = ; ° Ha Sed eI Z aa f Hl BAS aa casck valve Oh eee yey E| aa A | ee M ) @~ ae fvérantie tent The oil from the PPC pump enters port P of the PPC valve, but the circuitis closed by spool {8), so the oil is drained from relief valve (1). At the same time, the oil at port PA1 of the ‘main control valve is drained from port f of spool (8). In addition, the oil at port PBI is drained from port g of spool (10). 10-8STRUCTURE AND FUNCTION PPC VALVE FUNCTION OF PPC VALVE The PPC valve supplies pressure oil from the charging pump to the side face of the spool of each control valve according to the amount of travel of the control lever. This pressure oil actuates the spool. Bi Operation 1. Control lever at “hold” (Fig. 1) | ld] Ports PAs, P4, PBi and P1.are connected to drain chamber D through fine control hole {fh in valve (8). 2. Control lever operated slightly (fine contro!) (Fig. 2: When piston (2) starts to be pushed by plate pl (10), retainer (5) is pushed. Valve (8) is also pushed by spring (7) and moves down. ‘When this happens, fine control hole (f) is shut off from drain chamber D. At almost the same time it is connected to pump pres- 8 sure chamber Pr, and the pilot pressure of Po the control valve is sent through fine control PAL hole (f) to port Pa. When the pressure at port Convol vale Ps rises, valve (8) is pushed back. Fine con- trol hole (f) is shut off from pump pressure ot) chamber Pr. At almost the same time it is connected to drain chamber D, so the pres- sure at port Ps escapes to drain chamber D. Valve (8) moves up and down until the force of spring (7) is balanced with the pressure of port Pa. The position of valve (8) and body (9) (when fine control hold (f) is midway between drain chamber D and pump pressure chamber Pr) does not change until the head of vaive (8) contacts the bottom of piston (2). Therefore, spring (7) is compressed in pro- portion to the travel of the control lever, so the pressure at port Ps also rises in propor- tion to the travel of the control lever. The spool of the control valve moves to a posi- tion where the pressure of port PAt (same as pressure at port P4) and the force of the return spring of the contro! valve are bal- anced. Ke‘STRUCTURE AND FUNCTION 3. Control lever moved back from slightly oper- ated position to hold (Fine control) (Fig. 3): When plate (10) starts to be pushed back, piston (2) is pushed up by a force corre- sponding to the force of centering spring (6) and the pressure at port Ps. At the same time, fine control hole (f) of valve (8) is connected to drain chamber D, so the oil at port Pa escapes. If the pressure at port Ps drops too far, valve {(8) is pushed down by spring (7). Fine con- trol hole (f) is shut off from drain chamber D, and at almost the same time it is con- nected to pump pressure chamber Pp. The Pump pressure is supplied until the pres- sure at port PAr retums to a pressure equiv lent to the position of the lever. When the spool of the control vaive returns, the oil in drain chamber D flows in from fine control hole (f) of the valve which has not moved. The extra oil then flows through port Ps to chamber Pr. 4. Control lever operated to end of travel (Fig. 4): Plate (10) pushes piston (2) down, and pis- ton (2) forcibly pushes in valve (8). Fine control hole (f) is shut off from drain chamber D, and is connected to pump pres- sure chamber Pr. Therefore, pressure oil from the charging pump passes through fine control hole (f), and flows from port Ps to chamber PA to push the spool of the control valve. The oil returning from chamber PB: flows from port P1 through fine control hole (f) to drain chamber D. 10-10 10 8 PPC VALVE 2. | fe) a Sat D f. A ' 8 Pa PL Pe (Fenian —— ! 8 nA Gee os aa muhSTRUCTURE AND FUNCTION MAIN CONTROL VALVE PAI. PA2. Pat. PB2. Pt. From PPC valve P4 From PPC vaive P3 From PPC valve P1 From PPC valve P2 From pump 10-12 MAIN CONTROL VALVE Pie Az, 81. B2. T p2B sim04s03, To tit cylinder bottom end To lift cylinder bottom end To tit cylinder head end To iift cylinder head end Drain portMAIN CONTROL VALVE ‘STRUCTURE AND FUNCTION suv04se4 5. Valve body 1. Tilt spool return spring 2. Lift spool return spring 3. Lift spool 4. Tilt spool 6. Suction valve 7. Safety valve (with suction) 8. Main relief valve 10-13‘STRUCTURE AND FUNCTION MAIN CONTROL VALVE RELIEF VALVE Main valve Valve seat Pilot poppet Spring Adjustment screw Peers Funetion ‘The relief valve is installed to the inlet por- tion of the main control valve. If the oil goes above the set pressure, the relief valve drains the oil to the tank to set the maximum pres- sure for the work equipment circuit, and to protect the circuit. Operation + Port A is connected to the pump circuit and port C is connected to the drain circuit. The oil passes through the orifice in main vaive (1), and fills port B. Pilot poppet (3) is seated in valve seat (2). + If the pressure inside ports A and B reaches the set pressure of pilot poppet spring (4), pilot poppet (3) opens and the oil pressure at Port B escapes from port D to port C, so the pressure at port B drops. + When the pressure at port B drops, a differ- ence in pressure between ports A and B is created by the orifice of main valve (1). The main valve is pushed open and the oil at port A passes through port C, and the abnormal pressure is released to the drain circuit. + The set pressure can be changed by adjust- ing the tension of pilot poppet spring (4). To change the set pressure, remove the cap nut, loosen the locknut, then turn adjustment screw (5) to adjust the set pressure as fol- lows. TIGHTEN to INCREASE pressure LOOSEN to DECREASE pressure 10-14STRUCTURE AND FUNCTION SAFETY VALVE (WITH SUCTION) Function + The safety valve is in the tilt cylinder circuit inside the main control valve. if any abnormal pressure is generated by any shock to the cylinder when the main control valve is at the neutral position, this valve relieves the abnormal pressure to prevent damage to the cylinder. Operation Operation as safety valve Port A is connected to the cylinder circuit and port B is connected to the drain circuit. The oil pressure at port A is sent to port D from the hole in pilot piston (4). It is also sent to port C by the orifice formed from main valve (2) and pilot piston (4). Pilot piston (4) is secured to the safety valve, and the size of the cross-sectional surface (cross-sectional area) has the following rela- tionship: de > di > da > de. + If abnormal pressure is created at port A, suction valve (1) is not actuated because of relationship dz > di >, but relationship be- ‘tween port A and port C is ds > dé, so main valve (2) receives oil pressure equivalent to the difference between the areas of da and da, If the oil pressure reaches the force (set pressure) of main valve spring (3), main valve (2) is actuated, and the oil from port A flows to port B. oerens MAIN CONTROL VALVE Suction valve Main valve Main vaive spring Pilot piston Suction valve spring Valve body 10-15‘STRUCTURE AND FUNCTION MAIN CONTROL VALVE Operation as suction valve If any negative pressure is generated at port A, port D is connected with port A, so there is also negative pressure at port D. The tank pressure of port B is applied to port E, so the safety valve receives oil pressure a, which is equal to the difference in the area of dz and dh because of the tank pressure at port E. Therefore, oil pressure e moves the valve the direction of opening, and oil pressure a acts to move suction valve (1) in the direc- tion of closing. When the pressure at port A drops (and comes close to negative pressure), it be- ‘comes lower than hydraulic pressure e. The relationship becomes oil pressure e > oil pressure a + force of valve spring (5), and suction valve (1) opens to let the oil from port B flow into port A and prevent any nega- tive pressure from forming at port A. SUCTION VALVE 1. Main poppet i‘ 3 i 2. Sleeve 3. Spring LMM ya MMMM sewwore: Funetion + This vaive acts to prevent any negative pres- sure from forming in the circuit. 1 Operation a + If any negative pressure is generated at port A (boom cylinder rod end) (when a pressure lower than tank circuit port B is generated), main poppet (1) is opened because of the difference in area between di and dz, and oil flows from port B at the tank end to port A at the cylinder port end. a a2 sevots03 10-16STRUCTURE AND FUNCTION LIFT AND TILT SPOOL HOLD POSITION To hydraulic tank From pump Operation + The oil enters port A from the pump, and the maximum pressure is set by relief valve (10. + Tilt spool (1).is at the HOLD position, so the bypass circuit is open and the oil at port ‘A passes around the spool and flows to port B. Lift spool (2) is also at HOLD, so the bypass circuit is open and the oil at port B Passes around the spool, enters port C of the drain circuit, passes through the filter, and returns to the tank. 3 FLOAT F RAISE MAIN CONTROL VALVE RIGHT TILT HOLD tower WNterT TILT m7 a S | From PPC pump To hydraulic tank To hydraulic tank The oil from the PPC pump passes through check valve (13), and enters port L of the PPC valve. However, the blade control lever are at the HOLD position, so the oil returns to the hydraulic tank from PCC relief valve (12). 10-17‘STRUCTURE AND FUNCTION LIFT SPOOL AT RAISE POSITION Bont ap Se nase MAIN CONTROL VALVE RIGHT TILT HOLD LEFT TILT Mas LOWER | 4 & t Tohydraulletank From pump Operation + When the lever (3) is pulled, the oil flows from port L of the PPC vaive to port N and port S. In addition, the oil at port T passes through port M and flows to the drain cir- cuit. The oil pressure at port S pushes lift spool {2) and moves it to the RAISE position. +The oil from the pump passes through the bypass circuit of the tilt spool-and flows 10-18 From PPC pump ‘accumulator To hydraulic tank to the bypass circuit of -lift spool (2). The bypass circuit is closed by the spool, so the cil pushes open check valve (10). The oil flows from port H to port I, and fiows to the oylinder rod end. + Atthe same time, the oil at the cylinder bot- ton enters drain port © from port K and returns to the tank. Therefore, the blade rises.STRUCTURE AND FUNCTION LIFT SPOOL AT LOWER POSITION MAIN CONTROL VALVE RIGHT TILT Deco valy nowy Lowen SUEFT TILT elk hc g From PPC pum accumulator A: a & e Operation + When the lever (3) is pushed, the oil flows from port L of the PPC valve to port M and port T. In addition, the oil at port S flows to the drain circuit. ‘The oil pressure at port T pushes |ift spool (2) and moves it to the LOWER position. + The oil from the pump passes through the bypass circuit of the tilt spool and flows to the bypass circuit of lift spool (2). The To hydraulic tank bypass circuit is closed by the spool, so the oil pushes open check vaive (10). The flows from port J to port K, and flows to the cylinder bottom. + At the same time, the oil at the cylinder rod end enters drain port C from port | and returns to the tank. Therefore, the blade goes down, 10-19STRUCTURE AND FUNCTION LIFT SPOOL AT FLOAT POSITION Dec FLOAT FR Sanase val MAIN CONTROL VALVE RiguT TILT From pump To hydraulic tank Operation When the lever (3) is pushed to the FLOAT position, the PPC vaive spool moves beyond the LOWER position to the FLOAT position. The pressure oil at port L flows to port M, and at the same time, it also flows to port T. In addition, the pressurized oil at port $ flows to port N. + The pressurized oil at port T pushes tift spool (2) to the FLOAT position. 10-20 e From PPC pump accumulator It ‘To hydraulic tank Therefore, the oil at the cylinder bottom flows from port J to port C, and flows to the drain circuit. The oil at the cylinder rod end flows from port I to port C, and then flows to the drain circuit. Therefore, the blade is set to the FLOAT condition.STRUCTURE AND FUNCTION MAIN CONTROL VALVE TILT SPOOL AT RIGHT TILT POSITION RIGHT TiLT oe RAISE Be mi t iH From PPC pump: iW Le & a % @ | a Operation moves tilt spool (1) to RIGHT TILT position So the blade is tilted to right. +The bypass circuit is clased by tilt spool (1), so the oi! from port A pushes open check valve (9). The oi! from check valve (8) flows from port F to port G and then flows to the botton of LH tilt cylinder 10-21‘STRUCTURE AND FUNCTION TILT SPOOL AT LEFT TILT POSITION 0 LEFT TILT Dec nak MAIN CONTROL VALVE RIGHT TILT noarep Sorase aN To hydraulic tank Operation “When the blade control lever (3) is pushed to LEFT TILT position, the pressure oi! at port L of the PPC valve flows from port P to port R In addition, the oi! at port V flows to the drain circuit, The pressure oi! at port R moves tilt spool! (1) to LEFT TILT position +The bypass circuit is closed by tilt spool (1), so the oi! from port A pushes open check valve (8). The oi! from check valve (9) flows from port D to port E and then flows to the rod end of LH. tilt cylinder, 10-22 From pump t From PPC pump accumulator To hydraulic tank “Therefore, the oi! at the LH cylinder bottom flows from port G to drain port C, and returns to tank. The circuit to RH the deco valve So the blade is tilted to left tilt cylinder is closed by‘STRUCTURE AND FUNCTION WORK EQUIPMENT LINKAGE WORK EQUIPMENT LINKAGE 1. BLADE 2. UFT CYLINDER 3. TILT CYLINDER 10-24STRUCTURE AND FUNCTION WORK EQUIPMENT LINKAGE 10-25‘STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM MACHINE MONITOR SYSTEM Alternator terminal Strating aator terminal & Battery waintenance novitor Parking Neviral Travel soe ear 1LEneine iter teneratire 2 Ait cleaner sloaa ine sov07336 1. Fuel level 5. Engine oil level 2. Engine water temperature 6. Brake oil prossure 3. Torque converter oil temperature 7. Engine oil pressure 4, Engine water temperature 8 Aircleaner clogging OUTLINE + The machine monitor system uses the sen- + There are also various switches built into the sors and other devices installed to various monitor panel which function to operate the parts of the machine to observe the condition machine. of the machine. It processes this information : swiftly and displays it on the monitor panel ~The main monitor uses the network wiring to to inform the operator of the condition of the, send signals to the controller, and functions machine. to display the following information, + The machine monitor system consists of the @ Shift indicator: 1st - 4th, N main monitor, maintenance monitor, sensors, @ HOLD. switches, relays, alarm buzzer, and power @Failure action code, failure code, time source, elapsed since failure (failure data display + The displays can be broadly divided into the mode) following: Cautions displayed on the moni- tors (abnormalities in the machine where an alarm is given) and normal conditions which are always displayed on the instrument panel (pilot lamps-and readings for the gauges, speedometer, and service meter). 10-26STRUCTURE AND FUNCTION MAIN MONITOR MAIN MONITOR 1. Check lamp 2. Caution tamp 3. Caution items 3A. Emergency steering actuated (option) 4, Pilotitems 4A. Turn signal (left) 48. Turn signal (right) 4C. High beam 4D. Shift indicator 4E. Speedometer OUTLINE + The main motor has a display function for the speedometer and other gauges and a switch- 4F. Shift hold 4G. Parking brake 4H. Emergency steering normal (option) 4. Preheating 4J. Failure action code ‘Switches 5A. Working lamp (front) switch 5B. Working lamp (rear) switch 5C. Transmission cut-off switch 5D. Auto shift, manual selector switch installed internally, and this processes the sig- nals from the sensors and outputs the display. ing function to control the electric compo- + _A liquid crystal display and LEDs are used for the display. The switches are embossed sheet nents and controllers. + There is one CPU (Central Processing Unit) switches. 10-27‘STRUCTURE AND FUNCTION MAIN MONITOR DISPLAY FUNCTION MAIN MONITOR Display Qiel2y | symbol Display item Display range Display method When there is Display flashes (for details, see check check abnormality display on | MAINTENANCE MONITOR maintenance monitor | DISPLAY FUNCTION). LS | pga 9 | nen eres Display ashes Parking brake actuated, eution Parking brake actua Display flashes anc butte feutral sounds Caution i shes [buzzer may When there ig, alse abun for detata see abnormality display on | RAINTENANCE MONITOR wintenance monitor | DISPLAY FUNCTION) ED) | Hibeam ‘When operated Display lights up “Turn signal : a | (lef. right) When operated Display lights up Display ghisue, ng broke oe raze sounds when parking Parting bros | When operated Bate Saenger sowezs4e eae Pitot ge_| Emergency steering | When normal (oil is 1 normal flowing in hydraulic | Display lights up circuit Tights up Lighting up time changes fo engine water Preheating When preheating temperature wien starting Switch is turned ON (for details, see PREHEATING OUTPUT. FUNCTION) Crete) | shitt nota Display lights up so¥02341 Digital display (display switches Speedo- Travel speed 0-99 kmh between tachometer and meter speedometer) Shite A Shift indicator 1-4N Digital display When controller detects | failure and action by. | Digital display Operator is needed Buzzer sounds BEB s0n02078) Failure action code CALL is displayed. or CALL AND ECO, {action code) are displayed in turn (For details of the travel data display mode, see TROUBLE DATA DISPLAY MODE) 10-28STRUCTURE AND FUNCTION MAIN MONITOR SWITCH FUNCTION MAIN MONITOR tem Function Actuation Front working lamp lights Lights u Front working lamp light Working tamp | orgoes out each time switch is °. emia {front) ressed when side lamps are ighted up Goes out Front working lamp goes out Roar working amp tights yp or | Liahts up Rear working lamp lights up Working lamp | goes out each time switch fe trean Bressed when side amps are Fighted up Goes out Rear working lamp goes out ie tiotts up Cutoff function actuated Transmission cutoff function is en actuated or stopped each time out-of switch is pressed Goes out Cutoff function stopped ‘Auto shift mode switches to | tights up Manual mode Manuat Imada mode wien switch cases Goes out Auto shift inode. 10-29STRUCTURE AND FUNCTION MAIN MONITOR PREHEATING OUTPUT FUNCTION Item Operation OR Power SOUFCE ope _| on Display or a Electrical intake | 9.44, air heater or Display time:T (sec) Gutout tine:T (sec) =30 0 = Engine water temperature (0) sovo2343 10-30STRUCTURE AND FUNCTION MAIN MONITOR TROUBLE DATA DISPLAY MODE (when optional controller are installed) tem ‘Switch operation Actuation Method of switching to ‘rouble data display mode 1@ stopped and starting switch turned ON, press 2nd switch from top on left side of main monitor (switch below emergency steering display) and working lamp {front) switch simultaneously for at least § seconds. All switch displays (LEDs) go out, and failure code is displayed on speedometer display and time elapsed since failure is displayed on failure action code display. (1) Failure code is a two-digit display given in numbers or letters. The display for the failure now ‘occurring flashes and the display for past failures lights up. If there is no failure, CC is displayed (000 is displayed for time elapsed since failure) (2) The time elapsed since failure is displayed as a three-digit number to show how long ago the failure occurred (the oldest failure time is displayed. Any time greater than 999H is displayed as 999H). (3) A maximum of 9 items are stored in memory for the failure code. Method of sending failure code Failure code and time elapsed since failure change to next item. Clearing failure code Press working lamp (rear) switch for at least 2 seconds, sowoa2s Failure code and time elapsed since failure being displayéd are cleared. Failure code for problem now occurring {flashing display) cannot be cleared. Resetting from travel data display mode Press 2nd switch from top on left side of main monitor (switch below ‘emergency steering display) and working lamp (front) switch simultaneously for at least 5 seconds, or start the engine. Changes to normal display 10-31‘STRUCTURE AND FUNCTION MAINTENANCE MONITOR MAINTENANCE MONITOR 1. Check items (Checks 3. Gauge items 4B. Service meter RUN before starting) 3A. Fuel level pilot famp 1A. Engine water level 3B. Engine water tempera- 5. Monitor module. 1B. Engine oil level ture 2. Caution items (warning 3C. Torque converter oil items) temperature 2A. Engine oil pressure 4. Service meter 2B. Battery charge 4A. Service meter numeric 2C. Brake oil pressure display 2D. Air cleaner (1A. Engine water level) Outline + The maintenance monitor has a display func- tion for the caution items and gauges, and switch functions to control the work equip- ment controller. + The maintenance monitor consists of the monitor module, service metet: case. and ‘other mechanisms. 10-32 The monitor module has a built-in CPU (Cen- tral Processing Unit). It processes the signal from the sensors, and carries out the dis- play and output. A liquid crystal display and LEDs are used for the display portions.STRUCTURE AND FUNCTION MAINTENANCE MONITOR DISPLAY FUNCTION MAINTENANCE MONITOR Display mi Dis it splay range Diseley | symbol isplay item Display rang play method Engine water level Below low level | Displays when engine is stopped and oO starting switch is ON Check Display when normal: OFF Engine oil level Below low level Display when abnormal: Flashes 40) CHECK lamp flashes Engine water level Below low level Displays when engine is running ce) Display when normal: OFF Display whan abnormal: Flashes We | Enaine oil pressure Below specified ‘CAUTION tamp flashes, oO pressure Buzzer sounds Brake oil pressure Below specified 2 pressure Gil | Fess weer tose Above zc Buzzer sounds if above 105°C Torque converter oi! | Above 120°C Buzzer sounds if above 130°C Caution temperature Fuel level Below low level | Displays when engine is running Display when normal: OFF Display when abnormal: Flashes ‘CAUTION lamp flashes Battery charge When charge is | Displays when engine is running & defective Display when normal: OFF Display when abnormal: Flashes Air cleaner ‘Above specified CHECK lamp flashes 5 negative pressure Service meter (0 9999.9h ‘Actuated when charge is normal iz ‘Advances 1 for every hour Service meter Service meter indicator Lights up when service motor is © running Fuel level ‘Al lamps light up below applicable wwe nan | Seven +BY Flashes when level is 1 ‘ied Ger Engine water temperature ‘One place lights up to show Gauges applicabie level a Flashes when level is 6 or 7 Torque converter oil One place lights up to show temperature applicable level Oo Flashes when level is 6 or 7 10-33‘STRUCTURE AND FUNCTION ALL-RANGE ELECTRONIC CONTROL AUTOM. SION SYSTEM OUTLINE OF SYSTEM Auto shift [+ All-range ECMV control |~ Hold function |— Kickdown function '— Safety function Manual shift Kickdown function Engine selection function (Komatsu/Cummins) Self-diagnostic function |- Condition display (output, failure code) ALL-RANGE ELECTRONIC Co! AUTOMATIC TRANSMISSION SYST ATIC TRANSMIS- |__ Troubleshooting (detection of system abnormality, system disconnection, short circuit) Communications function + The all-range electronic control automatic transmission system consists of the transmis sion controller, directional and speed levers, engine speed sensor, speed sensor and all- speed-range ECMV (transmission clutch modulation valve). + The transmission controller controls the shift- ing to the appropriate speed range according to the lever position and travel speed signal. + To reduce shock when shifting gear (engag- ing the clutch), all-speed-range ECMV carries out modulation control. + To improve durability, there is a safety func- tion which prevents the machine from mov- ing suddenly when the engine is started, and a transmission protection function which pro- tects the clutch when the direction of travel is changed. The self-diagnostic function always observes the input and output condition, and displays the output condition on the two 7-segment LED displays on the transmission controller. There is also a failure detection function, and if any abnormality occurs, it displays a failure ‘code. Depending on the condition, it also dis- plays a failure action code on the main moni- tor and flashes the caution lamp to improve safety. The transmission controller has a communi- cations function, and it sends the speed range (N, 1st - 4th) data to the main monitor, which displays the speed range. 10-35‘STRUCTURE AND FUNCTION SYSTEM STRUCTURE DIAGRAM ALL-RANGE ELECTRONIC CONTROL AUTOMATIC TRANSMISSION SYSTEM Direction switch y on Range switch | Feolenoid R solenoid ‘Manual switch | Fill switch (F, R, 1, 2,3, 4) Transmission cut-off switch o_,| Af 7st solenoid > KDS (kickdown switch) >| AF and solenoid D Hold ewiteh 5 A__.f 3rd scienoia P 3 ia Engine speed | § [ath solenoid Z| Travel speed P 5 As. Kickcown signal D 3 Neutralizer relay signal pe. 3 : Engine speed fe2—j § | S++[shittincicator i & |S ef Hota pilot amp : Leo s ; Failure code 4 | ——»[ Abnormality display buzzer output s Transmission F, N, Rewitch ee |-——»[ Main monitor F, No . |< 5 Tire compensation Backup lamp rela ke eere rey }+-S [Model selection D }+-2=I Damper function selection [2 +f Fi (cut-off output i ° ‘Transmission oll temperature rrr Engine select >{N output 10-36 A: Analog signal D: Digital signal‘STRUCTURE AND FUNCTION FUNCTION 1, ‘Auto-shift function Shifting the transmission up or down is car- ried out when the engine speed is above 1450 rpm. Shifting is decided by signals from the directional lever, speed lever, and travel speed sensor according to [Table 1 Automatic gear shift change point table] recorded in the memory of the transmission controll 1) Speed lever (1st - 4th) This controls the maximum speed range {available speed range) for automatic gear shifting. Example: Speed lever at 4th: 2nd - 4th Speed lever at 2nd: 2nd only 2), Directional lever N position To prevent the vehicle from moving acci- dentally, when the lever is at the neutral position, only the 2nd clutch is engaged. 3) Directional lever F position When the directional lever is operated from N to F, the transmission turns ON the F and 2nd ECMVs (F2). (Automatic start in 2nd) a). Shift up (when speed lever is at 4th) When the accelerator pedal is de- pressed to increase the engine speed and the travel speed rises, when the travel speed reaches approx. 9.3 km/ h, the ECMV 3rd is turned ON, and at the same time, 2nd is turned OFF. {Shifting to F3) Wher the travel speed rises further to approx. 17.6 km/h, the ECMV 4th is turned ON and at the same time, 3rd is turned OFF. (Shift to F4) b) Shift down (speed lever at 4th) ‘When traveling in 4th, if the accelera- tor pedal is let back, and the travel speed comes down to approx. 15.6 krmvh, the ECMV 3rd is turned ON and 4th is turned OFF. (Shift to F3) When the travel speed goes down to approx. 9.8 km/h, the ECMV 2nd is turned ON and 3rd is turned OFF. (Switches to F2) irectional lever R position Automatic gear shifting is carried out ac- cording to the travel speed between 2nd and 4th speeds (when the speed lever is at 4th) in the same way as when the speed lever is at the F position. 5) Skip shift When coasting (in engine speed OFF mode) in 3rd or 4th speed with the accel- 4) ALL-RANGE ELECTRONIC CONTR AUTOMATIC TRANSMISSION SYSTEM erator pedal depressed, if the travel speed is less than 8 km/h, the gear shifts down to 2nd to make it easier to accelerate. if the travel speed is more than 8 km/h, the speed range is maintained, and when the engine speed goes above 1450 rpm, the gear is shifted to a range that matches the travel speed. 6) Gear shift prevention interval To prevent shift hunting after shifting gear, atime interval is set to maintain the speed range. The gear shift prevention interval differs according to the’shift pattern. For details, see [Table 1 Automatic gear shift change point table). Modulation control The modulation control acts to reduce the shock when shifting gear (when engaging the clutch). It uses the data for the engine speed, transmission oil temperature, and gear shift pattern to control the clutch coil pressure (in- cluding the characteristics when starting) to ‘match the condition of the hydraulic circuit to control all speed ranges to the optimum according to the data in the transmission modulation table stored in the transmission controller memory. In addition, to reduce the torque cut, it carries out modulation control ‘ofthe ECMV at the side which is switched OFF also. The transmission modulation data table is set for each transmission oil temperature. In addition, it has a learning function (trans- mission clutch piston data) to prevent any ab- normal time lag when shifting gear. HOLD function ‘When the HOLD switch is pressed, the speed range is held at the optimum speed range, and even if the travel speed goes down, the transmission does not shift down. However, When switching between forward and reverse, the transmission normally shifts down to 2nd according to the travel speed, and then shifts up to the HOLD shift range according to the travel speed and gear shifting conditions. (This prevents any unnecessary shift down when leveling ground or when traveling downhill.) 10-37‘STRUCTURE AND FUNCTION 4. Kickdown function When the operator turns the kickdown switch ON, it overrides the auto shift and switches down forcibly to 1st if the conditions (speed range, travel speed) in (Table 1 Automatic gear shift change point table, 5. Kickdown] are ful- filled. In addition, the transmission controller out- puts the cut-off signal to the electronic gover- or controller during kickdown (‘st output). The conditions for canceling this are if the travel speed rises or if the direction is shifted between forward and reverse. In these con- ditions, the gear is shifted to 2nd. This func- tion is also effective when holding the speed range (hold, engine speed OFF mode). 5. Travel mode Manual mode Itis possible to switch between auto and manual shift. When using the manual mode, the gear is shifted according to the operation of the speed lever. When traveling in F2, it also possible to use the kickdown func- tion. 6. Safety function 1) Neutral safety When the engine is started, if the direc- tional lever is at any position other than N, the transmission controller keeps the transmission in neutral and prevents the machine from moving. If the N signal is input after the engine is started, the neu- tral safety is canceled. 10-38 ALL-RANGE ELECTRONIC CONTROL AUTOMATIC TRANSMISSION SYSTEM 2) Speed lever priority It is possible to shift down immediately by operating the speed lever, so the en- gine can be used as a brake when travel- ing downhill. 3) Transmission protection When traveling in 3rd or 4th speed, the travel speed is controlled and a warning buzzer sounds to protect the transmission when shifting between forward and re- verse. a) Speed range controt When the speed range control and travel speed fulfill the conditions for range |, the transmission shifts down to 2nd. When the speed range control and travel speed fulfill the conditions for range ll, the speed range is main- tained and the transmission shifts down to 2nd according to the decel- eration. (For details, see Fig. 1 F-R selection gear shift pattern, Table 1 Automatic gear shift change point table, 7. F-R selection.) b) Alarm buzzer When the speed range control and travel speed fulfill the conditions for range lll, the alarm buzzer sounds to warn the operator. (If the engine speed is above 1700 rpm and the travel speed is above 13 km/h, or the travel speed is above 14 kmvh) (See Fig. 2 F-R selection alarm buzzer range). 4). Manual shift Ifthe travel speed sensor is abnormal and itis impossible to detect the travel speed data, the transmission is set to manual (shift) mode.ALL-RANGE ELECTRONIC CONTI ‘STRUCTURE AND FUNCTION AUTOMATIC TRANSMISSION SYSTEM Table 1 Automatic gear shift change point table Item ‘Speed Travel speed Gear shift range (keayhy prevention interval 1. Basie shift change 132 | 5.1(53)orabove 2 2-3 | 87(9.2)or above 334 | 1650rabove 1 433 | Less than 145 1 332 | Less than 9.2 (8.7) 2 2. Engine speed 452 Less than 1.0 0 (less than 1450 eee ee 332 Less than 1.0 0 3. Engine speed 432 Less than 8.0 2 (less than 1450 rpm > more than 1450 rpm) 332 Less than 8.0 2 4, Shift up when HOLD is ON 132 54 0 233 87 0 334 165 ° 5. Shift down when kickdown is ON 21 Whole range 5 331 |. Less than 120 5 451 [Less than 12.0 5 6. FR selection (range |) 432 | Note) (Fo)NOR 332 2 (Ro)NSF 132 7. FR selection (range Il) Note 2) (F3)NOR a4 16.5 or above 2 (R>)NOF 3 _| Less than 145-165 8. FR selection 34 16.5 or above FINE +3 | Less than8.7-165 ° RoN5R 32 Less than 8.7 Note 1: When the engine speed is less than 1900 rpm and the travel speed is less than 16 km/h, or the travel speed is less than 13 km/h. Note 2: When the travel speed is 1900 rpm or above and the travel speed is 13 km/h or above, or the travel speed is 16 km/h or above, the speed range is maintained and the transmission shifts down to 2nd according to the deceleration. seed (roe) Envine aveed (roel a 2500 | 2000 ® Wl ® oy 1500 1000 500 ° ° o 58 10 18 2 25 30 oS 10 18 20 25 30 Travel soeed Gh) Travel soeed tea/t) Fis. 1 FR selection sear shift sattecn sovezses Fis. 2 FR selection alarm buzzer range sovo2348 10-39STRUCTURE AND FUNCTION 7. Self-diagnostic function The transmission controller always observes the input and output signals.of the automatic gear shifting system. It carries out self dia nosis and displays the results on the LEDs of the transmission controller. In addition, it sends the following data to the main moni- tor. ALL-RANGE ELECTRONIC CONTROL AUTOMATIC TRANSMISSION SYSTEM 1) Normal display: Transmission controller LEDs display output speed range. 2) Failure code display: fan abnormality is detected, the na- ture of the failure is displayed as a code. For details of the failure code, see Table 2 Failure code table. Table 2 Failure code table nee a System Main monitor Disconnection| Action code 10_| Backup lamp relay ° ° None 11_[ None = = 5 12_| FECMV Sol. ° ° CALL 13_ | RECMV Sol. ° ° CALL 14_| 1st ECMV Sol. 3 ° CALL 15_| 2nd ECMV Sol. ° ° CALL 16 _| 3rd ECMV Sol. ° ° CALL 17_| 4th ECMV Sol. ° ° CALL 18_[ None. = = = 19_| Joystick direction switch ° ° E00 20 [Direction signal ° ° CALL 21__[Range switch signal ° © None 22_| Travel speed sensor a ° E00 23_| Engine speed sensor ° ° E00 24_ [Abnormality in memory (EEPROM) = = None 25__| Transmission oil temperature sensor ° x E01 26_[ FECMV All switch ° x CALL 27_ | RECMV fill switch ° x CALL 28__[ 1st ECMV fill switch ° x CALL 29. | 2nd ECMV fill switch ° x CALL 30_ | 3rd ECMV fill switch ° x CALL 31_[ 4th ECM fill switch ° x CALL 32_| For RECMV fill switch x ° E00 33_[ 1st, 2nd, 3rd, or 4th ECMY fill switch x ° E00) 10-40‘STRUCTURE AND FUNCTION 8. Communications function The transmission controller is equipped with a communications function using S-NET. It always maintains communications with the main monitor, and when the engine is started, it receives model, travel damper availability, and tire compensation data. ‘When any abnormality occurs, it displays an action code on the main monitor according to the condition of the problem to warn the operator in order to increase safety. The failure code can recognize the codes re- corded in the main monitor memory using the main monitor problem history mode. For details of operating the main monitor, see the section on the main monitor. TRANSMISSION CONTROLLER POWER SOURCE + - When the starting switch is turned ON and the supply voltage is more than 20V, and +20V or more is supplied tothe transmission con- troller solenoid power source input, itis pos- sible to drive each solenoid valve. + Ifthe supply voltage is less than 19Y, all out- puts are turned OFF and the solenoids can- not carry out control (travel is impossible). INPUT SIGNALS 1. Directional lever (F, N, R) signal This signal is a +24V/OPEN digital signal, and when it is normal, one of FN, or R signals (+24V) is input. 2. Speed lever (1st - 4th) signal This signal is a +24V/OPEN digital signal and +#24V is input for the signal for the lever posi- tion. 3. Kickdown switch This signal is a +24V/OPEN digital signal and +24V is input when the kickdown switch on the work equipment control lever is pressed. ‘The switch operation is judged from the +24V starting signal from the OPEN condition at that point. 10. ALL-RANGE ELECTRONIC CONTROL AUTOMATIC TRANSMISSION SYSTEM FORWARD switch This signal is a +24V/OPEN digital signal and +24V is input when the HOLD switch on the work equipment control lever is pressed. The switch operation is judged from the +24V starting signal from the OPEN condition at that point. Neutralizer relay signal This signal is a +24V/OPEN digital signal and +24V is input when the parking brake switch is pressed. ‘When signal is OPEN, the transmission con- troller maintains the neutral condition. Transmission cut-off signal This signal is a GND/OPEN digital signal, and when the transmission cut-off switch is oper- ated (using the left brake), it changes to GND. When itis actuated, the transmission control- er changes to the neutral output condition, and when it is restored, it sets to a suitable speed range for the travel speed at that point. Manual mode signal This signal is a GND/OPEN digital signal when the manual mode switch is ON, GND is input. Fill switch (F, R, 1st - 4th signals) This signal is a GND/OPEN digital signal, and is installed to each ECMV. The switch is oper- ated by oil pressure. ‘When the ECMV is on, GND is input. Engine selection signal This signal is a GND/OPEN digital signal, and when the engine is started, the type of engine ‘mounted is judged from this signal. (The speed conversion data is different) Table 3 Engine selection signal table Input signal | Engine | Speed conver- sion data OPEN | Komatsu 6 GND — | Cummins 18 Memory clear signal This signal is a GND/OPEN digital signal. Itis normally OPEN. When clearing the memory, start the engine, then input OPEN->GND OPEN signals. 10-41‘STRUCTURE AND FUNCTION 11. Engine speed sensor signal This signal is a pulse signal, and it converts the pulses from the electromagnetic pickup sensor to rotation speed for control. When the engine speed is 1450 rpm or above, itis called the engine speed ON mode, and when the speed is less than 1450 rpm, it is called the engine speed OFF mode. + Komatsu engine: Speed P (rpm) = Input frequency (Hz) x 60/6 + Cummins engine: Speed P (rpm) = Input frequency (Hz) x 60/118 12. Travel speed sensor signal This signal is a pulse signal, and it converts the pulses from the electromagnetic pickup sensor to rotation speed for control. To convert to the travel speed, the tire com- pensation data (communications data from the main monitor) are added. In addition, the acceleration is also calculated to judge the travel speed for gear shifting. + Speed P (rpm) = Input frequency (H2) x 60/ 59 + Travel speed V (km/h) = Speed P (rpm) {101.6 x tire compensation value k) ‘or Travel speed V (km/h) = Input frequency (Hiz)(99.3 x tire compensation value k) 13. Transmission oil temperature sensor signal This signal is an analog signal and converts 0 =5V inside the controller to temperature. This is used for selecting the modulation table when shifting gear. 14. Communications signal (S-NET) This receives the following data set in the main monitor and is used for control. 1) Model selection It selects the automatic gear shift change point data table for each model to use for shifting gear. 2) Tire compensation data This adds the compensation value (cov- ering a range from 0.86 to 1.14) to the speed data from the travel speed sensor to obtain an accurate travel speed. 10-42 ALL-RANGE ELECTRONIC CONTROL AUTOMATIC TRANSMISSION SYSTEM OUTPUT SIGNALS 1. Transmission modulation valve (ECMV command current) This signal is an electrical output (0 - 1A). There are six types of ECMV: R and F for rection, and ‘st, 2nd, 3rd, and 4th for each speed range. This valve is a pressure control valve and converts to a pressure matching the. value of the current flowing to the solenoid. Therefore, it controls the oil pressure for the clutch selected for each speed range and con- trols the engagement of each independent clutch. In addition, only the 2nd clutch is ac- tuated when the transmission is at neutral. Table 4 Combination of speed ranges and ECMV ECM] F | R | ist ]and] ard | ath si range FT o o 2 ° S iz ° 2 Fa ° o N Ri oto R2, Oo 3 RS, oO oO Ra ° o O:0N 2. Backup lamp relay signal This signal is a +24V digital (ON/OFF) output. It is actuated when the directional lever is placed at R and lights up the backup lamp and caution lamp. . FI (cut-off) signal . This signal is a +24V digital (ON/OFF) output. ‘This signal is output when the kickdown is op- erated and sets the machine to F1. |. Engine speed signal This outputs a signal at the same cycle as the engine speed sensor signal input to the trans- mission controller.‘STRUCTURE AND FUNCTION §. Communications signal (main monitor display data) For details of the display position and opera- tion of the main monitor, see the section on the main monitor. 1) Speed range display 1st speed range output: [1] 2nd speed range output: [2] 3rd speed range output: [3] 4th speed range output: [4] Neutral: (NI 2) HOLD display The pilot display is given on the main ‘monitor when the HOLD function is ON. LED DISPLAY + When the engine is started, the display goes first to 1. “Program quality display mode”, and next to 2. “Output speed range display mode”. However, if any abnormality is de- tected, it goes immediately to the trouble- shooting mode. 1. Program quality display mode When the power source ison, itswitches once every second, 7.80 23 15 A ALL-RANGE ELECTRONIC CONTR AUTOMATIC TRANSMISSION SYSTEM 1, 0, 0, ~ To display mode 2 >> —| 2. Output speed range display mode LED display X. Y. (Both dots are out) X: Direction ECMV drive condition FORWARD [F]: F, REVERSE (RI: A, Neutral: 0 Y: Speed range ECMV drive condition 1-4 Example Display Content "0,2 Neutral, 2nd “FA FORWARD, ist. "AL2." REVERSE, 2nd "BF, Neutral safety condition 0, 2, F.2, 4 To display mode 3 if failure is detected or Gear shift (F2 speed range displayed continuously) 10-43ALL-RANGE ELECTRONIC CONTR STRUCTURE AND FUNCTION AUTOMATIC TRANSMISSION SYSTEM 3, Troubleshooting display mode (currently existing failure) Acycle of [E12 sec)], [Code (2sec)]is repeated. 1) When there is one abnormal item E.- | 2,3, Repeated 2) When there is two abnormal item EB 2.3, 1,8, — Repeated 10-44STRUCTURE AND FUNCTION TRANSMISSION CONTROLLER TRANSMISSION CONTROLLER a [2 se ot ae or t ae =] Fas ext ches 10-46STRUCTURE AND FUNCTION TRANSMISSION CONTROLLER CONNECTOR SIGNALS enct eNc3a cuca 1 [doy stick N output = TE 2 [Buzzer signal 2[— 2 | Engine speed 3 | Relist sol 3[— 3|= 4 [Engine speed output a[— a= 3 | Low pressure sol. 5[— 5[— 6 [GND 6 | Presue sensor power supe 20v) 6 | — 7 [Power supply (280) 7 | Potentio power supply T= 3 | Fr output 3[— @|— 9 [ECSS sol. 3[— 9 | GND ifor rotate sensor 70 | High pressure sol. 10 | Engine select 70 |= 1 [ Back lamp relay 11 [Transmission oll temp. sensor 11 | — 72 [GNO [= [= 73 | Power supply (24) l= wie enc2 18}— ones “sot power suppiy waa) te pA Mc memae senso —1 [gn@ trou 2 [ECMV 3) aT 2 | Speed al we AD ties “19 [Hoy sek OWOFF switch "Ta Too a 720 [Pressure switch “Slick down awich 7S Ta [TIM cutoff switeh snwro cnc3e 7 [doy stick N INC) “es lecuvnte 1 [Pressure switch 8 8 | Joy stick F (NC) ~s [ecw 1a 2 | Fill switch F & | Joy stick A (NC) Fo lecuv2t 3 | Fill switch 4 10 | GND (for puls) at [P eno 4 [ Network (9) 71 [Fil switch 3 "12 [ Sol. power supply (+24V) 5 | Direction F 12 | Fill switch 4 eleomvso 6 | Direction R 13 | Hold switch al— 7 | Range switch 1 14 | Manual switch ‘elemvan 3 | Range switch 3 1 | Joy stick N «NOD el 9 [ ECSS switch 16 | Joy stick F (NOD Tlemwro 70 [Fi switeh R 17 | Joy stick R (NOD ail comes “Hr Frit switen 2 elect 2 [Network =) Jolecwv2 CL Diation ap GND 4 | Neutralizer relay a (15 | Range switch 2 “6 [ Range switch 4 10-47STRUCTURE AND FUNCTION ELECTRIC TRANSMISSION CONTROL ELECTRIC TRANSMISSION CONTROL 1. Transmission cut-off selector switch 8. Fuse boxes 2. Parking brake switch 9. Transmission controller 3. Directional lever 10. Transmission control valve 4, Speed lever 11. Speed sensor 8. Kick-down switch 12. Transmission cut-off switch 6 Maintenance monitor 13. Brake valve (left) 7. Relays 14. Brake valve (right) Funetion | Selection of FR, and N postions Using directional ever 2 [ Selection of speed range Using speed lever When traveling in FZ, is possible to ahi down fo Tat using this Swhch 2. | Kick-down switeh without using the speed lover If directional lever is operated to R or N, Speed fange automaticaly returned to 2nd. [Transmission evt-off function “Transmission is shifted to neutral when left brake Is operated Tt is possible to select whether to actuate oF not actuate the. ‘tansmission cutoff function, In this Way, It is possible to obtain the 5 | Transmission cutoff selector function | same of greater ease of operation ae on conventional loaders with # Tefe brake when carrying out scooping work oF wien loading or unloading the machine from 2 taller. To prevent seizure of the parking brake when Gaveling wih the paring 6 | Neutratizer brake applieg, the tranemesion ie shifted to neutral when the parking brake is applied. TF the directional lever ie fat at the N postion, the engine will not art 7 | Neutrat safety function Wwhon the starting switch 's turned. This prevents the machine fore Starting suddenly. (Por details, see STARTING GRCUIT) Ea Se ‘When traveling in reverse, the backup lamp lights up and the backu 8 | Werring fu hom sounds 8 warn peogie inthe atean P 10-48STRUCTURE AND FUNCTION COMBINATION SWITCH Outiine + The directional lever has three positions and the speed lever switch has four positions. As an individual part, the switch does not have a detent mechanism; the detent mechanism. is in the combination switch. Each switch is positioned by two pins, and is secured to the General locations, function ELECTRIC TRANSMISSION CONTROL body by three screws. When each lever is operated to the desired position, the switch, which is interconnected by a shaft, acts to. allow electric current to flow to that circuit only. Directional lever switch Switches between F, R and N 2 | Speed lever switch Selects speed range 3 lever stopper : oeen ened operations. Stopper used to prevent speed lever from entering 3rd or 4th during 4 | Turn signal indicators Direction indicator lamps used when turning left or right Tum signal indicator lever automatically returns to central position Hf cancel 4 i iceelcnaee after machines turns left or right Lamp switch ‘Switches on clearance lamp, head lamp, parking lamp, ete. Dimmer switch Selects high beam for travel and low beam for passing 8 | Hazard switch L same time Makes both left and right turn signal indicator lamps flash at the 9 | Emergency flashing pilot lamp _| Flashes at the same time as the iergency flashing lamp flashes 30 | Parking brake switch ‘Applies or releases parking brake 10-49STRUCTURE AND FUNCTION Operation + Directional lever (1) and_ shaft (2) of the speed lever of the combination switch form one unit with magnet (3), and magnet {3) also moves together with lever (1). + Control switch (5) with built-in hole IC (4) is installed at the bottom of magnet (3), and hole IC (4) is positioned on the board to match each position. + When directional lever (1) is operated to the F position, magnet (3) is immediately above hole IC (4) for the F position of the control switch. The magnatism from magnet (3) passes through the gap and case (6), and magnetism is applied to hole IC (4). + When this happens, hole IC (4) is inside a magnetism detection circuit, so it detects the magnetism of magnet (3) and sends the F position signal to the electric current ampli- fication circuit. In the electric current ampli- fication circuit, a signal is output to actuate the transmission. 10-50 ELECTRIC TRANSMISSION CONTROL‘STRUCTURE AND FUNCTION KICK-DOWN, HOLD SWITCH KICK-DOWN SWITCH OPERATION + The kick-down (shifting down from 2nd — 1st) is actuated only when traveling in F2. + When traveling in F2, if it is desired to shift down to 1st without operating the speed le- ver, operate the kick-down switch on the blade control lever to ON to shift down to FI. + After this, even if the kick-down switch is pressed, the transmission is kept at F1 Cancellation (or not actuated) When directional lever is at N When directional lever is at R When speed lever is not at 2nd When starting switch is OFF KICK-DOWN, HOLD SWITCH 1. Kick-down switch 2. Hold switch HOLD SWITCH The hold switch is installed to the blade control lever, and when the hold switch is pressed, the speed range displayed on the main monitor transmission indicator is held. Press the hold switch again to cancel. 10-5120 TESTING AND ADJUSTING Table of judgement standard value Tool list for testing and adjusting-~ Measuring PITCH, TILT and LIFT control levers Adjusting PPC valve linkage~ Testing and adjusting PPC oil pressure: Testing and adjusting work equipment hydraulic pressure’ work equipment speed: hydraulic drift of work equipment cylinder: Connector types and mounting locations H-1 Blade does not rise cs H+2 Blade moves slowle or does not have sufficient lifting power 1-3 When raising blade, becomes slow at certain height: 1-4 Lift cylinder cannot hold down blade- 5 Blade has large amount of hydraulic drift---+-+--- 6 Blade fluctuates while workin 7 Blade drops momentarily when lever -8 Blade does not tilt 9 1 1 Blade moves slowly or has insufficient tilt power-~ H-12 Blade has large amount of hydraulic drift: H+13 Blade control lever do not move smoothly H+14 Blade tilt and blade pitch do not change The following precautions are necessary when using the Standard Value Tables to make judgements during troubleshooting or during testing and adjusting. 1. The values in these tables are based on the values for new machines leaving the plant, so they should be used as target values when repairing or when estimating wear after a period of use. 2. The standard values in these tables for judgement when troubleshooting are estimated values based on the standard values for the machine when shipped from the plant, and on the results of various tests. Therefore, they should be used as reference in combination with repair and operating records when making judgements. 3, These standard value tables must not be used for standard values when judging claims. In addition, do not use these values alone to make simple judgements. Ba Wien carrying out testing, edjusting or troubleshooting, stop the machine on level round, install he safety bar fon the frame, lower the Bucket to tne ground, and stop the engine. They apply the parking brake and block the tires. Da Wien installing oF removing gauges. loosen the oil filer cap slowly to release the pressure inside the hydraulic Tank. Then operate the contol levers several mes to release the remoining pressure in the hydraulic piping. By When taking measurements, do not allow unauthorized persons near the machine. By The cit in the circuits hot, so be careful not to get burnt 20-1TABLE OF JUDGEMENT STANDARD VALUE Testing and messing iam Westie condition a ee erp and ft cont ews "cnt ter paring tere (Hots Rae 1920 | Meso (Held + Lower) 20-30 Max.5.0, {Lower Float) ‘9 29-60 Max.7.0 (old Left (er pc) —— 1029 | Moes0 (Hold Right tilt (Forward pitch) “ssc 18-29 Max.5.0 + Eni seed: Low ing +t conta ter wove feconee eee Wold Rese) S08 Sst ange 55-85 ia old Lower on ae tal Flow) peed aa + Tatar pth conto ivr ra (Wold at Per sen sos on {Hola Ri se Forward ich) pas a Faia of rome , tenes + Ein seed Hh iting isient 5 10 o va + Coolant temperature aed * inne oprng aoe Operating weed ool enperare cae ‘rca ering tne Mocs ern “wggggigemowenre = * Lowering tne of bie (Foe) «eases bighising Mex itching tne of formar «ego some: ing = Nexo ching tine of Serre ren: Mox.7 "tng tine of i Moxts “Ting ie of et Moxts Vero ito tnde "cosines ‘sae oan = jdt it of ee to eee ex100 | Macias + Stop engine, ver for minut, Seema or ot + Extention of lift cylinder minutes. Max Max.65 + Blade maximum high position. 20-2TOOL LIST FOR TESTING AND ADJUSTING No.| Testing nd mnnting ie Tool nene Part umber Femorks Nic pressure Jraulic tester, 101-4 ressue gouge: 2559.38, 58.8 MPS 1 | yee art 7ee.t01s002 rave sug 25 8 RA EMM, Digital temperature 2 | otemeratre Digi tempat 78801-1502 “899-1200 1: e020 pm ensne seed Techometer 790203-001 ita oly 3 gi ‘a YH 60 ~ 19,999 prm ume ever and it ever a | Dump tee and snp cle 94-64-0020 0-294 (0-205) | eanring tae Comex sae Commercially ailebie - @ | _ Messing operating ine of Stoo wach Commerc avaiable | 1/10 scone work equipment AS wen carrying co texting, sting oF Woubeshooting, sop the machine on el round, nal testy torent fms lone tne uct othe ground, and ap the ero. aly he porting bake ene block the res AM, Do not allow unauthorized persons near the machine AR wiven measuring te eine sted, one worker should means the engine sped whl the attr ss inthe A Be caret not to et caught n rating prs. 20-3MEASURING PITCH, TILT AND LIFT CONTROL LEVERS + Measurement condition Coolant temperature: Inside operating range Hydraulic oll temperature: 45 — 55°C Engine speed: Low idling Special tool T Part Na, Part Name Qty ‘A | 7en264-0020 | __ Push-pull sate 1 AR, trae ate bar on te fame ‘Measuring procedure 1. Operating force of pitch, tilt and lift control levers + Fit push-pull scale A on pitch, tilt and lift control levers and measure operating force. % Hook the push-pull scale A on the center of the knob. # Operate at the same speed as normal and measure the minimum force needed to operate the knob. + Titt operation @ Left tit @ Hold Right vit + Lift operation @ Raise @ Hold @ Lower © Float + Pitch operation Press down the switch A or B at the tip of the lever and operate the lever. ® Rear piten @ Hola ® Forward pitch 2, Teravel of pitch, tlt and lift control levers Measure the travel of the pitch, tilt and lift control levers at each position. * Mark “a” the knob of the lever and use scale to measure, 20-4 awvoi4ey swvoiea Press down auvorseeADJUSTING PPC VALVE LINKAGE 1. Remove cover at the bottom of the work equip- ment control lever. 2. Adjust dimension a from nut (1) of the PPC valve linkage to the top surface of the floor. + Dimension a {target value): 54 mm t 3, Loosen nuts (2) and (3), then adjust the installed © height of trunnion (5) so that there is no play in lever (4). 4, After adjusting, tighten nuts (2) and (3). De 20-5TESTING AND ADJUSTING PPC OIL PRESSURE * Hydraulic oil temperature: 45 ~ 55°C Measuring 1. Measuring PPC pump pressure 1) Remove the cover at the top of the pump. 2) Remove oil pressure measurement plug (PT1/ 8) (1), then install oil pressure gauge C1 (39 MPa {400 kg/cm") Start the engine and measure the oil pressure at high idling 3) 2, Measuring PPC valve basic pressure (orbit-roll basic pressure) 1) Disconnect hose (1), then install the adapter and oil pressure gauge (5.9 MPa {60 kg/em*)) in tool C1 Start the engine, run the engine at high idling, then operate the work equipment control le- ver and measure the oil pressure. 2 20-6 eB | / a aev002283. Measuring PPC valve output pressure & Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. ° Ad Operate the contro! levers several times to re- 8 lease the pressure in the PPC accumulator cir- f cuit. 1) Remove the main control valve cover. : 1B 2) Remove oil pressure detection plug (PT1/8) Oo OanihB (1) of the circuit to be measured, then install > oil pressure gauge C1 (5.9 MPa {60 kg/m’). ¢ & 4 Plug A: Boom LOWER, boom FLOAT Plug 8: Boom RAISE aovooris Plug C: Blade RIGHT TILT Plug D: Blade LEFT TILT 3) Startthe engine, run the engine at high idling, then operate the work equipment control le- ver and measure the oil pressure. Adjusting 1. Adjusting PPC relief valve Loosen locknut (2) of PPC relief valve (1), then turn adjustment screw (3) to adjust. %* Turn.the adjustment screw to adjust as fol- lows. + To INCREASE the pressure, turn CLOCK- WISE + To DECREASE the pressure, turn COUN- TERCLOCKWISE. + Amount of adjustment for one turn of adjust- ment screw: 1.8 MPa (18.3 kg/cm’) SEI Locknut: 83.4 + 4.9 Nm {8.5 + 0.5 kgm} + After completion of the adjustment, re-check the accumulator charge cut-in pressure and cut-out pressure again referring to the section “Testing and Adjusting Accumulator charge pressure”. aoyoo222 20-7TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE ‘* Hydraulic oil temperature: 45 - 55°C A Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. MEASUREMENT 1, Measuring work equipment relief pressure 1) Reise blade portion @ approx. 30 —50 mm. 2) Stop the engine, then Operate the blade control lever and check that the bottom of the blade ‘end-bit is in contact with the ground. Aa dfer lowering the blade to the ground. Operate the brade control lever 2—3 Times to release the remaining pressure In the piping. 3) Remove plug (PT 1/8) (1) forblade RAISE circuit hydraulic pressure measuring, and install nipple C2 and oil pressure gauge 01(39.2 Mpa (40 ke/om*), 4) Start the engine and raise the blade, with the engine At the full speed and measure the hydraulic pressure When the relief valve operates A Aiter measuring, repeat. the procedure used when installing the oil pressure gauge to'release the pressure inside the circuit, then remove the oil’ pressure gauge. Fv 64s aevo0220 20-8ADJUSTING A When adjusting hydraulic pressure, be sure to stop the engine. 1, Remove the front cover of the work equipment valve. 2. Remove cap nut (2) of relief valve (1) and loosen lock-nut (3) 3. Adjust the pressure by turning adjustment sc rew (4). + Ifthe adjustment screw is + tumed clockwise, the pressure is heighte- ned, + tuned counterclockwise, the pressure is lowered. +& Pressure changed by 1 turn of adjustment screw: Approx. 3.50 MPa {35.7 kglem? + If the relief pressure cannot be adjusted accurately, do not adjust it. 4, Tighten lock-nut (3) and install cap nut (2) GED Lock-nut/Cap nut: 28 34.3 Nm {2.8 - 3.5 kgm} 5. After finishing adjustment, measure the relief pressure of the work equipment again. For details, see above MEASURING RELIEF VALVE OF WORK EQUIPMENT. cal awvoise4 20-9MEASURING WORK EQUIPMENT SPEED ++ Measurement conditions Engine oil temperature: Within operating range Hydraulic oil temperature: 45 ~ 50°C + Engine speed: High idling + Steering position: Neutral 1. Time taken for BLADE RAISE, LOWER Raise the blade from the ground and measure the time takes to reach the highest position. Then lower the blade from the highest position and meas- re the time it takes to reach the ground. 2, Time taken for PITCH FORWARD, PITCH REAR Raise the blase to the maximum height, and meas- ture the time taken for the blade tomove from the maximum rear pitch position to the maximum for- ward pitch position, ‘Then measure the time taken for the blade to move from the maximum forward pitch position to the maximum rear pitch position, Time taken for blade LEFT TILT, RIGHT TILT Raise the blade to the maximum hight, then tilt the blade to the left from the maximum forward pitch Position and measure the time taken for the tilt cylinder rod to move from the fully extended Position to the fully retracted position. Then tilt the blade to the right from the maximum rear pitch Position and measure the time taken for the tilt cylinder rod to move from the fully retracted Position to the fully extended position. 20-10 Faieo1107 ataMEASURING HYDRAULIC DRIFT OF WORK EQUIPMENT CYLINDER + Measurement conditions + Engine oil temperature: Within operating range, + Hydraulic cil temperature: 45 — 50°C. + Stop the engine and leave for & minutes, then measure for the next 15 minutes. + Noload BA Hroiy the sate tock to the work eaipment contol lever A 00 not tet anyone go under the work equip: ment 1, Method for measuring hydraulic drift. 1) Raise the blade to the maximum height, then stop the engine, 2) Leave for 5 minutes, then start measuring, 3) After 15 minutes, the amount the blade has moved down and the amount the lift cylinder rod has extended, A: Hydraulic drift of blade, B: Amount of extension of lift cylinder rod, 20-11CONNECTOR TYPES AND MOUNTING LOCATIONS + The connectors other than the below are the same as those of WAS00-3. For them, see WASO0-3. vezor| tye || paceoruse [M85] [Se] aye |G] escooruan | At te os te sis a — | clnemedaiecomesor | - lone || almomedate connesor | \CH3. = A |intermediate connector - ror | — | aloccovere - FOZ = A{GNO_ - cot | lorceeeee sia | — | alteversmcn - sisal — | loystcx scone JS148] — 8| Joystick steering - uns | — | shmemedate conscir | ora | =| tlmemeciatcornecior | _- 20-12H-1 Ask the operator the following points Checks before troubleshooting Blade does not rise Did the problem suddenly fail to rise? = Seizure or damage to various units. ‘Was unusual noise produced? (Where did it emanate from?) Were there previous signs of the boom slowing down? + Wear of parts of flattening of spring. Is oil level in hydraulic tank correct? Is travel of blade control lever and spool Correct? Remed No.| Problems 1 [Blade cannot be operated ond unable to se iS The machine body can be Hteg up bythe Bade however 2 | The blade Ig uneble to rise, dr. The Made tt operates lo} Jolo| But the Bada is unable to rise [fe boom ean rise under na oad bo conot re under iad—[O| [0] tal 1+ [Te neta pump produces en aboot nos elo &_ [Uf etinger has arg emcunt of yale ari. ola) 6 [en the engin at i teen ston igh and excess 7_[ When the engine i a full tearing scion is heavy and slow. | [O| in| 20-13H-2 Blade-moves slowly or does riot have sufficient lifting power Checks before troubleshootina + Is travel of blade contol lever and also The spool of the work equipment. control > Valve correct? ‘, * Seizure of work equipment linkage bush- s ing. (Does emits abnormal noise) 2 Fault check s/ There is a strong relationship between faults is involving lifting force and lifting speed, Such ‘ faults appear initially in the from of insuffi- Z cient lifting speed, Measure the lifting speed a of the blade ; when loaded and refer to the £/8 ig g /al¢ standard value table to determine whether or not theré is a fault. caf & re ke] § 1 | Blade lifting speed is low. ojo} © o Blade lifting speed is slow. 0} jQ}O| . particularly low when oll temperature rises. i) « [roeceerae : 9 20-14H-3 When raising Blade, becomes slow at certain height Checks before troubleshooting + External deformation of Lift cylinder. Cause + Swollen or internally damaged: Lift cylinder tube. * Regarding other faults occurring during blade rise, refer to item “ H-2 Blade moves slowly or does not have sufficient lifting power H-4 Lift cylinder cannot hold down Blade Refer to item ” H-2 Blade moves slowly or does not have sufficient lifting power”. Checks before troubleshooting * Is travel of blade control lever and also ‘The spool of the work equipment control Valve correct? Cause + Defective Lift cylinder rod side suction valve seat of work equipment control valve + Oil leakage from Lift cylinder piston seal H-5 Blade has large amount of hydraulic drift Ask the operator the following points * Did the hydraulic drift suddenly bécome large? = Dirt lodged in valve.or damaged parts. + Did the hydraulic drift gradually become large? ~ Worn parts. Checks before troubleshooting ; + Is the blade rise-lower spool in the hold position? ~ Seized ring bushing, defective spool detent. Troubleshooting and cause + When measuring hydraulic drift, internal leakage of Lift cylinder makes oil leakage noise. > Damaged cylinder packing. + When measuring hydraulic drift, Lift cylinder does not make oil leakage noise. ~ Defective oil sealing of blade rise-lower spool. > Defective check valve between pipings. 20-15H-6 Blade fluctuates while working During excavation or ground leveling when the: blade control lever is in the “HOLD" position, the blade move up and down in accordance with the terrain. Troubleshooting and cause Check the amount of hydraulic drift and whether or not the machine body can be lifted up by the ft cylinder. 1. If the amount of hydraulic drift is Greater than the standard value, refer to item ” H-5 Blade has large amount of hydraulic drift”. 2. If the machine body can not be lifted up by the Li cylinder, refer to item “ H-4 Lift cylinder cannot hold down bucket”. 3, Ifthe amount of hydraulic drift is normal and the machine body can be lifted up by the boo oylinder after the blade is moved several times to cause the: Lift cylinder to move through its. entire stroke -» the trouble is due to the generation of a vacaum in the cylinder. * Ifa vacuum is generated frequently > defective suction valve on Lift - cylinder rod side. H-7 Blade drops momentarily when lever is operated from HOLD to RAISE The blade drops momentarily under its own weight when the blade control lever is gradually shifted from the “HOLD” position to the “RAISE” position while the engine is at low idling. When the control lever is put completely into the “RAISE” position, the bladet moves normally, Cause + Defective seating of work equipment control valve or blade spool check valve. 20-16H-8 Blade does not tilt Ask the operator the following points + Did the blade suddenly cease to move? ~ Seized or damaged: equipment. + Was any abnormal noise emitted (where did it emanate from?) + Was there previous signs of the blade slowing down? = Worn parts or flattening of spring. Checks before troubleshooting + Is the travel of the blade: control lever and spool correct? No.| Problems tle /afi Blade cannot be operated and unable tose, ody can be lifted up by, the blada however tunable tose. Or The blade tit operates But the blade is unable to nse. [ Tie nyaraule pomp produces an several nolo “4 | Lie evlinder has erga hydraulic dit “Steering aetion ie ight and excessivly fat when the engine sat full | Steering ection ie heavy and slow when the engine so fl 20-17H-9 Blade moves slowly or has insufficient'tilt power Checks before troubleshooting + Is the travel of the blade: control lever and the work equipment control valve spool correct? + Seizure of bushing in blade control linkage? (Does emits abnormal noise?) Fault checks + Check deficient titt force by performing actual work. + Measure the operating speed of the bucket and check it against the standard value table.to determine whether or not it is normal. Remedy No,| Probiems Blade ining force and iting speed are abnormal and also Blade tik force and tt speed are abnormal. 7 | Boom lifting force and liting speed are normal but blade tit force and tit speed are abnormal. Phenomena of tem 1 become particularly bad when thee 3 temperature increases. Oo 4 | The hyeraulie pump emits an sbrovmal noe |S 7 ia light and excessively fast when the angina = 6 _| Stearing action is heavy and slow when the engine is at ull. |) 7_| The Litt eylindor has @ large amount of hydraulle rit ) lo) 0} 6 | Pssst recur oft valve of wok euipment cond lololo oO 8 | The discharge volume of the hydraulic pump is low. fe) 20-18H-10 Blade movement becomes slow during tilt Checks before troubleshooting + External deformation of Lift. cylinder. Cause + Swollen or internally damaged Lift cylinder tube. + As to other faults which occur when operating bucket, refer to item” H-9 Blade: moves slowly or has insufficient tilt power”. H-11 Lift cylinder cannot hold down Blade Refer to item “H-24 Blade moves slowly or has insufficient tilt power”. Checks before troubleshooting + Is the travel of Lit spool of work equipment control vaive correct? Cause + Defective seat of safety valve (with suction. valve) of the fod side of Lift éylinder of work equipment valve. + Oil leakage from seal of Lift cylinder piston. H-12 Blade has large amount of hydraulic drift Ask the operator the following points + Did the hydraulic drift suddenly become large? = Dirt lodged in valve or damaged parts. + Did the hydraulic drift graduslly become large? Worn parts. Checks before troubleshooting + Is the blade rise-lower spool in the hold position? ~ Seized ring bushing, faulty spool detent. Fault check + Use the standard value table to check whether or not the hydraulic drift of the blade is actually large. Cause + Oil leakage in Lift cylinder + Defective seating of safety valve (with suction valve) at bottom side. Defective oil sealing of blage rise-lower spool, + Defective check valve between pipings. 20-19H-13 Blade Control lever do not move smoothly Fault check Using the standard value table, check whether or not the operating effort of the lever is large. T Remed) No.| Problems ‘Movement of blade control lever; becomes sluggish when i lol lol | lolol lo} Io} 1, llesdis applied and ol pressure increas, Movement of Bade control lever. becomes suggsh along 2 [with change ia oil temperature. O| Md Movemene of blade contra lover becomes partly uggish 3 [respective fat pressure on terperture, lo [Movement ofblade contral lever” becomes gavel ugaish lo reaspective of oil pressure and teperstur, ovement of Blade Control lever does pot become light even '5 | when the lnk ofthe conte aver is ciszonsacted atthe valve |O) eanection pert and tho lever operated. 20-20H-14 Blade tilt and blade pitch do not change Inspection before diagnosis Check that the stroke of the til/pitch selector switch is 1.5 (+ 1/—0.8) mm, g : 8 & e| [lg 3 (elzle 3 |slslz 5 |s18|3 2 iele|2 3 |: 3 (31315 a cid Remedy No] Protims [When iipich slaclrewich ov lever Knob lop pressed, pc snot 1 | selected. © jO}OjO 2 [wen tivpichseoctor swith on oer knob tops pressed kis rotseleces| CO [O|OI 20-2140 MAINTENANCE STANDARD Engine mount ... Transmission mout... Damper. Torque converter charging pump Torque converter, PTO Transmission. Transfer Main relief, torque converter relief vaive Lubrication relief vaive Drive shaft Center support. Differential. Final drive ‘Axle mount Center hinge pin « Steering column .. Steering pump .. Steering valve Steering cylinder mount Brake valve Slack adjuster Brake ean Parking brake Hydraulic pump Switch, PPC pump... PPC valve Main control valve. Hydraulic cylinders Blade ROPS cab stata Bg shape SEAT ea ae a ae ae aE ea EE 40-8 40-10 40-12, * 3 The items marked ox in the List of Contents above are common with the WASOO-3 and are not given in this manual, For details of the marked sx, see the WASOO-3 Shop Manual. 40-1MAINTENANCE STANDARD ‘TRANSMISSION TRANSMISSION (12) Fae 166.712 0 evn Goma Tin seiz ae IS mn 117 bel 1H. 2521. 28len) 196.729. 6Ne {178 Heal 10.32 12. 3Na (1,288 1 25.0m) Tiere sme saeMAINTENANCE STANDARD TRANSMISSION Unit: mm No. Check item Criteria Remedy Siandard sie Repair ime Free length [rstaledlengilistalled toad] Free length | Load limi 1] No. 1 clutch spring (x 10) = * = ame 132.4 1128N 6s ses | das | ozo | aiaSN, 63.7 N 53.9.N 2.| No.2ciutch spring (x10) | 59 as | Sim | ss | SS 5 87.3N 745.N 2 | No. 3etutch spring 10) | 29.8 3s | gem | a | BSS No. 4 clutch spring S41W 48.08 4 | id each) ms 9 | 5k) | 74 | Ted ing te 66.50 56.68 5 | No. 5 clutch spring (x 10) 398 35.0 ake) a74 eae ‘No. 6 clutch spring 775N 65.7'N 81 a0 each) oe az {7.9 kgh wa {6.7 kg) Standard sie TToleran Repair limi A jSvaren mniceneee ote discs id kepair Henle ‘and 4 plates for No. ands 0 £0.28 36.3 ‘Overall thickness oF 4 discs 2 | and4 plates for No.2 0 £0.28 383 clutch Replace ‘Overall thickness of 3 discs 8 | and plates for No. 3 Fry 40.22 22.6 luteh ‘Overall thickness of 3 discs 10 | and2 plates for No. & 28 0.22 22.6 luteh Overall thickness of 3 discs 1 uy and 2 plates for No. 5 clutch: cae ca ae Overall thickness of 3 dises| 12 | and 2 plate for No. 6 clutch 2 aoa oe) 13 | Thickness of 1 dise 5 40.1 42 Thickness of 1 plate “ for No. 1, 2, 34,6 clutches 5 #04 48 Thickness of 1 plate he ¥ 29 ud for No.§ clutch cod Standard Tolerance Standard | Clearance Clearance between trans- size Shaft Hole Glearence Knit 16 iy input shaft bear- 5 aie ental ing and housin +0. 081 — 8 e 90 0.015 0.006 =0.006 | +0.037 Clearance between trans ° yo013 | +0026— 11| mission outputshattbear | 72 | Borg | “0.008 5006] +0031 ing and carrier Clearance between trans + 0.031 ~ 18 | mission outpurshatt bear | 100 | S915 | “e008 | **°2c06] +0.037 ing and housingMAINTENANCE STANDARD TRANSMISSION (2/2) a sxvo2i27 40-4MAINTENANCE STANDARD TRANSMISSION Unit: mm No, Check item Criteria Remedy ‘Standard size Tolerance Wear of trans- | Width 3 27 1 | mission input shaft seal fing Thickness 27 04 2.55 0.01 Wear of trans- | Width 3 0.03 27 2 | mission output shaft seal ring Thickness 3a 401 2.95 Backlash between No. 1 3 | Sun gear and planet gear 0.13 -0.32 Backlash between No. 7 4 | planet gear and ring gear 0.15 0.38 Inside teeth Backlash between No. 2 Replace 5 | sun gear and planet gear 0.13 -0.32 Backlash between No.2 6 | planet gear and ring gear 0.15 -0.38 Inside teeth Backlash between No. 3 7 | sun gear and planet gear 0.12-0.30 Backlash between No.3 8 | planet gear and ring gear 015-038 Inside teeth Backlash between No. 4 8 | sun gear and planet gear 0.13 -0.32 Backlash between No.4 10| planet gear and ring gear 0.15 - 0.38 Inside teeth Backlash between No. 5 7 11 | sun gear and planet gear seine Backlash between No.5 12| planet gear and ring gear 0.15 -0.38 Inside teeth 40-5MAINTENANCE STANDARD HYDRAULIC PUMP ‘SAR(3)-080 HYDRAULIC PUMP 2710:319Nn 12628533500) sen02i24 Unit: mm No, Check item Criteria Remedy ‘Standard size Clearance borw "| case and side pl 0.10 -0.15 og Clearance between inside dr Replace 2 | ameter of plain bearing and 0.06 -0.149 020 ‘utside ciamater of gear shaft 23 | Insertion depth of pin 14.85 4 | Rotating torque of spline 69-118Nm (0.7 -1.2 kgm} Discharge | Standard | Repair imit _ Revoluzon | Trereue | dcharge | ‘aeeharge, | — ischarge rpm a (éimin.) (e/mmin.) _ | Discharge mPa tkgse’s | (amin) 45 55°C 20.8 2500 ae 184 170 40-6MAINTENANCE STANDARD MAIN CONTROL VALVE MAIN CONTROL VALVE E133 15ye Se ses 100m Fee 282100 See] 2262 100 113520,1 Sian) (7a tinal 1234 tae) (234 thas! 1 Sas 77522040 (288 Stel enc eT] 192+25Ne Gee) 486 250 (1350250) (43522500) Fa osssann (315403500) Fae 312340 (3.152035 0, GE 1622500 U8 3ie) E-€ o-0 swvo4s27 40-8MAINTENANCE STANDARD MAIN CONTROL VALVE ait: mm No Check item Criteria Remedy Standard size Repair limit ; Free length] Installed | Installed | Free | installed 1 | Se00l_roturn spring Poo" | “engin | “oad |_tength | "toad (for TILT) om soxu | oss | ty | - Spoo! return spring ssn 7 - 2 Gor TILT and LIFT) GE Ge (oti Spool return spring ssn axes | 28 - - * | Gor TILT ane LIFT » feta Spoo! return spring aN 4 xis | 40 - - cain ssaxit chbke Replace Spo0! return spring eN 5 xr | a - - (tor LIFT) i S| atte ain vaive spring for mi aN - - « fain vale sina wsxuz | m2 | iy 7 | Check valve spring 26x109 45 rye ee - 7" a | suction vaive spring | aroxis | a - - a [Reet vaive poppet spring] waxiza | us | Bel, | a | yi, 40-9MAINTENANCE STANDARD HYDRAULIC CYLINDERS HYDRAULIC CYLINDERS ‘STEERING CYLINDER 2 Geel oszesae 4 See rsoteie 4g (9520500) 11802 Iélae) (Cwiath across at #608) LIFT CYLINDER ! oan 110412 38 (11, 2541. 25kg) 9 , S244 SN (16. $41.5 ke} TILT CYLINDER 1 SE RHI SH 3 2 [ (16.51. § ke} 4 si) LA BES [|< amass (05:40 5kera} 40-10MAINTENANCE STANDARD HYDRAULIC CYLINDERS Unit: mm No| Check item Criteria Remedy Name of [Standard | __Tolerances [Standard evlinder |" site [Shaft | Hole |olearance ; =0.030 | +0151 [o.os6— Steering | 55 7 0327 1 | Clearance between rod and 8 een E28 eaeic222| ushing -0.030 | 40.271 [0.091 ~ tft | ies [scat eas] OF -0. 030 | 40.271 0. 105~ mt 70 | -o.104 | sors | oars] 875 0 | +0174 [0.100 Steering | 60 | -ao7a | +0.100 | 0.248] 19 Clearance between piston =o 030 | 40.046 [0 o30~ 2 |rodmountingpin anddi- | Lift wo | as ameter of hove au anied Tilt wo |g, |e? | 0 | Replace 0 [40.174 [o.100— Steering | 60 | ~oo74 | +0:100 | 0248] 19 Clearance between cylin- “a 00 | aa.088 |e.020= 3 | derbottom mounting pin | Lift so | 2 ; as eee ao76 | 0 122 -0.3 [4oire [aw ge Sf os | iatoo [oer] 18 Standard size | Tolerance | Repair limit steering | 110 +945 - 4 | cylinder bore ite 0 sas . Tit 40 sas = 40-11WAINTENANCE STANDARD BLADE 450,9268.6Nm 460.9:58.6Nm (aT eTegen) (eT) 40-12BLADE MAINTENANCE STANDARD D-p 20 HH 40-1340-14 WAINTENANCE. STANDARD BLADE Wa Cheek ikea criteria i 5 voter | Stantra Tolerance Standard | Clearance earance botween bearing and | size 7 jie | clearance | “limit | 1 | pin at joint of lift cylinder an wae fod and blade | ~ ~ 5 6 en a aos~012 1 Clearance between bearing ard | Replace in at joint of support an ea aaa ae ee Oa eeOt 2 | Seat inia stared | at a FH a 1 "TP clearance between jovnt and — “03 ‘a3 3 | plelatvoint of fran ana «0 a a as~oe 2 Clearance between bearing and 4 | pinvat joint of tilt/osten 100 9 sa adjust with shia Adjust tylinder ang blade locos : ones Clearance between bushing and | 7 05 | sags | 0 26~ 5 | pinlat/oiat of sumprt ane rn ee ee 1 Clearance between bushing and T | -o3 wae | ae i |devlteestani freaena © as | 10 oars : Clearance betwoan bushing and | 1 | pin'at ovat of lift cylinder gan | 40.046 | 0 0a~ [aera tote |e | M| 4 me | | Clearance between bushing and sacs | inose | a. 02s~ 8 | plntat ovat of support and so aa H cae ' — as | Clearance between bushing and Ay ee ae 9 | aielaioin of Tit estinier | 60 om | ia a 2 Replace to | Clearance betwavn boss and pin | gg ons | ana a.025~ 7 a at Joint of support and blade sos | ine 69 Clearance between joint and | vv | pintat'iciet ot tee tnd wo | tt |e [ones] 2 lage | |" Clearance between boss and pin 1 0.06 | sas | oze~ 12 | gtllein of ipportane front” | 18 pe | ee cate 2 | Clearance between toss and nin | | “03 was 2 15 | atleim or loitehestiater | 60 a 125 asta 2 14 | Clearance betnean boss and pin | gg suo | a | oem 2 at Joint of support ee a3 | Clearance between bushing and ieee wa.0se | 0. 36~ 18 | Sets at oto sngnet and a | ° 0.144 | 7 T Joint of bat and front frame | | we 18 | and! joine'of Bar and suppor ba J wr fernem) oeMAINTENANCE STANDARD BLADE o (Check item Criteria Renedy rath between bosses | Widih of hieqos ] Standard clearance 17 | deint of 1itt cylinder roe ang | Nath Between 8 osama (clearance at 6) biace we 38 0? 0 15~0.64 18 | Joint of btade and frase wa PS aemte Replace Joint of tilt/piteh cylinder 2 + | rg | aint of af £07 arer | Joint of Lift eylinder and front #20 40.050 20 | frame 88 405 8840 140 0 45~2. 14 Joint of Hesupport and front ~ adjust with ahiw 24 | Trane, “and joint of Hsupport - 021 sieve Adjust and support 40-1590 OTHERS Transmission... Brake piping Hydraulic piping, 3 Work equpment hydraulic circuit diagram .... 90- 5 Electric circuit diagram (1/4) sesnes HE Electric circuit diagram (2/4) * Electric circuit diagram (3/4) x Electric circuit diagram (TILT and PITCH control) a .90- 7 Electric parking brake control wn. ra Connector arrangement diagram (1/2) ween Connector arrangement diagram (2/2) msn XK The items marked sr in the List of Contents above are common with the WASOO-3 and are not given in this manual. For details of the marked vr, see the WAS00-3 Shop Manual. 90-1OTHERS: HYDRAULIC PIPING to Tilt cylinder 5 HYDRAULIC PIPING OUTLINE + The hydraulic system consists of the work equipment circuit and the steering circuit. The work equipment circuit controls the movement of the blade. + The oil in hydraulic tank (5) is sent to main control valve (1) by hydraulic pump (13). When the tilt and lift spools of the main control valve are at HOLD, the oil passes through the drain circuit of the main control valve, is filtered by the filter inside the hydraulic tank, and then returns to the tank. + When the work equipment control levers are operated, the tilt or lift spool of PPC valve (6) moves, and the spools of the main control valves are actuated by hydrau- lic pressure, so cil flows from the main con- trol valve to lift cylinder (2) or tilt cylinder to move the blade. + Control of the maximum pressure in the hy- draulic circuit is carried out by the relief valve inside the main control valve. A safety-suction valve is installed to the tilt oylinder circuit to protect the circuit + Accumulator (10) is installed in the PPC pi- lot circuit, so this makes it possible to lower the blade to the ground even when the engine is stopped. + Hydraulic tank (5) is a pressurized sealed type and is equipped with a breather with relief vaive. This compresses the inside of the tank and also prevents negative pres- sure, 80 this prevents cavitation of the pump. |. Main control valve 10. Accumulator 1 2. Lift cylinder 11. Radiator 3. Steering valve 12, Oil cooler 4, Orbit-Roll 18. Hydraulic pump 5. Hydraulic tank ‘14. Steering pump 6. PPC valve 15. Steering cylinder 7. Solenoid vaive 16. Deco valve 8. Switch, PPC pump 8. Check valveWORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM 1. Hyérauive tank 2 Oi filter 3. Breather 4, Seiten, PPC pune 5. Toraut converter charging puna Hydraulic pump 1. Steering uso & Strainer 4. Aecuaulator charging valve 10 Check valve 11, Accumulator 1. PPC valve 12 ain contro! valve 13K Main celiet valve 138, THit spo0! 13G, Satety-suction valve 130. Litt speet 13E. Suction valve 14 Litt eylinger 1. Tit eylinder 16, Deco vaive 1. orbit-Rolt COSTES TESST 1B, Stop valve 18 Steering valve 184 Denane sp00! 198. Steering sp00! 18C. Steering reliet valve 180, Safety-suction valve 14 20, Steering cylinder 21, O11 cooler : IELECTRIC CIRCUIT DIAGRAM (TILT AND PITCH CONTROL) 1 ew Rot OE KICK-DOMN, HOLD, TILT AND PITCH SWITCH i 1 ' ow | t ' 1 ' ' i ft | cw FOI ow cart ! ' i 1 i L ooo vaLve | aDoITIONAL FRONT HARNESS : ow dete poo iTIONAL FLoOR HARNESS. | ae -- -- --L 1 -- -- t- = 1 1 FLOOR. HARNESS | — t Jou asin! ou 35148 |