D155A-2 # S6D155-4D Engine SEBM01750209

SEBM01750209 SHOW IMCAUNTOZA\ILs KOMATSU DID9A-2 MACHINE MODEL SERIAL No D155A-2 50001 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. ‘© D155A-2 mount the S6D15-4 engine. For details of the engine, see the 155-4 Series Engine Shop Manual. ©1904 MomaYSU All Rights Reserved Printed in Japan 11-94(03)03181 00-1 ®CONTENTS 10 STRUCTURE AND FUNCTION ......................005555 20 TESTING AND ADJUSTING 30 DISASSEMBLY AND ASSEMBLY ......................... 40 MAINTENANCE STANDARD ......................0...0055 00-2 @ No. of page 10-1 20-1 30-1 40-1 017502017502 ‘The affected pages are indicated by the use of the following marks. It is requested that necessary actions. must be taken to these pages according to the list Merk eaeten polenreaed below. © | Page to be newly added | Add + | Page to be replaced Replace (| Page to be deleted Discard Pages having no marks are not revised at this time. 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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 To prevent injury to workers, the symbol Ji is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. 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, ete. 3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work. 4, When carrying out any operation with two oF more workers, always agree on the operating 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 warning signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing 00-3‘SAFETY SAFETY NOTICE 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 components of the oil, water or air circuits, first remove the pressure completely from the circuit. 42, 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 hitting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18. As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts. 19. 20. 21. 22. 23. 24, Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. ‘+ When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. ‘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 separates suddenly, so never let anyone stand at either end of the track.FOREWORD GENERAL FOREWORD GENERAL This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components. ‘STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an 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 date.FOREWORD HOW TO READ THE SHOP MANUAL VOLUMES Shop manuals are issued as a guide to carrying out repairs. They are divided as follows: Chassis volume: Issued for every machine model Engine volume: Issued for each engine series. Each issued as one volume to cover all models Electrical volume: Attachments volume: These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work. FILING METHOD 1. See the page number on the bottom of the Page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume): 10-3 Item number (10. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume): Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. 3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example. Example: 12-203 5 12-203-1 2} Added pages {13 999.9 12-208 HOW TO READ THE SHOP MANUAL REVISED EDITION MARK When a manual is revised, an edition mark (OO...) 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 necessary when performing the work, Safety Special technical precautions or other precautions for pre- serving standards are necessary when performing the work. Caution Weight of parts of systems. Caution necessary when se- lecting hoisting wire, or when working posture is important, ete, kg Weight Places that require special attention for the tightening torque during assembly. [Tightening| torque Places to be coated with ad- Coat | hesives and lubricants, ete. Places where oil, water or fuel must be added, and the capacity. Oil, water Places where oil or water must be drained, and quan- tity to be drained. Drain beyFOREWORD HOISTING INSTRUCTIONS HOISTING By Heavy parts (25 kg oF 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 _+. Goa « If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existence of another part causing interference with the part to be removed. WIRE ROPES 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard "2" or "S* twist ropes without galvanizing) Rope diameter (mm) | Allowable load (tons) 10 10 12 14 125 16 4 22 16 28 18 36 20 44 22.4 56 30 10.0 40 18.0 50 28.0 60 40.0 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 r sult. Hooks have maximum strength at the middle portion. 100% 88% 79% «= 71% = 41%. 3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 4) Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. ‘When two ropes sling a load vertically, up to 2000 kg of total weight can be sus- pended. This weight becomes 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 4000 kg if they sling a 2000 kg load at a lifting angle of 150°. * 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. x ae 5 on i - i foeFOREWORD COATING MATERIALS COATING MATERIALS The recommended coating materials prescribed in Komatsu Shop Manuals are listed below. Category [Komatsu code] PartNo. | O%y | Container Main applications, features + Used prevent rubber gaskets, rubber cushions, Cita aeaiceeeen i anene Tube |" and cork plugs from coming out = 2 * Used in places requiring an immediately effec- ~ 29-908 g lastic_ |” tive, strong adhesive. Used for plastics (except LTB] 790-128-2050 ) 142) | container | polyethylene, polypropylene, tetrafluoroethyiene, {and vinyl chloride), rubber, metal, and non-metal Plaats | Features: Resistance to heat, chemicals 2 ov940-00030 | 50g | QPastic |* Used for ant-loasening and sealant purposes for Adhesive bolts and plugs. 0-1 soca [Aas > Used as adhesive or sealant Yor metal, glass, plastic. (Sex of adhesive | urs (Se ehametie| Hardening | Can rden9ig| agent: ert :500 9 tra |7e0-128.9000| 2509 | asta |» Used ws sealant Tor machined holes + Features: Resistance to heat, chemical (Loctite 648-50)|79A-128-9110 | 50 ec = | Used ‘at joint portions subject to high tempera ture > Used as adhesive or sealant for gaskets and ee eee eee | abe packings of power train case, etc > Features: Resistance to heat + Used as sealant for flange surfaces and bolts at high temperature locations, used to prevent sei- Le-3 | 790-128-8070] 1Ke can cetaeees eee + Used as sealant for heat resistant gasket for high temperature locations such as engine precomibustion ‘chamber, exhaust pipe + Features! Resistance to water, olf + Used as sealant for flange surface, thresd 29-90% ‘ube |* Aiso possible to use as sealant for flanges with Gasket seatat| — “O* | 790-128-9020 200 | Tub large clearance + Used as sealant for mating surfaces of final drive ‘case, transmission case Used as sealant for various threads, pipe joints, Plastic | flanges eee 790-128-9080 | 1KG | container |+ Used as sealant for tapered plugs, elbows, nip- ples of hydraulic piping > Features: Silicon based, resistance to heat, cold LG-6 | 09940-00011 | 250g | Tube + Used as sealant for flange surface, thread + Used as sealant for oll pan, final drive case, ete. Features: Silicon based, quick hardening type LG-7 | 09920-00150 | 150g | Tube + Used as sealant for flywheel housing, intake manifold, oil pan, thermostat housing, ete Rust prove Used a5 lubricant for sliding parts (0 prevent tion lubricant = sease-oooss | 900 = squeaking) ‘Molybdenum Used to provent seizure or scuffing of the thread disulphide tu- 7 09940-00040 | 200g | Tube when press fitting or shrink fitting bricant +_ Used as lubricant for linkage, bearings, ete SYG-350L1 >General purpose type S¥G-400L! Litium grease | G21 |S¥G-400L1-A | Various | Various SYG-160L1 ISYGA-1600NL [SSG2-400CA + Used for normal temperature, ight Toad bearing S¥G2-a50C8 2at places in contact with water or steam Cakiumgwase| G2-CA | SYG2-A00CA-A) Various | Various S¥G2-160CA SYGA-IGCNCA Molybdenum + Used Tor places with heavy Toad - 4009 | petiows mice 8¥62-400M | 9420 8. Bellows type 00-8FOREWORD STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUES OF BOLTS AND NUTS The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in section of DISASSEMBLY AND ASSEMBLY. STANDARD TIGHTENING TORQUE 1 Kgm = 9.806 Nm Thread diameter Width of bolt across flats a mm mm kgm Nm 6 10 1.35 20.15 13.2214 8 13 3.2203 31.4229 10 ” 6720.7 65.7268 12 19 11.5210 112498 “ 2 18.0+2.0 17719 16 24 28.523 279229 18 2 3924 383 +39 20 30 5626 549258 2 32 16+8 745278 24 36 94.5210 927 +98 2 a 135215, 1320140 30 46 175220 1720+190 33, 50 22525 2210240 36 55 28030 2750290 39 60 335235 3280+340 * This torque table does not apply to the bolts with which nylon packings or other nonferrous metal washers are to be used, or which require tightening to otherwise specified torque.FOREWORD STANDARD TIGHTENING TORQUE TIGHTENING TORQUE OF SPLIT FLANGE BOLTS Use these torques for split flange bolts. Thread diameter Width of bolt across flats Tightening torque mm mm kgm Nm 10 1“ 6.7207 65.7268 2 a 1521 112298 16 2 28.523 27929 TIGHTENING TORQUE FOR FLARED NUTS Use these torques for flared part of nut. Thread diameter | Width across flats of nut part of nut part Tightening torque mm mm kgm Nm 4 19 25205 24.5249 18 24 522 492196 2 27 822 78.52 19.6 24 32 1423 13732294 30 36 1823 176.5+29.4 33 a 2025 196.1249 36 46 2525 245.2249 42 55 3025 294.2249 00-10FOREWORD 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 5 6 =| 0.32 5.23 46 37 Charging and signal 15 84 0.45 13.36 7.0 59 Starting (Glow plug) || om | erm | ane | to | sig soo [a7 [am | voor [ne [ane | CLASSIFICATION BY COLOR AND CODE PHT Nciagah Charging | Ground | Starting | Lighting | Instrument | signal Other 1 | mary] cots] wee ae | aux ant | vaw | Gun | TT eee] [paw [aw ot wie] —— ec a ii ta wien |S i Cotte aa] — [a va ovo ftw 8S an ed] wad Tus com] me [=p | w]e | @ | ary Cotor| White & Blue = Black & Red |Red & Yellow |Yellow & Green|Green & Yellow|Blue & Yellow: | calves [=] - |. [|e |u ‘Cotorlwhite & Green] — — Ted & Green |Yetow 8 Blue[Green & Back] Blue & Back 0) [eos] ee m= fe eee eer fe cou] — | =| =| at i ftv iin ae] —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 65 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 decimal point one place to the left) to convert it to 55 mm. (2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. (3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches. Millimeters to inches 1mm = 0.03937 in ° 1 2 6 7 8 9 0 |o 0.039 | 0.079 10 | 0.394 | 0.433 | 0.472 20 | 0.787 | 0.827 | 0.866 30 | 1.181] 1.220] 1.260 40 | 1.575 | 1.614] 1.654 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 50._.| 1,969 | 2.008 | 2.047 | | 60°") "2.362"]"2.402 )"2.487 2: 70 | 2.756 | 2.795 | 2.835 go | 3.150] 3.189] 3.228 90 | 3543] 3.583 | 3.622 2.205 | 2.244| 2.283 | 2.323 2.598 | 2.638 | 2.677 | 2.717 2992 | 3.032] 3.071 | 3.110 3.386 | 3.425 | 3.465 | 3.504 3.780 | 3.819| 3.858 | 3.898FOREWORD Millimeters to Inches CONVERSION TABLE 1mm = 0.03937 in ° 1 2 3 4 5 6 7 8 9 0 o 0.039 | 0.079 | 0.118 | 0.157 | 0.197 | 0.236 | 0.276 | 0.315 | 0.354 10 0.394 | 0.433 | 0.472 | 0.512 | 0.551 | 0.591 | 0.630 | 0.669 | 0.709 | 0.748 20 0.787 | 0.827 | 0.866 | 0.906 | 0.945 | 0.984 | 1.024 | 1.063 | 1.102 | 1.142 30 1.181 | 1.220 | 1.260 | 1.299 | 1.339 | 1.378 | 1.417 | 1.457 | 1.496 | 1.536 40 1.675 | 1.614 | 1.654 | 1.693 | 1.732 | 1.772 | 1.811 | 1.850 | 1.890 | 1.929 50 1.969 | 2.008 | 2.047 | 2.087 | 2.126 | 2.165 | 2.205 | 2.244 | 2.283 | 2.323 60 2.362 | 2.402 | 2.441 | 2.480 | 2.520 | 2.559 | 2.598 | 2.638 | 2.677 | 2.717 70 2.756 | 2.795 | 2.835 | 2874 | 2.913 | 2953 | 2.992 | 3.032 | 3.071 | 3.110 80 3.150 | 3.189 | 3.228 | 3.268 | 3.307 | 3.346 | 3.386 | 3.425 | 3.465 | 3.504 90 3.543 | 3.683 | 3.622 | 3.661 | 3.701 | 3.740 | 3780 | 3.819 | 3.858 | 3.898 Kilogram to Pound 11 kg = 2.2046 Ib 0 1 2 3 4 5 6 7 8 9 ° 0 220} 441| 661! 882| 11.02] 13.23] 15.43) 17.64| 19.84 10 22.05| 24.25| 26.46) 28.66| 30.86) 33.07| 35.27| 37.48] 39.68| 41.89 20 44.09 | 46.30| 48.50] 50.71| 51.91| 55.12] 97.32] 5953} 61.73| 63.93 30 66.14) 68.34| 70.55] 7275| 74.96| 77.16| 79.37| 81.57] 8378| 85.98 40 88.18 | 90.39| 92.59] 94.80| 97.00] 99.21 | 101.41 | 103.62 | 105.82 | 108.03 50 110.23 | 112.44 | 114.64 | 116.85 | 119.05 | 121.25 | 123.46 | 125.66 | 127.87 | 130.07 60 132.28 | 134.48 | 136.69 | 138.89 | 141.10 | 143.30 | 145.51 | 147.71 | 149.91 | 152.12 70 154.32 | 156.53 | 158.73 | 160.94 | 163.14 | 165.35 | 167.55 | 169.76 | 171.96 | 174.17 80 176.37 | 178.57 | 180.78 | 182.98 | 185.19 | 187.39 | 189.60 | 191.80 | 194.01 | 196.21 90 198.42 | 200.62 | 202.83 | 205.03 | 207.24 | 209.44 | 217.64 | 213.85 | 216.05 | 218.26FOREWORD CONVERSION TABLE Liter to U.S. Gallon 1 = 0.2642 US. 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 2.662 | 2.906 | 3.170} 3.434 | 3.698 | 3.963 | 4.227 | 4.491) 4.755 | 5.019 20 5.283 | 5.548 | 5.812 | 6.076 | 6.340 | 6.604 | 6.869 | 7.133 | 7.397 | 7.661 30 7.925 | 8.189 | 8.454 | 8.718 | 8.982 | 9.246 | 9.510 | 9.774 | 10.039 | 10.303 40 10.567 | 10.831 | 11.095 | 11.359 | 11.624 | 11.888 | 12.152 | 12.416 | 12.680 | 12.944 50 13.209 | 13.473 | 13.737 | 14.001 | 14.265 | 14.529 | 14.795 | 15.058 | 15.322 | 15.586 60 15.850 | 16.115 | 16.379 | 16.643 | 16.907 | 17.171 | 17.435 | 17.700 | 17.964 | 18.228 70 18.492 | 18.756 | 19.020 | 19.285 | 19.549 | 19.813 | 20.077 | 20.341 | 20.605 | 20.870 80 21.134 | 21.398 | 21.662 | 21.926 | 22.190 | 22.455 | 22.719 | 22.983 | 23.247 | 23.511 90 23.778 | 24.040 | 24.304 | 24.568 | 24.832 | 25.096 | 25.361 | 25.625 | 25.889 | 26.153 Liter to U.K. Gallon 1 = 0.21997 UK. Gal 0 1 2 3 4 5 6 7 8 9 0 0 0.220 | 0.440 | 0.660 | 0.880 | 1.100) 1.320] 1.540| 1.760 | 1.980 10 2.200 | 2.420 | 2.640 | 2.860 | 3.080) 3300 | 3.520] 3.740| 3.950| 4.179 20 4.399 | 4.619 | 4.839] 5.059 | 5.279) 5.499 | 5.719 | 5.939] 6.159| 6.379 30 6599 | 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 | 10.559 | 10.778 50 10.998 | 11.281 | 11.438 | 11.658 | 11.878 | 12.098 | 12.318 | 12.528 | 12.758 | 12.978 60 13.198 | 13.418 | 13.638 | 13.858 | 14.078 | 14.298 | 14.518 | 14.738 | 14.958 | 15.178 70 15.398 | 15.618 | 15.838 | 16.058 | 16.278 | 16.498 | 16.718 | 16.938 | 17.158 | 17.378 80 17.598 | 17.818 | 18.037 | 18.257 | 18.477 | 18.697 | 18.917 | 19.137 | 19.367 | 19.577 90 19.797 | 20.017 | 20.237 | 20.457 | 20.677 | 20.897 | 21.117 | 21.337 | 21.567 | 21.777 00-14FOREWORD CONVERSION TABLE kgm to ft. Ib 1 kgm = 7.289 ft tb oO ‘1 a 3 4 5 6 ed 8 9 Oo 0 72 14.5 217 28.9 36.2 43.4 50.6 57.9 65.1 10 723 79.6 86.8 94.0 | 101.3 | 1085 | 115.7 | 123.0 | 130.2 | 137.4 20 | 1447 | 1519] 1591 | 1664 | 1736) 1808 | 1881 1953 | 2025 | 2098 30 | 2170| 2242| 2315 | 298.7 | 2459 | 2532 | 260.4 | 267.6 | 2749 | 262.1 4o | 2893 | 2966| 3038 | 311.0 | 3183 | 3255 | 332.7 | 340.0 | 347.2 | 354.4 50 361.7 | 368.9 | 376.1 | 383.4 | 390.6 | 3978 | 405.1 | 4123 | 419.5 | 426.8 60 | 4340 | 4412 | sas | 455.7 | 462.9 | 4702] 4774 | 4046 | 4x8 | 499.1 7o | 5063 | 5135 | 5208 | 5280 | 55.2| sazs| 59.7 | ss69 | so42 | 571.4 80 578.6 | 585.9 | 593.1 | 600.3 | 607.6 | 6148 | 622.0 | 629.3 | 636.5 | 643.7 90 651.0 | 658.2 | 665.4 | 672.7 | 679.9 | 687.1 | 694.4 | 701.6 | 708.8 | 716.1 roo | 7233 7305 | 7378) 745.0) 752.2 7595 | 7667 | 7739 | 7812 | 768.4 110 795.6 | 802.9 | 810.1 | 817.3 | 824.6 | 831.8 | 839.0 | 846.3 | 853.5 | 860.7 120 868.0 | 875.2 | 882.4 | 889.7 | 896.9 | 904.1 | 911.4 | 918.6 | 925.8 | 933.1 130 | 9403) 9475) 954.8 | 962.0 | 969.2) 9765 | 9837 | 9909 | 998.2 | 1005.4 140, 1012.6 | 1019.9 | 1027.1 | 1034.3 | 1041.5 | 1048.8 | 1056.0 | 1063.2 | 1070.5 | 1077.7 | | 150, 1084.9 1092.2 | 1099.4 | 1106.6 | 1113.9 | 1121.1 | 1128.3 | 1136.6 | 1142.8 | 1150.0 160 1187.3 1164.5 | 1171.7 | 1179.0 | 1186.2 | 1193.4 | 1200.7 | 1207.9 | 1215.1 | 1222.4 170 1129.6 | 1236.8 | 1244.1 | 1251.3 | 1258.5 | 1265.8 | 1273.0 | 1280.1 | 1287.5 | 1294.7 180 | 1301.9 | 1309.2 | 1316.4 | 1323.6 1330.9 | 1338.1 | 1345.3 | 1352.6 | 1359.8 | 1367.0 190 | 1374.3 | 1381.5 | 1388.7 | 1396.0 | 1403.2 | 1410.4 | 1417.7 | 1424.9 | 1492.1 | 1439.4FOREWORD CONVERSION TABLE kg/em? to Ib/in? Tkglom? = 14,2233 Ibyin? 0 1 2 3 4 5 6 7 8 9 ° 0 142| 284] 427) 969 | 71.1| 953] 996 | 1138| 128.0 10 142.2 | 156.5 | 170.7 | 1849] 199.1 | 2134 | 227.6 | 2418 | 2560 | 270.2 20 284.5 | 298.7 | 3129| 327.1 | 341.4| 355.6 | 3698 | 384.0 | 3083 | 4125 30 426.7 | 440.9 | 455.1 | 469.4] 483.6 | 4978 | 5120] 5263 | 540.5 | 554.7 40 568.9 | 5832 | 597.4| 611.6 | 625.8 | 640.1 | 6543 6685 | 682.7 | 696.9 50 711.2 | 725.4 | 739.6 | 753.8 | 768.1 | 782.3 | 7965 | 810.7 | 825.0 | 839.2 60 853.4 | 867.6 | 881.8 | 896.1 | 9103} 9245 | 938.7 | 953.0 | 967.2 | 981.4 70 995.6 | 1010 | 1024 | 1038 | 1053 | 1067 | 1081 | 1095 | 1109 | 1124 go} 1138 | 1152 | 1166 | 1181 | 1195 | 1209 | 1223 | 1237 | 1252 | 1266 90 | 1280 | 1294 | 1309 | 1323 [1337 | 1351 | 1365 | 1380 | 1394 | 1408 yoo | 1422 [1437 J 1451 | 1465 | 1479 | 1493 | 1508 | 1522 | 1536 | 1550 io | 1565 | 1579 1593 | 1607 | 1621 | 1636 | 1650 | 1664 | 1678 | 1693, 120 | 4707 |4721 J 1735 | 1749. | 1764 | 1778 | 1792 | 1806 | 1821 | 1895 130 | 1849 | 1863 [1977 | 1992 | 1906 | 1920 | 1934 | 1949 | 1963 | 197 140 | 1991 |2005 | 2020 | 2034 | 2048 | 2062 2077 | 2091 | 2105 | 2119 160 2134 |2t4s |2162 /2176 | 2190 | 2205 |2219 | 2233 | 2247 | 2262 160 | 2276 | 2290 | 2304 | 2318 | 2333 | 2347 | 2361 | 2375 | 2389 | 2404 yo |2418 | 2432 | 2446 | 2460 | 2475 | 2489 | 2503 | 2518 | 2532 | 2546 180 | 2560 | 2574 | 2589 | 2603 | 2617 | 2631 | 2646 | 2660 | 2674 | 2688 190 | 2702 | 2717 | 2731 | 2745 | 2759 | 2773 | 2788 | 2802 | 2816 | 2830 200 | 2845 | 2859 | 2873 | 2887 | 2901 |2916 |2930 | 2944 | 2958 | 2973 210 | 2987 |3001 | 3015 | 3030 | 3044 | 3058 |3072 | 3086 | 3101 | 3115 220 | 3129 3143 | 3158 |3172 | 3186 | 3200 | 3214 | 3229 | 3243 | 3287 230 | 3271 |3286 | 3300 | 3314 | 3328 |3343 | 3357 | 3371 | 3385 | 3399 240 | 3414 3428 | 342 | 3456 | 3470 | 3485 | 3499 | 3513 | 3527 | 3542FOREWORD CONVERSION TABLE Temperature Fahrenteit-Centigrade Conversion : @ simple way to convert a Fahrenheit temperature reading into @ Centigrade tempera: ture reading or vice versa is to enter the accompanying table in the center or boldface column of figures. ‘These figures refer to the tomperatue in either Fahvenheit or Centigrade degrees 1 itis desired 10 convert trom Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the lf. fits desired to conver from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right ree mer aaa: oe °c eee c oe a re ~oa | ao [woo] -nr| on | se | 22] a | wae | a2] or | oe “m2 |" | iso] ca | 2 | se] as] a | tee | ae) a2 | woe Sea | So | Go| os} is | see] go | ae | nee | aos | ao | sore cz | a | “30 | too} 1 | sr] sa] a | 202] ze | ce | ta fee | a0 | a | cen ise es |e ooo | azo) aoa |e | es aa} a2 | 22| 29] w | soe} io) s: | 1298] 200] os | r25 Sa | ce | oa] 333] 7 | ee | ma] s | ace] aoe | ar | wee Hera lion | tea [emai ne | ene | ate) sa | era tana ea | oo cer | “6 | 32] 32] a | os2 | iz] se | tz | ony | eo | toe mee rr ee Pa ee ype -se|-« | 6a] -s1| 2 | ee | 122] 6 | rae] 220) o1 | 150 Bien |e) ae |eceee | ais | ee or [ue es ar | re gael | Sra) toa | realli oa | aaa | ie oe ane ssa | ea | Gre “ae | on | wz | “ae | a | 52] iso | So | to02 | dea | ce | gone “3 | io | tao | “33 | 2s | m0 | tse | 60 | woo] aso | os | 090 -as| 2 | ws| -s3| 2 | re | 101] 0 | wre] ase) os | 2000 Has | ee |e |ocee (are | eas | ee | oe ae | ant | a7 | cone ar | > | toa | a2] 2 | eee | a2] oo | vase | aco | oe | cone cua | @ | a2 | Az] 2 | sez | ta] oe | 2 | ro | co | zoe “as | S| Bo] Ar | a | sso] saa | | seo | ae | sco | Z20 | 00) + | 2a | 06] a: | oe | ro] oo | soe} aoe | 105 | 2200 Tea] 3 | 28 | 0° | a2 | sce | ta | or | ase | coo | to | 2900 Tao | 2 | zac | oo| as | ove | ono] oo | tee] aoa | nis | 2000 saa} | a2 | 33 | se | saa | aoe | oo | ts62 | feo | 120 | 2ae0 Tre] 0 | 320] i] ss | sco | an | so | aseo | sty | tas | aro Sa a 33.8 om 36 96.8 217 1 159.8 544 130 «| 266.0 ser | 2 | 356 | 23 | 3 | see | 222 | 72 | are | ova | tas | aso wet) 3 | ars | 33) 3 | toe | 226 | 73 | tone | ooo | tao | auco Tse | 4 | go2| 39] 30 | toz2 | 23 | m | toez | oar | vas | aos “30 | 8 | suo | as] a | ico | ans | 5 | toro | ose | to | soz Bee |e aese |e sel me | mea | cae | ae lovee) canst | an | iin cae] 7 | us| se | a | sre | aso) a | aoe | oa | wo | soo was | 8 | ase] 61 | as toe | ze6 | 7 | ze | m9 | tos | sone vas | 9 | as2| 67 | a jamz | zr | 7 | a2 | yer | a0 | soso “22 | a | soo | 32] & | 130] 267 | a0 | woo} soa | te | sero | |WEIGHT TABLE eee Unit: kg Machine Mode! D155A-2, Serial No. 50001 and up Engine and torque converter assembly 2,936 Engine assembly 2,660 ‘© Torque converter assembly 221 ‘+ PTO assembly 80 Fuel tank assembly 720 TORQFLOW transmission assembly 860 * Control valve assembly 35 Bevel gear shaft and steering clutch assembly - ‘© Steering clutch and brake band assembly (each side) 160 ‘+ Bevel gear shaft 35 * Bevel gear 40 Steering control valve assembly 12 Final drive case (each side) 185 ‘Sprocket assembly (each side) 310 ‘Steering case and main frame assembly 3,000 * Sprocket shaft (each side) 145 Track group assembly (each side) 3,565 ‘Track frame (each) 1,330 ‘© Recoil spring assembly (each) 270 ** Idler assembly (each) 450 ‘+ Track roller assembly (Single flangel(each) 130 * Track roller assembly (Double flangel (each) 140 * Carrier roller assembly (each) 65 Track shoe assembly (each) 2,520 Equalizer bar 340 Hydraulic tank assembly 360 + Blade control valve assembly 95 —————————————————————— 017502017502 Unit: kg Machine Model D155A-2 Serial No, 50001 and up Blade lift cylinder assembly (each) 200 Blade tilt cylinder assembly 245 Ripper lift cylinder assembly (each) 265 per tilt cylinder assembly (each) 290 Straight tltdozer assembly 4,325 * Blade 2,245 © Straight frame (each) 660 © Tilt cylinder assembly 245 ‘Multiple shank ripper assembly 5,560 + Shank assembly (each) 285 * Lift cylinder assembly (each) 265 * Tilt cylinder assembly (each) 290 Radiator guard and blade lift cylinder assembly 1,570 © Radiator guard = ‘+ Radiator assembly 435 * Blade lift cylinder assembly (left and right) 400 Engine underguard 300 ‘Transmission underguard 175 Hood 87 Fender (left) 248 Fender (right) 259 Floor frame assembly 400 Cab assembly 460 ROPS assembly 490 00-19 @TABLE OF FUEL, COOLANT AND LUBRICANTS KIND OF AMBIENT TEMPERATURE CAPACITY (¢) RESERVOIR oa no -4 2 sort | Specitied | efit Engine ol pan | n 7 | Steering case (ine, torque converter and | 185 136 ‘wansmission case) Final drive case (each) ae 5 55 Recoil spring case (each) 8 5 Hydraulic tank 164 103 Idler (each) Jose — 04s ]oa9— 04s ‘Tack roller (each) Gear oit ee ee Carrer roller (each) Joss —072|063— 0.72 Fuel tank Diesel fue! 600 - is nae Cooling system Coolant ‘Add antifreeze 165 - * ASTM D975 No. 1 NOTE: (1) When fuel sulphur content is less than 0.5 %, change oil in the oil pan every periodic main: tenance hours described in this manual. Change oil according to the following table if fuel sulphur content is above 0.5 %. Fuel sulphur content | Change interval of oi in engine oil pan 0.5 to 1.0 % 1/2 of regular interval Above 1.0 % 1/4 of regular interval ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers API: American Petroleum Institute (2) When starting the engine in an atmospheric ‘temperature of lower than 0°C, be sure to use engine oil of SAEIOW, SAE10W-30 and SAE15W-40 even though an atmospheric tem- erature goes up to 10°C more or less in the day time. (3) Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to half. (4) There is no problem if single grade oil is mixed with multigrade oil (SAETOW-30, 15W-40), but be sure to add single grade oil that matches the temperature in the table on the left. (8) We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equip- ‘ment applications. Specified capacity: Total amount of oil including oil for components and oil in piping. Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance. 00-20 ® 017502017502 10 STRUCTURE AND FUNCTION General ...... _ 10-2 Power train hydraulic system ........s.. 10+ 4 Power train hydraulic circuit diagram 10-5 Torque converter ...........c0ecccceee 10° 6 ‘TOROFLOW transmission 10-10 Transmission control ..... ceeeess 1046 ‘TOROFLOW hydraulic piping 10-17 TOROFLOW hydraulic system ........... 1018 ‘TOROFLOW hydraulic circuit diagram .... 10-19 Transmission control valve ceeee 10-20 ‘Transmission lubrication relief valve ..... 10-25 Transmission pump... sees 10-26 Transmission and steering oil strainer... 10-27 Transmission oil filter. 10-28 Steering oil filter ..... ceees 10-29 Bevel gear shaft and steering clutch 10-30 Steering control .. seves 1082 Steering control (For assist brake) 10-33 Steering and brake piping 10-33-41 Steering and brake hydraulic system 10-34 Steering and brake hydraulic circuit diagram teteeteeeeteeeess 1085 Steering pump fe 10-36 Steering main relief valve ...........1.. 1037 Steering brake 10-42 Spring assist brake system seven 10051 Final drive .......0...0+ 10-46 PTO (Power take off) ...........002206. 1087 Track group ..eeeeeeeeeeee 10-48 Idler cushion poorenrnneeerra TC) Idlers... 10-50 Track roller and carrier roller ........+... 10-51 Track (Lubricated track link) 10-52 Track (Ory type track link) + 10 83 Guspencloni se io oa Hydraulic piping 10- 56 Hydraulic control 62... sseeeeeee 10 60 Hydraulic system 10- 62 Hydraulic circuit diagram ............. 10° 63 Hydraulic tank 10- 64 Hydraulic pump ..... seeeees 10 65 Blade lift and ripper control valve 10- 66 Biade tilt control valve 10-71 Ripper selector valve and pilot check valve 10 72 Hydraulic lever operation .............. 10+ 76 Hydraulic cylinder 10- 80 Cylinder stay voces 10° 84 Work equipment control hydraulic system... cose 10> 86 Work equipment control hydraulic circuit diagram ..........ceeecseee 10 87 Pilot solenoid valve «0... eeeeeseeee 10+ 88 Pin-puller solenoid valve (For giant ripper) ......- seve 10> 89 Pin-puller cylinder (For giant ripper) 10- 91 Rotary Servo valve... eeeeeeeeeeenes 10+ 92 Straight tilt dozer 10- 96 Variable multiple shank ripper 10- 98 Variable giant ripper 10-100 Electrical circuit diagram = 10-1024 EVMS (Electronic vehicle monitoring system . 10-103 APS (Auto priming system). 10-109 Air conditioner : 10-110 10-1 ®GENERAL 1. Engine (S6D155-4) 2. Torque converter 3. Universal joint 4. TOROFLOW transmission 5. Transfer Motive power generated by diesel engine (1) is transmitted to drive case of torque converter (2) through the engine flywheel. The drive case revolves with the pump wheel and power from the engine turns the turbine Wheel with oil according to load fluctuations to turn the turbine shaft. The power passes from the turbine shaft through universal joint (3) to the input shaft of TOROFLOW transmission (4). In accordance with changes in load, transmission control valve which is mounted at the top of the transmission case is operated to select an appropriate speed stage. The power which is selected by the make and break action of the speed change clutch inside the transmission passes through the output gear of transfer (5) to bevel pinion. The power which is transmitted from the engine — torque converter — transmission at the rear of the machine is then diverted into the left and right directions by means of the bevel pinion and bevel gear on the bevel gear shaft. 10-2 F17502001 6. Steering clutch 7. Steering brake 8. Final drive 9. Sprocket 10. Track shoe Steering clutches (6) is installed at both ends of the bevel gear shaft make and break the flow of power from the bevel gear shaft to the final drive, and are used to change the direction of the machine. The direction of the machine is changed by operating the steering control valve mounted at the top of the steering case in order to cut off power from the clutch at the side of the machine to which it is to be steered. The size of the turning radius is varied by means of steering brake (7) which is mounted on the periphery of the brake drum of the steering clutch. Power from the steering clutch is transmitted to the flange of final drive (8) where speed reduction takes place through pinion — gear prior to rotating sprocket (9). The rotation of the sprocket drives track (10) of the undercarriage, causing the machine to travel 017502017502 No. 1 clutch No. 2 clutch Faas No. 3 clutch No.4 clutch No.5 clutch Lt 1. Engine (S6D155-4) 2. Torque converter 3. Universal joint 4, TOROFLOW transmission 5. Transfer 6. Steering clutch 7. Steering brake 8. Final drive ‘9. Sprocket 10. Track shoe 11.P.T.0. 10 175F02011 P,. Hydraulic pump (PAL200) Ps. Transmission pump (FALO45) Ps. Steering pump (FAR100) 10-3POWER TRAIN HYDRAULIC SYSTEM 17502002 017502017502 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 31. Applicable Serial No, 50901 and up a 5 2% Set pressure cn Ord uo : uA 7 ue off lon [OFF ! 2 | 15.7 kg/eme | aa h I |_| Set pressure: r 1 22 kg/em? Ww q ‘Set pressure [TT 12 Salem = c Pa cracking DA TR= 11 15 pressure: 1 1.2 kg/cm* Cracking No. 5 clutch (1st) ® pressure: oT n 1.2 kg/em? No.4 clutch (2nd) Set pressure. i Ae sil A No.3 clutch (3rd) [43 4-5 ka/om* ! a ‘CH S 5 Set pressure: 21 I 8.7 kglem! 5 I ! FAR100 M {F—No. 2 clutch (R) 4 Discharge: 172.52/min Pies % a L____fF— no. 1 clutch (F) ot press - — - (Engine at 2,000 rpm) Discharge: 938/min heat oanoen 1 (Engine at 2,000 rpm) 3 I | - 1 | HA }— 1s | WY wf-> ' “ i a j easazor Beith T San Tg wt _ ul yee (AN ts . a : 2 1. Steering case 2.0il strainer 3. Transmission pump (FALO45) 4, Transmission oil filter 5. Modulating valve 6. Quick return valve 7. Reducing valve 8. Speed valve 9.F-R valve 10. Torque converter relief vaive 11. Torque converter 12. Torque converter regulator valve 13. Torque converter oil cooler 14.PTO lubrication 15. Torque converter case 16. Scavenging pump 17. 18. 19 20. 21 22. 23. 24. Transmission lubrication 24a. Transmission lubrication relief valve 248. Brake lubrication 25. Brake lubrication relief valve 26 Steering pump (FAR100) 27. Steering oil filter 28 Steering main relief valve 29 Steering and brake control valve A 8. c. Steering valve Brake valve Steering clutch Brake booster Servo valve and solenoid valves Spring assist brake cylinder Grease valve Plug for transmission main relief pressure Plug for torque converter relief pressure Plug for torque converter regulate pressure CL. CR. BL. BR. 175F020134, Plug for LH. steering clutch pressure Plug for RH. steering clutch pressure Plug for LH. brake boost pressure Plug for R.H. brake boost pressure 10-5 ®TORQUE CONVERTER TCS43-4E D155A-2 50001 — 50900 Drive gear Drive case Turbine Housing Pump Drive gear Stator shaft Housing Coupling PENT RYN 10-6 ® 10. Turbine shaft 11. Stator boss. 12. Stator 13. Scavenging pump 14, Drive gear 15. Strainer 16. Drain plug 17. Turbine boss 18. Holder 017502 175F02014 19.Pilot 20. Relief valve 21. Regulator valve 22. Relief valve spool 23. Relife valve spring 24. Regulator valve spool 25, Regulator valve spring017502 moomp> 20. 2a A ip : Section Y-Y To lubrication circuit From transmission modulating valve To oil cooler Outlet for oil temperature gauge To steering case a 184F21007 10-7TCS43-4F D155A-2 50901 and up 1. Drive gear 10. Turbine shaft 2. Drive case 11. Stator boss 3. Turbine 12. Stator 4. Housing 13. Scavenging pump 5. Pump 14. Drive gear 6. Drive gear 15. Strainer 7. Stator shaft 16. Drain plug 8. Housing 17. Turbine boss 9. Coupling 18. Holder 10-7-1 ® i JD all 2 aes 6 senile: 13 15 178F03000 19.Pilot 20. Relief valve 21, Regulator valve 22. Relief valve spool 23. Relife valve spring 24, Regulator valve spool 25. Regulator valve spring017802 moom> 0 a || n—_ Section Y—Y To lubrication circuit From transmission modulating valve To oil cooler Outlet for oil temperature gauge To steering case SectionZ—Z 175F02651 15421008 10-7-2 ®FUNCTION OF TORQUE CONVERTER 1. Transmission of power The motive force produced by the engine is. transmitted to pump (5), which forms one unit with guide gear (1) and drive case (2), and these rotate together. The motive force transmitted to the pump rotates turbine (3) through the oil, and is transmitted to turbine shaft (10) and coupling (9), which form one unit with turbine @). The motive force transmitted to the coupling passes through the universal joint and is transmitted to the transmission input shaft. 2. Flow of oil The pressure of the oil is set to 8.7 kg/cm? by the torque converter relief valve. It passes from port A through the oil hole inside the stator shaft (7), and enters pump 6). Pump (5) is kept rotating by the motive force from the engine, so centrifugal force is applied to the oil entering the pump, and the oil then goes to turbine (3). Turbine (3) is rotated by the centrifugal force of the oil. When this happens, turbine shaft (10), which forms one unit with the turbine, is also rotated, and the motive force from the engine is transmitted to the transmission. The oil leaving turbine (3) is sent to stator (12) and again enters pump (5). However, part of the oil passes through the clearance between turbine shaft (10) and stator shaft (7), enters port B, and is sent to the oil cooler. 10-8 17502003 i ( ZY ee a / Wis I q I sf | 3 : | i i — : \ FA WCD,) \" WJ ‘i UN ope F17502004 017502017502 FUNCTION OF TORQUE CONVERTER RELIEF VALVE + In order to protect the torque converter from excessively high pressures, a relief valve is installed in the inlet circuit to prevent the pressure inside the torque converter exceeding 8.7 +39 kg/em*, Pressurized oil from the transmission and steering pumps enters port A, and then Passed through the passage A’ in the torque Converter housing to enter the torque converter. When the oil reaches port A and the pressure rises above 8.7 kg/cm®, the oil compresses the spring (23), pushing the spool (22) open, and is then relieved though port B into the steering case. FUNCTION OF TORQUE CONVERTER REGULATOR VALVE + In order to obtain the maximum performance from the torque converter, a regulator valve is installed in the outlet circuit to maintain the pressure inside the toque converter at 4.5 +0.5 kg/cm’. Oil leaving the torque converter passes through passage C’ into port. When the pressure at port C exceeds 4.5 kg/em?, the oil compressed the spring (25), Pushing the spool (24) open, and then flows from port D into the oil cooler. From transmission valve To oil cooler To torque converter case To torque converter g 5 3S 5 2 5 g § B From transmission valve 10,bevel gear shaft 2 8 3 ° 2 case To torque converter To torque converter case F15421005A To torque converter case From torque converter F15421006A, 10-9TOROQFLOW TRANSMISSION No.1 No.2 No.3 Nod No.5 eet 4 oo" 1 22 2 se [ele (ej edly as ls 18 19 0 2 2 - ne i u vf EE iss Se ee P oa eT oy tt [fie \ is | | ‘ I | i Ab 45 44 43 42 41 40-39-3837 3635 34 33-3231 Gy 29 28 27 me 25 D155A-2 50901 and up F17502005A Detail P 10-10 017502017502 1 12. 13, 14. 15, 16. 7. 18. 19. 20. 2. 22. 23, 24. 2. 26. 27. 28. 29, 30. 31 32. 33, 34, 36. 36. 37. 38. 39, 40. 4a 42, 43, 44, 45. 46. Swoonomsenn Input coupling Front cover Input shaft (with gear No. 8) No. 1 sun gear (33 teeth) Pinion shaft No. 1 planet gear (24 teeth) No. 1 ring gear (81 teeth) No. 2 sun gear (21 teeth) No. 2 ring gear (81 teeth) No. 2 planet gear (24 teeth) No. 3 ring gear (81 teeth) No. 3 planet gear (24 teeth) No. 4 ring gear (81 teeth) No. 4 planet gear (19 teeth) Pinion shaft No. 3, 4 sun gear (33 teeth, 42 teeth) Transmission case No. § gear No. 5 clutch piston No. § clutch spring Output shaft Transfer drive gear (29 teeth) Transfer case Bearing cage Bevel pinion (21 teeth) Cover Bearing cage Transfer driven gear (24 teeth) No. § piston housing No. 5 clutch housing Rear housing No. 4 carrier No. 4 plate No. 3, 4 piston housing No. 1, 2, 3 carrier No. 2 piston housing No. 2 planet gear (23 teeth) Pinion shaft No. 1, 2 plate Clutch spring Clutch plate Clutch disc Clutch piston Tie bolt Front housing Bearing cage ‘Speeds and operating clutches Speed Operating clutch Neutral No.5 clutch Forwara | Fitstspeed | No.1 andNoS clutches Second speed | No.1 and No.4 clutches Third speed | No.1 and No.3 clutches Neutral No clutch First speed | No.2 andNoS clutches Reverse | Second speed | No.2 and No.4 clutches Third speed | No.2 and No.3 clutches Number of discs and plates on each clutch Clutch No. | Number of discs | Number of plates No.1 clutch 4 3 No.2 clutch 4 3 No.3 clutch 3 2 No.4 clutch 2 1 No.5 clutch 5 4 10-11 ®FUNCTION OF PISTON To lock ring gear (7), the discs (42) and plates (41) are brought into close contact. The clutch consists of a clutch piston (43), cluthc plates (41), clutch discs (42), pins (50) and piston return springs (40) The disc's internal teeth engage with the ring gear’s external teeth. The plates, whose notch on the outside diameter engage with pins (50) on housing (45), are locked against the rotating direction. Piston (43) also is locked against the rotating direction. * Clutch engaged (oil pressure is acting) Oil from the control valve flows under pressure through the port in housing (45) to the piston (43). The piston presses clutch plates (41) and clutch discs (42) together, and the nal force developed stops clutch discs (42) revolution, thus ring gear (7) meshing with the disc’s internal teeth is locked. + Clutch disengaged (oil pressure is not acting) When the supply of pressure oil from the control valve is shut off, piston (43) returns to the initial position by the force of piston return spring (40), thus relieving the frictional force between plates (41) and discs (42), making the ring gear (7) free. 10-12 543 From the contro! 0 50 7 017502017502 FUNCTION OF NO.5 CLUTCH ‘= The No. 5 clutch is a rotating clutch, and it is used for 1st speed. 1, Clutch engaged When the gear shift lever is put “Ist speed”, oil from the control valve passes through the oil hole in the housings and output shaft (21), and then enters chamber A of piston housing (29). The oil entering chamber A pushes ball check valve (52) and closes passage a, and pushes piston (19) to the left, and then lock disc (42) and plate (41) with No. 5 gear (18) In other words, the motive force from No. 4 carrier (32) passes through No. 5 gear (18), clutch housing (30) and piston housing (29), and transmitted to output shaft (21) 2. Clutch disengaged When the gear shift lever is put into 2nd or 3rd speed, the oil entering chamber A returns to the control valve, and the hydraulic force pushing piston (19) is lost. When this happens, piston (19) is returned to the right by the tension of spring (20), and the force pushing disc (42) and plate (41) together is lost, so the transmission of motive force from No. 4 carrier (32) to output shaft (21) is lost. During this action, if the return of oil from ‘chamber A to the control valve is not carried out quickly, No. § clutch will slip, and this will cause premature wear of the disc and plate. To prevent this, ball check valve (52) stalled to drain the oil from chamber A to the transmission case to carry out disengage- ment of the clutch quickly. If the oil entering chamber A returns to the control valve, the force pushing ball check valve (52) on to seat (51) is lost. Ball check valve (52) then move to the outside under the centrifugal force caused by the rotation As a result, the oil entering chamber A passes through the passage a and drains to the transmission case. From the control vaive F15A01013 Tothe control valve FISA01014 10-13POWER TRAIN OF TRANSMISSION FIRST FORWARD SPEED Non Nez, Sich clteh Sich clutch clutch clutch clutch chat eee nee Seen i No. 1 clutch and No. 5 clutches engaged and No. 1 ring gear fixed, No. 5 gear and output shaft are engaged. With No. 1 and No. 5 clutches engaged, No. 1 ring gear (7) is fixed and No. 5 gear (18) and output shaft (21) are engaged. When No. 1 ring gear (7) is fixed, the rotation of the engine is transmitted to No. 1, 2, 3 carrier (35) with Teduced turning speed through input shaft (3) and No. 1 sun gear (4). No. 1, 2, 3 carrier (35), then, rotates in the same direction as input shaft (3) Looe! / / 30 a a B F17502008 Since No. 5 gear (18) and output shaft (21) are engaged, No. 3, 4 sun gear (16), No. 3 ring gear (11), No. 4 carrier (32), No. 5 gear (18), No. 5 clutch housing (30) and No. 5 piston housing (29) are all engaged as a unit. The rotation of No. 1, 2, 3 carrier (35) is then transmitted to output shaft (21) in the same direction and at the same speed. The rotation of output shaft (21) is transmitted to bevel pinion (25) with reduced turning speed through transfer drive gear (22) and transfer driven gear (28) Bevel pinion (25) then rotates in the opposite direction to output shaft (21) g B g 6017502 FIRST REVERSE SPEED No.1 No.2 No.3 No.4 No.5 clutch clutch clutch clutch clutch 4 1, FOR 3rd), 2nd ist 13 18 a a No, 2 clutch and No. 5 clutches engaged and No. 2 ring gear fixed, No. 5 gear and output shaft are engaged. With No. 2 and No. 5 clutches engaged, No. 2 ring gear (9) is fixed and No. 5 gear (18) and output shaft (21) are engaged ‘When No. 2 ring gear (9) is fixed, the rotation of the engine is transmitted to No. 1, 2, 3 carrier (35) with reduced turning speed through input shaft (3), No. 2 sun gear (8) and 2 sets planetary gears. No. 1, 2, 3 carrier (35), then, rotates in the opposite direction as input shaft (3). 17502007 Since No. 5 gear (18) and output shaft (21) are engaged. The rotation of No. 1, 2, 3 carrier (35) is transmitted to output shaft (21) in the same way as in first forward speed. The rotation of output shaft (21) is transmitted to bevel pinion (25) with reduced turning speed through transfer drive gear (22) and transfer driven gear (28). Bevel pinion (25) then rotates in the opposite direction to output shaft (21). 10-15TRANSMISSION CONTROL 1. Gear shift lever 2. Lock lever 3. Transmission control valve 10-16 178F02017 017502017502 TORQFLOW HYDRAULIC CIRCUIT DIAGRAM %#1. Applicable Serial No. 50901 and up ~ 5 ‘Set pressure: 20 kg/em? 1 G81. 22 kg/em?) B =< ae +——F--L_ Set pressure: 12.5 kg/cm? ‘ae NE foe 2nd 3nd 8 YTD TE» A L___fF uo. clutch (180 9 L__{F No.4 clutch (2nd) MH a {E-No. 3 clutch (3rd) Cracking 4 at el o-R-=--3 : pressure: i Set pressure takg/em ALIX 2 pe 7 H {E 2 clutch (R) cl ea [Set pressure: ratoae (__TF_ Wo. 1 clutch (F) 2 Discharge ee 18.7 kg/em? 930/min (Engine at 2,000 rpm) 1 2 Le L Jy Set pressur mh Greene F17502009 1. Steering case 11. Torque converter A. Plug for transmission 2. Oil strainer 12. Torque converter clutch pressure 3. Transmission pump regulator valve B. Plug for relief pressure (FALO45) 13. Oil cooler C. Plug for regulater 4. Oil filter 14. P.T.O. lubrication pressure 5. Modulating valve 15. Transmission lubrica- D. To steering pump 6. Quick return valve tion relief valve E. From steering main 7. Reducing valve 16. Transmission lubrication relief valve 8. Speed valve 17. Torque converter case 9.F-R valve 18. Scavenging pump 10. Torque converter 19. Brake lubrication relief valve relief valve 20, Brake lubrication 10-19TRANSMISSION CONTROL VALVE D155A-2 50001 — 50900 de eet | a 0 12 a V4 15 Mahe ee lr ls B 4 a5 6 e F | 178F02016 10-20 017502017502 1, Cover 2. Modulating valve spring 3. Modulating sleeve spring 4. Spring seat 5. Modulating valve spring 6. Valve body 7. Modulating valve spoo! 8. Modulating valve sleeve 9. Piston 10. Piston spring 11. Piston 12. Stopper 13, Cover 14. Quick return valve sleeve 15. Quick return valve 16.Piston 17. Spring 18. Piston 19. Reducing valve 20. Reducing valve spring 21. Stopper 22. Stopper 23.F-R valve 24. Valve body 25. Spacer 26. Cover 27. Speed valve spo! To torque converter circuit From transmission pump To speed valve H To speed valve K To forward clutch port (No. 1) To reverse clutch port (No. 2) To Ist speed clutch port (No. 5) From reducing valve C To 2nd speed clutch port (No. 4) From reducing valve D To 3rd speed clutch port (No. 3) rrAeZrOmmoOeD MODULATING VALVE OUTLINE + The modulating valve consists of a modulating relief valve and a quick return valve, and acts to modulates the pressure. + When the gear shift lever is operated to shift gear, the clutch is pushed into close contact by the piston. However, if high pressure is suddenly applied, the piston will suddenly engage the clutch. This will make the machine suddenly start, and it will receive an excessive shock To prevent this, the modulating valve is installed. When the gear shift lever is operated to shift gear, the pressure on the piston gradually rises to the set pressure and the clutch is engaged smoothly. This allows the machine to start without any shock, thereby improving the durability of the power train and at the same time providing a comfortable ride for the operator. ‘+ The figure shows the relationship between the time and the increase in the hydraulic pressure of the modulating valve. For example, when the gear is shifted from F1 to F2, the oil from the pump passes throug the speed vaive spool, flows to the second clutch and fills the circuit up to the clutch piston port. The time taken for the circuit to be filled up to the clutch piston port is called the “filling time”, and the oil pressure during this time is O kg/om? When the circuit up to the clutch piston port is filed with oil, the oil pressure starts to rise. The time taken for the pressure to rise to the set pressure is called the “build-up time”. The filling time and build-up time together are called the “modulating time”. * Modulating graph Modulating ti tle | etgs © pat Aa D rot t Oil pressure b> aE 7o'See! Time F15A01022 10-21D155A-2 50901 and up aa etle fap yn \\ \ delle as n ey ° | rol ; \ { \ \ oo ab 10-21-1 ® 175F03001 017502017502 1.Cover, To prevent this, the modulating valve is in- 2. Modulating valve spring stalled. When the gear shift lever is operated 3. Modulating sleeve spring to shift gear, the pressure on the piston grad- 4. Spring seat ually rises to the set pressure and the clutch 5.Modulating valve spring is engaged smoothly. This allows the ma- 6. Valve body chine to start without any shock, thereby 7. Modulating valve spool improving the durability of the power train 8. Modulating valve sleeve and at the same time providing a comfortable 9. Piston ride for the operator. 10. Piston spring ‘+ The figure shows the relationship between 11. Piston the time and the increase in the hydraulic 12. Stopper pressure of the modulating valve, 13. Cover For example, when the gear is shifted from 14. Quick return valve sleeve F1 to F2, the oil from the pump passes 15. Quick return vaive throug the speed valve spool, flows to the 16.Piston second clutch and fills the circuit up to the 17. Spring clutch piston port. 18.Piston The time taken for the circuit to be filled up 19. Reducing valve to the clutch piston port is called the “filling 20. Reducing valve spring time”, and the oil pressure during this time is 21. Stopper O kg/cm? 22. Stopper When the circuit up to the clutch piston port 23. F-R valve is filled with oil, the oil pressure starts to rise, 24. Valve body The time taken for the pressure to rise to the 25. Speed valve spool set pressure is called the “build-up time” The filling time and build-up time together To torque converter circuit are called the “modulating time”. From transmission pump To speed vaive H * Modulating graph To speed valve K To forward clutch port (No. 1) To reverse clutch port (No. 2) (kg/em) |B: fing C: bai To 1st speed clutch port (No. 5) eee From reducing valve C \ To 2nd speed clutch port (No. 4) From reducing valve D To 3rd speed clutch port (No. 3) Modulating time P rACTA™moom> Oil pressure 3 MODULATING VALVE OUTLINE ——— (Sec) ‘+ The modulating valve consists of a modulat- ° Os To! ing relief valve and a quick return valve, and Time acts to modulates the pressure. ‘+ When the gear shift lever is operated to shift F15A010228 gear, the clutch is pushed into close contact by the piston. However, if high pressure is suddenly applied, the piston will suddenly engage the clutch. This will make the machine suddenly start, and it will receive an excessive shock. 10-21-2 ®OPERATION 1, While traveling Ttorque From (Range A and D in Fig. F15A01022) KA Rameau A 8 The oil from the transmission pump en- tr ters port A, chamber B and chamber E. The oil passes through orifice b and goes from chamber F through the reducing e valve, speed valve and F-R valve to fill the two sets of clutch piston ports. 4 The pressure in this circuit is always set by the action of modulating valve to 20 kg/cm? (31. 22 kg/cm?).When the press- 2 > ure inside the circuit becomes higher, the modulating valve (7) and sleeve (8) moves to the left. It opens the passage isd Oceana ys rodclog vale! 15 between chamber B and port D, so the oil from the pump is relieved to port D. If the pressure inside the circuit drops because of leakage of oil from the clutch 0g eA ee piston or valve, the modulating valve (7) here M and sleeve (8) moves to the right. This closes the passage between chamber B and port D, so the oil from the pump all flows from port A into the circuit to the £ clutch piston port. u F15421018 | 2. Immediately after shifting gear shift 4 lever (Range B in Fig. F15A01022) 1 be When the gear shift lever is moved, the circuit from the transmission pump to the piston port of the clutch after gear shifting is opened and oil flows to the clutch piston port. ‘To reducing valve 5 F15421019 When this happens, a difference in press- § 1p Totorue From aq ag ure is generated between chamber E and converter pump " chamber F because the oil is restricted by teNey va orifice b. Because of the pressure at Fy chamber E, quick return valve (16) moves = to the left. This connects chamber G and ee drain port H and relieves the back press- = ure on sleeve (8). 4 When this happens, modulating valve (7) y 4 S and sleeve (8) are moved to the right by the tension of springs (2), (3) and (5). 2 31. Applicable Serial No. 50901 and up 5 To reducing valve 15421020 017502017502 3. While clutch pressure is rising (Range C in Fig. F15A01022) When the oil sent under pressure from the pump fills the circuit from port A to the clutch piston port. the oil pressure starts to rise. When this happens, the difference in pressure on both sides of orifice b is removed. Quick return valve (15) moves to the right and the passage between chamber G and drain port H is closed. The oil flows through orifice a to chamber © and pushes piston (11). The reaction to this makes modulating valve (7) compress springs (2) and (5) and move to the left. This opens the passage from chamber B to port D. At the same time, the oil passing from orifice ¢ through the chamber in the cener of quick return valve (15) then passes through orifice d and enters chamber G. The oil becomes the back pressure of sleeve (8), compresses spring (3) and move the sleeve (8) to the left to the passage between close chamber B and port D. This operation is repeated continously to increase the load on springs (2), (3) and (5). In this way, the hydraulic pressure inside the circuit gradually rises and finally sleeve (8) comes into contact with the cover and cannot move any further. When this happens, modulating valve (7) stops in a position where the passage between chamber B and port D is open, and the rise in pressure is completed. The hydraulic pressure at this point is 20 kg/em®, The oil relieved from chamber B to Port D flows from port D into the torque converter circuit Lo Gite SE A ey eat S G zi a . e 4 in 4 2 b ee 35 Foredueing vee 15 15421021 Totorque From § 1 converter pump A £ 35 © Toreducing valve 15 F1421023 10-23REDUCING VALVE OUTLINE ¢ The reducing valve is in the circuit between modulating vaive and the speed valve. It reduces the hydraulic pressure in the 1st clutch circuit to 12.5 kg/cm?, The hydraulic pressure in the whole circuit is set to 20 kg/cm? (31. 22 kg/cm?) by the modulating vaive. © The 1st clutch circuit is filled with oil by the action of the reducing valve when the speed lever is at the NEUTRAL position. In other words, the ‘st clutch is engaged. As a result, when the lever is moved to 1st FORWARD, it is enough for the oil from the pump to fill the forward clutch circuit. This reduces the time lag produced when shifting gear, and guaran- tees that the machine will start to move an appropriate time lag. OPERATION 1. Start of rise in hydraulic pressure The oil from the modulating valve enters chambers J and K from chamber F. Part of the oil flows from chamber J to the speed valve, and other part flows from chamber K to the 1st clutch circuit. When the whole circuit is filled with oil, the hydraulic pressure starts to rise. 2. Completion of rise ure When the hydraulic pressure in the circuit rises, oil passes through orifice e and enters chamber L. This oil balances with the tension of spring (20) and gradually moves valve (19) to the left. When the hydraulic pressure in the circuit reaches 12.5 kg/cm, valve (19) closes the passage between chambers F and K. This shuts off the flow of oil to the 1st clutch circuit and prevents the hydraulic pressure from rising any further. The hydraulic pressure to chambers F and J rises to 20 kg/cm? (31. 22 kg/cm’), the set pressure of the modulating valve. hydraulic press- 41. Applicable Serial No. 50901 and up 10-24 ® Tospeedvalve To Istclutch circuit F15A01023 0 16 From modulating valve L To Istoluteh circuit F16A01024 To speed valve 017502= TRANSMISSION LUBRICATION RELIEF VALVE 7 4 at j / Va ° er 7 L ° Section ¥—¥ 5 g 8 Ss ay 21087 1. Valve body 2. Cover 3. Valve guide 4. Valve spring 5. Lubricating valve 6.Cover 7.0-ring 8. Sleeve 9. Sleeve 10. Gasket A. From oil cooler B. To transmission lubrication C. To transmission lubrication D. To steering case 10-25TRANSMISSION PUMP FALO45 1. Drive gear 2. Bracket 3. Gear case 4. Housing 5. Driven gear A. Intake B. Discharge 10-26 Item Discharge Setting pressure Engine revolution F15A01026 FALO45 93¢/min. 20 kg/cm?* 2,000 rpm 017502017502 TRANSMISSION AND STEERING OIL STRAINER 2D ohONe Cover Magnet Passage flow Screen Screen mesh From steering case To transmission and steering pump 175F091-1 . Spring —~ Case 5108/min 80 10-27TRANSMISSION OIL FILTER Filter cover Filter case Element Spring Valve Cage Bolt NOBRONS > From pump 10-28 Cracking pressure Passage flow Filter ability Transmission 1.21 kg/em? 938/min. 10 microns 17502031 017502oa STEERING OIL FILTER 8 & Ss F17502032 1, Filter cover —__—— 2. Filter case Steering 3. Element ——_ 4. Spring Cracking pressure 1.21 kg/em? 5. Valve ——_ 6. Cage Passage flow 172.58/min. 7. Bolt —} Filter ability 10 microns ‘A. From pump rarer: 10-29BEVEL GEAR SHAFT AND STEERING CLUTCH 175F02018 1. Outer drum (Brake drum) 8. Bearing cage 2. Pressure plate 9. Bevel gear shaft 3. Clutch plates (11 plates on one side) 10. Bevel gear (49 teeth) 4. Clutch discs (12 discs on one side) 11. Case 5. Inner drum (clutch drum) 12. Clutch spring (large) 6. Clutch piston 13, Clutch spring (small) 7. Hub 14. Collar 10-30 017502017502 OPERATION 1. LH, steering clutch ENGAGED When the left steering lever is not being pulled, no oil enters chamber A from the steering control valve. As a result, piston (6) is not actuated, and the tension of clutch springs (12) and (13) makes pressure plate (2) push clutch disc (3) and clutch plate (4) into close contact with inner drum (6). In this condition, the motive force from bevel gear shaft (9) is transmitted from inner drum (5) through the clutch disc and clutch plate to outer drum (1). It is then transmitted to final drive from flange (15), which forms one unit with the outer drum, Therefore, if the right steering clutch is also engaged, the machine will travel in a straight line. 2. LH. steering clutch DISENGAGED When the left steering lever is pulled, the steering control valve is actuated and oil enters port A. As a result, piston (6) is pushed to the left, and pressure plate (2) move to the left. When this happens, the close contact between clutch disc (3) and clutch plate (4), and inner drum (5) is released. In this condition, the motive force from bevel gear shaft (9) is transmitted only as far as inner drum (6). It is not transmitted to outer drum (1). Therefore, if the right steering clutch is engaged, the machine will turn to the left. F17502010 F17502011 10-31STEERING CONTROL 1. Brake pedal 2. Lock lever 3. Steering lever 4. Steering control valve 5. Steering brake 10-32 F17502012 017502STEERING CONTROL (For assist brake) 017502 178F02029 1. Brake pedal 2. Lock lever 3. Steering lever 4. Assist brake cylinder 5. Steering control valve 6. Steering brake 10-33 ®STEERING AND BRAKE PIPING Steering oil filter Steering pump (FAR100) Brake lubrication relief valve . Oil strainer Steering control valve Steering brake booster Steering main relief valve Noapens 10-33-1 cL. cr. BL. 175F097-1 Plug for LH. steering clutch pressure Plug for RH. steering clutch pressure Plug for LH. brake boost pressure Plug for R.H. brake boost pressure 017502STEERING AND BRAKE HYDRAULIC SYSTEM i i i ' Reese ijt Ja eB 6B 8 I | co hy) 4 Be, od aR c 4 a a 3 © 3 1 F17502013 10-34 017502STEERING AND BRAKE HYDRAULIC CIRCUIT DIAGRAM 1 cr : i] : 6 a Stee real 1 ‘OFF ‘ON ON [OFF c ——— g os g Set pressure: 22kg/em? BL BR 3 o Cracking pressure © 1.2 kg/em? ~ : . 2 tl FAR100 . Goce tee 4 HL | (Engine at 2,000 rpm) ! ee ' . = ih OF ILE F17502014 1, Steering case A. To TORQFLOW circuit 2. Oil strainer B. To torque converter circuit 3. Steering pump C. To servo valve and solenoid valves 4. Steering oil filter CL. Plug for LH. steering clutch pressure 5. Steering main relief valve CR. Plug for RH. steering clutch pressure 6. Steering and brake control valve BL. Plug for LH. brack boost pressure 6A. Steering control valve BR. Plug for R.H. brack boost pressure. 6B. Brake control valve 7. Steering clutch ~ 8. Brake booster 10-35STEERING PUMP FAR100 Drive gear Brakcet Gear case Housing Drive gear gReRe Intake Discharge p> 10-36 ® Item. Discharge Setting pressure Engine revolution FAR100 172.50/min. 22 kg/em? 2,000 rpm 017502017502 STEERING MAIN RELIEF VALVE HL SectionZ—Z OUTLINE + The steering main relief valve is in the circuit between the steering pump and the steering control valve. It sets the pressure of the oil sent from the steering pump to 22 kg/cm’. The steering main relief valve is installed on top of the torque converter relief valve. OPERATION + The oil from the steering pump enters the steering control valve and port A. When the circuit is filled with oil, and the hydraulic pressure in the circuit reaches 22 kg/cm, the oil at port A compresses spring (3) and opens the circuit between ports A and B. The oil at port B then flows to the torque converter circuit, Valve body Stopper Spring Relief valve Piston Stopper PaRON= > From steering pump B. From transmission valve C. To torque converter circuit D. Drain 175F109 To torque converter circuit t 3 « To steering valve From pump 175F110 To torque converter circuit fen a To steering valve From pump V7SFIV 10-37STEERING AND BRAKE CONTROL VALVE 1. Valve body 2. Lever 3. Shaft 4. Spring 5. Stopper 6. Spring 7. Stopper 8. Steering valve 9. Piston 10-38 Section B-B 10. Spring 11. Plug 12. Plug 13. Spring 14, Piston 15, Brake valve 16. Valve body 17.Shaft 18. Spring 15421015 19. Spring 20, Guide 21, Adjustment bolt 22. Lever 23. Stopper 24, Spring 25. Stopper 26. Spacer 017502017502 OPERATION 1, Steering lever not operated; The oil from the steering pump enters main relief valve (27) and ports A and D of the steering control valve. Since the circuits to the steering clutch and brake booster are closed, only the oil pressure in the circuit rises. As a result, main relief valve (27) opens, and the oil flows to the torque converter circuit. If the steering lever at the operator's seat is not operated, oil is continuously relieved to keep the clutch applied and the brake released. The oil pressure in the circuit in this state is 22 kg/cm’. 2. When the oil pressure at the steering valve starts to rise; When the steering lever is pulled, lever (22) pushes shatt (3) to the right, and ‘compress the springs (4) and (6). The reaction force of compressed springs (4) and (6) pushes steering vaive (8) to the right, and close the circuit between ports B and G. The path between ports A and B ‘opens at the same time, and the oil flows to the steering clutch When the circuit form the pum to the clutch is filled with oil the oil pressure starts to rise again. The oil entering chamber © through orifice a pushes piston (9), and the reaction force pushes back steering valve (8) to the left and compress spring (6), and close the path between ports A and B. In this state, the oil pressure in the circuit from port B to the clutch balances with the installed load of spring (6) to keep the oil pressure at @ constant level. When the steering lever is pulled further, the installed load of spring (6) gradually increases to increase oil pressure in the circuit from port B. As a result, the clutch is partially applied. To torque : converter circuit rain a = ll From steering pump —= To-brake ~~ A D } B To steering clutch ‘To brake booster F15421034 To steer clutch i 15421035 22 a4 To steering clutch F15421036 10-393. When the oil pressure at the steering valve rises to the maximum level; When the steering lever is pulled further from the state explained in paragraph 2, stopper (5) comes into contact with steering valve (8) and spring (6) assumes the minimum installation height. In this state, shaft (3) starts to push steering valve (8) via spring (4) 0 that the force required to operate the steering lever rises sharply. When the steering lever is pulled further, shaft (3) compresses spring (4) to gradually increase the installation load and the oil pressure in the circuit after port B. When the installation load of spring (4) is maximized and the oil pressure in the circuit becomes 16 kg/cm’, the steering valve modulation ends and the clutch is released. 4, When the oil presssure at the brake valve starts to rise; When the steering lever is pulled further from the state explained in paragraph 3, adjustment bolt (21) moves shaft (17) to the right, and push brake valve (1) The path between ports E and H is closed and the path between ports D and E is opened so that the oil flows to the brake booster. On the other hand, the oil entering chamber F through orifice b pushes piston (14). The reaction force pushes back brake valve (15) to the left and contract spring (18), and close the path between ports D and E. In this state, the oil pressure in the circuit from port E to the booster balances the installation load of spring (18) to keep the oil pressure at a constant level. When the steering lever is pulled further from this state, the installation load of spring (18) increases gradually and the oil pressure after port E rises to start operation of the brake. 10-40 To steering case F15421037 | To steering clutch F15421038 From steering valve » D =) | we} ¥ Tota eee From steering valve oe > naa le 8 Tobrake |9 ie booster 15421040 017502017502 5. When the oil pressure at the brake valve reaches the maximum level When the steering lever is pulled to its stroke end, shaft (3) moves to the right until it contacts stoppers (23) and (25). Steering valve (8) does not moves any further. Adjustment bolt (21) moves shaft (17) to the right, and push brake valve (15). Shaft (17) does not reach the stroke end even when shaft (3) reaches the stroke end, and the oil entering chamber F via orifice b of brake valve (15) pushes piston (14). The reaction force pushes back brake valve (15) to the left and compress spring (18) and close the path between ports D and E. In this state, the oil pressure in the circuit from port E to the booster balances with the tension of spring (18), reaching the maximum installation load so that the oil pressure is kept at a constant level and the brake operation is completed. The oil pressure in the circuit after port E in this state is 19.3 kg/cm? 6. When steering lever is released; When the steering lever is released, the tension of each spring returns shaft (3), shaft (17), brake valve (15) and steering valve (8) to the left. Steering vaive (8) then closes the path between ports A and B and opens the path between ports B and G so that the oil in the steering clutch is drained to the steering case via port G Brake valve (15) closes the path between ports D and E and opens the path between ports E and H so that the oil in the brake booster is drained to the steering case via port H. * ie Dy} e To steeri ‘ \ Neuter? UT 1G Tobe 15 4 booster 15421041 From steering valve > b t D * HE } F Wow eae oso F1sazi0a2 From pump. From 11 0288°°""9 brake booster F15421043STEERING BRAKE SectionA—A 1, Brake cover 9. Cover 2. Lever 10.Rod 3. Lever 11, Return spring 4. Booster spring 12. Cover 5. Booster spool 13, Adjustment bolt 6. Booster body 14. Bracket 7. Booster piston 15. Lever 8. Lever 16. Block 10-42 & i SectionB—B SectionC—C {For right brake side) eB Section E-E a Section E—E (For left brake side) (For right brake side) 17.Rod 18.End 19. Brake lining 20. Brake band 21.Lift spring 22. Bushing 23. Retainer 175F02020 017502017502 OPERATION OF BRAKE 2 ‘When either the right or left steering lever is, pulled part way, the corresponding steering valve operates to disengage the steering clutch. Since some power transmission of the steering clutch remains because of the attendant rotation of the disengaged clutch, the machine will make a gradual turn. When the steering lever is pulled fully, the brake valve corresponding to the steering lever being pulled opens a passage through Which oil flows to the brake booster and actuates the steering brake. Also, when a brake pedal is depressed, oil delivered to the brake booster actuates the steering brakes. Brake operation during forward turning ‘One end of brake band (20) is held on lever (15) at A and the other end is on rod (17) at B. When the steering lever is pulled fully or the brake pedal is depressed, lever (8) pulls rod (10) and lever (15) to the left by piston m. As a result, points A and B tend to move downward and upward, respectively, around fulcrum C of the lever. Because of forward-travel turning, point A acts as a fulcrum to make the brake band fasten the brake drum, the opposite point B being pulled upward. Brake operation during reverse turning Like when turning in forward-travel, point A and B tend to move downward and upward, respectively, when the steering lever is pulled or the brake pedal is depressed. Be- cause of reverse-travel turning, point B acts a8 a fulcrum to make the brake band fasten the brake drum, the opposite point A being pushed downward. F15421044-1 18421045-1 10-43OPERATION OF BRAKE BOOSTER 1, When brake pedal is not depressed, and steering lever is not pulled (brake not applied) If steering and brake valve (25) operates, one oil line from the steering pump flows to port A, another oil line flows directly to port B without passing through steering and brake valve. The steering lever is not being pulled, 80 valve (25) does not move. The oil does not flow to port A, but only flows to port B. It then passes through orifice a and flows to chamber C. However, the brake pedal is not being depressed, 80 the flow of oil at chamber C and chamber D is shut off. As a result, the hydraulic pressure rises, and when it exceeds the set pressure of the relief valve (26), it flows to the torque converter circuit, and the hydraulic pressure is maintained at 22 kg/em?, 2. When steering lever is pulled fully (brake applied) Steering and brake valve (25) operates and oil flows to port A. When the hydraulic pressure in the circuit rises, the oil at port A pushes piston (7) to the left. Lever (8) moves and applies the brake. The hydraulic pressure at this point is 19.3 kg/em*. * For details of the operation of the steering and brake valve, 10-44 To torque converter circuit F15421046 From steering pump From brake valve 18421047 017502017502 . When brake pedal When brake pedal is depressed (brake applied) When the brake pedal is depressed, lever (2) pushes spool (6) to the left, and the flow of oil at chamber C and chamber D is connected. Because of this, the oil from the Pump passes from port B and flows through orifice a to chambers C and D. ‘When the hydraulic pressure at chamber D rises, it pushes piston (7) to the left and connects the flow of oil at chamber D and port A. The oil then drains from port A to the steering case. The brake pedal travels the same distance that piston (7) moves by slight depressing force. This movement of the piston (7) and pedal, and the oil flow is repeated over a short period (follow-up movement) ‘Spool (5) moves further to the left and con- ects the flow of oil at port B and chamber D. The volume of oil flowing to chamber D increases and piston (7) moves faster. Piston (7) continues to push lever (8), then brake band contracts smoothly and the brake is applied. depressed fully (brake applied) ‘When the brake pedal reaches the end of its travel, the flow of oil at chamber D and port A remains shut off, and the hydraulic pressure rises further. When the pressure reaches 22 kg/cm’, the main relief valve functions and the oil flows into the torque converter circuit From steering pump F15421048 From steering pur From brake valve eee F15421049 From steering pump To brake valve F15421050 10-45SPRING ASSIST BRAKE SYSTEM 1. Brake lever 2.Brake 3. Spring assist brake cylinder 4. Check valve 5. Automatic drain valve 6. Steering and brake control valve 7. Grease valve 8. Grease input nipple 9. Grease removal nipple ‘A. From transmission pump B. From steering pump 10-45-1 175F02021 Outline + The assist brake consists of the assist brake cylinder, automatic drain valve, and grease tube. If the engine stops when the machine is traveling uphill or downhill, and it is necessary to stop the machine suddenly, this brake is applied automatically to make it possible to stop the machine The grease tube is installed to cancel the brake if it remains automatically applied when the engine cannot be started 017502017502 SPRING ASSIST BRAKE CYLINDER 2 E 1. Piston rod 2. Cylinder head 3. Cylinder 4. Piston 5. Piston 6. Spring AUTOMATIC DRAIN VALVE 175F02022 From transmission pump To automatic drain valve To steering case (drain) Inlet port of grease Outlet port of grease 1. Cover 2. Valve body 3.Spool 4.Spring 5. Cover A A. From transmission pump roy 10 B. To steering case (drain) C. From steering pump 175F02023 10-45-2Operation 1, When engine is running The oil from transmission pump (1) pushes ‘open check valve (2) and enters port A at the head end of the assist brake cylinder. When the pressure of the oil entering port A rises above the tension of spring (4), it Pushes piston (3) out to the right. At the same time, piston rod (5) is pulled into the right, so the tip separates from lever (7) of the brake linkage, and the brake is released. At this point, oil from steering pump (10) enters pilot port F of the automatic drain valve. As a result, spool (8) is kept pushed to the right, and ports D and E are closed, so the oil from the transmission pump is not drained. The oil at port A also pushes piston (6) to the left, and drains the grease in port C. (When this happeds, valve (11) must always be kept open) 2. When engine stops ‘When the engine is stopped, the operation of all hydraulic pumps also stops. When this happens, the hydraulic pressure in pilot port F of the automatic drain valve is lost, so spool! (8) is pushed out to the left by the tension of spring (9), and the passage between port D and E is opened. As a result, the oil entering port A at the head ‘end of the assist brake cylinder is pushed out by the tension of spring (4) and is drained from port D of the automatic drain valve to port E. When this happens, piston rod (5) pushes lever (7) of the brake linkage and the brake is actuated. 10-45-3 175F02028 178F02025 017502017502 3. Assist brake canceled To cancel the brake when the engine cannot be started, pump grease into the assist brake cylinder. Close valve (11), and pump in grease through nipple (12). The grease enters port C of the assist brake cylinder and pushes out piston (6) to the right. When the piston moves to the right, it contacts piston (3) and compresses spring (4) In another words, the condition in the assist brake cylinder is the same as explained in item 1, so the brake is released. 175F02026 10-45-4FINAL DRIVE u 12 13 - Final drive flange . Bearing cage Final drive 1 st pinion (12 teeth) Final drive 1 st gear (45 teeth) . Final drive 2nd pinion (12 teeth) . Final drive 2nd gear (55 teeth) . Final drive hub }. Sprocket (Segment teeth type) . Sprocket boss 10. Sprocket nut 11. Floating seal 12. Sprocket support CONOMRONS 10-46 " 1 178F02027 13. Cover 14. Seal guard 18. Floating seal 16. Seal guard 17. Wear guard 18. Final drive case 19. Sprocket shaft POWER TRAIN + Steering clutch — flange (1) — pinion (3) gear (4) — pinion (5) — gear (6) — hub (7) = sprocket boss (9) — sprocket (8) — track. 017502PTO (POWER TAKE OFF) 017502 = 175F014 1. Flywheel housing 8. Work equipment pump drive gear 2.P.7.0. case 9. Lubrication tube 3. Transmission drive gear 10. Block 4. Main shaft A. Steering pump 5. Drive gear B. Transmission pump 6. Case cover C. Work equipment pump 7. Case 10-47TRACK GROUP 175F02028 + Number and order of track roller 1. Idler 2. Carrier roller 3. Idler caution 4. Sprocket 5. Track shoe 6. Track roller 7. Track frame D155A-2 10-48 Number and order 7 (0.D.D.S.D.0s) 017502017502 IDLER CUSHION 1. Yoke 2. Shaft 3. Cylinder 4. Piston 5. Cover 6. Front pilot 7. Pipe Section A—A. 17502015 8. Recoil spring 9. Shaft 10. Stopper 11. Rear pilot 12.Plug 13. Lubrication valve 10-49IDLER 10-50 1. Idler 2. Bushing 3. Guide 4. Bushing 5. Support 6. Shaft 7. Floating seal Section A—A 1 8.Track frame fea 9. Plate 10.Plate 11. Spring 12. Guide plate 13.Bolt 017502~ TRACK ROLLER AND CARRIER ROLLER CARRIER ROLLER 1. Support 2.Shaft 3. Seat 4. Floating seal 5. Seat 6. Roller 7.Cover 8.Plug 017602 TRACK ROLLER 9. Shaft 10. Collar 11. Floating seal 12. Bushing 13. Bushing 14. Roller 15. Plug 17502017 10-51TRACK (LUBRICATED TRACK LINK) 1, Bushing 2.Pin 3. Regular link 4. Track shoe 5. Shoe bolt 6. Shoe nut 7, Master link (pin side) 8. Master link (shoe side) 10-52 F16A01038 OUTLINE + Track shoe (4) for the D155A-2 is a single sgrouser type Number of Shoe width anaes (Standard) (each side) D155A-2 4 560 017502017502 TRACK (DRY TYPE TRACK LINK) 1, Regular bushing 2, Regular pin 3. Link 4. Master pin 5. Master bushing 6. Track shoe 7. Shoe bolt 8. Shoe bolt KAD) ‘ i 6 F15A01039 OUTLINE + Track shoe (6) for the D155A-2 is a single rouser type. Number of Shoe width shoes (Standard) (each side) 560 10-53SUSPENSION 175F177-1 1. Equalizer bar 2.Pad 3. Support 4. Center pin 10-54 017502HYDRAULIC PIPING BLADE 7 ea Blade tilt cylinder . Blade lift cylinder Work equipment pump Blade lift and ripper control valve 5. Hydraulic tank Blade tilt control valve |. Hydraulic oil filter NOopens 10-56 175F02030 017502017502 VARIABLE MULTIPLE SHANK RIPPER 175F02031 1. Hydraulic tank 5. Ripper selector valve 2. Blade lift and ripper control valve 6. Steering control valve 3. Ripper tilt cylinder 7. Pilot solenoid valve 4. Ripper lift cylinder 10-57VARIABLE GIANT RIPPER 175F02032 1. Hydraulic tank 6. Ripper selector valve 2. Blade lift and ripper control valve 7. Pin puller solenoid valve 3. Ripper tilt cylinder 8. Steering control valve 4. Pin puller cylinder 9. Pilot solenoid valve 5. Ripper lift cylinder 10-58 017502SERVO VALVE 8 3 = 6 175F02033 1. Servo valve for blade lift 2. Servo valve for blade tilt 3. Servo valve for ripper 4, Steering control valve 10-59HYDRAULIC CONTROL zogz10 175F02045 aSaeors w Qa < « ” 3 a 10-60017502 RIPPER 178F02046 - Ripper control lever Ripper selector switch cock lever . Ripper control valve . Raise, decrease ripper angle . Lower, increase ripper angle 10-61 ®HYDRAULIC SYSTEM 20 017502 17502021 10-62017502 HYDRAULIC CIRCUIT DIAGRAM n } Set pressure: | [160 kg/em? 4 re “7 140 kgier 1 Set pressure’ PAL200 200.48/min, (Engine at 1000 rpm] ee 2: Hydraulic tank Work equipment pump (PAL200) Main relief valve Check valve Blade lift control valve ‘Suction valve (for blade raise side) ‘Suction vaive (for blade lower side) Quick drop vaive Blade lift cylinder Check valve Ripper control valve ‘Suction vaive (for ripper raise side) 13, 14, 15, 16. 17. 18, 19, 20. 21 22. 23. 17502034 Suction vaive (for ripper lower side) Safety valve (for ripper lower side) Ripper selector valve Ripper lift cylinder Ripper pilot check valve Ripper tilt cylinder Pilot solenoid valve Check valve Blade tilt contro! vaive Blade tilt cylinder Hydraulic oil filter Plug for main relief pressure From steering circuit 10-63HYDRAULIC TANK = Oil level gauge Blade lift and ripper control valve Tube Blade tilt control valve Oil filler By-pass valve Hydraulic oil filter NO PONS 10-64 175F02035 From work equipment pump To blade lift cylinder head To blade lift cylinder bottom To ripper lift cylinder bottom To ripper lift cylinder head To blade tilt cylinder head To blade tilt cylinder bottom To work equipment pump 017502017502 PPOAONS HYDRAULIC PUMP PAL200 Drive gear . Bracket . Gear case Housing Driven Intake Discharge Item Discharge Setting pressure Engine revolution 175F197 PAL200 200.48/min 140 kg/cm? 1,000 rpm 10-65 ®BLADE LIFT 10-66 AND RIPPER CONTROL VALVE 178F02036 017502017502 (fe n a 20 1. Main relief valve 2. Suction valve for blade lift 3. Suction and safety valve for ripper 4. Seat 5. Spring 6.Check valve 7. Blade lift valve spool 8. Valve body 9. Retainer 10. Spool return spring 11.Collar 8 Section A—A. 178F02037 12. Retainer 13.Plate 14 Plate 15. Retainer 16. Collar 17. Spool return spring 18. Retainer 19. Ripper valve spool 20. Check valve 21. Spring 22.Seat 10-67MAIN RELIEF VALVE 0995 P PP Os °°. SectionB—B 19 2 2 Section E-E Main relief valve 1, Adjustment screw 2. Poppet spring 3. Case 4. Pilot poppet 5. Seat 6. Main valve spring 7. Valve body 8. Main valve 10-68 @ Blade suction valve 9. Suction valve 10. Valve spring 11. Valve body 12. Spring seat Ripper suction valve 13. Buffle 14. Suction valve 15. Valve body BLADE SUCTION VALVE $M SectionC—C RIPPER SUCTION VALVE 175F023 16. Valve spring 17. Spring seat Rip fety valve 18. Adjustment screw 19. Poppet spring 20. Poppet 21. Valve body 22. Valve seat 017502017502 MAIN RELIEF VALVE + The main relief valve is in the circuit between the hydraulic pump and the blade lift control valve. When the control valve is operated, the main relief valve sets the pressure of the oil flowing from the hydraulic Pump to the blade and ripper cylinders to 140 kg/em?. +The set pressure of the main relief valve can be adjusted by adjustment screw (1). One turn of the adjustment screw adjusts the pressure by 29.2 kg/cm’. OPERATION ‘+ Chamber A forms the circuit from the pump to the cylinders. Chambers and D forms the tank drain circuit. The oil flows into chamber B through orifice a to keep the chamber filled. If the pressure in chamber B is less than the poppet spring force (set pressure), the pilot poppet sits in the seat of the body. + If the pressure in chamber B reaches the Poppet spring (2) force (set pressure), the pilot poppet (4) moves, allowing the oil in chamber B to flow into port C. In addition, the oil flows from chamber A to B through orifices. * If the oil flows through the orifice a, a differential pressure occurs between the chambers A and B, moving valve (8) to the left. This allows the oil in chamber A to flow into port D. F15801048A 1 \ F15801050A, 10-69SUCTION VALVE FUNCTION + The suction valve is in the circuits between the blade lift control valve and blade lift cylinder bottom and head, and ripper control valve and ripper cylinders bottom and head. When negative pressure is generated at the cylinder bottom end or head end, the oil in the tank drain circuit is supplied to the cylinder bottom end or head end to prevent negative pressure. FLOW OF OIL + When negative pressure is formed in the cylinder bottom circuit, the hydraulic pressure in chambers A also becomes negative pres ‘sure. When this happens, the hydraulic pressure in port B becomes relatively higher. Therefore, the hydraulic pressure in port B becomes the surface pressured d, — dj, and acts on valve (9), At the point where this surface pressure becomes greater than the tension of spring (10), valve (9) moves to the ight, the passage between port B and A is. ‘opened and the oil in the tank is supplied to the cylinder bottom circuit to prevent negative pressure. 10-70 4 From cylinder bottom To cylinder bottom 2 F17502022 F17802023 017502017502 BLADE TILT CONTROL VALVE a 1. Plate 2. Retainer 3. Collar 4. Spool return spring 5. Retainer 6. Blade tilt valve spool 7.Valve body 8. Plate 9.Seat 10. Valve spring 11, Check valve 12. Collar Section A—A 175FO2 039RIPPER SELECTOR VALVE AND PILOT CHECK VALVE 1. Ripper selector valve 2. Pilot check valve 3.Plug 4.Piston 5. Valve body 6. Valve body 7.Spool 8.Retainer 9. Spring 10. Plug 10-72 11. Retainer 12. Cover 13. Seat 14. Spring 15. Guide 16. Poppet 17.Check valve 18. Valve body 19. Piston 20. Plug 21.Cover 175F211 RIPPER SELECTOR VALVE + The ripper selector valve is interposed between the ripper control valve and the two hydraulic circuits (the ripper lift cylinder circuit and the ripper tilt cylinder circuit). The selector valve at its original spool! position connects with the ripper lift cylinder circuit. When the spool is moved, the selector valve connects with the ripper tilt cylinder circuit. Therefore, the ripper selector valve acts as a two-circuit changeover valve. For this changeover operation, the selector valve is provided with a pilot solenoid valve using steering cirucit oil pressure. 017502017602 ee 13 2 Section A-A. PILOT CHECK VALVE ‘+ The pilot check valve is at the inlet of the tipper tilt cylinder circuit and prevents the oil in the bottom of the tilt cylinder from flowing in reverse. When ripping with the ripper lever in the HOLD position, the ripper shank tip is subjected to an external force in the direction of the increase in digging angle. As the force acts ‘on the tilt cylinder piston rod, the oil pressure ‘on the bottom of the cylinder increases. If no 175F212 pilot check valve is provided, oil will leak from the periphery of selector valve spool (7), The cylinder piston rod retracts with oil leakage to cause a gradual increase in the digging angle, and hinder normal ripping operations. With the pilot check valve installed, oil on the cylinder bottom can not flow in reverse, and thus a constant cutting angle is maintained. 10-73RIPPER SELECTOR VALVE OPERATION ‘+ The ripper selector vaive is operated by the hydraulic pressure from pilot solenoid valve (22) The pilot solenoid valve is operated by the ripper selector switch on the knob of the ripper control lever in the operator's compartment. The hydraulic pressure from the pilot solenoid valve is supplied by the steering pump. 1. Ripper selector switch “OFF” (ripper lift circuit connected) If the selector switch is not operated, the solenoid of pilot valve (22) is de-energized, and pilot pressure is not supplied from port G of the selector valve. Therefore, spool (7) of the selector valve is pushed up by the tension of spring (9), and the circuit between ports A and C and between ports B and D are opened. When this happens, if the ripper lever in the operator's compartment is moved to the RAISE position, the oil from the ripper valve flows from port A to port C, enters the head ‘end of the lift cylinder, retract the cylinder, and raises the ripper. 2. Ripper selector switch “ON” (ripper tilt circuit connected) When the selector switch is switched “ON”, the solenoid of the pilot valve is excited, and pilot pressure is supplied to port G of the selector valve. Therefore, spool (7) of the selector valve is moved down by piston (4) that receives the pilot pressure, and the circuit between ports A and E and between ports B and F are opened. When this happens, if the ripper lever in the ‘operator's compartment is placed in the “DE- CREASE" (RAISE) position, the oil from the ripper valve flows from port A to port E, enters the bottom end of the tilt cylinder, extends the cylinder, and makes the digging angle of the ripper smaller. To connect the ripper tilt circuit, keep the ripper selector switch pressed and operate the ripper lever. 10-74 “OFF” To lift cylinder head, From control valve To lift cylinder bottom: From control valve To lift cylinder head == From control valve mama To lift cylinder bottom: Os From control valve ===> cylinder F head 175F02056 017502017502 PILOT CHECK VALVE OPERATION + Port F of the pilot check vaive is connected to the head end of the ripper tilt cylinder. Port E is connected to port J when check valve (17) opens, and port J is connected to the bottom end of the ripper tilt cylinder. 1, Ripper digging angle “INCREASE” If the ripper lever is placed in the “INCREASE” Position, the oil from the selector valve ‘enters port F and flows to the cylinder head end, When the oil pressure in the circuit rises, the oil passing through orifice a enters port L and pushes piston (19) to the left. Piston (19) first pushes poppet (16), opens the circuit between ports K and E, and relieves the back pressure of check valve (17) to port Next, it pushes check valve (17), and directly ‘opens the circuit between ports J and E. The oil at the bottom end of the cylinder returns from port E to the hydraulic tank and the cylinder is retructed. The outside diameter of the check valve is larger than the piston, so the area with the surface pressure acting as the hold pressure for the check valve is higher. As a result, the piston first pushes ‘open poppet (16), which has a lower surface pressure, and relieves the back pressure of the check vaive, and then it can easily open the check valve. 2. Ripper digging angle “DECREASE” If the ripper lever is placed at the "DE- CREASE” position the oil from the selector valve enters port E. When the oil pressure in the circuit becomes higher than the tension of spring (14), the oil pushes open check valve (17) and flows from port J to the cylinder bottom to extend the cylinder. The oil at the cylinder head returns to port F and is drained to the hydraulic tank. From tilt cylinder bottom To tilt cylinder head To selector valve From selector valve 175F2148 From tit cylinder bottom To tilt cylinder head To selector valve From selector valve From tilt cylinder bottom To tilt eylinder head wnt ita \ / To selector valve From selector valve 175F2158 To tilt cylinder bottom From tit cylinder head K ola te From selector valve To selector vate 178F2168 10-75HYDRAULIC LEVER OPERATION BLADE CONTROL LEVER IN “LOWER” ct 17502026 10-76 017502017502 15 Lift 7 1 rT] au LH tilt 7B Al x Jn t 18 rE = 18 jp na From Steering circuit es u ——— 2 Tay Raise Lower I! t i Set pressure: ¢ a,| | 180 ko/eme i ee Raise Hold H Float § +! \ 3 Cnc) THe set pressure 140 kg/om? Qa PAL200 M 200.42/ min. {Engine at 1000 rpm) wt F17502027 FLOW OF OIL ‘+ When the blade control lever is operated to the “LOWER” position, blade lift spool (5) moves to the left. When this happens, the pump port P and blade lift cylinder bottom port A;, and the tank port T and blade lift cylinder head port B, are connected. ‘+ The pressurized oil from the pump (2) passes through pump port P, and pushes open check valve (4). It then goes from the blade lift spool and enters the bottom end of blade lift cylinder (9). ‘+ When the hydraulic pressure in the circuit rises, the blade lift oylinder is extended and the blade is lowered. At the same time, the oil at the blade lift cylinder head is pushed out by the cylinder Piston, returns to the blade lift spool and is drained to the hydraulic tank. When this happens, if the blade lift cylinder is extended suddenly because of the weight of the blade, there will be a shortage of oil from the pump and negative pressure will form at the cylinder bottom end. Therefore, suction vaive (7) opens, and oil is sucked in from the hydraulic tank to prevent negative pressure from forming in the circuit at the cylinder bottom end. ‘+ When the blade lift cylinder reaches the end of its stroke, the hydraulic pressure in the circuit rises to the set pressure and the oil is relieved from main relief valve (3) 10-77RIPPER CONTROL LEVER IN “LOWER” 10-78 n Ati] 2 sha —From steering circuit F17502028 017502017502 4 ut iL al le 1 iT "eyes RH. til | 11 =e Eri uife_Titt Ly? 78 old TTA" | ‘Set pressure: 160 kg/em? 0 ~ | T JSet pressure 140 kg/em? : a : pazoo aA 200.40/min IM (Engine at 1000 rpm) eo, 17502028 FLOW OF OIL + When the ripper control lever is moved to the “LOWER” position, ripper lift spool (11) moves to the left. When this happens, the pump port P and ripper lift cylinder bottom port A, and the tank port T and ripper lift cylinder head port B, are connected. + The pressurized oil from the pump (2) Pushes open check valve (10). It then goes from the ripper lift spool and enters the bottom end of ripper lift cylinder (16). + When the hydraulic pressure in the circuit rises, the ripper lift cylinder is extended and the ripper is lowered At the same time, the oil at the ripper lift cylinder head is pushed out by the cylinder piston, returns to the ripper lift spool and is drained to the hydraulic tank. When this happens, if external force is applied to the ripper lift cylinder and the pressure in the circuit exceeds 160 kg/cm, safety valve (14) acts to relieve the oil, so the Pressure in the circuit does not rise any further. + However, if the ripper lift cylinder reaches the end of its stroke, the hydraulic pressure in the circuit rises to the set pressure of main relief valve (3) (140 kg/cm!) and the oil is relieved from the main relief valve. 10-79CYLINDER BLADE LIFT CYLINDER F17502024 BLADE TILT CYLINDER il 2 4 4 5 “ = 1 " 1 1 6 178F203 1. Piston rod 10. Bushing 2. Gland 11. Quick drop valve assembly 3. Cylinder head 12.Seat 4. Cylinder 13. Piston valve 5. Piston 14. Piston nut 6. Lock plate 18, U-packing 7. Wear ring 16. Bushing 8. Seal ring 17. Retainer 9. Bushing 10-80 017502017502 RIPPER LIFT CYLINDER RIPPER TILT CYLINDER 1 175F204 10 OUTLINE + Each hydraulic cylinder has a reciprocal motion piston. The dimensions and strokes are as shown below. 16 175F205 Unit: mm. Item Blade lift Blade tilt Ripper lift Ripper tit ‘Outside diameter of piston rod 75 90 90 90 Cylinder bore 140 225 225 225 Piston stroke 1,346 160 640 ‘600 ‘Max. distance between pins 2,380 1,468 1,840 1,850 Min. distance between pins 1,026 1,308 1,300 1,350 Width across flats of piston nut = 95 95 95 10-81PISTON VALVE OUTLINE + The piston valve is installed to the piston of the blade lift cylinder. When the piston reaches the end of its stroke, the piston valve releases the oil from the hydraulic pump and lowers the hydraulic pressure acting on the piston, With the straight tiltdozer, when the blade is tilted, the pistons of the left and right cylinders become out of line. As a result, when ‘one of the pistons is at the end of its stroke, the other piston is not at the end of its stroke, so a twisting force is applied to the blade. The piston valve is installed to prevent this twisting. When one piston reaches the end of is stroke, the piston valve opens to relieve the hydraulic pressure. The piston valve also acts to release the oil before the piston contacts the bottom or head of the cylinder. This reduces the shock when the piston contacts the end of the cylinder, and also acts to relieve the surge pressure that is generated when this happens. OPERATION 1. Piston valve CLOSED The oil from the hydraulic pump acts on piston (15) and piston valve (22). The piston valve is pushed to the right, and seals the tapered part of piston valve seat (23). Therefore, the pressure inside the cylinder rises, and piston (15) is moved to the right. 2. Piston valve OPEN Immediately before piston rod reaches the end of its stroke, the tip of piston valve (22) contacts the cylinder bottom (or cylinder head). The piston valve then stops moving, and only piston (15) continuous to move. When this happens, the oil at the cylinder head, which was sealed by the piston valve, escapes through piston valve seat (23) and the hydra. Pressure inside the cylinder stops rising. 10-82 175F208 Contact 175F207 017502017502 QUICK DROP VALVE STRUCTURE ‘+ The quick drop valve consists of valve body (1), spring (2), spool (3), check valve (4), and collar (5). The quick drop valve serves to increase the blade lowering speed and to reduce the occurrence of vacuum when the blade is lowering, thereby shortening the time lag before digging is started The blade lowering speed, which is generally determined by the pump discharge, can be made faster with the quick drop valve. 1. Valve body 2. Spring 3. Check valve 4. Spool 5. Collar OPERATION 1. Start of lowering When blade control lever is moved to the LOWER position, the oil from the control valve enters the cylinder bottom through port A and pushes the piston. In the mean- time, the oil in the cylinder head is pushed out into the piston, enters valve port B, and flows into the tank 2. While lowering Pressurized oil from the cylinder head flows into port € through port B. At this time, the oil flow is restricted by an orifice provided along the way, causing a differential pressure before and after the orifice. When the differential pressure becomes Greater than the force of spring (2), it compresses the spring and moves spool (3) and valve (4) to the right. When the spool and the valve have moved, part of the oil flowing from the cylinder head to the tank enters the passage to the cylinder bottom together with the oil from the control valve, Thus, the blade lowering speed increases in accordance with the amount of oil that flows to the bottom of the cylinder and reduces the formation of vacuum at the bottom of the cylinder. 175F208 175F209 175F210 10-83CYLINDER STAY 10-84 17502025 1.Cap 2. Yoke 3. Support shaft 4. Bushing 5. Bushing 017502WORK EQUIPMENT CONTROL HYDRAULIC SYSTEM For giant ripper =, ao F17502030 10-86 017502017502 WORK EQUIPMENT CONTROL HYDRAULIC CIRCUIT DIAGRAM For giant ripper 12 set pressure: 22 kg/em* FAR100 172.52/min {Engine at 2,000 rpm) A Lit Steering case Oil strainer Steering pump (FAR100) Oil filter . Steering main relief valve Rotary servo valve (for blade lift operation) Rotary servo valve (for ripper operation) . Rotary servo valve (for blade tilt operation) SNOT RONA wn] [our Litt, Tilt 43 175F02041 9. Blade lift and ripper control valve 10. Blade tilt control valve 11. Pin puller solenoid valve 12. Pin puller cylinder 13. Pilot solenoid vaive 14. Ripper selector valve 15. Pilot check valve A. To TORQFLOW circuit B. To torque converter C. To steering circuit 10-87PILOT SOLENOID VALVE ° © ° QO ° © ° Plug Spring Spring retainer Spool Spring retainer Spring Push pin Solenoid assembly From steering pump Blocked To ripper selector valve To steering case APP VENomaena 10-88 175F02040 OUTLINE + The pilot solenoid valve uses the hydraulic pressure in the steering circuit to actuate the spool of the ripper selector valve, and acts to ‘open the circuit from the ripper control valve to either the ripper lift cylinder circuit or the ripper tilt cylinder circuit. + The pilot solenoid valve is actuated by the selector switch on the knob of the ripper lever inside the operator's compartment. 017502017502 PIN-PULLER AP PrR@VHOMAONE Plug Spring ‘Spring retainer Spool Spring retainer Spring Push pin Solenoid assembly From steering pump To bottom end of pin-puller cylinder To head end of pin-puller cylinder To steering case SOLENOID VALVE (FOR GIANT RIPPER) Cua i ey 175F02040 OUTLINE + When changing the position of the shank of the giant ripper, remove the shank mounting pin, move the shank up or down, and then push the mounting pin into the new alignment of holes. + The pin-puller solenoid valve uses the hydraulic pressure in the steering circuit and actuates the pin-puller cylinder at the tip of the shank mounting pin to make it easier to change the position of the shank + The pin-puller solenoid valve is actuated by the pin-puller switch inside the operator's ‘compartment. 10-89OPERATION 1. Pin-puller switch “OFF” When the pin-puller switch is at the “OFF” position, solenoid (8) is not excited, so spool (4) is held by the tension of springs (2) and (6) ina position where it opens ports P and A. Therefore, the oil from the steering pump flows from port P to port A, enters the bottom end of pin-puller cylinder (9), and extends the cylinder. ‘When this happens, shank mounting pin (10) enters the mounting hole of shank (11) and fixes the shank in position. The oil at the cylinder head end returns from port B to port T, and is drained to the steering case. 2. in-puller switch “ON” When the pin-puller switch is placed in the “ON” postion, solenoid (8) is excited, spool (4) is pushed by push pin (7), and is moved down, opens port P and port B and opens port T and port A. Therefore, the oil from the steering pump flows from port P to port B, enters the head end of pin-puller cylinder (8), and retracts the cylinder. When this happens, shank mounting pin (10) ‘comes out of the mounting hole of shank (11), and the shank is made free. The oil at the bottom end of the cylinder returns from port A to port T and is drained to the steering case. 10-90 “OFF” " io 175F02044 017502017502 PIN-PULLER CYLINDER (FOR GIANT RIPPER) 1. Bushing 2. Ground 3. Cylinder head 4. Cylinder 5. Piston nut 6. Retainer 7, Packing m8 8 7 6 175F224 8. Wear ring 9. Piston 10. Retainer 11. Bushing 12. Packing 13. Bushing 14, Dust seal 10-91ROTARY SERVO VALVE FOR BLADE LIFT CONTROL TT [hz Section Y—Y SectionZ—Z a 1 b Section X—X 1. Valve body 10. Detent 2. Lever 11. Spring 3.Pin 12. Cover 4. Sleeve (output shaft) 13.Pin 8. Rotor (input shaft) 14. Pin 6. Piston A. RAISE 7. Lever B. HOLD 8. Detent spring Cc. LOWER 9. Pin D. FLOAT 10-92 017502017502 FOR BLADE TILT CONTROL, FOR RIPPER CONTROL OUTLINE ‘+ The rotary servo valve is installed to reduce the operating force of the work equipment control levers and to shorten the stroke. The rotary servo valve consists of the following: rotor (5), which is interconnected with the work equipment control lever in the operator’s compartment; sleeve (4), which is interconnected with the spool of the main control valve; lever (2), which is secured to the sleeve with a key; piston (6), which makes Wie 14 13.1012 Section XX 175F230 valve body (1) slide under hydraulic pressure; and pin (3), which makes it able to operate manually instead of hydraulically when the engine is stopped. The rotary servo valve for blade lift uses a’ detent mechanism for FLOAT operations. 10-93FUNCTION 1. Neutral Putting the input lever (1) on the “HOLD” position closes the passage between ports A and C (or B and C) by the rotor (2) directly connected to the input lever. Cylinder (4) is then sealed off and piston (5) returns to the neutral position and stops. Sleeve (3) and the output shaft (6) connected to the sleeve also at the neutral position. EEG 2. Clockwise es Shifting the input lever (1) to the upward turns the rotor (2) connected to it to the clockwise and opens the passage between ports A and C. The pressurized oil from the pump flows from port D to A, then to C and to the bottom of cylinder (4). The pressurized oil which has flowed into ‘the cylinder bottom pushes the bottom because of the difference in area of the bottom and head resulting in pushing the piston (5) to the left The piston then pushes the lever of the sleeve (3) causing the sleeve to turn, and the output shaft (6) connected to the sleeve is moved to the right. The rotor (2) also turns to the clockwise until the sleeve being pushed by the piston reaches the position where the passage between ports A and closes. The pressurized oil is then shut off from the cylinder bottom and the sleeve stops in that position, 175F232 10-94 017502017502 3. Counterclockwise Shifting the input lever (1) to the downward turns the rotor (2) connected to it to the counterclockwise and opens the passage between ports B and C. The drain circuit is then connected and the oil from the bottom. of the cylinder (4) flows from port C to B and is drained out via port E. Oil pressure at the cylinder bottom drops since the bottom is connected to the drain circuit. Pressurized il from the pump pushes the head side of cylinder and pushes the piston to the right. The piston pulls the lever of the sleeve (3) when it is pushed, turning the sleeve and moving the output shaft (6) connected to the sleeve to the left. The rotor (2) also turns to the counterclockwise until the sleeve (3) pulled by the piston reaches the position where the passage between ports B and C closes. The sleeve stops at that position without the oil being drained from the cylinder bottom. The above operation is repeated successive- ly until the control valve spool connected to the output shaft (6) enters the designated position. 178F233 10-95STRAIGHT TILT DOZER 1 Detail P Detail a Section G-G sy Section HH if oe Section A-A. ar Section B-B SectionD-D SectionC—¢ View Z S é End bit Section E—E Section F—F 175F02047 10-96 017502017502 1. Blade 2.Arm 3.Brace 4. Straight frame 5. Trunnion 6.End bit 7..Cutting edge 8. Blade tilt cylinder (Right frame side) 8. Brace (Left frame side) 9. Blade lift cylinder OUTLINE + The dozing attachment can be broadly divided into the blade and the hydraulic control Which operates the blade. The diagram shows the straight tiltdozer. The table shows the dimensions and specifications of the straight tltdozer. OPERATION + The blade is moved by hydraulic cylinders. RAISE: The left and right lift cylinders retract and raise the frame and blade together. + LOWER: The left and right lift cylinders extend and lower the blade to the ground. © LEFT TILT: The tilt cylinder extends and lowers the left side of the blade to the ground. + RIGHT TILT: The tilt cylinder retracts and lowers the right side of the blade to the ground. + Table of comparisons letangtight ame 3,180 Length of frame 3,696 Width of blade 4,130 Height of blade 1,790 Max. blade re 1,560 Max. blade lower 560 Max. blade ti 1,000 10-97VARIABLE MULTIPLE SHANK RIPPER 017502 Detail P fa Detail 175F02048 10-98017502 1 2. 3. 4. 5. 6. 7. 8. Ripper bracket Ripper tilt cylinder Ripper lift cylinder Beam Shank . Protector . Ripper point Lower link ‘Shank pitch (with 3 OUTLINE + The ripping attachment can be broadly divided into the ripper and the hydraulic control which operates the shank. The diagram shows the variable mutti-shank ripper. The table shows the dimensions and specifications of the variable multi-shank ripper. OPERATION ‘+ The shank is moved by hydraulic cylinders. + RAISE: The left and right lift cylinders retract and raise the beam and shanks together. + LOWER: The left and right lift cylinders extend and lower the beam and shanks together to the ground. + TILTON: The left and right tilt cylinders extend and move the shank to the forward. + TILT BACK: The left and right tilt cylinders retract and move the shank to the rearward. ‘+ Table of comparisons Unit: mm — D155A-2 Length of beam 2,420 No. of shanks 3 shanks installed) tae ‘Shank pitch (with 2 2240 shanks installed) ~stage selection possible ing depth Max. ripping depth 835 Max. raise 890 10-99VARIABLE GIANT RIPPER zogzto 178F02049, 10-100017502 SNOTAONE Ripper bracket Ripper tit cylinder Ripper lift cylinder Beam Shank Protector Ripper point Lower link OUTLINE + The ripping attachment can be broadly divided into the ripper and the hydraulic control which operates the shank. The diagram shows the variable giant ripper. The table shows the dimensions and specifications of the variable giant ripper. OPERATION ‘+ The shank is moved by hydraulic cylinders. + RAISE: The left and right lift cylinders retract and raise the beam and shank together. + LOWER: The left and right lift cylinders extend and lower the beam and shank together to the ground. + TILTON: The left and right tilt cylinders extend and move the shank to the forward. ‘+ TILTBACK: The left and right tilt cylinders retract and move the shank to the rearward. ‘+ Table of comparisons Unit: mm —~ D155A-2 Length of beam 1,156 Ripping depth ‘4-stage selection ‘Max. ripping depth 1,240 Max. raise 965 10-101017502 ELECTRICAL CIRCUIT DIAGRAM CHASSIS ELECTRICAL CIRCUIT Monitor panel | Monitor module jews Monitor caution buzzer pai W APS. nota APS. glow plug oms|_ pt M. = gel 1 i noms Service meter Horn switch ] | Bymetat switch —if S. relay nm 8 Resse sort reley a j 131) exer RH, cose L wore] Ed i H. work amp J. Pre-heat switch ree To cab and air conditioner ‘asso Ripper selecter solenoid AS Air conditioner Work amp switch | O° ‘compressor magnet clutch Engine oil pressure switch | 1 TGS ome Tal Back-up alarm oy Head lamp switch ee Monitor caution lamp |@t T/C oil temp. sensor Las Engine water temp. sensor == Radiator water level sensor ‘cN405 FES Pin puller solenoid caf, ie Ripper work lamp Batter ny 12V, 170Ah x 2 Safety relay ae Ee - Starting switch Ke ion HEAT 4 ON [ITE Jerr [re] [ace] resi START fF TO i PS Eon tos =} 10-102-1 ®CAB ELECTRICAL CIRCUIT AIR CONDITIONER ELECTRICAL CIRCUIT Control panel unit oa a Exchange of “Heater ‘it conditioner Exchange of air plow pat termpratre omy - ni ey LH. door wiper “ v itch I Ai conditioner compressor ‘magnet clutch RH. door wiper i} v tag_Safety relay PAE Front wiper i} A ange motor for ioarpon te) xchange motor for Blow'part (232) Rear wiper Room lamp 017502 Cigarette lighter LL=5eH Caution lamp as Fuse box 2 Ground to air conditioner unit Front and rear window washer Converter sae SSeS SSpTEE, Carstereo Pesos Antenna Magnet Pressure ° RH. speaker ‘Amplifier ayy baw a rei t window washer “] — ameipe ore oss} 175F03002 175F03003 10-102-2 ®017502 EVMS (ELECTRONIC VEHICLE MONITORING SYSTEM) 1. Monitor panel 21 Panel switch 3. Warning buzzer ie 4, Monitor warning lamp A From sensors OUTLINE ‘+ The vehicle monitoring system monitors various conditions of the vehicle by means of sensors provided throughout the vehicle. It processes the information immediately, and informs the operator of the condition by making a display on the panel. There are two major kinds of panel display. 1. The monitor assembly, which gives a warning when any fault is monitored on the vehicle. 2. The gauge assembly and service meters, which constantly indicate the condition of the vehicle. (Engine water temperature, torque converter oil temperature and fuel level) 175F02051 The vehicle monitoring system consists of a monitor panel, sensors, warning lamps, warning buzzers, and the power source. The monitor panel, and sensors are connected by wiring harnesses. The power is supplied from the battery to the monitor panel. As soon as any trouble occurs, the monitor and warning lamps start flashing and the warning buzzer sounds to protect the vehicle 10-103MONITOR PANEL 178F02053, 1. Battery charge 6. Service meter indicator 11. Torque converter oil 2. Engine oll pressure 7. Service meter temperature 3. Radiator water level 8. Engine preheating 12. Engine cooling water 4. Cooling water temperature 9. Radiator water level temperature 5. Torque converter oil 10. Fuel level temperature aie The monitor panel consists of the following parts: the monitor, which gives warning when any abnormality occurs in the machine; and the service meter and gauges, which always display the condition of the machine. Microcomputers are installed for both the monitor section and gauge section. These process the signals from each sensor and display the result. A liquid crystal display is used for the display panel. The items dis- played on the monitor and gauges are given in the table on the next page. OPERATION 1, Power ON (starting switch ON) 1) All gauge and monitor items light up for 3 seconds. 2) The warning lamps light up for 2 seconds, and the alarm buzzer sounds for 1 second. 2. CHECK 1) After all the items in Section 1 light up. if there is any abnormality in any of the CHECK items, that item will flash, and the warning lamp will flash at the same time. 10-104 2) The CHECK items will go out when the engine is started. (Judge whether the engine is running or not by looking to see if the engine oil pressure has risen ‘or by checking that the voltage from the alternator is more than 10V.) CAUTION The CAUTION items check the condition of the machine from the item when the engine is started to the time when the engine is stopped. If there is any abnormality, that item will flash, and the warning lamp will flash at the same time. Apart from the battery charge, the alarm buzzer will also sound at the same time when the CAUTION item flashes, When the monitor and warning lamp flash, they stay on for approx. 0.8 sec, then go out. This cycle is repeated. The cycle for flashing of the monitor may vary slightly when the ambient temperature is low (below approx. — 10°C). This is not an abnormality 017502017502 Monitor panel indications Indication iteme Range of indication Method of indication Coolant level Below LOW level Indicates when the starting switch is turned ON with the engine stopped. If normal, the amps do not light. If abnor- ‘mal, the lamps flash. Caution Battery charge level Insufficient charge Indicates when the starting switch is turned ON while the engine is running. If normal, the lamp does not light. If abnormal, the lamp flashes and the warning lamp flashes at the same tim Engine oil pressure Below 0.8 kglem? Coolant level Below LOW level Engine water temperature When the engine water temperature gauge indicates the Fed range'(102°C.or higher) Torque converter oil When the torque converter oll ‘temperature gauge indicates Indicates when the starting switch is turned ON while the engine is running If normal, the lamp does not light. If abnormal, the lamp and ‘the warning lamp flash and the ‘warning buzzer sounds. dcreecruitinad the red range (over 130°C) Preheatin When preheating hen the starting switch i at a i" Peary PREHEAT, the lamp lights up_ nes @ Engine water temperature Green Lights up in the applicable range white 4 3 Red 130 + 3°C s : ' 02 8¢ Z eee S| | emperatre a 120°C) ights up in the applicable range 70°C 50°C c a Green 8h BW | Fuct ever an Al light up below the 37 | Sopteaoi eve 27 fea euery Indicates between zero and ‘Will operate when the engine oy ie 89089 hours eee 9 BE [© | semicemeerinaanor | When te sevior meters | Flashes while the service mater working is working 10-105SENSOR * The signals from the sensors are input directly to the machine monitor panel. Of the contact type sensors, the radiator water level and engine oil pressure sensors must always be grounded on one side to the chassis. When the points close and the signal wire is connected to the chassis, the panel judges this as a normal signal. Type of sensor ‘Sensor method When normal | When abnormal Radiator water level Contact ‘ON OFF Engine oil pressure Contact ‘ON OFF ‘Temperature (engine water temperature, fee. _ torque converter oil temperature) Fu eve RADIATOR WATER LEVEL SENSOR ‘+ The radiator water level sensor is installed to the radiator upper tank. When the cooling water drops below the specified level, float (2) goes down and switch (1) goes OFF. The monitor panel display and warning lamp flash, and the alarm buzzer sounds. 10-106 star 017502 Circuit block diagram ON ——= oFF (up) (own) 175F02054 1. Switeh 2. Float 3. Plug (tightening torque: 28 + 3 kgm) 4.Wire 5. Connector017502 ENGINE OIL PRESSURE SENSOR 5 4 a i ‘+The engine oil pressure sensor is installed at the front top of the right side of the cylinder block. If the engine oil pressure is the same as or higher than the specified pressure, it is ON; and if the engine oil pressure is below the specified pressure; it is OFF. The monitor panel display and warning lamp flash, and the alarm buzzer sounds. ENGINE WATER TEMPERATURE, TORQUE CONVERTER OIL TEMPERATURE SENSOR 1 2 3 =? + The engine water temperature sensor is installed to the thermostat housing at the front top of the left side of the engine. Thermistor (1) detects the temperature and sends a signal to the monitor panel. On the monitor panel, when this signal enters the appropriate range for the gauge display, the gauge lights up. If the temperature is above the specified temperature, the monitor panel display and warning lamp flash. + The torque converter oil temperature sensor is installed in the torque converter outlet tube on the left side of the torque converter case, and it acts in the same way as the engine water temperature sensor. 2 \ / \ ie lo [Ee - eS Circuit diagram 1 Ee 423F177 1. Plug (tightening torque: 0.15 —0.20 kgm) 2. Diaphragm 3. Switch 4. Wire 5. Connector ep Circuit block diagram 184F21043, 1. Thermistor (bead type) 2. Plug (tightening torque: 28 + 3 kgm) 3. Tube 4. Wire 5. Connector 10-107FUEL LEVEL SENSOR + The fuel level sensor is installed at the bottom right of the front face of the fuel tank. Float (1) moves up and down according to the amount of fuel remaining. The movement of the float passes through gear (2) and actuates contact (4). This deter- mines the signal to send from variable resistance (3) to the monitor panel. On the monitor panel, the signal is received and if it is below the appropriate range for the gauge display, all lamps light up. 1. Float 2. Gear 3. Variable resistance 4. Contact 5. Connector 10-108 154F21042 017502017502 APS (AUTO PRIMING SYSTEM) Panel switch Engine Controller APS SYSTEM CIRCUIT DIAGRAM From injection Engine intake a manifold os ar “4 oe gane — a ae - fe = = 1]t Power source Glow plug str a) ty 2/2 Glow 1 as ps ( 54 —| cow? a 2) ee motel pt) ST CE a aa ‘APS water temperature 10-109APS ACTUATION CHART APS start Flow of time Glow plug APS stons completely ‘Starting motor’ Engine stars, intake air heated snes, — aring switch ON iran ean, on Freteaing switch ana] OFF ON fara OFF menue ‘Weter temperature 20°C or below 20°C or above Wonitorpareidepiy | ofF | onczeea oF uses tea/3 el ow os oF on oF Nexto = on oF oo on © The APS burns fuel inside the intake manifold to heat the intake air. © The APS acts in the following order. 1. When the temperature of the engine cooling water is below 20°C, the contacts of the APS water temperature sensor close and the water temperature sensor ON signal is input to the controller. 2. Under the above conditions, if the preheating switch on the control panel is pressed, the controller sends electricity to the glow plug to heat it When the glow plug is being heated, the preheating pilot lamp on the monitor panel lights up. 3. After the preheating time (approx. 12 sec) for the glow plug has passed, the pilot display goes out. ‘When the pilot display goes out, it shows that the glow plug has been heated sufficiently to actuate the APS. 4, After the APS pilot goes out, if the starting switch is turned to the START position, the APS controller is actuated, and the fuel injection nozzle inside the intake manifold is switched ON/OFF (10 times/sec) to inject fuel intermittently. 5. When the engine cooling water temperature goes above 20°C, the APS water temperature sensor contacts open, and the action of the glow plug and fuel injection nozzle is stopped. 10-109-1 ® 6. If the glow plug or nozzle system are short cir- cuited with the ground, the lamp will light up Until the short circuit is canceled. If the lamp does not go out when the preheat: ing is completed (after 12 seconds have assed), or the lamp goes out and then lights up again, stop the engine and check for any short circuit with the ground. 017502AIR CONDITIONER AIR CONDITIONER PIPING u FLOW OF REFRIGERANT 1) The gaseous refrigerant is compressed into a high-temperature, high-pressure (approx 70°C, 15 kg/em?) state where the refrigerant will easy liquefy, and the refrigerant is then delivered to condenser (3). 2) In condenser (3), the gaseous refrigerant is cooled by the outside air whic is forced through the condenser by the fan. Thereaf- ter, the refrigerant is liquefied approx. 50°C) and flows into a liquid tank (4), where is stored. The moisture is removed with silica-gel, and dust is removed when the re- jerant passes through a strainer. 3) The liquid refrigerant flowing out of liquid tank (4) is suddenly expanded by passing through the restricted passage of expansion valve (5) into a low-temperature, low- pressure (approx. 0°C, 2 kg/cm*) atomized refrigerant, which flows into an evaporator ©) 4) The automized refrigerant which has flowed into the evaporator (6) will evapo- rate, absorbing the heat from the air on the 10-110 ® Engine Compressor Condenser Liquid tank (receiver) Expansion valve Evaporator Water valve Heater core PONe exo 19802004 evaporator surface (the air in the operator's room), and will be further heated and drawn into compressor (2) in the form of a gas. The air in the operator's room is drawn into evaporator (6) by the blower fan and is cooled on the evaporator surface. Then, the coo! wind blows into the room. The warm air in the room is thus cooled on the eva- Porator surface and the moisture in the air is liquefied. Thus, the moisture is removed from the air. By repeating steps 1) through 4), the heat is removed from the room air which flows into the evaporator and is dissipated over the condenser surface. Thus, the operator's room is cooled. When the cool wind is cooled to a certain degree (cooling is set to 1°C and warming to 17°C), the magnetic clutch of the compressor will be disengaged by the action of the thermostat, ceasing the cooling operation. * The temperature and pressure of the refrigerant vary with the temperature at the front of the condenser, the air flow, etc. 017502017502 AIR CONDI SNOTEON= TONER SYSTEM DRAWING Engine V-belt Magnetic clutch Compressor Coupler Condenser Liquid tank (receiver) High pressure switch 9. Low pressure switch 10. Expansion valve 11. Thermo cylinder (temp. sensor) 12. Evaporator 13. Thermistor 14. Blower 15. Valve 16. Heater core moom> F15A02053-K To LH. door glass To rear glass To RH. door glass External air of cab Internal air of cab 10-111017502 20 TESTING AND ADJUSTING Table of standard values for engine ......20- 2 Table of standard values for chassis .....20- 3 Table of electrical judgement standard value .. Pe 2028 Testing and adjusting . = 20-101 H-Mode troubleshooting .. = 20-201 M-Mode troubleshooting : 20-227 E-Mode troubleshooting ..... - 20-255 + The following precautions are necessary when using the STANDARD VALUE TABLE for testing and adjusting, or for troubleshooting. 1. The values in the table are for new machines, and are obtained from reference to values for new machines and the values when shipping from the factory. Therefore, they should be used as target values for judging the progress of wear, or when repairing the machine. 2. The values for judging failures are based on standards when shipping the machine from the factory, and on the results of various tests. These values should be used as reference together with the repair condition and operating record of the machine to make judgements on failures. 3. The values in the table should not be used for judging claims. Ay When carrying out testing, adjusting or troubleshooting, stop the machine on level ground, install the safety pins and block the tracks. By When working in groupe, use agreed signals and do not allow unauthorized persons near the machine. When checking the water level in the radiator, wait for the water to cool. Do not remove the radiator cap while the water is hot. Boiling water may spurt out. Ay Be careful not to get caught in rotating parts.TABLE OF STANDARD VALUES FOR ENGINE Engine $6D155-4 Machine model DI55A-2 (Check item Conditions Unit ee | ee, High idling 2.160250 - Engine speed Low idling pm 570+50 - At rated speed 2,000 = ‘Sudden acceleration Max. 7.0 90 Exhaust color Bosch index. At high idling Max. 3.0 40 Vane ct Intake valve (20°C) oO - We clearan mm e ee Exhaust valve (20°C) 0.6 ceed Oil temp.: 40 — 60°C Compression pressure | Engine speed: 180—210rpm | ka/em? | Min. 24 7 (SAE30 oil) (Water temperature inside operat- Blow-by pressure ing range) mmH:0° Max. 200 400 At high idling (SAE30 oil) (Water temperature inside operating range) [At high idling (SAE30) 35-45 25 Oil pressure At low idling (SAE30) kavem? Min. 1.5 1.0 At igh idling (SAE10W) 30-45 24 At low idling (SAE1OW) Min. 1.0 07 Oil temperature Whole speed range (inside oil pan) | °C 80—100 120 Fuel injection timing | Compression B.T.0.¢. degree 3841 3841 Projection "a" of adjustment bolt Fan belt tension 855 - mm 175F02101. ‘Alternator drive belt Slack when pushed with finger 76426 = tension force of 6kg 20-2 ® 017502017502 TABLE OF STANDARD VALUES FOR CHASSIS Clas Standard] Permissibe ‘Classi [Check item Conditions unit | Stender a * Engine oll pressure orque converter ‘within operating range stall speed © Engine oll temperature: 1.630270 | 1.880270 g wathin operating range 5 + Powertrain oll temperature: om © | Torque converter 70--80°C Jai avarautg. | © Hydraulic oi temperature: relief speed. 45 — 55°C 1,370£70 1,300+70 «No.of speed range: F3 Engine: low ing 170130 | 170230 Fuel control ever | *Centerof, = full throttle fever knob Engine: low idling re eo atop * Center of pedal Decelerator pedal | « Engine: full throttle — Low idling Goehis fee Between each = Enavesooea EON mais | sass Gear shit lever * Center of loverknob Fa=R 6325 6335 * Epaine low ul sroke yaez10 | 126410 Steering lever © Center of Until clutch is fully lever knob_ disengaged 687 6847 ® Engine low idling S| Brake pedal © Center of pedal mm 16010 Max. 230 E Full stroke 3 * Engine low RAISE : ‘ding 7ot10 | 70x10 z © Center of N— LOWER | lade controt ever | tever knob Hydraulic ol! yy LEFT TILT temperature: ee : (3945 (3945 emperature: Ny — RIGHT TILT © Engine low RAISE idling ee 606 60+6 © Center of N—LOWER Ripper contro! lever |” lever knob eHydreulicol! TH temperature: vl soll 60+6 60+6 arreeretere TILT BACK z Engine: fow ing 3s — full throttle iota Max. 14 8 center of Engine: full throttle | Fuetcontrt lever Cente ee ow an 1042 Max. 14 : Engine: lw idling ose ene os 5 oop 3 * Engine speed “o 3 800-850 rpm_ Engine: full throttle % § | Decelerator pedal © Center of — low idling ee bce 7 pedal = ‘Between each: 3 * Engine stopped Bere nnea sit Max. 7.5 3 | Gear shitt lever * Comer of é leverknob Fak ait Max.6.0 20-3 ®Clas Standard] Permissibe fication] _Chedk tom Ceara Grit |e Value value Una etch Teo Engine low — gigengaged 4.0405 | Max.65 a co er when brake is 7621.5 | Max.125 lever knob applied : e * Engine: low idling B | erate pel * Engine stops or stalls with one | ae 3 + Center of pedal 5 “Engine low N— RAISE 25405 | Max65 5 idling ko 3 * Center of lever — LOWER : Max. 45 & | ade contatiever | ofhnob sean 2 + Hydrautie ol 2 N—LeFT TUT 2 temperature: Mox. 5 ‘45—-55°C | N—RIGHTTILT cae ae é *Enginelow idting, Sp 20405 | Max.36 * Center of ever N~LOWER Ripper control ever | _ of knob Hydraulic ol! ut temperature: 20205 | Max.35 ‘45 55°C N—TILTBACK T averior Telit pressure (inlet) Beis | B5t1s Torque converter outlet pressure 5.5215 5.521.5 Transmission modu= : : lating pressure 20(-1. 22) | 20". 22) Transmission reduc] ® Oil temperature in power train Seep’ 70 80°C 125210 | 125210 § | ingpressure | engine speed: fll throttle 3 | cation pressure Max.2.0 | Max. 2.0 E kg/em* Steering cluch oper- 2 | ming pressure 15.0420 | 150420 3 [Broke operating pros 3 eater 17.0220 | 17.0220 = Blade iting pressure Blade titing pressure | # Hydraulic oll temperature: 45— 55°C 142546 | 142.5445 Ripper lifting pressure | © Engine speed: full throttle Ripper ting pressure F ist 37 37 * On tovel surface § Engine atfullthrottle _F_2nd 68 68 & * Engine water tempera- : ture: Inside operating F 3rd 118 118 S| Travel speed wr km/h § * Run-up distance. Rist 45 45 i 1030 m # Measurement distance: m2 Mensa R 2nd 82 82 R 3rd 137 137 “1. Applicable Serial No. 50901 and up. 017502017502 Check item Conditions Permissibe value po nave fv ira 110-180] 200 — Ft a I | 2 E becl 30-50 55 Blade speed (lift) 7 sec. idling 15-25 30 © Hydraulic oil temper- uote see” S Blade: no load os © From ground to ma throttle 05-15 20 imum height Pasture of work equipment a, ao-so | 60 z= 5 eu = é throttle eed 58 Blade speed tit) : see 5 Low 2 isting 20-45 55 © Hydraulic oil temper-'r € ature: 45 — 55°C S ean : Blade: no load eae 15-36 45 5 # Loft tit — Right it g Posture of work equipment > 4 iaing 100-180] 200 3 throttle as—4s | 55 Ripper speed (lit) sec Low * Hydraulic il temper- ging 30-45 55 aureas—ssec | & Shank set at second hole fromthe lower pyy ‘© From ground to max- ire 35-45 55 imum height Posture of work equipment idling Full throttle Ripper speed (tt) see ye Low © Hydraulic oil temper & jing aturesaS— 55°C ‘© Shankset at second ® hole fromthe tower gyi «From tilt back — inoue tittin 20-5Classi fication| — Check item Conditions Unit ‘Standard value Permissibe value Time lag (biade) * Hydraulic oil tempera-—g, ture: 45 — 55°C. re * Lower the blade from [OW the maximum height, ‘4196 and measure the time Max. 8 taken from the point when the blade touches the ground to the point where the idler is raised from the ground Engine full throttle sec. Max. 1.6 20 Time lag (ripper) ‘© Hydraulic oil temperature: 45 — 55°C ‘© Lower the ripper from the maxi mum height, and measure the time taken from the point when the ripper touches the ground to the point where the sprocket is raised from the ground * Engine full throttle Max. 1.5 20 Hydraulic drift (blade tft) Posture of work equipment ‘© Hydraulic oil temperature: 45 — 85°C ‘ Engine stopped ** Center of blade cutting edge: from height of 800 mm to ground mm/min Max. 100/15 200/15 017502 ‘Werk equipment Hydraulic drift (machine moves down) Posture of work equipment © Hydraulic oil temperature: ‘45 — 86°C © Engine stopped © Blade pushed down, movement at coonter of il l/min Max. 50/15 100/15 Hydraulic drift {blade tilt) Posture of work equipment LEFT TILT rar Min. 7 | + Hydraulic oil temperature: 45 — 55°C ‘Tilt blade to raise RIGHT TILT] machine, engine stopped immediately to Min. 5 reach ground017502 Classi fication| Work equipment Check item Conditions Unit eens pormeeale mat | coe osare of war oipmert an AS Oe fe prccautio dre Imm/min} Max. 80/15 | Max. 160/15, (Papert « Hyrautioltemperture peas + Enoine stopped FE eto me shove ie eure Posture of wor euipment ‘Hydraulic drift tachine moves mm/min} Max. 400718 Max, 500/18 sown) + Hysrauti oil omporature ies + Eneine stoped 5 Riopor ble pushed down move: ent at comer sf rset 207TABLE OF ELECTRICAL JUDGEMENT STANDARD VALUE st Measurem $151 component connector No,fTea] Judgement table conditions 1) When carrying out a continuity test, 1) Starting following results show that the sensor is switch OFF 2 | normal Coolant level sensor | CN405 2 (Wate) i Coolant level normal | Continuity Coolant evel abnormal | No continuity Engine water tempera- | CN402 The following results show that the sensor is | 1) Starting tur scr (Male) | normal 2) Beene temperature gauge) 5 “Ambient Wie aa {engine Z temperature water tem- Torque converter oil | cNA53 z 38°C Approx, 29k sauge) a | temperaturesenior | Wale) 5 i i Disconnect 8 | (Torque converter oi! 2 ore Aooron: Ska Naas 5 | temperature gauge) 2 , (T/Coit Bee . 10°C Approx. 80 ki temperature g sause) 2 1) When earrying out a continuity test, the | 1) Engine following results show that the sensor is started 2 normal Engine oll pressure | cN403 2 | ear bts ag 2 ngine ol presaye over aa se (Male) a es Continuity Engine oil pressure under ‘oko No continuity Fuel level sensor onazs | The following results show thet the sensor is | 1) Starting (fuel gauge) (Mate) 5 | normal switch OFF = | (Normal temperature 25°C) 2) Disconnect z onaa3 2 CN423 (Male) © - @ © | [Fut | Approx. 109 or less 2 Empty | Approx. 852 — 1109 2 1 20-8 017802017502 Sys nsec] Measurement SYS-) Name of component | Connector No. "see Judgement table ene Glow plug signal | Between CN ifthe condition is as shown in the table | 1) Turn starting (2.13) CN2| g g | below, itis normal switch ON. 0 ge 2) inser T- 3 & | [ Average voltage 4—2RVv adapter. 7 Effective voltage Ww 14V Nozze signal Between CN1 | g | Ifthe condition is as shown in the table | 1) Turn starting (a) cn2in | § | below, itis normal switch ON. a 2) inser T- 23 | [Average vonage 04—5V adapter. Lamp signal Between CN2 ifthe condition is as shown inthe table | 1) For 12sec. (@)—CN210) | gg | below, itis normal gs 12-30V 23 fg | Water temperature | Between CN2 ifthe condition is as § | sonsor signa! @—cn2i) below, tis normal 2) 7 Below specified | water temperature starting signal Between CN2 |g g | Ifthe condition is as shown inthe table | 1 ing | @—cN2™ | $8 | below, tis normal switch ON, s 2) Insert T- 28 70-20v adapter. Glow plug resistance | Between CNi |» g | ifthe condition is as shown inthe table | 1) Remove value (21,3) — body] 5 E | below, itis normal CN. 2 2) Insert T- 23 an adapter. Nozzle resistance | Between CNi | 9 8 tion is as shown in the table | 1) Remove value (a) body | $2 | below, itis normal Nt | 88 2) insert T- | 33 3-50 ‘adapter.017502 TESTING AND ADJUSTING Testing and adjusting tool list ....... 20-102 Adjusting valve clearance .......... 20-103 Measuring compression pressure .. Adjusting fuel injection timing Measuring torque converter stall speed .. Bleeding air from hydraulic oylinder .....eee6 = 20-107 Measuring oil pressure ............ 20-108 Adjusting fuel control linkage . 20-110 Adjusting gear shift lever linkage .... 20-112 Adjusting steering clutch linkage .... 20-114 Adjusting travel of brake pedal. 20-115 Adjusting brake pedal linkage . . 20-116 Adjusting spring assist brake. 20-117 Adjusting brade control linkage 20-118 Adjusting ripper control linkage ..... 20-120 sees es 20-106 Ay Wher carrying out testing, adjusting or troubleshooting, stop the machine on level ground, install the safety pins and block the tracks, Ay Wher working in groups, use agreed signals and do not allow unauthorized persons near the machine. Dy Wien checking the water level in the radiator, wait for the water to cool, Do not remove the radiator cap while the water is hot. Boiling water may spurt out. A Be careful not to get caught in rotating parts, A Bleeding air from hydraulic eylinder. After replacing or installing hydraulic cylinders or hydraulic piping, bleed the air from the hydraulic cylinders as follows 1, Start the engine and run at idling for about 5 minutes, 2. Run the engine at low idling, and raise and lower the blade or ripper 4 — 5 times + Stop the piston rod about 100 mm from the end of the stroke, Never operate it to the relief Position 3. Run the engine at full throttle and repeat the above procedure. Then run the engine at low idling and operate the piston rod to the end of the stroke to relieve the circuit, 20-101TESTING AND ADJUSTING TOOL LIST Check tem No] Pan Tool Remarks 799-203-8000 _| mult-tachometer oat Engine speed A Digital display “ ®° ee (799-203-8900) | (Clamp set) H: €0—20,000 rpm Water oitandintake | | 799-101-6000 | thermistorkit | ~50— 200% Lubseatongresare | [788-101-5001 [ Arto a tester | 2560, 40, 6004a/em ene eareuue Paeeete 790-261-1201 | Digital hyd. tester Max. 700kg/em? 725-502-1890 | Compression gouge : 0 — 70 kg/cm’ Compression pressure | D foe eae KT No. 786-502-1208 Biow-by pressure € | 799-201-1608 | Blowy checker | 0— 500 mmHuo IN. value : 0.4mm poaoes Commercial pene fe available Feeler gauge EX. value :0.6mm_ Discoloration 0 — 70% with tand- Exhaust color 6 | 709-201-8000 | smoke checker | ardcolor (Discoloration Se 171 Bosch inden Commercially Operating force | Commercity | push-pull scale . Travel and hydrate Commercially drift, ! available a Eee | Work equipment speed | J | Commercial | stopwatch = Pump pertormance | x | 790-303-1002 | Flowmeter kt ia 799-601-2500 | T-edapter box Wiring naross ana |, | Uf 72200-2500 S veneot 607 799-601-3550, Adapter Voltage and Commercially i: _ realsionoe _ ‘available a 20-102 ® 017502017502 ADJUSTING VALVE CLEARANCE % Adjust clearance between crosshead and rocker lever as follows: Unit: mm Intake valve_| Exhaust valve ‘At 20°C. 0.4 0.6 1. Remove cylinder head cover (1). 2. Rotate crankshaft in normal direction while watching valve to align “1.6 TOP” mark on crankshaft pulley (7) with pointer (2) when No. 1 cylinder is at compression TDC. 3. While No. 1 cylinder is at compression TOC, adjust the valves marked @ in the table below: While No. 6 cylinder is at compression TOC, adjust the valves marked ©. intake vave fe] le] fo] le] [2] lo exhaust vaive | Jel Jol Jel fof [ef To 4. Insert feeler gauge F between rocker lever (3) and crosshead (4) and adjust adjustment screw (5) until feeler gauge F is a sliding fit Tighten lock nut (6). SD Lock nut: 6.9 +1.0 kgm 5. Next, rotate crankshaft one turn in the normal direction and adjust the valves marked ©. + It is also possible to adjust as follows: Adjust valve clearance of No. 1 cylinder when it is at compression TDC, then turn crankshaft 120° each time and adjust valve clearances following firing order. @ firing order: 1-5 -3—6—2—4 % After tightening lock nut, confirm valve clearance 178F02108MEASURING COMPRESSION PRESSURE * If performance tests or troubleshooting shows that the piston, piston ring or cylinder liner may be worn, measure the compression Pressure. Ay Wher measuring the compression pressure, be careful not to touch the turbocharger, or to get caught in rotating parts. 1. Adjust the valve clearance. * For details, see ADJUSTING VALVE CLEARANCE. 2. Run engine to warm up the oil to 40 ~ 60°C. 3. Remove the nozzle holder assembly to be measured, * For details, see REMOVAL OF NOZZLE HOLDER ASSEMBLY. 4. Install too! D, in the mount of nozzle holder assembly and connect tool Dy. 5. Set tool Ay to the fuel injection pipe and connect tool A, . 6. Place the fuel contro! lever in the NO INJEC- TION position. Crank the engine with the starting motor and ‘measure compression pressure. %* Measure the compression pressure at the point where the pressure gauge indicator remains steady. * When measuring the compression pressure, measure the engine speed to confirm that it is within the specified range. * For details of installing the nozzle holder assembly after measuring the compression pressure, see INSTALLATION OF NOZZLE HOLDER ASSEMBLY. 20-104 017802017502 ADJUSTING FUEL INJECTION TIMING 1, Rotate the crankshaft in the opposite direction in 40 to 50° from No. 1 cylinder ‘compression TDC. 2. Rotate the crankshaft in the normal direction, and align pointer (2) correctly with the 38° line on crankshaft pulley (1). 3. Disconnect fuel injection pipe (3) of No. 1 cylinder. 4. Remove delivery valve holder (4), take out spring (5) and delivery valve (6), then install delivery valve holder (4) again. 5.Place the fuel control lever at the FULL position. 6. Loosen bolt (7) of the injection pump bracket and loosen four injection pump mounting bolts (8). 7. Operate priming pump and turn the injection pump at the cylinder block end a little at a time. Stop at the point where the fuel stops flowing from the delivery valve holder. * When the fuel injection pump is rotated, the injection time is changed as follows. Turn TOWARDS cylinder block to ADVANCE timing. Turn AWAY from cylinder block to RETARD timing. 8. Tighten four injection pump mounting bolts (8) in turn, 9. Tighten bolt (7) of the injection pump bracket 10. Remove delivery valve holder (4), assemble delivery valve (6) and spring (5), then install delivery valve holder (4) again. S= Delivery valve holder: 11.5 + 0.5 kam 11. Connect fuel injection pipe (1). Sleeve nut: 2.2 + 0.2 kgm 175F0210341 423F3028 20-105 ®MEASURING TORQUE CONVERTER STALL SPEED Procedure for measuring stall speed 1.Set tool A; to the fuel injection pipe and connect tool Ay. 2. After warming up the engine, depress the brake pedal fully and set the gear shift lever to F3 or R3. Stall the torque converter with the engine running at full throttle, and raise the torque converter oil temperature to the red range on the torque converter oil temperature gauge. Depress the brake pedal fully, and do AX 10t let the machine move under any cir- cumstances. 3.When the torque converter oil temperature gauge enters the red range, return the gear shift lever immediately to the “N” position to lower the torque converter oil temperature, When the torque converter oil temperature goes down to the green range, relieve the work equipment circuit to raise the hydraulic oil temperature. 4, Repeat Steps 2 and 3 three times. 5.When the torque converter stalls for the 4th time, measure the engine speed at the moment the torque converter oil temperature gauge goes into the red range. 20-106 ® (Reference) The stall speed differs according to the machine serial number because of the following differences, 1) Variations between engine series numbers. 2). Variations in engine output caused by differences in atmospheric pressure and ambient temperature, 3) Differences in consumption torque of auxiliary equipment. 4) Differences in torque converter proper- ties. 5) Differences occurring because of method of measuring stall. For these reasons, the stall speed must be measured extremely carefully. 017502017502 BLEEDING AIR FROM HYDRAULIC CYLINDER + After replacing or installing hydraulic cylinders ‘or hydraulic piping, bleed the air from the hydraulic cylinders as follows: 1. Start the engine and run at idling for about 5 minutes. 2. Run the engine at low idling, and raise and lower the blade or ripper 4 — 5 times. * Stop the piston rod about 100 mm from the end of the stroke. Never operate it to the relief position. 3. Run the engine at full throttle and repeat the above procedure. Then run the engine at low idling and operate the piston rod to the end of the stroke to relieve the circuit. 20-107MEASURING OIL PRESSURE A 82° the machine on level ground, lower the work equipment completely to the ground, and apply the parking brake. 2. 8228 the engine before removing oF instal ing any plug or pressure gauge. % When measuring the oil pressure, remove all dirt and mud from around the plug. ‘* When measuring the oil pressure, measure at the specified oil temperature. 1, Measuring oil pressure in power train ‘© Measuring torque converter relief pressure 1) Remove plug (1). 2) Install tool C (gauge: 25 ka/em?). 3) Start the engine, raise the engine speed gradually, and measure the oil pressure with the engine at full throttle, % Measure with the gear shift lever at the “N” position. © Measuring torque converter output pressure 1) Remove plug (2). 2) Install tool € (gauge: 25 kg/cm?) 3) Start the engine, raise the engine speed gradually, and measure the oil pressure with the engine at full throttle. + Measure with the gear shift lever at the “N" position, ‘¢ Measuring transmission reducing pressure 1) Remove the cover, then remove plug (3). 2) Install tool C (gauge: 25 kg/cm? ). 3) Start the engine, raise the engine speed gradually, and measure the pressure with the engine at full throttle. © Measure with the gear shift lever at the “N" position. ‘¢ Measuring transmission modulating pressure 1) Remove plug (4). 2) Install tool C (gauge: 60 kg/cm? ), 3) Start the engine, raise the engine speed gradually, and measure the pressure with the engine at full throttle. © Measure with the gear shift lever at the “'N" position. 20-108 — 7 __175F02119) 017502017502 ‘® Measuring steering clutch actuating pressure 1) Remove plug (5) or (6). 2) Install tool C (gauge: 25 kg/em?). 3) Start the engine, pull the lever to the position to disengage the clutch, raise the engine speed gradually, and measure the pressure with the engine at full throttle. % Measure with the gear shift lever at the “N" position. * R.H. clutch (5) + LH. clutch (6) ‘* Measuring brake actuating pressure ] 1) Remove plug (7) or (8). 2) Install tool C (gauge: 25 kg/em?). 3) Start the engine, depress the pedal fully, raise the engine speed gradually, and | measure the oil pressure with the engine at full throttle. ‘+ Measure with the gear shift lever at the “N"" position. + RAH. brake (7) + LH, brake (8) —__175F02121 2. Measuring work equipment main relief pressure 1) Remove plug (9). 2) Install tool C (gauge: 400 kg/cm?). 3) Start the engine, operate the blade tilt or ripper control lever, raise the engine speed gradually, and measure the oil pressure with the engine at full throttle. 20-109 ®ADJUSTING FUEL CONTROL LINKAGE 1. Fix fuel contro! lever (1) at a position where clearance A between idling set spring box (2) isO mm, 2. Set governor lever (3) of the engine fuel injection pump to the idling position. 3.With decelerator pedal linkage rod (4) not interconnected, pull fuel control lever (1) towards the rear of the machine, Check that. lever (3) of the engine fuel injection pump, contacts the FULL stopper. 4, Keep the lever in this position, and rotate FULL stopper (5) until it contacts the fuel control lever. Hold the stopper in this position. With decelerator pedal linkage rod (4) not interconnected, pull fuel control lever (1) towards the front of the machine. Check that lever (3) of the engine fuel injection pump contacts the STOP stopper. 20-110 ® tating Stop | Full throttle 175F02124 184F21112 017502017502 6.With the lever in this position, turn stop adjustment bolt (6) attached to idling set spring box (2), and adjust clearance B to Omm. Hold the bolt in this position. 7. Adjust with screw (7) so that the travel of the decelerator pedal is 44mm, Determine the full throttle position of the decelerator pedal, then connect decelerator pedal linkage rod (4). Adjust decelerator pedal linkage rod (4) so that clearance D at the tip of the joint is 0 when the engine is at full throttle. 8. Start the engine and depress decelerator pedal (8). At the position where the engine speed is 800 — 850 rpm, turn adjustment bolt (9) attached to the decelerator pedal to adjust clearance E to 0 mm. % After adjusting all parts of the linkage, set the fuel control lever at the full throttle Position, Check that the engine fuel injection pump is always in contact with the FULL stopper. % Set the fuel contro! lever to the stop position, and check that the engine always stops. 154F21112 175F02125 ey clearance D 1saF21118 175F02126ADJUSTING GEAR SHIFT LEVER LINKAGE T 6 8 Wo 2 § 4 FT 4 175F02127 % Tighten the lock nuts of the rods and cables securely, and bend the cotter pins securely. + Speed selector rod (1) and direction selector rods (2) and (2A) are installed to the transmission control valve. The speed position and direction position of each lever is determined by the detent inside the valve. 1, Set rod (1) in the N position, and connect gear shift cable (3) to bracket (4) and rod (1). 2. In this position, adjust the mounting height of the switch, so that neutral safety switch (5) Pushed in 1.5 mm. * Move rod (1) N+ 1>2+3+2>1-N, Check that the push-pull cable moves the correct distance. 3. Set gear shift lever (6) to the N position (N position of change guide(7) ),and put safety lock lever (8) in the LOCK position. * If the LOCK position of the safety lever does not match the position of the change guide, adjust the length of rod (9). 175F02128 154721118 20-112 ® 017502017502 4.With gear shift lever (6) at neutral and FORWARD, interconnect rods (10), (11) with push-pull cables (3). 5. After adjusting all the parts of the linkage, check that gear shift lever (6) moves the correct distance for all eight positions. (FORWARD: N > 1+ 23; REVERSE: N 31523), 6. Check that when the gear shift lever is put in ‘the N position for FORWARD and REVER- SE, it cannot move to 1+ 2 +3 when the safety lock lever (8) is in the lock position. 20-113 ®ADJUSTING STEERING CLUTCH LINKAGE % Tighten the lock nuts of the rods and cables securely, and bend the cotter pins securely. 1. Adjust the length of stopper bumper (2) so that steering lever (1) is 45mm from the front face of the guide box. 2. Pull steering levers (3) and (4) attached to the steering brake valve lightly towards the front ‘of the machine, and connect push-pull cable (5) where they contact the spool inside the valve, 3. After connecting all the linkage, if there is any play in steering lever (1), adjust turn- buckle (6) of push-pull cable (5) to remove the play. 20-114 ® 154F211198 4. After adjusting all parts of the linkage, pull the steering lever fully and check that it travels 126 + 10 mm, Check also that there is a clearance between the steering lever and the guide box. 017502017502 ADJUSTING TRAVEL OF BRAKE PEDAL ‘© Run the engine at idling, and adjust the brake lining so that the travel of the brake pedal is 160+ 10mm. 1, Remove the fender rear cover, then remove brake adjustment cover (1). ighten adjustment bolt (2) to bring the lining into close contact. =) Adjustment bolt: 5 kgm 3. After bringing the lining into close contact, turn adjustment bolt (2) back 1-1/6 turns. (Check that the travel of the brake pedal is within the standard value.) % The travel of the left and right brake pedals must both be the same. If it is different, it will cause the machine to pull to one side. % If dimension A of brake adjustment bolt (2) is less than 127 mm, replace the lining. 154F211208, 154F21121ADJUSTING BRAKE PEDAL LINKAGE + Tighten the locknuts of the rod and cable securely, and bend the cotter pin securely. 1. Adjust with the bumper (8) so that dimension A at the brake pedal is 40 mm, 2. Set lever (1) vertical. 3. In this condition, connect rod (2) 4, Pull rod (3), and adjust the yoke of rod (3) so that lever (4) lightly contacts the spool inside the brake housing, then connect lever a. * After connecting each rod, check that there is no play at the connecting pin. + Standard length of rods * Rod (2): 423 mm * Rod (3): 946 mm + Rod (6): 312mm © Rod (7): 371mm 5. Run the engine at idling, and check that the travel of brake pedal (6) is 160 + 10 mm. + Check that there is no dragging of the brake when the engine is running at low idling. + Adjust the clearance of the brake lining. For details, see TESTING AND ADJUSTING, Adjusting travel of brake pedal. 20-116 ® FIBAOITI3K-A 017502017502 ADJUSTING SPRING ASSIST BRAKE = Check that the brake and steering linkages are adjusted. Screw nut (1) so that rod length dimension Ais 106 mm. Adjust with nut (3) so that the clearance B between lever (2) and the end face of nut (3) isO—0.5 mm - Loosen nut (4), set so that dimension C is 36 — 41 mm, then secure it in position with locknut (5). 175021294. 1756021304, 20-117 ®ADJUSTING BLADE CONTROL LINKAGE 1 L Seen 1. Align the match marks for the neutral position of input lever (3) and output lever (4) of servo valves (1) and (2), then secure with lock bolts (5) and (6) 2. Connect rods (7), (8), (9), (10), and (11). % Standard length of rods © Rod (7): 555mm Rod (8): 194 mm Rod (9): 725 mm Rod (10): 300 mm Rod (11): 144 mm Adjust the lengths of rods (7) and (10) to remove the parts error and assembly error. 3. Remove lock bolts (5) and (6) tightened in Step 1 4. Set blade lever (12) at the HOLD position, move blade lock lever (13) between the LOCK and FREE positions, and check that blade lever (12) does not move. % If blade lever (12) moves, or lock lever (13) does not move smoothly, adjust the position of bracket (14). 20-118 175F02131 175F02132 017802017502 5. After adjusting all of the linkages, run the engine at low idling, operate blade lever (12) to all five positions (RAISE, LOWER, FLOAT, LEFT TILT, RIGHT TILT), and check the travel of blade lever (12). Check the travel of the lever. See TABLE OF STANDARD VALUES FOR CHASSIS. 4 If the blade moves with the blade lever at HOLD, or the blade speed is not within the standard value, the neutral position of servo valves (1) and (2) is improperly adjusted, so adjust with rods (7) and (10). 20-119ADJUSTING RIPPER CONTROL LINKAGE 175F02133 175F02134 1. Align the match marks for the neutral position 2 3 of input lever (2) and output lever (3) of servo valve (1), then secure with lock bolt (4). 2. Connect rods (5) and (6). % Standard length of rods © Rod (5): 191 mm © Rod (6): 564 mm + Adjust the lengths of rod (5) to remove the parts error and assmembly error. 3. remove lock bolt (4) tightened in Step 1 4. Set ripper lever (7) at the HOLD position, move ripper lock lever (8) between the LOCK and 178F02135 FREE positions, and check that ripper lever (7) does not move. + If ripper lever (7) moves, or lock lever (8) does not move smoothly, adjust the position of bracket (9) 5. After adjusting all of the linkages, run the engine at low idling, and operate ripper lever (7) to both positions (RAISE, LOWER), and check the travel of ripper lever (7). 20-120 a 017502017502 + Check the travel of the lever See TABLE OF STANDARD VALUES FOR CHASSIS. + Adjust the travel of ripper lever (7) with bolts (10) and (11). % If the ripper moves with the ripper lever at HOLD, or the ripper speed is not within the standard value, the neutral position of servo valve (1) is improperly adjusted, so adjust with rod (5). 20-121 ®017502 H-MODE TROUBLESHOOTING 20-202 20-204 seeee+ 20-207 20-208 Preparation for troubleshooting . Method of reading troubleshooting table . Preventing recurrence of the same trouble Troubleshooting table H- 1 Torque converter temperature too high 20-210 H- 2 Machine does not move ...... 20-210 H- 3. Machine lacks power or speed . 20-211 H- 4 Machine moves when engine is started 20-211 H- 5 Excessive time lag when starting machine or shifting gear . ee 20-211 H. 6 Excessive shock when starting machine or shifting gear ... 20-212 H- 7 Machine travels in one direction only (FORWARD or REVERSE) ....... H- 8 Steering clutch does not disengage 20-212 20-213 H- 9 Steering clutch slips ++ 20-214 H-10 Steering brake does not work 20-215 H-11 Blade lift lacks power and speed 20-216 H-12 Blade does not lift . 20-217 H-13 The front of machine cannot be raised off ground by the blade oe++ 20-218 H-14 Hydraulic drift of lift cylinder is large . = 20-219 H-15 Blade moves unsteadily when leveling the ground (Control lever in "HOLD") . eantre -+ 20-220 H-16 Blade lowers under the following conditions . - 20-220 H-17. Travel of the piston rods in the right and left lift cylinders is different (Applicable to straight-tilt dozer only) 20-220 H-18 Blade tilting force is lack, blade tilting speed is slow, the machine cannot be raised off ground by blade tilting force . H-19 Tilt cylinder does not move off (Tilting is impossible) H-20 Hydraulic drift of tilt cylinder is large H-21 Hydraulic drift of ripper cylinder is large . H-22 Operating force is heavy .......... 20-221 20-222 20-223 20-224 = 20-225 H-Mode: Troubleshooting for hydraulic or mechanical system. 20-201 ®PREPARATION FOR TROUBLESHOOTING SAFETY A « Place the machine on level ground and apply the brakes without fail ‘ During joint work, keep close contact with cooperators and keep off other people, ‘© Be careful not to touch hot or rotating parts. ‘ Keep the negative terminal of the battery disconnected when disconnecting wiring, ve ; : “AS «Be sure to release remaining oil, water or air pressure, before removing a plug or cap. Connect testing equipment securely. CAUTION Pay attention to the following during troubleshooting, especially when removal and disassembly are necessary. ‘¢ Proceed with the disassembly by confirming the fitting conditions of the relative parts; their positions fore-and-aft, left-and-right and upper-and-lower, and their proper removal sequence, '® Put match marks across mating joints where required, before disassembling parts, and identify each part by scribe marks. ‘© The part should be clearly marked to prevent confusion at the time of assembly. ‘* When a part, after removal of mounting nuts and bolts, still does not move, never force the part; carefully check for the cause, © Before assembly or installation, throughly clean parts and remove scratches and nicks, ‘© Throughly remove dust, grease and oil from surfaces to be coated with liquid gasket. 017502 20-202 ®017502 1. Never attempt to disassemble thoughtlessly. Hasty disassembly will cause © needless disassembly of unrelated parts, and hindrance of troubleshooting. Such faults will not only result in losses from unnecessary replacement parts and man-hour costs; but also in failure to prove yourself worthy of user’s and operator's trust. Careful examination and systematic diagnosis should be made before disassembly. 2. Inquire of the user and operator the follow- in 1) Are there trouble symptoms other than that you have already been informed of? 2) Were any abnormal indications noticed previous to the trouble? 3) Whether the trouble arose suddenly or gradually. 4) What were the conditions under which the trouble arose? 5) If repair of the machine was made previous to the trouble, When? and Who? 6) Whether or not the same trouble has occurred before. 3. Check the following before troubleshooting: 1) Oil level 2) Oil leaking out from the pi hydraulic devices, 3) Control lever travel. 4) Control valve spool travel 5) Other necessary maintenance items which can be checked visually from the outside of the machine, 4, Examine the trouble symptoms. 1) Ask the user and operator how they judged the machine is out of order on the basis of some data, in comparison with something, or by senses, 2) Examine the magnitude of trouble by yourself in reference to critical values. © Be sure to confirm safety before testing the machine. @ Never make any tests which would ‘cause further trouble. (Consult with the user and operator about examination.) 3) Roughly locate a possible cause of the trouble + Proceed to problems © Strictly observe the specified test conditions when inspecting matters largely dependent on oil temperature (such as spontaneous drift speed of work equi ment supported by hydraulic cylinders). 5. Problems After finishing checks and inspections described in steps 2 to 4, proceed to problems, referring to the troubleshooting tables and using the following procedure: 1) Start checking from a portion easy to check, 2) Start checking from a portion where the trouble is most probable. © The concept of 1) and 2) above is corporated in the compilation of the ‘troubleshooting tables, 3) Check related matters too, 4) Check to see whether other trouble symptoms or faulty parts are noted. See the next pages for use of the troubleshooting tables. 6. Removing the fundamental cause of trouble, Dealing with the present trouble is not always enough to prevent repetition of the same trouble, if the fundamental cause of trouble is left. It is necessary to find out and remove the fundamental cause of trouble, For details, see the paragraph “Preventing Recurrence of the Same Trouble.” 20-203METHOD OF READING TROUBLESHOOTING TABLE DESCRIPTION OF SYMBOLS USED IN TROUBLESHOOTING TABLE The following symbols are used in the “"Re- medy” column to indicate the method of eli- minating the cause of a fault. METHOD OF READING TROUBLESHOOT- ING TABLE ‘© The symbol 0 in the table is inserted only for causes which can be diagnosed. If a cause cannot be diagnosed, the corresponding box is left blank. © If the result of problems 1 using the trouble. shooting table shown at right is abnormal, the cause of the trouble can be assumed to lie between a and d. Because it is not possible to make a problems regarding e, it is necessary to perform the next problems (owing to the pos- sibility of a multiple fault). If the result of problems 1 is normal, the cause of the fault does not lie between a and d._ In such a case, before diagnosing the cause as e, however, carry out a check by means of problems 2 or 5. © If now the result of problems 1 is abnormal and the result of problems 2 normal, the cause is one of a, b or d. In addition, if the result of problems 3 is abnormal, the cause will be narrowed down to one of b or d. To determine which of b or d is the actual cause, perform problems 4, If the result of problems is abnormal, blacken ‘out the corresponding © in the table and then perform the next problems on these causes in order to narrow the likely causes, Example 1: Problems 1 > Abnormal Problems 2 Normal | example 1, the Problems 3» Abnormal { cause of the fault Problems 4> Normal? isb. From the table of Example 2: From the table of example 2, the cause of the fault ise, Problems 1 + Normal Problems 2+ Abnormal 20-204 ® Not necessary Example 1 fale R oregon — 2 J] 72a] 1 elgfele 2 Hol lo 3 el Te Not necessary _ OmmD) Probiemss = 3 Example 2 “i conan — ee fale la fy lojofofof* ee robiems © —= * In example 2, it is evident that the cause is e without carrying out problems 2, however problems 2 is performed by way of an additional check. 017502

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