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    692 views108 pages

    Service Manuals OLD MODELS

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    leogerguz

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    © All Rights Reserved
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    SIHIRVUCIE IMLAUNTUA\ILs MST sEnies RUBBER CRAWLER CARRIER MACHINE MODEL SERIAL No. MST-500 50101 and up MST-600 1601 and up MST-700 70101 and up MST-800 866 and up MST-1100 MO1101 and up MST-1100 K 11101 and up MST-1500 15001 and up MST-2000 M02107 and up MST-2000 K 20101 and up MST-2200 22001 and up MST-2500 25101 and up MOROOKA INTRODUCTION ‘To allow the machine to meintain ite performance over along period, and to prevent bresk- downs or trouble before they occur, it is important to carry oUt suitable operation, mainto- hance und inspection, troubleshooting, and repair work. ‘This sorvice manusl gives detalls of the GENERAL, STRUCTURE AND FUNCTION, TES- TING AND ADJUSTING, AND TROUBLESHOOTING for the machine that are needed ‘0 carry out this work, in partlcular, inspection, troubleshooting, and repair work. For details of the engine, see the shop manual for engine. “This service manual has been prepared to help you to improve the quality of your repairs by siving cottect knowledge of the product and correct methods of repair, and by enabling You to carry out correct judgment Please read the contents thoroughly and make good use of them in your work, Wo are constantly trying to imprave the contonts of our service manuals, o if you have any opinions or suggestions about the manual, please do not hesitate to contact us. MS7YSERIES 02 GENERAL NST SERIES General view .... Assembly drawing Dimension table ..... Specifications Table of lubri 201-2 O14 01. 5 01. 6 01-12 01-1 GENERAL VIEW 11, Drive sprockot 12, Track roller 6, Operator's seat 1. Travel control fever 2. Dump control fever 7, Head lamp 3, Rear idler 8, Hood 19, Carrier 4, Dump oylinder 8, Fuel tank 5, Rubber crewler 10, Hydraulte oll tank (MST SERIES ASSEMBLY DRAWING 01-4 MST SERIES Seraine. | Biot nd wp | Teor=aI00 | z7Otanlan Toor eww | eeeAdeoo | asar anon a A 3,600 3,840 3.830 4,200 4,500 4,365 8 1950 [eco | an00 | 2180 [200 | avo e Er ae oD 350 5 365, 366 440 470, cae 800, 500 500 00 580 636 zi "00 | sso | suo | 1600 | i700 | ~a700 A 0 soo | sco | 80 a z zaso | aa00 [aa | aan0 | 2a | ~aaea woo | tas |= seco | sao | 3 0 oo [0 [10a | 1.00 | an x 20 wo | 0 | 0 30 | wo t aso _aaso_| ae | ane | aa00 [ao GSC | YS (J SEY 8 pool EE eravol er EE eens] -Ellayon i ee woot [ wsraieo [ werasoo | nevaow [wera | wor2eoo Sera No, 1104 and up| 16001 en wp | Boro a wp | 200 au | 250% ae vn a a B 2,400 2,500 2,700, 2,750 3,000 ~ € ane [aes [ eae | ano] a0 ° 0 so [0 [ am 29 E 20 wo | ee [a 200 cs GS 700 700 800 750 900 4 aw | aaa | 200 | 2800 | 2700 1 wo [_1700 | 1.00 : 2.000 a 3 ‘wo | 1200 | asso | anes | 80 K 360. 360 400 400 450 i t aso] soo | sao [3600 | aco uw [2100 | 2200 | 2280 | 2480 | 260 w 12900 | 200 | 2400 7 2.80 st sens 01-5 SPECIFICATIONS Model st-s00 MST-600 MST-700 Serial No. 60101 and up | 1601-2700 | 2701 and up | 70101 and up Machine wight tig) | 3890 3,900 3,900 5210 11509 Max. lading capacity tes) | 2500 3,000 3,000 soo 1g. | Dump body capacity (Struck) (m*) 12 14 14 16 B | Min, exning ratios (} 19 20 20 22 2 | Grade ability (es) % 38 35 35 * | rove speed (kent) 0-12 0-1 0-10 Overall length (mm) |, 3,600 3,840 3,860 4200 1% ‘Overall width (mm) | 1,850 2,000 2,000 2,180 Overall eight (mm) | 2,180 2,200 2,200 2,260 {Fe the top of hood Track gouge mm) | 1,400 1,500 1,800 1,600 J, | Track shoe width om) 480 500 500 550 & | Number of tinks 6 78 78 76 E | ston timmy 100 90 80 100 Ground pressure {eofem?) | 0.12 ot ont 012 (Without ioad) Ground learence (mm) 360 312 312 355 (To the under surface of ross tube} Dump body width {mm} | 1,600 1.700 1,700 1.860 ‘Bump body length (mm) | 2,180 2,250 2,250 2.560 Dump bosy height oom) 360 380 350 350 [NST SERIES 01-6 MST-800 wst-i00 | mst-100 | mst-1600 MST-2000 ‘66-2000 | 2401andup | MmO1101 and up | K11101 end up | 16001 and wp | mozI01 and we 5.740), ay 5.740 6,300 6.300 0 7,500 11,370 ust “er 7 400 4,000 5,000 5.000 6.000 8,000 18 18 24 24 24 30 24 24 26 26 27 28 s % % 26 6 ra 0-13 o-18 o-10 o-10 o-12 400 M6 | as00 "| a7 Ue 4.075 5.245 5,490 2004 | 2.20025 | 2,400 2,400 2,800 2.700 2,300 77 230077" 2,300 2,300 2,440 2,800 1.700 170 4,700 1,700 1.800 1.900 00 600 700 700 700 80 0 80 80 98 100 109 100 100 100 013 013 0.12 on oa 440 440 440 440 530 2,000 2,000 2100 2,100 2,200 2,000 2,600 2,060 2.860 3,100 360 350 260 360 20 MST SERIES SPECIFICATIONS Model asT-2000 Mst-2200 MST-2500 Serial No. 20101 and up | 22004 and up | 25101 end up ‘machine weight es) | 11,370 12,280 14,500 Mex, loading capacity te) | 8,000 10,000 10,000 gg | Dum body capac (Stuck) fa?) 30 3.82 44 E | in, uring radius (en) 28 3.23 a4 £ | rade abitiey (Dea) % % % 0-145, | 9 12 frwo stage Travel speed tiamvh) 0-10 Gia ihSy | 0-92 to sone) veal length (om) 6.430 5,860 6500 Overall wien (rom) 2,700 2,928 3,000 Overall height om) 2,500 2,600 2,700 {To the top of hood) Track guuge (mm) 1,200 2,000 2,100 “Track shoe width {onm) 800 750 900 | Number of inks 80 66 | 80 (Sarat No, 8 25101-26106) é 74 (Serial No, g 28107 and up) 5 Link pitch (com) 125 150 150 Ground pressure tkafem?) 014 oa7 0.18 {Without toed) Ground clerance (nm) 540 00 600 (To the under surface of cross tube) Dump body width oom 2,260 2.460 2,460 Dump body tngth (eam) 3300 3,600 4,000 ‘Dump body height feo) 400 400 450 MST SERIES 01-8 Model MST-500 MsT-600 Mst:700 Seal No, 80101 end up | 1601 ~ 2700 | 2701 ana up | 70101 and up Ergine model Komatsu | errsupisni [artsusishi | Komarsu S0861-1 4031 aosiT | sapesta Type cycle, dacyela, ——facyate, daa, stright vertical fsrtght vertical orate vertical, | sal vertical, water cooling, [nator cooling, water cocting, | woter cooling, Slvact injection [erect injection (iret injection | sree alec ‘yee type vee, pe, jurbocharoed | turbocharged No.of evinders bore x stroke (mm) | 495.118 | 4~ 100x105] 4 ~ 100 x 105 | 4-96 x 118 Piston displacement tec) 3,260 3208 3,298 3,260 Flywheel horsepower (HP/rpm) 77/2,800 74 (2,800 87/2,800 87/2,500 ‘Max, torque (kgr/rpm} 22/1,600 21/1,800 (28/2,200 (29/1,800 Fuel consumption ratio (g/PSh) 164 170 188 185 Stating motor zav,2akw | rav,aze |] oev,s.2ew | rev, 2.0K Altarastor zav.18a | 2av,25a | zav,25a | zay, 158 eatery 12V, 70An x2 | 12V, 1008nx2]32V, ro0Ahx2 |12V, 100Ah x2 Tee st Ast Hs ust Mala pump: Delivery teale) | 480 518 516 516 E | Max, hydrautic pressure tkp/em?) 280 a8 a5 360 B | rake system serviceparking |Service/perking| Service/earking [Service parking = | caution pressure of hydrautic charging (ka/em?) Max, 9.5, Max, 9.5 ‘Max. 9.5. ‘Max. 9.5. | Cheraing pump: Ostivery ——feclrer | 205 200 200 200 & | sox. nydravicpresure tafe?) | 175 176 178 & | Dump contro! valve Single-train | Single-teain | Si Single-train 2 spool p00! soo! soo! = | ump eytinder Double-acting, |Doubte-acting, |Double-acting, { Double-ecting, 5 piston type x 1 | piston type x 1 {piston type x 1 |piston type x 2. 3 | Cylinder stroke 600 600 600 ‘600 e ¥ | cylinder tore 0 0 90 80 = | piston cod 0.0. 6 45 46 6 01-9 MST SERIES Model ‘MST-800 MST-1100 ‘MST-1100 Serial No. 866-2400 | 2401 end up |MO1101 and up} K11101 and up ‘ Engine model mirsuaisui | mrtsueisit | wiTsusisir | KoMarsu apait | 40347 sore | SapesL-t Tyee lacycle, __Jecycte. oye, |a-evte oto vertical stato vertical strlght verti, |stralght vera, fwetr cooling, water cooling, wate cooling, [water cooling, ex injection fate injection fest Injection [ect ection vee, pe, pe ype, Juroseharged_|rurbocherge turbocharged 12 | Novotetnder — borex token) |é— 100% 108 |4— 108 116 [b— 110x118 Jo~ 953115 & | ston displacement ea | 3208 3.907 oss? 4890 Flywheel horsepower (HP/rpm) 99/3,000 114/3,000 116/2,500 132/2,500 Max. torque (kgm/rpm) 28/2,100 33/1,800 39/1,600 45/1,600 Fuel consumption rato tasty | 160 162 170 155 Starting moter zav,saxw | 2ev, soxw | 24v, askw | 2Av, 5.5%W Aernator zav,264 | 24v,a08 | 24v,z0a | 24v,t5a battery 2, 100Ah x2 12v, 100A 2] 12V, 100An:2| 12V, OA x2 Type Hs ust st ust Main pump: Datvary tone) | 516 516 518 510 | Max: hydraulic pressure tkg/em?) 350 360 (385 386 é © | Brake system Service/perking | Service/parking| Service/parking| Servico/parking Caution pressure of hyrautic charging {kafem*) | Max. 9.5 Max. 9.5 Max. 9.5, Max, 9.5 Charging pump: Delivery tea) | 20.0 200 200 200 € & g Max, hydreulic pressure {kg:em?) 165, 165, 165 5 | ume convo vave sirgletroin | Sinalbsrsin Sioa z spe spool spool : B | bump cylinder Double-scting, } Double-acting) Double-acting, | Double-scting, 5 Binton tybe 2 | piston spss] alton type? | isto type x2 E | cylinder stroke 600 600 710 70 2 | ovtinger bore 60 0 100 10 Piston rod 0.9. 4s 4 0 © MST SERIES: 01-10 Mst-1600 MsT-2000 MsT-2000 Mst-2200 MsT-2600 {5001 end up | MO2101 and up | K20101ardup | 22001 endup | 26101 and up MITSUBISHI | MITSUBISHI Komatsu CATERPILAR | MITSUBISHI eit eo1eT SAGD110-1 33060 'T 60227 cycle, Acydle, acycle, 4-cydle, Acycle, elon vertical, [straight vertical, | straight vertical, straight vertical, —|streight vertical, Tre cooling, | [water cooling, | water cooling, ' |water cooling, " [water cooling, Waect injection [direct injection | dieect injection direct injection | cirect injection ype, rye, type, Itvpe, type, WUibacharged | urbocherged | turbocharged turbocharged | turbocharged e-oox1s fe-118x118 | e—tt0x125 | 6—121x 152 ]6— 190% 140 6.557 7545 7,490 10,500 41449 152/2,500 197/2,600 283/2,600 281/2,200 298/2,200 51/1,400 67/1,800 81,5/1 800 99/1,400 117/400, 168 160 160 162 185 24V, 4.5KW 2ay,4.5ew | 24V, 7.5K 2av,7.5kW | 24V, 55KW 24V, 308 24V, 208, 24V,254 2aV, 358, 2aVv, 304, 42Vv, 120A x2 | 12v, 120ANx2 | 12V,120ANx2 | 12V, 120Ahx2 | 12V, 120Ahx2 HST ust HsT HST st 08 29.0 89.0 110.9 125.0 385 1250 {Serial No. | 360 (Serial No. 328 360 102105 and up) |” K20128 and upl }985 (Serial No. | 386 (Seriel No. ‘Moz 101-0204) k20101~20128 Service/parking Service/parking Service/patking | Service/parking | Service/parking Max. 95 Max.9.5 Max. 0.5 Max. 9.5 Max. 95 200 36.0 360 56.0 63.0 (Seria No. '25101~25106) 45.0 (Serial No. 25107 and vp) 165 165 165 165 185 Single-train Single-trein Single-train Single-train spool spool spool spool Doubleacting, | Double-acting, | Doublo-ecting, Double-scting, Fatontype x2 | piston type x2 [pistontypex2 | pistontype x2 | piston type x 2 700 1,000 1,900 1,000 1,000 10 190 130 130 130 0 70 70 70 70 (MST SERIES 01-11 cea SSE SSE SST OT TABLE OF LUBRICANT AND WATER scseavoin [kno oF|_____ AMBIENT TewPERATURE CAPACITY @) ru) = eS EL_| Sermon [prc | I i ‘MST-600 : 9.0 75 eas wst-eo : 70/80 usr: oo] 73 Engine : wsram : 7o| 90 nine ot pon |G Soe Ti sTv1o0: 125 | 1085 oy st-1600: 200 | 180 nsT-2000; 240 | 220 SAE 1OW- 30 MST-2200: 27.0 25.0 Mst2s00: 310 | 270 NST-G00 : 52 | 50 Te Nst.e0 + 53} 50 nst-7eo + 6a | 60 ee eee ane ae wstano.; 73} 70 Hivdrutctene | ne wsrrrao: 73 | 70 4 8 ustasoo: 74 | 70 hst-2noe: 74 | 70 #58 MST-2200: 120 110 st-2600: 120 | 110 HST'SOD + ST-600 See y hie wsr-800 Pon tank Die! RSM pare STN - fo oe wst 2000: st 220 ist. 250 wST-500 ws-600 sT.700 + wsT-000 : Coating sistem | Wet, | at anronze ws : vs-1800 wusr-200 sT-220 MST-2600: 36.0, ASTM: American Society of Testing and Materiel SAE: Society of Automotive Engineers API: American Petroleum Institute Specified capacity: Tatal emount of oll including olf for components and oil in piping Refill capecity: Amount of off needed to eefll system during norma! inspection and maintenence, NOTE: (1) When fuel sulphur content is les then 0.5%, change ‘ll in the oll pan every periodic maintenance hours described in this manual. Cchange oll according to the following table if fuel (2) When starting the engine in an atmospheric tempers ture of lower than 0°C, be sure to use engine oil of SAEIOW, SAEYOW.30 and SAE1BW40, even ‘though an atmospheric temperature goes up to 10°C sulphur contort is above 0.5%. sore oes in the dy tm. {31 Use API clasifiaton CD as engine ail and if API Fat sulphurcontent | henge Intra of i clsfcaion CC, rede the erin olf charge inter bd athe val to half. 0810 1.0% | 1/2of egtarinera Above 1.0% | 1/4 of regular ints! MST SERIES 10 STRUCTURE AND FUNCTION MST SERIES +10 2 10 8 10. 4 Hydraulic Hydraulic circuit diagram (MST-600, 700) Hydraulic circuit diagram {MST-600} ... Hydraulic circuit diagram ing (MST-800 — 1500) seteveseees 1068 Hydraulic circuit diagrem (MST-1500, 2000) .. 10-10 Hydrautie circuit diagram (MST-2200) ....... 10-12 Hydraulic circuit diagram (MST- 2600) «oss 1014 |ydreulie pump (MST-600) : 10-46 Hydraulic pump (MST-600 — 1500) 10-17 10.18 210-24 10.25 10.28 Hydraulic pump (MST-1600, 2000} Hydraulic pump (MST-2200) Hydraulic pump (MST-2600) Travel motor (MST-500) , Travel motor (MST-600) .. : +1027 Travel motor {MST-700 — 2000} ..........., 10.28 Travel motor (MST-2500) ........ = 10-32 Travel motor (MST-2200, 2500) ............ 10-33 Travel motor speed changing circuit (MST-2200, 2600) ......esesevee + 10-84 Elecrtrical circuit diagram (MST-600, 700, 1100, 2000) ..........12. 10-36 Electrical circuit diegram {MST-600, 800, 1500, 2500) .. ++, 10-38 Electrical circuit dlagram (MST-600, 800} ......... : 10-39 Electrical circuit diagram (MST-2200) = 1040 10-1 HYDRAULIC PIPING 1, Travel motor 8, Hydraulle tine fitter 2, Dump contro! valve 7. Hydraulic ol tank 3, Main pump 8 Engine 4. Charging pump 8, Gil cooler 5. Dump cylinder 10. Parking brake valve (MST SERIES 10-2 GENERAL 4s The MST series adopt the HST (Hydrostatic Trans mission) by swash plate hydraulic pumpé and motors, ‘Thorefore, they can withstand high-speed, high-pros sure service conditions. In particuler not only sufficient strength is achieved against torsional vibration of the engine or sudden fluctuations in the engine load but also stable per- formance is obtained througout the engine speed range. In. addition, the volumetric efficiency fs so high that there is scarcely any oi leakage and the efficiency does not drap even if the oil tempereture rises. “Tho original servo transmission mechanism which is adopted fecliftates the forward/neutral/reverse lever operation, {In addition to above, the HST is of a maniblock type, which eliminetes the piping of servo valves, relief valves, ete,, s0 that It is easy to disassemble and reassemble Furthermore, the travel motor of the MST-2200 and MST-25007fiee « high/low speed selector mectianism, s0 it is possible to select 2 speed to match the change In the load. (MST SERIES OUTLINE OF HYDRAULIC CONSTITUTION ‘© There ore basically 2 hydraulic circuits, Le., the HST ‘to generate traveling power and the work equipment circuit to control the dump body. ‘The HST has 8 pump charging circuit with 2 sets each of hydraulic variable pumps and hydraulic motors ot the center of the circuit, The 2 sets of tandem hy- draulie pumps are equipped with a charging pump the rearmost section. “Tho power tran is connected directly to the engine. “The 2 sets of hydraulle motors are equipped with a final reduction gear and a parking brake; they are mounted in the right and left front. “The work equipment circuit consists of a dump con trol valve and 2 dump evlinder. The dump control valve is of @ singletrain spool system for all models. ‘A double-octing, pistontype dump cylinder is adopt: fed. One #et are used In the MST-500 and 600, Two sets are used in the MST-700, 800, 1100, 1500, 2000, 2200 and 2500. In addition to the above hydraulic equipment, the MST-2200 and 2600 are also equipped with a high- fow 2-speed travel motor which can be, switched ‘botween high and low speed by a solenoid valve ‘operated by a switch In the operator’s compartment. 10-3 HYDRAULIC CIRCUIT DIAGKAM (MS1I-5UU) ye ie E a, - apt ; }__ moene9 eve, GENERAL + The travel motors are mounted in the right and left front of the main frame. They drive the sprooket to run or turn the vehic ‘Swath plate-type travel motors are adopted A parking disc brake and a planetary reduction gear are mounted. There is a high/low speed selector mechanism install- ed to the travel motor. This is actuated by the high/ low speed selector switch in the operator's compart: ment, ond provides tworstage selection of the swash plate angle to allow selection of a travel speed to ‘match the load of the operation, ‘The high/low speed selector mechanism consists of the high/low speed selector valve and eylinder thot switches the swash plate inside the travel motor, the high/low speed solenoid selector valve outside the travel motor that sends the pilot pressure to the high/ low speed selector valve, and the switch In the opera tor's compartment. ‘The pressure of the pilot circuit is set to 26 kg/em* by the cherge relief valve at the rear of the operator's ‘compartment. ‘+ The table below shows the travel motor's discherge ond ih-presire reli prevsr i angina Motor lecarge | let pregure | sax, cutout cs Brake pepe Model ‘eae feats | speed teom) | ems | islet wsraa00 | 1727105 <0 2/04 180 34 wwsrasco | r7ar2a 0 ears 160 1a 10-33 (ST SERIES (MST-2200, 2500) OUTLINE + The high/low speed selector efroult of the travel ‘moter consists of the high/low speed selector valve (built into the travel motor) and piston cylinder that switches the swesh plate angle of the travel motor, the high/low speed solenoid seleatar valve installed on top of the travel motor that sencs the pilot pressure to the high/low speed celector valvo, and the switch lngide the operator's compartment. The pressurized cll in the circuit Is supplied from the main pump charge circuit o1L FLOW + ‘The pressurized oi for the travel motor high/low speed selector circuit is supplied from the main pump charge circuit, so the explanation will start from the flow of the oil in the main pump charge circuit, ‘The pressurized oil in the parking brake circuit Is also supplied from the main pump charge circuit, + The oll in the hydraulic tank Ie sueked up by the ‘charge pump, passes through main control valve (1), ‘ond hose (2), and then enters hycraulic fine filter (3) at the rear of the operator's cab, The ol Is cleaned by the line filter, then parses through hose (4) and entors mein purnp charge relief valve (5). After being set to 20 ka/om?, it passes ‘through hoses (6) and (7), and flows to the charge port of main pump (8), Hose (9) takes the ol! relieved by the charge role! valve through the oil cooler back to the hydraulic tank, This explains the flow of the all in the main ump charge circuit, Hose {17) connected to the inlet port of hydraulic line filter (3) tekes oll to the parking brake valve stalled in the operator's cab, and when the parking brake lever is set to the TRAVEL position, the oll is then sent to the brake port of the travel motor from hose (17) to release the perking brake, In other words, hose {17} sonds pressurized oll to the parking brake eircult, 10-34 MST SERIES # The high-low speed selector circuit of the travel motor takes its hydraulic power from the oll coring from hose (10) connected to main pump charge relief valve (51 ‘© The oi passing through hose (10) flows to high-low speed solenoid selector valve (11] on top of the left travel motor. ‘The flow of the oll ie switched according to the operation of higiiow speed selector switeh (18) in the operator's compartment, the high-low speed selector switch ts st the low position, the solenold selector valve is not actuated, and the high pressure oil passing through hose (10), does not flow beyond the solenoid selector valve ‘At the same time, the pilot pressure bearing on the travel motor pases through hose (12) and returns to the solenoid selector valve. It is then returned to the hydraulic tank and the travel motor is set in the low speed condition. If the high-low speed selector ‘witch is set to the high position, the solenoid selec: tor valve is ectuated, and the high pressure oil passing through hose (10) goes out from hose (12) and is divided to the left and right, It passes through hose (13) and becomes the pilot pressure for the high-low speed selector valve inside travel motor (14), ewitehes the valve, and sets the travel motor to the high speed condition. In other words, the high-low speed solenoid selector valve switches the pilot pressure operating the highs low speed selector valve bullt Into the travel motor. The high-low speed selector valve switches the high pressure oll from the maln pump and sends it to the piston cylinder thet operates the swath plate angle of the travel mot When the high-low speed selector switch is at the high position, the above actuation is carried out. At the same time, high speed indicator lamp (16) beside the witch lights up to inform the operator that the ‘machine is in the high spood condition. [MST SERIES 10-35 Serial No. 70279 — 70767 MST-1100 Serial No. 11272 ~ 11789 MST-700 vinunan ELEUINIVAL Uinuuls (MST-500, 700, 1100, 2000) MST-2000 Serial No. 20160 — 20488 MST-2000 Serial No. 201 samunoes (05 ‘ue, peon, (yar yorccoorsi ooLr si) we we ‘duel poet “sr ue Busou 908900 13H (MST SERIES 10-36 (MSI-DUU, /U0, TTU0, 2000) Br 2500 Serial No: 30485 — rum signa ews Sting ith — ey i st pose ergo (MST SERIES Sorial No, 1347 — 2400 MST-1500 Serial No. 15061 — MST-2500 Serial No. 25134 — MST-800 (MST-600, 800, 1500, 2600) ~~ se outs wing, (cos ‘oost-16% one eee (MST SERIES 10-38 srmieans CD t ieuioeeeee lar 2 aa \ : yyy i Ue 3 ies rma Ee ee al tT aaccaa) | ps cone seated autates oes and veameiagn i 10-39 (ST SERIES ELECTRICAL CIRCUN DIAGRAM (MST-2200) Co} ames cmvnontionna santas omesntican | anane tf ‘arn 3 MST SERIES 10-40 20 TESTING AND ADJUSTING Stendrads of testing and adjusting 20. 2 Adjusting rubber crawler ... ‘Measuring hydraulic pressure Checking main pump parts. Checking travel motor paris Test run of HST ....-s+- How to release parking br 20-1 MST SERIES STANDARDS OF TESTING AND ADJUSTING MST-500 ate ae eae eee it | Standard value | —dudgomene gory anal Measuring conditions om for new car criteria Main pump charsing pressure | + At engine high fling 20 keg/om® + Vehicle fixing device used 55 | Teovel motor vl presure | * Ves unning, ening 280 2 eoncition i “Time required for traveling Traveling speed 20 matter approssh not | swconds | 6.50.5 at least 10 mon fiat ground Control valve main elt |. 2 [pressure Ovlinder stroke end kam’ 178 z Peseta nae 45 | oump ody operating spaed | {Rated erin need sone - ze Down 45 3 * Amount of fll rom max. S| weturat fall of dump body | reise postion of dump mm 20 body after § minutes MST-600 a Check iter ‘Measuring conditions aie | erent are |e ~ At engine tow idling wo Main pump cherging pressure + Atenging high iting 16-18 Vehicle fixing deve ‘Travel motor relief pressure + Vehicle running, turning kg/cm? 315 . condition | travel motar charging + Vehicle running, turning 12-13 prossure eandition * Time required for trevaing Traveling speed ZOmotwr approschnun of | seconds | 60406 at least 10 mon flat ground Control valve main elie |. qyjnder stroke on lm? we [pressure Cylinder stroke end kale 75 ie § : ine wea Pale 45 F | pump body operating speed | Rat sncine peed seconde, 2 Down ag zg + Amount of fll from max, E | Nowra fat ot dump body | raise position of dump mm 20 body after 6 minutes 20-2 MST SERIES MST-700 Cate- i i ‘Standard val Judger Check item feasuri nditions Init eet ett gory - Me pace a for new car ceriteria ‘Atengine tow ialing 13-14 Main pump charging presure, F———— j_8=" | —__—. ~ At engine high iting 16-18 * Vehicle fixing device used ‘Travel motor relief pressure: + Vehicle running, turning ‘kglcm? 380 5 condition = ; “Travel motor charging = Vehicle running, toring asia pressure consition ~ Time requieed for traveling “Trovalng speed Bee Git approcch run of | seconds | 6.0206 Bt laest 10 m on flat ground Control valve mals relief — |. Gy i we | pressure Cylinder stroke end kale 175 2 7 Rated engine speed Pale 2.0 Ey cemnoen| | neannattt a 3 Down 720 z ~ Amount of fall from max. & | neural faltot dump body | rae poston of dump ram 20 boul after 6 minutes MST-800 Cate = casing conditions van | Stenderd vive [Judgement gory Seceet Measuring condition ue for new car criteria ~ Rtengine low fing 13-14 taain pump charging pressure At engine high ina 16-18 ~ Vehicle fixing dviee used ‘Travel motor relief pressure » Vehicle running, turning Kg/em? 380 e condition 2 : “Travel motor charging « Vehicle running, turning ee pressure condition “Time required for travaing “Traveling speed Fee eepprowch run of | seconds | 6,0 0.5 tewst 10 m on fot ground eae natn elit Cylinder stroke end aor? 165 é alee 90 é + Rated engine speed E | pump body opersting speed |’ seconds 3 ee No load Down 10.0 # + Amount of fall from max 8 | Natural fall of dump body raise position of dump men 20 body after 5 minutes (MST SERIES 20-3 MST-1100 ‘gory Cheek item Me ae a fornew car criteria ‘Travel motor relief pressure: * Vehicle running, turning kgfem? 386 7 aoe * | Travel motor charaing + Vehicle punning, turning pate E Raise. 13.0 & No load Down 14.5 s Amount of fall from max, 5B ‘Natural fall of dump body raise position of dump. mm 20 MST-1500 ‘Travel motor relief prassure * Vehicle running, turning ‘kglem? : a = | Pressure overc valve * Vehicle fixing device used Pressure condition Beate Sion setae cite & Raise 16.0 He No load Down 10.5 5 * Amount of fall from max, ta ‘Natural fall of dump body ais pute of dump mm 20 suai 20-4 MST SERIES MsT-2000 ate. ck tem ea nit_| Stendardvatue | udgemant on Check ite Measuring condition | Uri | Standard vale [dere = At engine low idling 1314 Main pump charging pressure “Ast ongine high fling = Vehicle fixing device used Travel motor elit pressure | « Vehicte running, turning condhtion etacros- tesa | kalo? 5 tiogror-msoasoa | Pressure overcrive vole | » Vehicte fixing davice used eeseietc ee sulting presure * Vehicle running conction 3 ‘Stozice-) fecaiay rarel motor cheral + Vehiele running, twain Trae motor charg Vehicle running, wena notes “Time required for traveling Traveling speed 20 m after approach run of | seconds| 7.2205 at lees 10 m on flat ground Control valve main relist |. vy 2 | pressure Ovlinder stoke end bale 165 i Pe nas 120 E | oun cpemtingspas | Retedoncne peed stone g Down 12.0 3 ~ Amount of fall from mae 3 | Natural fell of dump body | rite position of dump mom 20 body after § minutes msT-2200 Cate fea wit | Standard value | Judgement _ heck item Messringconations | unit | Standardvalue | Jucheme Nain pume charging pressure | = At engine 1000 rom 25 * Vehicle fixing dovioe ved Trevel motor relief pressure | + Vehicle running, curning | kpfem® | 306 condition 1 [Travel motor charging + Vehicle running, turning * | pressure condition ae “Tine raquied Yor waving Traveling speed 20m after approach ruriot | seconds | 630.5 Bi leest 10 mon fat ground Eonar vaio rain ralet TS Cynder evoke end kale? | 65 : + Rated engine speed Reise 125) § | eum crring sees Seas oan ws p88 = “Amount of fall from max. | Netural feof dump body | rake position of dump boey | mam 20 & after 5 minutes 20-5 MST SERIES MST-2500 cote. mnie | Standard value | Judge a cheek tem ‘Measuring conditions nie | Standard val pie Main pump charging pressure | + At engine 1000 rem 25 = Vehicle fixing device used Travel motor relief pressure | « Vehicle running, turning kafem? 350 [Travel motor charging + Vehiele running, turning * | pressure condition ie Time required for traveling ‘Traveling speed 20m after spproach ruviof | seconds | 6.3206 at least 10 m on flat ground Contra vive mein relief |. cyindr stoke ond kaon? | 165 7 ~—T- Rated engine speed Foleo 15 E | pump operating spose seconds fe eee ee eee No load Down 110) & “Amount of fall from max. & | notural fa of amp body | “ras position of durap boxy | mm 2 g after 5 minutes 20-6 (MST SERIES peeve ew IN AUDELA UAE If the rubber erswler comas off or its tension must be adjusted, it should be remounted and adjusted at follows. 1. Apply jacks to the front and rear of the main frame and lift the relevant side, Then put a support under ‘the frame, + Confirm that the eupport Is supporting the body securely 2, Remave the cover (1) and loosen the lubricator (2), to purge the cylinder Interior or grease, 4% ‘Never remove the lubricator, 3, Push in the idler holder (3) towards the body front. 4. Engage the rubber crawler first with the front sprocket and then with the idler in the rear part. ‘Take sufficient care because the rubber crawler Is very heavy. ‘5. Push In the rubber crawler while turning the sprock- at 6. Set stuel pipes, te,, In the rubber erawler, and turn the sprocket gain, + The sprocket must be tumed in the direction shown In the diagram below. ‘Stee pipe + Check that the rubber crawler is sacurely engoged with the sprocket and the rear idler. 7. Tighten the lubricator (2), feed grease under pree- sure with @ grease pump, and adjust dimension A from’ the rear end of the truck frame to the rear Idler center to the standard velue, 8, Install the greste cover (1). 9. Check that the rubber crawler is securely engeged swith the sprocket and the rolls and that ts tension Iecufficient, and then lower the body. % Dimension A Unit: men Unit rm Model Standard value Mode! Standard value MST-500 280 6 ¥ 440 2 5 (Serial No. 15001 — 15150) -— MST-1800 | 370 5 (Serial No. 16151 end vp) MST-800 26£5 ~ 00 MST-2000 47026 MST-700 33525 j__47056 — =~ MST-2200 495 5 MST-800 316 £5 f—___"S=> _ ce ————__ MeT-2500 | 60025 (Serial No. 25101 — 26106) MST-1100 3055 £550 & 8 (Seriol No. 25107 and up) 20-7 (MST SERIES WICAOUNIVG NIVNAULIL PNEDOUNE MEASURING MAIN PUMP CHARGING PRESSURE %* Applicable to MST-600 1. Oparate the travel lever to the “NEUTRAL” posi ton and stop the engine. 2. Remove the low-pressure switch (1) behind the ‘operator's seat and Install the ofl pressure gauge (50 kglem?). + Low-pressure switch serow size: PT 1/4 3. Operate the travel lever to the “NEUTRAL” posi- tion and start the engine. Measure the charging pressure when the engine speed is 1,000 tem and 2,000 rpm. * Charging pressure Unit: kg/em? Engine Charging pressure 1,000 rpm 20 2,000 rpm 21 % Uf the pressure is below 10 kg/em®, there may be @ fault somewhere. In such a cate, stop the tengine and locate the fault, ‘* Applicable to MST-600, 700, 800, 1100, 1500 and 2000 1. Operate the travel lover to the "NEUTRAL" posi- tion and stop the engin 2. Remove the plug {1) of the charging pressure port and install the oil pressure gauge (50 kg/am?), 4% Plug screw size: 7/16—20 UNE 3. Operate the travel lever to the "NEUTRAL" posi jon and start the engine, Measure the charging pressure at low idling and high fling, Charging pressure Unit: ka/om? Engine speed | Charging pressure | fe 13-14 Unlose High tling 16-16 On load |Lowidting | = 18 High fling i4—16 + If the pressure is below 10 kg/cin®, there may be 2 fault somewhere, In such @ cate, stop the ‘engine ond locste the fault, 20-8 ‘* For MST:600 % For MST-1100 MST SERIES * Applicable to MST-2200 and MST-2500 1+ Operate the travel lever to the “NEUTRAL” pod For MST:2500 tion and stop the engine, 2. Remove the low-pressure switch (1) behind the : operator's seat and install the oil pressure gouge (60 glen?) * Low-pressur switch part: Quick coupler 3. Operate the travel lever to the “NEUTRAL” post lon and start the engine, Measure the charging Sretsure when the engine speed is 1,000 rpm. * Cherging preseure kgfom? Engine Cheraing pressure fH 1,000 vowels] esse ag ESSE * If the pressure fs below 10 kg/em®, there may be 8 fault somewhere, In such 2 case, stop the engine and locate the fault. * If the pressure of pump charge relief valve (2) does not reach 26 kg/om?, remove cap (3) of the valve, loosen the locknut, and adjust the pressure swith the acjustment screw, 20-9 MST SERIES MEASURING PRESSURE OVERRIDE SWITCHING PRESSURE + Appliceble to MST-1500 Serial No. 15094 and up, and MST-2000 1. Operate the travel lever to the “NEUTRAL” posi- ton and stop the engine, 2, Remove the plug (2) of the mein pump’s pressure ‘override valve (1) snd install the oi pressure gauge {600 kg/em? or 470 kg/m). + Plug screw size: 7/16-20UNF 3, To prevent the vehicle from running away during the hydraulic prossure measurement, connect it to fim fixtures such as fixed concrete blocks, ete, by wire ropes + The fixtures must be strong enough to not break. by the vehicle's tractive power. In addition, use rather big wire ropes, 4, Oporste the travel lever to the “NEUTRAL” posi- ton and start the engine, Start the vehicle by ‘operating the lever and measure the pressure when the vehicle enters the shoe slipping condition due to the fixtures ++ Prossure override switching pressure, Units_kg/em? Model Switching pressure ST 1505 Gtg094— 15164) | te Msi-1500 (GA15165 and uo! 360 wsT-2000 ieee een (#Mo2101 — 02704) 370 #20101 — 20128) WST-2000 eee eeeceaeEEC (#M02105 and up} 350 (9K 20120 and uo) 4k If the pressure Is below the standard value, there may be @ fault somewhore, In such 2 cate, stop the engine and locate the foul. 5, If there is no fault, adjust the pressure using the adjustment craw (3). To adjust, loosen the locknut (4) and screw in the adjustment screw (3), 4% The pressure increases/docreases 70ka/em? when the adjustment screw is turned one complete turn, 20-10 (MST SERIES MEASURING TRAVEL MOTOR RELIEF PRESSURE * Applicable to MST:600, 600, 700, 800, 1100 and ‘MST-1800 Serial No. 16001 — 15083. 1. Operate the traval lever to the “NEUTRAL” tion and stop the engine, % Remove the plug (2) of the travel motor’s high: Pressure port and install the oll pressure gauge (600 ka/em? or 470 kelemn®), % Applicable: to MST-600, 700, 800, 1100 and 1800, Plug screw size: 7/16-20 UNE The MST-600 doesn't have the pressure detection POF mentioned above, Therefore, put an adap. tor, ete, between the eloow (4) of the high. Pressure hose connecting the main pump and the travel motor and the main pump and. install the oil pressure gauge, + Main pump sizcherge port serew size: PTa/4 3. To provent the vehicle from running away during the hydraulic pressure measurement, connect it to firm fctures such a8 fixed conerete blocks, ete, by wire ropes, * The fixtures must be strong enough not to be broken by the vehicle's tractive power, In addi. tion, use rather big wire ropes. Operate the travel lever to the "NEUTRAL" posie tion ond start the engine. Start the vehicle by ‘operating the lever and massure the pressure when the vehicle enters the shoo slipping condition due to the fixtures, % Relief prossure Posi. Unit:_kg/em? ‘Model pressure MST-500 | 280 MST-800 315 __wsr-700 |] 350) fe MST-800 360 MST-1100, 386 NST-1500, 386 ‘If the pressure is below the standard value, there ‘may be a fault somewhere, In such a case, stop the engine and locate the feutt. (MST SERIES 20-17 ‘Applicable to M1ST-1500 Serie! No. 15084 anc uP, and MST-2000 * 1, Oporate the travel Iever to the “NEUTRAL” post tion and stop the enaine, 2. Remove the plug (2) of the travel_motor's High posure port and Install the oil proseure anus (600 kglem? or 470 ka/em*) 4 Plug serew size: 7/1620 UNF 3, To prevant the vohicle from running evey during the nydraulic pressure messurement, connect 1 19 firm fixtures such a5 fixed concrete Blocks, #12 DY wire ropes. sae fixtures must be strong enough not to be broken by the vehicle's tractive power In addl ‘ion, use rather big wire rope 4. When, measuring high-pressure, sore? adjustment crew (1}of the pressure override valve to ono turn, Miter adjusting highpressure, return edjustment ferew {1) and tock with locknut (4) 5. Opmrte the travel ever wo the "NEUTRAL" pos: ceersrnd start. the engine. Start the vehicle BY operating the lever and measure the pressure when gre vehicle enters the shoe slipping condition due to the fixtures. 4 Rel pressure Unit: kg/em™ Modet Relief pressure MST-1600 360 a wST-2000 (eMoz101 — 02108) 385 (#K 20101 — 20128), ‘wST-2000 (#02108 and uP) 350 (#520129 and vp _{itic20129 and ve} __ “+ If the pressure is below the standard value, there may be 2 foult somewhere. In such & cas, s10P the engine and locate the fault 20-12 MST SERIES. Applicable to MST-2200 and 2600 1 2 Operate the travel lever to the “NEUTRAL” posi- tlon and stop the engine Remove the plug (2) of the travel motor’s high- pressure port and Install the oll pressure gauge (600 kkgfem?® or 470 kg/em?), + Applicable to MST-2500 Serial No, 25101 ~ 25186. Remove the plug (2) of the main pump’s high: pressure port and install the off pressure gauge {600 kg/em? or 470 kg/em?). + Plug serew size: PF 1/4 + Applicable to MST 2200 and MST-2500 Serial No, 25187 and up, To provent the vehicle from running awey during the hydraulic pressure measurement, connect it to firm fixtures such as fixed concrete blacks, etc,, by wire ropes, % The fixtures must be strong enough not to be broken by the vehicle's tractive power. In eddi- use rather big wire ropes, Operate the trevol lever to the “NEUTRAL” posi- thon ond stort the engina, Start the vahiele by operating the lever and measure the pressure when the vehicle enters the shoe slipping condition due to ‘the fixtures, > Relief pressure Unit:_ka/om? ‘Mode! Relief pressure MST-2200) 325 MST-2500 360 + If the pressure is below the standard value, there ‘may be a fault somewhere, In such 8 cas9, stop ‘the engine and locate the fault. MST SERIES For MST-2500 Serial No, 25101 — 25186 20-13 MEASURING TRAVEL MOTOR CHARGING PRESSURE + Applisble to BST-600, 700, 800, 1100, 1500 and * FOr NST-B00 i 2000 1. Operate the travel lever to the “NEUTRAL” posi tion and stop the encine. 2, Remove the plug (3) of the charging pressure port and install the oll pressure gauge (60 kg/cm”). Plug seraw sia: 7/16-20UNF 3. Operate the travel lover to the “NEUTRAL” pos tion and start the engine, Meesure the charging pressure when the vehicle i sterted by operating the lover. + The charging pressure is common to the models, 12— 13 kgfom™ + Ifthe pressure isbelow 10 kg/em®, there may be 2 fault somewhere, In such 2 case, stop the engine and locate the faut, 20-14 sr SERIES ot MEASURING MAIN RELIEF PRESSURE OF DUMP CYLINDER CIRCUIT % Applicable to MST-800, 600 and 700 1. Operste the travel lover ané dump lever to the “NEUTRAL” position and stop the engine, 2, Remove plug |1) of dump control valve end install the oll pressure gauge (470 kg/em?), 2% Plug sew size: PT 1/8 3, Operate the travel lever to the "NEUTRAL" pork tion and start the engine. Reise the dump body by operating the dump lever and measure the pressure when the dump body (Gump eylindr) is brought to the stroke end, % Moin cli pressure Unit: Kkgfem? Model pressure MST:500 - 700 175 % Applicable to MST-800, 1100, 1500, 2000, 2200 and 2500 1. Operate the travel lever and dump lever to the "NEUTRAL" position and'stop the engine. Remove plug (1) of the adapter on the dump con- trol valve and install the oll pressure gauge (470 kg/em?}. “ Applleable to MST-800, 1100 and 1500, Plug screw size: PT 3/8 % Applicable to MST:2000, 2200 and 2600. Plug screw size: PT 1/2 3. Operate the travel lever to the "NEUTRAL" posi- tion and start the engine. Raise the dump body by operating the dump lever and messure the pressure when the dump body (dump cylinder) is brought to the stroke end. + Mein cell pressure Unit: kg/em? Mode! Main selef pressure wsT-800 ~ 2600 165 MST SERIES * For MST-800 20-15 CHECKING MAIN PUMP PARTS CHECKING GHARGE RELIEF VALVE AND HIGH-PRESSURE RELIEF VALVE % Applicable to MST-600 °F the cll pressure warning lamp on-the instrument panel lights up or In the event of such trouble as the vehicle does not move, lacks power, and so on, check the main purnp’s charge rellef valve and high-pressure relief valve as follows, © The MST:600 high-prossure relief valve is mounted cn the main pump unike in other models, 1. Operate the travel lever to the “NEUTRAL posi- tion and stop the engine, 2. Check the charge relief valve Remove the charge relief valve (1) and check it for catching dust, foreign matter, oto, spring break down or dilation, the seat abrasion, etc. ‘Chock the high-pressure teliof valve Remove the high-pressure relief valve (2) and check it for bitingin of dust, foreign matter, ote., spring breakdown or dilation, seat abrasion, ete, 3, CHECKING CHARGE RELIEF VALVE % Applicable to MST-600, 700, 800, 1100, 1500 and 2000. * If the oll pressure warning lomp on the instrument panel fights up or in the event of such trouble as the Vehicle does not move, lacks power, and s0 an, check, the main pumps charge relief valve es follows. 1. Oparste the travol lever to the "NEUTRAL" posi- tion and stop the engine, 2. Check the charge rolief valve Remove the plug (1) and draw out the poppet (2) and check the charge relief valve for biting-in of dust, foreign matter, atc, teat abrasion, spring (3) breakdown or dilation, ete 20-16 MST SERIES CHECKING CHECK VALVE * Anplicable to MST-600, 700, 800, 1100, 1500 and 2000 '@ In the event of such trouble as the vehicle does not ‘move, lacks power, and so on, chack the main pump’s check valve as follows, 1. Operate the travel lever 10 the "NEUTRAL" posi- ‘tion and stop the engine, 2. Check the front pump check valve emove the check valve (1) and check it for catch: ing of dust, foreign matter, ete, the ball end sleeve seat abrasion, ete. 3. Check the rear pump check valve 4) Disconnect the hydraulic piping and remove the charging pump (2) by removing 2 tolts. 2) Disconnect the charging part block {3}. 3) Remove 2 sets of chock valves (4) and check them for bitingin of dust, foreign matter, etc, spring breakdown or dilation, ball abrasion, etc, (MST SERIES 20-17 CHECKING PUMP CONTROL VALVE * ‘Applicable to MST-600, 700, 800, 1100, 1800 and 2000 Jn the event of such trouble af the vehicle does not rove, forward/reverse shifting malfunction, ete, the main pump's pump control velve must be checked, Check it as follows. Operate the travel lever to the "NEUTRAL" posi- tion and stop the engine. Disconnect the travel lever's control linkage on the pump side. Remove the main purnp’s purnp control vaive (1) by removing its fixing bolts. 4 The control valve is connected to the servo evl- inder in the main pump. Remove it, therefore, ‘after drawing out the pin of the lever (2} on the valve side from the hole in the link on the eyl- Inder side white lifting the valve a Title. 4 The control valve | equipped with 3 sets of orifices, When removing the valve, thorefore, hold down the orifice (3) and the O-ring with ‘your finger taking care not to let them drop into the pump interior. Ccheck the control valve for the following. 1) Is the orifice (3) hole clogged? 2) Is the control thaft’s (4) spring pin broken? 3) Does the valve epool (5) move smoothly? 44) Has the Exing of the link (6) on the serva cyl- Indor side fallen off? 20-18 (MST SERIES CHECKING SERVO CYLINDER ‘Applicable to MST-600, 700, 800, 1100, 1600 and 2000 In the event of euch trouble as the vehicle does not move, forwardireverse shifting malfunction, ete., check the functioning of the servo cylinder in the ‘main pump os follows, ‘Operate the travel lever to the "NEUTRAL" post- tion and stop the engine. Disconnect the travel lover's control linkage on the pump side. Remove the valve referring to the item on the c’cheeking pump control valve. Insert @ bar @) , ete,, between the servo cylinder (1) and the pump body and engage the tip of the bar with the servo cylinder Check whether the servo cylinder (1) moves smoothly or not By trying to move it beck end forth using the ber @ ag 8 lever the fulerum of wich is the pump body. 4 If the operating force is too light, the cylinder piston spring may break. 4 If the operating force is to heavy, the servo dor may possibly selze up or make @ one- 1d contact. MST SERIES 20-19 REPLACING AND ADJUSTING PUMP CONTROL VALVE + Applicable for MST-2500 + I the machine does not move, or trouble such ae failure to switch between forward and reverse has ‘occurred, the control valve on top of the main pump must be checked and then replaced. The procedure for replacing the control velve and ‘adjusting after replacement is as follows. 1. Removal of contrat valve 1) Set tho travel lever at neutral and stop the cngine. 2) Disconnact control finkege (1) for the travel lever atthe purnp and, 3} Disconnect rubber hoves (2) and (3). + Put blind plugs in the hoses efter disconnect: ing them. 4) Remove mounting bolt (4), then remove lever {6} from shaft (6). ‘% Mounting bolt: Hexagon socket heed screw (Ms x20) 5) Remove 4 mounting bolts (7), then remove con trot valve (8) from the pump housing # Mounting bolt: Hexagon socket hood serow (Me x 20) 2, Installing control valves 1) Ingart rod (9) in the groove of the servo oylinder, install control valve (8) 10 the pump housing, then tighten 4 mounting bolts (7) 4 Tightening torque: 1.2 ~ 1.8 kam 2) Install ever (6) to shaft (5), then tighten mount ing bolt (4) temporarily. 4% Tighten the mounting bolt fully after adjust: Ing the 2ero point. ‘ 3) Connect rubber hoses (3) and (2). 4) Connect control linkage (1) of the travel lever. 20-20 (MST SERIES a Bleeding alr from servo cylinder After replacing the control valve, always bleed the air from the servo evlindor es follows. 1) Start the engine and run at approx. 1000 rpm, 2) With the parking brake lever engaged, operate the steering lever 4 — 5 times between forward and roverse Adjustment method (Adjustment of zara point) Adjust 25 follows. 1) Install hydraulic gauges (500 kg/em?) to main pump perts At and B1 (or A2 and 82) * Screw size of ports AT and Bi: M18 x 1.6 % Using an Uchide Yustsu bushing [Port No. 110078195), make the screw size PT 3/8, 29} Start the engine and run et approx, 1000 rpm, then adjust with adjustment screw (10) of the controf valve so that the pressure gauges at both ports Al and B1 are approx. 20 ko/em?. %* Loosen nut (11), screw in adjustment serew fully, then turn It back one turn, {The adjustment can bs mede within one turn.) 4) When ports At and 81 are the same pressure, Jock adjustment screw {10} with aut (11). % Tightening torque of nut: 1.0 kgm 5} Remove the pressure gauges and bushing, and Install blind plugs in ports A1 and 81 + This is the method for adjusting the zero point of shaft (6) and barrel (12), and the zero point of the pump angle. Always carry out this adjust- ‘ment when the control valve has been replaced. ST SERIES 4 5 ". 5 2 7 4. Lever mounting bolt 9, Red 5. Shaft 10. Adjustment serew 8 Lever 11, Locknue 7. Valve mounting bolt 12, Barrel 20-21 CHECKING TRAVEL MOTOR PARTS CHECKING HIGH-PRESSURE RELIEF VALVE % Applicable to MIST-800, 700, 800, 1100, 1600 and 2000 ‘© In the event of such trouble as the vehicle does not move, locks power, etc,, check the traveling motor's igh-pressure relief valve a: follows, 1 1. Operato the travel lever to the "NEUTRAL" posi tion and stop the engine. 2. Remove the high-pressure relief valve (1) ané check it for catching of dust, foreign matter, ete, spring breskdown or dilation, seat abrasion, etc. CHECKING FLUSHING VALVE + Applicable to MST-600, 700, 800, 1100, 1500, 2000, and 2500, © In the event of such trouble as the vehicle does not move, the hydraulic oil overheats, et, the traveling motor’s flushing valve must be checked. Chock it as follows, (© The flushing valve is equipped with shuttle valve and arge relief valve. 1. Operate the travel lever to the "NEUTRAL" posi- tion and stop the engine, 2. Check the shuttle valve Remove the plug (1) and draw out the shuttle valve and check it for bitingin of dust, foreign matter, fte,, spool (2) abrasion, spring (3) breakdown or lation, ete, In eddition, check whother the shutue valve operates smoothly or not by pushing the spool with your finger 3, Check the charge relief valve Remove the plug (4) and draw out the poppet (5) ‘and chock the charge relief valve for catching of dust, foreign matter, etc; seat abrasion, spring (6) breakdown or dilation, etc. 20-22 (MST SERIES 1% Applicable to MST-800, 700, 800, 1100, 1500 and 2000 ‘Test run the HST as follows whenever a hydraulic motor, travel motor, piping ete, is replaced. Fill, the hydraulic oll tank with oil and check that | Flows out by loosening the sucking part of the ‘charging port piping (1). Then, tighten the pi If oil ie put into the hydrauiie oll tank, air in the it escapes and the oil Is sucked into the case, 2, Remove the front and rear main pump case drain plugs (2} and the right and left travel motor drain plugs (3), fil each case with ol snd connect the piping, 3, The main pump inust be left at the “NEUTRAL” position and the control linkage (4) must be left d+ connscted. 4. Connect esch piping securely, 5, Remove the main pump housing's charging pressuré port plug (5) and install the ofl pressure gouge (60 kglem?). ‘Plug screw size: 7/16~20 UNE 6. Start the engine and run it at the lowest possible speed and check that the charging pressure is at least 10 kgfem?, % Never raise the engine speed before tho HST circuit fg fled sufficiently with oil, or selzure will rosult, 7. Raise the engine spsed to about 1,000 rpm and check that the charging pressure is within the range of 13 ~ 14 kglom?. Stop the engine and connect the control linkage (4) ‘% Cheok the loyer on the pump side, which must be at the "NEUTRAL" position, 9. Sot the travel laver to the "NEUTRAL" position ‘and restart the engine, Raise the speed to 1,500 — 2,000 rpm end run for soveral minutes under no load, % The main pump is min in order to bleed the circuit completely of si 10. Operate the travel fever slowly to the forward/ reverse position and check that it interlocks with the direction of rotation of the motor. ‘The cherging prossure reading fs 16 ~ 16 kg/cm? while the main’pump is running, 11. Apply load gradually after checking thet no bubbles enter the hydraulic of! tank, “Check the oil lavel in the hydraulic olf tank end add oll, if necessory, up to the specified level. ‘Tighten the cap securély after adding oil, + If bubbles In the tenk don't disappear and the oll is turbid and white, air must have been sucked in from the suction side, In such a case, check, (MST SERIES 20-23 HOW TO RELEASE PARKING BRAKE %* Excluding MST-500 In the event of # fault In the HST and for the vehi- cle to be transported to a safe place, release the traveling motors’ parking brake 8 follows, 1. Remove the right and feft traveling motor plugs (1). Ingert s bott (2) and a washer (3) into the plug hole ‘and serew them into the broke piston (4) 4 Bolt size and type: + MST-600, 700, 800, 1100, 1600 and 2000: M10 x 25, Pltsh = 1.5, hexagon socket head cap screw ‘© MST-2200 and 2600: M10 x 65, Pitch = 1.8, hexagon socket head cap screw, 3, As vou tum the bolt (2) about twice, the brake piston (4) is pulled towards the cover side and the parking brake is released, 4, Conneot hoses between the travel motor’s high- pressure and low-prossure sides, + Fora short circuit, one side of the hose connect- {ed to the motor should be disconnected and the 4 pump side of the remaining side should be dis- ‘connected and then connected to the motor. Carry it out on either of the right or left sides. + After manually releasing the parking brake, the Vehicle must not be moved a long distance. s Rother it must be moved just several meters to a safe place, or the HST will break, F ry (MST SERIES 20-24 30 TROUBLESHOOTING Troubleshooting procedure «+++ ++ seederesessees BOF 2 Check before troubleshooting table setseneeneses B02 2 Troubleshooting 1. Machine does not move in any direction, and dump cylinder also does not move...» + eects 30- 3 2, Machine does not move in any direction, but dump eylinder moves. . 30-4 3. Dump cylinder does not move, but machine moves. seeseenes BO 6 4, Left (right) travel motor does not move at all 30-7 5 Left (righ) travel motor does not mova in forwerd (reverse) direction. 30- 8 6. When steering lever is set at neutral, steering does not return to neutral. seers 80-10 7. Machine travels only in forward (reverse) direction. seeeneesenes BOO ..Machino stoors to one sido and does not travel in a straight line. 30-10 9, Engine stops. . i cee 30-11 10. Machine tacks power. fae 30-12 11, Machine sometimes doas not move. tees 1630-14 42, When trovling at low speed, the machine jerks... 26 80-14 13, Response of steering lever is poor. ....- 80-15 14. Operating forcé for stesring lever is abnormally heavy. 30-15 18, Hydraulic oll overheats. Seer 30-16 16, Parking brake cannot be released. ....-. 30-18 17, Parking brake does not take effect. .... = 30-19 18, Abnormal noise generated. ..... = 30-20 49, Hydraulic hose vibrates. oe ae 30-21 20. Hydroulie charge lamp in operator's compartment é 30-22 21, Rubber crawler often comes off. «. ef = 30-23, 22, Even when the low/high speed selector switch is set to HIGH speed does not change. .-- 7 7 pete aerator 30-24 23, Battery does not charge, -.- . 30-26 30-1 MST SERIES TROUBLESHUU IING PROCEDURE Carry out troubleshooting in the following order. 1, Ia request for repairs has been received, first ask about the following items, + Name of customer ‘+ Model and serial number of machine + Details of jobsite, ete. Get ar-outline of the problem, © Symptoms of fallure + Details of work being carried out when problem ceccurred s, details of maintenance, ate. 3, Prepare the necsssary tools, testers, hydraulic kits 45 Try to re-enact the problem, + Operste the machine in the same way (travel, ‘wotk) to check the symptoms. 5. Use the CHECKS BEFORE TROUBLESHOOTING ‘TABLE to locate simple problems, and cary out repairs, + Checks before starting + Other check items 8. _ Carry out troubleshooting (full troubleshooting) ‘Select troubleshooting item that matches symo- toms, and carry out troubleshooting. ee, Method of using troubleshooting chart 1. Select the problem symptoms from the trouble: shooting Table of Contents, 2. First, carry out the checks written under the prob- lem, then earry out troubleshooting aecording to the troubleshooting flow. 3. I the result of the inspection or measurement inside iis YES, go to the (2) on the upper and if it is NO, goto the (below. 4. The Action column on the right side gives the action to take for the result of the inspection or measure ment, 5. The precaution items for troublethcoting are marked * under the frame, 30-2 CHECKS BEFORE TROUBLESHOOTING TABLE item Action 1. Check fuel level ‘Add fuel 2. Check for impurities in| Clean, drain £) tut E |S creck nvaracieotevel | Add ct £ | 4, Chock hydreuic strainer | Clean, drain 5} & Check engine oltre! |Add of! B | 6 Check coolant level Add water J | 7. Check dst indicator Clean, renlace E | 8. Check for loose or corroded} Tighten, replace © | witing of electrical equip- ment 1. Abnormal noise or smell, | Repair from pump, motor 2. Cheek for leakage of oi! | Repair, replace from equipment or hydrau- £]_ ticpiping 2/3, Check charge line fier | Clear, replace % | 4 Bleoaing of er Bleed air £5. Check battory voltece | Charge, replace 5} (20~30v) & | 6. check battrysactolyte | Ade replace level 7, Check olecrical wiirg | Repair, place 8. Check for blown or Replace corroded fuses (MST SERIES 1, Machine does not move in any direction, ana aump cyuinaer aso aves nUL MUve, [Ask the operator the following points. © Did the machine suddenly stop moving? Yes = Component seized or broken © Vise there any abnormal noise when the machine stoppped moving? (From what ares?) Yes = Compor broken Checks before troubleshooting ‘© soil level in hydraulic tank correct? © Is there interference of disconnection of steering control linkage? «Is there damage o leakage from piping betw/een charge pump and dump control valve? aso rsa iin oe 2 crete at Inspect stain seb] ce neentctn | ® esate sare piesa eet Be oie 1 pao reptace hare ® epravepace msin Pos es Tablet naga isa ot epee pacer - odot | iEgine 9 1000 Got weobinhaning ‘ee x Sis MgT.600 ao kava THST-G00 [Rewwal ts — 14 ig/en wst2000 fonioad| tt — 19 keen ‘MS¥-2200, 2500 | _26a/en? “#1; When replacing the mein pump, tighten the mounting nut of the center coupling securely S=HD Mounting nut: 20 ~ 24 kgm {MST-600 ~ MST-1800) 51 — 9 kgm (MST-2000) (MST SERIES 30-: 2, Machine does not move in any direction, but dump oy ‘Atk the operator the following points. © Did the machine suddenly stop moving? Yes = Component seized or broken ‘© Wes there any abnormal noise when the machine stopped moving? (From what area?) Yes = Component broken Checks before troubleshooting Is oll leva in hydraulic tank correct? © Is there interference or disconnection of steering control linkage? © Is there damage or leakage from piping between dump control valve and main purnp? Is there damage or leakage from piping between main pump and travel motor? \s there domoge or leskage from parking brake piping? °, aaa O-4 frac peeire ‘met Gere 2) © ete ve x retecie eae BER Tigges he femomeS © xL sings meee ie 5 net ot ans Ly faethe Lf rosie itera co see s wares] aotgren™ are ——] ste area E Tay Tonner | ~ Dare wsrmieo | sestarenr—] ate} Tatiea oe [Crecting pressure ere 385 igen? Charge pressure ng pressure estore z Shave eu vosst farsa ait on were ED Ver Ein 100 a) aa rent = watcoaenieten | S7k/en? wigan 1 —aabigz nas ae ese trcave—2012520120 “eon {ions Tarate si] Ta tere ii cS rans Seog e = wero) aaa wren oreo nstogo_[6rmea| 11 Tare incaro\—7or25 22a 57-226 325 kg/em?_ (MST-2200, 2800 25 ka/emn? #ne02101—02104) ST 2500 3 a MST.2000 1 “380i em? S700 —— (WK20127, 20128—}HMO2105—} MST SERIES 30-4 reac il mamta ee Inepact ha ai pap epat ot alce presse ‘verse ae af as ‘ui (See epee ne wae! mot dei tna te. Wash cope Be irate “+1; When replacing the main pump, tighten the mounting nut of the canter coupling securely. GISEI Mounting nut: 20 ~ 24 kom {MST:600 ~ MST-1600) 51 — 69 kgm (MST-2000) #2: When checking or replacing any val MST SERIES ways check that there Izno dirt or dust ceught in it 30-5 3, Dump cylinder does not move, or does not move properly, but machine moves. ‘Ask the operator the following points, © Did the cylinder suddenly stop moving? Yes = Component seized or broken ‘© Was there eny abnormal noise when the eylinder stoppped moving? (From what area?) Yes = Component broken, © Was the speed of the carrier slow before? Yes = Parts worn Chocks before troubleshooting © Iso level in hydraulic tank correct? © Is there excessive play, breakage at dump lever pin? {from piping between dump contro! valve and dump cylinder? © Ie there damage or teak a emesr @ ome Op Srp Inept iad of esos ryote OF eaten tea i @ crested eee = ot reser ane 2 keine stow x ee Bee Ieee nue doe? ois [inane aaa | Tatar a f ‘Model ‘Hydraulic dritt [ieee et © apace pasting an san), ov Spate pos eps epac dm ® 0, Convelvee ee 8 x ‘dumpeowelsive snd ‘timp erin Adj reps a epiace ln ve me ‘ont eee A) ii ot tots Ropar or replace charge “#1: When checking oF replacing any valve, elways check that there is no dirt or dust cought in it 30-6 (MST SERIES Me Rete yeiginyy Gaver muir Uues HOE Move at all, Ask the operetor the following points £ Did the motor suddenly stop meving? Yes = Component selzed or broken * fhe: there any sbnormal nolse when the motor stoppped moving? (From what rea?) Yes = Component Cheeks before troubleshooting © [soll level in hydraulle tank correct? ‘Is there interference of disconnection of steering contra linkage? Is there damage or leakage from piping between main pump and travel motor? '# le there damage or leakage from parking brake piping? ° sere ang a cog parte carl ae Bons conion apa orepace cart merece? io est yanentee eases prove snout? ops o cptace io x pa eo +1: When ceplacing the mein pump, tighten the mounting nut of the center coupling securely. BE) Mounting out: 20~ 24 kgm (MST-600 ~ MST-1500) 51 ~ 59 kgm (MST-2000) 42: When checking or replacing sny valve, alweys check that there eno dirt ar dust caught In it. (MST SERIES. 30-7 5. Left (right) travel motor does not move in forward (reverse) direction, ‘Ask the operator the following points. ‘© Did the motor suddenly stop moving? Yos = Component seized or broken ‘© Wes there any stnormal noise when the motor stoppped moving? {From what area?) Ye ‘Component broken. ‘Checks before troubleshooting ls oil level in hydraulic tank correct? Interference or disconnection of steering contro} linkage?

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