WA180-3 Série 50001 e Acima

SEBM005802
Shop
Manual
WA1
80=3
WHEEL LOADER
SERIAL NUMBERS VVA180-3 - 50001 andw

This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or
disclosed except in accordance with written authorization from Komatsu America International Company.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or add improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication.
It is recommended that customers contact their distributor for information on the latest revision.
June 1997 Copyright 1997 Komatsu America International Company

WA18 O-3
MACHINE MODEL SERIAL NUMBER
WA1 80-3 50001 and up
. This shop manual may contain attachments and optional equipment that are not avail-
able in your area. Please consult your local Komatsu distributor for those items you may
require. Materials and specifications are subject to change without notice.
. WA180-3 mount the S6D95L engine.

For details of the engine, see the 95 Series Engine Shop Manual.
00-l
0
CONTENTS
No. of page
01 GENERAL . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 01-l
10 STRUCTURE AND FUNCTION . . .. ... ... . .. .. . ... .. ... . ... .. .. . ... .. . IO-I
20 TESTING AND ADJUSTING .. .. .. .. .. . ... .. .. . .. .. ... .. .. .. .. .. .. .. .. . 20-I
30 DISASSEMBLY AND ASSEMBLY .................................. 30-I
40 MAINTENANCE STANDARD .......................................... 40-I
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The affected pages are indicated by the use of the
following marks. It is requested that necessary actions Mark Indication Action required
must be taken to these pages according to the list
below.
0 Page to be newly added Add
a Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are not revised at this time.
LIST OF REVISED PAGES
Revision Revision Revision Revision Revision

Mark Pages number Mark Pages number Mark Pages number Mark Paws number Mark Pages number
0 oo- 1 @ 10-15 IO-56 IO- 98 IO-141

a oo- 2 @ IO-16 IO-57 IO- 99 IO-142
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$ oo- 9 IO-26 IO-68 IO-109 20- 8
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IO- 1 IO-43 l IO-85 0 IO-129 20- 25
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lo- 4 IO-45 IO-87 IO-131 @ 20- 27
IO- 5 lo-46 IO-88 lo-132 20- 28
lo- 6 IO-47 IO-90 IO-133 20- 29
IO- 8 IO-48 IO-91 IO-134 20- 30
IO- 9 IO-49 IO-92 IO-135 20- 31
IO-IO IO-50 IO-93 IO-136 20- 32
IO-II IO-51 IO-94 10-137 20- 33
IO-12 IO-52 IO-95 IO-138 20- 34
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20- 42 0 20-143 @ 0 30-50 @ o 30-106 0 o 30-161
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20-.45 @ 20-146 0 0 30-53 @ 0 30-109 @ o 30-164
20- 46 0 20-147 @ 0 30-54 @ 0 30-110 @ o 30-165
20- 47 0 20-148 @ 0 30-55 @ 0 30-111 @ o 30-166
20- 48 @ 0 30- 1 @ o 30-56 @ o 30-112 @ o 30-167
20- 49 @ 0 30- 2 @ 0 30-57 0 0 30-113 @ o 30-168
20- 50 @ 0 30- 3 @ o 30-58 @ 0 30-114 @ o 30-169
20- 51 @ 0 30- 4 @ 0 30-59 @ 0 30-115 @ 0 30-170
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20-105 @ 0 30- 12 @ o 30-67 @ o 30-123 @ o 30-178
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20-107 0 0 30- 14 @ o 30-69 @ o 30-125 @ o 30-180
20-108 0 0 30- 15 @ 0 30-70 @ o 30-126 @ o 30-181
20-109 @ o 30- 16 @ 0 30-71 @ o 30-127 0 o 30-182
20-110 0 0 30- 17 @ o 30-72 @ o 30-128 @ o 30-183
20-111 @ o 30- 18 @ 0 30-73 @ 0 30-129 @ o 30-184
20-112 @ 0 30- 19 @ 0 30-74 @ 0 30-130 @ o 30-185
20-113 @ 0 30- 20 @ 0 30-75 @ 0 30-131 @ o 30-186
20-114 @ 0 30- 21 @ o 30-76 @ o 30-132 @ o 30-187
20-115 @ 0 30- 22 @ 0 30-77 @ 0 30-133 @ o 30-188
20-116 @ o 30- 23 @ o 30-78 @ 0 30-134 @ o 30-189
20-117 0 o 30- 24 @ 0 30-79 @ 0 30-135 @ 0 30-190
20-118 @ o 30- 25 @ o 30-80 @ o 30-136 @ 0 30-191
20-119 @ o 30- 26 @ o 30-81 @ 0 30-137 @ 0 30-192
20-120 @ o 30- 27 @ o 30-82 @ o 30-138 @ 0 30-193
20-121 0 o 30- 28 @ o 30-83 @ 0 30-139 @ 0 30-194
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00-2-3
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SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The
service and repair techniques recommended by Komatsu and described in this manual
are both effective and safe. Some of these techniques require the use of tools specially
designed by Komatsu for the specific purpose.
To prevent injury to workers, the symbol A is used to mark safety precautions in this
manual. The cautions accompanying these symbols should always be followed care-
fully. If any dangerous situation arises or may possibly arise, first consider safety, and
take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to

keep tools and removed parts. Always keep
Mistakes in operation are extremely dangerous. the tools and parts in their correct places.
Read the Operation and Maintenance Manual Always keep the work area clean and make
carefully BEFORE operating the machine. sure that there is no dirt or oil on the floor.
1. Before carrying out any greasing or repairs, Smoke only in the areas provided for smok-
read all the precautions given on the decals ing. Never smoke while working.
which are fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK

wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs,
missing. park the machine on hard, level ground, and
. Always wear safety glasses when hitting block the wheels or tracks to prevent the
parts with a hammer. machine from moving.
. Always wear safety glasses when grind-
8. Before starting work, lower blade, ripper,
ing parts with a grinder, etc.
bucket or any other work equipment to the
3. If welding repairs are needed, always have a ground. If this is not possible, insert the
trained, experienced welder carry out the safety pin or use blocks to prevent the work
work. When carrying out welding work, al- equipment from falling. In addition, be sure
ways wear welding gloves, apron, hand to lock all the control levers and hang warn-
shield, cap and other clothes suited for welding signs on them.
ing work.
9. When disassembling or assembling, support
4. When carrying out any operation with two the machine with blocks, jacks or stands
or more workers, always agree on the oper- before starting work.
ating procedure before starting. Always in-
10. Remove all mud and oil from the steps or
form your fellow workers before starting any
other places used to get on and off the ma-
step of the operation. Before starting work,
chine. Always use the handrails, ladders or
hang UNDER REPAIR signs on the controls
steps when getting on or off the machine.
in the operator’s compartment.
Never jump on or off the machine. If it is
5. Keep all tools in good condition and learn impossible to use the handrails, ladders or
the correct way to use them. steps, use a stand to provide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19. Be sure to assemble all parts again in their
original places.
11 When removing the oil filler cap, drain plug Replace any damaged parts with new parts.
or hydraulic pressure measuring plugs, . When installing hoses and wires, be sure
loosen them slowly to prevent the oil from that they will not be damaged by contact
spurting out. with other parts when the machine is be-
Before disconnecting or removing compo- ing operated.
nents of the oil, water or air circuits, first
20. When installing high pressure hoses, make
remove the pressure completely from the sure that they are not twisted. Damaged
circuit. tubes are dangerous, so be extremely care-
12. The water and oil in the circuits are hot ful when installing tubes for high pressure
when the engine is stopped, so be careful circuits. Also, check that connecting parts
not to get burned. are correctly installed.
Wait for the oil and water to cool before
21. When assembling or installing parts, always
carrying out any work on the oil or water
use the specified tightening torques. When
circuits. installing protective parts such as guards,
13. Before starting work, remove the leads from or parts which vibrate violently or rotate at
the battery. Always remove the lead from high speed, be particularly careful to check
the negative (-1 terminal first. that they are installed correctly.
14. When raising heavy components, use a hoist 22. When aligning two holes, never insert your
or crane. fingers or hand. Be careful not to get your
Check that the wire rope, chains and hooks fingers caught in a hole.
are free from damage. 23. When measuring hydraulic pressure, check
Always use lifting equipment which has that the measuring tool is correctly assem-
ample capacity. bled before taking any measurements.
Install the lifting equipment at the correct
places. Use a hoist or crane and operate 24. Take care when removing or installing the
slowly to prevent the component from hit- tracks of track-type machines.
ting any other part. Do not work with any When removing the track, the track sepa-
part still raised by the hoist or crane. rates suddenly, so never let anyone stand at
15. When removing covers which are under in- either end of the track.
ternal pressure or under pressure from a
spring, always leave two bolts in position
on opposite sides. Slowly release the pres-
sure, then slowly loosen the bolts to remove.
16. When removing components, be careful not

to break or damage the wiring. Damaged
wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil
from spilling out. If any fuel or oil drips onto
the floor, wipe it up immediately. Fuel or oil
on the floor can cause you to slip, or can
even start fires.
18. As a general rule, do not use gasoline to

wash parts. In particular, use only the mini-
mum of gasoline when washing electrical
parts.
00-4
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.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
VOLUMES REVISED EDITION MARK
Shop manuals are issued as a guide to carrying When a manual is revised, an edition mark
out repairs. They are divided as follows: (@@@....) is recorded on the bottom of the
Chassis volume: Issued for every machine model pages.
Engine volume: Issued for each engine series
Each issued as one
Electrical volume:
Attachments volume: volume to cover all REVISIONS
I models
Revised pages are shown in the LIST OF RE-
These various volumes are designed to avoid VISED PAGES next to the CONTENTS page.
duplicating the same information. Therefore, to
deal with all repairs for any model , it is neces-
sary that chassis, engine, electrical and attach- SYMBOLS
ment volumes be available.
So that the shop manual can be of ample prac-
DISTRIBUTION AND UPDATING tical use, important safety and quality portions
are marked with the following symbols.
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
T
1. See the page number on the bottom of the Symbol Item Remarks
page. File the pages in correct order.
Special safety precautions are
2. Following examples
page number.
show how to read the
Example 1 (Chassis volume):

a Safety necessary when performing
the work.
Special technical precautions

10 - 3 or other precautions for pre-
* Caution serving standards are neces-
Item number (IO. Structure sary when performing the
and Function) work.
Consecutive page number for
Weight of parts of systems.
each item. Caution necessary when se-
Example 2 (Engine volume):

elkg Weight lecting hoisting wire, or when
working posture is important,
etc.
Places that require special at-

TghteningI
Unit number (1. Engine) tention for the tightening
torque torque during assembly.
Item number (2. Testing and
Adjusting) Places to be coated with ad-
Consecutive page number for Coat
hesives and lubricants, etc.
each item.
Places where oil, water or fuel
Xl, water must be added, and the ca-
3. Additional pages: Additional pages are indi- pacity.
cated by a hyphen 6) and number after the
Places where oil or water
page number. File as in the example. Drain must be drained, and quan-
Example: tity to be drained.
IO-4 12-203
10-4-I -
> Added pages -c~~~~~~~~
1O-4-2
1o-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may
Heavy parts (25 kg or more) must be cause the rope to slip off the hook during
lifted with a hoist, etc. In the DISAS- hoisting, and a serious accident can re-
sult. Hooks have maximum strength at
every part weighing 25 kg or more is the middle portion.
indicated clearly with the symbol &
. If a part cannot be smoothly removed from

the machine by hoisting, the following checks
should be made:
I) Check for removal of all bolts fastening 88% 79% 71% 41%
the part to the relative parts. SAW0479
2) Check for existence of another part caus- 3) Do not sling a heavy load with one rope
ing interference with the part to be re- alone, but sling with two or more ropes
moved. symmetrically wound onto the load.
Slinging with one rope may cause
g turning of the load during hoisting,
untwisting of the rope, or slipping of
WIRE ROPES
the rope from its original winding
I) Use adequate ropes depending on the
position on the load, which can re-
weight of parts to be hoisted, referring to sult in a dangerous accident.
the table below:
Wire ropes 4) Do not sling a heavy load with ropes form-

(Standard “z” or “S” twist ropes ing a wide hanging angle from the hook.
without galvanizing) When hoisting a load with two or more
ropes, the force subjected to each rope
Rope diameter T Allowable load will increase with the hanging angles. The
table below shows the variation of allow-
mm kN tons
able load kN {kg) when hoisting is made
10 9.8 1.0 with two ropes, each of which is allowed
11.2 13.7 1.4 to sling up to 9.8 kN (1000 kg) vertically,
at various hanging angles.
12.5 15.7 1.6
When two ropes sling a load vertically, up
14 21.6 2.2 to 19.6 kN (2000 kg) of total weight can be
16 27.5 2.8 suspended. This weight becomes 9.8 kN
18 35.3 3.6 (1000 kg) when two ropes make a 120“
20 43.1 4.4 hanging angle. On the other hand, two
ropes are subjected to an excessive force
22.4 54.9 5.6
as large as 39.2 kN (4000 kg) if they sling
30 98.1 10.0
a 19.6 kN (2000 kg) load at a lifting angle
40 176.5 18.0
50 274.6 28.0
60 392.2 40.0
* The allowable load value is estimated to

be one-sixth or one-seventh of the break-
ing strength of the rope used.
2) Sling wire ropes from the middle portion 30 60 90 120 150

of the hook. Lifting anole (denreel SAD00480
00-7
FOREWORD COATING MATERIALS
COATING MATERIALS
Ir The recommended coating materials such as adhesives, gasket sealants and greases used for
disassembly and assembly are listed below.
Ir For coating materials not listed below, use the equivalent of products shown in this list.
Category <omatsu code Part No. Q’ty Container Main applications, features
l Used to prevent rubber gaskets, rubber

LT-IA 790-129-90301 150 g 1 Tube / cushions, and cock plug from coming out.
l Used in places requiring an immediately

effective, strong adhesive. Used for plas-
790-129-9050 20 g Polyethylene
LT-1 B tics (except polyethylene, polyprophylene,
(2 pes.) container
tetrafluoroethlene and vinyl chloride), rub-
ber, metal and non-metal.
I I I* Features: Resistance to heat and chemi-

LT-2 09940-00030 1 50 g cak
Used for
l anti-loosening and sealant pur-
I I pose for bolts and plugs.
790-129-9060 Adhesive: l Used as adhesive or sealant for metal, glass

(Set of adhe- 1 kg and plastic.
LT-3 sive and Hardening Can
hardening agent:
agent) 500 g
Adhesives
LT-4 790-129-9040 1 250 g /p;;t$;,/*Used as sealant for machined holes.
Holtz l Used as heat-resisting sealant for repair-

790-126-9120 75 g Tube
MH 705 ing engine.
l Quick hardening type adhesive

Three bond Polyethylene l Cure time: within 5 sec. to 3 min.
790-129-9140 50 g Used mainly for adhesion of metals, rub-
1735 container l
bers, plastics and woods.
Quick hardening type adhesive

l
Quick cure type (max. strength after 30 min-

l
Aron-alpha Polyethylene
790-129-9130 29 utes)
201 container
Used mainly for adhesion of rubbers, plas-
l
I 1 tics and metals.
l Features: Resistance to heat, chemicals

Loctite Polyethylene
79A-129-9110 50 cc l Used at joint portions subject to high tem-
648-50 container
peratures.
l Used as adhesive or sealant for gaskets

LG-1 790-129-9010 200 g 1 Tube 1
and packing of power train case, etc.
l Features: Resistance to heat

l Used as sealant for flange surfaces and
Gasket bolts at high temperature locations, used
sealant 790-129-9070 Can to prevent seizure.
LG-3 1 kg
l Used as sealant for heat resistance gasket
for high temperature locations such as en-
gine precombustion chamber, exhaust
pipe, etc.
00-8
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q’ty Container Main applications, features
l Features: Resistance to water, oil

l Used as sealant for flange surface, thread.
200 g Tube l Also possible to use as sealant for flanges
LG-4 790-129-9020
with large clearance.
l Used as sealant for mating surfaces of fi-
nal drive case, transmission case.
l Used as sealant for various threads, pipe
/ LG-5 (190-129-90601 1 kg /‘;$;;:‘/ ‘,srr~~eft~;~~raulic piping.

Used as sealant for tapered plugs, elbows,
l Features: Silicon based, resistance to heat,

Gasket cold
sealant LG-6 09940-00011 250 g Tube l Used as sealant for flange surface, tread.
l Used as sealant for oil pan, final drive case,
etc.
l Features: Silicon based, quick hardening

type
LG-7 09920-00150 150 g Tube l Used as sealant for flywheel housing, in-
take manifold, oil an, thermostat housing,
etc.
Three bond l Used as heat-resisting sealant for repairing

790-129-9090 100 g Tube engine.
1211
l Used as lubricant for sliding portion (to pre-

LM-G 09940-00051 60 g Can vent from squeaking).
Molybde-
num
disulphide l Used to prevent seizure or scuffling of the
lubricant LM-P 09940-00040 200 g Tube thread when press fitting or shrink fitting.
l Used as lubricant for linkage, bearings, etc.
SYG2-4OOLI l General purpose type

SYG2-350LI
G2-LI SYG2-4OOLI-A Various Various
SYGP-16OLI
SYGA-16OCNLI
l Used for normal temperature, light load

SYG2-400CA bearing at places in contact with water or
Grease
SYG2-350CA steam.
GP-CA SYGP-4OOCA-A Various Various
SYG2-16OCA
SYGA-16OCNCA
Molybdenum 400 g l Used for places with heavy load

disulphide SYG2-400M (10 per Belows type
lubricant case)
00-9
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUES OF BOLTS AND NUTS

Use these torques for metric bolts and nuts. (Always use torque wrench).
Thread diameter Width

of bolt across flats
I I
mm mm Nm kgm
6 10 13.25 1.4 1.35kO.15
8 13 31+3 3.2kO.3
10 17 66+7 6.7kO.7
12 19 113flO 11.5*1
14 22 177f19 18f2
16 24 279f30 28.5f3
18 27 382k39 39f4
20 30 549+59 56+6
22 32 745k83 76k8.5
24 36 927k103 94.5* 10.5
27 41 132Ok140 135c15
30 46 172Ok190 175+20
33 50 2210f240 225k25
36 55 275Ok290 280f30
39 60 329Ok340 335k35
Thread diameter Width

of bolt across flats
mm mm Nm kgm
6 10 7.85k1.95 0.8kO.2
8 13 18.6k4.9 1.9zko.5
10 14 40.2f 5.9 4.1kO.6
12 27 82.35k7.85 8.4k0.8
TIGHTENING TORQUE OF HOSE NUTS

Use these torques for hose nuts.
Thread diameter Width across flat Tightening torque

Nominal No.
mm mm Nm kgm
02 14 19 24.5k 4.9 2.5f0.5
03 18 24 49k 19.6 5f2
04 22 27 78.5? 19.6 8?12
z: 30
24 36
32 176.5k29.4
137.3k29.4 18f3
14+3
10 33 41 196.1?49 20f5
12 36 46 245.2k49 25+5
14 42 55 294.2* 49 30+5
TIGHTENINGTORQUE OFSPLIT FLANGE BOLTS

Use these torques for split flange bolts.
mm mm Nm bm
10 14 65.7k6.8 6.7f0.7
17 17 112f9.8 11.5fl
is 22 279+29 28.5+3
00-l0
FOREWORD STANDARD TIGHTENING TORQUE
TIGHTENING TORQUE OF O-RING BOSS CONNECTOR

Use these torques for O-ring boss connector

Nominal No.
mm mm Nm kgm
02 14 34.3+ 4.9 3.5f0.5
03,04 20 Varies depending on 93.1 k 9.8 9.5+1
05,06 24 type of connector. 142.1f19.6 14.5k2
IO,12 33 421.4f 58.8 43f6
14 42 877.1k132.3 89.5f 13.5
TIGHTENING TORQUE OF O-RING BOSS CONNECTOR

Thread diameter Width across flat Tighteni 1 torque

Nominal No.
mm mm Nm kgm
08 8 14 7.35c 1.47 0.75f0.15
10 IO I7 11.27+ 1.47 1.15f0.15
12 12 I9 17.64kI.96 1.8kO.2
14 14 22 22.54k1.96 2.3f 0.2
16 16 24 29.4f4.9 3f0.5
18 18 27 39.2f4.9 4a0.5
20 20 30 49k4.9 5kO.5
24 24 32 68.6f9.8 7fl
30 32 107.8f14.7 IIf1.5
33 z: - 127.4f 19.6 13f2
36 36 36 151.9f24.5 15.5f2.5
42 42 - 210.7k29.4 21.553
52 52 - 323.4f44.1 33f 4.5
,Sealingsurface
TIGHTENING TORQUES OF FLARE NUT

SAD00483
mm mm Nm km
14 19 24.5+ 4.9 2.5f0.5

I8 24 49f 19.6 5f2
22 27 78.5f 19.6 8+2
24 32 137.3k29.4 14f3
30 36 176.5k29.4 18+3
33 41 196.If49 20+5
36 46 245.2f49 25+5
42 55 294.2f49 30+5
00-l1
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Cable O.D. Currerkrating Applicable circuit
(mm)
0.85 2.4 12 Starting, lighting, signal etc.
2 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal

I I I
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 I 127 I 0.80 I 63.84 13.6 178 Starting
100 I 217 I 0.80 109.1 I 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Prior- Charging Ground Starting Lighting lnstriyent / Sicyal 1 Ot;

itv
x Code W B B R
I I-
nav Color White Black Black Red Yellow Green Blue
Code WR - BW RW YR GW LW
Color White & Red - Black &White Red & White j fellow & Red Green &White Blue & White
Code WB - BY RB YB GR LR
3
Color White & Black - Black & Yellow Red & Black I
iti Code WL - BR RY
iary
Color White & Blue - Black & Red Red & Yellow IY
ICode WG 1 - 1 - 1 RG YL I GB I LB
I I I I I
Color White & Green - - Red & Green Y‘ellow & Blue Green & Black1 Blue & Black
Code - - - RL YW 1 GL I -
6 I I I I
1Color1 - I - I - I Red & Blue Y‘ellow & WhiteIGreen & Blue1 -
00-12
FOREWORD CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For
details of the method of using the Conversion Table, see the example given below.
EXAMPLE
. Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(I) 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 @I, then draw a perpendicular line
down from @I.
(3) Take the point where the two lines cross as 0. This point 0 gives the value when converting
from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

(I) 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.
03
Millimeters to inches 1 mm = 0.03937 in
0 1 2 3 4 5; 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197! 0.236 0.276 0.315 0.354
00-l 3
FOREWORD CONVERSIONTABLE
Millimeters to Inches
1 mm = 0.03937 in
7 8 9
0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
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 2.874 2.913 2.953 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 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
6 8 9
0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
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
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-14
Literto U.S. Gallon

I! = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 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 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Literto U.K. Gallon

le = 0.21997 U.K. 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 3.300 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 6.599 6.819 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 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
L
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
\
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
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
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 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 1432.1 1439.4
- -
00-16
kg/cm* to lb/in*
1 kg/cm2 = 14.2233 Ib/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 214.8 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-17
FOREWORD CONVERSION TABLE
Temperature
Fahrenheit-Centigrade Conversion ;a simple way to convert a Fahrenheit temperature reading into a 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 temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values,
and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8”F
“C “F “C “F “C “F “C “F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 48 114.8 27.2 81 117.8

-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-22.2 -6 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 IO 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-18
01 GENERAL
General assembly drawing ......................... Ol- 2

Specifications.. .............................................. Ol- 3
Weight table ................................................. Ol- 6
List of lubricant and water.. ........................ Ol- 7
01-l
GENERAL GENERAL ASSEMBLY DRAWING
GENERAL ASSEMBLY DRAWING
028
,I , II , I II II I II
I I II I II
’ (,,I Lh8Z
AD073680
% The diagram shows the values for the machine with ROPS cab.
01-2
GENERAL SPECIFICATIONS
SPECIFICATIONS
Machine model WA1 80-3
Serial No. 50001 and up
Operating weight (kg) 8,700

, Distribution (front) (kg) 3,540
Distribution (rear) (kg) 5,160
Bucket capacity (piled) (with BOC) (m3) 1.7
Rated load (kg) 2,720
Travel speed FORWARD 1st (km/h) 7.2
FORWARD 2nd (km/h) 12.0
FORWARD 3rd (km/h) 22.0
FORWARD 4th (km/h) 34.5
REVERSE 1st (km/h) 7.7
REVERSE2nd (km/h) 12.6
REVERSE 3rd (km/h) 22.9
REVERSE 4th (km/h) 35.0
Max. rimpull (Forward) (N (kg)) 81,350(8,300)
(Reverse) (N (kg)) 76,450(7,800)
Gradeability (de@ 25
Center of outside wheel (mm) 4,650

Min. turning
radius Outside portion of
chassis (mm) 5,385
Overall length (with BOC) (mm) 6,250
Overall width (chassis) (mm) 2,320
Bucket width (mm) 2,440
Overall height (top of cab) (mm) 3,100
(Bucket raised) (mm) 4,700
Wheelbase (mm) 2,700
Tread (mm) 1,820
Min. ground clearance (mm) 430
Height of bucket hinge pin (mm) 3,545
Dumping clearance (tip of bucket edge) (mm) 2,780
(tip of BOC) (mm) 2,720
Dumping reach (tip of bucket edge) (mm) 945
(tip of BOC) (mm) 970
01-3
Bucket dump angle (de@ 46
Bucket tilt angle (SAE carring position) (deg) 46
Digging depth (IO” dump)(tip of bucket edge) (mm ) 245
(tip of BOC) (mm) 285
Model Komatsu S6D95L

4-cycle, water-cooled, in-line,
Type 6-cylinder, direct injection, with turbocharger
No. of cylinders - bore x stroke (mm) 6-95x115
Piston displacement (cc) 4,890
Flywheel horsepower (kW (HP)/rpm) 82 (110)/2,400
Maximum torque (Nm (kgm)/rpm) 417 (42.5)/1,600
Fuel consumption ratio (g/kWh (g/HPh)) 218 (162)
High idling speed (rpm) 2,600
Low idling speed (rpm) 750

:
7
Starting motor 24 V 5.5 kW
Alternator 24 V 35 A
Battery 12V llOAhx2
Torque converter 3-element, l-stage, single-phase (Komatsu TCA30-6A)
Spur gear, constant-mesh multiple-disc,

Transmission hydraulically actuated, modulation type
Reduction gear Spiral bevel gear
Differential Straight bevel gear, torque proportioning
Final drive Planetary gear, single reduction
Drive type Front/rear-wheel drive
Front axle Fixed-frame, semi-floating
Rear axle Center pin support type, semi-floating
Tire 18.4-24-lOPR(L-2)
Wheel rim W16L x 24
Inflation pressure Front tire (KPa (kg/cm*)) 216 (2.2)
Rear tire (KPa (kg/cm*)) 216 (2.2)
Main brake Front/rear wheel independent braking wet-type

sealed disc brakes with hydraulic booster
Parking brake Thrust shaft (transmission shaft) braking,

wet-type disc brake, mechanical type
01-4
Type Articulated type
Structure Fully hydraulically power steering
Hydraulic pump type Gear type

(Hydraulic+Steering pump) (SAL(2)40+14)
Delivery @/min.) 144
$ Set pressure for work equipment Spool type

? (MPa (kg/cm2)) 20.59 (210)
5
z Set pressure for steering Orbit-roll valve type
s (MPa (kg/cm2)) 20.59 (210)
Boom cylinder Reciprocating piston

No. - bore x stroke u-m-r-r) 2-110x618
&I
-o Bucket cylinder Reciprocating piston
.g
No. - bore x stroke (mm) 1-120x423
E
Steering cylinder Reciprocating piston
No. - bore x stroke (mm) 2 - 60 x 340
Link type Single link
Bucket edge type Flat edge with BOC
01-5
GENERAL WEIGHT TABLE
WEIGHT TABLE
ALThus. weight table is a guide for use when transporting or handling components.
Unit: kg
Machine model WA1 80-3 Machine model WA180-3
Serial No. 50001 and up Serial No. 50001 and up
Engine 510 Hydraulic, Steering pump 10
Radiator 48 Main control valve 21
Torque converter 35 Boom cylinder (each) 61.5
Transmission (with torque converter) 480 Bucket cylinder 56
Front drive shaft 12 Engine hood assembly 127
Center drive shaft 11 Front frame 710
Rear drive shaft 6.3 Rear frame 536
Front axle 387 Bucket link 17

VI
Rear axle 393 Bellcrank 125 x
;
Boom (including bushing) 520 0
Axle pivot (rear axle) 69
Wheel (each) 56 Bucket (with BOC) 710
Tire (each) 123 Counterweight 1,310
Orbit-roll valve 8.2 Fuel tank 68
Priority valve 5.5 Battery (each) 30
Steering cylinder (each) 14 ROPS Cab assembly 500
Brake booster 11 Floor support 152
Hydraulic tank 53 Operator’s seat 38
01-6
GENERAL LIST OF LUBRICANT AND WATER
LIST OF LUBRICANT AND WATER

AMBIENT TEMPERATURE CAPACITY
KIND OF
RESERVOIR
FLUID -22 -4 14 32 50 68 86 104122°F
-30 -20 -10 0 10 20 30 40 50°C Specified/
Engine oil pan 12.5 e 10.5 e
Brake Engine oil IQ 1 e
Transmission case 28.0 J? 23.5 .@
Hydraulic system 80 k? 41 e
Axle
(Front and rear) See Note 1 14 a 14 e
(Each)
2
Pins Grease -
I
2
0
Fuel tank Diesel fuel
Cooling system Water Add antifreeze 20 e
% ASTM D975 No. 1
Note 1:
For axle oil, use only recommended oil as follows.
SHELL: DONAX l7 or TD
CALTEX: RPM TRACTOR HYDRAULIC FLUID
CHEVRON: TRACTOR HYDRAULIC FLUID
TEXACO: TDH OIL
MOBIL: MOBILAND SUPER UNIVERSAL
It is possible to substitute engine oil CLASS-CD SAE30 for axle oil.
If noise comes from the brake, it is no problem of durability.
01-7
GENERAL LIST OF LUBRICANT AND WATER
REMARK
When fuel sulphur content is less than 0.5%, change oil in the oil pan every periodic maintenance
hours described in this manual.
Change oil according to the following table if fuel sulphur content is above 0.5%.
Change interval of oil in

Fuel sulphur content
engin oil pan
0.5 to 1.0% l/2 of regular interval
Above 1.0% l/4 of regular interval
When starting the engine in an atmospheric temperature of lower than OC, be sure to use engine
oil of SAEIOW, SAEIOW-30 and SAE15W-40, even though an atmospheric temperature goes up to
10°C more or less in the day time.
Use API classification CD as engine oil and if API classification CC, reduce the engine oil change
interval to half.
There is no problem if single grade oil is mixed with multigrade oil (SAEIOW-30, 15W-401, but be
sure to add single grade oil that matches the temperature in the table.
We recommend Komatsu genuine oil which has been specifically formulated and approved for use
in engine and hydraulic work equipment applications.
(r,
Specified capacity: Total amount of oil including oil for components and oil in piping. z
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance. z
ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
API: American Petroleum Institute
01-8
10 STRUCTURE AND FUNCTION
Power train.. .................................................. IO- 3 Electrical circuit diagram (l/2) . .. . . . . . . . .. . . . .. . . . .. . . 1 O-l 22

Power train system.. .................................... IO- 4 Air conditioner electrical circuit
Torque converter, transmission piping ..... IO- 6 diagram (2/2) _......._..................................... IO-125
Transmission hydraulic system diagram . . IO- 8 Central panel(cluster gauge) . . .. . . . . . . . .. .. . . . . . .. IO-126
Transmission hydraulic circuit diagram .... IO- 9 Sensor .. . . . . . . . . .. . .. . . . .. .. . . . . . . .. . .. . . . . . .. . .. . . . . . . .. .. . . . . IO-127
Torque converter ......................................... IO-IO Engine starting circuit . . . .. .. . . . . . . .. .. . .. . . . .. . . . . . . . IO-128
Torque converter oil filter.. ......................... IO-12 Engine stop circuit . . . . .. .. . . . . . . . . . .. . . . . . .. . . . . . . .. .. . . IO-129
Transmission ............................................... IO-13 Automatic preheating circuit
Transmission control valve.. ....................... IO-23 (Q.G.S. circuit) . . . . . . .. . . . . . . . . .. .. . . . . . .. .. . . . . . .. . .. . . . . IO-130
Transmission control .................................. IO-44 Automatic air bleed mechanism .. . .. . . . . . . .. . . IO-133
Drive shaft ..................................................... IO-45 Electrical transmission control . .. . . . . . . .. .. . . . .. IO-134
Axle.. .............................................................. IO-46 Combination switch . . . . . . .. . . . . . . .. .. . . . . . . . . .. . . . .. .. IO-135
Final drive ..................................................... IO-52 Transmission cut-off function . . . .. . . . . . . .. . . . . . . . IO-136
Axle mount.. .................................................. IO-54 Parking brake function . . . . .. . . . . . . .. .. . .. . . . .. . . . . . . . IO-138
:
z Center hinge pin .......................................... IO-56 Kick-down switch . . . . . . .. . . . . . . . . .. . . . . . . .. . . . . . . .. .. .. . . IO-139
0
Steering piping ............................................ IO-57
Steering column .......................................... IO-58
Priority valve ................................................. IO-59
Cushion valve .............................................. IO-62
Steering valve (orbit-roll) ............................ IO-64
Brake piping .................................................. IO-72
Brake control ................................................. IO-73
Brake booster.. ............................................. IO-74
Brake.. ............................................................ IO-78
Parking brake control .................................. IO-80
Parking brake ............................................... IO-81
Hydraulic piping .......................................... IO-82
Work equipment hidraulic system
diagram ...................................................... IO-84
Work equipment hydraulic circuit
diagram ...................................................... IO-85
Hydraulic tank .............................................. IO-86
Main control valve.. ..................................... IO-90
Work equipment lever linkage.. ................ 10-l 03
Work equipment linkage.. ......................... 10-l 04
Bucket.. ........................................................ 10-l 06
Bucket positioner and boom kick-out ...... 10-l 07
Proximity switch ........................................ 10-l 09
Canopy ........................................................ 10-l 11
Rops cab.. .................................................... 10-l 12
Air conditioner ............................................ 10-l 13
Travel damper system ............................... IO-I 14
Electrical wiring diagram ........................... IO-I 19
10-l
STRUCTURE AND FUNCTION POWER TRAIN
POWER TRAIN
4 5 6 7 8
SEW00839
1. Transmission 4. Front axle 7. Rear drive shaft

2. Torque converter 5. Front drive shaft 8. Rear axle
3. Engine 6. Center drive shaft
Outline
. The motive force from engine (3) passes l The motive force from the output shaft of
through the engine flywheel and is transmit- the transmission passes through center drive
ted to torque converter (2), which is con- shaft (61, front drive shaft (5) and rear drive
netted to the input shaft of transmission (1). shaft (71, and is then transmitted to front
. The transmission has six hydraulically actu- axle (4) and rear axle (8) to drive the wheels.
ated clutches, and these provide four speed
ranges for both FORWARD and REVERSE.
The transmission speed ranges are selected
manually.
1o-3
STRUCTURE AND FUNCTION POWER TRAIN SYSTEM
POWER TRAIN SYSTEM
6 t-----8
21 17 18 19 20
SEW00840
1o-4
STRUCTURE AND FUNCTION POWER TRAIN SYSTEM
1. Engine Outline
2. Torque converter . The motive force from engine (I) passes
3. Steering pump through the flywheel and is transmitted to
4. Hydraulic pump torque converter (2).
5. Torque converter charging pump The torque converter uses oil as a medium.
6. Transmission It converts the transmitted torque in accord-
7. Parking brake ance with the change in the load, and trans-
8. Center drive shaft mits the motive force to the input shaft of
9. Flange bearing the transmission.
10. Front drive shaft In addition, the motive force of the engine
11. Front axle passes through the pump drive gear of the
12. Front differential torque converter, and is transmitted to hy-
13. Front brake draulic, steering pump (41, (3) and torque
14. Front final drive converter charging pump (5) to drive each
15. Front tire pump.
16. Rear drive shaft l Transmission (6) operates the directional
17. Rear axle spool and speed spool of the transmission
18. Rear differential valve through the solenoid valves, and actu-
19. Rear brake ates the six hydraulically actuated clutches
20. Rear final drive to select one of the four FORWARD or RE-
21. Rear tire VERSE speeds.
The transmission speed range is selected
manually.
. The output shaft of transmission (6) trans-
mits the power to the front and rear axles.
At the front, the power is transmitted to front
axle (11) through center drive shaft (91, flange
bearing (91, and front drive shaft (IO).
At the rear, the power is transmitted to rear
axle (17) through rear drive shaft (16).
. The motive force transmitted to front axle
(11) and rear axle (17) has its speed reduced
by the bevel gear and pinion gear of differ-
entials (12) and (181, and is then transmitted
to the sun gear shaft through the differential
mechanism.
l The motive force of the sun gear is rduced
further by the planetary mechanism and is
transmitted to the wheels through the axle
shaft.
1o-5
STRUCTURE AND FUNCTION TORQUE CONVERTER, TRANSMISSION PIPING
TORQUE CONVERTER, TRANSMISSION PIPING
Outline
. The oil from the torque converter charging
1. Transmission pump passes through the oil filter and flows
2. Oil filter to the brake booster. From the brake
3. Torque converter booster, it flows to the main regulator valve
4. Torque converter charging pump and is divided into three lines: the torque
5. Radiator converter circuit, clutch circuit, and sole-
6. Oil cooler noid pilot circuit.
l The oil flowing to the torque converter cir-
cuit enters the torque converter. The oil
pressure is adjusted by the torque converter
outlet port valve, the oil is cooled by the oil
cooler, lubricates the transmission and re-
turns to the transmission case.
1O-6
STRUCTURE AND FUNCTION TRANSMISSION HYDRAULIC SYSTEM DIAGRAM
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM

(Engine low idling, directional lever at Neutral, Speedd lever at 2nd)
r
22
/
I’L _
1
-_
/
‘t
I
27
1 SDW00842
10-8
STRUCTURE AND FUNCTION TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM

(Engine stopped)
0.2-0.5MPa O.l-0.5MPa
(2.0-5.0kg/cmz) (l.O-5.0kg/cm*)
1. Transmission case 11. Transmission lubrication 21. Accumulator valve

2. Strainer 12. Pilot reducing valve 22. FORWARD clutch
3. Torque converter charging 13. Pilot oil filter 23. REVERSE clutch
pump 14. Quick return valve 24. 4th clutch
4. Oil filter 15. Modulation fill valve 25. 3rd clutch
5. Priority valve 16. Accumulator 26. 2nd clutch
6. Main regulator valve 17. Solenoid valve 27. 1st clutch
7. Torque converter 18. Speed spool 28. Brake booster
8. Torque converter outlet 19. Directional spool
valve 20. Emergency manual spool
9. PTO lubrication
10. Oil cooler
1o-9
STRUCTURE AND FUNCTION TORQUE CONVERTER
TORQUE CONVERTER
2 3 4 5 6
,
if I
--------i
______-_-__
+__________-__
;
I2
i________! _E~:~-_-_-+
=-------~_________ \;,y+-tiL.
_
) il--$i,
1. Pilot 6. PTO gear (drive) Specifications

2. Turbine 7. Housing (Transmission case) Model: TCA30-6A
3. Stator 8. Stator shaft Type: 3 element, 1 stage, 1 phase
4. Drive case Stall torque ratio: 2.77
5. Pump
10-10
STRUCTURE AND FUNCTION TORQUE CONVERTER OIL FILTER
TORQUE CONVERTER OIL FILTER
1. Relief valve
2. Element
3. Center bolt
4. Drain plug
Specifications
Filter mesh size: 10 microns
Filtering area: 8900 cm2
Relief pressure: 0.34 MPa (3.5 kg/cm*)
SEWOoo~4
A - B
To Transmission
control valve
Operation
l The oil from the torque converter charging
pump enters filter inlet port A. It is filtered
from the outside of element (2) to the in-
side, and flows to outlet port B.
SEW00015
IA- B
. If element (2) becomes clogged with dirt, or To Transmission

control valve
the oil temperature is low and the pressure
rises at inlet port A, the oil from inlet port A
opens relief valve (I) and flows directly to
outlet port 6 in order to prevent damage to
the pump or element (2).
SEW00016
10-12
STRUCTURE AND FUNCTION TRANSMISSION
t B--B t
C C
t-t
D-D
A SDW00847
1. Transmission control valve 6. 4th gear (Teeth 33)

2. Oil filter 7. 4th shaft
3. Accumulator valve 8. 4th gear(Teeth 45)
4. Transmission 9. Strainer
5. Parking brake lever
10-13
A----
‘9-l
18’
A-A SDWoo848
IO. Torque converter charging pump 19. Parking brake

11. Input shaft 20. 3rd clutch
12. Torque converter 21. 2nd clutch
13. FORWARD clutch 22. FORWARD, 2nd shaft
14. 4th clutch 23. REVERSE, 1st shaft
15. 3rd, 4th shaft 24. 1st clutch
16. Rear coupling 25. REVERSE clutch
17. Output shaft 26. Input gear (Teeth 34)
18. Front coupling
10-14
Outline
. The motive force from the torque converter
passes through the transmission input shaft
and enters the transmission.
l The transmission uses the combination of

the forward or reverse clutches and the four
speed clutches to shift to Fl - 4 or RI - 4,
and transmits the motive force from the in-
put shaft to the output shaft.
CLUTCH
REVERSE, IST CLUTCH
1 2 3 4 5 6 7 8 b
1. Spacer 7. REVERSE clutch disc (x9) a. REVERSE clutch oil port

2. Thrust washer 8. REVERSE gear (Teeth: 45) b. 1st clutch oil port
3. 1st gear (Teeth: 29) 9. REVERSE, 1st shaft c. Lubricating oil port
4. 1st clutch plate (x6) 10. REVERSE ring gear (Teeth: 59)
5. 1st clutch disc (x5) 11. 1st ring gear (Teeth: 59)
6. REVERSE clutch plate (x10)
10-15
FORWARD, 2ND CLUTCH
11
/ tu
10 9
1 \
8 a
SDWOO850
1. Spacer 7. FORWARD gear (Teeth: 47) a. FORWARD clutch oil port

2. Thrust washer 8. FORWARD, 2nd shaft b. 2nd clutch oil port
3. 2nd clutch plate (x6) 9. FORWARD ring gear C. Lubricating oil port
4. 2nd clutch disc (x5) (Teeth: 58)
5. FORWARD clutch plate (x10) 10. 2nd ring gear (Teeth: 58)
6. FORWARD clutch disc (x9) 11. 2nd gear (Teeth: 27, 49)
3RD, 4TH CLUTCH
8 a SDW00851
1. Spacer 7. 4th gear (Teeth: 51) a. 4th clutch oil port

2. Thrust washer 8. 3rd, 4th shaft b. 3rd clutch oil port
3. 3rd clutch plate (x6) 9. 4th ring gear (Teeth: 59) c. Lubricating oil port
4. 3rd clutch disc (x5) 10. 3rd ring gear (Teeth: 59)
5. 4th clutch plate (x6) 11. 3rd gear (Teeth: 40, 52)
6. 4th clutch disc (x5)
lo-16
Operation of clutch
When operated 5 6 2 3 4 1
. The oil sent from the transmission valve
passes through the oil passage inside shaft
(I), and goes to the rear face of piston (6) to
actuate the piston.
. When piston (6) is actuated, clutch plate (2)
is pressed against clutch disc (3) and forms
shaft (I) and clutch gear (4) into one unit to
transmit the motive force.
l Oil is drained from oil drain hole (5) at this
time, but this does not affect clutch opera-
S BWW437
tion since less oil is drained than supplied.
When not actuated

. If the oil from the transmission valve is shut 5 6 7 4 1
off, the pressure of the oil acting on the rear
face of piston (6) drops.
l The piston is returned to its original position
by wave spring (7), so shaft (I) and clutch
gear (4) are separated.
. When the clutch is disengaged, the oil at the
rear face of the piston is drained by centrifu-
gal force through oil drain hole (5), prevent-
ing the clutch from remaining partially en-
gaged. SBWoO438
10-17
FORWARD 1ST
SDWoo852
Note: Input gear (26) is always meshed with

REVERSE gear (27) and FORWARD gear
(28).
Operation
. In the case of FORWARD 1st gear, FORWARD . 1st driven gear (31) forms one unit with 2nd
clutch (13) and 1st clutch (24) are connected gear (321, so the power of 1st driven gear
by the oil pressure from the transmission (31) passes through 2nd gear (32), is trans-
valve. mitted to 3rd gear (33) and output gear (341,
l The power from the torque converter is trans- and is then transmitted to output shaft (17).
mitted from input shaft (II) and input gear
(26) to FORWARD gear (28). FORWARD
clutch (13) is engaged, so the power is trans-
mitted to REVERSE, 1st cylinder gear (29).
. 1st clutch (24) is engaged, so the rotation of
REVERSE, 1st cylinder gear (29) rotates 1st
gear (30) and is transmitted to 1st driven
gear (31).
lo-18
FORWARD 2ND
32
Note: input gear (26) is always meshed with RE-

VERSE gear (27) and FORWARD gear (28).
Operation
. In the case of FORWARD 2nd gear, FOR- l
The power is transmitted from 3rd gear (33)
WARD clutch (13) and 2nd clutch (21) are and output gear (34) to output shaft (17).
connected by the oil pressure from the trans-
mission valve.
. The power from the torque converter is trans-
mitted from input shaft (I I) and input gear
mitted to FORWARD, 2nd cylinder gear (35).
. 2nd clutch (21) is engaged, so the rotation
of FORWARD, 2nd cylinder gear (35) rotates
2nd gear (32) and is transmitted to 3rd gear
(33).
10-19
FORWARD 3RD
26 11
-1 ‘36
‘20
SDWoo854
Note: Input gear (26) is always meshed with RE-

VERSE gear (27) and FORWARD gear (28).
Operation
. In the case of FORWARD 3rd gear, FORWARD l 3rd clutch (20) is engaged, so the power of
clutch (13) and 3rd clutch (20) are connected 3rd, 4th cylinder gear (36) is transmitted to
by the oil pressure from the transmission 3rd gear (33). The power is then transmit-
valve. ted through output gear (34) to output shaft
. The power from the torque converter is trans- (17).
mitted from input shaft (11) and input gear
mitted to 3rd, 4th cylinder gear (36).
1O-20
FORWARD 4TH
40 39 38
26
28
37
13
36
SDWO0855
Note: lnout oear (26) is always meshed with RE-

34’ VERSE gear (27) and FoRWARD gear (28).
Operation
. In the case of FORWARD 4th gear, FORWARD 3rd, 4th cylinder gear (36) is transmitted to
clutch (13) and 4th clutch (14) are connected 4th gear (37). The power is then transmitted
by the oil pressure from the transmission to 4th gear (381, 4th shaft (39), and 4th gear
valve. (40).
. The power from the torque converter is trans- l The power of 4th gear (40) is transmitted to
mitted from input shaft (II) and input gear 4th gear (41), which forms one unit with 3rd
(26) to FORWARD gear (28). FORWARD gear (33), so the power passes through 3rd
clutch (13) is engaged, so the power is trans- gear (33), is transmitted to output gear (34)
mitted to 3rd, 4th cylinder gear (36). and output shaft (17).
. 4th clutch (14) is engaged, so the power of
10-21
REVERSElST
Operation
. In the case of REVERSE 1st gear, REVERSE . 1st clutch (24) is engaged, so the power of
clutch (25) and 1st clutch (24) are connected REVERSE, 1st cylinder gear (29) passes
by the oil pressure from the transmission through 1st gear (30) and is transmitted to
valve. 1st driven gear (31).
. The power from the torque converter is trans- . 1st driven gear (31) forms one unit with 2nd
mitted from input shaft (II) and input gear gear (32), so the power of 1st driven gear
(26) to REVERSE gear (27). REVERSE clutch (31) passes through 2nd gear (321, is trans-
(25) is engaged, so the power is transmitted mitted to 3rd gear (33) and output gear (34),
to REVERSE, 1st cylinder gear (29). and is then transmitted to output shaft (17).
1o-22
TRANSMISSION CONTROL VALVE
SDWOO857
1. Lower valve a. Pilot oil pressure measurement port

2. Upper ‘valve b. To oil cooler
3. Emergency manual spool c. From pump
4. Solenoid valve d. Pump oil pressure measurement port
e. Clutch oil pressure measurement port
1O-23
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
UPPER VALVE
A-A
1. Upper valve body 9. Check valve

2. Main regulator valve 10. Lower valve body
3. Pilot reducing valve 11. Torque converter outlet valve
4. Priority valve 12. FORWARD and REVERSE spool
5. Modulation fill valve pressure 13. HIGH and LOW spool
adjusting screw 14. Speed range spool
6. Modulation fill valve 15. Solenoid valve
7. Accumulator 16. Emergency manual spool
8. Quicck return valve
lo-24
LOWER VALVE
10
11
16
12
13
14
B-B SOW00859
Outline
. The oil from the pump passes through the l The pressure of the oil which flows to the
torque converter oil filter, enters the trans- circuit is adjusted by the pilot reducing valve.
mission valve, and is divided into the pilot During gear shifting, the oil flows in accord-
circuit and the clutch actuation circuit. ance with ON-OFF position of the solenoid
The priority valve gives priority to the oil valves and actuates the FORWARD, RE-
sent to the pilot circuit, so the pilot pressure VERSE and speed spools.
is always kept the same. . By switching the FORWARD, REVERSE, and
l The pressure of the oil flowing to the clutch speed spools, the oil regulated by the modu-
actuation circuit is adjusted by the modula- lation fill valve is sent to the selected clutch
tion fill valve and actuates the clutch. The oil to obtain the necessary gear combination.
which is relieved is sent to the torque con-
verter.
l The quick return and modulation fill valve
are interconnected during gear shifting. They
act to raise the clutch oil pressure smoothly,
thereby reducing the shock when shifting
gear. During traveling, the clutch pressure is
kept the same.
1o-25
TRANSMISSION SOLENOID VALVE
7 8
A-A
B-B
\
6
-__ I
1. Connector 6. FORWARD solenoid

2. Valve body valve Solenoid Operating table
3. Ist, 4th solenoid valve 7. Emergency manual
4. 3rd solenoid valve spool
5. REVERSE solenoid valve 8. Lock plate
Structure
STRUCTURE
. The transmission solenoid valve is installed
to the transmission together with the trans-
mission valve. When the directional lever or
speed control lever are operated, the sole-
noid valve is actuated and moves the spool
o : Solenoid ON
inside the transmission valve.
1O-26
TORQUE CONVERTER OUTLET PORT VALVE
Function
. The torque converter outlet port valve is in-
stalled in the outlet line of the torque con-
verter and adjusts the maximum pressure of
the torque converter.
To oil cooler From torque converter
Operation t+ ,a C
I
l The oil at port a passes through the orifice
in spool (I) and flows to port c.
i SEW00861
To oil cooler From toraue converter
. When the pressure at port a rises, the pres- b\ t+ ;

sure at port c also rises. This overcomes the
tension of spring (2) and moves spool (I) to
the left in the direction of the arrow to allow
oil to flow from port a to port b.
i i SEW00862
To oil cooler From torque converter
. If the pressure at port a becomes even b t+ a C
higher, spool (I) is moved further to the left

in the direction of the arrow, and the oil
flows from port a to port b and drain port d.
(Cold relief)
1 ‘d SEW00863
1O-27
PILOT REDUCING VALVE
Function
. The pilot reducing valve controls the pres-
sure used to actuate the directional selector
spool, H-L selector spool, range selector
spool.
Operation
. The oil from the pump enters port a, passes
through port b of pilot reducing spool (I), Lower valve
enters spool (2) in the lower valve, and fills
the pilot circuit.
The oil at port b passes through the orifice
(3) and flows to port c. b
u / I J
Upper valve
i
From pump
SEW00864
. When the pressure in the pilot circuit rises,

the pressure at port c also rises. This over-
comes the tension of spring (4) and moves
Lower valve
pilot reducing spool (I) to the right in the 4
direction of the arrow.
For this reason, port a at port b are shut off,
so the pressure at port c is maintained.
b
From pump
SEW00865
1 O-28
TRANSMISSION SOLENOID VALVE
Function
. There are four solenoid valves installed to
Pilot filter ?
the transmission control valve. When the
gear shift lever in the operator’s compart-
ment is operated, the solenoid valves are
switched ON/OFF, and the oil is drained to
actuate the gear shift spool.
Operation
1. Solenoid valve OFF
The oil from pilot reducing valve (3) flows
to ports a and b of gear shift spools (I) and
(2). The oil at ports a and b is stopped by
solenoids (4) and (51, and gear shift spools
(I) and (2) move to the right in the direction
of the arrow. As a result, the oil from the
pump flows to the 2nd clutch.
4th clutch 2nd clutch
F
z
0
2. Solenoid valve ON
When the gear shift lever is operated, the Pilot filter
_ -
drain port of solenoid valves (4) and (5)
opens.
The oil at ports a and b of gear shift spools
(I) and (2) flows from ports c and d to the
drain circuit. Therefore, ports a and b be-
come the low pressure circuit, and the gear
shift spool is moved to the left in the direc-
tion of the arrow by the tension of spring C Ia I1
(6).
As a result, the oil at port e flows to the 4th
clutch and the clutch is switched.
4th clutch 2nd clutch
SDW00867
1 O-29
PRIORITY VALVE
Function To lower valve To torque converter

. The priority valve gives priority to sending 1 t t
oil to the pilot circuit of the lower valve.
When the pressure in the circuit goes above
the set pressure, it acts as a main relief valve
to protect the circuit.
Operation
. The oil from the pump is divided into two
lines. One oil flow enters port a, passes
around priority valve (21, goes through pilot SEW00868
reducing valve (I), and flows to the pilot

To lower valve To torque converter
circuit of the lower valve. The other oil flow
t t
goes to priority valve (2).
To clutch circui
. The oil flowing to priority valve (2) passes

through orifice (3) and flows to port b.
As a result, it pushes priority valve(2) to the
left in the direction of the arrow against the
force of spring (4), and flows to port c.

t t
d 2
. When the pressure at port b goes above the To clutch circui

set pressure, priority valve (2) is pushed fur-
ther to the left in the .pa direction of the
arrow, and the oil is drained from port d to
protect the circuit. (The main relief func-
tion)
1O-30
MAIN REGULATOR VALVE
Function
. The main regulator valve controls the flow
of oil to the clutch circuit, and sends any
excess oil to the torque converter circuit.

+ t
1
Operation To clutch ‘-
. The oil from the pump enters port a of prior-
ity valve (I), and then passes from port c
through modulation fill valve (3) and main
orifice (21, and flows to the clutch circuit.
To accumulator
. The oil passing through orifice (4) and en- To lower valve To torque converter
tering port b moves the spool to the left in P

the direction of the arrow against the force
of spring (51, so the oil passes through port
c and flows to the torque converter circuit.
To clutch circuit
To accumulator
SEW00872
10-31
QUICK RETURN VALVE
Function
. The pressure of the transmission clutch is raised Clutch
smoothly by the modulating action. This re-
duces any shock when shifting gear and pre-
vents the generation of peak torque and the
power train. Therefore, it reduces operator fa-
tigue and ensures a comfortable ride for the 1.6~0.2
operator. At the same time, it also increases
the durability of the power train.
Operation
1. After starting engine, clutch fully engaged
(clutch pressure at point A) (FORWARD 1st)
Second
SDW00873
RD clutch
E clutch
SDW00874
1 O-32
2. When shifting from FORWARD to REVERSE

(clutch pressure at point B)
Torque converter
FORWARD c
E CIIutch
SDW00875
l When the directional lever is moved from valve (7) opens and the oil at port b flows to
FORWARD to REVERSE, FORWARD solenoid port a. At the same time, quick return valve
(I) closes, REVERSE solenoid (2) opens, and (6) is moved to the left in the direction of the
directional spool (3) moves to the right in arrow by the pressure of the accumulator,
the direction of the arrow. FORWARD clutch and the oil from accumulator (8) is suddenly
(4) is connected to the drain circuit and the drained from port c.
oil is drained. . Accumulator (8) is returned fully to the left
l At the same time, the oil from the pump by the force of spring (9).
flows to REVERSE clutch (51, but while the * To reduce the shock when shifting gear, the
oil is filling the clutch, the clutch pressure is pressure in the clutch circuit must be com-
low. As a result, the oil pressure at port a of pletely lowered and accumulator (8) must
quick return valve (6) also drops, so check move fully to the left.
1o-33
3. Clutch pressure starting to rise (clutch

pressure at point Cl
Torque converter
FORWARD clutch
E clutch
er
Qi
. The oil from the pump fills the REVERSE

clutch and the pressure in the clutch circuit
starts to rise. As a result, the pressure at
port a rises, so quick return valve (6) is
moved to the right in the direction of the
arrow, and closes drain port c.
1o-34
4. Start of accumulator action, clutch com-

pletely engaged (clutch pressure at point D)
Torque converter
I WJ FORWARD clutch
E clutch
To aear shift SDOOI
er
913
SDWOO877
. Because of the differential pressure cre- l When accumulator piston (8) moves to the
ated by modulation fill valve (I I), a constant end of its stroke, the rise in the pressure at
flow of oil passes through 1st orifice (IO) port d finishes, so the specified pressure is
and enters accumulator (8). As this oil flows maintained and the REVERSE clutch is com-
in, the accumulator piston gradually moves pletely engaged.
to the right in the direction of the arrow, When the gear shift spool is operated, the
and spring (9) is compressed, so the accu- action is the same as above.
mulator pressure rises. As this accumulator
pressure rises, it raises the clutch pressure.
Except in Ist, oil flows into the accumulator
from 1st orifice + 2nd (3rd) orifice, so the
modulating time is shorter than for 1st.
1o-35
MODULATION FILL VALVE
Function
. The modulation fill valve adjusts the pres- Mpa
sure and controls the amount of oil flowing (kg/m-P) Modulation characteristics
to the accumulator while allowing the clutch 2.5(25

J-l.? d
pressure to rise. 2.0(20)
1.5(15)
l.O(lO)
0.5( 5)
0 (0) 1
0 0:5 l:o 1:5 210 (set)
SDW00878
Operation
1. Clutch completely engaged (point a) To directional spool To torque converter a
/
/ P4
/
/ p3
From /From
pump torque
*converter
TO gel outlet port
shift
>
spool
3rd orifice
SEW00879
To directional spool To torque converter

t t
2. Shifting from FORWARD to REVERSE

(point bl
. The oil inside the accumulator is drained by From
pump *
the quick return valve, and accumulator pis-
To gear
ton (1) moves to the left. When this hap-
shift c
pens, the pressure in chamber c and cham- spool
ber d drops, and spring (2) moves modula-
tion fill valve (3) to the right to open port a.
1 C 2 SEW00880
1 O-36
3. Clutch pressure starting to rise (point c -

point d)
. When the oil from the pump fills the clutch
piston, the pressure in the clutch circuit starts
to rise. When this happens, the drain circuit
of the quick return valve is closed.
When the drain circuit of the quick return
valve closes, the oil passing through port a
enters chamber d and pressure P2 in cham-
ber d starts to rise. When the relationship
between PI and P2 becomes P2 > PI + P3
(tension of spring (2)), the fill valve moves
to the left, shuts off port a, and prevents the
clutch pressure from rising suddenly.
PI c d P2 2 SEW00881
l At the same time as the oil from port a flows To directional spool To torque converter
to the directional spool, the relationship is t t
P2 > PI, so oil also passes through the ori-
fice in the quick return valve and flows into
chamber c. PI rises and P2 also rises at the
same time. This process is repeated while
maintaining the relationship P2 = PI + P3
(tension of spring (2)), and the clutch pres-
sure rises. From
pump*
l The oil from the torque converter outlet port
To gear
circuit forms the pilot pressure to the modu- shift l
lation fill valve and flows to port e. The spool
pressure at port e changes according to the & *k?kice
engine speed. The relationship is P2 = PI + :e
P3 + P4 (changes according to engine speed),
so if pressure P4 changes, pressure P2 also
changes by the same amount. Therefore,
pressure P2 rises at the same time by the
same amount that pressure P4 changes, so
it is possible to create oil pressure charac-
teristics that matches the engine speed.
1o-37
DIRECTIONAL SELECTOR SPOOL
Operation
1. When at neutral
. Solenoid valves (4) and (5) are OFF and the From pilot reducing circuit
Accumulator
4
drain port is closed. The oil from the pilot 4-- rl
circuit passes through the oil hole in the
emergency manual spool and fills ports a
and b of the directional spool.
. In this condition, PI + spring force (1) = P2 +
spring force (2), so the balance is maintained.
Therefore, the oil at port c does not go to
the FORWARD or REVERSE clutch.
fill valve
SEW00043
2. When at FORWARD
. When the directional lever is placed at the From pilot reducing circuit
4 Accumulator
FORWARD position, solenoid valve (4) is m- n
switched ON and drain port d opens. The oil
which is filling port a is drained, so PI +
spring force (I) c P2 + spring force (2). When
this happens, the directional spool moves to
the left, and the oil at port c flows to port e
and is supplied to the FORWARD clutch.
d
fill valve
SEW00044
1 O-38
EMERGENCY MANUAL SPOOL
Function
. If there should be any failure in the electrical
circuit and the directional solenoid valvegs
does not work, this spool can be operated
manually to engage the FORWARD or RE-
VERSE clutch.
From pilot reducing valve

Accumulator
Operation
1. Emergency manual spool at neutral
l The oil from the upper valve (pilot reducing
valve) passes around emergency manual
spool (I), and is blocked by solenoid valves
(2) and (3).
l When the operating condition is normal, the
emergency manual spool is at the neutral
position.
From pilot reducing va;ve

2. Emergency manual spool actuated IFOR-
Accumulator
WARD) 4 I
When emergency manual spool (I) is pushed
in, port a and the drain port are connected,
so the oil in chamber b is drained. As a
result, directional spool (4) moves to the left
in the direction of the arrow, and the oil
flows to the FORWARD clutch to engage the
clutch.
1o-39
OPERATION OF FORWARD 1ST
III
IL
1
1O-40
. The oil from pump (I) passes through prior-

ity valve (2) and is divided to the pilot circuit
and clutch actuation circuit.
. When the gear shift lever is operated to FOR-
WARD Ist, FORWARD solenoid (3) and gear
shift solenoid (6) are actuated. The oil fill-
ing ports a and b is drained and directional
spool (7) and gear shift spool (9) move to
the left.
. When directional spool (7) moves, the oil
flows from clutch pressure port c to port d,
and engages the FORWARD clutch.
. Gear shift solenoid (5) is closed, and H-L
spool (8) is pushed fully to the right, so the
oil flows from clutch pressure port e to port
f, passes through spool (9) and engages the
1st clutch.
. When the oil completely fills the clutch cyl-
inder, the action of accumulator (IO) and
quick return valve (II) raises the oil pres-
sure gradually, and when it reaches the set
pressure, the FORWARD and 1st clutches
are completely engaged.
10-41
ACCUMULATOR VALVE
B-B
14
13
12
11
10
/ \
9 8
SDW00884
1. Piston (2nd clutch) Outline

2. Piston (1st clutch) . The accumulator valve is installed in the FOR-
3. Body WARD, Ist, 2nd clutch circuit. When the
4. Piston (FORWARD clutch) transmission shifts gear, the accumulator
5. Spring (FORWARD clutch) valve slowly reduces the oil pressure to the
6. Stopper (FORWARD clutch) clutch that was first engaged in order to pre-
7. Cover vent loss of torque and to reduce the trans-
8. Spacer (FORWARD clutch) mission shock when shifting gear. It tempo-
9. Spacer (1st clutch) rarily stores the clutch oil pressure in order
10. Spacer (2nd clutch) to allow gear shifting to be carried out
11. Stopper (1st clutch) smoothly without any time lag.
12. Spring (1st clutch) (To make it possible to reduce the oil pres-
13. Stopper (2nd clutch) sure to the clutch slowly, there are throttles
14. Spring (2nd clutch) installed in the directional spool, H-L spool
and range spool of the transmission control
valve.)
1 O-42
Operation
1. Shifting down when digging (kick-down F2
+ Fl)
When the transmission is in F2, oil pressure 2nd clutch oil pressure 1st clutch oil pressure
is stored in the 2nd clutch accumulator.
When the kick-down is operated, the Fl
clutch is engaged, but the oil pressure in the I Oil pressure
accumulator is maintained for the 2nd clutch h maintained so
remains of torque
until the torque is transmitted to the 1st
clutch. In this way, it is possible to shift gear
smoothly without losing the torque.
T%e
SDW00040
Moving out after digging (Fl + R2)

FORWARD clutch oil REVERSE clutch oil
When the transmission is in Fl, oil pressure pressure, 1st clutch pressure, 2nd clutch
is stored in the accumulator for the FOR- oil pressure oil pressure
WARD clutch and 1st clutch. ti
When shifting to R2 after completi,ng dig- 2
: Oil pressure
ging operations, the R2 clutch is engaged, z maintained so
but the oil pressure for the FORWARD clutch h torqe is lowered
and 1st clutch is maintained in the accumu- z
lator. This makes it possible to reduce the -z
5
loss of torque due to the reaction force to G
the product being handled, and to move back
smoothly without shock. Tze
SDW00041
1o-43
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
TRANSMISSION CONTROL
SDW00885
1. Directional lever Outline

2. Gear shift lever . With the transmission control, an electrical
3. Gear shift lever stopper signal is sent to the transmission solenoid
4. Turn indicator, lamp, dimmer switch valves when the directional and gear shift
levers are operated. This opens or closes
the solenoid valves and moves the spool
inside the transmission valve.
1o-44
STRUCTURE AND FUNCTION DRIVE SHAFT
1. Front drive shaft . The drive shaft has the following purpose
2. Flange bearing in addition to simply transmitting the
3. Center drive shaft power. The drive shaft has a universal
4. Rear drive shaft joint and sliding joint to enable it to re-
spond to changes in the angle and length.
Outline This enables the drive shaft to transmit
. The motive force from the engine passes through the motive force when the machine is ar-
the torque converter and the transmission. Some ticulated and to protect the components
of it is transmitted from rear drive shaft (4) to from damage from shock when the ma-
the rear axle, while the rest goes from center chine is being operated or shock from the
drive shaft (3) through flange bearing (2) and road surface when the machine is
front drive shaft (I) to the front axle. traveling.
1o-45
AXLE
AXLE
FRONT AXLE
1 2 3 4 5 6 7
SKWOO887
1. Oil supply port

2. Differential
3. Differential housing
4. Wet-type single-disc brake
5. Final drive
6. Axle housing
7. Axle shaft
8. Drain plug
9. Level plug
lo-46
STRUCTURE AND FUNCTION AXLE
FRONT DIFFERENTIAL
1 2 3 4 5
1. Side gear (Teeth 12)

2. Pinion gear (Teeth 9)
3. Shaft
4. Bevel gear (Teeth 47)
5. Sun gear shaft
6. Bevel pinion (Teeth 13)
1o-47
REAR AXLE
r
0
1. Oil supply port

2. Differential
3. Differential housing
4. Wet-type, single-disc brake
5. Final drive
6. Axle housing
7. Axle shaft
8. Drain plug
9. Level plug
1 O-48
REAR DIFFERENTIAL
1 2 3 4 5
SKWOO890
1. Side gear (Teeth 12)

2. Pinion gear (Teeth 9)
3. Shaft
4. Bevel gear (Teeth 47)
5. Sun gear shaft
6. Bevel pinion (Teeth 13)
1o-49
Outline
. The motive force from the engine is trans-
mitted to the front and rear axles via the
torque converter, the transmission and the
propeller shaft.
. In the axle, the motive force is transmitted
from bevel pinion (I) to bevel gear (51, shifted
90” and reduced, and transmitted to sun gear
shaft (2) via pinion gear (4).
l The motive force of the sun gear is further
reduced by planetary gear-type final drive,
and transmitted to the axle shaft and wheel.
SEW00077
When moving straight forward

. When moving straight forward, the speed of
rotation of the left and right wheels is equal,
so pinion gear (4) in the differential assem-
bly does not rotate, and the motive force of
carrier (6) is transmitted equally to the left
and right sun gear shafts (2) via the pinion
gear (4) and side gear (3).
3
When slewing
. When slewing, the speed of rotation of the
left and right wheels is unequal, so pinion
gear (4) and side gear (3) in the differential
assembly rotate according to the difference
in the left and right rotation speeds, and the
motive force of carrier (6) is transmitted to
the sun gear shafts (2).
1O-50
TORQUE PROPORTIONING DIFFEREN-

TIAL Ordinary differential
Function
. Because of the nature of their work, 4-wheel-
drive loaders have to work in places where the
road surface is bad. In such places, if the tires
slip, the ability to work as a loader is reduced,
and also the life of the tire is reduced. The
torque proportioning differential is installed to
overcome this problem.
. In structure it resembles the differential of an
automobile, but differential pinion gear (4) has
an odd number of teeth. Because of the differ-
ence in the resistance from the road surface,
the position of meshing of pinion gear (4) and SEW00080
side gear (3) changes, and this changes the
traction of the left and right tires. Torque proportioning differential
Operation
When traveling straight (equal resistance from road
surface to left and right tires)
. If the resistance from the road surface to the
left and right wheels is the same, the distance
between pinion gear (4) and meshing point
“a” of left side gear (7) is the same as the
distance between pinion gear (4) and meshing
point “b” of right side gear (3).
F . Therefore the left side traction TL and the right
2 SAWMMSO
0 side traction TR are balanced.
When traveling on soft ground (resistance from Spider rotating direction

road surface to left and right tires is different)
. On soft ground, if the tire on one side slips,
the side gear of the tire on the side which has
least resistance from the road surface tries to
rotate forward. Because of this rotation, the
meshing of pinion gear (4) and side gear
changes.
. If left side gear (7) rotates slightly forward, the
distance between the pinion gear and the
meshing point “a” of the left side gear be-
I
comes longer than the distance between the SAWCO491
pinion gear and the meshing port “b” of the

right side gear. The position is balanced as
follows.
axTL=bxTR Spiden rotating direction
The ratio between the distances to “a” and t
“b” can change to 1 : 1.38.
. Therefore when the ratio of the distances to
“a” and “b” is less than 1 : 1.38 (that is, the
difference between the resistance from the road
surface to the left and right tires is less than
38%), the pinion gear will not rotate freely, so
drive force will be given to both side gears,
and the tires will not slip.
Because of this effect, the tire life can be in-
SAW03492
creased by 20 - 30%, and at the same the
operating efficiency is also increased.
10-51
STRUCTURE AND FUNCTION FINAL DRIVE
FINAL DRIVE
SKW00891
Outline
1. Sun gear shaft (Teeth 15) l As the final function the final drive operates
2. Ring gear (Teeth 69) to reduce the rotative speed of the motive
3. Planetary gear (Teeth 26) force from the engine and increases the driv-
4. Planetary carrier ing force.
5. Axle shaft . Ring gear (2) is press-fitted in the axle hous-
ing and fixed in place by a pin.
. The motive force transmitted from the dif-
ferential to the sun gear shaft (I) is reduced
using a planetary gear mechanism, increas-
ing the driving force.
The increased driving force is transmitted to
the tires via planetary carrier (4) and axle
shaft (5).
1O-52
STRUCTURE AND FUNCTION AXLE MOUNT
AXLE MOUNT
_-_____ ----
~z__.____j+ ____?_-A
‘\ 7
i__i
I I
CY
‘\ ‘\-\ /’
\\ I J’
\
.. ,/’ ‘\
‘. ,/’
‘. <* ‘- <I
--____-H --_____.
II I I II
i 0
-__-__
-__-__
1 100
A-A
SKW00892
1o-54
STRUCTURE AND FUNCTION AXLE MOUNT
(I
/i
/i
/i
/i
/i
/i ji I
Ii ii I
Z
‘is.
i1
ii
/i
ji
ij
:,,
Y .J
SKWO0893
1. Front axle Front axle

2. Front frame . The front axle (I) receives the force di-
3. Rear frame rectly during operations, so it is fixed di-
4. Rear axle rectly to the front frame (2) by tension
5. Tension bolt bolts (5).
6. Pivot
Rear axle
. The rear axle (4) has a structure which
allows the center of the rear axle to float,
so that all tires can be in contact with the
ground when traveling over soft ground.
1o-55
STRUCTURE AND FUNCTION CENTER HINGE PIN
CENTER HINGE PIN
,’
/
/’
,’
I'
i
A-A
SKWOOS94
Outline
1. Front frame l The front frame (1) and rear frame (2) are
2. Rear frame connected through a bearing by the center
3. Upper hinge pin hinge pin (31, (4). The steering cylinders are
4. Lower hinge pin connected to the left and right front and rear
frames, so when the cylinders are operated,
the frame bends at the middle to give the
desired angle, that is the desired turning ra-
dius.
1 O-56
STRUCTURE AND FUNCTION STEERING PIPING
STEERING PIPING
6
5 I
SKWO0895
1. Main control valve

2. Steering valve (orbit-roll)
3. Hydraulic tank
4. Priority valve
5. Hydraulic pump
6. Steering pump
7. Cushion valve
8. Steering cylinder
1o-57
STRUCTURE AND FUNCTION STEERING COLUMN
STEERING COLUMN
;c;
I f
___________(
,
___________#
SKWO0896
1. Steering wheel
2. Steering column
3. Steering valve (orbit-roll)
1 O-58
STRUCTURE AND FUNCTION PRIORITY VALVE
PRIORITY VALVE
1 A 23 B 4 5
x-x SKWOO897
1. Plug
2. Valve body
3. Spool
4. Return spring
5. Plug
6. Relief valve body
7. Screw
Outline 8. Valve spring
. 9. Holder
The priority valve is in the circuit between the
steering pump and the steering valve and main 10. Relief valve ball
control valve. It acts to divide the flow of oil 11. Screen
from the steering pump and send it to the steer- A. To steering valve
ing valve or main control valve circuit. It also B. To main control valve
sets the oil pressure in the circuit from the pri- C. From steering valve
D. To hydraulic tank
ority valve to the steering valve to 18.6 MPa
(190 kg/cm? to protect the circuit. E. From steering pump
1o-59
Operation
1. Steering wheel at neutral
When the engine is stopped, spool (3) are pushed
fully to the left by the tension of spring (4). In
this condition, the circuits between ports M and
N are fully open, while the circuits between ports
M and Q are fully closed.
If the engine is started and the steering pump
start to turn, the oil from the pump goes from
port M to port N, and then enters port A of the
steering valve.
The oil entering port A is throttled by orifice a,
so the pressure in the circuit rises.
When this happens, the oil passing through ori-
fices m in spool (3) enters port P. It then com-
presses spring (41, and moves spool (3) to the
right in the direction of the arrow. This stabi-
lizes the condition so that the circuits between
ports M and Q are almost fully open and the
circuits between ports M and N are almost fully
closed. Therefore, the oil from the steering pump
almost all flows to the work equipment circuit.
From steering pump
2. Steering wheel turned to left

When the steering wheel is turned to the left, an From girotor To right cylinder
angle variation is generated between the spool
and sleeve of the steering valve, and the oil
flow is switched. (For details, see STEERING
VALVE.)
The oil from the pump flows from port M to
port N, and enters port A. The degree of open-
ing of the sleeve (pot-t A) and spool (port B) of
the steering pump creates a difference between
the pressure up to port A and the pressure be-
yond port B. Some of the oil from port B flows
to the Girotor E, and then goes to the front right
cylinder. The remaining oil passes through ori-
fice b, flows to port J, and then enters port R.
When this happens, spool (3) stabilizes at a po-
sition where the differential pressure between
the circuit up to port A and circuit beyond port
B (pressure of port P - pressure of port RI and
the load of spring (4) are balanced. It adjusts
the degree of opening from port M to ports N
and Q, and distributes the flow to both circuits.
The ratio of this distributed flow is determined
by the degree of opening of port A and port B,
in other words, the angle variation between the From steering pump
sleeve and spool of the steering valve. This
degree of opening is adjusted steplessly by the
amount the steering wheel is turned.
1O-60
3. Steering cylinder at end of stroke

If the operator tries to turn the steering wheel From girotor To right cylinder
further when the steering cylinder has

reached the end of its stroke, the circuit from
pot-t M through port N to port S is kept open
and the pressure rises.
When this pressure rises above 18.6 MPa
(190 kg/cm?, relief valve (IO) opens and the
oil is relieved to the hydraulic tank. Because
of this flow of oil, a differential pressure is
created on both sides of orifice r. Therefore,
the balance is lost between the load of spring
(4), and the pressure up to port A and the
pressure beyond port 6. As a result, the
pressure up to port A becomes relatively
higher.
For this reason, the pressure at port P moves
spool (3) even further to the right from the
condition in Item 2. It stabilizes the condi-
tion at a position where the circuits between
ports M and N are almost fully closed, and
the circuits between ports M and 0 almost
fully open.
/ + i0
M From steering pump
lo-61
STRUCTURE AND FUNCTION CUSHION VALVE
CUSHION VALVE
A
B-l -I
A-A B-B g
SAWW731
b
G
1. Valve seat 6. Plug 11. Poppet 0
2. Valve body 7. Spring

3. Spring 8. Spool
4. Poppet 9. Plug L. Steering cylinder port
5. Orifice 10. Spring R. Steering cylinder port
Outline
. When there is a reaction to the sudden rise on the steering, and the steering operates
in the pressure of the steering cylinder, the as normal.
cushion valve acts to prevent shock by re- l When the pressure rises slowly and there is
lieving the momentary high pressure oil to no need for any cushion effect, spool (8)
another line. closes more quickly than poppet (4) opens,
Function so there is no unnecessary cushion action.
. If high pressure oil suddenly enters from
port R, the high pressure oil compresses
spring (3), and pushes open poppet (4). It
then passes through the center groove of
spool (81, goes through poppet (II) of port
L, and flows to port L.
. At the same time, the high pressure oil
passes through orifice (5) and goes to the
pressure chamber of plug (6). When it be-
comes greater than the pressure at port L
and the force of spring (71, it pushes spool
(8) fully to the left. This shuts off the flow
of high pressure oil from port R through
poppet (4) to port L. This temporary flow
of oil has a cushion effect. The valve is not
actuated any further, so there is no effect
1 O-62
STRUCTURE AND FUNCTION STEERING VALVE
STEERING VALVE (ORBIT-ROLL)
SBWCQ714
6
14
1. Ground
2. Valve body
3. Check valve
4. Rotor
5. Stator
6. Spacer
15 7. Cover
8. Spacer
A-A 9. Drive shaft
10. Sleeve
11. Center pin
a. To hydraulic tank 12. Spool
b. To steering cylinder 13. Center spring
c. To steering cylinder 14. Check valve
d. From steering pump 15. Overload valve
1 O-64
Outline
. The steering valve is connected directly to
the shaft of the steering wheel. It switches 12
the flow of oil from the steering pump to the
left and right steering cylinders to determine
the direction ,of travel of the machine.
. The steering valve, broadly speaking, con-
sists of the following components: rotary
type spool (3) and sleeve (51, which have the
function of selecting the direction, and the
Girotor set (a combination of rotor (8) and
stator (911, which acts as a hydraulic motor
during normal steering operations, and as a
hand pump (in fact, the operating force of
the steering wheel is too high, so it cannot
be operated) when the steering pump or
engine have failed and the supply of oil has
stopped.
Structure
. Spool (3) is directly connected to the drive
shaft of the steering wheel, and is connected
Connected to
to sleeve (5) by center pin (4) (it does not + steering
contact the spool when the steering wheel wheel shaft
is at neutral) and centering spring (12).
F . The top of drive shaft (6) is meshed with
2 center pin (41, and forms one unit with sleeve
(5), while the bottom of the drive shaft is
meshed with the spline of rotor (8) of the
Girotor.
. There are four ports in valve body (2), and
they are connected to the pump circuit, tank
circuit, and the circuits at the head end and
SSWO3716
bottom end of the steering cylinders. The
pump port and tank port are connected by
the check valve inside the body. If the pump
Groove for meshing
or engine fail, the oil can be sucked in di- with,center pin
rectly from the tank by this check valve.
SSWOO718
lo-65
Operation
1. Steering wheel at neutral
L4
3.
To main control valve
SKWOOSOl
lo-66
0 Spool groove hole

A
@j Sleeve hole
a
a
*
Spool
Drain
x-x
Girotor
ri Sleeve Spool
\/
Kk
,
IIf! 6
Valve body z-z
. When the steering wheel is at neutral,

centering spring (12) makes spool (3) and
sleeve (5) stop at a position where center
pin (4) is at the center of the oblong hole in
spool (3).
At this point, pump port A of the sleeve and
ports E, F, and G to the steering cylinder
and Girotor, and vertical grooves B, C, and
D of the spool are shut off.
d
However, orifice a of pump port A is con-
nected to orifice d (connected to drain port SBWO0721
H) of the spool.
Orifice b of port J from the priority valve is
connected to vertical groove B of the spool.
In addition, port K of the sleeve is connected
to drain port L of the spool and vertical
groove B.
. By shutting off and connecting these ports
and grooves, the oil from the pump passes
from port A through orifices a and d, and is
drained to the hydraulic tank.
In addition, the oil which forms the pilot
pressure of the priority valve passes from
port J through orifice b, then through verti-
H J K
cal groove B and port K, and is returned to SBWCO722
the hydraulic tank from port L.
1 O-67
STEERING VALVE
2. Steering wheel turned (turning to left)
Steermy pum
SKW00903
1 O-68
Spool groove
n hole To priority valve
a Sleevehole From left cylinder
To p&ity valv; /ml , To right cylinder
lump B
From left cylinder ‘o hvdraulic tank I II
sLw00904
l When the steering wheel is turned to the flows from port G to the head end of the
left, spool (31, which is connected by the right cylinder.
spline of the steering shaft, also turns to the The oil entering vertical groove B passes
: left. The spool and sleeve (5) are intercon- through orifice b and flows to port J. From
netted by centering spring (121, so the spool port J, it becomes the pilot pressure of the
z
compresses the centering spring. priority valve.
Therefore, a difference in the angle of rota- The oil from the head end of the left cylin-
tion (angle variation) is generated between der enters vertical groove D from port F and
the spool and sleeve equal to the amount is drained to the hydraulic tank.
that the centering spring is compressed. 3. Steering wheel stopped
When this happens, first, port A and vertical When the operation of the steering wheel is
groove B are connected. Then vertical stopped, the difference in rotation between
groove B and port E to the Girotor, and port the spool and sleeve is returned to the neu-
E from the Girotor to vertical groove C are tral condition by the reaction of centering
connected. Finally, vertical groove C and spring (12).
port G to the head end of the right cylinder
are connected.
In addition, vertical groove B is kept con-
nected to orifice b of port J to the priority
valve, but port K of the sleeve gradually
closes the connection of vertical groove B
and port L.
Port F from the head end of the left cylinder
is connected to vertical groove D (connected
to drain port H) at the same time as port A
and vertical groove B are connected.
. By shutting off and connecting the above
ports and grooves, the oil from the pump
enters vertical groove B from port A, then
flows to port E to the Girotor, and turns the
Girotor.. The oil discharged from the Girotor
enters vertical groove C from port E’ and
1O-69
CONNECTION BETWEEN HAND PUMP AND SLEEVE
-
SBWCO726
. Suctiion I
The diagrams above show the connections discharge port
with the sleeve ports used to connect the
suction and discharge ports of the Girotor. /
. If the steering wheel has been turned to the
right, ports a, c, e, g, i, and k are connected
by the vertical grooves in the spool to the
pump side. At the same time, ports b, d, f,
h, j, and I are connected to the head end of
the left steering cylinder in the same way.
In the condition in Fig. 1, ports 1, 2, and 3
are the discharge ports of the Girotor set. SEW00727
They are connected to ports I, b, and d, so
the oil is sent to the cylinder.
Ports 5, 6, and 7 are connected and the oil
flows in from the pump.
If the steering wheel is turned 90”, the condi-
tion changes to the condition shown in Fig.
2. In this case, ports 1, 2, and 3 are the
suction ports, and are connected to ports i,
k, and c. Ports 5, 6, and 7 are the discharge
ports, and are connected to ports d, f, and h.
1O-70
. In this way, the ports acting as the discharge

ports of the Girotor are connected to the
ports going to the steering cylinder, while
the ports acting as the suction ports are con-
nected to the pump circuit.
. Adjustment of discharge according to
amount steering wheel is turned.
For each Ii7 turn of the steering wheel, the
inside teeth of the Girotor advance one tooth,
and the oil from the pump is discharged in
an amount that matches this movement.
Therefore, the amount of oil discharged is
directly proportional to the amount the steer-
ing wheel is turned.
Role of centering spring
l Centering spring (12) consists of four X-

shaped leaf springs and two flat leaf springs.
It is assembled between spool (3) and sleeve
(5) as shown in the diagram on the right.
When the steering wheel is turned, the spool
compresses the spring, and a difference (an-
gle variation) is generated in the turning
z? angle of the spool and sleeve. r
I-
z
0
As a result, the port of the spool and sleeve
is connected and oil is sent to the cylinder.
However, when the rotation of the steering
wheel is stopped, the rotation of the Girotor
also stops, so no more oil is sent to the
cylinder, and the oil pressure rises.
To prevent this, when the turning of the
steering wheel is stopped, the action of the
centering spring only allows it to turn by an
amount equal to the difference in angle of
rotation (angle variation) of the sleeve and
spool, so the steering wheel returns to the
NEUTRAL position.
10-71
STRUCTURE AND FUNCTION BRAKE PIPING
BRAKE PIPING
SKWOO905
1. Front axle Outline

2. Right brake pedal Brake booster (7) consists of a hydraulically
3. Left brake pedal actuated boosting mechanism. It is designed
4. Rear axle to reduce the operating force of the pedal,
5. Brake oil tank and to ensure a powerful braking force.
6. Rear brake When the brake pedal is depressed, the oil
7. Brake booster sent from the pump shuts off the transmis-
8. Transmission cut-off switch sion circuit inside the valve and actuates the
9. Front brake piston to apply the front and rear brakes.
A relief valve is installed in the circuit to
protect the circuit from damage if any ab-
normal pressure should be generated in the
oil sent from the pump.
1 O-72
STRUCTURE AND FUNCTION BRAKE CONTROL
BRAKE CONTROL
A-A
ii
SKWOO906
==z=
4
Z
1. Brake pedal (R.H.)

:=_~=---__ 2. Brake pedal (L.H.)
3. Brake booster
4. Stop lamp switch
5. Cut-off switch
5
1o-73
STRUCTURE AND FUNCTION BRAKE BOOSTER
BRAKE BOOSTER
4 5 6 7 8 9 10 11 12
SLWOO907
1. Dust cover Outline

2. Spool . The brake booster is a boosting system to
3. Relief valve increase the braking force. It increases the
4. Cylinder cover pressure in the master cylinder in propor-
5. Power piston tion to the operating force by using the oil
6. Return spring (for power piston) pressure delivered from the oil pump.
7. Return spring (for connector)
8. Connector
9. Reaction spring
10. Reaction piston
11. Secondary piston
12. Primary piston
1o-74
Operation
Brake OFF
. When the push rod connected to the brake
pedal is returned, spool (2), connector (81,
and power piston (5) are returned towards
cylinder cover (4) by return springs (6) and
(7).
Therefore, primary piston assambly (12) and
secondary piston assembly (11) of the mas-
ter cylinder are each in their respective neu-
tral positions. The respective pressures in
the chambers E and F (the chambers con-
nected to the discharge pot-t) pass through
the relief port and are released to atmos-
pheric pressure chambers C and D in the
reservoir.
The oil from the pump flows from port A to
Rear axle Front axle
port B and then flows into the transmission
circuit.
SKWOO908
In addition, the oil in the master cylinder is
connected to the front and rear axles.
Hydraulic pressure starting to rise

. When the brake pedal is depressed, the push
rod connected to the pedal compresses re-
action spring (9) and moves spool (2) for-
ward. Connector (8) is pushed towards the
power piston by return spring (71, so the
passage between power piston (5) and spool
(2) is restricted. A difference in pressure is
generated between the front and rear walls
of the power piston, so the power piston
moves forward, pushes connector (81, and
actuates secondary piston assembly (11) of
the master cylinder.

SKWOO909
1o-75
Hydraulic force rising

When secondary piston (11) moves forward
and primary cup (13) closes relief port (141,
pressure is generated in chamber E. Reac-
tion piston (lO)(piston with small diameter)
built into secondary piston (11) moves to
the rear and is in continuous contact with
the tip of spool (2). The pressure generated
in the master cylinder and bearing on the
area of reaction piston (IO) passes through
push rod (16) and is transmitted to the pedal
as the operating force.
The pressure generated at chamber E of sec-
ondary piston (11) of the master cylinder is
also generated at the same time in chamber u u u
Rear axle Front axle”
F of primary piston (12). SKWOOSlO
In addition, when the brake pedal is de-
pressed, power piston (5) moves to the right,
and the pressure of the oil in chamber E and
chamber F rises, so the braking force of the
front brake and rear brake is also increased.
Relief valve
l When the brake is being operated, if the
pressure inside the power cylinder ( port A)
goes above the specified level, relief valve
(3) is actuated. The oil is relieved to the
transmission circuit to prevent abnormal
pressure in the brake system.
. If there should be any failure in the hydrau-
lic pump sending oil to the power cylinder,
the operating force of the pedal is transmit-
ted through spool (2) and connector (81, so
the piston in the master cylinder can be ac-
tuated. However, when this happens, the op-
erating force of the brake pedal is heavier
than usual.
SKWOOSll
lo-76
Brake actuated (oil leaking from front brake)

. The brake oil tanks from independent sys-
tems, so if there is any leakage of oil in
either the front or rear brake systems, only
one of the brakes (front or rear) will be ap- To transmission
plied. From pump valve
This increases the safety and ensures that 6 0
the machine can always be stopped.
U U U
Rear axle uFront axle
SKWOOSIZ
Brake pedal released

l When the pedal is released, spool (2) is re-
turned by reaction spring (91, so the pas- \
sage between spool (2) and power piston (5)
is restricted. It is released to the same con-
ditions as when not actuated (brake OFF), To transmission
From pump valve
and the difference in pressure between front
and rear chambers of power piston (5) is
removed, so the power piston and connec-
tor (8) are acturned by return springs (6) and
(7). Following this, the pistons of the master
cylinders are also returned to the neutral
position by their respective return springs.
The relief ports are connected to the reser-
voir, and the pressure returns to atmospheric
pressure.
SKWO0913
1o-77
STRUCTURE AND FUNCTION BRAKE
BRAKE
1. Differential housing 4. Disc 7. Axle housing

2. Piston 5. Outer ring 8. Sun gear shaft
3. Inner ring 6. Bearing carrier
Function
. The brake is a wet-type, single disc brake. It Inner ring (3) is installed to the notched part
consists of piston (2), inner ring (3), disc (4), of bearing carrier (6). Outer ring (5) is se-
and outer ring (5). cured to axle housing (7) by pin.
. The brake cylinder consists of differential l
Disc (4) has a lining stuck on both faces. It is
housing (I) and bearing carrier (6). Piston assembled between inner ring (3) and outer
(2) is assembled inside the brake cylinder. ring (5). It is connected by the spline of the
sun gear shaft.
lo-78
STRUCTURE AND FUNCTION BRAKE
Operation
Brake operated
. When the brake pedal is depressed, the rod
of the master cylinder is pushed. Oil pres-
sure P is generated, and this acts on the
piston inside the brake cylinder to slide pis-
ton (6) slightly.
Therefore, the rotation of disc (4), which is
between inner ring (3) and outer ring (5), is
stopped, and the brakes are applied to stop
the machine.
SLWOO915
d
0 Brake released
. When the oil pressure is released, piston (6) 5 4 3 6 9
moves back slightly because of the return
force of piston O-ring (9). A gap is created
between inner ring (3) and outer ring (51, so
1
disc (4) is free.
Grooves are cut in a lattice pattern on the
lining stuck to disc (4). When the disc is
rotating, oil flows in these grooves to cool
the lining.
1o-79
STRUCTURE AND FUNCTION PARKING BRAKE CONTROL
PARKING BRAKE CONTROL
C
A-A
B-B
SKWO0917
Outline
l When parking brake pedal (I) is depressed,
control cable (3) pulls brake lever (4) up and
actuates the multiple disc brake installed to
the output shaft of the transmission.
l To release the parking brake, pull parking
1. Parking brake pedal brake release lever (2).
2. Parking brake release lever l When the parking brake is applied, the neu-
3. Control cable tralizer relay acts to shut off the electric cur-
4. Parking brake lever rent to the transmission solenoid valve and
5. Transmission keep the transmission at neutral.
1 O-80
STRUCTURE AND FUNCTION PARKING BRAKE
PARKING BRAKE
SKW00918
Outline
1. Transmission . The parking brake is a mechanically oper-
2. Parking brake lever ated wet type multiple disc brake which ap-
3. Disc plies braking force to transmission output
4. Plate shaft (5).
5. Transmission output shaft . Lever (2) is connected to the control cable,
6. Bail and when the lever is pulled, ball (61, which
7. Cover is between cover (7) and piston (8) connected
8. Piston to the lever, moves on the slope of the pis-
ton groove. The piston pushes the discs
and plates together, and applies braking
force to output shaft (5).
lo-81
STRUCTURE AND FUNCTION HYDRAULIC PIPING
HYDRAULIC PIPING
1. Bucket cylinder
2. Boom cylinder (R.H.)
3. Steering valve
4. Hydraulic tank
5. Priority valve
6. Hydraulic pump
7. Steering pump
9. Boom cylinder (L.H.)
lo-82
STRUCTURE AND FUNCTION HYDRAULIC PIPING
Outline
The hydraulic system consists of the work
equipment circuit and steering circuit. The
work equipment circuit controls the opera-
tion of the bucket or other attachments.
The oil from hydraulic tank (4) is sent from
hydraulic pump (6) and steering pump (7) to
priority valve (5). The amount of the oil
flow is controlled and sent to main control
valve (8). If the bucket and boom spools of
main control valve (8) are at neutral, the oil
passes through the drain circuit of the main
control valve, is filtered by the filter inside
hydraulic tank (41, and returns to the tank.
. When the work equipment control lever is
operated, the bucket or boom spool of main
control valve (8) move, oil flows from main
control valve (8) to boom cylinder (2) and (9)
or to bucket cylinder (I), and operates the
boom or bucket.
. The maximum pressure of the hydraulic cir-
cuit is controlled by priority valve (5) and
the relief valve inside the main control valve.
A safety valve (with suction) is installed in
E?
f+
the bucket cylinder circuit to protect the cir-
7 cuit.
s . Hydraulic tank (4) is a pressurized sealed
type and has a breather with a relief valve.
It pressurizes the inside of the tank and also
prevents negative pressure in order to pre-
vent cavitation of the pump.
lo-83
STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM

(Engine low idling, work equipment lever in “HOLD”)
SKI’00920
1O-84
STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
IL 122.5MPa I
I i : i
L
i_i__~______________-fii-_-I-___%
i (230kdcm2)
1
L___________-_______J
16
-_-_-_-_-_--
r-----
I
r
I
44
I
r
I
‘_ _ 1 I
r-------i
li
I
I---T
i ’ I I I
I
i2, i
-_ _-_-_-
SKWO0921
1. Hydraulic tank 7. Overload valve 13. Boom spool

2. Filter 8. Steering cylinder 14. Suction valve
3. Steering pump 9. Cushion valve 15. Bucket cylinder
4. Hydraulic pump 10. Relief valve 16. Boom cylinder
5. Priority ‘valve 11. Safety valve (with suction)
6. Steering valve (Orbit-rol valve) 12. Bucket spool
1O-85
0
STRUCTURE AND FUNCTION HYDRAULIC TANK
HYDRAULIC TANK
A-A
--_-i--ii;
_-__-__-__
\
6
SKWO0922
1. Cap, breather Outline

2. Air bleed plug . The oil from the hydraulic tank is sent from
3. Oil filter bypass valve the pump through the priority valve and main
4. Oil filter control valve to each cylinder. It merges in
5. Oil level gauge the return circuit with the oil from various
6. Drain plug parts, is filtered by the oil filter, and returns
to the tank.
. The oil filter filters the whole oil flow in the
circuit. When the oil filter becomes clogged,
the bypass valve is actuated to allow the oil
to return directly to the tank and prevent
damage to the filter.
1O-86
OIL FILTER BYPASS VALVE
When the filter is clogged From main

. Bypass valve (I) opens and the oil returns control valve
directry to the tank without passing through

the filter (2).
Bypass valve set pressure:
0.15 MPa (1.5 kg/cm?
SKW00923
When negative pressure is formed in the return To main

control valve
circuit.
. Bypass valve (I) moves up and acts check
valve.
Check valve set pressure:
0.024 MPa (0.24 kg/cm?
lo-87
BREATHER
1. Cover
2. Sleeve
3. Spring
4. Spring
5. Poppet
SM 6. Filter element
Preventing negative pressure inside tank

. The tank is a pressurized sealed type, so if
the oil level inside the hydraulic tank goes
down, there will be negative pressure in the
tank. If this happens, a sleeve (2) is opened
by the difference between the pressure in-
side the tank and the atmospheric pressure,
and air is let in to prevent negative pressure
from forming inside the tank.
SKWOO926
Preventing rise in pressure inside tank

. If the pressure in the circuit rises above the
set pressure during operations because of
the change in the oil level in the hydraulic .5
cylinders or the rise in the temperature, the
poppet (5) is actuated to release the pres-
sure inside the hydraulic tank.
SKWO0927
1O-88
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
MAIN CONTROL VALVE

2-SPOOL
SDW00928
A. To bucket cylinder rod side

B. To boom cylinder rod side
C. Drain port (to tank)
D. To boom cylinder bottom side
E. To bucket cylinder bottom side
F. From pump
1O-90
B-B
7 8
A-A
SDW00929
1. Main relief valve

2. Bucket spool
3. Boom spool
4. Magnet for boom
5. Magnet for bucket
6. Safety valve (with suction)
7. Suction valve
8. Check valve
10-91
3-SPOOL
h-- C
P-D
SDW00930
A. To attachment cylinder
6. To bucket cylinder rod side
C. To boom cylinder rod side
D. Drain port (to tank)
E. To boom cylinder bottom side
F. To bucket cylinder bottom side
G. To attachment cylinder
H. From pump
1 O-92
B-B
c-c
8 9
\ /
A-A
D-D
SDW00931
1. Main relief valve

2. Attachment spool
3. Bucket spool
4. Boom spool
5. Magnet for boom
6. Magnet for bucket
7. Safety valve (with suction)
8. Suction valve
9. Check valve
1o-93
MAIN CONTROL VALVE
RELIEF VALVE
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjustment screw
SEW00932
Function
The relief valve is installed to the inlet por-
tion of the main control valve. If the oil goes
above the set pressure, the relief valve drains
the oil to the tank to set the maximum pres-
sure for the work equipment circuit, and to
protect the circuit.
Operation
. Port A is connected to the pump circuit and
port C is connected to the drain circuit. The
oil passes through the orifice in main valve
(l), and fills port B. Pilot poppet (3) is seated
in valve seat (2).
. If the pressure inside ports A and B reaches
the set pressure of pilot poppet spring (4),
pilot poppet (3) opens and the oil pressure at
port B escapes from port D to port C, so the
pressure at port B drops.
. When the pressure at port B drops, a differ-
ence in pressure between ports A and B is
created by the orifice of main valve (1). The
main valve is pushed open and the oil at port
A passes through port C, and the abnormal
pressure is released to the drain circuit.
. The set pressure can be changed by adjust-
ing the tension of pilot poppet spring (4). To
change the set pressure, remove the cap nut,
loosen the locknut, then turn adjustment screw
(5) to adjust the set pressure as follows.
TIGHTEN to INCREASE pressure
LOOSEN to DECREASE pressure
1o-94
SAFETY VALVE (WITH SUCTION)

1. Suction valve
2. Main valve
1 2 3 4 5 6
3. Main valve spring
4. Pilot piston
5. Suction valve spring
6. Valve body
SEW00166
Function
. The safety valve is in the bucket cylinder
circuit inside the main control valve. If any
abnormal pressure is generated by any shock
to the cylinder when the main control valve
is at the neutral position, this valve relieves
the abnormal pressure to prevent damage
to the cylinder.
A BC2 4 D
Operation
Operation as safety valve
. Port A is connected to the cylinder circuit
and port B is connected to the drain circuit.
The oil pressure at port A is sent to port D
from the hole in pilot piston (4). It is also
sent to port C by the orifice formed from
main valve (2) and pilot piston (4).
Pilot piston (4) is secured to the safety valve,
SEW00167
and the size of the cross-sectional surface
(cross-sectional area) has the following rela-
tionship: d2 > dl > d3 > d4.
. If abnormal pressure is created at port A,
suction valve (I) is not actuated because of
relationship d2 > dl >, but relationship be-
tween port A and port C is d3 > d4, so main
valve (2) receives oil pressure equivalent to
the difference between the areas of d3 and
d4. If the oil pressure reaches the force (set
pressure) of main valve spring (3), main valve
(2) is actuated, and the oil from port A flows
to port B. SEW00168
1o-95
Operation as suction valve

. If any negative pressure is generated at port
.A B 1 e 5 D
A, port D is connected with port A, so there
is also negative pressure at port D. The tank
pressure of port B is applied to port E, so
the suction valve (I) receives oil pressure a,
which is equal to the difference in the area
of d2 and dl because of the tank pressure at
port E. Therefore, oil pressure e moves the
valve in the direction of opening, and oil
pressure a acts to move suction valve (I) in
the direction of closing.
When the pressure at port A drops (and
comes close to negative pressure), it be-
comes lower than hydraulic pressure e. The
relationship becomes oil pressure e > oil
pressure a + force of valve spring (51, and
suction valve (I) opens to let the oil from
port B flow into port A and prevent any nega-
tive pressure from forming at port A.
SUCTION VALVE
1. Main poppet
2. Sleeve
3. Spring
SEW00170
Function
. This valve acts to prevent any negative pres-
sure from forming in the circuit.
Operation
. If any negative pressure is generated at port
A (boom cylinder rod end) (when a pressure dl d2
lower than tank circuit port B is generated), I SEW@3171
main poppet (I) is opened because of the
difference in area between d? and d2, and oil
flows from port B at the tank end to port A
at the cylinder port end.
1 O-96
Boom and bucket spool at neutral position
FLOAT(;I
-
LOWER Q
h
TILT BACKQ $3 DUMP
>riorityq + To steering valve
SOW00936
Operation
. The oil from hydraulic pump (I) passes
through the priority valve, and enters port
A. The maximum pressure is set by relief
valve (2).
. Bucket spool (3) is at the neutral position, so
the bypass circuit is open and the oil in
chamber A passes around the spool and
flows to port B. Boom spool (4) is also at
the neutral position, so the bypass circuit is
open and the oil in chamber B passes around
the spool, enters chamber C of the drain
circuit, passes through the filter, and returns
to the tank.
1o-97
Boom spool at RAISE position
FLOATQ
DUMP
SDW00937
Operation
. When the boom lever is pulled, boom spool The oil from port B then flows from port E
(4) is pulled out to the RAISE position. to the bottom end of the cylinder.
. The oil from the pump flows through the l
At the same time, the oil at the cylinder rod
bypass circuit of the bucket spool and flows end flows from port D to drain port C and
to the bypass circuit of boom spool (4). The returns to the tank. As a result, the boom is
bypass circuit is closed by the spool, SO the raised.
oil from port B pushes check valve (5) open.
1O-98
Boom spool at LOWER position
FLOAT Q
-
DUMP
‘N
To steering valve
SDW00938
Operation
. When the boom lever is pushed, boom spool l At the same time, the oil at the cylinder
(4) is pushed in to the LOWER position. bottom end flows from port E to drain port
. The oil from the pump flows through the C and returns to the tank. As a result, the
bypass circuit of the bucket spool and flows boom is lowered.
to the bypass circuit of boom spool (4). The
bypass circuit is closed by the spool, so the
oil from port B pushes check valve (5) open.
The oil from port B then flows from port D
to the rod end of the cylinder.
1o-99
Boom spool at FLOAT position
3UMP
J\
N
ity@$ + To steering valve
SDWO0939
Operation
. If the boom lever is pushed beyond the l When the bucket is in contact with the
LOWER position, boom spool (4) is pushed ground surface, the bucket can move up or
in to the FLOAT position. down in accordance with the shape of the
l The oil from the pump passes around the ground surface.
bypass circuit of the bucket spool and flows
to the boom spool bypass circuit. The oil in
the bypass circuit is sent to the drain circuit
by the spool and cannot push open check
valve (5). Both the RAISE circuit E and
LOWER circuit D of the boom cylinder are
connected to the drain circuit, so the boom
goes down under its own weight.
10-100
Bucket spool at TILT BACK position
FLOAT (?
-
RAISE
I) To steering valve
Operation
l When the bucket lever is pulled, bucket spool
(3) is pulled out to the TILT BACK position.
. The bypass circuit is closed by the spool, so
the oil from pot-t A pushes open check valve
(7). The oil from port A then flows from
pot-t H to the bottom end of the cylinder.
. At the same time, the oil at the cylinder rod
end flows from port G to drain port C, and
returns to the tank. As a result, the bucket is
tilted back.
10-101
Bucket spool at DUMP position
FLOATQ
DUMP
Operation
. When the bucket lever is pushed, bucket
spool (3) is pushed in to the DUMP position.
. The bypass circuit is closed by the spool, so
the oil from port A pushes open check valve
(7). The oil from port A then flows from
port G to the rod end of the cylinder.
. At the same time, the oil at the cylinder bot-
tom flows from port H to drain port C, and
returns to the tank. As a result, the bucket is
tilted forward.
10-102
STRUCTURE AND FUNCTION WORK EQUIPMENT LEVER LINKAGE
WORK EQUIPMENT LEVER LINKAGE
A-A
1. Bucket boom control lever

2. Kick-down switch
3. Lock lever
SKW00942 4. Main control valve
10-103
STRUCTURE AND FUNCTION WORK EQUIPMENT LINKAGE
WORK EQUIPMENT LINKAGE
___________- ------
,_--__-__-__-__- ------______
--- -----__
L)
D--I /
I / __---TdFL
: ’ L__J
!/
i,I I
n
6 5 4
SKWO0943
1. Bellcrank 4. Boom
2. Bucket cylinder 5. Bucket link
3. Boom cylinder 6. Bucket
10-104
STRUCTURE AND FUNCTION WORK EQUIPMENT LINKAGE
A-A B-B
D-D E-E F-F
__L__
G-G H-H 2
__-__
J-J
SKWO0944
10-105
BUCKET
BUCKET
L
A-A
SKWO0945
1. Bucket (l.7m3)
2. Bolt-on cutting edge (BOC)
10-106
STRUCTURE AND FUNCTION BUCKET POSITIONER AND BOOM KICK-OUT
BUCKET POSITIONER AND BOOM KICK-OUT
1111
&_-I!-__-__;!! : ;, I, :
-- -r----- ii
I\(?__ _,,’
).-/
SKW00946
1. Bucket cylinder rod

2. Lever
3. Proximity switch
4. Proximity switch
10-107
STRUCTURE AND FUNCTION BUCKET POSITIONER AND BOOM KICK-OUT
BUCKET POSITIONER
. The bucket positioner is an electrically actu-
ated system which is used to set the bucket
to the desired angle when the bucket is
moved from the DUMP position to the TILT
position. When the bucket reaches the de-
sired position, the bucket lever is returned
from the TILT position to the HOLD position,
and the bucket is automatically set to the
suitable digging angle.
. Lever (2) is secured to bucket cylinder rod
(I) by bolts. In addition, proximity switch (3) SLWOO947
fixed to the cylinder by bolts.
. When the bucket is moved from the DUMP
position to the TILT position, the bucket cyl-
inder rod moves to the left, and at the same
time, lever (2) also moves to the left. Prox-
imity switch (3) separates from lever (2) at
the desired position, and the bucket lever is
returned to neutral.
BOOM KICK-OUT
. The boom kick-out is an electrically actuated
system. It acts to move the boom lever to
the HOLD position and stop the boom at the
desired position before the boom reaches
the maximum height.
. Plate is fixed to the boom. In addition, prox-
imity switch (4) is fixed to the frame.
When the boom is moved from the LOWER
position to the RAISE position, the boom
rises, and when it reaches the desired posi- SKW00948
tion, the proximity switch and lever come

together and the system is actuated to re-
turn the boom lever to the HOLD position.
lo-108
STRUCTURE AND FUNCTION PROXIMITY SWITCH
PROXIMITY SWITCH
. The proximity switches are installed to the
boom and bucket cylinder by a support. In
accordance with the operating condition, a
pulse is generated from the sensor at the
desired point when moving to the boom
RAISE position and bucket TILT BACK posi-
tion. This electric current is transmitted to a
magnet, and the boom and bucket lever are
returned to neutral. Therefore, the main
control valve also returns to neutral and the
movement of the boom and bucket are
stopped.
0 @ Boom RAISE detent coil
@ @ Boom FLOAT detent coil
Connector
Boom spool detent
0.85B(black)
IOAfuse
OB5GW(green~hit~
$$ Detection surface
Detector (steel plate)
@
rm
Y
D”MTLT BACK
Bucket
proxim’w switch
Connector
SKWO0949
10-109
STRUCTURE AND FUNCTION PROXIMITY SWITCH
OPERATION OF PROXIMITY SWITCH

Boom RAISE switch Bucket TILT BACK switch
. If the boom goes below the set position for l If the bucket is dumped beyond the set posi-
the boom kickout, the detector (plate) is tion for the bucket positioner, the detector
above the detector surface of the boom prox- (plate) is above the detector surface of the
imity switch, so the proximity switch sends bucket proximity switch, so the proximity
the battery current to the magnet switch switch sends the battery current to the mag-
coil. net switch coil.
l When the boom lever is operated to the l When the bucket lever is operated to the
RAISE position, the boom spool is held at TILT BACK position, the bucket spool is held
the RAISE position by the magnet at the at the TILT BACK position by the magnet at
boom spool detent of the main control valve, the bucket spool detent of the main control
and the boom rises. valve, and the bucket is tilted back.
. When the boom rises and reaches the set l When the bucket tilts back and reaches the
position for the boom kickout, the detector set position for the bucket positioner, the
(plate) separates from the proximity switch detector (plate) separates from the proxim-
detector surface. When this happens, the ity switch detector surface. When this hap-
proximity switch cuts the electric current to pens, the proximity switch cuts the electric
the magnet coil. The boom spool is then current to the magnet coil.
returned to the neutral position by the re- The bucket spool is then returned to the neu-
turn spring. tral position by the return spring.
ACTION OF PROXIMITY SWITCH
detection surface of proximity

tection surface of proximity switch
switch
Proximity switch sends electric cur- Proximity switch cuts electric cur-
Boom, bucket prox-
rent to magnet coil. (magnet is ac- rent to magnet coil. (magnet is not
imity switch
tuated) actuated)
10-110
STRUCTURE AND FUNCTION CANOPY
CANOPY
A-A
\
2
SKWOO950
1. Canopy roof
2. Pipe
3. Cap
4. support
10-111
STRUCTURE AND FUNCTION ROPS CAB
ROPS CAB
--B
r-- ---T-l
A-A B-B
SKW00951
1. Front glass
2. Front wiper
3. Rear wiper
4. Door
10-112
STRUCTURE AND FUNCTION AIR CONDITIONER
AIR CONDITIONER
AIR CONDITIONER PIPING
SKWOOS52
1. Vent
2. Air conditioner unit
3. Hot water inlet port
4. Hot water outlet port
5. Compressor
6. Dry receiver
7. Air conditioner condenser
10-113
TRAVEL DAMPER SYSTEM
TRAVEL DAMPER SYSTEM
SKW00955
Outline
. The travel damper system is a system to
1. Accumulator (ACCI)
2. Accumulator (ACC2) suppress the travel vibration when traveling
3. Solenoid valve on unpaved surfaces, snow, or other rough
4. Actuation selector switch road surfaces at high speed, or when
5. Main control valve traveling loaded. It is effective in reducing
the vibration of the chassis and makes it
possible to carry out stable travel operations.
10-114
STRUCTURE AND FUNCTION TRAVEL DAMPER SYSTEM
TRAVEL DAMPER HYDRAULIC, ELECTRICAL CIRCUIT DIAGRAM
Boom cvlinder
Actuatio
Relay 1 Relay 2 Relay 3
System actuation table
Actuation se- Boom cylinder bottom pressure Solenoid valve actuation

lector switch Actuation of system
MPa (kg/cm*) SOL1 SOL2 SOL3
OFF O-(0-) - - Not actuated
I 0 - 5.9 ( 0 - 60 ) 1 o 1 o 1 o 1 ACCI actuated
ON I 5.9 - 14.7 ( 60 - 150 ) I o 1 o 1 - I ACC2 actuated
14.7 - ( 150 - ) - - Not actuated
10-l 15
OPERATION
Electrical circuit -+-
Hydraulic circuit =
1. Boom cylinder g
b
2. Actuation selector switch
3. Accumulator 2
4. Pressure switch
5. Solenoid selector valve
. With this system, there are two intercon- For this reason, when traveling unloaded,
nected accumulators (3) charged with gas accumulator (3) ACCI acts as a spring, and
under different pressures. These two accu- when traveling loaded, ACC2 acts as a spring.
mulators are installed between the bottom Even if the operator forgets to switch
end of boom cylinder (I) and main control actuation selector switch (2) when operat-
valve (6). ing, if the pressure at the bottom end goes
The two accumulators (3) are equipped with above PSW2, solenoid selector valve (5) is
pressure switches (4) and solenoid selector automatically switched and the circuit of
valves (5) to open and close the oil circuit. accumulator (3) is closed, so accumulator
There is also a further solenoid selector valve (3) is protected from any excessive pressure
(5) between the head end of boom cylinder generated at the bottom end.
(I) and control valve (6) to open or close
the flow of oil to the cylinder head.
. The pressures (ACCI, ACC2) of the gas in
the two accumulators (3) and the set pres-
sures (PSWI, PSW2) of the two pressure
switches (4) are set as follows.
% ACCI c Load pressure at bottom end
when empty c ACC2 c Load pressure at
bottom end when loaded
% Load pressure at bottom end when
empty c PSWI c Load pressure at bot-
tom end when loaded < PSW2
lo-116
0
1. Actuation selector switch OFF

. Solenoid selector valves (I), (21, and (3) are
at the shut-off position, so the system is not
actuated.
Actuati
SKWO0958
2. Actuation selector switch ON, traveling

Boom cylinder
unloaded (boom cylinder bottom pressure:
0 - 5.9 MPa (0 - 60 kg/cm?
. Accumulators ACCI and ACC2 are both in-
terconnected, but gas pressure of accumula-
tor ACC2 > boom cylinder bottom pressure,
so ACC2 is not actuated as a spring. Only
accumulator ACCI is actuated as a spring.
10-117
3. Actuation selector switch ON, traveling

loaded (boom cylinder bottom pressure:
5.9 - 14.7 MPa (60 - 150 kg/cm?
. Electricity flows to pressure switch (I)
and solenoid selector valve (3) is at the
shut-off position, so only accumulator
ACC2 is actuated as a spring.
4. Actuation selector switch ON, excess pres-

sure generated (boom cylinder bottom Boom cylinder
pressure: above 14.7 MPa (150 kg/cm21
. Electricity flows to both pressure
switches (I) and (21, and solenoid selec-
tor valves (I), (21, and (3) are at the shut-
off position, so the system is not actu-
ated, and no excess pressure is brought
to bear on accumulator ACCI or ACC2.
Actuation selector switch
lo-118
ELECTRICAL WIRING DIAGRAM
ELECTRICAL WIRING DIAGRAM 1. Central panel

2. Bucket positioner proximity switch
3. Head lamp
4. Transmission cut-off switch
5. Starting switch
6. Combination switch
7. Fuse box
8. Parking brake switch
9. Engine stop motor relay
10. Slow blow fuse
11. Alternator
12. Water temperature sensor
13. Working lamp
14. License lamp
15. Rear combination lamp
16. Battery
17. Fuel level sensor
18. Battery relay
19. Transmission solenoid valve
20. Directional lever
21. Gear shift lever
22. Wiper switch
23. Horn
24. Boom kickout proximity switch
\
16
10-l 19
ELECTRICAL CIRCUIT DIAGRAM (l/Z)
R. H. tront 25’
combination IdOlD
51
R. H. hesa IdtW
62”161
L.H. front 5v
:omDination lam0
2%
-t
r=I_
-
-
C” L35
3oom oroximi tY
;wi ten
loom k ickout Kick-down

switch
3oom float
Chassis ground
SOY00963
10-122
__---- ----- --- --------------------
r---- Washer tani c4ii ?
4
I 1
T/M ComDination SwitCn connection table iDer Switch

------- connection table
r----- ------7
Rear
101 combinatioi
R. H.
Rear frame
Chassis ground
F ,Working connector
lam0 tar machine

for Toro”e cO”Yerter
snow an0 CCJIO wearner
oi I temersture
Fuel lerel
StartingSwitch COnneCtion table
r - - connection
7x7 - - -
T/M solenoid valve actuation table

O( - continuous1
T/M cut-o
Selector
switch
_
i/M Cut-Ott
switcn
ON wnen traveling
10423
STRUCTURE AND FUNCTiON. AIR CONDITIONER ELECTRICAL CIRCUIT DIAGRAM
AIR CONDITIONER ELECTRICAL CIRCUIT DIAGRAM (2/2)

servo motor
To air conditioner Swith
Comoressor
Condenser
R
CtoD)
Condenser
(EOD)
L. H. OischarQe
servo motor
Pressure switch
----
r----
I Thermostat
I
I
servo
ComDressor amo
Blower relay
(MAIN)
R. H. discha ree
Blower relay servo motor
(HI
Blower relay
(hl2)
SDWOO965
Condenser rel av
Blower relay FlOOr

(Ml)
Magnet relay
condenser relay
10-125
STRUCTURE AND FUNCTION CENTRAL PANEL
CENTRAL PANEL (CLUSTER GAUGE)
1 2 3 4 5 3 6
17 16 15 14 13 12 11
SKW00966
1. Service meter indicator 11. Working lamp switch

2. Fuel gauge 12. Parking brake pilot lamp
3. Turn signal pilot lamp 13. Engine oil pressure warning lamp
4. Speedometer 14. Battery charge warning lamp
5. Head lamp high beam pilot lamp 15. Transmission cut-off selector lamp
6. Coolant temperature gauge 16. Emergency steering lamp
7. Torque converter oil temperature gauge 17. Brake boost pressure warning lamp
8. Brake oil level warning lamp 18. Transmission cut-off selector switch
9. Working lamp pilot iamp 19. Emergency steering lamp
10. Preheating pilot lamp 20. Service meter
lo-126
STRUCTURE AND FUNCTION SENSOR
SENSOR
ENGINE OIL PRESSURE
1. Plug
1 234 5 6 2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Terminal
SEW00290
Function
. The engine oil pressure sensor is installed
to the engine block and detects the oil pres-
sure. If the oil pressure goes below the
specified pressure, it lights up the engine
oil pressure warning pilot lamp on the clus-
ter gauge to warn the operator of the ab-
normality.
c-3
x BRAKE OIL LEVEL

5
1 2
6
1. Cap
2. Ring
3. Float
4. Connector
5. Tank
6. Diaphragm
Function
. The brake oil level sensor is installed to the
top of the brake oil tank. When the brake oil
goes below the specified level, the float goes
down and the switch is turned on. This
lights up the brake oil level lamp on the
cluster gauge to warn the operator of the
abnormality.
lo-127
STRUCTURE AND FUNCTION ENGINE STARTING CIRCUIT
ENGINE STARTING CIRCUIT
Start End
I---- -------6--
Neutral relav -_-_-_-_-_-_

Engine stop motor
Alternator
M
f$
SKW00969
2
0
Function
. A neutral safety circuit is used to prevent When the motor rotates, terminal D also ro-
the engine from starting if the directional tates at the same time. When the non-con-
lever is not at the N position. This ensures tinuous portion of terminal D reaches termi-
safety when starting the engine. nal B, the circuit from terminal A to B is
Operation opened and the current from the battery to
. When the directional lever is placed at the N the motor is cut.
position, the N contacts of the directional The motor tries to continue rotating under
lever switch are closed. inertia, but when the continuous portion of
. When the starting switch is turned to the terminal D contacts terminal B, both poles
ON position, electric current flows from bat- of the motor contact the ground, and the
tery @ + starting switch terminal B - BR + rotation of the motor is stopped.
battery relay. The battery relay is closed, so In this condition, the stop motor cable is
current flows in the following circuit: @ bat- fully extended and the fuel injection pump
tery @ + battery relay + slow blow fuse + stop lever is moved to the FULL position to
directional switch terminal N + neutral reset to the operating condition.
lay terminals 1 - 2 + ground, and the relay If the starting switch is turned to the START
coil is excited. When this happens, neutral position, current flows from starting switch
relay terminals 3 - 4 are closed. terminals B - C + neutral relay terminals 4 -
. In addition, electric current flows from switch 3 3 starting motor terminal S + ground,
terminal BR + stop motor relay terminals 1 and a circuit is also formed from the battery
- 2 -+ ground, so the stop motor relay is + battery relay -+ starting motor terminal B,
excited and terminals 3 - 5 are closed. The so the engine starts.
current from the battery flows from stop If the directional lever is not at the N posi-
motor terminals A - B + stop motor relay tion, circuit 0 is not formed, so the engine
terminals 5 - 3 + motor, and rotates the does not start.
rotor (the cable extends).
lo-128
STRUCTURE AND FUNCTION ENGINE STOP CIRCUIT
ENGINE STOP CIRCUIT
Start End
,______-_-_-_-_- ,________-_-_-_-,
Engine stop I”
motor relay
60’
501
R
Engine stop motor
Starting To starting motor
SKWOO970
Function
. The system is equipped with an electrical When the motor rotates, terminal D also ro-
fuel cut device (engine stop motor) which tates at the same time. When the non-con-
makes it possible to start or stop the engine tinuous portion of terminal D reaches termi-
by turning the starting switch ON or OFF. nal C, the circuit from terminal A to C opens,
This improves the ease of operation. and the current from the battery to the mo-
tor is shut off. The motor attempts to con-
Operation tinue rotating under inertia, but when the
. When the starting switch is turned OFF, stat-t- continuous portion of terminal D contacts
ing switch terminals B and ACC are opened. terminal C, both poles of the motor are con-
. The current in the stop motor relay is shut nected to the ground, and the motor stops
off by the starting switch, so the coil is not rotating.
excited. Therefore, terminals 3 and 6 are In this condition, the stop motor cable is
closed. completely pulled in, and the fuel injection
. The current from the battery flows from en- pump lever is set to the STOP position to
gine stop motor terminals A - C + relay stop the engine.
terminals 6 - 3 + motor to rotate the mo-
tor. (The cable is pulled in)
lo-129
STRUCTURE AND FUNCTION AUTOMATIC PREHEATING CIRCUIT
AUTOMATIC PREHEATING CIRCUIT (Q.G.S. CIRCUIT)
Batten/
Starting motor
QGS controller
Glow relay
Alternator
I
(‘A A QGS water temperature sensor
Preheating pilot lamp y
10A
Y
Outline
. To make it easier to start the engine in cold l When the starting switch is turned to the
weather, a Q.G.S. (Quick Glow System) au- START position and the starting motor stops
tomatic preheating system is installed. This turning, it is judged that the engine has
consists of a controller, a water temperature started, and post-heating starts.
sensor, and an ultra-quick heating glow plug.
. The Q.G.S. automatically sets the preheating Operation
time to match the coolant temperature sim- l When the starting switch is turned to the
ply by turning the starting switch ON. It ON position, a signal flows from the starting
also acts to reduce the preheating time. switch terminal ACC to Q.G.S. controller ter-
. When the starting switch is turned to the minal 4. The controller instantaneously de-
ON position, the preheating pilot lamp lights tects the water temperature and determines
up, and the glow plug carries out preheating the length of time for lighting up the
while the lamp is lighted up. The water preheating pilot lamp and the preheating
temperature sensor detects the water tem- time for the glow plug.
perature and the preheating time is set by l Controller terminal 5 is connected to the
the controller. ground, and lights up the preheating pilot
. While the preheating pilot lamp is lighted lamp. At the same time, it sends a signal
up, preheating is being carried out, so keep from terminal 2 to the glow relay to actuate
the starting switch at the ON position. When the glow relay and make the glow plug red
the glow plug reaches a temperature which hot.
makes it possible to start the engine, the l When the preheating end signal is sent from
preheating pilot lamp goes out, so the en- the controller, the glow relay is turned OFF
gine can be started. Preheating is still car- and preheating is completed.
ried out during this time.
10-130
. The diagrams on the right show the actua- less than water temperature 60 “C
tion sequence. (Fig. 1, Fig. 2)
Fig. 1
ST
ST w.!%...._.__. ON
KEYSW ON_
OFF
LAMP :,$a
REALAY $
GLOW PLUG _ _ _ _ . : when starting

TEMP switch is left ON
More than water temperature 60 “C

Fig. 2
REALAY gpF
GLOW PLUG
TEMP
L
SLWOO973
. The diagrams on the right show lighting up Fig. 3

time Tl for the preheating lamp and
preheating/post heating time T2 according
to the water temperature. (Fig. 3, Fig. 4)
Ode- 50 60 70
water temperature (‘Cl
SLWOO974
Fig. 4
Q.G.S. CONTROLLER 1. Q.G.S. controller body

2. Lead wire
3. Connector
4’ 8
SKWO0976
Q.G.S. GLOW RELAY 1. Connector

2. Lead wire
3. Q.G.S. glow relay body
SKWO0977
Q.G.S. GLOW PLUG 1. Bi-material Q.G.S. glow plug

2. Resistor coil
3. Preheating coil
% When the preheater goes
above a fixed temperature,
the resistance of the resis-
tor increases to prevent the
temperature from rising any
further.
SKWO0978
Q.G.S. WATER TEMPERATURE SENSOR
1. Lead wire
2. Q.G.S. water temperature
sensor body
SKWO0979
1O-l 32
STRUCTURE AND FUNCTION AUTOMATIC AIR BLEED MECHANISM
AUTOMATIC AIR BLEED MECHANISM
- Flow of fuel
-c& Flow of air
SKW00980
z
Y 1. Overflow valve 6. Fuel injection pump
0* 2. Fuel filter 7. Priming pump
3. Nozzle holder 8. Feed pump
4. Nozzle 9. Gauze filter
5. Fuel tank
Outline
. After the machine has run out of fuel, it is
possible to bleed the air automatically sim-
ply by operating the starting switch.
. Turn the starting switch to the START posi-
tion, carry out cranking 2 or 3 times for 15 -
20 seconds each. The air passes through
overflow valve (I) and is automatically re-
leased inside the fuel tank.
1o-133
STRUCTURE AND FUNCTION ELECTRICAL TRANSMISSION CONTROL
ELECTRICAL TRANSMISSION CONTROL
Kick-down switch
ys (inside right console)
Transmission cut-off
selector switch
mission valve
SKWOO981
Function
Electrical control is used to actuate the transmission solenoid and

select the F, R, or N position.
If the directional lever is not at the N position, the engine will not start
even if the starting switch is turned to the START position. This is to
prevent any accident if the machine should start suddenly. (For de-
tails, see ENGINE STARTING CIRCUIT.)
When traveling in reverse, it lights up the backup lamp to warn people
c
in the surrounding area.
Electrical control is used to actuate the transmission solenoid and
4 Gear shift lever
select the speed range.
Transmission cut-off This is used to select between actuation and non actuation of the
5
selector switch transmission cut-off function.
6 Transmission cut-off When the left brake pedal is depressed, the transmission is returned to
switch neutral and the normal brake is actuated (transmission cut-off function)
To prevent seizure of the parking brake, the transmission is returned
7 Parking brake switch
to neutral when the parking brake is applied.
When traveling in F2, it is possible to operate the switch to shift down

to Fl without moving the gear shift lever. If the gear shift lever is
8 Kick-down switch
1
moved to the R or N position, the speed range is automatically re-
turned to the original 2nd position.
10-134
STRUCTURE AND FUNCTION COMBINATION SWITCH
COMBINATION SWITCH
9 4 67 5
I L II;] Id u
SKW00982
Outline
. The directional lever has three positions and body by three screws. When each lever is
the speed lever switch has four positions. As operated to the desired position, the switch,
an individual part, the switch does not have which is interconnected by a shaft, acts to
a detent mechanism; the detent mechanism allow electric current to flow to that circuit
is in the combination switch. Each switch is only.
positioned by two pins, and is secured to the
General locations, function
1 Directional lever switch Switches between F, R, and N

2 Speed lever switch Selects speed range
Stopper used to prevent speed lever from entering 3rd or 4th during
3 Speed lever stopper
operations
4 Turn signal indicators Direction indicator lamps used when turning left or right
Turn signal indicator lever automatically returns to central position
5 Self’cancel
after machines turns left or right
6 Lamp switch Switches on clearance lamp, head lamp, parking lamp, etc.
7 Dimmer switch Selects high beam for travel and low beam for passing
Makes both left and right turn signal indicator lamps flash at the
8 Hazard switch
same time
9 Emergency flashing pilot lamp Flashes at the same time as the emergency flashing lamp flashes
10-135
STRUCTURE AND FUNCTION TRANSMISSION CUT-OFF FUNCTION
TRANSMISSION CUT-OFF FUNCTION
Outline
. If the transmission cut-off selector switch on
the cluster gauge is turned ON (pilot lamp
lights up), the transmission cut-off switch
installed to the left brake pedal is actuated.
When the left brake is operated, the brake
is applied and the transmission is also shifted
to neutral at the same time.
. If the transmission cut-off selector switch is
turned OFF (pilot lamp goes out), the trans-
mission is not shifted to neutral and the left
brake operates in the same way as the right
brake.
Transmission solenoid
FORWARD REVERSE Kickdown Neutral Neutralizer

relay relay relay relay relay
Transmission cut-off
selector switch
Parking brake Transmission
switch cut-off switch
SKWOO983
Operation
1. Transmission cut-off selector switch ON
. If the transmission cut-off selector switch is . When the left brake pedal is depressed, the
turned ON, a voltage of +24V is applied to transmission cut-off switch is turned OFF,
the transmission F solenoid or R solenoid and the electric current to the FORWARD
through the transmission cut-off switch to relay or REVERSE relay is cut. As a result,
the neutralizer relay + FORWARD relay or the transmission is shifted to neutral in ad-
REVERSE relay. dition to the normal operation of the brake.
Electric current flows from the directional
lever to the FORWARD relay or REVERSE
relay, so the relay coil is excited and a cir-
cuit is formed.
lo-136
STRUCTURE AND FUNCTION TRANSMISSION CUT-OFF FUNCTION
G&down Neutral Neutralizer

relay relay
Parking brake Trans%sion

2. Transmission cut-off selector switch OFF

. If the transmission cut-off selector switch
is turned OFF, a voltage of +24V is applied
to the transmission F solenoid or R solenoid
from the transmission cut-off selector switch
+ neutralizer relay + FORWARD relay or
REVERSE relay. The transmission cut-off
switch does not form part of this circuit.
. If the left brake pedal is depressed, the trans-
mission is not shifted to neutral. The brake
is simply applied as a normal brake.
1o-1 37
STRUCTURE AND FUNCTION PARKING BRAKE FUNCTION
PARKING BRAKE FUNCTION

Outline
. When the parking brake is applied, the trans-
mission is kept at neutral. This means that
even when the engine is run at full throttle,
there is no load on the parking brake, and
this prevents any dragging caused by mis-
taken operation.
Transmission solenoid
Directi
Parking brake Transmission

SKWOO985
Operation
. When the parking brake pedal is depressed,
the parking brake switch is turned ON, an
electric current flows from the neutralizer
relay coil to the parking brake switch +
ground, and the neutralizer relay coil is ex-
cited.
. As a result, the neutralizer relay is actuated,
so the circuit is cut. No electric current flows
to the FORWARD relay or REVERSE relay
and the transmission is placed in neutral.
lo-138
STRUCTURE AND FUNCTION KICK-DOWN SWITCH
KICK-DOWN SWITCH
1. Kick-down switch
2. Spring
3. Side cap
4. Wiring harness
SEW00303
KICK-DOWN SWITCH
Operation
l The kick-down (shifting down from 2nd +
1st) is actuated only when traveling in F2.
l When traveling in F2, if it is desired to shift
down to 1st without operating the speed
lever, operate the kick-down switch on the
boom lever to ON to shift down to Fl.
. After this, even if the kick-down switch is
pressed, the transmission is kept at Fl.
Cancellation (or not actuated)

. When directional lever is at N
. When directional lever is at R
. When speed lever is not at 2nd
. When starting switch is OFF
10-139
KICK-DOWN ELECTRICAL CIRCUIT

Normal operation
Battery
Direction al Gear shift
lever swii tch lever switch
kz F N
Parking brake switch

i
II 1 I
,
I,, ,
I In
Kick-dowl
switch
FORWARD REVERSE l$&down Neutralizer

relay relay zip’ relay SLWOO986
Directional lever operated to F Gear shift lever operated to 2nd

. When the directional lever is operated to the . When the gear shift lever is at the 2nd posi-
F position, current flows from battery @ + tion, no electric current flows to solenoids
directional lever switch terminals 1 - 2 + (2), (31, or (4). In this condition, the trans-
FORWARD relay terminals 5 - 6 + ground. mission valve is set to F2 by the action of
As a result, the FORWARD relay is actuated solenoid (1).
and terminals 1 and 2 and terminals 3 and 4 . If the kick-down switch is not pressed, no
are connected. electric current will flow to the kick-down
. Next, electric current flows from battery @ relay coil (relay terminals 5, 6). Therefore,
+ transmission cut-off switch + neutralizer the kick-down relay is not actuated and the
relay terminals 3 - 6 + FORWARD relay ter- transmission is held in F2.
minals 3 - 4 + solenoid (I) + ground, and Solenoid actuation table
solenoid (I) is actuated.
10-140
Kick-down switch operated

(During operation or during travel when gear
shift lever is at F2)
Batterv
Directional Gear shift
lever switch lever switch
To transmission
cut-off monitor
selector switch
ransmlsslon cu itch
itch
Kick-down
switch
-I Solenoids
35
8
FORWARD REVERSE KiCi;;down Neutral Neutralizer
relay relay relay relay SLW00987
Kickdown switch pushed to ON position

. When the kickdown switch is pushed, cur- and solenoid (4) is actuated. Solenoid (I) is
rent flows from battery @ + directional le- also being actuated, so the speed range is
ver switch terminal 1 + gear lever switch set to Fl.
terminal 6 + FORWARD relay terminals 1 - . In this way, if the kick-down switch is pressed
2 + kickdown switch -+ kickdown relay ter- when the gear shift lever is at F2, the gear is
minals 5 - 6 + ground. As a result, the shifted down to Fl. The self-hold function
kickdown relay is actuated and terminals 1 of the kick-down relay then keeps the trans-
and 2 and terminals 3 and 4 are connected. mission in Fl even if the kick-down switch
. A circuit is formed from gear shift lever is released or pressed several times.
switch terminal 6 + FORWARD relay termi-
nals 1 - 2 + kick-down relay terminals 1 - 2 Solenoid actuation table
+ terminals 5 - 6 + ground. From this
point, even if the kick-down switch is re-
turned, the kick-down relay continues to be
actuated (kick-down relay self-hold circuit).
. When the kick-down relay is actuated and
terminals 3 and 4 are connected, electric cur-
rent flows from battery @ -+ kick-down re-
lay terminals 3 - 4 + solenoid (4) + ground,
10-141
KICK-DOWN SWITCH ACTUATION

CANCELED (1)
(Directional lever at N or R)
Battery
Transmission cut-off switch
lamp
Kick-dowr
switch
r
To
backup
ouzzer
r
lamp
Solenoids
FORWARD REVERSE Neutral Neutralizer

relay relay relay relay SLWOO988
. If the directional lever is moved to the R . When the directional lever is moved to the
position, the contacts of terminal F are turned R position, electric current flows from bat-
OFF, so the current flowing from FORWARD tery @ + directional lever switch terminals
relay terminals 5 - 6 --+ ground stops flow- 1 - 4 + REVERSE relay terminals 5 - 6 +
ing, the FORWARD relay is reset, and FOR- ground, so REVERSE relay terminals 1 and
WARD relay terminals 1 and 2, and termi- 2, and terminals 3 and 4 are connected, and
nals 3 and 4 separate. solenoid (2) is actuated.
. When FORWARD relay terminals 1 and 2 l Therefore, there is no electric current flow-
separate, the electric current stops flowing ing to solenoids 1, 3, or 4, so the transmis-
from kick-down relay terminals 1 - 2 -+ ter- sion is set to R2, the position of the gear
minals 5 - 6 + ground, the kick-down relay shift lever.
is reset, and the self-hold circuit is canceled. Solenoid actuation table
(The self-hold circuit is also canceled at the
N position.)
. When the kick-down relay is reset, the elec-
tric current flowing from kick-down relay ter-
minal 3 - 4 + solenoid (4) + ground stops
flowing and the actuation of solenoid (4) is
canceled.
lo-142

CANCELED (2)
(Gear shift lever at position other than 2nd)
tiaaery
To transmission
cut-off monitor
Transmission cut-
l--l -
/p&king
i / /
414, , , , I monitor
i ‘lamp I II I I
I
Parking braGwitch
I Solenoids
Illiii IllIll
,,,,,I
IIIIII III1 III
%
FeqaRyWAARDFe:aVyERSE Kick-down Neutral ~e~$alizer
relay relay SLWOO989
. If the gear shift lever is moved to any posi- . At the same time, kick-down terminals 3 - 4
tion other than 2nd, the current flowing from also separate, so the actuation of solenoid
gear shift lever relay terminal 6 + FORWARD (4) is canceled.
relay terminals 1 - 2 + kickdown relay ter- . If the gear shift lever is placed in 3rd, elec-
minals 1 - 2 + terminals 5 - 6 + ground tric current flows from gear shift lever switch
stops flowing, and kickdown relay terminals terminal 7 + solenoid (3) + ground, and
1 and 2, and terminals 3 and 4 separate. solenoid (3) is actuated. Solenoid (I) is be-
. When kick-down relay terminals 1 - 2 sepa- ing actuated, so the transmission is set to
rate, the self-hold circuit is canceled, and F3, the position of the gear shift lever.
the kick-down is not actuated even if the Solenoid actuation table
gear shift lever is moved again to F2.
10-143

CANCELED (3)
(Starting switch turned to OFF)
Battery
To transmission
cut-off monitor
10A
Transmission cut-
Kick-down
switch
111 x4
Solenoids
II IIII III I
FO;yWARD FC&RSE K2&down Neutral Neutral

relay relay sLw00990
l When the starting switch is turned to the

OFF position, the battery @ power source is
cut off by the battery relay, and the kick-
down self-hold circuit is canceled.
l When the starting switch is at the OFF posi-
tion, the kick-down switch is not actuated
even if the kick-down switch is pressed ON.
10-144
20 TESTING AND ADJUSTING
Standard value table for engine.. ............... 20- 2 Measuring steering oil pressure.. ............ .20- 31
Standard value table for chassis ................ 20- 3 Measuring operating force,
Tools for testing, adjusting, travel of brake pedal .......................... .20- 33
and troubleshooting .............................. 20- 7 Testing and adjusting brake pedal
Adjusting valve clearance ........................... 20- 9 linkage ................................................... 20- 34
Measuring compression pressure .............. 20-10 Measuring brake performance.. ............... .20- 36
Testing and adjusting fuel injection Measuring brake oil pressure .................. .20- 37
timing ...................................................... 20-l 1 Testing for brake disc wear ..................... .20- 38
Measuring exhaust color.. ........................... 20-12 Bleeding air from brake system .............. .20- 39
Measuring blow-by pressure ...................... 20-13 Measuring parking brake performance ... 20- 40
Measuring intake air pressure Testing and adjusting parking
(boost pressure) ..................................... 20-14 brake linkage ....................................... .20- 41
Measuring engine oil pressure ................... 20-15 Testing parking brake disc wear ............. .20- 42
Testing and adjusting fan belt tension.. .... 20-15 Measuring parking brake disc wear ........ 20- 43
Measuring engine speed ............................. 20-16 Measuring work equipment
Method for adjusting engine control lever ......................................... 20- 44
stop motor cable.. .................................. 20-17 Measuring stroke of work equipment
: Measuring accelerator pedal.. ..................... 20-19 valve spool ........................................... 20- 47
z
0 Measuring operating force, Measuring work equipment
travel of speed lever.. ............................ 20-21 hydraulic pressure ............................. :.20- 48
Measuring stall speed ................................. 20-22 Measuring work equipment ..................... .20- 50
Measuring torque converter, Testing and adjusting bucket
transmission oil pressure ..................... 20-24 positioner.. ............................................ 20- 52
Method of operating emergency Testing and adjusting boom kick-out ..... 20- 53
manual spool ......................................... 20-26 TROUBLESHOOTING ................................ .20-101
Testing and adjusting steering wheel.. ..... .20-28
* When using the standard value table to make judgement for testing and adjusting, and trouble-
shooting, the following precautions are necessary.
1. The standard values in the table are the values for a new machine and are given as reference
values for the time when the machine is shipped from the factory. These values should be used as
a guide when estimating wear and tear after the machine is operated, and when carrying out
repairs.
2. The permissible values given in the table are values estimated based on the results of various tests
carried out on the machines shipped from the factory, so they should be used together with the
information on the repair condition and other information such as the operating history of the
machine when judging the condition of the machine.
3. These standard values do not form a basis for judging claims.
g When carrying out testing, adjusting, or troubleshooting, park the machine on level ground and
use the safety pins and blocks to prevent the machine from moving.
a When carrying out work together with other workers, always use signals and do not let unauthor-
ized people near the machine.
AWhen checking the water level, always wait for the water to cool down. If the radiator cap is
removed when the water is still hot, the water will spurt out and cause burns.
ABe careful not to get caught in the fan, fan belt, or other rotating parts.
20-l
0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE
Machine model WA180-3
Engine
I S6D95L-1
Measurement
Item Unit Standard value Permissible value
conditions
High idling 2,600 :r$r -
Engine speed Low idling rpm 775 -‘$ -
Rated speed 2,400 -
Intake resistance
At rated output nmHg Min. 500 400
(Boost pressure)
At sudden acceleration Bosch Max. 6.0 8.0

Exhaust gas color
At high idling index Max. 3.0 5.0
Intake valve 0.35 -

Valve clearance
mm
(cold) Exhaust valve 0.50 -
Oil temperature:
Compression pressure 40 - 60°C MPa Min. 2.7
(SAESO oil) (Engine speed: kg/cm? (Min. 28.0)
320 - 360 rpm)
At high idling
Blowby
(SAE30
pressure
oil)
(Water temperature: nmHn0 Max. 50 100 H
Operating range) 2
(Water temperature:
Operating range)
At high idling 0.34 - 0.69 0.25

(SAE30) (3.5 - 7.0) (2.5)
At low idling Min. 0.10 0.07
Oil pressure
(SAESO) (Min. 1.0) (0.7)
At high idling 0.29 - 0.69 0.21
(SAEIOW) (3.0 - 7.0) (2.1)
At low idling Min. 0.08 0.07
(SAEI OW) (Min. 0.8) (0.7)
OC I
Whole speed range
Oil temperature 80 - 110 120
(inside oil pan)
0
Fuel injection timing Before top dead center 22 f 1 22 f 1

deareel
Deflection when
pressed with finger
force of approx. 8 6- 10
Fan belt tension mm
58.8 N (6 kg)
Alternator pulley
- Fan pulley)
20-2
0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS
Cate-
Item Measurement conditions
gory
Engine water temperature
Torque converter stall
gauge: white range
Torque converter oil
Hydraulic stall 2,500 f 100 2,500 ? 200
temperature: 60 - 80°C rpm
I
Hydraulic oil temperature:
Full stall 1,700 rt 200 1,700 f 300
45 - 55°C
49 - 98 147
Operating force (5 - IO) (15)
a1 48 + 3 -
Oper,ating angle deg.
a2 32 ? 2 -
Stopper height mm 45 + 5 -
Operating
force
N - FORWARD
+49 +0.5 13.7

5.9-2:g (0.6-0.3 1 (1.4)
. Engine speed: Low idling
. Torque converter oil 13.7
temperature: 60 - 80°C (kgNm) 5.9$: (0.6$::) (1.4)
+4.9 +0.5 13.7
5.9-2.9 (O.6-0.3 1 (1.4)
40+ IO 40 + 20
mm 40f 10 40 * 20
3rd + 4th 40+ IO 40 f 20
2.3 * 0.2 2.3 + 0.2

Priority valve pressure / (23 * 2) (23 f 2)
1.0 + 0.1
MPa (IO + I) l.o$r::(lo~; 1
kg/cm? 2.3 k 0.2
(23 + 2) 2.3$,‘; (23 4 )
0.38 + 0.05 0.38 f 0.10
port pressure (3.9 f 0.5) (3.9 f 1.0)
l Engine speed: Low idling
Play l Machine facing straight to mm 20 * 20 o- 120
front
8.8 - 11.8 Max. 21.6
Operating force . Flat, horizontal, straight, dry (0.9 - 1.2) (Max. 2.2)
paved road surface
Operating
time
Low idling
High idling
. Hydraulic
l
oil temperature:
45 - 55°C
Engine speed: Low idling
Sec. )
l Engine speed: High idling
MPa 18.6 ? 0.69
Relief pressure l Hydraulic oil temperature:
kg/cm? (190 + 7)
45 - 55°C
20-3
0
Cats Standard Permissible

Item Measurement conditions Unit
gor! value value
206
Operating force l Engine speed: Low idling -
l Engine water temperature (21)
gauge:,white range
a2 18.5 f 4 18.5:;
Operating angle - deg.
0.1 48
s * Flat, horizontal, straight, dry

E paved road surface
m
l Speed when applying brake:
20 km/h, braking delay:
Performance 0.1 set m Max. 4.0 Max. 5.0
. Brake pedal operating force:
294 N (30 kg)
* Tire inflation pressure:
Specified pressure
Drop in hydraulic l 4.1 MPa (42 kg/cm*) MPa Max. 0.34 Max. 0.34
pressure in 5 minutes kg/cm21 (Max. 3.5) (Max. 3.5)
Wear of disc l Thickness of disc mm 1.08 + 0.06 Min. 0.7
l Tire inflation pressure:

Specified
Flat paved road with l/5
pressure
E-
Performance
l
(I 1’20’) grade Stopped - z

0
l Dry road surface
Machine at operating
condition
Piston stroke (XI mm 1.85 f 0.28 Min. 3.5
l Parking brake ON: a ’

l Parking brake OFF: b
*X=a-b
Max. 29.4 Max. 44.1
HOLD + RAISE (Max. 3.0) (Max. 4.5)
Max. 27.5 Max. 44.1
RAISE + HOLD (Max. 2.8) (Max. 4.5)
Max. 29.4 Max. 44.1
HOLD -+LOWEI * Engine speed: Low idling (Max. 3.0) (Max. 4.5)
Boom p Hydraulic oil temperature:
LOWER+HOL[ 45 - 55°C - -
Max. 46.1 Max. 66.7
LOWER-FLOA (Max. 4.7) (Max. 6.8)
I FLOAT + HOLC
Max. 27.5
(Max. 2.8)
Max. 44.1
(Max. 4.5)
20-4
0
Cate
Item Measurement conditions
gory I
HOLD +DUMP
Bucket HOLD +TILT
TILT -+HOLD
HOLD-+ RAISE l Engine speed: Low idling

l Hydraulic oil temperature:
Boom HOLDtLOWER 45 - 55°C
i HOLD + FLOAT
HOLD+DUMP
Bucket

Relief pressure 45 - 55°C
l Engine speed: High idling
HOLD-RAISE
Boom
Hydraulic oil temperature:

45 - 55°C
Bucket
HOLD *DUMP
~ j Boom lifting time 1
Hydraulic
oil temperature:
45 - 55°C
Engine speed: High idling
WGi Steering valve: Neutral
?5 At full :
0 Bucket No load
stroke
: tilting
Bucket
time
horizontal
EL Retraction of boom 45 - 55OC
mm
Max. 17 Max. 25
3-7 -
positioner switch
l Hydraulic oil temperature: mm
Clearance of boom 45 - 55°C -
3-7
kick-out switch
20-5
0
TESTING AND ADJUSTING TOOLS FOR TESTING. ADJUSTING. AND TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
Check or measurement item Symbol1 Part No. Part Name I Remarks
II
Digital display
1 799-203-8001 Multi-tachometer L : 60 - 2,000 rpm
Engine speed A H: 60 - 19,999 rpm
1 2 16142-82-5112 1Adapter I
Coolant, oil temperatures B 1799-101-1502 / Digital temperature gauge -99.9 - 1299C
Oil pressure
~ 3 wi Adapter
I
I
-
-
1 795-502-I 590 Compression gauge 0 - 6.9 MPa (0 - 70 kg/cm*)
Kit Part No. 795-502-1205
Compression pressure D
2 795-502-I 370 Adapter -
I-i -]7&oml ITool I

2 799-201-1541 Gauge
8 E 3 799-201-1571 Tube Kit Part No.
r- Blowby pressure
799-201-1504
2 4 799-201-1411 Adapter
5 799-201-1460 Plug
Commercially Feeler gauge

Valve clearance F
available
Discoloration 0 - 70 % (with
standard color)
1 799-201-9000 Handy smoke checker (l$se;loration % x l/IO k Bosch
Exhaust color G
Commercially -
Smoke meter
2 available
intake air pressure H 799-401-2310 Pressure gauge 1,500 mmHg
Troubleshooting of wiring -
I 799-601-7400 T-adapter
harnesses and sensors
20-7
0
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
-
Tools for testing, adjusting, K L 0
and troubleshooting - -
G
:
s
%
c
Fii
?iJ
2
.o
7
aJ i.!
m u
Cz I’
, -
1 Measuring accelerator pedal 0
- -
-0
2 Measuring gear shift lever
-
31M easuring stall speed
-
4 Measuring torque converter,
0
transmission oil pressure
-
51 Measuring steering wheel play 0
-
8 Measuring steering oil pressure c

-
9 Measuring brake pedal 0
5
-
-
Bleeding air from brake system
-
13 / Wear of parking brake disc
-
14 Measuring work equipment control lever
-
15 Measuring main control valve spool
16 Measuring work equipment oil pressure 0

-
17 1 M easuring work equipment
-
18 Hydraulic drift of work equipment
-
19 Testing bucket positioner
-
20 Testing boom kick-out
-
20-8
TESTING AND ADJUSTING ADJSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE
. Remove engine hood assembly.

1. Remove muffler assembly (I), then remove head
cover.
2. Rotate the crankshaft in the normal direction to

align pointer (2) with the “1.6” TOP mark on the
crankshaft pulley. When rotating, check the
movement of the valves.
When the pointer is in line with the “1.6” TOP
mark, No. 1 cylinder is at compression top dead
center.
3. When No. 1 cylinder is at compression top dead

center, adjust the valves marked l .
When No. 6 cylinder is at compression top dead
center, adjust the valves marked o.
1Winder No. 1 I 1 2 1 3 1 4 1 5 1 6 1
= Intake valve 0 0 0 0 0 0
8
Exhaust valve l 0 0 0 0 0
4. To adjust, insert tool F between rocker lever (3)

?J and valve stem (4) and turn adjustment screw
(5) until the clearance is a sliding fit. Then tighten
2
locknut (6) to hold adjustment screw in position.
w Locknut: 44.1 f 4.9 Nm (4.5 * 0.5 kgm)
5. Next, rotate crankshaft one turn in the normal

direction and adjust the valve clearance of the
remaining valves marked o.
* After adjusting No. 1 cylinder at compres-
sion top dead center, it is also possible to
turn the crankshaft 120” each time and ad-
just the valve clearance of each cylinder ac-
cording to the firing order.
. Firing order: 1 - 5 - 3 - 6 - 2 - 4
TEW00734
* After tightening the locknut, check the valve
clearance once again.
4 3 5 6
20-9
0
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
PRESSURE
* If performance tests or troubleshooting shows

that the piston, piston ring or cylinder liner may
be worn, measure the compression pressure.
g When measuring the compression pressure, be

careful not to touch the exhaust manifold or
muffler, or to get caught in rotating parts.
1. Adjust valve clearance.

j, For details, see ADJUSTING VALVE CLEAR-
ANCE.
2. Warm up engine (oil temperature 40 - 60°C).
3. Remove nozzle holder assembly (I).

* For details, see REMOVAL OF NOZZLE
HOLDER ASSEMBLY.
4. Install adapter D2 in mount of nozzle holder as-

sembly, and connect pressure gauge Dl.
5. Set engine tachometer A in position.

TEW00736
6. Disconnect connector of stop motor, set to the

NO INJECTION position, then crank the engine
with the starting motor and measure the com-
pression pressure at the point where the pres-
sure gauge indicator remains steady.
t 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.
* Installing the nozzle holder assembly after meas-

TEW00737
uring the compression pressure, for details, see
INSTALLATION OF NOZZLE HOLDER ASSEM-
BLY.
20-10
0
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING

FUEL INJECTION TIMING
TESTING FUEL INJECTION TIMING
1. Disconnect fuel injection pipe (I) of No. 1 cylin-

der.
2. Remove delivery valve holder (2), then remove

delivery valve (3) and spring (4), and install de-
livery valve holder (2) again.
TEW00738
w Delivery valve holder: 42.2 + 2.9 Nm
(4.3 + 0.3 kgm)
3. Place accelerator pedal at FULL position.
4. Operate priming pump and rotate crankshaft

slowly in normal direction. Check point where
fuel stops flowing from delivery valve holder
(2).
5. Check that 16” I.J. line on crankshaft pulley and

pointer (6) are aligned at point where fuel stops
flowing.
* BEYOND injection timing line:
:
Timing RETARDED
% * BEFORE injection timing line:
Timing ADVANCED
ADJUSTING FUEL INJECTION TIMING
* If the test shows that fuel injection timing is

incorrect, adjust as follows.
1. Loosen nut (7), (8) on the injection pump mount-

ing bolt. (inside, outside each 2 bolts)
2. Move injection pump towards OUTSIDE to RE-

TARD timing.
TEW01029
Move injection pump towards CYLINDER BLOCK
to ADVANCE timing.
TEW00740
20-11
0
TESTING AND ADJUSTING MEASURING EXHAUST COLOR
MEASURING EXHAUST COLOR
t When measuring in the field when there is no

air or power supply, use smoker the checker;
when recording official data, use the smoke
meter.
Measuring with handy smoke checker Gl
Gl
a When measuring the exhaust gas color, be care-
ful not to touch the exhaust pipe or any other
high temperature part.
TBWO0715
* Warm up the engine (oil temperature: 60°C) be-
fore measuring the exhaust gas color.
1) Fit filter paper in tool GI.
2) Insert the exhaust gas intake port into the
exhaust pipe, accelerate the engine suddenly,
and at the same time operate the handle to
catch the exhaust gas on the filter paper.
3) Remove the filter paper and compare it with
the scale provided to judge the condition.
Measuring with smoke meter G2
When measuring the exhaust gas color, be care-

a
ful not to touch the exhaust pipe or any other !!zzzsd/j 8
I-
high temperature part.

TEW00021
s
0
* Warm up the engine (oil temperature: 60°C) be-

fore measuring the exhaust gas color.
1) Insert the probe into the outlet port of the
exhaust pipe, then tighten the clip to secure
it to the exhaust pipe.
2) Connect the probe hose, accelerator switch
plug, and air hose to tool G2.
* The pressure of the air supply should be
less than 1.5 MPa (15 kg/cm*).
3) Connect the power cord to the ACIOOV out-
let.
Ir When connecting the cord, check first
I TBWOO500
that the power switch is OFF.
4) Loosen the cap nut of the suction pump,
then fit the filter paper.
* Fit the filter paper securely so that the
exhaust gas does not leak.
5) Turn the power switch.
6) Accelerate the engine suddenly, and at the
same time, depress the accelerator pedal and
operate the relief valve to catch the exhaust
gas color on the filter paper.
7) Lay the filter paper used to catch the ex-
haust gas color on top of unused filter pa-
pers (IO sheets or more) inside the filter pa-
per holder, and read the indicated value.
20-12
0
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY PRESSURE
. Remove the engine hood.

1. Procedure for measuring blow-by
. Warm up the enginethoroughly so that the
water temperature is in the white range on
the engine water temperature gauge.
. Stop the engine, remove muffler (I), then
remove the head cover.
. Set tool E5 to air vent tube (2) at three places.
. Install the head cover, then install muffler
(I).
1) Assemble tool E4 to tool El, then set blow-
by hose (3) to the tip.
2) Connect tool E2 and tool El with tool E3.
3) Run the engine at high idling, and measure
the blow-by pressure.
* After measuring the blow-by, remove the
blind plug from the air vent tube.
2. Precautions when measuring blow-by

* The blow-by should be measured with the
engine running at rated output.
l When measuring in the field, a similar value
.
can be obtained at stall speed.
If it is impossible to check at rated output or zqjnl-pq
n
F stall speed, measure at high idling. In this
Q GP TEW00741
z case, the blow-by value will be about 80% of
the value at rated output.
* Blow-by varies greatly according to the con-
E5
dition of the engine. Therefore, if the blow-
I \
by value is considered abnormal, check for
problems connected with defective blow-by,
such as excessive oil consumption, defec-
tive exhaust gas color, and prematurely dirty
or deteriorated oil.
TEW00742 TEW00743
E2
uyf$::
TBW00714
20-13
TESTING AND ADJUSTING MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
MEASURING INTAKE AIR

PRESSURE (BOOST PRESSURE)
AWhen removing or installing the measuring
equipment, be careful not to touch any high
temperature parts.
1. Remove intake air pressure measurement plug

(I) (PT l/8) and install coupler of oil pressure
gauge kit C.
2. Connect oil pressure measurement hose to cou-

pler and pressure gauge H (1500 mmHg).
A When
careful
carrying out the measurement,
not to touch any high temperature
be
parts or rotating parts.
Note:
Run the engine at a mid-range speed or above,
and use the self-seal portion of the gauge to
bleed the oil from inside the hose.
. Insert the gauge about half way, and repeat-
edly open the self-seal portion to bleed the
oil.
* The gauge does not work if there is any oil

inside the hose, so always be sure to bleed
all the oil.
3. Run the engine at the rated speed and measure

the pressure indicated by the gauge.
20-14
0
MEASURING ENGINE OIL PRESSURE
TESTING AND ADJUSTING TESTING AND ADJUSTING FAN BELT TENSION
MEASURING ENGINE OIL

PRESSURE
A When measuring, be careful not to let your

clothes get caught in any rotating part.
* Always stop the engine before removing or in-

stalling any oil pressure sensor or oil pressure
gauge.
* When measuring the oil pressure, always meas-
ure at the specified oil temperature.
TEW00746
1. Remove oil pressure sensor (I).
2. Install tool C2 (gauge: 0.98 MPa (IO kg/cm2)).
8mm
3. Start the engine and measure the oil pressure.
Fan
FAN BELT TENSION
Testing the fan belt tension

1. Apply a force of approximately 98N (IOkg) to
E? the fan belt midway between the fan pulley and
b
alternator pulley and check its deflection. TEW00747
G
0
Adjusting the fan belt tension

1. Loosen the alternator assembly installation bolt
(I) and belt tension adjustment bolt (2).
2. Move the alternator using a pipe, etc., check the
belts (3) tension, then first tighten the adjust-
ment nut, then the alternator installation bolt.
20-15
0
TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE SPEED
AWhen removing or installing the measuring

equipment, be careful not to touch any high
temperature parts.
* Measure the engine speed under the following

conditions.
I) Coolant temperature: Within operating range
2) Torque converter oil temperature : 60 - 80°C
3) Hydraulic oil temperature : 45 - 55°C
1. Remove cap (I) from speed pick-up port, then

install adapter A2 of tachometer Al.
2. Connect tachometer Al and the adapter A2 with

the cable.
g When carrying out the measurement, be

careful not to touch any high temperature
parts or rotating parts.
3. Start the engine, and measure the engine speed

when the engine is at low idling and high idling.
TEW00750
/ ’ TEW00751
20-l 6
0
TESTING AND ADJUSTING METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE
METHOD FOR ADJUSTING

ENGINE STOP MOTOR CABLE
1 5 2 3
; TEW00752
1. Temporarily install ball joint (2) to cable (I) of

engine stop motor (6) (screw in fully, then turn
back approx. l/2 turns), then install the ball joint
to the stop lever (3) of the injection pump.
2. Pull stop lever (3) of the injection pump by hand

to the engine stop position (no injection of fuel),
and temporarily assemble the cable (I) to the
bracket.
When this is done, secure the cable at a point
where stop lever (3) contacts engine STOP stop-
per (41, and temporarily assemble to the bracket TEW00753
with locknuts (5).

* Engine stop motor (6) is at the engine STOP
position with cable (I) pulled.
t Stop lever (3) of the fuel injection pump is at
the RUN position when the lever is free (it is
pulled by a spring to the RUN side).
3. Adjust stop lever (3) of the injection pump and

STOP stopper (4) at the stop end so that clear-
ance “a” is 1 - 2 mm.
Adjust with nuts (5) which secures the cable to
the bracket or carry out fine adjustment by
changing the depth that ball joint (2) is screwed
in.
20-17
0
TESTING AND ADJUSTING METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE
4. Tighten all nuts and bolts. * Problems caused by improper adjustment

of engine stop motor cable
5. Turn the engine starting switch repeatedly
to the ON and OFF positions, and check that
the engine stop motor and cable work
smoothly, then carry out the following checks
again.
1) Check visually that there is slack in the

engine stop motor cable when the en- lever and RUN stopper
gine is running, and that the stop lever
of the fuel injection pump has returned
fully to the RUN position.
2) Check that the clearance between the

stop lever (3) and stopper at the STOP
end is 1 - 2 mm when the engine is
stopped.
* With the engine stop motor, there are

built-in limit switches at both ends of
the cable stroke.
* Engine stop motor stroke: 35 mm

Fuel injection pump stop lever stroke:
30 mm
sr When the engine is running, there is slack

in the engine stop motor cable, and the
RUN position is maintained by the ac-
tion of a spring (this is frequently built
into the fuel injection pump).
* There is a loose spring inside the engine

stop motor, and this absorbs the error in
the stop motor when the engine is
stopped.
However, if this is absorbed by the loose
spring in the engine stop motor, force is
brought to bear on the injection pump,
so depending on the machine model, this
system may not be possible to use.
With such models, there is a danger of
problems arising with the injection pump
if the clearance between the stop lever
and the stopper at the STOP end is set
to 0 when the engine is stopped.
20-18
0
TESTING AND ADJUSTING MEASURING ACCELERATOR PEDAL
MEASURING ACCELERATOR
PEDAL
OPERATING FORCE OF ACCELERATOR PEDAL
1. Measuring
1) Set push-pull scale @ at a position 150 mm
from pedal fulcrum “a”.
* Put the center of push-pull scale @ in
contact with a point 150 mm from the
pedal fulcrum.
TEW00754
2) Start the engine, then measure the maxi-
mum value when the pedal is moved from
the pushed position (low idling) to the end
of its travel (high idling).
2. Testing
1) Stop the engine.
2) Disconnect the cable (I) at the bottom of the
accelerator pedal, and check that the plate
(2) and ball joint (3) at the bottom of the
pedal move smoothly.
* Carry out the above inspection, and adjust
or replace parts if necessary. Then carry out
the measurement of the operating force
again to check that it is within the standard
value.
TEW00755
TESTING AND ADJUSTING MEASURING ACCELERATOR PEDAL
OPERATING ANGLE OF ACCELERATOR PEDAL
1. Measuring
1) Stop the engine.
2) Put angle gauge 0 in contact with the accel-

erator pedal, and measure operating angle
a (a = al - a~) when the pedal is operated
from low idling position al to high idling
position oz.
TEW00757
2. Adjusting
1) Open the inspection cover of the engine
hood.
2) Set accelerator pedal (I) to the FREE condi-
tion (lever (2) in contact with U-bolt (3)), ad-
just cable (5) so that governor lever (4) is at
the low idling position, then tighten nuts (6)
and (7).
m Locknuts (61, (7): 46.6 + 12.3 Nm
(4.75 + 1.25 kgm)
m Locknut (9): 3.9 k 1.0 Nm TEW00758
(0.4 & 0.1 kgm)

m Mounting nut (IO): 13.2 + 1.5 Nm
(1.35 + 0.15 kgm)
10
Low idling TEW00761
3) Keep accelerator pedal (I) depressed, then

adjust stopper bolt (8) so that governor le-
ver (4) is at the high idling position.
* Screw in ball joint (3) at least 8 mm.
20-20
0
TESTING AND ADJUSTING MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER
MEASURING OPERATING
FORCE, TRAVEL OF SPEED
LEVER
Ir Measurement conditions
. Torque converter oil temperature: 60 - 80°C
A Block the tires securely.
OPERATING FORCE OF SPEED LEVER
1. Stop the engine.
2. Install push-pull scale @ or a spring balance to

the center of the control lever knob, and meas-
ure the operating force when the lever is pulled
in the direction of operation.
t Carry out the measurement for each speed
range.
z2
b
5
TRAVEL OF SPEED LEVER
1. Stop the engine.
2. Make mark “a” at the center of the control lever

knob, and measure the travel when the lever is
operated in the direction of operation.
TEW00764
20-21
0
TESTING AND ADJUSTING MEASURING STALL SPEED
MEASURING STALL SPEED
* Measurement conditions
. Engine water temperature: Within white range
on engine water temperature gauge
. Hydraulic oil temperature: 45 - 55°C
Engine speed: High idling
Torque converter oil temperature: 60 - 80°C
g Apply the parking brake and put blocks under
the tires.
AL When measuring each stall speed, be careful
not to touch any rotating part or high tempera-
ture part.
Check that low idling and high idling are the
standard values.
Before measuring each stall speed, remove
cover (I) from the speed pickup port, install
adapter @ of tachometer @, then connect
tachometer @ and the adapter with a cable.
Check that the engine speed is the standard
value. If it is not within the standard range,
check for loose linkage or play.
I TEW00766
TORQUE CONVERTER STALL SPEED

* Before starting the operation, check that there
are blocks under the tires, then release the park-
ing brake.
1. Start the engine and run at low idling.
2. Place directional lever (4) at FORWARD or RE-

VERSE, and set speed lever (3) to the highest
position.
TEW00767
3. Use the brakes to stop the machine, then meas-
ure the speed when the engine is run at high
idling.
* Turn transmission cut-off selector switch (2)
OFF and use the left brake.
(Check that the pilot lamp goes out.)
* Do not keep the stall condition for more than
20 seconds. Make sure that the torque con-
verter oil temperature does not exceed 120°C.
TEW00766
20-22
0
TESTING AND ADJUSTING MEASURING STALL SPEED
HYDRAULIC STALL SPEED
Start the engine and run at high idling.
Operate the bucket or boom lever (4), set the

cylinder to the stroke end, and activate the work
equipment valve relief valve.
Use multi-tachometer to measure the engine

Ir Do not keep the stall condition for more than
20 seconds. Operate the control lever quickly.
TEW00769
FULL STALL SPEED
. Measure the engine speed when the torque con-

verter stall and hydraulic stall are both carried
out at the same time.
* Before measuring the full stall, check that
the torque converter stall and hydraulic stall
speeds are normal.
If either of the stall speeds are abnormal,
correct the problem and measure again.
20-23
0
MEASURING TORQUE CONVERTER,
TESTING AND ADJUSTING TRANSMISSION OIL PRESSURE
MEASURING TORQUE
CONVERTER, TRANSMISSION
OIL PRESSURE

Torque converter oil temperature: 60 - 80°C
e Apply the parking brake and put blocks under

the tires.
Preparatory work
* The following preparatory work is necessary

when measuring all oil pressures.
* Before starting the operation, check that there
are blocks under the tires, then release the park-
ing brake.
. Remove cover (I) on the left side of the rear
frame.
. Turn transmission cut-off selector switch (2)
OFF and use the left brake.
.(Check that the pilot lamp is OFF.)
. Remove the plug from the measurement port K
2’ I \ I TEW00768
of the transmission valve.
. Install hydraulic tester kit 0 to the measure-
ment port, extend the gauge to the opera-
tor’s compartment, then start the engine and
measure the pressure.
* Check that no oil is leaking from any connec-
tion.
* After removing the measurement plug, always

coat the plug with adhesive.
& plug: Sealing agent (LG-1)
TEW00771
l-l Sealing agent coating part

/
TBW00435
20-24
0
MEASURING TORQUE CONVERTER,
TESTING AND ADJUSTING TRANSMISSION OIL PRESSURE
1. Measuring pilot pressure

I) Measurement port: 1
2) Start the engine and measure the pressure
at high idling.
2. Measuring priority pressure

at high idling.
3. Measuring all clutch pressures

at high idling.
4. Measuring torque converter outlet port

pressure
at torque converter stall.
i-3 2 TEWOO772
-
5. Adjusting modulating time
Turn screw (A) to make the modulating time
shorter or longer.
I) TIGHTEN screw to give PATTERN 1).
2) LOOSEN screw to give PATTERN 2).
4 l/2 turns
TEW00773
Time + TEW0077b
* The standard length is 6.75 mm (return fully,

then screw in 4 l/2 turns).
* Do not adjust excessively. After adjusting,
always check that there is no abnormality in
the pressure.
* Keep the range of adjustment to within +I
turn.
20-25
0
TESTING AND ADJUSTING METHOD OF OPERATING EMERGENCY MANUAL SPOOL
METHOD OF OPERATING
EMERGENCY MANUAL SPOOL
Outline
The transmission valve is controlled electrically, but

if there should be any failure in the electrical sys-
tem, or if there is any failure in the solenoid valve
or spool and the machine cannot move, it is possi-
ble to operate the emergency manual spool to move
the machine.
AThis operation of the spool is designed only for

use if the machine cannot be moved because of
a failure in the transmission control, and it is
necessary to move the machine from a danger-
ous working area to a safe place where repairs
can be carried out.
This spool must not be operated except when
there has been a failure.
a When carrying out this operation, keep strictly

to the order of operation and pay careful atten-
tion to safety when moving the machine.
A To prevent the machine from moving, lower the

bucket to the ground, apply the parking brake, TEW00775
and put blocks under the tires.
AAlways stop the engine before operating the

spool.
1. Remove cover (I) from the left side of the rear

frame.
2. Remove lock plate (2) from emergency manual

spool (3) of the transmission valve.
Ir The lock plate can be removed simply by
loosening the mounting bolts.
3. Operate emergency spool (3) to the operating

position according to the direction of movement
of the machine (forward or reverse).
. FORWARD: Push in the spool until it enters
the detent.
“a” = Approx. 8 mm
. REVERSE: Pull the spool until it enters the

detent.
“b” = Approx. 8 mm
TEW00777
20-26
0
TESTING AND ADJUSTING METHOD OF OPERATING EMERGENCY MANUAL SPOOL
Check that the area around the machine is safe,

then remove the blocks from under the tires.
Sit in the operator’s seat and depress the left

brake pedal (4) fully.
Start the engine, then release the parking brake

and slowly let the brake pedal out to start the
machine.
A When the engine is started, the transmission is

also engaged and the machine will start, so al- TEW00778
ways check carefully that the area around the
machine and in the direction of travel is safe,
and keep the brake pedal depressed fully when
starting the engine.
7. After moving the machine, stop the engine, then

apply the parking brake and put blocks under
the tires.
8. Return the manual spool to the neutral position

and install the lock plate.
20-27
.o
TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING WHEEL

STEERING WHEEL
Measuring steering wheel play

. Engine: Stopped.
. Vehicle posture: Facing straight
Measuring procedure
1. Turn the steering wheel lightly clockwise and
counterclockwise two or three times to check
that the steering mechanism is in neutral, then
put a mark “a” on the outer frame of the vehicle
monitor.
2. Turn the steering wheel lightly clockwise, align

the position where it stops with mark “a”, and
place mark “b” on the steering wheel.
3. Turn the steering wheel lightly counterclockwise,

align the position where it stops with mark “a”,
and place mark “c” on the steering wheel. Meas-
ure the straight distance “d” between mark “c”
and the position marked in step 2.
20-28
0
MEASURING OPERATING FORCE OF

STEERING WHEEL
+ Measurement conditions
. Road surface: Flat, horizontal, dry paved surface

. Tire inflation pressure: Specified pressure
. Engine speed: Low idling (bucket empty)
Measurement method
1. Install push-pull scale @ to the steering wheel

knob.
2. Start the engine.

* After starting the engine, raise the bucket
approx. 400 mm and remove the safety bar.
3. Pull push-pull scale @ in the tangential direc-

tion and measure the value when the steering
wheel moves smoothly.
P7 * Avoid measuring when the steering wheel
g starts to move. TEW00780
s
0
20-29
0
MEASURING OPERATING TIME FOR

STEERING WHEEL

. Engine speed: Low and high idling
/ \- TEW00781
Measurement method

* After starting the engine, raise the bucket
approx. 400 mm and remove the safety bar.
2. Operate the steering wheel (I) to the end of its

stroke to turn the machine to the left or right.
3. Measure the time taken to operate the steering

wheel to the end of the stroke to the right (left).
* Operate the steering wheel as quickly as
possible without using force.
* Carry out the measurements both at low
idling and high idling, and to both the left
and right.
20-30
0
TESTING AND ADJUSTING MEASURING STEERING OIL PRESSURE
MEASURING STEERING OIL

PRESSURE
. Hydraulic oil: 45 - 55°C

. Engine speed: High idling
METHOD OF MEASURING MAIN RELIEF PRESSURE
A Loosen the oil filler cap to release the pressure

inside the hydraulic tank, then turn the steering I 1' TEW00782
wheel several times to release the remaining

pressure inside the piping.
1. Apply safety bar (1) to the frame.
2. Remove cover (3) at the bottom right of floor

frame (2).
3. Remove measurement plug (4) for the right turn

steering circuit.
4. Install hydraulic tester kit @ to the measure-

ment port.
!
z 5. Start the engine, run the engine at high idling,
then turn the steering wheel to the right and
measure the pressure when the relief valve is
4
actuated.
-f To measure the pressure when turning the
steering wheel to the left, remove the plug
(5) for the left turn steering circuit. -
--;
&
YI--
TEW00784
TESTING AND ADJUSTING MEASURING STEERING OIL PRESSURE
Adjusting
Ah Always stop the engine before adjusting the oil

pressure.
1. Stop the engine.
2. Remove hose (2) and union (3) from port T of

priority valve (I ).
3. Remove double screw (4).

1 ----k?k ’ TEW00787
4. Turn adjustment screw (5) to adjust.

Pressure adjustment for one turn of adjust-
ment screw: Approx. 6.9 MPa (70 kg/cmz)
Turn the adjustment screw to adjust the set
pressure as follows.
TIGHTEN screw to RAISE pressure
LOOSEN screw to LOWER pressure
Tool @ for turning adjustment screw: Size 7/
32 inch, hexagon wrench
If the relief pressure cannot be measured
accurately, do not try to adjust the pressure.
m Adjustment screw (5): 4.5 If: 2.3 Nm

(0.46 f 0.23 kgm) TEW00788
w Double screw (4): 14.7 f 2.0 Nm

(1.5 f 0.2 kgm)
TEW00789
20-32
0
TESTING AND ADJUSTING MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL
MEASURING OPERATING
FORCE, TRAVEL OF BRAKE
PEDAL

. Engine speed: Low idling
Operating force of pedal

1. Fit push gauge @ to your foot.
* Set the push gauge at “a” position 150 mm
from the pedal fulcrum.
2. Start the engine and measure the pedal pushing

force at low idle.
Travel of pedal
1. Fit push gauge @ to your foot.
* Set the push gauge at “a” position 150 mm
from the pedal fulcrum.
2. Start the engine and measure the pedal pushing

F angle at low idle with a pedal pushing force of TEW00791
z
0 206 N (21 kg).
3. Install angle gauge C$ on the brake pedal and

measuring pushing angle cxwith a pushing force
of 206 N (21 kg). It is also possible to measure
al and a~ and calculate a = al - oz.
TEW00792
20-33
0
TESTING AND ADJUSTING TESTING AND ADJUSTING BRAKE PEDAL LINKAGE
TESTING AND ADJUSTING BRAKE PEDAL LINKAGE
6a
TDW00793
Testing
1. Check for play in rod mounting pin (I), pin hole
of lever (21, and lever bushing.
2. Measure length Xl of rod, and check that it is
within the standard value.
* Standard length of rod Xl: 175 mm
+ Measure the length from the center of pin
(I) and the center of ball joint (6a).
3. Measure the distance of movement of rod (8)
and check that clearance “a” is within the stand-
ard value.
* Standard clearance “a” : 0 - 0.7 mm TEW00794
* When doing this, check that the brake pedal
is in contact with the stopper.
Adjusting
1. Adjusting link Xl
I) Remove pin (I) and ball joint (6a), remove
rod and loosen locknut (51, then turn yoke
(6) and ball joint (6a) to adjust the length.
2) After adjusting the length of rod Xl, connect
it to the brake pedal.
20-34
a
TESTING AND ADJUSTING TESTING AND ADJUSTING BRAKE PEDAL LINKAGE
2. Adjusting rod X2
1) Loosen locknut (7), turn rod (8) so that tip of
rod C contacts the master cylinder piston,
then turn rod (8) back l/4 turn.
* Standard length of rod X2: 154.3 mm
* Movement for l/2 turn of rod: 0.75 mm
2) Tighten locknut (7) to hold in position.
3. Adjusting transmission cut-off switch (left pedal)

I) Loosen mounting screw of switch (9) and
adjust switch (9) so that the protrusion of
the tip of transmission cut-off switch (9) from
the end face of the transmission cut-off
switch plate is dimension “b”.
* Dimension “b”: 1.1 - 1.9 mm
* When doing this, check that the switch
is ON.
Transmission
cut-off switch
plate
TDW00795
2) To adjust the cut-off timing, adjust plate (IO)

so that dimension “d” from the center of the
stopper bolt of plate (IO) to the end face of
plate (IO) is 24 mm.
* When doing this, check that plate (1-O)
contacts portion “e” of the switch plate.
* Adjust with the pedal in the FREE condi-
tion.
. _
TDW00796 TEW00797
4. Adjusting stop lamp switch (right pedal)

Adjust with mounting nuts (11) of stop lamp
switch (12).
1) Adjust with nuts (II) so that the tip of the
switch is dimension “f”.
t Dimension “f”: 3.5 - 5.0 mm
* When doing this, check that the switch is
OFF.
* Adjust with the pedal in the FREE condi-
tion.
TDW00798
20-35
0
TESTING AND ADJUSTING MEASURING BRAKE PERFORMANCE
MEASURING BRAKE
PERFORMANCE
l Travel speed: 20 km/h when brakes are applied
. Delay in applying brakes: 0.1 set
l Tire inflation pressure: Specified pressure
Measurement method
1. Start the engine and move the machine.
2. Set the speed lever to the highest speed posi-

tion and drive the machine.
3. When the travel speed reaches 20 km/h, depress

the left brake pedal with the specified operating
force.
Specified operating force: 294 N (30 kg)
* Before carrying out this operation, determine
the run-up path and the point for applying
the brakes, then apply the brakes when the
machine reaches that point.
4. Measure the distance from the point where the

brakes were applied to the point where the ma-
chine stopped.
* Repeat this measurement three times and
take the average.
I Point where braking I

Stopping point effect started Point where operator put
foot on brake pedal
I (Operation pomt)
Stopping distance Run-up path
TEW00799
20-36
0
TESTING AND ADJUSTING MEASURING BRAKE OIL PRESSURE
MEASURING BRAKE OIL PRESSURE
on engine water temperature gauge 1
Brake pressure: 4.1 MPa (42 kg/cm21
a Apply the parking brake and put blocks under

the tires.
Measuring
1. RaiseThe boom, set support (IA) or boom drop
prevention stopper 0 in position, then remove TEWOOSOO TEW00801
front cover (1).

* When leaving the operator’s seat, apply the
lock to the work equipment control levers
securely.
2. Stop the engine.
3. Remove brake tube (2) on the side to be meas-
ured, then remove adapter (3).
4. After removing the adapter, install hydraulic test
kit @I.
* Connect the quick coupler of hydraulic test
kit 0.
5. Loosen bleeder screw (4) and bleed the air.
8 * Operate pump @ to bleed the air.
b 6. Tighten the bleeder screw, operate pump 0,
$ raise the pressure to 4.1 MPa (42 kg/cm2), then
tighten stop valve @_I.
7. After applying the pressure, leave for 5 minutes
and measure the drop in the pressure.
* If the hose is moved while measuring the
pressure, the pressure will change, so do
not move the hose.
* When removing hydraulic test kit @ after
testing, operate pump @ to lower the pres-
sure of hydraulic test kit 0, then remove it.
* After completing the operation, install the
brake tube, then bleed the air from the brake
circuit.
TEW00803
20-37
0
TESTING AND ADJUSTING TESTING FOR BRAKE DISC WEAR
TESTING FOR BRAKE DISC WEAR
A tires.
Apply the parking brake and chocks under the
Measuring
1. Loosen drain plug (I) and drain the axle oil.
- : Axle oil: 14 1
2. Install measuring plug (2).
3. Lightly press the brake pedal. TEW00805

* Check that plate (4) and plate (5) are in tight
contact with disc (3).
4. Insert feeler gauge @ between disc (3) and plate

(41, and measure the clearance.
5. Fasten the drain plug and supply axle oil to the

specified level through the oil supply port.
G Axle oil: 14 1
I f TEW00806
TEW00807
20-38
a
TESTING AND ADJUSTING BLEEDING AIR FROM BRAKE SYSTEM
BLEEDING AIR FROM BRAKE

SYSTEM
\
a Apply the parking
the tires.
brake and put blocks under bzi-
IA
‘(1 _ir
q
1
Procedure
1. Raise the boom, set support (IA) or boom drop
/’ T
prevention stopper @I in position, then remove
front cover (1).
3‘
2. Remove cap (2) of the bleeder screw, insert vi- t -/
/
nyl hose (3) into the screw, and insert the other P II TEW00800 TEW00801
end in a container.
TEW00808
4. Depress the brake pedal, then loosen the bleeder

screw and bleed the air. Keep the brake pedal
depressed, tighten the bleeder screw, then re-
lease the brake pedal slowly.
* Add brake oil when necessary during the
operation to keep the brake oil tank full.
Front axle
TEW00809
5. Repeat this operation, and when no more bub-

bles come out with the fluid from the hose, de-
press the pedal fully and tighten the bleeder
screw while the oil is still flowing.
* Repeat the operation to bleed the air from
the other cylinders, and after completing the
operation, check the level in the oil tank and
add more oil if necessary.
* To bleed the air completely, bleed the air
first from the cylinder which is farthest from
the brake pedal.
* After bleeding the air, carry out a brake per-
formance test then bleed the air again and
check that there is no air in the circuit.
20-39
0
TESTING AND ADJUSTING MEASURING PARKING BRAKE PERFORMANCE
MEASURING PARKING BRAKE
r
PERFORMANCE
. Road surface: Flat, dry paved road surface with
slope of l/5 grade (ll”20’).
. Machine: Operating condition
Measurement method
1. Start the engine, set the machine facing in a

straight line, then drive the machine up a l/5
grade slope with the bucket empty.
I TEW00811
2. Depress the brake, stop the machine, set the

directional lever to the neutral position, then
stop the engine.
3. Depress the parking brake pedal (to apply the

parking brake), then release the brake pedal
slowly and check that the machine does not
move.
* Measure the parking brake performance with
,the machine facing uphill and again with the
machine facing downhill.
I TEW00812
20-40
0
TESTING AND ADJUSTING TESTING AND ADJUSTING PARKING BRAKE LINKAGE

PARKING BRAKE LINKAGE
AApply the parking brake and put blocks under

the tires.
Testing
Depress the parking brake pedal with a force of
approx. 294N (30 kg). If the travel of brake pedal is
more than 13 clicks, check for looseness of the con-
trol cable mount (pedal end and brake end). If any
looseness is found, tighten and then adjust as
follows.
Adjusting linkage
1. Pull release lever (I) and release the parking
brake.
2. Loosen locknut (2) and remove clevis pin (4).
3. Set lever (5) at the parking brake end in the
release position.
* With lever (5) at the FREE position, move
the link up by the amount of play. c3
4. Screw in clevis (31, align the hole with the pin Direction of
hole in lever (5) at the parking brake end, then / \\ F release
assemble clevis pin (4) and tighten locknut (2).

5. After adjusting, depress parking brake pedal (6)
E
with a force of approx. 294 N (30 kg), and check 4 5 TEW00813
z that the travel of the pedal is 7 - 11 clicks.
If it is impossible to adjust only at parking brake

end
6. Loosen locknut (7) at pedal (6) end, then re-
move clevis pin (9).
7. Screw in clevis (8) and adjust so that the mount- 6
ing dimension is X.
* Standard dimension X: 148 mm
==- TDW00814
Adjusting parking brake switch

1. Adjust with nut (11) so that the mounting di-
mension at the tip of parking brake switch (IO)
is “c”.
* Mounting dimension “c” of switch: 4 - 6 mm
* When doing this, check that the parking brake
switch is OFF.
TDW00815
20-41
0
TESTING AND ADJUSTING TESTING PARKING BRAKE DISC WEAR
TESTING PARKING BRAKE

DISC WEAR
AStop the machine on level ground, install the

safety bar to the frame, lower the bucket to the
ground, stop the engine, then apply the parking
brake and put blocks under the wheels.
* Check that there are blocks under the tires.
* Carry out this operation with the drive shaft still
installed.
Testing
TEW00816
1. Check that the parking brake is applied.
2. Remove plug (I).
l Width across flats of hexagon socket wrench:
6mm
3. Inset-t calipers @ into measurement port (Z), and
measure dimension “a” from end face “c” of
cover (3) to piston (4).
m
P
5
0
4. Release the parking brake.

5. Insert calipers @ into measurement port (2), and
measure dimension “b” from end face “c” of
cover (3) to piston (4).
. Piston stroke X’= “a” - “b”
t If X is more than 3.5 mm, the brake disc is
worn, so replace the disc.
* For details of the method of replacing the
brake disc, see DISASSEMBLY AND ASSEM-
BLY OF TRANSMISSION.
* After measuring, check the oil level in the
transmission.
TDW00818
20-42
0
TESTING AND ADJUSTING MEASURING PARKING BRAKE DISC WEAR
MEASURING PARKING BRAKE

DISC WEAR
A Put blocks under the tires.
* If the braking effect is poor, or if the transmis-

sion has been overhauled, measure the wear of
the parking brake disc.
* For details of the method of dissembling and
assembling the parking brake, see DISASSEM-
BLY AND ASSEMBLY OF TRANSMISSION.
Measuring
To measure the thickness of brake disc (I), check
that dimension “w” is greater than the value
given below.
* Dimension “w”: Min. 1.97 mm
* For details of adjusting the parking brake
linkage, see TESTING AND ADJUSTING
PARKING BRAKE LINKAGE.
TEW00821
20-43
0
TESTING AND ADJUSTING MEASURING WORK EQUIPMENT CONTROL LEVER
MEASURING WORK
EQUIPMENT CONTROL LEVER
a Install the safety bar to the frame.
Measurement method
Operating force of work equipment control
lever
Install push-pull scale @ to the work equipment
control lever and measure the operating force.
* Install the push-pull scale to the center of
the knob.
* Operate the control lever at the same speed.
as for normal operations, and measure the
minimum value for the force needed to op-
erate the knob.
Travel of work equipment control lever

Measure travel at each position when operating
the work equipment control lever.
TEW00823
* Mark “a” the lever knob and use scale @ to
measure.
* If the travel is not within the standard value,
check for play of the linkage and wear of the
bushing.
Adjusting
1. Adjusting work equipment control lever linkage
1) Remove right control box (I), top cover (2),
and front cover (3).
* Remove boot (4) first from the top cover.
* When removing the top cover, be care-
ful of the wiring for the switches.
TEW00824
TEW00825
20-44
0
2) Adjust with locknuts (8) and yoke (7) so that

the length of work equipment control cable
(5) is standard length “a” at main control
valve (6) end.
* Standard value “a” : 173 mm
-/ TEW00826
a
1
I i 6 TEW00827
3) With work equipment control lever (9) at the

neutral position, loosen locknuts (12) and
(13) at the bottom of ball joint (11) so that
the levers can be locked by lock lever (IO),
then turn joint (14) to adjust length “b”.
* Standard length “b”: 200.5 mm
4) After adjusting the length, tighten locknut

(12), then secure joint (14) with locknut (13).
TEW00829
20-45
0
2. Adjusting stopper of work equipment control

lever
I) When adjusting boom RAISE stopper bolt
(I), connect control cable (2). Then operate DUMP N TILT
the work equipment control lever gradually
to the RAISE position and adjust the length
of stopper bolt (I) so that stopper bolt (I)
contacts the control lever at the point where
the control lever suddenly starts to feel
heavy.
2) When adjusting boom FLOAT stopper bolt

(3), connect control cable (2). Then operate
to the FLOAT position and adjust the length
of stopper bolt (3) so that stopper bolt (3)
heavy.
3) When adjusting bucket DUMP stopper bolt

(41, connect control cable (5). Then operate
to the DUMP position and adjust the length
of stopper bolt (4) so that stopper bolt (4)
heavy.
20-46
TESTING AND ADJUSTING MEASURING STROKE OF WORK EQUIPMENT VALVE SPOOL
MEASURING STROKE OF
W,ORK EQUIPMENT VALVE
SPOOL
ALsafety
Stop the machine on level ground, install the
bar to the frame, lower the bucket to the
ground, stop the engine, then apply the parking
brake and put blocks under the wheels.
. Engine speed: Stopped
Measuring
1. Adjusting stroke of valve spool
1) Put scale @ in contact with spool (2) of main
control valve (I) from the bottom of the front
frame.
TEW00832
2) Measure the stroke of the valve spool when

work equipment control lever (3) is moved
to each position.
* Carry out the measurement with two
workers and give signals while carrying
out the operation.
* One worker operates the control lever,
and the other worker measures the
stroke.
TEW00833
20-47
0
TESTING AND ADJUSTING MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE
MEASURING WORK
EQUIPMENT HYDRAULIC
PRESSURE
Work equipment relief valve pressure measuring

procedure / 1’ TEW00834
ALoosen the oil supply cap to release the pres-

sure inside the hydraulic oil tank, then operate
the control levers two or three times to release
any pressure remaining in the piping.
1. Remove bucket cylinder circuit oil pressure.

measuring plug (1).
2. Install hydraulic test kit 0 to the measuring port.

* Check that there is no oil leakage from any
joints.
* Use a hose which is long enough to reach
the operator’s seat.
TEW00835
3. Start the engine, raise the boom about 400 mm,

tilt back the bucket using the control lever, and
measure the pressure when the relief valve is
activated.
Ir Be careful not to apply any sudden pressure

to the pressure gauge.
A When removing the hydraulic pressure gauge,

release the pressure inside the circuit in the same
way as when it was installed.
20-48
0
TESTING AND ADJUSTING MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE
Adjusting
g Apply the parking brake and put blocks under

the tires.
a Always stop the engine before adjusting the oil

pressure.
1. Stop the engine, then measure the relief valve

pressure of main control valve (4) inside the
front frame.
* Disconnect differential (6) end of front drive
\\ I\ ’ -i ‘6 TEW00836
shaft (5), and move it to the left.
m Front drive shaft: 65.7 f 6.9 Nm

(6.7 f 0.7 kgm)
2. Remove the relief valve cap nut (I).
3. Loosen lock nut (2), and turn adjust screw (3) to

adjust.
* Pressure adjustment for one turn of adjust-
ment screw:
Approx. 2.5 MPa (25 kg/cm*)
F * Turn the adjustment screw to adjust the set

s
0
pressure as follows.
TIGHTEN to INCREASE pressure
LOOSEN to DECREASE pressure
Ir Do not carry out any adjustment if the relief
pressure cannot be measured accurately.
I TEW00838
20-49
0
TESTING AND ADJUSTING MEASURING WORK EQUIPMENT
MEASURING WORK
EQUIPMENT
Boom RAISE time
b4
Ir Measurement conditions
. Steering position: Neutral
. No load
Measurement method
1. Boom RAISE time TEW00839
Set the bucket at the lowest position from the

ground with the bucket tilted back fully, then
raise it and measure the time taken for the bucket
Boom LOWER time
to reach the maximum boom height.
2. Boom LOWER time

Set the bucket horizontal, then lower the boom
from the maximum height and measure the time
taken for the bucket to reach the lowest position
from the ground.
3. Bucket DUMP time

Bucket DUMP time
Raise the boom to the maximum height, and
measure the time taken to move the bucket from
the tilt position (bucket fully tilted back) to the
dump position (bucket fully tipped forward).
TEW00841
4. Bucket TILT time

Bucket TILT time
1) Raise the boom to the maximum height, and
measure the time taken to move the bucket
to the tilt position (bucket fully tilted back).
2) Set the bucket horizontal to the ground and
measure the time taken to move the bucket
from the horizontal position to the tilt posi-
tion (bucket fully tilted back).
20-50
0
TESTING AND ADJUSTING MEASURING WORK EQUIPMENT
MEASURING HYDRAULIC DRIFT WORK EQUIPMENT
. Stop the engine, leave for 5 minutes, then meas-
ure for 15 minutes.
. Boom: Horizontal
. Bucket: Horizontal
. No load
A Apply the safety

control levers.
lock to the work equipment
g Never go under the work equipment.
Measurement method
1. Set the boom and bucket in a horizontal posi-
tion, then stop the engine.
2. Leave for 5 minutes, then start the measure-

ment.
3. Wait for 15 minutes, then measure retraction
r:
b
amount A of the bucket cylinder rod and retrac-
2
tion amount B of the boom cylinder rod. I TEW00843
I TDW00160
A: Retraction amount of bucket cylinder rod

B: Retraction amount of boom cylinder rod
20-51
0
TESTING AND ADJUSTING TESTING AND ADJUSTING BUCKET POSITIONER

BUCKET POSITIONER
* Measurement conditions -, \
1. Testing
1) With the engine stopped, check that the clear-
ance between switch (I) and bar (2) is the
standard value.
2) Start the engine, run at high idling, and check 1 TEW00844
the actuation position. (Check three times
and take the average value.)
2. Adjusting
1) Lower the bucket to the ground, operate the
bucket to the desired digging angle, then
return the lever to the HOLD position, and
stop the engine.
2) Adjust so that the clearance between bracket
(3) and detection bar (2) is “a”, then secure
the bracket in position.
.* Clearance “a”: 0.5 - 2.0 mm
3) Secure support (4) to the bucket cylinder
bracket so the tip of detection bar (2) is in TEW00845
line with the center of the switch sensing

surface.
4) Adjust the switch so that the clearance be-
tween the switch sensing surface and detec-
tion bar (2) is “b”, then secure in position.
w Switch mounting nut: 17.7 + 2.0 Nm

(1.8 f 0.2 kgm)
* Clearance “b”: 3 - 7 mm
(The clearance must be less than 7 mm,
and there must be no interference be-
tween the switch and detection bar
(plate).)
* After adjusting, operate the bucket lever TEW00846
and check that the bucket positioner is

actuated at the desired position.
/ TEW00847
20-52
0
TESTING AND ADJUSTING TESTING AND ADJUSTING BOOM KICK-OUT

BOOM KICK-OUT
1. Testing
1) Stop the engine, and check that the clear-
ance between switch (1) and plate (2) is the
standard value.
TEW00849
2) Start the engine, run at high idling, and check

the actuation position. (Check three times
and take the average value.)
2. Adjusting
1) Raise the boom the desired position and
mark it at the position where the center of
the switch is at the lower end of the plate.
2) Adjust the position of the plate so that the

center of the switch (I) is in line with the
bottom of plate (2), then secure in position.
TEW00849
w Plate mounting bolt: 88.3 + 34.3 Nm
(9 + 3.5 kgm)
3) Adjust the switch (I) so that the clearance

“a” between the switch (I) sensing surface
and plate (2) is the standard value, then
secure the switch in that position.
* Clearance “a”: 3 to 7 mm
* After adjusting, operate the boom lever
and check that the kick-out is actuated at
the desired position.
20-53
0
TESTING AND ADJUSTING TESTING AND ADJUSTING BOOM KICK-OUT
Proximity switch actuation pilot lamp (red)

The proximity switch is equipped with a pilot lamp Actuation pilot lamp
which shows when it is being actuated, so use this
when adjusting. \ \
‘roximity switch
actuation Lights up Goes out
pilot lamp
When detector is positioned at detection When detector has moved away from
letector position
surface of proximity switch detection surface of proximity switch
3ucket
3ositioner
/ \
De;ector ProxiAity switch Detector Proximity switch
TEW00851 TEW00852
Proximity\switch
3oom kick-out
20-54
0
Using troubleshooting charts for engine-related failure.. .................................................................. 20-102
Points to remember when troubleshooting ........................................................................................ 20-106
s- 1 Starting performance is poor (Starting always takes time). ................................................... 20-107
s- 2 Engine does not start.. ................................................................................................................ 20-108
s- 3 Engine does not pick up smoothly (Follow-up is poor). ......................................................... 20-I 11
s- 4 Engine stops during operations.. ............................................................................................... 20-I 12
s- 5 Engine does not rotate smoothly (hunting) ............................................................................. 20-I 13
S- 6 Engine lacks output (no power). ................................................................................................ 20-I 14
s- 7 Exhaust gas is black (incomplete combustion). ....................................................................... 20-I 15
S- 8 Oil consumption is excessive (or exhaust gas is blue). .......................................................... 20-I 16
s- 9 Oil becomes contaminated quickly ........................................................................................... 20-I 17
S-IO Fuel consumption is excessive .................................................................................................. 20-I 18
S-II Oil is in cooling water, or water spurts back, or water level goes down ............................. 20-I 19
s-12 Oil pressure lamp lights up (drop in oil pressure) .................................................................. 20-120
E s-13 Oil level rises ................................................................................................................................ 20-121

2 becomes too high (overheating) ............................................................... 20-122
0 s-14 Water temperature
s-15 Abnormal noise is made ............................................................................................................ 20-123
S-16 Vibration is excessive ................................................................................................................. 20-124
20-101
0
TROUBLESHOOTING USING TROUBLESHOOTING CHARTS FOR ENGINE-RELATED FAILURE
USING TROUBLESHOOTING CHARTS FOR ENGINE-RELATED

FAILURE
This troubleshooting chart is divided into three
sections: questions, check items, and troubleshoot-
ing. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspection with-
out using troubleshooting tools.
Next, troubleshooting tools or direct inspection
are used to check the high probability causes to
make final confirmation.
[Questions]
Sections @ + @ in the chart on the right corre-
sponds to the items where answers can be ob-
tained from the user. The items in @ are items
that can be obtained from the user, depending
on the user’s level.
[Check items1
The serviceman carries out simple inspection to
narrow down the causes. The items under 0 in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information @ that he has obtained from the
user and the results of 0 that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
20-102
0
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions1 and [Check items1 that
have a relationship with the Cause items are marked
with 0, and of these, causes that have a high prob-
ability are marked with Q.
Check each of the [Questions] and [Check items1 in
turn, and marked the 0 or 6%in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is
the most probable cause, so start troubleshooting
for that item to make final confirmation of the cause.
’ %I. For [Confirm recent repair history] in the
[Questions] Section, ask the user, and mark
the Cause column with n to use as reference
for locating the cause of the failure. How-
+ ever, do not use this when making calcula-
tions to narrow down the causes.
, ~2. Use the LI in the Cause column as reference
for [Degree of use (Operated for long pe-
riod)] in the [Questions] section as reference.
As a rule, do not use it when calculating the
points for locating the cause, but it can be
included if necessary to determine the order
for troubleshooting.
zz
b
G
0
20-l 03
CD
. Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three
symptoms have causal relationship with this problem: [Exhaust gas slowly became black], [Power
slowly became weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with
five causes. Let us explain here the method of using this causal relationship to pinpoint the most
probable cause.
s-7 Exhaust gas is black (incomplete combustion)

General causes
. Insufficient intake of air
. Improper condition of fuel injection
. Excessive injection of fuel
Non-specified fuel h*s bee” used I I
Engine pickup is poor and combunion is irregular
1Seal
on injection pump has come off I I
When compression pressure is measured. it is found fo be low
Speed of some cylinders does not change when Operating

,E on reduced cylinders
s
0 yhe” check is,made using delivery method. injection timing
+j IS found to be ,“correct
2 Injection pump fe*t shows that injection amwnt is incorrect
z When valve clearance IS checked directly it is found to be

outside nandard value
When control rack is pushed, it is found to be heavy or does

not return
20-104
0
ril++
Five causes
Step 1
Clarify the relationship between the three

symptoms in the [Questions] and [Check items1
section and the five Cause items in the vertical
column.
:li
Three symptoms
Step 2
Add up the total of Oand 0 marks where the

horizontal lines for the three symptoms and the
vertical columns for the causes intersect.
(I) Clogged air cleaner element: 000
(2) Air leakage between turbocharger
and head: 00
(3) Clogged, seized injection nozzle: 0
(4) Defective contact of valve, valve seat: 0
(5) Worn piston ring, cylinder: 0
The calculation in Step 2 show that the closest

relationship is with [Clogged air cleaner
element]. Follow this column down to the
troubleshooting area and carry out the
troubleshooting item marked 0. The Remedy is
given as [Clean], so carry out cleaning, and the
- exhaust gas color should return to normal.
20-105
Q
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
A Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
a
allow any unauthorized person to come near.
A If the radiator
the engine to cool
cap is removed
down before
when
starting
the engine
troubleshooting.
is hot, hot water may spurt out and cause burns, so wait for
A Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
A When disconnecting wiring, always disconnect the negative (-) terminal of the battery first.
A When
.
the Internal
removing
pressure
the plug or cap from
first. When
a location
installing measuring
which is under
equipment,
pressure from
be sure to connect
oil, water, or air, always
it properly.
release
* The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and function.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry 4) Check the stroke of the control valve spool.
to disassemble the components. 5) Other maintenance items can be checked ex-
If components are disassembled immediately any ternally, so check any item that is considered
failure occurs: to be necessary.
. Parts that have no connection with the fail- 4. Confirming failure
ure or other unnecessary parts will be disas- . Confirm the extent of the failure yourself,
and judge whether to handle it as a real fail- =;
sembled. 0
. It will become impossible to find the cause ure or as a problem with the method of op-
of the failure. eration, etc.
It will also cause a waste of manhours, parts, or * When operating the machine to reenact
oil or grease, and at the same time, will also lose the troubleshooting symptoms, do not
the confidence of the user or operator. carry out any investigation or measure-
For this reason, when carrying out troubleshoot- ment that may make the problem worse.
ing, it is necessary to carry out thorough prior 5. Troubleshooting
investigation and to carry out troubleshooting in . Use the results of the investigation and in-
accordance with the fixed procedure. spection in Items 2 - 4 to narrow down the
2. Points to ask user or operator causes of failure, then use the troubleshoot-
1) Have any other problems occurred apart from ing flowchart to locate the position of the
the problem that has been reported? failure exactly.
2) Was there anything strange about the ma- * The basic procedure for troubleshooting
chine before the failure occurred? is as follows.
3) Did the failure occur suddenly, or were there 1) Start from the simple points.
problems with the machine condition before 2) Start from the most likely points.
this? 3) Investigate other related parts or in-
4) Under what conditions did the failure occur? formation.
5) Had any repairs been carried out before the 6. Measures to remove root cause of failure
failure? . Even if the failure is repaired, if the root cause
When were these repairs carried out? of the failure is not repaired, the same failure
6) Has the same kind of failure occurred be- will occur again.
fore? To prevent this, always investigate why the
3. Check before troubleshooting problem occurred. Then, remove the root
1) Check the oil level cause.
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
20-106
TROUBLESHOOTING S-l
S-l Starting performance is poor

(Starting always takes time)
General causes why starting performance is poor
. Defective electrical system
. Insufficient supply of fuel
. Improper selection of fuel
(At ambient temperature of - 10°C or below, use ASTM D975
No. 1, and - 10°C or above, use ASTM D975 No. 2 diesel fuel.)
t Battery charging rate.
. The specific gravity should exceed the value for the charg
rate of 70% in the above table.
. In cold weather the specific gravity must exceed the value
the charging rate of 75% in the above table.
Legend
0 : Possible causes (judging from Questions and check items)
: Most probable causes (judging from Questions and Check items)
A : Possible causes due to length of use (used for a long period)
0 : Items to confirm the cause
I) Little fuel comes out even when injection pump sleeve I I I I I I I I I I I I I

m nut is loosened I I I I I I I I I I I I I I
I II
I
6 2) Littlefuel
is loosened
comes out even whenfuelfilterair bleed plug
-
I / 1 1-_1 1
I I I IWIQI
1
I
/
I
I 1 I /_I
I I I IUI I
1
I I
Leakage from fuel piping 00
There is hunting from engine (rotation is irregular) 00 00
When compression pressure is measured, it is found to be low l 0

When air element is inspected directly, it is found to be
‘oltage is26-30V betweem alternatorterminal Band I Yes 1 1.1

terminal E with engine at low idling 1 No-~
Either specific gravity of electrolyte or voltage of battery is low
Stop fuel injection to one cylinder at a time. If there is no
chanae in enaine weed. that cvlinder is not workina
When check is made using
is found to be incorrect
delivery method, injection timing
I I I I I I I I I I I.1 I I
When control rack is pushed, it is found to be heavy or does
not return (when blind plug at rear of pump is removed, it 0
can be seen that plunger control sleeve does not move)
When fuel cap is inspected directly, it is found to be clogged 0
8 .= ccr”““““z~‘cm0rJmal
Remedy z $2 1; $$$$Esz Qz
~,vuvmmmwm<~,u
cccccc~~
20- 107
0
TROUBLESHOOTING s-2
S-2 Engine does not start

(I) Engine does not turn
General causes why engine does not turn

. Internal parts of engine seized
* If internal parts of the engine are
seized, carry out troubleshooting for
“Engine stops during operations”.
. Failure in power train
. Defective electrical system
Legend
0 : Most probable causes (judging from Questions and Check items)
n : Possible causes due to length of use (used for a long period)
l : Items to confirm the cause.
Confirm recent repair history
Degree of use Operated for long period

g
‘g Condition of horn when starting Horn does not sound 0

I switch is turned ON
Horn sound level is low
5
Rotating speed is slow
Makes grating noise

When starting switch is turned to
START, pinion moves out, but Soon disengages again
Makes rattling noise and

does not turn
When starting switch is turned to START, pinion does not

move out 0
When starting switch is turned to ON, there is no clicking sound
Batten/ terminal is loose
When starting switch is turned to ON, linkage does not move ~~

e
When battery is checked, battery electrolyte is found to be low ‘B
_
.g
ipecific gravity of electrolyte, voltage of battery is low m
t;
or the following conditions 1) - 5), turn the starting switch B
)FF, connect the cord, and cam/ out troubleshooting at ON ,g
.:
5
1) When terminal B and terminal C of starting switch are
.-?
connected, engine starts
z
$
2) When terminal B and terminal C of starting motor are
b
connected, engine starts
P
._
3) When terminal B and terminal C of safety relay are 6
connected, engine starts _?
2
=
4) When terminal of safety switch and terminal B of z
starting motor are connected, engine starts b
2
5) There is no 24V voltage between battey relay terminal B c
and terminal E s
vVhen ring gear is inspected directly, tooth surface is found

tlo be chipped
I:)oes not move even when engine stop motor linkage is

dlisconnected I
L
I Remedy
I I
20- 108
0
TROUBLESHOOTING s-2
(2) Engine turns but no exhaust gas comes out

(Fuel is not being injected)
General causes why engine turns but no exhaust gas comes out
. Supply of fuel impossible
. Supply of fuel is extremely small
. Improper selection of fuel (particularly in winter)
Standards for use of fuel
Ambient temprature
Type offuel -22 -4 32 50 68 86 104 122°F
-30 -20 z 0 10 20 30 40 50°C
Legend
0: Possible causes (judging from Questions and check items)
0 : Most probable causes (judging from Queaions and Check items)
A: Possible causes due to length of use (used for a long period)
Confirm recent repair history
Degree of use Operated for long period nn a
Exhaust gas suddenly stops coming out (when starting again) 0 0 0
Replacement of filters has not been carried out according to

operation manual I I I I I 1 I
2) No fuel comes out even when fuel filter air bleed plug is
loosened 0 00 0
3) No fuel spurts out even when injection pipe sleeve nut is

loosened 000
Rust and water are found when fuel is drained 00
Check injection pump directly 1.1 1 1 1 j I 1 I I

III I I I II II
When control rack is pushed, it is found to be heavy, or does
not return 0
Checkfeed pump directly a
When fuel filter, strainer are inspected directly, they are found
to be clogged 0
When feed pump strainer is inspected directly, it is found to be

clogged
When fuel cap is inspected directly, it is found to be clogged
Does not move even when engine stop motor linkage is

disconnected
I I I I I I I I I@/ I
$ $ $ E
6
Remedy $ $ z 2 2
0 0
B d z
20-109
Q
TROUBLESHOOTING s-2
(3) Exhaust gas comes out but engine does Causes

not start
(Fuel is being injected)
General causes why exhaust gas comes out

but engine does not start
. Lack of rotating force due to defective
electrical system
. Improper selection of fuel
Legend
0 : Mostprobable causes (judging from Questions and Check items)
l : items to confirm the cause.
When engine
around head
is cranked, abnormal noise is heard from
IIlIIIIIII
Engine oil must be added more frequently Q
Non-specified fuel has been used 0 0
When fuel lever is placed at FULL position, it does not

contact stopper 0
When engine is cranked with starting motor,
I) Little fuel comes out even when injection pump sleeve 0

nut is loosened
C
5 2) Little fuel comes out even when fuel filter air bleed plug
Y
is loosened QQ C
8
6 There is leakage from fuel piping Q
When exhaust manifold is touched immediately after

starting engine, temperature of some cylinder is low Q
When fuel filter is drained, no fuel comes out I I I Ic
Remove head cover and check dirsctlv Irl I I I I I

When control
does not return
rack is pushed, it is found to be heavy, or
I I@/I I I I I I I I I
When comoression oressure is measured. it isfound to be low 1 l lOI l l I I I I 1 I
When fuel filter, strainer are inspected directly, they are
found to be clogged I I I 1.1 I I I I I I I@
When feed pump strainer is inspected directly, it is found to
be clogged I I I I I@~ I I I I I I
When air element is inspected directly, it is found to be clogged 0
Glow plug mount does not become warm 0
Either specific gravity of electrolyte or voltage of battery is low 0
When feed pump is operated, there is no response, or pump

is heavy 0

change in engine speed, that cylinder is not working
I I / I I I I I / 1.1 /
E 8 : & 5 & .i % .z c c
Remedy a sa mas 2 u g-a
m am“: I
gg;uoo,;gaa
20-110
0
TROUBLESHOOTING s-3
S-3 Engine does not pick up smoothly (Follow-up is poor)

General causes why engine does not pick
up smoothly
. Improper fuel used
Legend
Q : Most probable causes (judging from Questions and Check items)
e to length of use (used for a long period)
‘Iters has not been carried out according to
Dust indicator is red
Noise of interference is heard from around turbocharger 0
/ Engine pick-up suddenly became poor 0 000

starting engine, temperature of some cylinders is low
00
Blow-by gas is excessive 0
pump strainer is inspected directly, it is found to
When feed pump is operated, operation is too light or too heavy 0
Remedy
20-l 11
0
TROUBLESHOOTING S-4
S-4 Engine stops during operations

General causes why engine stops during
operations
l Seized parts inside engine
. insufficient supply of fuel
l Overheating
* If there is overheating and insuffi-
cient output, carry out troubleshoot-
ing for overheating.
. Failure in power train
* If the engine stops because of a fail-
ure in the power train, carry out trou-
bleshooting for the chassis.
Legend
Q: Mostprobable causes (judging from Questions end Check items)
Condition when engine

stopped
There was hunting and

000 0
engine stopped
1-rI I I I I I
Fuel gauge lamp lights up I I IQ1 I I I I I I
Fuel tank is found to be emotv
I lfil I I I I I I
Engine turns, but stops when transmission control lever is

operated I I I I I I I I I I I
Try to turn by hand using

barring tool
s fond to be heavy or does

TROUBLESHOOTING s-5
S-5 Engine does not rotate smoothly (hunting)

General causes why engine does not rotate
smoothly
. Air in fuel system
. Defective governor mechanism Causes
. Defective engine throttle controller
mechanism
(engine throttle controller type)
Legend
A: Possible causes due to length of use (used for a long period)
Ic on f Irm recent reoair historv I I I I I I I III

Degree of use Operated for long period aa
Occurs atcertain speed range 0 0 0 0

Occurs at low idling 0 0 0000
2 Condition of hunting
whenspeed is
.G Oclc;seven 0 0 0 (
77
5 Ocuurs on slopes 0
CY
Fuel tank is found to be empty 0
Replacement of filters has not been carried out according to

operation manual 00
Rust is found when fuel is drained 00
/ Leakage from fuel piping 00
When feed pump is operated,
I) No response, light. return is quick
2) No response, light, return is normal 0
Engine speed sometimes rises too high 00
Engine is sometimes difficult to stop 0 0
Seal on iniection oumo has come off Q 0
When governor lever is moved it is found to be stiff l 0
When injection pump is tested, governor is found to be

0
improperly adjusted
P
‘E When control rack is pushed, it is found to be heavy, or
r8 does not return 0
I II.1I II II II II IIa
:
II
a When fuel cap is inspected directly, it is found to be clogged
z I
c When
be clogged
feed pump strainer is inspected directly, it is found to
a
When
found
fuel filter,
to be clogged
strainer are inspected directly, they are
l
20-l 13
Q
TROUBLESHOOTING S-6
S-6 Engine lacks output (no power)

General causes why engine lacks output Causes
. insufficient supply of fuel
. Improper fuel used
(if non-specified fuel is used, output
drops)
. Lack of output due to overheating
* If there is overheating and insufficient
output, carry out troubleshooting for
overheating.
Legend
@ : Most probable causes (judging from Questions and Check items)
0 : Items to confirm the cause.
5
placement of filters has not been carried out according to
ii eration manual
Noise of interference is heard from around turbocharger 0

Slow-by gas is excessive Q
Enaine oickuo is ooor and combustion is irreaular Q 0 00
High idling speed under no load is normal, but speed
suddenly drops when load is applied I I I lH4 I I I I I loI
starting engine, temperature of some cylinders is low
I I I I I I I I I
When air element is inspected directly, it is found to be clogged l

When trubocharger is rotated by hand, it is found to be heavy 0
When compression pressure is measured, it is found to be low 0 0
When fuel filter, strainer are inspected directly, they are

found to be clogged 0
When feed pump strainer are inspected directly, it is found

to be clogged I I I I 1.1 I I I I I I
change in engine speed, that cylinder is not working I I I I I IeI I I I I I
When control rack is pushed, it is found to be heavy, or
dose not return I I I I I I l*I I I I I
When valve clearance is checked directly, it is found to be
outside standard value I I I I I I I 1.1I I I
I I I I I I I I I 1.1I
When lever is placed at FULL position, it does not contact
stopper
When feed ourno isooerated.ooeration istoo liahtortoo heaw 1 l / l 1 l l I / I IOI

When fuel cap is inspected directly, it is found to be clogged 1 10
20-l 14
0
TROUBLESHOOTING s-7
S-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black
Legend
0 : Items to confirm the cause.
Color of exhaust gas

starting engine, temperature of some cylinders is low Q 0
Match marks on fuel injection pump are out of alignment 0
Seal on iniection oumo has come off 0
Clanging sound is heard from around cylinder head Q

Exhaust noise is abnormal 0 0 Q
Muffler is crushed 0
Leakage of air between turbocharger and head, loose clamp 0
L
When turbocharger is rotated by hand, it is found to be heavy l

When air cleaner is inspected directly, it is found to be clogged 0
When compression pressure is measured, it is found to be low 0 0

change in engine speed, that cylinder is not working 0
When check is made using

is found to be incorrect
delivery method, injection timing
IIII III I
Injection pump test shows that injection amount is incorrect
When valve clearance is checked directly it is found to be

outside standard value
When muffler is removed, exhaust gas color returns to normal
When control rack is pushed, it is found to be heavy, or does

not return
20-115
0
TROUBLESHOOTING S-8
S-8 Oil consumption is excessive (or exhaust gas is blue)

* Do not run the engine at idling for more
than 20 minutes continuously. (Both low
and high idling)
General causes why oil consumption is ex-
cessive
l Abnormal combustion of oil
. External leakage of oil
l Wear of lubrication system
Causes
Leqend
-A : Possible causes due to lenath of use (used for a lona oeriod)
Degree of use
W&;rhaust pipe is removed, inside is found to be dirty

I I I I I I I I I
Inside of turbocharger intake pipe is dirty with oil
Oil level in torque converter, transmission damper chamber

rises
I 1 Clamps for intake system are loose I I I I I I I I I I I IQ/
20-l 16
0
TROUBLESHOOTING s-9
S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated
quickly
. Intake of exhaust gas due to internal wear
. Clogging of lubrication passage
. Improper combustion
. Improper oil used
. Operation under excessive load
Causes
ible causes (judging from Questions and check items)
e to length of use (used for a long period)
Color of exhaust gas
Amount of blow-by gas
When compression pressure is measured, it is found to be low
When safety valve is directly inspected, spring is found to be catching or
20-l 17
0
TROUBLESHOOTING S-IO
S-IO Fuel consumption is excessive

General causes why fuel consumption is ex-
cessive
. Leakage of fuel / Causes /
,gend
) : Possible causes (judging from Questions and check items)
> : Most probable causes (judging from Questions and Check items)
1: Possible causes due to length of use (used for a long period)
b : Items to confirm the cause.
I~
Conflrm recent repair history
Degree of use
More than for other machines of
Condition of fuel
/ Slack
Exhaust gas color
White
Seal on injection pump has come off
There is irregular combustion
When exhaust manifold is touched immediately

temperature of some cylinders is low
after starting engine,
00
Match mark on injection pump is misaligned 0
There is external leakage of fuel from engine 0
Engine oil level rises and smells of diesel fuel 0 00

1 Engine low idling speed is high lOI I I I I I IPI
Injection pump test shows that injection amount is excessive a
Stop fuel injection to one cylinder at a time. If there is no change in engine

0
speed, that cylinder is not working
When control rack is pushed, it is found to be heavy, or does not return l

When check is made using delivery method, injection timing is found to be
0
incorrect
Remove head cover and check directlv I T I I I I./ I I

Remove feed pump and check directly
1When engine speed is measured, low idling speed is found to be high I I I I I I I Irnl
20-118
0
TROUBLESHOOTING S-l 1
S-l 1 Oil is in cooling water, or water spurts back, or water level goes
down
General causes why oil is in cooling water
. Internal leakage in lubrication system
. Internal leakage in cooling system
I Causes I
/
2 Degree of use Operated for long period &A a
2
tj
Suddenly increased 00 0
5 Oil level
u
Gradually increased 00
/
I/’
Hard water is being used as cooling water
lOI I I 101 I
Engine oil level has risen, oil is cloudy white 0 00
IE
C
Excessive
Hydraulic
air bubbles
oil, torque
inside
converter,
radiator, spurts
transmission
back
oil is cloudy white

00
When hydraulic oil, torque converter, transmission oil is drained, water is

found 0
P Pressure-tightness test of oil cooler shows there is leakage 0 0

‘Z
z Pressure-tightness test of cylinder head shows there is leakage l

3
Remove cylinder head and check directly a
2
2
+ Remove oil pan and check directly 00
20-l 19
CC
TROUBLESHOOTING s-12
S-12 Oil pressure lamp lights up (drop in oil pressure)

General causes why oil pressure lamp lights
up
. Leakage, clogging, wear of lubricating
system
. Defective oil pressure control
. Improper oil used (improper viscosity)
. Deterioration of oil ‘due to overheating
Standards for enaine oil selection
Selection of oil SAE number according

to ambient temperature
Type of oil
-22 -4 14 32 50 68 86 l&‘y~
-30 -20 -10 0 10 20 30 0
Engine oil
Legend
Q : Most probable causes (judgingfrom Questionsand Check items)
n : Possible caus.es due to length of use (used for a long period)
: Items to confirm the cause.
Condition when oil pressure
There is catching of relief valve, regulator valve, spring, or

_z?
valve guide is broken
I ‘y
? When oil level sen.sor is replaced, oil pressure sensor lamp
0 0 ;
goes out
c %
When oil pressure is measured, it is found to be within
0;
standard value
20- 120
0
S-13 Oil level rises

* If there is oil in the cooling water, carry
out troubleshooting for “Oil is in cooling
water”.
General causes why oil level rises
l Water in oil (cloudy white)
. Fuel in oil (diluted, and smells of diesel
fuel)
. Cause
Entry of oil from other component
Legend
a: Possible causes due to length of use (used for a long period)
Oil level goes down in hydraulic tank
Engine oil smells of diesel fuel
Fuel is added more frequently

S-14 Water temperature becomes too high

(overheating)
General causes why water temperature becomes too hig
Lack of cooling water (deformation, damage of fan)
Drop in heat dissipation efficiency
Defective cooling circulation system
Rise in oil temperature of power train
* Carry out troubleshooting for chassis.
Legend
0: Possible causes due to length of use (used for a long period)
Water temperature gauge

Does not go down from red
I I i I I I I I I I I
Radiator water level sensor lights up 0
Fan belt whines under sudden load 0
Cloudy white oil is floating on cooling water 0
Cooling water flows out from overflow hose I I I I I I I I 101 I I I

Excessive air bubbles inside radiator. water sow-ts back I I I I I I I I I It3 I
Power train oil temperature enters red range before engine

water temperature
I I I I I I I I I I I IU
Temperature difference between top and bottom radiator
Temperature difference between top and bottom radiator
When measurement is made with radiator cap tester, set
en compression pressure IS measure
Remove oil pan and check directly
20- 122
0
S-15 Abnormal noise is made

* Judge if the noise is an internal noise or
an external noise.
General causes why abnormal noise is made
. Abnormality due to defective parts
. Abnormal combustion noise
. Air sucked in from intake system
Legend
: Items to confirm the cause.
Blue under light load 0

Color or exhaust gas
Slack 0 0 0
Abnormal noise is loud when accelerating engine 00000 0

Clanging sound is heard from around cylinder head 00
Leakage of air between turbocharger and head, loose clamp 0
Vibrating noise is heard from around muffler
0
-
When compression pressure is measured, it is found to be low l
When trubocharger is rotated by hand, it is found to be heavy 0
Remove tear cover and check directlv a

change in engine speed, that cylinder is not working
I I I I I I I I I
When control rack is pushed, it is found to be heavy or does not return I I I I I.1 I I I I I I
Injection pumptest showsthat injection amount is incorrect 1 I I / ) Il I 1 I I / I
Fan is deformed, or belt is loose I I I I I I Ial I I I I
When valve clearance is checked directly, it is found to be
outside standard value
I I I 1 I I I /aI I I I
Remove cylinder head cover and check directly
I I I I I I I I I.1 I I
When muffer is removed, abnormal noise disappers
0
z : z z : ;; .= ;; : .= .= z
Remedy $ $ $ 2 $ 5 p 5 $ g E $
$ d $ $ $ accazaag
20- 123
0
TROUBLESHOOTING S-16
S-16 Vibration is excessive

+ If there is abnormal noise together with
the vibration, carry out troubleshooting
for “Abnormal noise is made”.
General causes why vibration is excessive
. Defective parts (abnormal wear, break-
age)
. Improper alignment
. Abnormal combustion
Legend
I I Confirm recent repair history
Degree of use Operated for long period anna
Suddenly increased 0 0
Condition of vibration
Gradually increased 0000
Non-specified fuel has been used lO(O\ 1 1 j 1 1 I 1

’ Metal particles are found in oil filter 00
Metal particles are found when oil is drained 00
Oil oressure is low at low idling 00

I-
Vlbratlon occurs at mid-range speed I I I lolol
Vibration follows engine speed )(01
Exhaust gas is black
Seal on injection pump has come off
Remove oil pan and check directly
I Remove
Check
side cover
directly for worn

and check directly
support pilot, play

a
Check directlyfor loose engine mounting bolts, broken cushion a
Check inside of output shaft (damper) directly l

When radial runout, face runout are measured, they are
found to be outside standard value
Remove front cover and check directly
Remove head cover and check directly
Injection pump test shows that injection amount is incorrect 0
z % 8 : !j .= .f $ ;;
Remedy E $ $ d $ z 4 $ s
~;$~~cccc$~
20- 124
0
TROUBLESHOOTING OF HYDRAULIC AND
MECHANICAL SYSTEM (CHASSIS RELATED)
POWER TRAIN
T-l Machine does not start.. ............................................................................................................... 20-126
T-2 Travel speed is slow, thrusting power is weak, lacks power on slopes ............................... 20-128
T-3 Excessive shock when starting machine or shifting gear ........................................................ 20-130
T-4 Excessive time lag when starting machine or shifting gear.. ................................................. .20-131
T-5 Torque converter oil temperature is high.. ................................................................................ 20-132
STEERING SYSTEM
S-l Steering wheel does not turn ..................................................................................................... 20-133
S-2 Steering is heavy.. ........................................................................................................................ 20-134
S-3 Steering wheel shakes or there is excessive shock ................................................................ .20-135
S-4 Deviates to one side when traveling.. ........................................................................................ 20-136
S-5 Turning radius is different between left and right .................................................................. .20-136
S-6 Excessive shock to machine when steering wheel is turned fully to left or right.. ............. 20-136
BRAKE SYSTEM
A-l Brakes do not work or braking effect is poor . . . .. . . . . . . .. . .. . . . . . .. . . . . . . . .. . . . . . . . . . . .. .. . . . . . . . . . .. .. . . . . . . . .. . . .. .. . 20-137
B A-2 Brake is not released, brake drags . . . . . . .. . .. . . . .. .. . . . . . . .. . . . . . . .. . . . . . . .. .. . . . . . . .. . .. . . . . . . . . .. .. .. . . . . . . .. .. . . . . .. . .. . . . . . 20-138
b
z
WORK EQUIPMENT
H- 1 Boom does not rise ...................................................................................................................... 20-139
H- 2 Boom movement is slow or boom lacks lifting power.. ......................................................... .20-140
H- 3 When boom is raised, it moves slowly at a certain height.. .................................................. .20-141
H- 4 Bucket cannot be pushed with boom cylinder (bucket floats) ............................................... .20-141
H- 5 Excessive hydraulic drift of boom .............................................................................................. 20-141
H- 6 Boom shakes during operation.. ................................................................................................. 20-141
H- 7 Boom drops momentarily when control lever is operated from HOLD to RAISE ................ 20-142
H- 8 Bucket does not tilt back ............................................................................................................. 20-143
H- 9 Bucket movement is slow or tilt-back lacks power ................................................................. .20-144
H-10 Bucket movement becomes slow during tilt-back operation ................................................. .20-145
H-l 1 Bucket cannot be pushed with bucket cylinder ....................................................................... .20-145
H-12 Excessive hydraulic drift of bucket.. ........................................................................................... 20-145
H-13 Bucket shakes during loading operation ................................................................................... 20-146
H-14 Bucket dumps momentarily when control lever is operated from HOLD to TILT ................ 20-146
H-15 Boom, bucket control levers are heavy or do not move smoothly ........................................ 20-147
Explanation of symbols in Table

The following symbols are used on the Cause column to show the action to be taken to remove the
cause.
X: Replace, A: Correct, A: Adjust, C: Clean
20-125
Q
TROUBLESHOOTING T-l
POWER TRAIN
T-l Machine does not start
Ask the operator the following questions.

. Did the problem suddenly start?
Yes = Internal part seized or broken
. Was there any abnormal noise when this
happened?
Yes = Component broken.
Checks before troubleshooting

. Does the machine monitor function prop-
erly?
. Is the transmission oil level correct?
Is the type of oil correct?
. Is the transmission filter or strainer
clogged?
. Does the electrical circuit of the trans-
mission control work properly?
. Is the transmission oil deteriorated?
Does the oil smell of burning?
. Is there any damage or leakage of oil
that can be seen externally?
. Is the drive shaft broken?
. Is the wheel brake or parking brake /
locked?
Torque converter stall speed does not go down to specified speed

4 0000 0
in any transmission range
Torque converter stall speed does not go down to specified speed

5
in certain transmission ranges
6 Torque converter charging pressure does not rise 00000
7 Transmission clutch pressure does not rise in any speed range 000 00 0
Transmission clutch pressure does not rise in certain speed

8
ranges
9 Metal particles (aluminium, copper, iron, etc.) stuck to filter or

strainer I I I I I
20- 126
0
TROUBLESHOOTING T-l
20- 127
0
TROUBLESHOOTING T-2
T-2 Travel speed is slow, thrusting power is weak, lacks power on

slopes
Checking for abnormalities

. Measure digging operations and speed
when traveling on level ground and on
slopes, and check if there is actually an
abnormality or whether it is just the feel-
ing of the operator.

clogged?
. Is there any oil leaking from the joints of
the piping or valves?
. Is there any dragging of the wheel brake
or parking brake?
. Is the tire inflation pressure and tread
pattern normal?
. Is the method of operation correct?
0
When oil temperature is low, abnormal noise comes from
3
charging pump
4 Torque converter oil overheats 00 00

5 Abnormality in high idling and low idling speeds 0
6 Abnormality in each stall engine speed 0000
7 Torque converter relief pressure is low 00000
8 Low in every transmission range 00
Transmission
clutch pressure :ransmission ranges 0
10 Indicator is unstable and fluctuates violently 0
11 Transmission oil level changes
,* Metal particles stuck to transmission strainer or torque converter

filter
I loI I loI I I
20- 128
0
TROUBLESHOOTING T-2
20-129
Q
TROUBLESHOOTING T-3
T-3 Excessive shock when starting machine or shifting gear

It is difficult to measure if the shock is ex-
cessive or normal, so judge that the shock
is excessive in the following cases.
. When it is clear that the shock has be-
come greater than before.
. When the machine is compared with
another machine of the same class and
the shock is found to be greater.

. Is the engine idling speed too high?
. Is there play in any of the drive shafts?
TROUBLESHOOTING T-4
T-4 Excessive time lag when starting machine or shifting gear

. Was there excessive time lag? Was there
any abnormality in the travel speed or
thrusting force? Was there any lack of
power when traveling up slopes?
Yes = Go to T-2 Travel speed is slow,
thrusting power is weak, lacks
power on slopes

. Is there any oil leaking from the joints of
the piping or valves?
2 1 Time lao is excessive in certain transmission ranaes IIIII 0 IO I

3 I Clutch Dressure is tow in everv transmission renoe I lol lol I I
Clutch oil pressure is low in transmission ranges where time lag is
4
excessive I I I 101 O I O I
20-l 31
0
TROUBLESHOOTING T-5
T-5 Torque converter oil temperature is high

. Does oil temperature rise during torque
converter stall and go down when there
is no load?
Yes = Selection of transmission range
. Does oil temperature rise only when car-
rying out scooping work?
Yes = Improvement in method of opera-
tion

. Are the radiator water level and fan belt
tension correct?
clogged?
checking for abnormalities

. Measure the torque converter oil tem-
perature. Is it actually high?
Yes = Defective oil transmission gauge
Transmission
Metal particles stuck to transmission strainer or torque converter

11 0 0 0
filter
20-l 32
0
TROUBLESHOOTING S-l
STEERING SYSTEM
S-l Steering wheel does not turn

Yes = Steering equipment damaged or
broken
. Was there previously any symptom, such as
heavy steering?
Yes = Wear of internal parts of steering
equipment, defective seal

. Is the hydraulic oil level correct? Is the type
of oil correct?
. Has the safety bar been removed from the
frame?
Steering wheel does not turn either to left or to right
% There is a close connection between the steering circuit and the work equipment circuit, so if any
abnormality is felt in the steering, check the operation of the work equipment also.
20- 133
0
TROUBLESHOOTING s-2
S-2 Steering is heavy

Yes = Steering equipment damaged or
broken
. Was there previously any symptom, such as
heavy steering?
Yes = Wear of internal parts of steering
equipment, defective seal
Checks before troubleshooting.

of oil correct?
. Is there any leakage of oil from the hydrau-
lic hoses, valves, or cylinders?
. Is there any scuffing of the center hinge pin
bearing or steering cylinder pin or bushing?
. Is the tire inflation pressure correct?
Checking for abnormalities.

. Measure the operating force of the steering
wheel and the time taken to turn the steer-
ing, and check the values in the Standard
Value Table to see if there is really any ab-
normality.
20- 134
0
TROUBLESHOOTING s-3
S-3 Steering wheel shakes or there is excessive shock

of oil correct?
. Is there any play in the center hinge pin
bearing or steering cylinder pin or bushing?
. Is there any variation in the tire inflation
pressure?
l Is the steering wheel play correct?

. Operate at a safe place and check how the
steering wheel shakes and under what con-
ditions.
% In cases where the steering wheel is
heavy but does not shake, go to “T-7
Steering is heavy.”
20- 135
0
TROUBLESHOOTING S-4, S-5, S-6
S-4 Deviates to one side when traveling

Cause
. Defect inside Orbit-Roil
l Oil leakage inside steering cylinder
. Variation in inflation pressure of tires
S-5 Turning radius is different between left and right

Cause
. Defective cylinder piston packing
. Defect inside Orbit-roll
S-6 Excessive shock to machine when steering wheel is turned fully to ;

left or right z0
Cause
. Deteriorated, damaged, or missing front frame bumper
20-l 36
0
TROUBLESHOOTING A-l
BRAKE SYSTEM
A-l Brakes do not work or braking effect is poor
Ask the operator the following questions
Yes = Brake equipment broken
. Did the problem gradually appear?
Yes = Deterioration of seal, wear of
lining, disc

. Is the brake oil level correct?
. Is the brake pedal play correct?
. Is there any leakage of oil from the brake
tube or connector?
Is there any deformation of the tube?
. Is the tire inflation pressure and tread
pattern normal?

. Measure the braking force and compare
with the Standard Value Table to check
if the braking effect is poor
No. Problems
zo- 137
0
TROUBLESHOOTING A-2
A-2 Brake is not released, brake drags

. Is the play of the brake pedal correct?

. Does the machine travel smoothly un-
der inertia on flat ground?
. Jack up the four wheels and check the
rotating resistance of the tires.
No. Problems
When oil is drained from air bleed plug in brakes fluid high
1
pressure circuit, circuit pressure drops and brake is released
When four wheels are jacked up, axles are put on stands, engine
is stopped, parking brake is released, and tires are rotated by
2
hand, certain wheels are heavy
When four wheels are jacked up, axles are put on stands, engine
is stopped, parking brake is released, transmission is set to
3
neutral, and tires are rotated by hand, wheels rotate smoothly, but
become heaw when enaine is started.
20-138
0
TROUBLESHOOTING H-l
WORK EQUIPMENT
H-l Boom does not rise
Yes = Equipment seized, damaged
Was there any abnormal noise
when this happened? (from
where?)
. Was there previously any symptom, such
as the speed becoming slow?
Yes = Wear of internal parts, dete-
rioration in spring

. Is the hydraulic oil level correct?
. Is the travel of the boom control lever
and spool properly adjusted?
Bucket cannot be operated and boom cannot be raised
Chassis can be raised with boom but boom cannot be raised, or

bucket can be operated but boom cannot be raised
Boom can be raised when there is no load but cannot be raised
4 Abnormal noise comes from hydraulic pump 0 0
5 Excessive hydraulic drift of boom cylinder 00
20- 139
a
TROUBLESHOOTING H-2
H-2 Boom movement is slow or boom lacks lifting power

. Is the travel of the boom control lever
and main control valve spool properly
adjusted?
. Is there any seizure of the work equip-
ment linkage? (Is there any abnormal
noise?)

. There is a strong connection between
lifting power and speed, so this problem
first appears as a lack of lifting speed.
Measure the boom lifting speed when
the bucket is loaded and use the Stand-
ard Value Table to judge if there is any
abnormality.
Bucket tilting power and speed are abnormal and boom lifting
1 000
speed is slow
Bucket tilting power and speed are normal but boom lifting speed
2 0 0
is slow
As in Item 1, but lifting speed is particularly slow when oil

3
temperature rises I lol lol O I
4 Abnormal noise comes from hydraulic pump
5 Excessive hvdraulic drift of cvlinder I lol 0

61 Rehef oressure of relief valve in main control valve is low I I lolol 0 I
20- 140
0
TROUBLESHOOTING H-3, H-4, H-5, H-6
H-3 When boom is raised, it moves slowly at a certain height

. Can any deformation be seen in the boom cylinder?
Cause
. Swelling or internal damage to boom cylinder tube
* For other abnormalities when the boom is raised, go to “H-2 Boom movement is slow or boom
lacks lifting power.”
H-4 Bucket cannot be pushed with boom cylinder (bucket floats)
See “H-2 Boom movement is slow or boom lacks lifting power.”

. Is the stroke of the boom spool in the main control valve properly adjusted?
Cause
. Defective seating of suction valve at boom cylinder rod end of main control valve
. Oil leakage from boom cylinder piston seal
H-5 Excessive hydraulic drift of boom

Yes = Dirt caught in valve, broken part
. Did the problem gradually appear?
Yes = Worn parts
. Is the boom spool at the neutral position?
Yes = Seized link bushing, defect in spool detent
Troubleshooting and Cause
. When measuring the hydraulic drift, is there any sound of oil leakage from inside the boom
cylinder?
Yes = Defective cylinder packing
H-6 Boom shakes during operation

When digging or leveling operations are carried out with the boom control lever at HOLD, the
bucket and boom move up and down to follow the shape of the ground.
Troubleshooting and Cause
Measure the hydraulic drift of the boom and check if it is possible to lift the chassis with the boom
cylinder.
1. If the hydraulic drift of the boom cylinder is outside the standard value, go to “H-5 Excessive
hydraulic drift of boom.“
2. If the chassis cannot be raised with the boom cylinder, go to “H-4 Bucket cannot be pushed
with boom cylinder.”
3. If the hydraulic drift of the boom is normal, operate the boom several times, and operate the
boom cylinder to the end of its stroke. Is it now possible to raise the chassis with the boom
cylinder?
Yes = Vacuum had formed inside cylinder
+ However, if this problem appears frequently, the suction valve at the boom cylinder rod end is
defective.
20-l 41
Q
TROUBLESHOOTING H-7
H-7 Boom drops momentarily when control lever is operated’ from

HOLD to RAISE
Checking problem
. When the engine is run at low idling and the boom control lever is operated slowly from HOLD
to RAISE, the boom goes down under its own weight. When the lever is operated fully to the
RAISE position, the condition returns to normal.
Cause
. Defective seating of check valve for boom spool in main control valve
20-l 42
0
TROUBLESHOOTING H-8
H-8 Bucket does not tilt back

Yes = Equipment seized, damaged
Was there any abnormal noise
when this happened? (from
where?)
. Was there previously any symptom, such
as the speed becoming slow?
Yes = Wear of internal parts, dete-
rioration in spring

. Is the travel of the bucket control lever
and spool properly adjusted?
Chassis can be raised with bucket but bucket cannot be tilted

2
back, or boom can be operated but bucket cannot be tilted back
I I I I I O lol O
Bucket can be tilted back when there is no load but cannot be
3
tilted back during digging or scooping operations
101 lolo: O I I
4 1 Abnormal noise comes from hydraulic pump loI lol I I I
5 Excessive hydraulic drift of bucket cylinder 1 / 0101 0
20-l 43
0
TROUBLESHOOTING H-9
H-9 Bucket Movement is slow or tilt-back lacks power

. Is the travel of the bucket control lever
and main control valve spool properly
adjusted?
. Is there any seizure of the work equip-
ment linkage? (Is there any abnormal
noise?)

l Check if there is lack of tilt-back power
during actual operations.
. Measure the operating speed of the
bucket and use the Standard Value Ta-
ble to check if there is any abnormality
20- 144
0
TROUBLESHOOTING H-10, H-II, H-12
H-10 Bucket movement becomes slow during tilt-back operation

. Can any deformation be seen in the bucket cylinder?
Cause
. Swelling or internal damage to bucket cylinder tube
. For other abnormalities when the bucket is operated, go to “H-9 Bucket movement is slow or
tilt back lacks power.”
H-II Bucket cannot be pushed with bucket cylinder

See “H-9 Bucket movement is slow or tilt back lacks power.”

. Is the stroke of the bucket spool in the main control valve properly adjusted?
Cause
. Defective seating of safety valve (with suction valve) at bucket cylinder rod end of main control
valve
. Oil leakage from bucket cylinder piston seal
H-12 Excessive hydraulic drift of bucket

zz
r- Yes = Dirt caught in valve, broken part
G .
0 Did the problem gradually appear?
Yes = Worn parts

. Is the bucket spool at the neutral position?
Yes = Seized link bushing, defect in spool detent

. Use the Standard Value Table to check if the hydraulic drift of the bucket is actually excessive.
Cause
l Oil leakage inside bucket cylinder
. Defective seating of safety valve (with suction valve) at bottom end
. Defective oil tightness of bucket spool
20- 145
Q
TROUBLESHOOTING H-13. H-14
H-13 Bucket shakes during loading operation

(Main control valve at HOLD)

. Is there play in the work equipment linkage pin, bushing? (Is there any abnormal noise?)
Cause
. Defective bucket cylinder piston seal
. Defective operation of safety valve (with suction valve) at bucket cylinder rod end. If any other
problem occurs at the same time, carry out troubleshooting according to the nature of the
problem.
H-14 Bucket dumps momentarily when control lever is operated from

HOLD to TILT
Checking problem
. When the engine is run at low idling and the bucket control lever is operated slowly from
HOLD to TILT, the bucket dumps momentarily under its own weight. When the lever is
operated fully to the TILT position, the condition returns to normal.
Cause
. Defective seating of check valve for bucket spool in main control valve
20- 146
0
TROUBLESHOOTING H-15
H-15 Boom, bucket control levers are heavy or do not move smoothly
. Check that the values in the Standard Value
Table to check if the operating force of the
lever is actually excessive.
Levers are always heavy during operation regardless of oil

4
pressure or temperature
I O /0/3l I I loI
Levers are still heavy after control lever link is disconnected at
5
valve connection
loi I I I I I I
20-l 47
0
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL . . . . .. .. . . . . . . . . .. 30- 3 CLUTCH PACK

PRECAUTIONS WHEN CARRYING OUT Disassembly ........................................ .30- 69
OPERATION . .. . .. . . . . . .. . .. . . . . . .. . . . . . . .. . .. . . . . . . . . . 30- 4 Assembly ............................................. .30- 75
SPECIAL TOOL LIST .. . . . . . .. .. . . . . .. .. .. . . . . . . .. . .. . . . . 30- 6 TRANSMISSION CONTROL VALVE
STARTING MOTOR Removal ................................................ 30- 89
Removal and Installation . . . . .. . . . .. . . .. . .._.. 30- 8 Installation ............................................ 30- 90
ALTERNATOR Disassembly ......................................... 30- 92
Removal and Installation . . .. .. . . . .. . .. . . . . . . . 30- 9 Assembly .............................................. 30- 94
FUEL INJECTION PUMP TRANSMISSION SOLENOID VALVE
Removal . . .. . . . . . . .. . . . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . .. .. . . 30-10 Disassembly and Assembly.. ............. .30- 96
Installation . .. .. . . . . .. .. . . . .. . .. . . . .. .. . . . . . . . .. . . . . . .. . 30- 11 TRANSMISSION ACCUMULATOR VALVE
ENGINE OIL COOLER Disassembly ......................................... 30- 97
Removal and Installation . . . . .. . .. . . . . . . . .. . . . 30- 12 Assembly .............................................. 30- 98
E
WATER PUMP DRIVE SHAFT
2 Removal and Installation . . . . .. . . . . . . . . . .. . . . . 30-13 Disassembly ......................................... 30- 99
NOZZLE HOLDER Assembly .............................................. 30-101
Removal and Installation . . . . .. . . . . . . .. . .. . . . . 30-14 FRONT AXLE
THERMOSTAT Removal ................................................ 30-103
Removal and Installation . . . . .. . . . . . . .. . .. . . . . 30-15 Installation ............................................ 30-104
TURBOCHARGER REAR AXLE
Removal and Installation . . .. .. . . . . . . . .. ..._.. 30-16 Removal ................................................ 30-105
CYLINDER HEAD Installation ............................................ 30-109
Removal . . . .. . .. . . . . . .. . . . .. .. . .. . . . .. . . .. . . . . . .. . . .. . . . . . 30-17 DIFFERENTIAL
Installation . . . .. . .. . . . .. . .. . . . .. .. . . . . . . . . . .. . . . .. .. . . . . 30-20 Disassembly ........................................ .30-l 14
RADIATOR Assembly .............................................. 30-I 18
Removal . . .. . .. . . . . . . .. . . . . . .. . .. . . . .. . . .. . . . . . . . .. .. . . . . . 30-22 AXLE HOUSING
Installation . .. .. . . . . . . .. . .. .. . .. . . . . . . . . . . . .. . . . . . . ...__ 30-25 Disassembly ......................................... 30-128
ENGINE Assembly .............................................. 30-133
Removal . . .. . .. . . . . . . . .. . . . . .. . .. . . . . . . . . .. . .. . . . .. .. . . . . . 30-26 CENTER HINGE PIN
Installation . . . .. . .. . . . . . . .. .. . . . . . . .._..._....__........ 30-29 Removal ................................................ 30-141
TORQUE CONVERTER CHARGING PUMP Installation ........................................... .30-149
Removal and Installation . . . . .. .._........ 30-30 PRIORITY VALVE
TORQUE CONVERTER, TRANSMISSION Removal ................................................ 30-158
Removal . . .. . .. . . . . . . .. .. . . . .. . .. . . . .. . . .. . . .. . .. . . .. . . . . . 30-31 Installation ............................................ 30-159
Installation . .. .. . .. . . . .. . .. .. . .. .. . . . . . .. . . .. . . . .. .. . . . . 30-38 STEERING VALVE
TORQUE CONVERTER Removal ................................................ 30-160
Disassembly .. . .. . . . . . . .. . . . . . ..._..............._.._. 30-39 Installation ............................................ 30-162
Assembly . . . .. .. . . . . .. .. . . . .. . .. . . . . . . . .._......._._.._. 30-41 Disassembly ......................................... 30-I 63
TRANSMISSION Assembly .............................................. 30-166
Disassembly ._.._......................_......._._.__. 30- 43 STEERING CYLINDER
Assembly .. . .. . . . . . . .. .. . . . .. . . . . . . .. . .. . . . . . . .. .. . . . .. . 30-54 Removal ................................................ 30-171
Installation ............................................ 30-172
30-l
0
BRAKE BOOSTER
Removal ................................................ 30-173
Installation ............................................ 30-175
Disassembly ......................................... 30-176
Assembly.. ............................................ 30-179
PARKING BRAKE
Removal ................................................ 30-I 84
Installation ............................................ 30-186
HYDRAULIC TANK
Removal ................................................ 30-187
Installation ............................................ 30-188
HYDRAULIC FILTER
Removal and Installation ................... .30-189
HYDRAULIC, STEERING PUMP
Removal ................................................ 30-190
Installation ........................................... .30-191
MAIN CONTROL VALVE
Removal ................................................ 30-192
Installation ............................................ 30-I 94
Disassembly ........................................ .30-196
Assembly .............................................. 30-198
BUCKET CYLINDER
Removal ................................................ 30-200
Installation ........................................... .30-201
BOOM CYLINDER
Removal ................................................ 30-202
Installation ............................................ 30-203
HYDRAULIC CYLINDER
Disassembly ......................................... 30-204
Assembly ............................................. .30-206
WORK EQUIPMENT
Removal ................................................ 30-208
Installation ............................................ 30-21 1
FUEL TANK
Removal ................................................ 30-214
Installation ............................................ 30-215
COUNTERWEIGHT
INSTRUMENT PANEL
30-2
0
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
METHOD OF USING MANUAL
1. When removing or installing unit assemblies
(1) When removing or installing a unit assembly, the order of work and techniques used are given
for the removal operation; the order of work for the installation operation is not given.
(2) Any special techniques applying only to the installation procedure are marked a, and the
same mark is placed after the relevant step in the removal procedure to indicate which step in
the installation procedure it applies to.
(Example)
REMOVAL OF 0 0 0 ASSEMBLY . . . . .. . . . .. . Title of operation
a . . . . . . . .. . .. . . . . . . . . .. . . . . . .. . .. .. . . . .. . .. . . . . . . . .. . . . . . . . .. .. . . . Precautions related to safety when carrying out
the operation
1. XXXX(1) . . . . . . . ..._.................................. Step in operation
* . . .. . . . . . . .. .. . .. . . . . . .. . .. . . . . . . .. . . . . . .. . .. . . . . . . .. .. . . . Technique or important point to remember when
removing XXXX (1).
2. n n a (2): .. . . . . . . .. . . .. . . . . .. .. . . . . . . .. .. . . . . . . .. . . . . . . a Indicates that a technique is listed for use
during installation
3. 0 0 0 0 assembly (3)
. . . . . . .. .. . . . . .. .. .. . . . . .. .. . . . . . . .. . . . . . . . . .. . . . . . . See Lubricant and Coolant Table
INSTALLATION OF 0 0 0 ASSEMBLY . . . . Title of operation

l Carry out installation in the reverse
order to removal.
p .. ......................... ..................... Technique used during installation
8
I- . . .. . . . . . .. . .. . . . . . . .. . . . . . .. . . . . . . .. .. . . . . . . . . . Technique or important point to remember when
=;
0
installing n n n (2).
l Adding water, oil . . . . . .. . .. . . . .. .. . . . . .. .. .. . . Step in operation
* . . . . .. . . . . . . .. .. . . . . . . .. .. . . . . . . .. . . . . . . .. . . . . . . Point to remember when adding water or oil
Ia ................................................ Quantity of filling oil and water
2. General precautions when carrying out installation or removal (disassembly or assembly) of units
are given together as PRECAUTION WHEN CARRYING OUT OPERATION, so be sure to follow
these precautions when carrying out the operation.
3. Listing of special tools
(1) For details of the description, part number, and quantity of any tools (Al, etc.) that appear in
the operation procedure, see the SPECIAL TOOLS LIST given in this manual.
30-3
0
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the
general precautions given below when carrying out the operation.]
Precautions when carrying out removal work
If the coolant contains antifreeze, dispose of it correctly.

After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from
entering.
When draining oil, prepare a container of adequate size to catch the oil.
Confirm the match marks showing the installation position, and make match marks in the neces-
sary places before removal to prevent any mistake when assembling.
To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors.
Fit wires and hoses with tags to show their installation position to prevent any mistake when
installing.
Check the number and thickness of the shims, and keep in a safe place.
W,hen raising components, be sure to use lifting equipment of ample strength.
When using forcing screws to remove any components, tighten the forcing screws alternately.
Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt
from entering after removal.
Precautions when handling piping during disassembling

Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
I) Hoses and tubes using sleeve nuts
~~~~e~’ Plug (nut end) Sleeve nut (elbow end) ?

Usethetwo items below as a set F
02 07376-50210 07221-20210 (Nut),07222-00210 (Plug) g
03 07376-50315 07221-20315 (Nut),07222-00312 (Plug)

04 07376-50422 07221-20422 (Nut),07222-00414 (Plug)
05 07376-50522 07221-20522 (Nut),07222-00515 (Plug)
06 07376-50628 07221-20628 (Nut),07222-00616 (Plug)
IO 07376-51034 07221-21034 (Nut),07222-01018 (Plug)
12 07376-51234 07221-21234 (Nut),07222-01219 (Plug)
2) Split flange type hoses and tubes
/~~~e~' Flange (hose end) Sleeve head Splitflange

(tube end)
04 1 07379-00400 1 07378-10400 1 07371-30400

05 1 07379-00500 j 07378-10500 1 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
24 1 07049-02430 1 24 1 20 1 30 DEW00401
27 1 07049-02734 1 27 1 22.5 1 34
30-4
0
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
Precautions for installation operations
Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
Install the hoses without twisting or interference.
Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
Bend the cotter pin or lock plate securely.
When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded
portion with 2 - 3 drops of adhesive.
When coating with gasket sealant, clean the surface and remove all oil and grease, check that there
is no dirt or damage, then coat uniformly with gasket sealant.
Clean all parts, and correct any damage, dents, burrs, or rust.
Coat rotating parts and sliding parts with engine oil.
When press fitting parts, coat the surface with antifriction compound (LM-P).
After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then
connect securely.
When using eyebolts, check that there is no deformation or deterioration, screw them fully, and
align the direction of the hook.
When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one
side.
When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and
other hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idling.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 - 5 times,
stopping 100 mm from the end of its stroke.
3) Next, operate the steering, bucket, and boom cylinders 3 - 4 times to the end of their strokes,
then stop the engine and loosen air bleed plug (I) to bleed the air from the hydraulic tank.
After bleeding the air, tighten plug (I).
4 Following this, raise the engine speed, repeat the procedure in Step 3)
to bleed the air. Repeat this operation until no more air comes out from 1
the plug hole.
w Plug : 11.3 f 1.5 Nm (1.15 Ifr 0.15 kgm)
5) After doing this, run the engine at normal speed.
* When using the machine for the first time after repair or
long storage, follow the same procedure.
Precautions when completing the operations
If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run
the engine to circulate the water through the system. Then check the water level again.
If the hydraulic equipment has been removed and installed again, add engine oil to the specified
level.
Run the engine to circulate the oil through the system. Then check the oil level again.
If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been
removed for repair, always bleed the air from the system after reassembling the parts.
*For details, see TESTING AND ADJUSTING, Bleeding air.
Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
related parts.
30-5
0
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST
Nature of work Symbol Part No. Part Name Q’ty Remarks
Removal, installation
A 793-305-I 600 Lifting tool 2 of rear housing
Disassembly, assembly of
transmission assembly Removal, installation
B 1 793-310-2100 1 Lifting tool 1 1 of clutch assemblv
Disassembly, assembly
Disassembly, assembly of of clutch assembly
transmission clutch pack 1 4 1 793-310-1370 l Pin 15
assembly
Jig for settling

piston seal
Disassembly,
differential
assembly
assembly
of
B I zxxzo-zoo I Installer I5 Insertion of brake piston
C I 793-605-1001 I Brake tester I1 Checking for oil leakage
A 1 mo-ioi-3100 1 Puller assembly I 1
Disassembly of axle Removal of axle shaft

housing bearing
1 1 I 793-520-2730 I Seal support I 2

Holder for oil seal when
Assembly of axle B 1 2 1 793-52o-274o l Bolt 14 press fitting oil seal
housing 3 Adjustment bolt 6
01016-30840
C m-sio-1500 I-Mder 1 For adjusting shim
A 1 ~~~~~~:~?l~~ 1 Cylinder repair stand / 1
Steering Removal,
Disassembly, assembly of installation
Boom,
hydraulic cylinder of round head
bucket
Bucket
Removal,
Boom installation
of nylon nut
Steering
30-6
0
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Nature of work SYmbol I Part No.

I
Part Name
I
Q’ty
I
Remarks
-
790-101-5021 Grip 1
Press fitting of coil bushing
Bolt 1 Kit Part No.: 790-201-1702
01010-50816
D 1 790-201-1811 1 Push tool III Boom I

790-201-1781 Push tool 1 Bucket
790-201-1741 Push tool 1 Steering

-
790-201-5021 Grip 1 Insertion of dust seal
01010-50816 Bolt 1 Kit Part No.: 790-201-1500
E 790-201-1620 Plate 1 Boom

Disassembly, assembly of
790-201-1590 Plate 1 Bucket
hydraulic cylinder
790-201-1550 Plate 1 Steering
-
c
/ I 1 790-720-1000 1 Expander 1 1 [installation of piston ring
Ring I 1 Boom,
Clamp bucket
F 796-720-I 630
Steering
07281-00709
Bucket
-
30-7
0
DISASSEMBLY AND ASSEMBLY STARTING MOTOR
REMOVAL OF STARTING
MOTOR ASSEMBLY
ADisconnect the cable from the negative (-) ter-
minal of the battery.
1. Open engine hood side cover and lock in posi-

tion.
2. Disconnect wiring (I), then disconnect wiring

connector (2).
3. Remove starting motor assembly (3).
INSTALLATION OF STARTING
MOTOR ASSEMBLY
l Carry out installation in the reverse order to
removal.
30-8
0
DISASSEMBLY AND ASSEMBLY ALTERNATOR
REMOVAL OF ALTERNATOR
ASSEMBLY
A Disconnect the cable from the negative

(-1 ter-
1. Open engine hood side cover and lock in posi-

tion.
2. Disconnect wires (I), (2) and (3).
3. Remove bolt (4) of adjustment plate, then loosen

mounting bolt and nut (5).
4. Move alternator assembly (6) towards cylinder

block to loosen belt tension, then remove belts
(7). a
5. Remove mounting bolt and nut (5), then remove

alternator assembly (6).
INSTALLATION OF
ALTERNATOR ASSEMBLY
. Carry out installation in the reverse order to
removal.
Adjust the belt tension. For details, see TEST-

ING AND ADJUSTING, Testing and adjusting
fan belt tension.
30-9
0
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
REMOVAL OF FUEL INJECTION

PUMP ASSEMBLY
1. Remove fuel supply hose (1).
* After removing the fuel supply hose, bend
hose (I) and tie it with wire to prevent the
fuel from spilling.
2. Disconnect 2 fuel filter tubes (2) and return hose

(3).
3. Remove fuel filter assembly (4) together with

bracket.
4. Disconnect axle cable (5) and stop motor cable

(6).
5. Remove lubrication tube (7) and 6 fuel injection

pipes (8). a
6. Remove cover (9), and crank to a position where

pin @ (84.0 - 4.5 mm, length = approx. 100 mm)
enters injection pump drive gear from portion
II II
a .
7. Remove bracket (IO), then remove fuel injection

pump assembly (II). m
30-10
0
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY
removal.
Match mark C
w Fuel injection pipe sleeve nut:
23.5 f 1.0 Nm (2.4 + 0.1 kgm)
a
. Install the injection pump as follows.
I) Set No. 1 cylinder at compression top dead DEW02371
(Seen from flywheel)
center.
* Rotate the crankshaft in the normal di-
rection and align the pointer with the I-
6 TOP line on the crankshaft pulley. If no
match mark can be seen on the idler
gear, rotate the crankshaft one more turn.
2) Using bolt 0, and lock drive gear (12) in
position.
3) Injection pump assembly
* Insert pin @ (04.0 - 4.5 mm, length =
approx. 100 mm) through cover mount-
ing bolt hole “a”, and check that pin en-
ters the casting hole in drive gear
! smoothly.
2 4) Remove bolt @ and replace with normal bolt.
* Adjust the injection timing and bleed the air
from the fuel system. For details, see TESTING
AND ADJUSTING.
I DEW02373
30-l 1
0
DISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER
REMOVAL OF ENGINE OIL

COOLER
1. Lift off engine hood assembly (1).
Engine hood assembly: 130 kg
2. Drain coolant.
3. Remove oil level gauge (2) and turbocharger

lubrication return tube (3).
4. Remove oil filter and bracket assembly (4).
5. Remove cover (5).
6. Remove cooler assembly (6) from cover (51.
INSTALLATION OF ENGINE OIL

COOLER
removal.
. Refilling with water

Add water through the water filler to the speci-
fied level. Run the engine to circulate the water
through the system. Then check the water level
again.
30-12
0
DISASSEMBLY AND ASSEMBLY WATER PUMP
REMOVAL OF WATER PUMP

ASSEMBLY
1. Lift off engine hood assembly (I).
&I kg Engine hood assembly: 130 kg
2. Drain coolant.
3. Remove radiator reserve tank (2) and radiator

upper hose (3).
4. Remove adjustment bolt (5) of alternator assem-

bly (4), loosen mount bolt (6), move alternator
assembly (4) towards block, and remove belt (7)
from alternator assembly. m
5. Remove adjustment plate (8).
8 6. Remove muffler (91, and disconnect water tem-

b
perature sensor connector (IO), heater hose (II),
z
0 and radiator lower hose (12).
7. Remove fan guard (13).
8. Remove fan pulley (141, then remove belt (7).
9. Remove water pump assembly (15).
INSTALLATION OF WATER
PUMP ASSEMBLY
1\
removal.
u
* Adjust the belt tension. For details, see TEST-
ING AND ADJUSTING, Testing and adjust-
\
ing of fan belt tension.

again.
\
DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER
REMOVAL OF NOZZLE
HOLDER ASSEMBLY
&l kg Engine hood assembly: 130 kg
2. Remove muffler assembly (2), muffler bracket

(3), and air cleaner assembly (4).
3. Remove spill tube (51, fuel injection pipe (61,

and holder (7). a
4. Remove holder assembly (8).
INSTALLATION OF NOZZLE
HOLDER ASSEMBLY
removal.

22.1 f 2.5 Nm (2.25 f 0.25 kgm)
Qd Holder mounting bolt: 44.1 + 4.9 Nm

(4.5 + 0.5 kgm)
30-14
0
DISASSEMBLY AND ASSEMBLY THERMOSTAT
REMOVAL OF THERMOSTAT
ASSEMBLY
1. Open engine hood side cover.
2. Drain engine coolant.
3. Remove cover (I).

* Do not disconnect the hose.
4. Remove thermostat (2).
INSTALLATION OF
THERMOSTAT ASSEMBLY
removal.

again.
30-l 5
0
DISASSEMBLY AND ASSEMBLY TURBOCHARGER
REMOVAL OF
TURBOCHARGER ASSEMBLY
1. Lift off engine hood assembly (1).
Engine hood assembly: 130 kg
2. Remove adiabatic plate (2).
3. Remove adiabatic plate bracket (31, then remove

muffler assembly (4).
4. Remove turbocharger lubrication tubes (5) and

(6).
Ir Lubrication tube (5) is clamped at the bot-
tom of the exhaust manifold, so remove the
clamp.
5. Loosen clamp of connector (7).
6. Remove mounting bolts of turbocharger assem-

bly (81, then remove turbocharger assembly.
m
INSTALLATION OF
TURBOCHARGER ASSEMBLY
removal.
w Turbocharger mounting bolt:

37.3 & 7.8 Nm (3.8 + 0.8 kgm)
30-l 6
0
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
REMOVAL OF CYLINDER HEAD

ASSEMBLY
elkg Engine hood assembly: 130 kg
2. Drain coolant.
3. Remove adiabatic plate (2), adiabatic plate

mounting bracket, and reserve tank (3).
4. Remove muffler assembly (4), air cleaner as-

sembly (51, and drain tube (6).
5. Remove clamp of heater hose (71, then remove

8 9 7 10
muffler mounting bracket (81, disconnect con-
nector (9), and remove stop motor assembly
(IO) and stop motor mounting bracket.
6. Remove 2 tubes (1 I), then remove fuel filter

assembly (12) together with mounting bracket.
30-l 7
0
7. Remove radiator upper hose (131, heater hose

(7), radiator lower hose (141, and fan guard (151,
and disconnect water temperature sensor con-
nector (16).
8. Remove adjustment bolt (18) of alternator as-

sembly (17), loosen mount bolt (19), move alter-
nator assembly towards block, then remove belt
(20). m
‘18
9. Remove fan pulley (211, remove belt (201, then

remove water pump assembly (22).
10. Disconnect glow wiring (23), and remove plate

(24).
DEW02394
I
30-18
0
11. Remove intake connector (25), turbocharger and

exhaust manifold assembly (261, spill tube (27).
fuel injection pipes (281, blowby hose (29), and
nozzle holder (30), then remove intake manifold
assembly (31) and head cover (32). a
12. Remove rocker arm assembly (33).

* Loosen the locknut, then loosen the adjust-
ment screw 2 - 3 turns. m 33
DEW02396
13. Remove push rod (34).
14. Remove cylinder head assembly (35).
A kg Cylinder head assembly: 55 kg
DEW02398
INSTALLATION OF CYLINDER
HEAD ASSEMBLY
removal.
-f Adjust belt tension. For details, see TEST-

ING AND ADJUSTING, Testing and adjust-
ing of fan belt tension.
w Turbocharger, exhaust manifold

assembly: 44.1 k 9.8 Nm (4.5 + 1.0 kgm)

23.5 f 1.0 Nm (2.4 k 0.1 kgm)
m Nozzle holder mounting bolt:

44.1 I!Z4.9 Nm (4.5 f 0.5 kgm)
w Intake manifold mounting bolt:

40.2 f 5.9 Nm (4.1 + 0.6 kgm)
m Head cover mounting bolt:

8.8 f 1.0 Nm (0.9 f 0.1 kgm)
m3
* Tighten the mounting bolts and nuts in turn
starting from the center and working to the
outside.
* Check that the ball of the adjustment screw
is fitted securely in the socket of the push
rod.
. Adjust the valve clearance. For details, see
TESTING AND ADJUSTING, Adjusting valve
clearance.
m Rocker arm mounting bolt:
24.5 f 9.8 Nm (2.5 f 1.0 kgm)
m Rocker arm mounting nut:

24.5 f 4.9 Nm (2.5 k 0.5 kgm)
m Locknut: 44.1 + 4.9 Nm (4.5 f 0.5 kgm)
1141
* If any rust of more than 5 mm square is
found on the shank or thread of the bolt,
replace the head bolt with a new bolt.
It Be careful to check that there is no dirt or
dust on the mounting surface of the cylinder
head or inside the cylinder.
* When installing the gasket, check that the
grommets do not come out.
30-20
0
+ Tighten the cylinder head mounting bolts 2

- 3 turns by hand, then tighten in the order Order tightening head bolts
given in the diagram.

Intake side
6 Mounting bolt:
Anti-friction compound (LM-P)
Front fii Rear
@Q Cylinder head mounting bolt:
Tightening torque (Nm (kgm)) Exhaust side
1st step 68.6+9.8(7&l)

DEW02399
2nd step 107.9 * 4.9 (11.0 * 0.5)
+30" (Make a mark on the cylinder
3rd step 90°_,,o head and bolt before tiqhtenina.)
Ir After tightening, make one punch mark on Make one punch m,ark on
the bosand the cylinder head
the bolt head to indicate the number of times
it has been tightened.
. If any bolt already has five punch marks, do
not reuse it. Replace it with a new bolt.
DEW01401

Add water through the water filler to the
specified level. Run the engine to circulate
the water through the system. Then check
the water level again.
30-21
0
DISASSEMBLY AND ASSEMBLY RADIATOR
REMOVAL OF RADIATOR
ASSEMBLY
A the
Stop the machine on level ground and install
safety bar on the frame. Lower the bucket to
the ground and stop the engine. Then apply the
parking brake and put blocks under the wheels
to prevent the machine from moving.
A Loosen the oil filler cap slowly to release the

pressure inside the hydraulic tank. Then operate
the control levers several times to release the
remaining pressure in the hydraulic piping.
1. Drain
1) Loosen drain valve (1) and drain coolant.
Sr If the coolant contains antifreeze, dispose
of it correctly.
- : Coolant: 20 e
2) Loosen radiator cap (2) and release internal

pressure.
I DEW02401
2. Fenders
Loosen mounting bolts at rear of left and right
center fenders (3) and put a block at clearance
II II
a.
3. Hood
1) Disconnect connector (4) of electric wiring.
* Open the left and right inspection cdv-
ers first.
* Remove the clips and bands from the
wiring and hoses.
* Remove the grease gun inside the en-
gine room, then move the left cover to
the outside.
* Remove cover (4-1) at the bottom rear
of the radiator.
30-22
0
RADIATOR
2) Assemble eyebolts to hood (5).

3) Sling hood (5), then remove mounting bolts
and lift off. m
* Be careful not to hit the cab.
Ir Raise the hood approx. 150 mm, stop
and check that there is no interference,
then lift off slowly.
iI+ kg Hood: 127 kg
!406
4. Hydraulic piping
Disconnect hydraulic pipings (6) and (7‘) from
radiator. a
r,
DEW0240 6
5. Radiator hoses
Disconnect radiator hoses (8) and (9) at engine
end. m
DEW02408 DEW02409
30-23
0
6. Fan guard
Remove fan guard (IO). m
* Be careful not to damage the radiator fins.
* Remove the left and right fan guards with
them still connected.
7. Radiator
1) Sling radiator and remove radiator supports
(11) from rear frame end.
* Remove the left and right radiator sup-
ports.
-/
11 DEW0241 1
2) Remove radiator (12) and mounting bolts

(13), and lift off. a
+ Be careful not to damage the radiator
fins, and lift off perpendicularly.
A kg Radiator assembly: 50 kg
(with supports and hoses)
-_-_-_-_ ----_-_-_-_-_
DDW02413
30-24
0
INSTALLATION OF RADIATOR
removal.
Be careful not to hit the air cleaner cover

when installing.
Be careful not to hit the cab.
Lower the hood to a point approx. 150 mm
above the mounting position, stop and check
that there is no interference, then install
slowly.
Tighten the hoses without twisting.
Install so that the clearance between the fan

and fan guard is uniform.
Temporarily tighten the mounting bolts and

fix the position, then tighten fully.
When installing the radiator, the difference
in the clearance between the fan and radia-
tor on the left and right must be within 3
mm.
Install so that the clearance between the ra-
diator fins and the front face of the fan is
uniform at the top, bottom, left, and right.
The difference between the left and right in
the position of the radiator in the front-to-
rear direction must be within 5 mm.
Adjust so that the clearance between the
Center of chassis
shroud and fan is uniform.
w Radiator mounting bolt: 112.8 * 9.8 Nm
(11.5 + 1.0 kgm)
m Radiator support mounting bolt:

112.8 f 9.8 Nm (11.5 + 1.0 kgm)
. Refilling with oil and water

I) Tighten drain valve and add water through
water filler to the specified level.
Ii3 Coolant: 20 e
2) Add transmission oil through oil filler to the

specified level.
* Run the engine to circulate the oil
through the system. Then check the oil
level again.
30-25
0
DISASSEMBLY AND ASSEMBLY ENGINE
REMOVAL OF ENGINE
A Stop the machine on level ground and install

the safety bar on the frame. Lower the bucket to
g, Loosen the oil filler cap slowly to release the

Disconnect the cable from the negative (-1 ter-
Radiator
Remove hood and radiator. For details, see RE-
MOVAL OF RADIATOR. a
j, When an air conditioner is installed, discon-
nect the heater hose, then remove the com-
pressor together with the bracket, and move
to the side.
Electric wiring
Disconnect following electric wiring.
. Disconnect ground wiring from starting mo- Rear frame right side’ ”
tor.
. Disconnect cable (7) between battery relay
and starting motor from starting motor.
. Disconnect rear wiring harness from left rear
frame connectors (8), (91, and (IO).
. Disconnect wiring connector (I I) between
engine wiring and slow blow fuse.
. Disconnect wiring connector (12) between
engine wiring and transmission valve, then
remove clamps (13).
. Disconnect connector of wiring (14) for en-
gine stop motor relay.
valve wiring Rear frime left side
3. Fuel control linkage DEW02417
1) Disconnect fuel control cable (15) at engine
end.
2) Remove fuel control cable bracket (16) to-
gether with cable (15).
30-26
0
4. Fuel hoses
1) Disconnect hose (17) between fuel tank and
fuel feed pump from feed pump (18).
2) Disconnect fuel return hose (19) from fuel
tank.
3) Remove return hose (20) from fuel filter.
4) Disconnect fuel level sensor connector (21).
DEW02420
5. Ennine oil drain valve

Remove engine oil drain valve (22) from rear
axle pivot portion.
\
I DEW02421
6. Engine
1) Set stand 0 under transmission (23).
-Lr Adjust the height properly and set stand
@ in position.
Y I DEW02422
2) Sling engine and remove bolts connecting

to transmission (24). m
3) Remove mount bolts (25) and lift off engine

(26). m
* Be extremely careful not to damage the
fuel tank breather tube and engine oil
drain hose when removing.
el
kg Engine: 510 kg
DEW02425
30-28
0
INSTALLATION OF ENGINE
removal.
+ Install radiator and hood. For details, see

INSTALLATION OF RADIATOR.
w Mounting bolt:
652 f 34.3 Nm (66.5 k 3.5 kgm)
(Width across flats: 32 mm)
m
* Check that there is an O-ring installed to the
mating face of the torque converter.
& Outside circumference of O-ring:

Soapy water
* When connecting the engine and torque con-

verter, adjust the height so that the torque
converter pilot goes in smoothly. Never use
force when connecting.
* When assembling the rubber, never use
grease, oil, or soapy water.
. Refilling with oil and water

1) Tighten drain valve and add water through
water filler to the specified level.
G Coolant: 20 .Q
2) Add transmission oil through oil filler to the

specified level.
through the system. Then check the oil
level again.
30-29
0
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER CHARGING PUMP
REMOVAL OF TORQUE
CONVERTER CHARGING PUMP
ASSEMBLY
AhStop the machine on level ground and install

1. Cover, wiring
I) Remove cover (I) under left center fender.
2) Remove clamp and wiring clamp (2) of air
conditioner hose.
-”
2. Hydraulic piping
I) Disconnect hose (3) between transmission
strainer and torque converter charging pump
from torque converter charging pump. m
2) Disconnect tube (4) between torque converter
charging pump and filter from torque con-
verter charging pump. m
3. Torque converter charging pump

Remove mounting bolts, then remove torque
converter charging pump (5). m
DEW02429 DEWd2430
INSTALLATION OF TORQUE
CONVERTER CHARGING PUMP
ASSEMBLY
removal.
m Tube flange mounting bolt:

66.2 f 7.4 Nm (6.75 + 0.75 kgm)
w Tube flange mounting bolt:

30.9 f 3.4 Nm (3.15 + 0.35 kgm)
m
Ir Be careful not to get the O-ring caught when
installing.
m Mounting bolt: 66.2 f 7.4 Nm

(6.75 f 0.75 kgm)
30-30
0
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER, TRANSMISSION
REMOVAL OF TORQUE
ASSEMBLY

* Remove cover (I) at the top of the hydraulic
tank on the right side, then remove covers
(2) on the left and right under the floor.
A pressure
Loosen the oil filler cap slowly to release
inside the hydraulic tank. Then
the
op-
erate the control levers several times to re-
lease the remaining pressure in the hydrau-
lic piping.
. Loosen plug (3) to prevent the oil inside the

hydraulic tank from flowing out.
* Disconnect the cable from the negative (-1
terminal of the battery.
F
-Ir Machines equipped with air conditioner
z .
0 Release the gas at a point far from the com-
pressor. Loosen the hose connection slightly
to release the gas.
1. Draining oil
Loosen drain plug (3-I) and drain transmission
oil.
- : Transmission oil: 28.0 JZ
2. Cover
I) Sling left ladder rail (41, then remove mount-
ing bolts, and lift off together with center
fender (5).
* Carry out the operation in the same way
on the right side.
* When lifting off the ladder, be careful of
the center of gravity.
* Be careful not to damage the cab glass.
30-31
0
2) Disconnect connector for left brake oil level

sensor.
3) Remove brake oil tank mounting bracket (8)
together with oil tank (7) from under floor.
* Leave the oil hose installed to the brake
oil tank and tie it to the top surface of
the rear frame with wire.
. For machines equipped with an air con-
ditioner, it can be placed on top of the
condenser.
* When carrying out this operation, do not
disconnect the brake oil hose. Move it to
the side and tie it temporarily with wire.
3. Electric wiring
Disconnect following electric wiring from con-
nector.
. Disconnect front wiring (9) and rear wiring
(IO) from connectors (II), (12), (13), (141, (151,
(16), and (17).
. For machines with cab, disconnect wiring
for cab from connector.
. Disconnect ground wiring (18) from rear
frame.
. IO'
Disconnect transmission cut-off switch (19) Rear wiring
and wiring connector (20). v v
.
I DEW02437
Remove wiring clamp and bracket (21) from

rear frame (22).
* Fit tags to identify the wiring.
4. Brake booster
1) Remove locknut of ball joint (24) and brake
linkage (231, and pull out linkage rod. a
2) Set block under brake booster (251, then re-
move mounting bolts (26).
I I
DDW02441
30-32
0
5. Fuel control cable
then remove bracket (28) together with control

cable.
* For machines equipped with cab
. Disconnect the washer hose from the tank,
then coil up and bend the end of the hose.
. After removing the hose, fit a blind plug in
the washer tank.
I-_:
DEW02442
6. Transmission valve wiring

Disconnect connectors (33) of transmission valve
wiring.
DEW02443
7. Work equipment control cable

Disconnect work equipment
at valve end.
control cables (34)
y -71
1
Ir Fit tags to the cables before disconnecting.
- 34 - I I
* Remove the cable clamp.
30-33
0
8. Parking brake cable

1) Disconnect parking brake cable (38) from le-
ver, and remove bracket (40) from front face 38 40 41
of transmission (39). a
Ir After removing the cable, tie it tempo-
rarily to the bottom surface of the floor
with wire.
2) Disconnect speedometer cable (41).
3) Remove transmission oil filler tube (42).
42 39 DDW02445
9. Steering piping
1) Remove hoses (44) and (45) from Steering
valve (43).
2) Disconnect hoses (471, (481, and (49) between

steering valve (43) and priority valve.
3) Remove hose (50) between steering valve

and hydraulic tank.
* Fit blind plugs after disconnecting the
hoses.
, / DEW02447
30-34
0
10. Floor frame, cab assembly

Sling floor frame and cab assembly (511, then
remove mounting bolts, and lift off. m
When raising the floor frame and cab as-
sembly, pull the brake booster out gradually
from the mounting bracket, and lift the cab
slowly.
The brake hose is not disconnected, so be
careful not to catch the brake booster.
Check that there is no interference from the
hoses and wiring, then lift off.
sembly, lift slowly for approx. 40 - 50 mm,
stop and check that there is no interference,
then continue to lift.
el kg Floor frame, cab assembly: 680 kg
Floor frame assembly: 155 kg
11. Drive shafts m

I) Disconnect center drive shaft (52) at trans-
mission end.
2) Remove rear drive shaft (53).
F 12. Hydraulic, steering pump D DEW02451

z
0 I) Disconnect hose (55) between hydraulic,
steering pump and priority valve at priority
valve end.
2) Loosen clamp of hose (56) between hydrau-
lic tank and hydraulic, steering pump, then
disconnect at tank end.
Ir Remove hose clamp (56-I) between the
main control valve and the hydraulic tank
first.
3) Remove mounting bolts of hydraulic, steer-
ing pump (571, then remove.
30-35
0
13. Hydraulic piping m

1) Disconnect drain hose (60) of brake booster
at transmission end.
2) Disconnect hose (61) between priority valve

and main control valve, then remove hose
support bracket (62) from rear frame.
3) Disconnect hose (58) between main control

valve and hydraulic tank, then disconnect
hose clamp (59).
14. Torque converter, transmission m

1) Disconnect hose (63) between transmission
valve and cooler from transmission valve
(64).
2) Disconnect hose (65) between transmission

and cooler from elbow under rear housing I
58 ’
of transmission (68). DEW02454
3) Remove oil filler tube (66) from transmis-

sion.
DEW02458 DEW02457
30-36
0
4) Set hydraulic jack @ under engine.

* Adjust the height properly and support
the engine.
\ 1 ’ DEW02459
5) Remove left and right transmission mount

bolts (67) and (67-I). m 67-l
I / DEW02460 DEW0246
6) Sling torque converter and transmission (681,

and remove bolt connecting to engine (69).
* Sling at two points. m
7) Lift off torque converter and transmission

(68). m
* Check that there is no interference from
the hoses and wiring, then lift off.
* Be extremely careful that the torque con-
verter and transmission does not hit the
rear frame when lifting off.
&I kg Torque converter, transmission:

480 kg
INSTALLATION OF TORQUE
ASSEMBLY
removal.
Bend the cotter pin securely. 7 Check that the O-ring is inserted securely
in the mating surface of the torque con-
verter.
Adjust the parking brake. For details, see
& Outside circumference of O-ring:
TESTING AND ADJUSTING, Adjusting park-
Soapy water
ing brake.
When connecting the engine and torque

m Mounting bolt: 277 + 32 Nm
converter, adjust the height so that the
(28.25 + 3.25 kgm)
torque converter pilot goes in smoothly.
Never use force when connecting.
m Tighten the mounting bolts a little at a
* Be careful of the direction of the yoke, and
time on the left and right, and be careful
align the pilot portion correctly to install.
not to damage the O-ring.
w Mounting bolt: 66.2 + 7.4 Nm
w Mounting bolt: 66.2 f 7.4 Nm
(6.75 + 0.75 kgm)
(6.75 k 0.75 kgm)
[51fi/W . Refilling with oil !?

* install the hoses without twisting or inter-
1) Tighten drain plug and add transmission 5
ference.
oil through oil filler to the specified level. g
m Transmission oil: 28 .Q
Ir To position the transmission, adjust with the Q
adjustment screw to make clearance “a” the
2) Tighten plug and add hydraulic oil
specified value, then tighten the mounting
through oil filler to the specified level.
bolts.
-f When assembling the rubber, never use
%# Hydraulic oil: 80 e
grease, oil, or soapy water.
Clearance “a”: 1 - 2 mm
w Mounting bolt: through the system. Then check the
745 f 83.4 Nm (76 f 8.5 kgm) oil level again.
30-38
0
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
DISASSEMBLY OF TORQUE
CONVERTER ASSEMBLY /
1. Turbine case assembly
1) Remove stator shaft and pump assembly (2)
from turbine and case assembly (3).
DEW03154
2) Disassemble turbine and case assembly as

follows.
i) Remove pilot (4).
ii) Remove snap ring (5).
4
DBWKI155
iii) Push boss portion of turbine (6) and re-

move from case (7).
6,
DBW00157
iv) Remove bearing (8) from case.
DBWCuX58
2. Stator
1) Remove snap ring (9).
2) Remove stator (IO).
3. Stator shaft
Using forcing screws 0, push from stator shaft
(11) end, and disconnect from pump assembly
(12).
DEW02467
4. Gear
Remove gear (13) from pump (14).
5. Bearing
Remove bearing (15) from gear (13).
DEW00162 DBWCQ1.53
30-40
0
ASSEMBLY OF TORQUE
CONVERTER ASSEMBLY
1. Bearing
Install bearing (15) to gear (13).
2. Gear
Install gear (13) to pump (14).
w Mounting bolt: 66.2 + 7.4 Nm i

(6.75 + 0.75 kgm)
&
DEW162
3. Stator shaft
I) Install seal ring (16) to stator shaft (11).
& Seal ring: Grease (G2-LI)

* Make the extension of the seal ring uni-
form.
2) Push inner race end of bearing, and install
pump assembly (12) to stator shaft (11).
DEW02469 DEW02470
4. Stator
I) Install stator (IO).
2) install snap ring (9).
5. Turbine, case assembly

I) Assemble turbine and case assembly as fol-
lows.
i) Install bearing (8) to case.
li Press fit until the ring contacts the
9 DEW02466 L k2471
case.
ii) Push inner race of bearing and install

turbine (6) to case (7).
30-41
0
iii) Install snap ring (5).

iv) Install pilot (4).
4
6 Mounting bolt:
Thread tightener (LT-2)

(6.75 + 0.75 kgm)
A
DBWCO155
2) Install stator shaft and pump assembly (2)

to turbine and case assembly (3).
& Mounting bolt:

m Mounting bolt: 30.9 IL 3.4 Nm

(3.15 + 0.35 kgm)
DLW00163
30-42
0
DISASSEMBLY AND ASSEMBLY TRANSMISSION
DISASSEMBLY OF
l After removing transmission assembly (9) from

the chassis, remove the left and right mount
brackets first.
. Remove the PTO lubrication tube.
1. Hydraulic piping
L
Disconnect hoses (1) and (2), and each tube.
* Be careful not to to crush tube (3) during the
operation.
* After removing the tubes, fit a cover to pro-
DEW02472
tect the thread.
2. Oil filter
1) After removing each hose, remove mount-
ing bracket (5) of filter (4) with filter still
installed.
I DEW02473
2) Remove O-ring (8), cover (7), and speedom-

eter pickup port assembly (6) of idler
countershaft portion.
* After removing the speedometer pickup port

assembly, be careful not to damage the gear
portion of the idler countershaft.
I r’ , ,,,
DEW02475
3) Raise transmission assembly (91, and install

to assembly stand.
* After installing the transmission assem-
bly to the assembly stand, turn over, then
set a support under the REVERSE and
1st side. (To keep it parallel)
DEW02476
3. Strainer, rear coupling

I) Pull out rear coupling (IO).
Sr Fit a cover to prevent dirt or dust from
entering.
2) Remove hose and tube (I I) between strainer

and pump.
4. Charging pump
After removing hoses, remove charging pump
assembly (12) and O-ring.
DEW02478
5. Transmission control valve

I) Remove accumulator valve (13).
2) Sling transmission control valve (141, then

remove mounting bolts and lift off.
* After removing the mounting bolts, fit 2
guide bolts in the bolt holes.
elkg Transmission control valve: 46 kg
30-44
0
6. Rear housing
1) install tool A to rear housing (15), then sling.
* Install tool A securely to prevent it from
coming off. 15
2) Using forcing screws, raise rear housing (151,

then use tool A to lift off.
* Remove slowly and be careful not to
damage the seal ring.
* When removing, install guide bolts to
front housing (16) and lift off horizon-
tally.
&I kg Rear housing, torque converter

assembly: 160 kg
DEW02482
7. Torque converter
Lift off torque converter (17) from rear housing
(15).
* Before removing, make match marks on the
housing and torque converter mating face
with a felt pen.
* When turning over the rear housing, remove
pilot cap (18) or set the housing on blocks.
A kg Torque converter: 35 kg
18 DEW02485 DEW02484
8. Pump (torque converter, work equipment)

1) demove snap ring (19) at tot&e converter
pump mount.
DEW02486
I
2) Turn over rear housing (15), and remove

snap ring (21) of pump gear (201, then re-
move ring washer (22) and split spacer (23).
3) Inset-t screwdriver into stepped portion be-

tween rear housing (15) and shaft (241, then
lever with screwdriver, push shaft down and
pull it out.
24 23 22
DDW02491 DEW02469
30-46
0
4) Remove bearing (25) from shaft (24).

93mm
* Carry out the operation in the same way -I
at the work equipment hydraulic pump

end. 25
24
I DDW02492
9. Seal ring
I) Remove seal ring (26) from each clutch shaft.
21 Remove input shaft (27). 26

/
26
10. REVERSE, 1st clutch assembly

I) Install tool B to REVERSE and 1st clutch as-
sembly (28).
2) Using tool B, lift off REVERSE and 1st clutch

assembly (28).
* Be careful not to hit the other gears when
removing.
& kg REVERSE, 1st clutch assembly: 30 kg
DEW02494
11. FORWARD, 2nd clutch assembly

1) Install tool B to FORWARD and 2nd clutch
assembly (29).
2) Using tool B, lift off FORWARD and 2nd (FORWARD-2nd clutch

clutch assembly (29).
* When doing this, 3rd, 4th clutch assem-
bly (30) and the gear are engaged, so
pull up each part in turn to a point where
the bearing comes out from the front
housing.
&I kg FORWARD, 2nd clutch assembly:

37 kg
3) When bearing of 3rd, 4th clutch assembly

(30) comes out from housing, pull to output
shaft end and tie with wire.
a Be careful not to get your fingers caught’

between the gear and housing when car-
rying out this operation.
12. 3rd, 4th clutch assembly

1) Install tool B to 3rd and 4th clutch assembly
(30).
* Install the lifting tool before removing
the wire.
2) Using tool B, lift off 3rd and 4th clutch as-
sembly (30).
A kg 3rd, 4th clutch assembly: 42 kg
13. Idler countershaft assembly

I) Remove idler countershaft (31) from front
housing (16).
16
DEW02499
30-48
0
2) Remove bearings (32) and (33). and gears

(34) and (35) from shaft (31).
Sr If speedometer worm gear (36) is in-
stalled, remove it before carrying out the
operation.
14. Rear dust seal, oil seal

Remove dust seal (37) and oil seal (38).
15. Coupling
Remove mounting bolts, then remove front cou-
pling (391, holder (401, and O-ring.
38 ’ III DDWO2501
16. Parking brake assembly

I) Turn over front housing (161, and set sup-
port stand under housing.
2) Remove plug of portion “a” at parking brake
front housing end, and be sure to assemble
set bolt @ for securing piston.
* Set bolt for securing piston:
P=1.25,M=8,L=35
Washer: 01643-30825
3) Remove housing mounting bolts (42).

* Install a guide bolt to prevent the hous-
ing from falling.
* Before removing the parking brake as-
sembly, sling the output gear to prevent .42
the output shaft bearing cone from com-
ing out from the bearing cup.
42 DEW02503
4) Tighten 2 forcing screws in forcing screw

hole, and remove housing and piston as-
sembly (43).
Sr Check that a set bolt is installed to hold
the part in position.
Sr Using housing mounting bolts as forc-
ing screws.
I LLJ DEW02504
5) Loosen mounting bolts of parking brake re-

tainer assembly (441, and pull out left and
right shims (45).
* For reference when installing, check the
number and thickness of the shims.
DEW02505
6) Remove hub spline (461, then remove park-

ing brake retainer assembly (44).
46 DEW02506
17. Output shaft gear

1) Loosen mounting bolts of gear cover (47)
and leave them fitted temporarily, then turn
over front housing (16).
47’
30-50
0
2) Remove mounting bolt (48), then remove

gear cover (47) from bottom of housing.
* Be careful not to get your fingers caught
between the gear and housing.
!L DDW02599
3) Hold spline portion of output shaft gear as-

sembly (49) and pull up.
* Be extremely careful not to get your fin- .49
gers caught between the gear and hous-
ing (16) when removing. 16-
* Clearance (one side) between gear and
housing: Approx. 20 mm
* If there is oil on the output shaft spline,
wipe it off completely and be extremely
careful when removing.
4) Remove bearing cone (511, snap ring (521, DEW02510
gear (53), and bearing cone (54) from shaft

(50) in order.
18. Bearing cup

Remove bearing cup of front housing with puller.
* Do not remove unless necessary.
52 51 50
DEW0251 1
30-51
0
DISASSEMBLY OF PARKING BRAKE
1. Plate, disc
I) Remove holder bolts (6) from retainer as-
sembly (44).
I 44 DDWO2512
2) Remove separator plate (7), wave spring (81,

and disc (9).
-7
6 DEW02513
2. End plate
Remove end plate (IO), then remove hub spline
(II).
11
3. Retainer
Turn over retainer (4), and remove bearing cup
(12) with puller.
I DDW02515
30-52
0
4. Housing
Remove 2 set bolts @ for securing piston, then
remove piston (13) and balls (14).
* If it is necessary to disassemble the lever
portion, remove lock bolt (151, check the
match marks on inner lever (16) and outer
lever (17), then pull out the inner lever, and
remove bearings (18) and oil seal (19).
DEW02516
14 DEW02517
DON02518
30-53
0
ASSEMBLY OF
TRANSMISSION
ASSEMBLY OF PARKING BRAKE
1. Housing
1) Press fit oil seal (20) and dust seal (21) to
housing (5).
* Press-fitting dimension “a”: 25.8 f 1.0 mm
Sr Press-fitting dimension “b”:
18.3 f 1.0 mm
6 Lip of oil seal: Grease (G2-LI) DEW02519
Ir Coat with grease when assembling the

housing.
2) Press fit needle bearing (18) and oil seal (19)

to housing (5) to specified dimensions.
Needle bearing press-fitting dimension
“I?‘: 38.5 + 0.15 mm (1st)
Needle bearing press-fitting dimension
“d”: 18.0 + 0.5 mm (2nd)
Oil seal press-fitting dimension “8”:
7.5 + 0.3 mm
& Lip of oil seal: Grease (G2-LI)
3) Insert outside lever (17) from oil seal end.

* Clean and remove all oil and grease from
the bolt hole of the outside lever.
4) Align with match mark and assemble inside

lever (16).
16
’ Match marks
5) Tighten lock bolt (15).

16
Ir Clean and remove all oil and grease lock \ 1”
bolt and bolt hole.
* Be sure to assemble the washer.
& Lock bolt: Thread tightener (LT-2)
m Lock bolt: 30.9 f 3.4 Nm

(3.15 + 0.35 kgm)
DEW02522
30-54
0
6) Fit balls (14) in groove of housing (5), install

piston (13) from top, then temporarily tighten
2 set bolts @ for securing piston.
Ir Assemble temporarily to prevent the pis-
ton from falling out during assembly.
Jr Set bolt for securing piston:
P = 1.25, M = 8, L = 35
Ii DEW02523
2. Retainer
Press fit bearing cup (12) to retainer (4).
* After press fitting the cup, check that there
is no clearance at portion “a”.
a
DDWO2525
3. End plate
Turn over retainer and assemble end plate (IO),
then assemble hub spline (II) to center.
Jr Use the hub spline as a guide when assem-
bling the disc.
DEW02514
30-55
0
r
4. Separator plate, disc
1) Assemble separator plate (71, wave spring
8 9 7 22
(81, and disc (9) in order in turn.
Soak disc (9) in clean transmission oil
for at least 2 minutes before assembling.
Use one spring.
Insert pins (22) into the guide of the sepa-
rator plate spline.
DEW02526 DEW02527
2) Tighten holder bolt (6) of separator plate (7)

to retainer (4).
* Remove all oil and grease from the bolt
thread and bolt hole.
& Holder bolt: Thread tightener (LT-21
m Holder bolt: 53.9 + 19.6 Nm

(5.5 * 2.0 kgm1
DDW02528
5. Brake housing, retainer

Assemble temporarily parking brake retainer
assembly (44) and parking brake housing and
piston (43).
* When assembling housing and piston (43),
do not remove the 2 set bolts @ for holding
the piston.
I DEW02529
43 DDWO2531
30-56
0
ASSEMBLY OF TRANSMISSION
* Press fit the oil seal and dust seal before assem-
bling each clutch assembly.
_j, Press fit the bearing cup fully to the stepped
portion of the housing so that there is no clear-
ance.
* Keep the front housing horizontal.
1. Bearing cup
Press fit bearing cup (55) to front housing (16). n
0 DEW02532
2. Output shaft gear

I) Press fit bearing cone (54) to shaft (501, as-
semble gear (53) and snap ring (521, then
press fit bearing cone (51).
+ To prevent improper adjustment of the
end play, press fit the cone securely up
to the shoulder of the shaft.
* Fit the snap ring securely in the shaft
groove.
8
I+ 52 51 50
DEW0251 1
z
0
2) Assemble output shaft and gear assembly

(49) to bearing cup portion of front housing
(16). .49
between the gear and housing when car- 16-
* Clearance (one side) between gear and
housing: Approx. 20 mm
* If there is oil on the output shaft spline,
wipe it off completely and be extremely
careful when assembling.
DEW02510
3) Insert gear cover (47) from under housing,

rotate gear cover a half turn and align mount-
ing bolt holes.
between the gear and housing when car-
30-57
0
4) Remove all oil and grease from mounting

bolt (48) and bolt hole, coat thread of mount-
ing bolt of gear cover (47) with gasket seal-
ant, then tighten.
& Mounting bolt:


(11.25 f 1.25 kgm)
!I&_ DDW02593
3. Adjusting rotating torque of bearing

1) Assemble O-ring (44-I) to parking brake re-
tainer assembly (441, and coat outside cir-
cumference thinly with grease.
6 O-ring outside circumference:
Grease (G2-LI)
2) Turn over front housing (16), and install

guide bolt, align with guide bolt, assemble
brake retainer assembly (441, and temporar-
ily assemble mounting bolts.
* When doing this, check that the bearing u
DEW02533
cone is properly fitted inside bearing cup
“a”, then assemble.
‘16
DDW02536 DEW02534
3) Inset-t desired shim (45) from left and right

of parking brake retainer assembly (441, then
tighten mounting bolts. 45

(11.25 k 1.25 kgm)
44
* Do not install the hub spline until Step
6).
DEW02535
30-58
0
To settle the bearing, rotate the shaft

while tightening. After tightening, hit the
end face of the shaft several times with
a plastic hammer.
Coat the bearing thoroughly with oil.
Standard shim thickness “a”:
0.85 k 0.83 mm
& Bearing: Transmission oil
4) Tighten coupling mounting bolts to shaft

(50), then measure rotating torque.
* Rotating torque:
0.10 - 1.0 Nm (0.01 - 0.1 kgm)
J, If no small torque wrench is available, it
is also possible to measure as follows. ml! / ,J\ __,Push-pull scale
* Fit measurement plate (56) to shaft (501,
tighten the coupling mounting bolts, then
install a push-pull scale to the tip of plate
(56), and carry out the measurement.
. Plate length .r? 100 mm
. Push-pull scale reading:l.O - 9.8 Nm
(0.1 - 1.0 kgm)
* When measuring the rotating torque, do
not measure at the beginning of the
movement. Measure the torque when the
DDW02538
shaft is rotating.
* If the rotating torque is not within the
standard value, add or remove shims to
adjust again.
Ir If the rotating torque is within the stand-
ard value, check that the end plate is
“0”.
5) Insert selected shim (45) from left and right

of parking brake retainer assembly (44), then
tighten mounting bolts uniformly.
Ir Insert the thim shims in the middle, and
the thick shims on the outside when as-
sembling.

(I 1.25 f 1.25 kgm)
6) Align with parking brake disc spline, and

assemble hub spline (46) to output shaft (50).
* Use a screwdriver to align the disc spline.
46
* If the spline is not aligned, rotate lightly
while assembling. Never push with force.
DEW02539
30-59
0
4. Parking brake assembly

1) Assemble new gasket to mounting surface
“b” for housing and piston assembly on park-
ing brake retainer assembly (44).
2) Align housing and piston assembly (43) with

guide bolt and assemble.
* Check that the lock set bolt is assem-
bled.
* When assembling, be careful not to dam-
age the oil seal lip.
UJ DEW02504
3) Tighten mounting bolts (42) of housing and

piston assembly (43) on diametrically oppo-
site sides.
m Mounting bolt: 110.3 + 12.3 Nm

42
(11.25 & 1.25 kgmj
4) Remove lock set bolt and install plugs (41-

I).
47-l DEW02541
30-60
0
5. Coupling
Coat oil seal lip portion thinly with grease, as-
semble coupling (391, then tighten O-ring (57),
holder (401, and mounting bolt (58).

58
w Mounting bolt: 277 k 32 Nm
(28.25 f 3.25 kgm)
* Slide the coupling several times to prevent

the oil seal lip from turning over.
* Insert the O-ring into the shaft groove, and
be careful not to get it caught. I - DDtVOZ542
* Check that the lock set bolt has been re-

moved and the plug has been assembled in
its place. 38 37 16
6. Rear oil seal, dust seal

Turn over front housing (16), then press fit oil
seal (38) and dust seal (37).

* Press-fitting dimension “a”: 29 f 1 mm
* Press-fitting dimension “b”: 21.5 f 1.0 mm
7. Idler countershaft
In:, 34 Oil groove 33
1) Assemble to shaft (31) so that oil groove of
gear (34) is on inside, then press fit bearing
(32).
2) Assemble to shaft (31) so that oil groove of

gear (35) is on inside, then press fit bearing
(33).
* Press fit the bearing securely to the face
of the gear.
I
I
DOW02544
3) Assemble speedometer worm gear (36) to

spline of shaft (311, then tighten mounting
bolt (59).
* Remove all oil and grease from the
mounting bolts and bolt holes.
& Mounting bolt:

QZ Mounting bolt: 30.9 If: 3.4 Nm

(3.15 + 0.35 kgm)
30-61
0
4) Assemble idler countershaft (31) to front

housing (16).
* When assembling, be careful not to dam-
age the speedometer worm gear.
16
DEW02499
8. 3rd, 4th clutch assembly

Using tool B, assemble 3rd and 4th clutch as-
sembly (30) to housing, then move it towards
output shaft end.
* ‘Secure with wire in the same way as when
disassembling.
* Do not fit the bearing at the bottom of the
clutch into position.
9. FORWARD, 2nd clutch assembly

1) Using tool B, raise FORWARD and 2nd clutch
assembly (29).
Sr Be careful that the stopper pin does not
come out.
2) Mesh gear of 3rd, 4th clutch assembly (30)

with gear of FORWARD, 2nd clutch assem-
bly (29), then lower slowly.
* Do not fit the bearing at the bottom of
the clutch into position.
&L Be careful not to get your fingers caught

in the gear.
3) After checking that each gear is engaged,

press fit bearing at bottom of 3rd, 4th clutch
assembly (30) to front housing.
* Check the meshing of each gear when
press fitting the bearing.
Ir When doing this, the 3rd, 4th clutch gear
and FORWARD, 2nd clutch gear must be
meshed.
30-62
0
4) Press fit bottom bearing of FORWARD and

2nd clutch assembly (29) to front housing
portion.
* Coat the bearing press-fitting portion of
the front housing thinly with transmis-
sion oil.
6 Bearing press-fitting portion:

Transmission oil
10. REVERSE, 1st clutch assembly

Using tool B, press fit bottom bearing of RE-
VERSE and 1st clutch assembly (28) to front
housing.
ABe careful not to get your fingers caught in

the gear.
-28
F
q
0
11. Seal ring 61 60

I) Press fit bearing (60) to input shaft (271, as-
semble gear (61) so that oil groove of gear &I
is on bearing side, then secure with snap
ring (62).
2) Press fit bearing (63) to input shaft (27).
6 Bearing press-fitting portion:

Transmission oil
Ir Fit the snap ring securely in the groove.

63 62 Oil groove 27 DDWO2551
3) Assemble input shaft (27) to front housing

(16).
27
--II
30-63
0
4) Install seal rings (26) to each clutch.

* Coat the seal ring thoroughly with oil,
then install, and check that it rotates
lightly by hand.
I A
& Seal ring: Oil (transmission oil)
26
12. Pump (Torque converter, work equipment) Press

1) Press fit bearing (25) to shaft (24). R
Sr Press fit so that there is no clearance at
the stepped portion of the shaft.
2) Assemble gear (20) and snap ring (21) in-

side rear housing (151, and insert shaft (24)
from pump mount end.
m 24 Shaft insertion portion
DDW02555
* Install the gear so that the oil groove of

the gear is on the pump mount side.
3) Assemble ring washer (22) and split spacer

(23) to stepped portion of shaft (241, then
install snap ring (21).
24
24 23 22’
23)
DDW02557 DEW024Ei9
30-64
0
4) Turn over rear housing (15), and assemble

snap ring (19) at pump mount end.
I DES02486

at the work equipment pump end.
13. Torque converter

Using eyebolts, raise rear housing (15), set to
mount of torque converter, then tighten mount-
ing bolts (64).
* Install guide pins to the torque converter.
* Align the mqunting bolt hole properly, and
be careful of the meshing with the pump
DEW02558
gear when installing.
* When installing, align the match marks made
during assembly.

(11.5 + 1.0 kgm)
14. Rear housing

I) Using tool A, raise rear housing (15), and
assemble to front housing (16).
* Install guide bolts (M = 10, P = 1.5, .&?
=
150 mm) to the front housing.
& Mating surface of housing:

Gasket sealant (Three Bond 1207B) 16
* Be careful not to coat with too much

gasket sealant, and be sure that the gas-
ket sealant is not squeezed out to the
inside of the case. Procedure for coating with gasket sealant
DDW02560
When inserting the input shaft, be care-

ful not to let the tip of the shaft contact
portion “a” of the housing.
Lower slowly until it meshes with the
spline of the input shaft.
Mesh the spline of the input shaft se-
curely.
Be careful not to damage the seal rings
of each shaft.
m Housing mounting bolt:

112.8 f 4.9 Nm (11.5 f 0.5 kgm)
I I DDW02562
2) Install pilot cap (18).

& Cap mounting bolt:

m Pilot cap mounting bolt:

66.2 + 7.4 Nm (6.75 f 0.75 kgm)
Ir Remove tool A from rear housing (15).
15. Transmission control valve

1) Install guide bolt to mount of control valve
(14).
* Clean and remove all oil and grease from
the mounting bolt thread and mounting
bolt hole of the control valve.
2) Align with guide bolt, assemble gasket, then

fit control valve (14) temporarily.
14
* Use a new part for the gasket.
3) Coat mounting bolts of control valve (14)

with thread tightener, and tighten.
* Tighten the mounting bolts on diametri-
cally opposite sides, and be careful not
to tighten too much.
Ir The length of the mounting bolts is dif-
ferent, so be careful when using them.
@:L=120mm @:L=130mm
@:L=135mm @:L=115mm
@:L=lOO mm
& Mounting bolt:

w Mounting bolt: 34.3 ? 4.9 Nm

(3.5 + 0.5 kgm) DEW02565
30-66
0
4) Assemble O-ring to accumulator valve (131,

and install to transmission.
+ Remove all oil and grease from the
6 Mounting bolt:

(3.5 f 0.5 kgm)
16. Charging pump

Assemble O-ring to charging pump (12), and
install to transmission.
* Be careful not to get the O-ring caught.
@El Mounting bolt: 66.2 f 7.4 Nm

(6.75 f 0.75 kgm)
DEW02478
17. Strainer, rear coupling

1) Install hose and tube (II) between strainer
and pump.
@El Mounting bolt: 66.2 _+ 7.4 Nm

(6.75 k 0.75 kgm)
2) Align center line of key groove to align rear

coupling (IO) with front coupling.
* Coat the oil seal lip portion thinly with
grease.
* Slide the coupling to prevent the oil seal
lip from turning over.

18. Oil filter

1) Sling transmission assembly (91, and lift off
from assembly stand.
Sr When standing the transmission assem-
bly, be careful of the center of gravity
(lift off slowly).
2) Install O-ring (8) to idler countershaft por-

tion, then install speedometer pickup port
assembly (6) and cover (7).
* Do not use force to mesh the gears. DEW02476

(11.25 f 1.25 kgm)
3) Install oil filter (4) and bracket (5).

@EI Mounting bolt: 112.8 k 9.8 Nm
(11.5 f 1.0 kgm)
19. Hydraulic piping

Install hoses (I) and (2) and tube.
* Be careful not to to crush tube (3) during the
.operation.
It Install the hoses without twisting, and be
I ,,,
I 4
careful not to get the O-rings caught. DEW02475
l Connect PTO lubrication tube.
. Install mount brackets to left and right
of transmission assembly (9).
l Wipe the bracket mounting surface clean.
w Mounting bolt: 277 k 31.9 Nm

(28.25 f 3.25 kgm)
DEW02472
I DEW02473
30-68
0
DISASSEMBLY AND ASSEMBLY CLUTCH PACK
DISASSEMBLY OF CLUTCH
PACK
I. DISASSEMBLY OF lST, REVERSE
Dl
CLUTCH
g When setting the clutch pack on the stand, be /

careful not to let your hands slip because of oil,
and be extremely careful not to get your fingers
caught between the stand and the clutch pack.
* Set with the 1st side facing up, and set on tool
Dl.
DEW02568
1. Bearing
Remove bearing (I) with puller.
DEW02569
2. Gear
Remove spacer (21, thrust washer (31, gear (4),
needle bearing (51, and thrust washer (6). 2 5 6
3. End plate
I) Install tools D2 and D3, tighten nut D5, and
remove ring (7).
* Set the spacer in position and push in
the end plate.
* After removing the ring, remove tools
D2 and D3.
I DEW02570
160mm
D2
D5
.$i4zq3& Spacer
25mm r 4.5
-Mac;;
D3
DEW02572 DEW02571
30-69
0
2) Remove end plate (8).
-8
DEW025573
4. Clutch plate
Remove plate (91, disc (IO), and spring (11) from
housing.
ll-
5. Piston
Blow air in through oil hole at 1st end of shaft
and remove piston (12).
* If the piston is at an angle and does not
come out, push the piston in and try again.
* If force is used to remove the piston, the
inside circumference of the cylinder will be
damaged. DEW02574
Bearing
Ir Set with the REVERSE side facing up, and
set on tool Dl.
Remove bearing (13) with puller.
REVERSE gear
Remove spacer (15), thrust washer (16), needle
bearing (171, REVERSE gear (18), and thrust
washer (19).
t Disassemble the REVERSE gear in the same
way as in Steps 3 - 5 for the 1st gear.
DEW02575
15 17 19
18 -Dl
16 18
I DEW02577 ( DEW02576
30-70
0
II. DISASSEMBLY OF FORWARD, 2ND

CLUTCH PACK
* Set with the 2nd side facing up, and set on tool
Dl.
1. Bearing
Using puller, remove 2nd gear (37) together with
bearing (35).
DEW02578
2. 2nd gear
Remove spacer (39) and thrust washers (361,
then remove needle bearings (38) from 2nd gear 39
36 36
(37).
Ir Remove the inside thrust washer after re-
moving the clutch plate.
38 DEW02579
02.
D5
Spacer
3. End plate
1) Install tools D2 and D3, tighten nut D5, then ‘D3
remove ring (40).
Sr Set the spacer in position and push in
the end plate.
-k After removing the ring, remove tools
D2 and D3.
16Omm
0120
DEW02572 Ill DEW02581
30-71
0
4. Clutch plate
Remove plate (421, disc (431, and spring (44)
from housing.
42
DEW02582
5. Piston
Blow air in through oil hole at 2nd end of shaft
Ir If the piston is at an angle and does not
* If force is used to remove the piston, the
damaged.
DEW02583
6. Bearing
* Set with the FORWARD side facing up, and
set on tool Dl.
Remove bearing (46) with puller.
* When installing the puller, put the center in 46
contact with the plate.
-Dl
7. FORWARD gear
Remove spacer (471, thrust washer (48), needle
bearing (49), FORWARD gear (50), and thrust 5? 56 48 4.7
washer (51).
+ Disassemble the FORWARD gear in the same
way as in Steps 3 - 5 for the 2nd gear.
I 49 DEW02585
30-72
0
III. DISASSEMBLY OF 3RD, 4TH CLUTCH

PACK
* Set with the 3rd side facing up, and set on tool
Dl.
1. Bearing
Fit puller to bearing (531, then remove bearing
(53).
2. 3rd gear
Remove spacer (541, thrust washer (55),3rd gear
(561, and needle bearings (57).
j, Remove the inside thrust washer at Step 4-
2).
I DEW02587
3. End plate
I) Install tools D2 and D3, tighten nut D5, then 02
D5
remove ring (58).
the end plate. D3
* After removing the ring, remove tools
D2 and D3. Spacer
58
DEW02588
16Omm
DEW02572 DEW02589
4. Clutch plate
1) Remove plate (601, disc (611, and spring (62) 6,O 61
from housing.
2) Remove inside thrust washer (71).
DEW02590 DEW02591
5. Piston
Blow air in through oil hole at 3rd end of shaft
* If the piston is at an angle and does not
Ir If force is used to remove the piston, the
damaged.
I DEW02592
6. Bearing
* Set with the 4th side facing up, and set on
tool Dl.
Using puller, remove bearing (64) and 3rd gear
(6%. 64
65
Dl
DEW02593
7. 4th gear
Remove spacer (661, thrust washer (671, needle
70 69 67
bearing (681, 4th gear (691, and thrust washer
(70).
* Disassemble the 4th gear in the same way
as in Steps 3 - 5 for the 3rd gear.
30-74
0
ASSEMBLY OF CLUTCH PACK

I. ASSEMBLY OF lST, REVERSE CLUTCH
PACK
g When setting the clutch pack on the stand, be

* Set with the REVERSE side facing up, and set
the shaft and housing assembly on tool Dl.
1. Piston seal
Assemble piston seal (71-I) to piston (71).
Ir When assembling a new piston seal, use
seal shaping jig El or E2 for approx. 2 - 3
minutes, then assemble the piston seal.
* If the seal is installed to the piston without
being shaped, the seal will be damaged.
6 Inside surface of shaping jig:
Oil (transmission oil)
DEW02596
REVERSE piston
El 71
Assemble REVERSE piston (71).
Jr Be careful not to damage the piston seal.
& Sliding surface of piston seal:

Oil (transmission Oil)
DEW02597
3. Clutch plate
74 72
Insert tool D4 in housing, then assemble plate
(721, disc (731, and spring (74) in turn.
Soak disc (73) in clean transmission oil for
at least 2 minutes before assembling.
Be careful not to let spring (74) and plate
(72) rest on top of each other.
Be careful not to let the plate or spring get
caught in the ring groove of the clutch hous-
ing when assembling.
A 3d, x 85 mm nail can also be used for tool
D4. \ DEW02598
30-75
0
4. End plate
76
I) Install tools D2 and D3, tighten nut D5 to
push in end plate (761, then remove tool D4.
the end plate.
16Omm
1
r-@-l?=
DEW02600 DEW02601
DEW02572
2) Assemble ring (77), then remove tools D2

and D3.
Sr Check that ring (77) is fitted securely in
the groove.
* Check that the disc rotates smoothly by
hand.
5. Thrust washer
Install thrust washer (19).
6. REVERSE gear
Use a screwdriver to align the spline on the
inside of the plate, and assemble REVERSE gear
(18).
Ir If the gear spline is not aligned, rotate lightly
7. Bearing
Assemble needle bearing (171, thrust washer (161,
and spacer (15).
* Check that the end face of thrust washer
(16) is level with or below the stepped por- DEW02603
tion of the shaft.
.I5
I6
-16
DEW02604
30-76
0
8. Bearing
PIess fit bearing (13).
* Press fit completely so that spacer (15) is in
tight contact with the stepped portion of the
shaft and bearing (13).
* After press fitting the bearing, check that

clearance “a” between thrust washer (16) C
13
and spacer (15) is within the specified range.
“a” = 0.07 - 0.93 mm
15
16
DEW02607
9. 1st piston
1) Turn over clutch pack.
g When turning over the clutch pack, be

careful not to get your fingers caught
between the stand and clutch pack.
2) Assemble piston (12) in same way as for

REVERSE piston.

10. Clutch plate

Inset-t tool D4 in housing and assemble plate D4
(9), disc (IO), and spring (11) in turn.
Ir A 30 x 85 mm nail can also be used for tool
D4.
* Assemble in the same way as for REVERSE.
‘bE’i02609
11. End plate

I) Install tools D2 and D3, tighten nut D5 to
* Set a spacer in position and push in the
end plate. D3
2) Assemble ring (7) and remove tools D2 and
Spacer
D3. 7
+ Assemble in the same way as for RE- 8
I! I
VERSE.
DFWO2611
12. Thrust washer

13. 1st gear

Assemble 1st gear (2).
* Assemble in the same way as for REVERSE.
DEW02612 DEW02613
14. Bearing
Assemble needle bearing (5).
15. Thrust washer, spacer

Assemble thrust washer (4) and spacer (3).
* Check that the end face of thrust washer (4)
is level with or below the stepped portion of
the shaft.
DEW02614
DEW02616 DEW02615
30-78
0
16. Bearing
Press fit bearing (1).
* Press fit completely so that the spacer is in
shaft and bearing (I).
DEW02617
* After press fitting the bearing, check that r

clearance “b” between thrust washer (4) and
spacer (3) is within the specified range.
b = 0.04 - 1.16 mm
b
DEW02618
17. Clutch pack operating test

Blow in compressed air through oil hole of shaft
and check if each clutch is actuated.
* If the gear at the point where the air is blown
in is held in position, the clutch is working
normally.
DEW02619
30-79
0
II. ASSEMBLY OF FORWARD, 2ND CLUTCH

PACK
A When setting the clutch pack on the stand, be

and be extremely careful not to get your fingers Dl
* Set with the FORWARD side facing up, and set
the shaft and housing assembly on tool Dl.
DEW02595
1. Piston seal
Ilr When assembling a new piston seal, use
& Inside surface of shaping jig:

orE2
2. FORWARD piston
Assemble FORWARD piston (83).
Ir Be careful not to damage the piston seal.

3. Clutch plate
D4
Insert tool D4 in housing, then assemble plate
(78), disc (791, and spring (80) in turn.
78
Soak disc (79) in clean transmission oil for
Be careful not to let spring (80) and plate
Be careful not to let the plate or spring get
A 30 x 85 mm nail can also be used for tool
D4. DEW02623
30-80
0
4. End plate
1) install tools D2 and D3, tighten nut D5 to
Ir Set the spacer in position and push in
the end plate.
2) Assemble ring (82) and remove tools D2 and
D3.
* Check that ring (82) is fitted securely in
the groove.
hand.
5. Thrust washer
6. FORWARD gear
Assemble FORWARD gear (501, then assemble
needle bearing (49).
Ir If the gear spline is not aligned, rotate lightly
!%iVO2626 DEW02627
7. Thrust washer
Assemble thrust washer (48).
Ir Check that the end face of the thrust washer
is level with or below the stepped portion of
Clearancei
the shaft. -
8. Bearing
Assemble spacer 47), then press fit bearing (46).
clearance “e” between thrust washer (48)
e = 0.07 - 0.93 mm
46
47
DEW02629
30-81
0
9. 2nd piston
a When turning over the clutch pack, be

2) Assemble piston (45) in same way as for

FORWARD piston.

DEW02631
10. Clutch plate

D4
Insert tool D4 in housing and assemble plate
42
* A 3g x 85 mm nail can also be used for tool
D4.
* Assemble in the same way as for FORWARD.
DEW02632
11. End plate

1) Install tools D2 and D3, tighten nut D5 to
end plate. D3
40
160mm
078 32mm 41
25mmrffzf ?
DEVvQ2633
25xt4.5
Spacer
098
L 0120 _I
DEW02672
2) Assemble ring (401, then remove tools D2

and D3.
Sr Assemble in the same way as for FOR-
WARD.
12. Thrust washer

Install thrust washer (36). DEW02634
30-82
0
13. 2nd gear

Assemble 2nd gear (37), then assemble needle
bearings (38).
t Assemble in the same way as for FORWARD.

Assemble thrust washer (36) and spacer (34).
(36) is level with or below the stepped por-
tion of the shaft.
34
36
15. Bearing
Ilr After press fitting the bearing, check that 36
clearance “f” between thrust washer (36) and
spacer (34) is within the specified range.
f = 0.04 - 1.16 mm
DEW02637

Blow in compressed air through oil hole at 2nd
end and check if each clutch is actuated.
* If the gear at the point where the air is blown
normally.
30-83
0
III. ASSEMBLY OF 3RD, 4TH CLUTCH PACK
g When setting the clutch pack on the stand, be

* Set with the 4th side facing up, and set the shaft
and housing assembly on tool Dl.
1. Piston seal El 84
* When assembling a new piston seal, use
& Inside surface of shaping jig:
84-l or E2
2. 4th piston
Assemble 4th piston (84).
Ir Be careful not to damage the piston seal.
6 Sliding surface of piston seal:
DEW02642
3. Clutch plate
Inset-t tool D4 in housing, then assemble plate ,
+ Soak disc (86) in clean transmission oil for
Ir Be careful not to let spring (87) and plate
* Be careful not to let the plate or spring get
* A 316 x 85 mm nail can also be used for tool
D4. DEW02643 DEW02644
30-84
0
4. End plate
I) Install tools D2 and D3, tighten nut D5 to D2
push in end plate (88), then remove tool D4. \e 5”
the end plate.
DEW02645
L 0120
DEW02572

and D3.
* Check that ring (89) is fitted securely in
the groove.
hand.
F
z 5. Thrust washer
6. 4th gear
Assemble 4th gear (69), then assemble needle
bearing (68).
.69
* If the gear spline is not aligned, rotate lightly
7. Thrust washer, bearing

Assemble thrust washer (671, and spacer (661,
then insert bearing (64) to shaft.
(67) is level with or below the stepped por- DEW02646
tion of the shaft.
I! w DEW02649
30-85
0
8. Bearing
Ir Press fit completely so that spacer (66) is in
DEM

clearance “g” between thrust washer (67)
“g” = 0.07 - 0.93 mm
9. 3rd piston
a When turning over the clutch pack, be

2) Assemble piston (63) in same way as for 4th

piston.
6 Sliding surface of piston seal:

10. Thrust washer

Ir Assemble 3rd inside thrust washer (71) be-
fore assembling the clutch plate.
DEW02654
30-86
0
11 Clutch plate
Insert tool D4 in housing and assemble plate
D4
+ A 3o x 85 mm nail can also be used for tool
D4.
* Assemble in the same way as for 4th.
DEW02655 DEW02656
12. End plate

1) Install tools D2 and D3, tighten nut D5 to D2
end plate.
and D3. Spacer
DEW02657
13. 3rd gear

Assemble 3rd gear (561, then assemble needle 56
bearings (57).

Install thrust washer (55), then assemble spacer
(54).
(55) is level with or below the stepped por-
tion of the shaft.
DEW02658
DEW02560 DEW02659
30-87
0
15. Bearing

clearance “h” between thrust washer (55)
h = 0.04 - 1.16 mm
DEW02662

Blow in compressed air through oil hole at 3rd
end and check if each clutch is actuated.
Ir If the gear at the point where the air is blown
normally.
DEW02663
DEW02664
30-88
0
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
REMOVAL OF TRANSMISSION
CONTROL VALVE
AStop the machine on level ground and install
. Remove inspection cover (I) of the left side of
the rear frame.
. Remove cover (2) at the left side of the floor.
1. Electric wiring a
I) Disconnect connectors (3), (4), (51, and (6) Transmission
and wiring for transmission solenoid valve.
2) Disconnect torque converter oil temperature
sensor connector (7).
* When disconnecting the wiring connec-
tors, fit tags to identify the connectors.
&
x 2. Hydraulic piping
.
a
Hose (8) between brake booster and trans-
mission valve
. Hose (9) between transmission valve and oil
cooler
. Disconnect hose (IO) between torque con-
verter oil filter and brake booster, and re-
move hose clamp.
3. Transmission valve m
Sling transmission valve (12) and remove mount-
ing bolts, then lower under machine.
A tremely
The working space
careful.
is confined, so be ex-
DEW02667
To prevent the valve from falling, remove 2

mounting bolts, then install guide bolts and
insert wooden blocks.
Remove the valve with a upper valve and
lower valve assembled. Disassemble the
upper and lower valve after removing.
When fitting a lifting tool, avoid the connec-
tors and fit the tool securely to the valve
body.
Transmission valve: 46 kg
(upper: 15.5 kg)
(lower: 30.5 kg)
INSTALLATION OF
TRANSMISSION CONTROL
VALVE
removal.
A The working space is confined, so be extremely

careful.
Connect the wiring connector securely.
Install the hoses without twisting or interfer-

ence. Position of upper, lower valve set bolts
w Nut of hose mouthpiece: +
176.5 + 29.4 Nm (18 + 3 kgm)
. Width across flats of hose mouthpiece
nut: 36 mm
When installing the transmission valve, re-

place the gasket with a new part.
When installing the transmission valve, use
guide bolts to prevent it from falling.
Secure with upper and lower valve set bolts
(13) and (14).
Remove all oil and grease from the valve Position of mounting
mounting bolts and mounting bolt holes. bolts of each lenath
The length of the mounting bolts is differ-
ent, so be careful when using them. I,
(I) L = 120 mm (2) L = 130 mm
(3) L = 135 mm (4) L = 115 mm
(5) L = 100 mm (6) L = 100 mm
\-
” 6
To prevent distortion of the valve, tighten

the transmission valve mounting bolts in the
order shown in the diagram.
6 Mounting bolt:
(3.5 f 0.5 kgm)
30-90
0
DISASSEMBLY OF TRANSMISSION
CONTROL VALVE
00 8
\9 io
Y A
5
I61 \ 459
DEW02672
30-92
0
1. Disconnection 3. Disassembly of lower valve

Remove mounting bolts, and disconnect 1) Remove mounting bolts, remove sole-
upper valve (I) and lower valve (21, then noid valve assembly (381, then remove
remove gasket (3). spring (39), retainer (401, spring (41), and
sleeve (42).
2. Disassembly of upper valve 2) Remove mounting bolts, remove cover
I) Remove mounting bolts, remove cover (43), then remove gasket (44), torque
(41, then remove gasket (51, pilot valve converter regulator valve (45), shim, (461,
(61, priority spring (7), quick return valve spring (41A), sleeve (42A), F-R selector
assembly (8), accumulator piston (91, and valve (47), H-L selector valve (481, range
spring (IO). selector valve (491, springs (501, and
2) Remove sleeve (11) from quick return spacers (51).
valve assembly, then remove spring (12) 3) Remove mounting bolts, then remove
and ball (13). pilot filter (52) and O-rings (53).
3) Remove plug (14) from sleeve (II). 4) Remove plug (54) from F-R selector valve
4) Remove mounting bolts, remove cover (47).
(15), then remove gasket (16), main regu- 5) Remove plugs (55) from lower valve (2)
lator valve (17), spring (181, priority valve and cover (43).
(191, modulating valve assembly (20), ac- 6) Remove orifices (56) from lower valve
cumulator shaft (211, and springs (22) (2).
and (23).
5) Remove load pistons (24) and (25) from
main regulator valve (17) and priority
valve (19).
6) Remove plug (26) from modulating valve
:
assembly (201, then remove retainer (271,
z
0 springs (28) and (29), sleeve (301, and O-
rings (31).
7) Remove nut (32) and washer (33) from
cover (151, then remove adjustment
screw (34) and O-ring (35).
8) Remove plug (36) and main orifice (37)
from upper valve (I).
30-93
0
CONTROL VALVE
1\ 56 24
EE 17 I
DEW02672
30-94
0
1. Assembly of lower valve 2. Assembly of upper valve

1) Install orifices (56) to lower valve (2). 1) Instail plug i36) and main orifice (37) to
Sr Screw in the orifice at least 2 mm upper valve (2).
from the valve body. * Screw in the orifice at least 2 mm
2) Install plugs (55) to lower valve (2) and from the valve body.
cover (43).
6 Plug: Sealant (LG-1 or LG-51
& Plug: Sealant ILG-1 or LG-5)
2) Fit O-ring (35) to adjustment screw (34),
then set cover (15) in mounting position,
and secure washer (33) and nut (32).
Ir For details of the adjustment proce-
1 Coat with sealant dure, see TESTING AND ADJUST-
H /
ING.
3) Fit plug (26) to modulating valve (201,
then assemble O-rings (31) to sleeve (301,
6-7mm and install springs (28) and (29) and re-
2-3mm tainer (27).
4) Install load pistons (24) and (25) to main
regulator valve (27) and priority valve
DLW00319
(19).
5) Assemble springs (22) and (23), accu-
mulator shaft (21), modulating valve as-
sembly (201, priority valve (191, spring
3) Install plug (54) to F-R selector valve (47). (181, and main regulator valve (171, then
4) Install O-rings (53) to pilot filter (52), then set gasket (16) to mount, and install cover
: (15).
set in mounting position and tighten
;
0 mounting bolts. m Mounting bolt: 68.6 + 4.9 Nm
m Mounting bolt: 68.6 f 4.9 Nm (7.0 + 0.5 kgm)
17.0 f 0.5 kgm) Assemble plug (14) to sleeve (II), then
6)
5) Install H-L selector valve (48), range se- set ball (13) and spring (12) to quick re-
lector valve (49), spacers (511, springs turn valve (81, and assemble sleeve (II).
(50), F-R selector valve (471, sleeve (42A), 7) Assemble spring (IO), accumulator pis-
spring (41A), shim (461, and torque con- ton (91, quick return valve assembly (81,
verter regulator valve (451, then set gas- priority spring (71, and pilot valve (6),
ket (44) in position, and install cover (43). then set gasket (5) to mount, and install
cover (4).
(7.0 * 0.5 kgm) m Mounting bolt: 68.6 f 4.9 Nm
(7.0 f 0.5 kgm)
6) Install sleeve (421, spring (41), retainer
(401, and spring (39), then set gasket
3. Connection
mount, and install solenoid valve assem-
Set gasket (3) to mount, then connect lower
bly (38) to lower valve (2).
valve (2) and upper valve (I).
(7.0 + 0.5 kgm)
(3.2 + 0.3 kgm)
30-95
0
DISASSEMBLY AND ASSEMBLY TRANSMISSION SOLENOID VALVE
DISASSEMBLY, ASSEMBLY OF TRANSMISSION SOLENOID

VALVE
w DEW02673
Disassembly Assembly
1. Remove mounting bolts from solenoid valve 1. Install plugs (IO) to solenoid valve body (I).
body (I), then remove solenoids (2) and O-
6 Plug: Sealant (LG-1 or LG-51
rings (4).
* Remove the connector from the plate.
2. Install orifice (8) and O-ring (7) to emergency manual
spool (61, then secure with lock plate (51, and install
2. Remove plate (3) from valve body (I).
plate (9).
3. Remove lock plate (51, then remove emer-

3. Install plate (3) to valve body (I).
gency manual spool (6) and O-ring (7).
I) Remove orifice (8) from emergency
4. Assemble O-rings (4) to solenoid valve (21, and
manual spool (6).
tighten bolts.
2) Remove plate (9).
+ Be careful not to get the O-ring caught.
4. Remove plugs (IO) from solenoid valve body w Mounting bolt: 68.6 f 4.9 Nm (7.0 f 0.5 kgm)
(I).
Coat with sealant

/
6-7mm
2-3mm
DLWco319
30-96
0
DISASSEMBLY AND ASSEMBLY TRANSMISSION ACCUMULATOR VALVE
DISASSEMBLY OF
TRANSMISSION
ACCUMULATOR VALVE
1. Remove accumulator valve (4) from transmis-

sion assembly (3).
2. Remove O-rings (I) and (2) from accumulator
valve (4).
3. Using pads, set accumulator valve body (9) in
vice.
DBbV’XGZ2
4. Remove mounting bolts (5) and (6), and assem-

ble guide bolts A.
. M = 10, P = 1.5, L = Approx. 40 mm
5. Remove bolts (7) and (8). then remove cover

(IO) together with guide bolts A.
* The internal parts will come off together with
the cover, so be extremely careful not to
damage them when removing.
6 8
DELvo2674
6. Pull out valves (II), springs (12) and (14), stop-

pers (13) and (151, and spacers (16) and (17)
from cover (IO).
* Fit tags to each spring, stopper, spacer, and
use for reference when assembling.
* Reference
Spring Stopper Spacer

2nd 1st FWD DEW02675
FWD e= 145 e = 95 e = 40
IST e= 145 e = 95 E = 40
2ND e= 145 E = 95 E = 50
30-97
0
DISASSEMBLY AND ASSEMBLY TRANSMISSION ACCUMULATOR VALVE
7. Remove plugs (19) and (20) from cover (IO).

. Plug : 5 mm (width across flats)
* Do not remove the plugs unless necessary.
* If plugs (19) and (20) have been removed,
coat the thread with thread tightener as
shown in the diagram below, then tighten
the plugs.
* Be careful not to let the thread tightener
drip on to the hatched portion when coating
with thread tightener.
6 Plug : Thread tightener (LG-1)
6-hnm 2-3rllm
DAW00327
ACCUMULATOR VALVE
ASSEMBLY
1. Using pads, set accumulator valve cover (IO) in

vice.
* Be careful not to tighten the vice on the
cover with excessive force.
2. Assemble spacers (17) and (161, stoppers (15)
and (131, and springs (14) and (12) to accumula-
tor valve cover (IO), then insert valves (11) from
top of each spring.
3. Fit O-rings (22) and (21) in each groove of accu-
mulator valve body (9).
* Assemble the O-ring securely in the body
groove.
4. Assemble accumulator valve body (9) perpen-
dicularly from above cover (IO), then temporar-
ily install with guide bolts.
* Assemble the body carefully and be sure
that the O-ring does not fall out.
5. Push in accumulator valve body (91, and remove
guide bolts, then secure with standard bolt.
m Mounting bolt :
.
54 + 19.6 Nm (5.5 f 2.0 kgm) w DEW02677
Mounting bolt : 8 mm (width across flats)
30-98
0
DISASSEMBLY AND ASSEMBLY DRIVE SHAFT
DISASSEMBLY OF DRIVE
SHAFT
a
1. Front drive shaft
I) Remove coupling and tube (1).
* Make match-marks “a” before removing
so that the direction of the coupling does
not change.
DEW00809
Cover (II) is caulked at 4 places with a
punch, so do not remove it unless nec-
essa ry.
When removing cover (II), be careful
not to damage cover (II) and tube (I). 1 Caulking
When removing, use a screwdriver to
raise the caulking.
Caulking 11
11
DEW02678
R
Seal DEW02661
2) Loosen bolt (21, then remove coupling (3)

and retainer.
* Make match marks before removing so
that the direction of the coupling does
not change.
I DEW02679
3) Using a press, remove flange bearing (4).
I DEW02680
2. Center drive shaft, rear drive shaft

Ir Follow the procedure in 1. Front drive shaft
Step 1).
Centerdriveshaft
Reardriveshaft
DEW02662
3. Spider, bearing
1) Remove seal and bearing caps (5).
DBWOO332
2) Remove ring (7) of spider (IO) and bearings

(6), then tap with plastic hammer to remove
spider and bearing.
Sr Repeat the same procedure for the front,
center and rear drive shafts.
30-100
0
ASSEMBLY OF DRIVE SHAFT

1. Spider, bearing
I) Set spider (IO) and bearings (6) in mount-
ing position, assemble rings (71, then install.
* Assemble so that the grease nipples face
in the same direction.
* Repeat the same procedure for the front,

center and rear drive shafts.
2) Assemble seal bearing caps (5).

* Check that the bearing and delrin washer 8
are inserted inside the bearing cap.
& Bearing cap: Grease (G2-LI) 5
* If the spider and bearing cap are worn,

replace the spider and bearing.
* The heat from welding will damage the
bearing, so do not use welding for strap
(8) of the cap.
+ If cover (11) has been removed, install it
as follows. DBWW33b
I) Insert seal to cover (II) and tube (I),
then assemble cover (II), and caulk
with a punch at diagonally opposite
points.
1 Caulking
11
&al DEW02681 DEW02676
2. Front drive shaft

1) Press fit flange bearing (4).
* Do not hit the flange bearing directly with
a hammer.
2) Align match marks, install coupling (3) and

retainer (91, then tighten mounting bolt (2).
* Tighten the bolts to the specified tight-
ening torque after installing on the ma-
chine.
& Spline: Grease (G2-LI)
w Mounting bolt: 279 f 29 Nm

(28.5 + 3.0 kgm)
3 DEW00818
3) Align match marks and install coupling and

tube (1).
* Check that the couplings are facing in
the same direction.
Ir If the spline is worn, replace the whole
drive shaft assembly.
& Spline: Grease (G2-LI)
3. Center drive shaft, rear drive shaft

* Follow the procedure in 1. Front drive shaft,
Step I) to 3).
30-102
0
DISASSEMBLY AND ASSEMBLY FRONT AXLE
REMOVAL OF FRONT AXLE

the safety bar on the frame. Lower the work
equipment to the ground and stop the engine.
Then apply the parking brake and put blocks
under the wheels to prevent the machine from
moving.
1. Jacking up the machine

Put block @ under front frame, and hold up
machine. m
* Raise the front frame with the bucket, and
set blocks @ in position with the tires raised
slightly from the ground.
2. Tire, wheel
Sling tire and wheel (I), remove mounting bolts,
then lift off. m
Tire, wheel: 180 kg
3. Drive shaft
Disconnect front drive shaft (2).
4. Axle
1) Disconnect brake tube (3)
DISASSEMBLY AND ASSEMBLY FRONT AXLE
2) Using jack and hoist, sling axle (41, remove

mounting bolts (51, then lift off. m
* Adjust the height of the jack when re-
moving the mounting bolts.
L&lkg Axle: 387 kg
3) Pull out axle from machine.

* Use a hoist and jack to remove the axle.
INSTALLATION OF FRONT
AXLE
removal.
m
* Raise the front frame slightly with the bucket,
and remove block 0.
w Mounting bolt:
927 f 103 Nm (94.5 f 10.5 kgm)
w Drive shaft: 65.7 rf:6.9 Nm (6.7 f 0.7 kgm)
Ir Be careful not to tighten the tube nut too

far.
w Tube nut: 11.8 f 2.9 Nm (1.2 * 0.3 kgm)
Ir When installing the axle, use the mounting

bolts as a guide and align the mounting po-
sition.
m Mounting bolt:
740 + 73 Nm (75.5 f 7.5 kgm)
. Bleeding air from brake system

Bleed the air. For details, see TESTING AND
ADJUSTING.
30-104
0
DISASSEMBLY AND ASSEMBLY REAR AXLE
REMOVAL OF REAR AXLE
A the
Stop the
safety
machine on level ground and install
bar on the frame. Lower the bucket to
Aopen the side inspection cover and apply the

lock.
Loosen drain valve (I) and drain fuel.
Fuel tank
1) Disconnect fuel hose (21, fuel return hose
(31, and fuel gauge wiring connector (4).
* Remove the clamp of breather tube (5-
I).
3) Remove inside cover (7), outside cover (8)

and rubber of fuel oil filler port (6) at left
side of rear frame.
4) Set transmission jack under fuel tank, and

support fuel tank (9) lightly.
5) Remove mounting bolts, then lower trans-
mission jack slowly and remove.
-k When there is a clearance of approx. 50
mm from the rear frame, stop and check
that there is no interference.
* The oil filler tube will hit the rear frame,
so move to the right and remove care-
fully.
elkg Fuel tank (dry): 70 kg
6) Pull out fuel tank (9) to right side of chassis.
30-l 05
0
2. Jacking UI) chassis

1) Remove engine oil drain valve (I I) from rear
axle pivot (IO).
2) Set block Q) between left and right rear ax-

les and rear frame.
3) Jack up chassis and put support stand @
under rear frame.
Ir Raise the rear frame with a garage jack,
and when the tires come slightly off the
ground, set stand @ in position.
DEW02697
3. Tire, wheel
Fit sling around tire and wheel (12), then re-
move mounting bolts and lift off.
A kg Tire, wheel: 180 kg

-.---I2
4. Drive shaft
Remove rear drive shaft (13).
* Make match marks to show the mounting
position.
30-106
0
5. Brake, grease tube

1) Disconnect brake hose (14).
2) Remove grease tube (15) from rear axle

pivot.
6. Axle
1) Secure pivot (IO) to axle with chain or wire.
* Fix securely so that the pivot does not
move.
2) Sling one end of axle (16), set garage jack

under axle housing at other end, then re-
move mounting bolts.
Sr Adjust the height of the garage jack when
removing.
* The pivot end will go down, so be ex-
tremely careful when removing the axle. DEW02702
kg
C&l Rear axle, pivot: 462 kg
3) Pull out axle assembly from chassis.

* Use a hoist and jack to pull out the axle
assembly.
* After pulling the axle assembly out from
the chassis, remove the chain or wire.
DEW02703
7. Rear pivot
1) Remove trunnion cap (16-I). Rear
* Before removing the cap, remove the axle
grease tube. pivot
* If there are shims installed, check the
number and thickness of the shims and
use for reference when assembling.
2) Remove thrust plate (17).
DEW0270, w DEW02705
30-107
0
3) Lift off rear pivot (18).

t Be careful that the hanging tool does
not slip when lifting off the rear pivot.
Rear pivot: 75 kg
DEW02706
4) Remove O-ring (19) and bushng (20) from

pivot (18). 18
8. Front pivot
Remove O-rings (22) and bushing (23) from pivot
(21).
23
DEW02708
30-108
0
INSTALLATION OF REAR AXLE

1. Front pivot
Assemble O-rings (22) and bushing (23) to pivot
(21).
* Assemble so that the chamfered side of the
bushing is on the axle housing side.
* Set with the join of the bushing at the side.
6 O-ring, bushing: Grease (G2-LI) 23
2. Rear pivot
I) Assemble O-ring (19) and bushing (20) to 18
pivot (18).
* Set with the join of the bushing at the
side.
& O-ring, bushing: Grease (G2-LI)
2) Raise pivot (181, and insert to mounting por-

tion of axle.
3) Install thrust plate (17) to mounting portion

of axle.
+ Wipe the mating surface of the thrust
plate clean.
* Assemble so that the 05 hole of thrust
plate (17) is at the top.
6 Outside circumference of pivot

DEW02706
mount: Grease (G2-LII

(11.5 f 1.0 kgm)
Rear axle
civet
I I
DEW02710
To make axle and pivot parallel, turn over

trunnion cap (16-I) and tighten down with 8
bolts uniformly.
w Mounting bolt: 68.6 9.8 Nm

(7 + 1 kgm)
* Check that the clearance between the

pivot and trunnion cap is uniform.
Ir Set on the mount on the machine body
with the cap still reversed.
DEW0271 1
3. Axle
Raise axle (16) with jack and hoist, set in mount-
ing position and tighten mounting bolts.
Use the bolts as guides when setting in the
mounting position.
When tightening the mounting bolts, do not
tighten in one pass. Tighten the mounting
bolts in three stages.
After installing the axle assembly, remove
the wire.
w Mounting bolt:
DEW02712
549 k 58.8 Nm (56 + 6 kgm)
4. Adjusting shim at rear pivot

1) Using depth micrometer 0, measure dimen-
sion “a” of trunnion cap (16-I). Measure at 4
places at 90” angles and take the average.
* Clean the probe contact surface before
measuring.
. Standard value “a”: 12.2 - 12.33 mm
DEW02713
DDW02716
2) Assemble thrust washer (17) at rear pivot.

Using depth micrometer 0, measure dimen-
sion “b” at 4 places at 90” angles and take
the average.
Sr Clean the contact surfaces of the thrust
plate.
* Clean the probe contact surface before
measuring.
. Reference value “b”: 12.10 - 12.30 mm
* insert a feeler gauge around circumfer-
ence “c” and at the joint of the thrust
plate, and check that there is no clear- \ DkV02714
ance.
30-110
0
* Joint rear pivot and trunnion cap

l Standard clearance “d”: 0.1 - 0.29 mm
. “a” - “b” - (0.1 - 0.29) = t (shim thick-
ness)
* Shim size = 0.2 mm
DEW02717
3) Assemble selected shims between rear pivot

(IO) and trunnion cap (16-l), then install
mounting bolts.
* Fill the trunnion cap with grease before
installing.
6 Trunnion cap: Grease (G2-LI)

(11.5 + 1 kgm)
5. Brake, grease tube

1) Secure grease tube (15) with mounting
clamp.
2) Connect brake hose (14).
* Be careful not to tighten the brake hose
too much.
DEWO27OO DEW02701
30-111
0
3) Install engine oil drain valve (I I) in axle pivot

(IO).
6. Drive shaft
Install rear drive shaft (13).
* Align the pilot correctly and install with the
yoke facing in the correct direction.
(3.2 f 0.3 kgm)
7. Tire, wheel
Sling tire and wheel (121, set in mounting posi-
tion, and tighten mounting bolts.
QFJ Mounting bolts:

927 f 103 Nm 194.5 * 10.5 kgm)
/--I2
DEW02598
8. Lowering machine
1) Pull out block @ from under rear frame and
lower machine to ground.
* Raise the rear frame with a garage jack,
and remove blocks @ when the frame is
raise slightly.
2) Remove block @ between left and right rear

axles and rear frame.
DEW02697
30-112
0
9. Fuel tank
I) Pull in fuel tank (9) under chassis.
* Pull in from the right side of the rear
frame.
2) Operate transmission jack and raise fuel tank

(9) slowly, then set in mounting position,
and fit mounting bolts temporarily.
* When setting to the mount, move from
the right to the left, raise, and stop at a
point where the oil filler passes the rear
frame, then check that there is no inter-
ference.
3) Position and tighten mounting bolt firmly.

7 6
(11.25 k 1.25 kgml
4) Install inside cover (7), outside cover (8), and

rubber of fuel filler port (6) at left side of
rear frame.
5) Install return hose (5) from fuel filter.
6) Install breather tube (5-I) and clamp.
7) Connect fuel hose (21, fuel return hose (31,

and fuel gauge wiring connector (4).
8) Close drain valve (I).
DEW02689
10. Bleeding air from brake system

Bleed air. For details, see TESTING AND AD-
JUSTING.
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
DISASSEMBLY OF
DIFFERENTIAL
1. Brake tube
Remove brake tube (1).
DEW02720
2. Differential cover
Remove bleeder screw (2), then remove differ-
ential cover (3).
* Install the differential assembly in a stand.
* Remove the axle housing.
3. Cage
I) Screw in a forcing screw, then using guide
bolt (41, remove cage (5).
* Check the number and thickness of the
shims, and keep them in a safe place.
* Loosen mounting bolts of coupling, and
temporarily install the cage.
4’
&I kg Cage: 17 kg
2) Remove O-ring from cage.

DEW02722
4. Brake piston
Screw in forcing screws (3 places) to raise evenly,
then remove piston (6).
* If the O-ring of the piston is not damaged, it
is possible to install the bleeder screw and
blow in air to remove the piston.
30-114
0
5. Bearing carrier
Screw in forcing screws to raise bearing carrier
evenly, and remove bearing carrier (7). Remove
angle ring.
Ir Mark the left and right bearing carriers to
avoid confusing them.
6. Differential carrier
1) Lift off differential carrier assembly (9) from
differential housing (8).
* When removing the assembly, be care-
ful that the lifting tool does not slip.
PIIkg Differential carrier assembly: 30 kg
8 9
I DEW32725
2) Remove bevel gear (IO), then remove bear-

ing (11) from bevel gear.
DEW02726
3) Remove thrust washer (13) from differential

carrier (12), then remove side gear (14).
CEWO2727
4) Remove lock pins (151, pull out shaft (16),

then remove pinion gears (17).
I I? 16’ DEW02728
5) Remove side gear (18).
7. Coupling
1) Remove mounting bolt (20), then remove
holder (21), coupling (22) and O-ring (23).
Ir Do not remove the protector press fitted
to the coupling unless necessary.
2) Remove oil seal (24).
30-116
0
3) Using a press, remove pinion gear (25) from

cage, then remove bearing (26).
Press
DEW02731
4) Remove spacer (27) and bearing (28) from

pinion gear (25).
\
28 DEW02732
5) Remove bearing cups (29) and (30) from cage

29
(5).
-30
DEW02733
30-117
0
ASSEMBLY OF DIFFERENTIAL
1. Pinion gear
1) Press fit bearing cone (28) in pinion gear
(251, then assemble spacer (27).
Ir There must be no clearance at the con-
I
tact faces of any parts.
I D&V02734
2) Press fit bearing

(5).
cups (29) and (30) in cage
1
3) Assemble pinion gear (25) in cage (51, then

press fit bearing cone (26).
Press
* Apply pressure to the bearing at the
specified load, and rotate the case to Plate
r
settle the bearing.
Ir Press load: 49 KN (5 ton)
*
6 Bearing: Oil (axle oil)
* When rotating the case at the specified
load, rotate lightly by hand. If the rota-
tion is not smooth, replace the bearing
and spacer, and again rotate lightly by
hand.
DEW02736
30-118
0
4) Press fit oil seal (24) in cage (5).

24
* Assemble oil seal (24) evenly so that it
has the specified depth “t”.
t=6*0.5mm
& Oil seal lip: Grease (G2-LI)
& Pinion gear shaft: Grease (G2-LI)
2. Coupling
Install coupling (221, O-ring (23) and holder (21)
to pinion gear (251, then tighten mounting bolts.
* Tighten the mounting bolts partially. Tighten
them fully after the completion of assembly.
* When inserting the coupling, be careful not
to damage the seal.
& Mounting bolt: Thread tightener (LT-2)
w Mounting bolt: 279 k 29 Nm

(28.5 k 3.0 kgm)
3. Differential carrier assembly

1) Install side gear (18) to differential carrier 12 18
(12).
DEW02733
DEW02741
2) Install pinion gears (17) and shaft (16) to

differential carrier (121, then insert lock pins
(15). 16
DEW02740
& Gears, shafts: Oil (axle oil)
30-119
0
3) Assemble side gear (14) and thrust washer

(13).
& Sliding surface of thrust washer:
Oil (axle oil)
4) Press fit bearing (11) on bevel gear (IO).
DEW02742
5) Assemble bevel gear (IO) in differential car-

rier (121, then tighten mounting bolts.
& Mounting bolts:

m Mounting bolts: 279 & 29 Nm
(28.5 + 3.0 kgm)
* Coat the thrust washer with grease and
stick it to the bevel gear to prevent it
from falling off during installation.
* Align the lock of the washer correctly
with the groove in the bevel gear. DEW02744
4. Adjusting shim of cage

1) Assemble cage (5) without shims in differ-
ential housing (8).
w Mounting bolts: 112.8 f 9.8 Nm
III.5 C 1.0 kgm)
DEW02745
2) Insert measuring tool A in differential (8),

and measure distance between end face of
bevel pinion gear and tool A with an inside
micrometer or a cylinder gauge.
* When inserting tool A in the differential
housing, coat thinly with oil, and insert
straight without twisting.
DEW02746
30-120
0
3) Selecting shims
t = C - (L + D/2)
t :Shim thickness A: 157.5
C: (A + a) - (B + b) B : 50.68
L :Actual value a : Error for distance A
D: Diameter of tool A b : Error for distance B
* Use the actual value for distance D
* Shim thickness “t” must be within 0.5 -

1.9 mm.
The end face of the pinion gear is marked
with an electric pen as follows.
MD +O.lO (-0.01)
L Distance “b” (mm)

/ Distance “a” (mm)
* Always use the bevel pinion gear and

bevel gear in a set with the same DWJQ2?41
number.
4) Remove cage.
5. Bearing carrier
Press fit bearing cups (32) and (33) in bearing
carriers (7) and (31).
& Press-fitting portion of bearing cup:

Oil (axle oil)
32 33
DEW02748
6. Adjusting bearing carrier shims

I) Raise differential carrier assembly (9), set in
mounting position, then install left and right
bearing carriers (7) temporarily.
* Assemble the differential carrier assem-
bly with the bevel gear on the right as
seen from the cage mount.
* Assemble the bearing carrier and adjust
without the angle ring and shim.
30-121
0
2) Tighten carrier (31) at differential carrier end

to specified tightening torque.
w Mounting bolts: 113 k 9.8 Nm

(11.5 k 1.0 kgm)
3) Tighten 4 mounting bolts of carrier (7) at

bevel gear end.
Ir Rotate the bevel gear and coat the bear-
ing with oil.
7
& Bearing: Oil (axle oil)
-k To settle all the parts, rotate the bevel

gear when tightening.
m Mounting bolts: 11.8 Nm (1.2 kgm) I-

\
I 1 / DEW02751
4) Loosen 4 mounting bolts at bevel gear end

until there is end play at bearing.
5) Tighten 4 mounting bolts uniformly again.
m Mounting bolts: 3.9 Nm (0.4 kgm)
+ When doing this, check that there is end

play at the bearing, and rotate the bevel
gear when tightening.
6) Using a feeler gauge at 2 places in groove

of bearing carrier (7) at bevel gear end, meas-
ure clearances T, and T,.
7) Selecting shims
Shim thickness = (T, + TJ2 f 0.035 mm
* Combine the following shims to give the
necessary shim thickness.
0.07 mm, 0.20 mm, 0.30 mm, 0.80 mm
30-122
0
8) Remove left and right bearing carriers (7),

and assemble selected shims (32).
* Rotate the bevel gear and tighten the
mounting bolts of the bearing carrier
uniformly.
w Mounting bolts: 113 f 9.8 Nm

(11.5 f 1.0 kgm)
9) Using a spring balance, measure preload of

bevel gear and check that it is within speci-
fied range.
* Preload: 7.8 - 25.5 Nm ( 0.8 - 2.6 kgm)
(Target: 25.5 Nm (2.6 kgm))
* If the preload is not within the specified
range, change the shim thickness to ad-
just.
7. Cage
1) Assemble O-ring (34) in bearing cage.
6 O-ring: Oil (axle oil)
DEW02755
2) install guide bolt, assemble shims (35) se-

lected in Step 4, and install cage (5).
m Mounting bolts: 113 + 9.8 Nm

(11.5 f 1.0 kgm)
- DEM I02756
8. Adjusting backlash
I) Measure backlash of bevel gear with a dial
gauge.
* First, measure with all the shims inserted
at the bevel gear end.
* Measure the backlash at 3 places around
the circumference of the bevel gear. The
variation between the measurement
must be within 0.1 mm.
DEW02757
2) To obtain backlash within specified range,

move some of the shims from bevel gear
side to opposite side.
* When moving the shims, do not change
the total shim thickness. The total shim.
thickness on the left and right must re-
main the same.
* Adjust the backlash as follows.
If backlash is too LARGE, move shims
from B to A
If backlash is too SMALL, move shims /
Shim(A)
from A to B
30-124
0
9. Adjusting tooth contact

Coat face of 7 or 8 teeth of bevel gear lightly with red lead (minimum). Hold the bevel gear by hand
to act as a brake, rotate the pinion gear forward and backward and inspect the pattern left on the
teeth.
Tooth contact Cause Procedure for adiustment

The tooth contact pattern Adjust the pinion gear by adjusting the shims at
should start from about the cage. Adjust the bevel gear in the same way as
5 mm from the toe of when adjusting backlash.
the bevel gear and cover
about 50% of the length
of the tooth. It should
be in the center of
the tooth height.
1 Bevel pinion gear is too 1. Reduce shims at pinion

far from bevel gear. gear to bring closer
to bevel gear.
2. Move bevel gear further 4
away from pinion
gear and adjust
backlash correctly.
?
DEW00908
Bevel pinion gear is too 1. Increase shims at pinion

::
r- close to bevel gear. gear to move away
=; from bevel gear.
0
2. Move bevel gear closer
to pinion gear and adjust
backlash correctly.
DEW00909
DEW00905
1 Bevel gear is too close to 1. Reduce shims at pinion gear

pinion gear. to bring closer to bevel gear.
2. Move bevel gear further
away from pinion
gear and adjust
backlash correctly.
’ u DEW00908
DEW00906
t Bevel gear is too far fron 1. Increase shims at pinion

pinion gear. gear to move away
from bevel gear.
2. Move bevel gear closer
to pinion gear and
adjust backlash correctly.
4‘L!LJ
i u DEW00909
f When adjusting the bevel gear, do not change the preload of the bearing. Adjust by moving shims between
the left and right. Always keep the same total thickness of shims.
30-125
0
10. Bearing carrier

Remove bearing carrier (7), assemble angle ring
(36) together with adjusted shims.
* Coat the angle ring with grease, and be care-
ful not to drop it when installing.
* When installing bearing carrier (7), the an-
gle ring may come out, so do not use a
hammer to install the bearing carrier.
& Angle ring: Grease (G2-LII
m Mounting bolt: 113 f 9.8 Nm

(11.5 f 1.0 kgm)
11. Brake piston

1) Assemble O-rings (37) and (38) securely in
grooves of brake piston (6) and bearing car-
rier (7).
Ir Coat the brake piston and piston mount
with grease to prevent the O-ring from
twisting or breaking.
& Piston and piston mounting face:
Oil (axle oil)
2) Install piston press fit tool B on housing,

and tighten screws (39) evenly to press fit.
* Press fit the piston completely until it
contacts the housing.
Sr The O-ring and piston will be damaged
if a plastic hammer is used to press fit
the piston.
39
761
12. Brake oil leakage test

1) Install bleeder screw.
2) Tighten screw (39) of piston press-fitting tool
B completely, then loosen one turn.
3) Install hose of tool C to brake tube mount
port (441, and bleed air from inside cylinder.
4) Operate pump and raise pressure to 1.4 MPa
(14 kg/cm?.
t When the pressure is 1.4 MPa (14 kg/
cm*), leave for 5 minutes. The drop in
pressure should be less than 0.34 MPa
(3.5 kg/cm*).
30-126
0
5) If the test shows that there is no air leakage,

raise pressure to 4.1 MPa (42 kg/cm*).
When the pressure is 4.1 MPa (42 kg/
cm2), leave for 5 minutes. The drop in
pressure should be less than 0.34 MPa
(3.5 kg/cm2).
If there is any oil leakage, remove the
brake piston, check the O-ring for dam-
age, then assemble again.
After checking for brake oil leakage, in-
sert the piston fully.
13. Coupling
Tighten mounting bolts of coupling (22) fully.
& Mounting bolt: Thread tightener (LT-2)
w Mounting bolts: 279 f 29 Nm

(28.5 f 3.0 kgm)
DEW02763

1) Install differential cover (3) to housing.
* Use a guide bolt when installing to pre-
vent thread tightener from entering the
mounting hole of the bleeder screw.
& Cover contact surface:
Gasket sealant (Loctite 5151
w Mounting bolts: 113 + 9.8 Nm

(11.5 + 1.0 kgm)
DEW02721
2) Remove guide bolt, install bleeder screw (2).

* Check that there is no thread tightener
stuck to the bleeder screw hole before
installing.
30-127
0
DISASSEMBLY AND ASSEMBLY AXLE HOUSING
DISASSEMBLY OF AXLE
HOUSING
-- --
1. Draining oil
Loosen drain valve (I) and drain oil
- : Axle oil: 14 e
d i \/ -1 \
i DEW02764
I) Remove bleeder screw (21, then using forc-
ing screw, remove differential cover (3).
2) Install axle assembly to stand.
DEW02721
3. Axle housing assembly

1) Sling axle housing (41, then remove housing
mounting bolts.
Ir Put match marks on the housings to dis-
tinguish the left and right housings.
2) Disconnect axle housing, and remove shaft

(5), brake disc (6) and brake ring.
* Be careful not to damage the surface of
the brake disc.
& kg Axle housing: 88 kg
30-128
0
4. Brake outer ring

Remove brake outer ring (7) and pin (8).
Ir Be careful not to damage the surface in con-
tact with the brake disc.
7 8 DEW02767
5. Planetary carrier
I) Remove axle shaft mounting bolt, then re-
move planetary carrier (9).
DEW02768
2) Remove shims.
I Shim
6. Axle shaft
I) Stand housing and shaft assembly upright,
then sling housing (IO).
2) Tap end face of axle shaft (I I) with a copper

hammer to remove the shaft.
Copper hammer
DEW02770
30-129
0
* When the axle shaft has been pulled out

a little way, put out portion “a” of oil seal
(12) with a screwdriver to prevent the oil
seal from being damaged by bearing
(73).
a DEW02772
3) Remove bearing (13) and seal (12) from shaft

(II).
* Never apply heat or use gas cutting to re-
move the bearing.
(This will affect the hardening of the shaft
and reduce the strength.)
DEW02773
Ir Remove the bearing as follows.
4) When removing bearing (13) of shaft (II),

use a screwdriver at point “b” of oil seal and
sleeve (121, and push towards flange uni-
formly around circumference.
5) Make clearance “c” in order to fit claws of
11
puller to connection of bearing (13) and
\
sleeve (12A).
6) Install bolt (30) (5/8 - 18UNF, e = approx.

L- ,A3
60mm) at point “d” to bearing puller Al.
* Screw in the bolt thread fully.
30-130
0
7) Set bearing puller Al to clearance “I?’ be-

tween bearing (13) and sleeve (12A), then
assemble bolt A2 and nut A3.
* When doing this, fix securely to prevent
any play in the bearing puller.
8) Insert washer between bolt (30) and flange
l--T
surface, turn in direction to loosen bolt (301,
and remove bearing (13). 11
The puller has only a small grip on the
13
bearing, so be extremely careful not to
Al \L-l
let it come off the bearing.
If the length of the thread of bolt (30) is
too short, add extra washers to the flange
surface to adjust the height of bolt (301, “y -.&&_
Washer ,&!.her
and remove bearing (13). -a. Flange
Replace the oil seal and sleeve assem- surface surface
bly with new parts. DEW02777
7. Ring gear
Using a puller, raise ring gear (14) evenly and
remove.
Puller
Retainer block
Axle housing
1I I I DEW02778
8. Axle housing
Remove bearing cups (15) and (16) from axle
housing (IO).
16
DEW02780
30-131
0
9. Planetary carrier r
1) Drive in spring pin (17).
* Be careful not to drive in the spring too
far.
DDW02781
2) Using a press, remove shaft (18).
3) Remove spring pin (17) from shaft (18).
DEW02783
4) Remove pinion gear (19) from planetary car-

rier (91, then remove bearing cone (20),
spacer (21) and shims.
DEW02784
30-132
0
ASSEMBLY OF AXLE HOUSING

1. Axle housing
Press fit bearing cups (15) and (16) in axle hous-
ing (IO).
0 $3
* After press fitting the cups, check that there / A_ ’
is no clearance at portion “a”. \
10
8
/
16
Q
DEW02780
DEW0285
2. Ring gear
Press fit ring gear (14) in axle housing (IO), then
insert pins (17).
Ir Cool ring gear (14) in dry ice to a tempera-
ture of about -30°C before press fitting.
+ Align the pin holes of the housing and ring
gear when assembling.
t Press fit the ring gear horizontally and be
careful not to fit it at an angle.
‘I 7
10'
\ / DEW02786
3. Axle shaft
Press
1) Using a press on axle shaft (I I), press fit oil
seal (12).
* Do not use a hammer as it may cause
deformation.
* Coat the press-fitting portion of the
sleeve surface “a” thinly with oil.
& Press-fitting portion of sleeve:

Axle oil
I I DEW02787
Set bearing (13) on press stand, and press

Press
fit axle shaft (11).
* Be careful not to fit the bearing at an
angle.
$L_vII
& Press-fitting portion of bearing:
Axle oil
Plate
Press stand
4. Housing, shaft I
1) Stand shaft (I I) upright and install tool (BII.

* Using the adjustment bolt, adjust the
height of the seal support. Set the top
surface of tool Bl lightly in contact with
seal (12) and make the clearance uni-
form.
Bl
* Secure tool Bl with tool B2 so that it
does not come out of position.
B2
12 DEW02799
2) Raise housing (IO) horizontally, and insert I
carefully on shaft.
* Stop housing (IO) before press fitting the
oil seal.
DEW02770
I
3) Align housing (IO) with press-fitting portion

for oil seal, then lower housing slowly.
* Use the weight of the housing to insert
it.
DEW02790
30-134
0
4) Remove tool Bl.
DEW02791
5) Press fit bearing (13) on shaft (11). Rotate

housing by hand and press fit until end play
is 0.3 mm.
* Do not make the end play 0 mm.
& Press-fitting portion of bearing cone:
Axle oil
* Press force: Approx. 19.6 KN (2 ton)

* After assembling the housing, the face
of the seal must be level with the hous-
ing face. If there is any clearance “b” at a
part “a”, it must be uniform and within I DEW02792
the standard range.

. Standard range
Clearance “b”: 0.21 - 1.91 mm
DEW02793
5. Adjusting end play

1) Stand axle shaft and housing assembly (22)
upright, and hold flange “a”.
.22
I - DEW02794
2) Install planetary carrier (9) to spline of axle

shaft (II), then assemble shim adjustment
tool C to portion “c” of planetary carrier, and
install mounting bolts.
* Assemble planetary carrier (9) without
the gear.
Sr Remove all thread tightener from the
mounting bolts and the bolt holes of the
axle shaft.
3) Rotate axle housing (IO) and tighten mount-

ing bolt (26) of retainer.
m Bolt: 55 Nm (5.6 kgml
4) Using a depth micrometer, measure distance

H from shim adjustment tool to end face of
axle shaft.
. Shim thickness X = (H - t):i::E
* When selecting the shims take the near-

est value to X + 0.10.
DEW02795
30-136
0
5) After selecting shims, loosen bolts, and re-

move planetary carrier (9).
I) Assemble bearing cone (20) on gear (191,
then set spacer (21) and pinion gear (19) in
carrier (9).
Ir Insert spacer (21) in the planetary carrier
before assembling.
It There is no need to adjust with shims.
Ir Reference value for end play: 0 - 0.17
mm
30-137
0
2) Check alignment of shaft hole of gear and

planetary carrier again, then press fit shaft Press
(18).
* Align the hole of spring pin (17) and shaft
(181, then drive in the spring pin until it
is level with the face of the carrier.
* Press force: 49 KN (5 ton)
6 Shaft: Axle oil
DEW02799
3) Tap end face of shaft (18) and differential

side of gear (19) to push back bearing (20)
and allow gear to rotate smoothly.
Ir The gear must rotate smoothly.
‘\
18
19
I) Assemble shims (24) selected in Step 5 in DEW02802
planetary carrier (9) at axle shaft end face,

then install mounting bolts.
mounting bolts and bolt mounting holes
of the axle shaft.
& Mounting bolt:

w Mounting bolt: 279 + 29.4 Nm
(28.5 k 3.0 kgm)
+ Clean the end face of the shaft and the

planetary carrier spline before installing.
g When installing the planetary carrier, be
DEW02803
careful not to get your fingers caught.
30-138
0
2) After settling bearing (23) fully, check “X” at

drill hole “b” of axle housing (IO).
* Reference value
. Rotation force “X”:
Approx. 26.5 N (2.7 kg) or less
DEW02804
3) Install stand of dial gauge to axle housing,

and measure end play of planetary carrier at
end face of planetary carrier.
. End play of planetary carrier:
0 - 0.098 mm
* If the end play is more than 0.098 mm,
repeat Step 5 and adjust again.
8. Brake outer ring

Assemble brake outer ring (7) in axle housing.
Ir Align pin and pin hole of outer ring to as-
semble.
* Be careful not to damage the surface of the
brake outer ring.
DEW02806
9. Axle housing assembly

1) Assemble brake ring (271, brake disc (6) and
shaft (5) in differential housing.
Jr Be careful not to damage the surface of
the brake ring when assembling.
* Soak the brake disc for 2 to 3 minutes in
clean axle oil before assembling.
I
27
5 DEW02807
30-139
0
2) Raise axle housing (IO) horizontally, align

spline groove and hole of pin (281, then as-
semble carefully.
* When assembling, be careful not to let
the brake ring or disc come out of place.
Ir Remove all oil and grease, and clean the
mounting surface fo the differential hous-
ing and axle housing, then coat with an
unbroken film of gasket sealant.
& Contact face of housing:

Gasket sealant (Loctite 515)
m Mounting bolt of housing:

279 k 29 Nm (28.5 f 3.0 kgm)
IO. Differential cover

I) Install differential cover (3) to differential
housing.
* Coat with an unbroken film of gasket
sealant.
* Be careful not to let the gasket sealant
enter the mounting hole of the bleeder
screw when assembling.
& Contact face of cover:

Gasket sealant (Loctite 515)
w Mounting bolt of cover:

113 f 9.8 Nm (11.5 + 1.0 kgm)
2) Install bleeder screw (2).
11. Refilling with oil

Tighten drain plug and add engine oil through
oil filler and gauge (29) to the specified level.
Oil level
measurementposition
Axle
assembly
30-140
0
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
REMOVAL OF CENTER HINGE

PIN
Ir Before starting the operation, set a pallet
under the bucket.
(2) on the left and right under the floor.
I
ALoosen the oil filler cap slowly to release the

* Machines equipped with air conditioner
. Release the gas at a point far from the
compressor. Loosen the hose connection
slightly to release the gas.
Ir Disconnect the cable from the negative (-)
?
;
0
1. Cover
I) Sling left side ladder rail (41, remove mount-
ing bolts, then lift off together with center
fender (5).
on the right side.
* When lifting off the ladder, be careful of
the center of gravity.
* Be careful not to damage the cab glass.
2) Disconnect connector for left brake oil level
sensor.
DEW02435
3) Remove brake oil tank mounting bracket (8)

together with oil tank (7) from under floor.
t Leave the oil hose installed to the brake
oil tank and tie it to the top surface of
the rear frame with wire.
. For machines equipped with an air con-
ditioner, it can be placed on top of the
condenser.
30-141
0
2. Electric wiring
Disconnect following electric wiring from con-
nector.
Connectors (II), (121, (13), (141, (151, (161,
and (17) of front wiring (9) and rear wiring
(IO).
For machines with cab, disconnect wiring
for cab from connector.
Disconnect ground wiring (18) from rear
frame.
Disconnect transmission cut-off switch (19)
and wiring connector (20). V
DEW02437
Remove wiring clamp and bracket (21) from
rear frame (22).
Fit tags to identify the wiring.
22 ’
DEW02438
3. Brake booster
1) Remove locknut of ball joint (24) of brake
linkage rod (231, and pull out linkage rod.
2) Set block under brake booster (251, then re-
move mounting bolts (26).

Disconnect fuel control cable (27) at engine end,
then remove bracket (28) together with control
cable.
* For machines equipped with cab
. Disconnect the washer hose from the tank,
then coil up and bend the end of the hose.
. After removing the hose, fit a blind plug in
the washer tank.
I DEW02442
30-142
0

Disconnect each connectors (33) from transmis-
sion valve wiring.
DEW02443

Disconnect work equipment control cables (34)
at valve end.
* Fit tags to the cables before disconnecting.
* Remove the cable clamp.
7. Parking brake cable

1) Disconnect parking brake cable (38) from le-
ver, and remove bracket (40) from front face
of transmission (39).
* Check that there are blocks under the
tires.
* After disconnecting the cable, tie it tem-
porarily to the bottom surface of the floor
with wire. 42
2) Disconnect speedometer cable (41).
3) Remove transmission oil filler tube (42).
30-143
0
8. Steering piping
1) Remove hoses (44) and (45) from steering
valve (43).
2) Disconnect hoses (47), (481, and (49) between

3) Remove hose (50) between steering valve

and hydraulic tank.
* Fit blind plugs after disconnecting the
hoses.
/ / DEW02447

Sling floor frame and cab assembly (511, then
remove mounting bolts (51-l) and lift off.
sembly, pull the brake booster out gradually
from the mounting bracket, and raise the
cab slowly.
The brake hose is not disconnected, so be
a
careful not to catch the brake booster.
Check that there is no interference from the
hoses and wiring, then lift off.
/I
DEW02813 DEWOZi49
sembly, lift slowly for approx. 40 - 50 mm,

stop and check that there is no interference,
then continue to lift.
f3 kg Floor frame, cab assembly: 680 kg
Floor frame assembly: 155 kg
* Eyebolts for removing cab assembly

M = 16mm, P = 2.0mm (4 bolts)
DEW02814
30-144
0

I) Disconnect hoses (52) and (53) between
steering valve and steering cylinder from
connection with tube.
* Disconnect both the left and right hoses.
2) Remove bottom lock bolt of steering cylin-

der, then remove pin (54).
11. Drive shaft

Disconnect center drive shaft (55) at transmis-
sion end.
* When removing the drive shaft, set a block
between the rear frame and the drive shaft
to prevent the grease fitting from being
crushed.
12. Electric wiring

Remove clamp mounting bolts (56) and (56-I)
of front frame wiring.
13. Brake tube

Remove clamp of brake hose and tube (57) for
front axle from frame.
DEW02818
14. Hydraulic piping

Remove mounting bolts of dump and lift cylin-
der hose clamp brackets (60) and (60-I) for front
frame (58) and rear frame (59) from frame.
15. Jacking up chassis

I) Adjust height of rear frame and set block @
in position.
2) Adjust height of front frame on left and right,

and set block @ in position.
* Be extremely careful when adjusting the
height of the frame.
DEW02821
3) Set support stand @ to counterweight.
16. Lower hinge pin

Remove lock bolt, then pull out lower hinge pin
(61).
DEW02824
30-146
0
17. Upper hinge pin

64
1) Remove locknut (62) and washer (63).
2) Remove pin mounting bolts, then pull out
upper hinge pin (64).
Ir There are shims between the retainer and
frame, so check the number and thick-
ness of the shims, and keep in a safe
place.
62
DEW02825
18. Disconnection of frame

I) Remove safety bar, jack up front differential
and palleter under bucket, then pull out to
front of front frame.
-k Carry out this operation with 2 workers
and rotate the tires uniformly on the left
and right.
* Be extremely careful to maintain the bai-
ante when carrying out this operation.
* Be careful not to let the spacer at the
bottom of the upper hinge get caught in
the rear frame, and insert a bar between DEW02827
the rear frame and front frame to raise
the front frame while disconnecting.
2) After disconnecting frame, remove spacer
(65).
19. Lower hinge

I) Remove washer (66).
2) Remove snap rings (67) and (68), then pull
out bearing (69).
DEW02828
DEW0283
67
Plate
/
DEW02831
20. Upper hinge

1) Remove spacer (70).
2) Remove mounting bolt, then remove retainer
(71).
* There are shims between the retainer and
frame, so check the number and thick-
ness of the shims, and keep in a safe
place.
-70
DEW02832
c
0
\\
:_
c,
DFVVOZW
3) Remove dust seal (73) from retainer (72).
73 72
DEW02834
4) Remove bearing (74) and spacer (75) from
front frame.
30-148
0
INSTALLATION OF CENTER
HINGE PIN
1. Upper hinge
1) Press fit bearing (74) and spacer (75) on front
frame.
* The clearance between the bearing and
spacer is adjusted, so do not change the
combination. When replacing the bear-
ing and spacer, replace as a set.
* When press fitting the bearing, press fit
correctly and make sure that there is no
I I I
clearance from the contact surface of the
DEW32837
frame.
6 Bearing: Grease (G2-LI)
2) Install dust seal (76) and spacer (70) from

under front frame.
* Be careful not to damage the seal lip,
and install with the lip on the outside.
6 Outside circumference of dust seal:

Thread tightener (Loctite 601)
& Seal lip: Grease (G2-LI)
& Inside circumference of spacer:

Grease (G2-LI) 70 76
DEW02838
3) Press fit dust seal (73) on retainer (72).

* When press fitting the dust seal, fit with
the lip on the outside.
72
& Seal lip: Grease (G2-LI)
;_;
DEW02839
4) Tighten retainer (72) with 4 mounting bolts,

then insert shims so that clearance “a” be-
tween retainer and frame is standard value.
Clearance “a”: 0.1 - 0.2 mm
w Mounting bolt (when adjusting shim):

4.9 f 0.98 Nm (0.5 + 0.1 kgm)
w Mounting bolt:
66.7 + 6.9 Nm (6.8 + 0.7 kgm)
DEW02841 DEW02842
30-149
0
2. Lower hinge Plate

I) Install snap ring (68), and press fit bearing
(69).
DEW02743
2) Install snap ring (67), and install washer (66).
3. Connecting frame
Jack up front differential, move front frame to-
wards rear frame and align pin holes.
A your
Use a bar to
fingers.
align the pin holes. Never use
Ir Be careful not to bite into the lower spacer

(65) of the upper hinge when connecting the
frames.
-k Align the pin holes correctly.
DEW02845
* Install the safety bar.
Safety bar
I DEW02845
30-150
0
4. Upper hinge pin

1) Insert upper hinge pin (64).
2) Fit washer (63) and tighten lock nut (62) to
specified tightening torque. Select shims to
give standard value for clearance “b” be-
tween rear frame and pin.
Ir Temporarily tighten the mounting bolt
to act as a stopper when tightening the
lock nut.
* Clearance “b”: Max. 0.4 mm
w Lock nut: 559 f 49 Nm (57 f 5 kgm)

I 63 A 62 DDW02847
62
I DEW02825 DEW02848
3) Assemble selected shims, and tighten

mounting bolts of pin.
Ir Before tightening the mounting bolts,
tighten the lock nut to the specified
torque again.
QEI Mounting bolt: 113 + 9.8 Nm

(11.5 f 1.0 kgm)
5. Lower hinge pin

Insert lower hinge pin (61), and secure with lock
bolt.
& Outside circumference of hinge pin:
Grease (G2-LI)
DEW02324
6. Lowering chassis
Remove blocks @ and @ from front and rear
frame and support stand @ from counterweight,
then lower chassis.
7. Hydraulic piping
Install mounting bolts of dump and lift cylinder
hose clamp brackets (60) and (60-I) for front
frame (58) and rear frame (59) to frame.
8. Brake tube
Connect front axle brake hose (57) to tube.
9. Electric wiring >/

DEW0281E
Install clamp mounting bolts (56) and (56-I) for
front frame wiring.
1
' DEW02817 DEW02818
30-152
0
10. Drive shaft

Connect center drive shaft (55) to transmission.
* Be careful of the direction of the yoke, and

(6.7 + 0.7 kgm)

I) Install pin (54) to bottom of steering cylin-
der, and secure with lock bolt.
2) Connect hoses (52) and (53) between steer-

ing valve and steering cylinder.

I) Raise floor frame and cab assembly (51),
stop approx. 100 mm from mount, assem-
ble mounting bracket (77) to brake booster
(76), and keep suspended.
2) Check mounting condition of brake booster,
then install cab assembly (51) to rear frame.
Ir Tighten floor mounting bolts (51-I) uni-
formly at left, right, front, and rear.
Ir Check that there is no interference with
any hoses or wiring when installing.
DEW0281A
(28.0 f 3.0 kgm)
77 76
4 I/
DEW02813 DEW02852
DEW02851
13. Steering piping

1) Connect hose (50) between steering valve
and hydraulic tank.
2) Connect hoses (47), (481, and (49) between
3) Connect hoses (44) and (45) to steering valve
(43).
* Install the hoses without twisting or in-
terference.
\ DEW02853 DEW02854
14. Parkina brake cable

I) Install bracket (40) of parking brake cable
(38) to front face of transmission, and con-
nect parking brake cable (38) to lever.
2) Connect speedometer cable (41).
3) Install transmission oil filler tube (42).
* Adjust the parking brake. For details, see
TESTING AND ADJUSTING.

Connect work equipment control cables (34) to
each spool of valve.
* Install the clamp of the cable.
30-154
0

Connect each transmission valve wiring connec-
tors (33).
Ir When connecting, check the tags used to
identify the wiring
DEW02443

Connect fuel control cable (27) to engine end,
and install bracket (28) to engine.
* For machines with cab
. Connect the washer hose to the tank end.
I-_;
DEW02442
18. Brake booster

I) Remove block under brake booster (25), and
install mounting bolts (26).
Ir Tighten the mounting bolts uniformly
and be careful not to tighten them too
much.
w Mounting bolt: 110.3 k 12.3 Nm
(11.25 + 1.25 kgm)
DEW02856
2) Insert brake linkage rod (23) in boot portion

of brake booster (25), and connect to linkage
lever.
3) Connect ball joint (24) and tighten locknut.
w Locknut: 29.4 f 4.9 Nm

(3.0 + 0.5 kgm)
24 23 25
DFm2857
30-155
0
19. Electric wiring

Connect connectors to followina electric wirina.
Connectors (II), (12), (13), (141, (15), and (16)
of front wiring (9) and rear wiring (IO).
Connector (17) of cab wiring
Connect ground wiring (18) to rear frame.
Connect transmission cut-off switch (19) and
wiring connector (20).
Install wiring clamp and bracket (21) to rear
frame (22).
When connecting, check the tags used to
identify the wiring V
DEW02858
20. Cover
I) Install brake oil tank mount bracket (8) to-
gether with oil tank (7) to bottom of floor.
2) Connect connector for left brake oil level sen-

sor.
3) Sling left ladder rail (4), then raise together

with center fender (5) and install.
on the right side.
* When raising the ladder to install it, be
careful of the center of gravity.
Sr Be careful not to damage the cab glass.
DEW02435
30-156
0
21. Refilling with oil

Tighten drain plug and add hydraulic oil through
oil filler to the specified level.
Ir Run the engine to circulate the oil through
the system. Then check the oil level again.
%3 Hydraulic oil: Add oil
22. Bleeding air from brake system

. If the hose has been disconnected from the
brake booster, bleed the air from the brake
system.
* For details of the procedure for bleeding
air, see TESTING AND ADJUSTING.
* Install cover (I) at the top of the hydraulic tank

on the right side, and covers (2) on the left and
right under the floor.
8
z
0
30-157
0
DISASSEMBLY AND ASSEMBLY PRIORITY VALVE
REMOVAL OF PRIORITY VALVE

* Turn the steering wheel to the left to articu-
late the chassis.
(I-l) on the left and right under the floor.

Disconnect following piping.
. Hose (3) between hydraulic pump and prior-
ity valve
* Remove rear right inspection cover (2-
1), disconnect hydraulic pump, and re-
move hose (2-3) while still installed to
DEW02860
the priority valve.
* This operation can also be carried out
by removing connector mounting bracket
(2-2) connecting the front wiring and rear
wiring.
* To prevent damage to the mounting
bolts, remove hose (2-3) after removing
the priority valve.
. Hose (4) between priority valve and main
control valve
. Hose (5) between steering valve and priority
valve
. Hose (6) between priority valve and hydrau-
lic tank DEW02861 1 -’ DEW02862 ’
. Hose (7) between priority valve and steering
valve
* Remove hose (7) after removing the pri-
ority valve.
From hydraulic pump (3)
Front
0 0
To steering To main control 6
valve (7) valve (4) OEW02864 DEW02853
30-158
0
DISASSEMBLY AND ASSEMBLY PRIORITY VALVE
2. Priority valve m
8
Remove mounting bolts (8), then remove prior- 3
ity valve (9).
* Remove hose (7) after removing the priority
valve.
INSTALLATION OF PRIORITY
VALVE I 8 9

removal.
w Hose (4) mouthpiece:

176.5 f 29.4 Nm (18 k 3 kgm)
w Hose (7) mouthpiece: DDW02866
78.5 + 19.6 Nm (8 + 2 kgm)

/12
Sr Install to the rear frame after installing hose
(3) to the priority valve.
w Hose mouthpiece:
176.5 + 29.4 Nm (18 + 3 kgml
w Mounting bolt (8): 31.4 Nm (3.2 kgm)
* If the mount plate had to be removed, as-

semble as shown in the diagram on the right.

(11.25 * 1.25 kgm)
Priority valve
/ Mount plate
DISASSEMBLY AND ASSEMBLY STEERING VALVE
REMOVAL OF STEERING
VALVE
(1-I) on the left and right under the floor.
ALoosen the oil filler cap slowly to release the

1. Column cover
Remove steering column cover (41, then remove
plugs (3) of bottom boot (5), and roll up.
Disconnect following hydraulic piping.
. Hose (6) between steering valve and priority
valve
. Hose (7) between priority valve and steering
valve
l Tubes (8) and (9) between steering valve
and steering cylinder
. Hose (IO) between steering valve and prior-
ity valve I
. 5 5
Hose (11) between steering valve and hy-
draulic tank DEW02869
e\
DEW02870
* Fit tags to identify the piping.
DEW02872
30-160
0
3. Steering valve
+ Carry out the steering valve removal opera-
tion with 2 workers, give signals to each
other, and be extremely careful when re-
moving the steering valve.
1) Remove lock bolt (12) of spline connecting
portion at steering column end. 14-
* Be sure to remove lock bolt (12). If it is
not removed, the lock bolt will catch in
‘14
the column shaft lock groove, and the
steering valve will not come out. 112/
15’
CEWOZ373
2) Support from below, and remove bracket

mounting bolt (14).
3) Remove steering valve (15). m

* Remove the steering valve together with
13’
bracket (13).
4) Remove lock bolt (12-I) from steering valve

(15), remove coupling (16) and mounting
bolts (171, then remove bracket (13) and col-
umn assembly (18). mmmmj DEW02874
I
* Make match marks before removing col-
umn assembly (18) from the steering
valve.
30-161
0
INSTALLATION OF STEERING
VALVE
removal.
* Carry out the steering valve installation op-
eration with 2 workers, give signals to each
other, and be extremely careful when in-
stalling the steering valve.
/I
* Install the hoses without twisting or interfer-
ence.
* Hoses (71, (8), (91, (11)
w Hose mouthpiece: 78.4 f 19.6 Nm
(8 f 2 kgm)
Width across flats of hose mouthpiece:
27 mm
* When assembling the lock bolt, align with

the column shaft groove and screw in.
w Lock bolt (12): 24.5 f 4.9 Nm

(2.5 f 0.5 kgm)
& Column shaft spline: Grease (G2-LIl
Oil seal
* When assembling the lock bolt, align with
the column shaft groove and screw in.
w Lock bolt (12-I): 24.5 f 4.9 Nm

(2.5 f 0.5 kgm)
m
* Tighten mounting bolts (17) on diametrically
opposite sides.
w Mounting bolt (17): 41.7 + 17.2 Nm

(4.25 + 1.75 kgm) (U3/8)
DOW02875
* If the oil seal of the column assembly has

been replaced, coat the oil seal lip with
grease.
6 Lip of oil seal: Grease IG2-LI)
. Refilling with oil

Tighten drain plug and add hydraulic oil through
oil filler to the specified level.
* Run the engine to circulate the oil through
30-162
0
DISASSEMBLY OF STEERING
VALVE
li Use a wire brush to remove all the dirt and dust

stuck to the joint around the outside circumfer-
ence of the unit.
+ Carry out the operation in a clean place to pre-
vent dirt or dust from sticking to the valve.
* As far as possible, hold the valve in a vice when
disassembling.
DISASSEMBLY OF ROTOR
1. Set rotor side facing up, and hold mounting

flange lightly in vice 0.
* Put a copper plate in contact with the vice and
be careful not to tighten the vice too hard.
2. Remove screw (I), then remove end cap (2).
3. Remove O-ring (3) from end cap (2).
DLW01701
4. Pull out rotor set (4), then remove O-ring (5).

Ir Be careful not to drop the star inside the
rotor set.
5. Remove spacer (6).
DLWO1702
30- 163
0
6. Remove drive shaft (7).
7. Remove spacer plate (8).
8. Remove O-ring (9) from housing (IO).
DLW01703
DISASSEMBLY OF CONTROL SIDE
9. Remove housing (IO) from vice, and place on a,

clean cloth. Be careful not to damage the fin-
ished surface.
10. Raise tip of snap ring (I I) with screwdriver, and

remove from housing.
DLW01704
11. Turn spool and sleeve to place pin in a horizon-

tal position, then push in spool and sleeve with
your thumb, and remove bushing (12) from hous-
ing.
DLW01705
12. Remove X-ring seal (13) from bushing (12).
13. Remove dust seal (14) from bushing (12) with

screwdriver.
* Be careful not to damage the bushing.
DLW01706
30-164
0
14. Remove 2 bearing races (15) and thrust needle

(16) from spool and sleeve.
15. Pull out spool and sleeve assembly (17) from

housing (10) in the direction of the arrow.
j, To prevent the spool and sleeve assembly
from catching in the housing, rotate the spool
and sleeve assembly slowly to the left and
right when pulling out from the housing.
16. Pull out pin (18) from spool and sleeve assem-
bly (17).
17. Push spool (20) inside sleeve (19) slightly to

front, and remove 6 centering springs (21) from
spool (20) carefully by hand.
18. Turn spool (20) slowly and pull out from rear of
sleeve (19) (in the direction of the arrow).
19. Remove O-ring (22) from housing.
20. Remove set screw (23) from housing.
21. Screw a threaded bar into check sheet (24), and

pull out check sheet (24).
22. Remove O-rings (25) and (26) from check sheet

(24).
28
23. Tap housing, and remove ball (27) and retainer DLW01710
(28).
30-165
ASSEMBLY OF STEERING
VALVE
Check all parts for damage or burrs.

Wash all metal parts in clean solvent and blow
dry with air.
Do not use a file or polish any part with rough
sandpaper.
Coat the O-rings with clean grease. (No need to
put grease on new X-ring seals)
Coat the O-ring for the rotor set with a small
amount of grease.
ASSEMBLY OF CONTROL SIDE
1. insert retainer (28) in housing with tweezers.

* Check that the retainer is not inserted at an
angle.
2. Insert ball (27). 27
3. Fit O-rings (26) and (25) in check sheet (241, and 28

push check sheet (24) into housing.
DLW01711
+ Be careful to set the top and bottom of the
check sheet facing in the correct direction.
4. install set screw (23).

* Check that the set screw is set in slightly
from the end face of the housing.
w Set screw: 11.8 Nm (1.2 kgm)
& Set screw: Loctite
5. Assemble spool (20) and sleeve (19) so that

spring groove is on same side.
* Rotate the spool and slide it in.
Ir Grip the splined portion of the spool lightly
and check that the spool rotates smoothly
inside the sleeve. SP
* If there are match marks, check that the
match marks are aligned.
DLW01712
30-166
0
6. Align spring groove positions of spool (20) and

sleeve (19), and set on flat plate, then insert
spring (21) in spring groove.
* Set so that the notches at both ends are at
the bottom.
I DLW01713
7. Insert pin (18) in spool and sleeve assembly

(17).
I DLW01714
8. Insert spool and sleeve assembly (17) in hous-

ing (IO) in the direction of the arrow.
1) Keep pin horizontal and rotate to left and
right a little at a time to insert.
Ir Be extremely careful not to get it caught.
2) Make the spool and sleeve assembly flush
with the rear end face of the housing.
* If it is inserted beyond the end face, the pin
will fall out.
3) Check that spool and sleeve rotate smoothly
inside housing.
DLW01715
9. Install O-ring (22) to housing (10).
IO. Fit 2 bearing races (15) and thrust needle (16) in ------nGD
$&//
-, -15
15
case (IO).
W
22-
LJ
10
I DLW01716
30-167
0
11. Insert dust seal (14) in bushing (12).
12. Insert X-ring seal (13) in bushing (12).
13. Insert bushing (12) in spool, and rotate to in-

stall.
* Tap with a plastic hammer to assemble to
the specified position.
. It must be in contact horizontally with the
bearing race.
14. Fit snap ring (11) in housing.
ASSEMBLY OF ROTOR
15. Hold flange of housing lightly in vice.

* Be careful not to tighten the vice too hard.
Ir Check that the spool and sleeve are set in
slightly from the housing surface with four-
teen holes.
16. Insert O-ring (9) in housing.
17. Put on spacer plate (81, and align positions of

bolt hole and tap hole of housing.
DLW01720
J
30-168
0
18. Turn spool and sleeve assembly to make pin

(18) and port surface of housing parallel, then
mesh pin and yoke of drive shaft (7).
* To position accurately, draw a line on the
end face of the drive shaft spline.
I DLW01721
19. Insert O-ring (5) in rotor set (4).
5
DLW01722
20. Make O-ring (5) end of rotor set to spacer plate

end, then align insert portion of star of rotor (4) Inset portion of star
with drive.
1) Check that lines A,B,C, and D are all parallel.
2) Without removing joint of drive shaft (7),
position bolt holes of rotor set. (Make line)
* This procedure is very important for deter-

mining the valve timing of unit.
Pin Port &ace

DLW01723
21. Insert spacer (6) inside rotor set.
22. Set end cap (2) on rotor set, and align bolt hole.
DLW01724
30-169
0
23. Coat thread of screw with grease, and tighten

end cap.
Ir Install the handle to the spool,
that the spool rotates.
m End cap mounting

First step: 14.7 Nm
Second step: 27.0
(2.75
screw
and check
(1.5 kgm)
f 1.5 Nm
f 0.15 kgm)
Q;;;;p
01
6x3
02
DLW01725
30-170
0
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER
REMOVAL OF STEERING
CYLINDER
Remove cover (1-I) on the right under the floor.
a Loosen the oil filler cap slowly to release the

. Loosen plug (I) to prevent the oil inside the
1) Disconnect steering cylinder rod hose (2)
from steering cylinder tube.
2) Disconnect steering cylinder bottom hose (3)
from steering cylinder tube.
2. Cylinder
ii Remove lock bolt at rod end, then remove
pin (4). a
2) Remove lock bolt at bottom end, remove
pin (51, then remove cylinder (6). a
* Be careful not to damage the rod plat-
ing.
EW02880 1 DEW02879
30-171
0
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER
INSTALLATION OF STEERING
CYLINDER
removal.
m
ence.
* Align the rod pin hole and assemble the

shims so that clearance “b” between the cyl-
inder and the frame is the specified value,
then lock pin (4) with the mounting bolt.
g Always use a bar when aligning the pin

holes. Never insert your fingers.
Clearance “b” = Max. 1.0 mm
113 a
* Align the bottom pin hole and assemble the
shims so that clearance “a” between the cyl-
inder and the frame is the specified value, a
then lock pin (5) with the mounting bolt.
DEW02882
a Always use a bar when aligning the pin
Clearance “a” = Max. 1.0 mm
. Add hydraulic oil through oil filler to the speci-

fied level.
30-172
0
DISASSEMBLY AND ASSEMBLY BRAKE BOOSTER
REMOVAL OF BRAKE
BOOSTER
. Turn the steering wheel to the right to articulate
the chassis.
\ I I \ DEWO2fS
1. Covers
I) Remove cover (I) under cab or on left and
right sides..of floor.
2) Remove cover (2) at left side of rear frame.
2. Machines equipped with air conditioner

I) Remove left ladder rail (3). m
* Be careful not to catch the brake hose
when removing the ladder rail.
2) Remove condenser front cover (4).
Ir Remove the hose clamp.
3) Remove condenser mounting brackets (51,
and open condenser (6) to rear.
6
6
30-173
0
3. Brake piping
1) Disconnect hose (7) between brake booster I ILL!-! 8 I 9
and torque converter filter from brake
booster.
2) Disconnect hose (8) between brake booster
and transmission valve from brake booster.
3) Disconnect hoses (9) and (IO) between brake
oil tank and brake booster from brake
booster.
4) Disconnect tubes (11) and (12) between brake
booster and front and rear brake from brake
booster. DEW02888
5) Disconnect hose (13) between brake booster

and transmission oil filler tube from brake
booster.
4. Brake booster
1) Pull out ball joint (15) of brake linkage (14). 16
2) Remove 4 mounting bolts (16), then remove
brake booster (17). m3
1 7
30-174
0
INSTALLATION OF BRAKE
BOOSTER
removal.
Be careful not to catch the brake hose when

installing the ladder rail.
Install the hoses without twisting or interfer-

ence.
Be careful to assemble correctly when con-
necting the hoses between the brake booster
and transmission.
w Tube nut between front and rear

brakes: 11.3 + 3.4 Nm
(1.15 + 0.35 kgm)
w Hose clamp between brake oil tanks:
3.3 f 0.5 Nm (0.34 f 0.05 kgm)
Check that the cylinder rod is inserted in the

brake booster piston groove.
m Ball joint nut: 29.4 & 4.9 Nm

(3.0 + 0.5 kgm)
w Rod locknut: 110.3 f 12.3 Nm
(11.25 f 1.25 kgm)
w Mounting bolt (16): 110.3 f 12.3 Nm

(11.25 f 1.25 kgm)
. Bleeding air
Bleed the air from the brake system.
* For details, see TESTING AND ADJUSTING.
l Adjusting rod
Adjust the rod. For details, see TESTING AND
ADJUSTING.
30- 175
0
DISASSEMBLY OF BRAKE
1. Power master cylinder

I) Remove linkage rod (2) and dust cover from
power master cylinder (1).
* Mask the tip of the piston of the linkage
rod to protect it from damage.
I 1'
DEbVXi92
2) Disconnect power cylinder (3) and master

cylinder (4).
2. Piston assembly
I) Remove snap ring (5) from body (41, then
e
remove secondary piston (6). 16
i-”
5
I I
DEW02895
i ‘9
DEW02897
2) Remove stopper bolt (71, then hold brake oil

hole (8) and stopper bolt hole (9) with fin-
ger. Blow in oil through brake oil hole (IO)
and remove primary piston (I 1).
* The piston may fly out, so do not blow
the air in strongly.
I I
DEW02696
30-176
0
3) Remove spring (12) from inside body (4). 1

* When removing the piston, be careful
not to damage the inside diameter of
the body or the sliding surface on the
outside of the piston.
* If there is any problem with the primary
or secondary pistons, replace the pistons
as an assembly.
3. Fine disassembly of power cylinder

I) Remove dust cover (13).
* Remove the elbow first.
2) Push in cylinder cover (14), remove snap 16 19 20

ring (15), then remove power piston (16),
connector assembly (171, spring seat (18),
and springs (19) and (20).
a When removing the spring, the cylinder

cover is pushed out by the spring, so
remove carefully.
3) Remove power piston (16) from connector
assembly (17).
14’
18 DEWO2WLl
4) Remove snap ring (21), disconnect spool (22)

and connector, then remove thrust washer
21 23
(23) and spring (24).
22 24
DEWO2Wl
30-177
0
4. Relief valve
Remove plug (25), then remove spring (26) and
spool (27).
26
27 DEW02902
5. Power piston
Remove seal ring (28) from piston (16).
16
30-178
0
ASSEMBLY OF BRAKE
BOOSTER
1. Elbow
Install elbow (29) to power cylinder body (3).
2. Relief valve
Insert spring (26) in spool (27), assemble in
power body, then install plug (25).
25
I i7 Ewoi%x
3. Fine assembly of power cylinder

1) Assemble spring (24) in connector (31).
2) Insert spool (22) in connector (31), and as-

semble thrust washer (23), then secure with
snap ring (21).
3) Set body (3) on block.
4) Insert springs (19) and (20), and spring seat

(18) inside body (3).
5) Assemble connector assembly (17).
19
18
Plate4 I
DEW02906
6) Assemble O-rings (32) and seal (33) in cylin-

33
der cover (14).
& Seal: Oil (brake oil)
32
14
DEW02907
7) Assemble seal ring (28) in power piston (16).

& Seal ring: Oil (brake oil)
I
IS
U28 DEW02933
30-180
0
8) Assemble power piston (16) and cylinder

cover (14) to spool (22), then set guide shaft Press
“a” in position. a
* To prevent power piston (16) and cylin-
der cover (14) from dropping inside the
body, stop them at the top of the body.
22
16
17.50
a’ DDW02910
9) Push in guide shaft “a” with a press, bend

springs (19) and (20), and keep in position.
* Keep snap ring (15) until the completion
of assembly.
Plate
IO) Lower power piston (16) only, and push in

evenly on the left and right with both
thumbs.
* When assembling the power piston, do
not hit it in with a hammer.
* When assembling the power piston (161,
apply the force evenly. Never use exces-
sive force.
11) Check that there is no damage to O-ring of

power piston (16), then assemble cylinder
cover (14).
12) Secure cylinder cover (14) with snap ring

(15).
Plate
30-181
0
13) Install dust cover (13).
4. Fine assembly of master cylinder

1) Insert primary piston (11) in body (4).
* Insert the pitson carefully to prevent
damage to the seal cup. Never force it
into position.
& Body and piston: Oil (brake oil)
2) Push piston (13) and tighten stopper bolt (7)

by hand.
* After tightening as far as possible by
hand, tighten fully.
w Stopper bolt: 10.8 f 2.0 Nm
(1.1f 0.2 kgm)
3) Insert secondary piston (6) in body (4).
& Body and piston: Oil (brake oil)

6 4
* When assembling the piston, be careful
not to damage the inside diameter of .5
the body and the outside diameter of
the piston.
Ir Be careful not to get the O-ring caught.
4) Push in secondary piston (6), then install C-

ring (5).
j, Fit the C-ring properly in the groove. DEwo2913
30-182
0
5. Power master cylinder

5) Connect power master cylinder (3) and mas-
ter cylinder (4).
* Use a new O-ring for the connection of
the master cylinder.
w Connecting bolt (34): 31.9 + 2.5 Nm

(3.25 k 0.25 kgm)
/ 34 4
3
DEW02914
2) Assemble linkage rod (2) to power master

cylinder (I).
* For details of adjusting the brake link-

age, see TESTING AND ADJUSTING.
I EWO2915
30-183
0
DISASSEMBLY AND ASSEMBLY PARKING BRAKE
REMOVAL OF PARKING BRAKE

Ir If further disassembly is necessary, see DISAS-
SEMBLY AND ASSEMBLY OF TRANSMISSION.

* After putting blocks under the tires, release
the parking brake.
. Loosen the plug of the transmission and drain
1 CEWOZ916
the oil.
- : Transmission oil: 28 e
1. Drive shaft
I) Disconnect drive shaft (I) from transmission
end. m
+ Set block @I to the rear frame.
2) Using hexagonal wrench, remove 2 plugs
on opposite sides, then install 2 piston lock
set bolts 0. m
+ Width across flats of hexagonal wrench:
6mm
* Piston lock set bolt:
P = 1.25, M = 8, L = 35
2. Coupling
Remove mounting bolt (71, then remove holder
(41, O-ring (51, and coupling (6). m
* Make match marks on the coupling.
DDW0.2918
3. Parking brake housing

Disconnect cable (9) from parking brake lever
(8). m
Ir Check that there are blocks under the tires,
then disconnect the cable.
+ Disconnect the cable with the parking brake
released.
DEW02919
30-184
0
4. Parking brake
I) Remove all mounting bolts (IO) of parking
brake housing (11). m
2) Tighten 2 forcing screws @ in forcing screw
hole and remove parking brake housing (11).
Use the housing mounting bolts as forc-

ing screws.
Do not remove bolts (20) used for in-
stalling retainer assembly (19).
The working posture is poor and the
housing is removed with the piston in-
stalled to the housing, so be extremely
I 11 cmo2sm
careful when removing.

Install guide bolt @to prevent the hous-
ing from falling.
Be careful not to let the oil seal lip hit
the shaft when removing.
elkg Parking brake housing: 15 kg
5. End plate
I) Remove separator plate holderbolt (14).
m
2) Remove separator plate (131, wave spring
(151, and disc (16) in turn, then remove end
plate (17). m
* If it is necessary to remove hub spline
(18), remove it as it is.
30-185
0
INSTALLATION OF PARKING
BRAKE
removal.
m
* Be careful of the direction of the yoke, * Soak the disc in clean transmission oil
and align the pilot portion correctly to for at least 2 minutes before assembling.
install. * Use one spring.
w Mounting bolt: 65.7 & 6.9 Nm
* When assembling the separator plate, be
careful that the hub spline does not rise
(6.7 + 0.7 kgm)
up.

* Remove 2 piston lock set bolts @ and
* Install drain plug and add engine oil
install the plug.
a
Q Transmission oil: 28 I?
+ Align with the coupling match mark, and
* If it is necessary to adjust the parking
assemble so that there is no misalign-
brake cable, see TESTING AND ADJUST-
ment of the front and rear couplings in
ING.
the circumferential direction.
w Mounting bolt: 277 + 31.9 Nm

(28.25 + 3.25 kgm)
* After connecting the parking brake ca-

ble, bend the cotter pin securely.

(11.25 f 1.25 kgm)
m
* The working posture is poor, so be ex-
tremely careful when installing the park-
ing brake housing.
* Install a guide bolt to prevent the hous-
ing from falling.
* Use a new gasket.
* Be careful not to let the oil seal lip hit
the shaft when installing.
pJ
* Remove all oil and grease from the sepa-
rator holder bolt thread and bolt hole.
* Tighten the separator holder bolts uni-
formly in turn.
& Holder bolt:

Thread tightener (LT-21
w Holder bolt: 53.9 + 19.6 Nm

(5.5 + 2.0 kgm)
30- 186
0
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
REMOVAL OF HYDRAULIC
TANK

oii filler cap DEW02924
. Loosen plug (I) at the top of the hydraulic
tank filter to prevent the oil inside the hy-
draulic tank from flowing out.
. Remove covers (2) at the side first.
1. Ladder rail
Lift off right ladder rail (3).
A kg Ladder rail: 22 kg
2. Hydraulic piping
1) Loosen clamp of hose (4) between hydraulic
tank and pump, and disconnect when re-
moving hydraulic tank.
2) Disconnect hose (5) between main control
valve and hydraulic tank from hydraulic tank.
. Width across flats of hose mouthpiece
(5): 36 mm
3) Disconnect hose (6) between steering valve
and hydraulic tank and hose (7) between
main control valve and hydraulic tank.
l Width across flats of hose mouthpiece I ) DEW02927
(6): 27 mm
3. Hydraulic tank
I) Set palleter @ and stand @ under hydraulic
tank (8).
2) Raise palleter @ slowly to support hydraulic
tank (8).
DEW02928
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
3) Remove mounting bolts of hydraulic tank

(8).
Ir Be sure to remove all the mounting bolts.
E-7
DEW02930 1
4) Pull out palleter @ and pull out hose be-

tween pumps while removing hydraulic tank
(8).
Sr When removing the hydraulic tank, tip it
to the outside and disconnect the hose.’
el kg Hydraulic tank (dry): 53 kg
DEW02931
INSTALLATION OF HYDRAULIC
TANK
removal.

(11.5 * 1.0 kgm)

Add hydraulic oil through oil filler to the speci-
fied level.
DISASSEMBLY AND ASSEMBLY HYDRAULIC FILTER
REMOVAL OF HYDRAULIC
FILTER
Loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank.
1. Hydraulic piping
Disconnect hydraulic hoses (I) and (2). m
l Width across flats of hose mouthpiece (1):
36 mm
. Width across flats of hose mouthpiece (2):
27 mm
I II DEW02932
2. Cover
Remove mounting bolts, then remove cover (3).
a
AThe cover is under the tension of a spring,

so be careful when removing it.
* Be careful not to damage the mating surface

of the cover and the tank and O-ring (4).
\
I DEW02933 DEW02934
3. Filter
Remove spring (5) and bypass valve (61, then
remove filter (7).
INSTALLATION OF HYDRAULIC
FILTER
\ DEW02935
removal.
m
ence.
pJ
* Replace the O-ring with a new part.
* Fit the O-ring securely in the groove and be
careful not to get it caught when assem-
bling.
* After installing the hydraulic tank and con-
necting the hose, bleed the air from the hy- \ ’
. DEiV02936
draulic tank.
30-189
0
DISASSEMBLY AND ASSEMBLY HYDRAULIC, STEERING PUMP
REMOVAL OF HYDRAULIC,
STEERING PUMP

* Disconnect the cable from the negative (-)
1. Cover, wiring
1) Remove cover (1) under right center fender. ’ ,-u
DEW02937 DEW02933
2) Remove covers (3) and (4) top of hydraulic
tank.
* Remove the wiring clamps.

3) Remove connector mounting bracket (7) con-

necting front wiring (5) and rear wiring (6),
then move to side.
* Do not disconnect the connector at this
point.
2. Hydraulic piping
1) Disconnect tube (8) between hydraulic tank
and hydraulic, steering pump at hydraulic
and steering pump end. m
2) Disconnect hose (9) between hydraulic, steer-
ing pump and priority valve at hydraulic and
steering pump end. m
3. Pump
Remove mounting bolts, then remove hydraulic
and steering pump (IO). m
AThe working space is confined, so be ex-

tremely careful when removing.
30- 190
0
DISASSEMBLY AND ASSEMBLY HYDRAULIC, STEERING PUMP
INSTALLATION OF
HYDRAULIC, STEERING PUMP
removal.
m
* Be careful not to get the O-ring caught when
installing the tube.

(6.75 k 0.75 kgm)
install the hoses without twisting or interfer-

ence.
Be careful not to get the O-ring caught when
installing.
w Mounting bolt: 34.3 rt 3.4 Nm
(3.5 f 0.35 kgm)
Be careful not to get the O-ring caught when

installing.
Tighten the mounting bolts uniformly at the
top and bottom.
8
r; w Mounting bolt: 110.3 + 12.3 Nm
z
0
(11.25 f 1.25 kgm)

Ir Run the engine to circulate the oil through
30-l 91
0
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
REMOVAL OF MAIN CONTROL

VALVE
* Raise the boom, set stand (IA) of boom hold-
ing stopper 0 in position, then remove front
cover (1).
Ir Remove cover (2) at the top of the hydraulic
tank on the right side. DEW02941

&
remaining pressure in the hydraulic piping. I I
. Loosen plug (3) at the top of the hydraulic tank
2
filter to prevent the oil inside the hydraulic tank
from flowing out.
b
1 ‘:I’
DEW02943 DEW02944
1. Drive shaft
Disconnect drive shaft (4) at front axle end.
m
* After disconnecting the drive shaft, move it
to the left and secure it with wire.
2. Electric wiring
Disconnect electric wiring connectors (5) and (6)
for main control valve.
* Fit tags with numbers to identify the wiring.
6
DEW02946
SO-192
0
3. Control cable
Pull out snap pin and remove pins (7), then re-
move control cables (8) from spools (9). m
* Fit tags with numbers to identify the wiring.
Disconnect following hydraulic piping.
. Tubes (IO) and (11) between main control
valve and boom cylinder
. Hoses (12) and (13) between main control
valve and bucket cylinder
. Hose (14) between hydraulic pump and main
control valve
. Hose (15) between main control valve and
hydraulic tank
. Between main control valve and oil return ii
:
hose (16) EWOZS49
2
5. Main control valve 18

I) Install eyebolt @) to front frame boss.
t Install the eyebolt to the boss portion
securely.
. M = 12, P = 1.75
2) Using eyebolt installed to front frame, fit lift-
ing tool and sling main control valve (18).
3) Remove mounting bolts (19) on top of

mounting bracket of main control valve (181,
then remove main control valve. m
&I kg Main control valve: 21 kg
t Loosen bottom bracket mounting bolts

(20).
* When removing the main control valve,
remove the top mounting bolts and lift
Off.
18’ DEW02952
30-193
0
INSTALLATION OF MAIN
CONTROL VALVE
removal.
m
Ir Be careful of the direction of the yoke, and

(6.7 f 0.7 kgm)
* Install the snap pin securely.
m
ence.
m Tube mouthpiece:
265 f 29.4 Nm (27 + 3 kgm)
m Hose mouthpiece:
176.5 f 29.4 Nm (18 + 3 kgm)
m
* Align with the bottom bracket mounting bolts
and install the main control valve.
* Be sure to tighten all of the bottom bracket
mounting bolts.
(11.25 + 1.25 kgm)

* Tighten drain plug and add hydraulic oil
30-194
0
DISASSEMBLY OF MAIN CONTROL VALVE
v
-12
25
@%---IO
25
\
3 DEW02953
DEW02954
30-196
0
1. Spool assembly
1) Remove mounting bolt (2) and plug (3) of
detent assembly (1).
2) Holding spool (4) from moving, loosen bolt
(5) inside detent assembly (I), then remove
detent assembly (1).
-Sr Remove joint (6) from spool (4).
3) Remove retainer (7), spring (8), retainer (9),
oil seal (IO) and plate (II).
4) Remove plate (12), then remove oil seal (10)
and spool (4).
2. Main relief valve assembly

1) Remove main relief valve assembly (13).
2) Loosen nut (14), and screw out holder (15),
then remove retainer (16), spring (17), pop-
pet (18), seat (19) and spring (20).
3) Remove plug (21), then remove valve (22) 63
from sleeve (23).
Ir Valve (22) and sleeve (23) are not avail-
able as individual parts, so replace them
as a set.
3. Remove safety valve assembly (25) with suction

valve and suction valve assembly (24).
4. Remove plug (26), then remove spring (27) and

valve (28).
23
21
DEW02955
30- 197
0
ASSEMBLY OF MAIN CONTROL VALVE
v
V-12
25
f&----lo
26
./
3 DEW02953 DEW02954
30-198
0
1. Assemble valve (28) and spring (27) in body

(291, and fit O-ring and tighten plug (26).
w Plug: 107.8 rt 14.7 Nm (11 f 1.5 kgm)
2. Fit O-rings and install suction valve assembly

(24) and safety valve assembly (25) with suction
valve.
m Safety valve (with suction):

142.2 f 19.6 Nm (14.5 + 2 kgm)
m Suction valve: 142.2 + 19.6 Nm

(14.5 + 2 kgm)
3. Main relief valve assembly

I) Assemble valve (22) -in sleeve (231, then
tighten plug (21).
2) Assemble spring (201, seat (19), poppet (18),
spring (17) and retainer (16) in sleeve.
3) Screw nut (14) into holder (151, fit O-ring on
holder, then install the holder into sleeve
(23) and tighten nut (14).
4) Fit O-ring and backup ring and install main
relief valve assembly (13).
w Main relief valve: 83.4 + 14.7 Nm
8
I- (8.5 + 1.5 kgm)
F.
;:
4. Spool assembly
1) Assemble spool (4) in body, then install oil
seal (IO) and plate (12).
2) Pull out spool slightly, then assemble re-
tainer (II), oil seal (IO), retainer (91, spring
(8), and retainer (7).
3) Holding spool from moving, turn bolt inside
detent assembly (I), and install joint (6) to
spool (4).
w Joint: 14.7 + 4.9 Nm (1.5 f 0.5 kgm)
4) Tighten bolt (5), then install detent assem-

bly (I).
5) Tighten plug (3).
w Plug: 13.7 + 3.9 Nm 11.4 f 0.4 kgm)
23
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
REMOVAL OF BUCKET
CYLINDER

Bucket positioner
Disconnect connector (I).
DEW02956
Rod pin m
Sling cylinder (71, then remove lock bolt, and
remove pin 12).
* Sling at 2 points and be careful of the center
of gravity.
1) Disconnect rod hose (3) from cylinder.
. Width across flats of hose (3) mouth-
piece: 36 mm
2) Disconnect bottom tube (4) at the connec-
tion with hose (5).
. Width across flats of hose (5) mouth-
piece: 36 mm
30-200
0
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
4. Bucket cylinder n
1) Remove lock bolt, then remove bottom pin
(6).
number and thickness of the shims, and
keep in a safe place.
2) Lift off bucket cylinder (7).
* Be careful not to damage the cylinder
rod portion.
&I kg Bucket cylinder: 56 kg
INSTALLATION OF BUCKET
CYLINDER
8
f-
2 l Carry out installation in the reverse order to
0
removal.
AWhen aligning the position of the pin hole,

use a bar. Never insert your fingers in the
pin hole.
. Bucket positioner
* For details of adjusting the bucket positioner,
see TESTING AND ADJUSTING.
m
ence.
Awhen aligning the position of the pin hole,

use a bar. Never insert your fingers in the
pin hole.
* Align the pin hole at the cylinder bottom,

assemble shims so that the total for clear-
ance “a” between the cylinder and frame is
within the standard value, then assemble pin
(6) and lock with the bolt.
-k Clearance “a”: Max. 1.5 mm
30-20 1
0
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
REMOVAL OF BOOM
CYLINDER
A pressure
Loosen the oil filler cap slowly to release the
inside the hydraulic tank. Then operate
* Set the support stand under the tip of the boom.
1. Rod pin m
I) Sling boom cylinder (I), then remove lock
bolt, and remove pin (2).
2) Start engine, and use control lever to retract
cylinder rod on side that was removed.
* Retract the rod to a point 20 mm before
the end of the stroke.
I) Disconnect rod tube (3) from connection of
hose (4).
2) Disconnect bottom tube (5) from connection
of hose (6).
* After disconnecting the tubes and hoses,
fit plugs to prevent the entry of dirt or
dust.
5 DEW02964
\ DEW02965
3. Boom cylinder m
1) Remove lock bolt, then remove bottom pin
(7).
2) Lift off boom cylinder (I).
* Be careful of the center of gravity and
lift off slowly.
j, Be careful not to damage the cylinder
rod.
&I kg Boom cylinder: 62 kg
30-202
0
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
INSTALLATION OF BOOM
CYLINDER
removal.
ALAlways use
holes. Never
a bar when aligning
insert your fingers.
the pin
* Start the engine, operate the control levers,

and extend the rod. Align the pin holes and
assemble shims so that clearance “b” is I DEW02967
within the standard value, then assemble pin

(2) and lock with the bolt.
* Clearance “b”: Max. 2 mm

ence.
A Always use a bar when aligning

the pin
+r Align the pin holes at the cylinder bottom,

assemble shims so that clearance “a” be-
tween the cylinder and frame is within the
standard value, then assemble pin (7) and
lock with the bolt.
* Clearance “a”: Max. 1.5 mm
30-203
0
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
DISASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
1. Set cylinder assembly (1) to tool A.
2. Raise lock portion of cylinder head (2), then us-

ing tool B, remove cylinder head (2) from cylin-
der.
DEW02973
3. Pull out cylinder head and piston rod assembly

(3) from cylinder (41, and lift off.
Sr Oil will flow out when the piston rod assem-
bly is removed from the cylinder, so place a
container under the cylinder to catch the oil.
Remove cylinder (4) from tool A.
Set cylinder head and piston rod assembly to DEW02971
tool A, then using tool C, loosen nut (5).
Cylinder ~~TyGZhGWidthacross flats (mm)
Boom I 60
Bucket 70
Steering 46
6. Remove nut (5), then remove piston assembly

(6), and retainer and cylinder head assembly (8)
from rod (9).
-+ The retainer is for the steering cylinder only. DEW02972
30-204
0
7. Disassembly of piston assembly

1) Remove wear ring (11).
2) Remove piston ring (12) from piston (13).
DEW02974
8. Disassembly of cylinder head assembly

I) Remove snap ring (14), then remove dust
seal (15). -
2) Remove rod packing (16).
3) Remove bushing (17) from cylinder head (18).
4) Remove O-ring (19) and backup ring (20).
1
DEW02975
30-205
0
ASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
+ Clean all parts, and check for dirt or damage.
Coat the sliding surfaces of all parts with engine
I +
oil before installing. Be careful not to damage
the rod packing, dust seals or O-rings when as-
sembling.
1. Assembly of cylinder head assembly

1) Using tool b, press fit bushing (i7) to cylin-
der head (18).
* Be extremely careful not to deform the
bushing when press fitting. I - DEW02976
2) Install rod packing (16).

* Be sure to install the rod packing facing
in the correct direction.
3) Using tool E, Install dust seal (15) to head
(18).
4) Install snap ring (14).
5) Install backup ring (20) and O-ring (19).
* Do not try to force the backup ring into
position. Warm it in warm water (50 -
60°C) before fitting it.
2. Assembly of piston assembly

1) Using tool Fl, expand piston ring (12).
* Set the piston ring on the expander and
turn the handle 8 - 10 times to expand
the ring.
2) Remove piston ring (12) from tool Fl, then
assemble to piston (13).
3) Using tool F2, compress piston ring (12).
4) Assemble wear ring (II).
DEW02978
20 19 17 18 16
Fl
p DEW02979
30-206
0
3. Set piston rod (9) to tool A.
4. Assemble cylinder head assembly (8) and re-

tainer and piston assembly (61, and install nut
(5).
Ir The retainer is for the steering cylinder only.
5. Using tool C, tighten nut (5).
& Rod thread: Thread tightener (LT-2)

m Nut:
CEWO2972
Width across flats Tightening torque
Cylinder Nm (kgm)
(mm)
Boom cylinder 60 mm 1765 k 176
(180 + 18)
2599 ? 259
Bucket cylinder 70 mm (265 * 26.5)
Steering cylinder 46 mm 784 f 78
(80 + 8)
6. Remove piston rod and head assembly from

tool A, then set cylinder (4) to tool A.
Raise piston rod and head assembly (3), and

assemble to cylinder (4).
Using tool B, tighten cylinder head nut (2).
w Cylinder head nut:
Cylinder Tightening torque Nm (kgm)
Boom I 932 f 93 (95 + 9.5)
Bucket I 980 f 98 (100 f IO)
Steering 441 f 44 (45 f 4.5)
9. Bend lock into notch at cylinder end.
10. Remove cylinder assembly (I) from tool A.
Steering cylinder
DEW02973
30-207
0
WORK EQUIPMENT
REMOVAL OF WORK
EQUIPMENT
the safety bar on the frame. Lower the work
euqipment to the ground and stop the engine.
Then apply the parking brake and put blocks
under the wheels to prevent the machine from
moving.
1. Bucket link
1) Remove bucket link mounting pin (I).
* Tie the bucket link to the tilt lever with DEWiZi82 DEW02993
wire.
2) Remove left and right bucket hinge mount-
ing pins (2).
ANever put your fingers in the pin hole.
3) Drive machine in reverse and disconnect

bucket.
ks
rz+l Bucekt (with BOC): 615 kg
DEW02984
2. Bucket cylinder mounting pin

Sling bucket cylinder (3), remove (4), then dis-
connect cylinder rod and bellcrank.
* Set block @ between cylinder bottom and
frame.
el ks Bucket cylinder: 56 kg
DEW02985 ( 1 \ DEW02981
3. Boom cylinder pin

Sling boom cylinder (5), then remove mounting
pin (6).
* Put a support under the tip of the boom.
* Inset-t block @ on top of the axle, then lower
the cylinder.
* if shims are inserted, check number of shims.
A kg Boom cylinder: 61.5 kg
30-208
0
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
4. Boom, bellcrank, bucket link

I) Remove bracket (7-l) of boom kickout switch
(7).
2) Sling boom, bellcrank and bucket link (81,

then remove mounting pin (9) of boom and
lift off boom.
A kg Boom, bellcrank, bucket link: 662 kg
* If there are shims inserted, check the

5. Bellcrank, bucket link

I) Remove mounting pin (11) of bucket link (IO),
and remove from bellcrank (12).
E?lkg Bucket link: 17 kg
* Remove the wire holding the bucket link

to the bellcrank.
A When the pin is removed, the bellcrank
will move up suddenly, so keep your
head and other parts away.
Ir If there are shims inserted, check the DEW02992

2) Sling bellcrank (12), remove mounting pin

(131, then lift off from boom.
Bellcrank: 125 kg
1 =T DEW02993
6. Dust seal, bushing

I) Remove dust seal (15) and bushing (16) from
boom (14).
2) Remove dust seal (17) and bushings (18)

from bellcrank (12).
18
3) Remove dust seal (19) and bushing (20) from

bucket link (IO).
30-210
0
INSTALLATION OF WORK
EQUIPMENT
d.i
Always use a bar when aligning the pin holes.
Never insert your fingers.
1. Dust seal, bushing

Press fit bushings (16) to bucket link, bellcrank, c
,pP
and boom with press, and assemble dust seals
(15). 0
& Bushing: Grease (G2-LI)
I 16 15
DEW02199
I=l I I I IA-
u-t-r- DLwo22ul
2. Bellcrank, bucket link

1) Align hole of boom (14) and bellcrank (121,
and assemble shims so that clearance “d” is
8
specified value, then assemble mounting pin
7
0 (131, and lock with bolt.
* Clearance “d”: Max. 2.0 mm
DEW02999
2) Align hole of bellcrank (12) and bucket link

DEW02997
(IO), and assemble shims so that clearance
“e” is specified value, assemble mounting
pin (II), and lock with bolt.
Ir Secure the bucket link to the bellcrank
with wire.
* Clearance “e”: Max. 2.0 mm
= DEW03000
30-211
0
3. Boom, bellcrank, bucket link

I) Raise boom, bellcrank, and bucket link (8)
and set in mounting position, align front
frame and boom mount hole so that clear-
ance “a” is specified value, then assemble
mounting pin (9) and lock with bolt.
* Clearance “a”: Max. 1.5 mm
Ir After assembling the pin, set a stand
under the tip of the boom.
2) Install bracket (7-l) of boom kickout switch

(7).
4. Boom cylinder
Sling boom cylinder (51, start engine, align cyl-
inder rod with boom mount hole, insert shims
so that clearance “f” is specified value, then as-
semble mounting pin (6) and lock with bolt.
LL When starting the engine, check that the di-

rectional lever is at neutral and that the park-
ing brake is applied.
Ir Remove the block after assembling the

mounting pin.
Sr Clearance “f”: Max. 2.0 mm
5. Bucket cylinder
Sling bucket cylinder (3), adjust control lever
and align pin hole, then assemble mounting pin
(4), and lock with bolt.
* Remove the block after assembling the
mounting pin.
30-212
0
6. Bucket
mounting pin (2). Insert shims to make clear-

ance “b” uniform on left and right, then install
mounting pin (2) and lock with bolt.
-f Clearance “b”: Max. 1.5 mm
DEW03008
7. Bucket link
Align hole of mounting pin (I) of bucket link
(IO). Insert shims to make clearance “c” uniform
on left and right, then install mounting pin (I)
and lock with bolt.
* Clearance “c”: Max. 2.5 mm
DEW03009
8. Greasing
Grease all pins.
DEW03010
30-213
0
DISASSEMBLY AND ASSEMBLY FUEL TANK
REMOVAL OF FUEL TANK
a Stop the machine on level ground and install

AOpen the side inspection cover and apply the

lock.
1. Draining fuel
Loosen drain valve (I) and drain fuel.
DEW0301 1
- : Fuel: 141 I?
2. Fuel, electric wiring m

1) Disconnect fuel hose (21, fuel return hose
(3), and fuel gauge wiring connector (4).
* Remove clamp of breather tube (5-I).
3) Remove outer cover (81, inner cover (71, and

rubber at oil filler port (6) on left side of rear
frame.
DEW02693 1
30-214
0
DISASSEMBLY AND ASSEMBLY FUEL TANK
3. Fuel tank m
1) Set transmission jack under fuel tank, and
support fuel tank (9) lightly.
2) Remove mounting bolts, then lower trans-

mission jack slowly and remove.
* When there is a clearance of approx. 50
mm from the rear frame, stop and check
that there is no interference.
* The oil filler tube will hit the rear frame,
so move to the right and remove care-
fully.
&?Ikg Fuel tank (dry): 70 kg
3) Pull out fuel tank (9) to right side of chassis.
INSTALLATION OF FUEL TANK

removal.
m
Jr Be sure to assemble the fuel hoses correctly.
m
Ir Be careful not to let the breather tube hit the
chassis when installing.
* When raising the transmission jack, main-
tain the balance, keep the fuel tank horizon-
tal, and set in the mounting position.
* Tighten the bolts in turn on the left and right.
m Mounting bolt: 113 k 9.8 Nm

(11.5 + 1.0 kgm)

Tighten drain plug and add fuel through fuel
filler.
, I -‘Id EWO3016
Fuel: 141 e
30-215
0
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
REMOVAL OF
COUNTERWEIGHT
* Set a pallet under the counterweight.
1. Counterweight
1) Put blocks on radiator guard (I), and sling
counterweight (2).
2) Remove mounting bolts (3) of counterweight
(21, then lift off. m
l Width across flats of mounting bolt:
30 mm
& kg Counterweight: 1030 kg
INSTALLATION OF
COUNTERWEIGHT
removal.
(I
w Mounting bolt: 549 + 59 Nm (56 k 6 kgm)
30-216
0
DISASSEMBLY AND ASSEMBLY INSTRUMENT PANEL
REMOVAL OF INSTRUMENT
PANEL

* Disconnect the cable from the negative (-1
1. Instrument panel
Remove mounting bolts, then remove panel as-
DEW03018
sembly (2) from instrument panel mount guard
(I), and pull up.
2. Tachometer cable
Disconnect tachometer cable (4) from housing
(3).
Sr Remove the clip of the tachometer from the
left side under the floor frame.
DEW03019
3. Electric wiring m
Disconnect following electric wiring connectors.
. Connectors (5) and (6)
* Remove the wiring from the clamp.
4. Panel
I) Remove panel assembly (2).
2) Remove each gauge from housing (3).
INSTALLATION OF
INSTRUMENT PANEL
removal.
Ir After inserting the connectors, arrange the

wiring so that there is no strain.
30-217
0
40 MAINTENANCE STANDARD
Engine mount, transmission mount.. ........ .40- 3

Torque converter charging pump ............. .40- 4
Torque converter.. ........................................ 40- 5
Transmission ................................................ 40- 6
Transmission control valve ......................... 40-18
Accumulator valve ....................................... 40-22
Drive shaft ..................................................... 40-23
Differential ..................................................... 40-25
Final drive ..................................................... 40-28
Axle mount ................................................... 40-30
Center hinge pin.. ......................................... 40-32
Steering column ........................................... 40-34
Priority valve ................................................. 40-35
Steering cylinder mount.. ............................ 40-36
Brake booster ........................................... .; ... 40-37
Brake .............................................................. 40-38
Parking brake.. .............................................. 40-39
Hydraulic pump ............................................ 40-40
Main control valve ....................................... 40-42
Hydraulic cylinder ........................................ 40-46
Work equipment linkage ............................ .40-48
Bucket ............................................................ 40-50
Bucket positioner and boom kick-out ...... ..40-5 1
40- 1
0
MAINTENANCE STANDARD ENGINE MOUNT, TRANSMISSION MOUNT
TRANSMISSION MOUNT
\__-____________________
_ __________________- j
c-___ ;i
--------- 4:
A-A II
I m 652.1+34.3Nm
ICC EL7 cc?.-\
B-B
B --f( /,
\
iI
li \\
\
/’
‘L____J
,’
‘. ,’
‘-_ -____- /-
Unit: mm
No. Check item Criteria Remedy
Clearance between
I transmission bracket I-2 Adjust
and adiustment bolt
40-3
MAINTENANCE STANDARD TORQUE CONVERTER CHARGING PUMP
TORQUE CONVERTER CHARGING PUMP

(LAL(l)-32)
SEW00992
Unit: mm
Check item Criteria Remedy
Standard clearance Clearance limit
1 Side clearance
0.05 - 0.10 0.15
Clearance between inside

2 diameter of plain bearing
0.060 - 0.119 0.200
and outside of diameter
Replace
of gear shaft
Standard size Tolerance
1
3 Depth for knocking in pin 10 0

- 0.5
4 Rotating torque of
spline shaft 2.0 - 4.9 Nm (0.2 - 0.5 kgm)
Standard Delivery
Rotating Delivery
delivery amount
Discharge amount speed pressure
- amount limit
Oil: EOIO-CD -
Oil temperature: 45 - 55°C 2.9 MPa
3,000 rpm 94 !/min 86 !/min
(30 kg/cm’)
40-4
MAINTENANCE STANDARD TORQUE CONVERTER
TORQUE CONVERTER
66.2i7.4Nm
..tl.. -_-__
i;-%_ __-$____ _____ _____ __

___ __-_- ----- _
‘Ly!&
SDWOO993
Unit: mm
1 Standard size 1 Tolerance 1 Repair limit 1

I I I I I
1 Outside diameter of pilot -0.009 Repair
42 41.75
I -0.034 I chrome
plating
Inside diameter of retainer or replace
+0.035
2 100 100.5
seal ring contact surface 0
Width 3 -0.01 2.7

-0.03
3 Wear of stator
shaft seal ring
Thickness 4 IL 0.1 3.6 Replace
Backlash between PTO

4 0.15 - ‘0.42
drive gear and drive gear
40-5
MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION (l/3)
m 66.2 f 7.4 Nm w 11.3*1.5Nm w llOf12.3Nm w 11.3?~1.5Nm

(6.75 f 0.75 kgm) (1.15 f 0.15 kgm) (11.25 f 1.25 kgm) (1.15 f 0.15 kgm)
w 66.2 k 7.4 Nm
(6.75 f 0.75 kgm j\
w 176.5 f 29.4 Nm
w 34.3 f4.9 Nm
(3.5 it 0.5 kgm)
53.9 f 19.6 Nm
(5.5 rt 2.0 kgm)
39.2 Nm
(6.75 f 0.75 kgm) (24f4 kgm)
m 30.9 + 3.4 Nm m 66.2 k 7.4 Nm

(3.15 f 0.35 kgm) (6.75 + 0.75 kgm)
d
w 66.9 f 9.8 Nm
c-c
3
w 110 f 12.3
“’ Nm ‘& k*a 309f34Nm
(11.25 f 1.25 kgm) (3.;5 * 0.35 kgm)
B-B
m 299.1 it 93.2 Nm
(30.5 A 9.5 kgm)
m 110 + 12.3 Nm m llO+ 12.3 Nm

(11.25 + 1.25 kgm) (11.25f 1.25 kgm)
D-D E-E
SDWOOS94
40-6
Unit: mm
T
No Check item Criteria Remedy
- L
Standard Tolerance Standard Clearance

clearance limit
1
0.008 -
0.033 -
-0.012 -
2
0.031 -
Clearance between 4th 30 0 +0.021 0.008 -

3
shaft and bearing (F) -0.012 +0.008 0.033 -
-
Clearance between 4th
shaft bearing (F) and 72 0 +0.018 -0.012 -
4 0.031 Replace
housina -0.013 -0.012 -
Clearance between pump -0.037 -

5
drive shaft and bearing -0.009 -
Clearance between pump

drive shaft bearing and 90 0 +0.022 -0.013 -
6
housing -0.015 -0.013 0.037 -
Clearance between pump -0.009 +0.041 0.034 -

7 35
drive shaft and bearing -0.025 +0.025 0.066 -

-0.011 -
8 drive shaft bearing and
housino 0.025 -
40-7
TRANSMISSION (2/3)
3
4
llO_+ 12.3 Nm
7
8
w llO+ 12.3 Nm
(11.25* 1.25 kg:.*
9
10
w 30.9 f 3.4 Nm
(3.15 rt 0.35 kgm)
w 277 f 31.9 Nm
53.9 + 19.6 Nm
w 110 f 12.3 Nm m 66.6 f 9.8 Nm

.-\
1-I I 1 kg,n,,
(11.252 1.25 kgm)
40-8
Unit: mm

size Shaft Hole clearance limit
’ drive shaft and bearing
+0.025 0 -0.037 -
50
+0.009 -0.012 -0.009 -

-
2 drive shaft bearing
housing and 80 -0.013
0 -0.012
+0.018 0.031
-0.012 -
7. 3 Clearance between pump 35 -0.009 +0.041 0.034 -

g drive shaft and bearing -0.025 +0.025 0.066 -

-
4 drive shaft bearing
housing and 47 -0.011
0 +0.014
-0.011 -0.011
0.025 -
-
5 shaft and bearing
Clearance between input 35 +0.009
+0.025 -0.012
0 -0.009
-0.037 -
-
6 shaft bearing
Clearance and housing
between input 72 -0.013
0 -0.012
+0.018 0.031
-0.012 -
-
shaft and bearing +0.009 -0.012 -0.009 Replace
7 Clearance between input 50 +0.025 0 -0.037 -
-
8 shaft
Clearance
bearing
between
and housing
input 90 -0.015
0 +0.022
-0.013 -0.013
0.037 -
Clearance between
-
9 REVERSE,
bearina (F) 1st
andclutch
housina 90 -0.015
0 +0.022
+0.013 -0.013
0.037 -
Clearance between
-
IO REVERSE,
bearing (R) 1st
andclutch
housing 90 -0.015
0 +0.022
-0.013 -0.013
0.037 -
Clearance between
-
11 bearing (F) and
FORWARD, 2nd housing
clutch 110 -0.015
0 +0.022
-0.013 -0.013
0.037 -
Clearance between
-
12 FORWARD,
bearing (R) and
2nd housing
clutch 90 -0.015
0 +0.022
-0.013 -0.013
0.037 -
Clearance between 3rd,

-
13 and
4th clutch
housingbearing (F) 130 -0.018
0 +0.026
+0.014 -0.014
0.044 -
Clearance between 3rd,

-
14 4th clutch
and housingbearing (R) 90 -0.015
0 +0.022
-0.013 -0.013
0.037 -
40-9
TRANSMISSION (3/3)
1 2 4 3
A-A SDW00996
40-l 0
Unit: mm

Clearance between output
’ shaft and bearing (F)
-
50 +0.031
+0.015 -0.012
0 -0.043
-0.015 -

2 shaft bearing (F) and 90 0 -0.015 -0.040 - 0 -
housing -0.015 -0.040
50
3 shaft and bearing
Clearance between (R)
output +0.031
+0.015 -0.012
0 -0.043
0.015
- -

4 shaft
housingbearing (R) and 90 -0.015
0 -0.040
-0.015 -0.040 - 0 -
5 housingoil seal (F) and

shaft 90 +0.170
+0.080 0
+0.054 -0.026-
-0.170 -
6 housingoil seal (R) and

shaft 90 +0.170
+0.080 0
+0.054 -0.026-
-0.170 -
Standard size Tolerance Repair limit

Inside diameter of
Replace
housing seal ring contact +0.05 0.05
surface 50
0 (Amount of wear)
Width of shaft seal ring +0.076

7 3.2 3.5
groove 0
Width of seal ring 3.0 0

-0.13 2.6
Thickness of seal ring 2.29 0

-0.1 2.1
Outside diameter of sliding

8 portion of 0 0.05
coupling oil 65
seal (F) -0.074 (Amount of wear)
Outside diameter of sliding

9 portion of coupling oil 0 0.05
65
seal (R) -0.074 (Amount of wear)
Standard size Standard clearance Clearance limit

,. Clearance between parking
brake housing and case 0.85 0.02 - 1.68 -
,, Free rotation torque of

0.10 - 1.0 Nm (0.01 - 0.10 kgm) Adjust shim
output shaft
40-11
REVERSE, 1ST CLUTCH
Unit: mm
No
Clearance
Clearance at bearing press-

-
3
fitting
clutch portion
shaft of REVERSE 50 +0.009
+0.025 -0.012
0 -0.009
-0.037 -

-
4
fitting
shaft portion of 1st clutch 50 +0.025
+0.009 -0.012
0 -0.009
-0.037 -
Clearance at spacer press-
-
5
fitting
1st clutch
portion
shaft of REVERSE, 51 +0.025
+0.009 -0.03
0 -0.055
-0.009 -
-
40-12
F
$
Unit: mm

Thickness of separator I. I
plate 1.8
6
Distortion of separator - 0.05 0.15

plate I I I
+0.05
Thickness of friction plate 3.0 -0.10 2.65
Distortion of friction plate - 0.07 0.14
Replace
902 N (92 kg)
8 Load of wave spring (Height: 2.975 mm) f90.2 N (f9.2 kg) 731 N (74.5 kg)
g Thickness of REVERSE,
1st clutch spacer
1o Thickness of REVERSE,
kO.1 2.7
1st clutch thrust washer
11 End play of REVERSE gear 0.07 - 0.93
12 End play of 1st gear 0.04 A.16
40-13
FORWARD, 2ND CLUTCH
6 6 6 987 653
Unit: mm
Standard 1
Clearance Fnce Hole
between
f-j-g +0.28
piston g Inside
+0.15
and cylinder
zp
-0.35 +0.08 0.30 -
E Outside 118 0.53
-0.40 -0.05 0.48
Clearance +0.28
Inside “~“““,,, ~ 0.24
between +0.15
piston I?- Replace
N
and cylinder +0.13 0.30 -
Outside 0.53
0 0.48
I- /
I
+0.025 0 -0.037 -
fitting portion of FORWARD 50
clutch shaft +0.009 -0.012 -0.009 -
J
+0.025 0 -0.037 -
fittina oortion of 2nd 50
clutch ‘shaft +0.009 -0.012 -0.009 -
Clearance at spacer
+0.025 0 -0.055 -
press-fitting portion of 51
+0.009 -0.03 -0.009 -
FORWARD. 2nd clutch shaft
-I_ *
40-14
Unit: mm

6 Thickness of FORWARD,
2nd clutch thrust washer 3.0 kO.1 2.7
Thickness of separator
1.8 +0.06 1.7
plate
7
Distortion of separator - 0.05 0.15
plate
+0.05
Thickness of friction plate 3.0 2.65
-0.10
8
Replace
Distortion of friction plate - 0.14
902 N (92 kg)

9 Load of wave spring (Height: 2.975 mm) ‘90.2 N ‘f9.2 kg’ 731 N (74.5 kg)
10 Thickness of FORWARD,
5.0 +0.05 _
2nd clutch spacer
11 End play of FORWARD

gear I
12 End play of 2nd gear 0.04 - 1.16

I
I I
40-15
3RD, 4TH CLUTCH
\H \ \ \ \ I /
3 10 5 14 10 1 1 9 11 13 SDW00999
Unit: mm

Clearance
between
1 +0.102 +0.28 0.048 -
piston Inside 85 0.24
+0.090 +0.15 0.19
and cylinder
-
Outside 140 -0.35
-0.30 0
+0.13 0.30 0.48 0.53 I
-
Clearance at outside diame-
-
2
ter
portion
of bearing
of 4th clutch
press-fitting
shaft 50 +0.025
+0.009 -0.012
0 -0.037
-0.009 -
Clearance at outside diame-

-
3
ter
portion
of bearing
of 3rd press-fitting
clutch shaft 60 +0.030
+O.Oll -0.015
0 -0.045
-0.011 -

-
4
fitting
clutch portion
shaft of 4th 51 +0.009
+0.025 -0.03
0 -0.055
-0.009 -

-
5
fitting
clutch portion
shaft of 3rd 61 +O.Oll
+0.030 -0.03
0 -0.060
-0.011 -
Standard size Tolerance Repair limit Replace

Thickness of separator
plate 1.8 f0.06 1.7
6
Distortion of separator -
plate 0.05 0.15
+0.05
Thickness of friction plate 3.0 2.65
-0.10
Distortion of friction plate - 0.07 0.14
902 N (92 kg)

Load of wave spring (Height: 2.975 mm) f90.2 N “9.2 kg’ 731 N (74.5 kg)
40-16
Unit: mm
thrust washer
thrust washer
14 End play of 3rd gear 0.04 - 1.16

I I
40-17

UPPER VALVE
11 18 17 19
40-18
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
Unit: mm
I I I
I
Clearance between pilot
’ valve and body
-
19 -0.02 +0.013 0.020 0.050
-0.03 0 0.043
2 Clearance between main 19 -0.02 +0.013 0.020 -

regulator valve and body -0.03 0 0.043 0.050
Clearance between main

3 regulator valve and load 13.5 -0.02 +0.018 0.020 -
0.055
piston -0.03 0 0.048
4 Clearance between priority 19 -0.02 +0.013 0.020 -

valve and body -0.03 0 0.050
0.043
5 Clearance between priority 12.5 -0.02 +0.018 0.020 -

valve and load piston 0.055
-0.03 0 0.048
6 Clearance between quick 28 -0.020 +0.013 0.020 -

return valve and body -0.028 0 0.041 0.044
-
7 Clearance between mbdu- 28 -0.02 +0.013 0.020 0.050
lation fill valve and body -0.03 0 0.043
8 Clearance between modu- 28 -0.02 +0.033 0.040 -

lation fill valve and sleeve 0.070
-0.03 +0.020 0.066
’ Clearance between modu- -0.04 +0.041 0.065 -

8
fi lation fill valve and sleeve 30 -0.05 +0.025 0.091 0.100
G
0 lo Clearance between sleeve 41 -0.050 +0.025 0.050 -
and body 0.110
-0.075 0 0.100 Replace
” Clearance between accu- 28 -0.02 +0.013 0.020 -

mulator valve and body 0.050
-0.03 0 0.043
Standard size Repair limit
Free Installed Installed Free Installed

12 Main regulator valve length length load length load
spring
82.55 62.6 230f11.5 N 207 N
79.3
(23.46f1.17kg) (21.1 kg)
13 Priority valve spring 69.5 52.6 254zt12.7N 228 N

66.7
(25.92+1.30kg) (23.3 kg)
14 Quick return valve spring 48.0 41.0 0.8+0.04N 0.7 N

46.1
(0.08f0.004kg) (0.072 kg)
,5 Modulation fill valve 24.1e1.2N 21.7 N

41.8 40.0 40.1
spring (inner) (2.46+0.12kg) (2.21 kg)
16 Modulation fill valve 138&7N 125 N

43.6 24.3 41.9
spring (outer) (14.07f0.70kg) (12.7 kg)
17 Accumulator spring (outer) -

99.6 99.6 0 95.6
,8 Accumulator
(Inner 1) spring 35.6 35.6 0 34.2 -
,g Accumulator spring -
40.8 40.8 0 39.2
(Inner 2)
40-l 9
LOWER VALVE
a=
Unit: mm
Standard . Tolerance Standard Clearance

Clearance between torque size Shaft Hole clearance limit
converter regulator valve
and body -0.02 +0.013 0.020 -
19 0.050
-0.03 0 0.043
Clearance between F-R -0.02 +0.013 0.020 -

selector spool and body 19 -0.03 0 0.043 0.050
Clearance between H-L

3
selector spool and body
-
Clearance between range -0.02 +0.013 0.020 - Replace
4 selector spool and body 19 -0.03 0 0.043 0.050
-
6 F-R selector spool spring

/ 48.8 / 36 / ,E:zkNg) 1 46.8 I ;?A!) 1
H-L range selector spool 69.8e 3.5 N 62.8 N

7 48.0 36.7 46.1
return spring (7.12?;0.36kg) (6.4 kg)
40-20
SOLENOID VALVE
A-A
B-B
Unit: mm

Clearance between size Shaft Hole clearance limit
1 emergency manual Replace
spool and body -0.02 +0.013 0.02 -
14 0.050
-0.03 0 0.043
40-21
MAINTENANCE STANDARD ACCUMULATOR VALVE
ACCUMULATOR VALVE
B-B
A-A
SDWO1003
Unit: mm

I
Standard Tolerance 1 Standard I Clearance I
Clearance between piston
’ and body
-
32 -0.035 +0.025 0.035 0.08
-0.045 0 0.070
~~ Replace
2 Forward clutch
accumulator spring
3 1st clutch accumulator 145 135 78.8 N 139.2 -

spring (8.04 kg)
4 2nd clutch accumulator 145 125 157.9 N 139.2 -

spring (16.1 kg)
40-22
MAINTENANCE STANDARD DRIVE SHAFT
DRIVE SHAFT
<.\
--____--
SKW01004
40-23
MAINTENANCE STANDARD DIFFERENTIAL
DIFFERENTIAL (l/2)
m 279.5229.4Nm
(28.5+3.0kgm)
/
m 112.8t9.8Nm
(11.5~l.Okgm)
\
m 5.4tl.5Nm
(0.55~0.15kgm) m 112.8+14.7Nm
(11.5+1.5kgm)
m 132.4+39.2Nm ti 181.4k53.9Nm
(13.5?4.0kgm) (18.5+5.5kgm)
sKw01005
Unit: mm
, Bevel gear free rotating 1.2 - 3.9 Nm (0.12 - 0.40 kgm)

torque (7.8 - 25.5 N (0.8 - 2.8 kg))
Thickness of shim at diffe-

2 rential side bearing carrier 0.085 - 1.295
(one side)
Replace
Thickness of shim for
3 differential housing 0.5 - 1.55
and aauae assemblv
4 Protrusion of pin 12
40-25
DIFFERENTIAL (2/2)
6 5114 7 10 1
‘9
14 13
SKW01006
40-26
Unit: mm

Clearance at
1 differential 0 -0.024 -0.059 -
side bearing Outer race 105 -0.020 -0.059 -0.004 -
-
Inner race 65 +0.051
+0.032 -0.015
0 -0.066
-0.032 -
Clearance of -
2 bearing at Outer race 110 -0.015
0 -0.041
-0.076 -0.076
-0.026 -
pinion shaft
gear end Inner 50 +0.039 0 -0.051 -
race +0.025 -0.012 -0.025 -
-
Clearance of Outer race 90 -0.015
0 -0.040
-0.075 -0.075
-0.025 -
3 bearing at
shaft
coupling
pinion end Inner race 40 +0.037
+0.026 -0.012
0 -0.049
-0.026- -
4 Clearance between pinion 25.18 -0.180 +0.02 0.16 -

gear and spider -0.193 -0.02 0.3
0.213
Assembly portion of piston

5 of differential housing 260.4 -0.250 +0.05 0.20 -
(housing, piston) -0.450 -0.05 0.50 -
Assembly portion of piston

6 of bearing carrier 215.95 -0.250 +0.05 0.20 - Replace
(piston, carrier) -0.450 -0.05 0.50 -
7 Backlash of bevel gear 0.15 - 0.30

I I
8 Backlash of differential
0.15 - 0.35
gear
9 End play of pinion gear Max. 0.172

I I
1o Thickness of side gear
washer
1.55 f0.05 1.35
,l Wear of outside diameter 0 -

8
of lock pin -0.09
12 Height of spacer between -

51.90 kO.025
pinion shaft bearings ! I I
13 Outside diameter of axle -0.043
150 149.6
mount (rear differential) -0.106
14 Axle mount -0.043

150 149.6
(rear differential) I -0.106 I I
40-27
MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
m 279:5*29.4Nm
(28.553.0kgm)
40-28
MAINTENANCE STANDARD FINAL DRIVE
Unit: mm

-
E er;
2 1 Clearance between axle

lousing and ring gear
+0.025
2 Clearance at guide pin 12 +0.007
I
-0.038 -0.077 -
Clearance at 0 -0.014 -
axle housing
bearing press-
fitted section +0.013 -0.050-
0 -0.016 -
Replace
-0.013 -0.076 -
Clearance at -0.051 -0.013 -
axle housing
bearing press-
fitted section +0.025 -0.063 -
0 -0.013 -
+0.063
- -
Axle shaft seal Housing 0 I
5 press-fitted
section
- - -
Jo54
I I
Clearance between pinion +0.025 +0.013 -0.025 -

6 33.338 0 0 -
gear bearing and shaft +0.013
I I
7 End play of axle shaft Max. 0.098

Adjust
Clearance between oil seal
8 0.21 - 1.91
and housing
40-29
MAINTENANCE STANDARD AXLE MOUNT
AXLE MOUNT
__- _-_z:-_
__-__-_-_.
1 r
__ rr:/:-=-f-_:’ ---- -__
L__ ------ \; ‘_y---y-- \,
, __-__-__-__-__-y---p-$--J,
F:r=:I=_.____________-_
6
ii8t
2 3
iI i
iI i
ii
iiI 8
I
---7 *_ /’
‘\
-.
\
,’
/”
‘\
L____-l’
A-A 4 SKW01008
Unit: mm
No Check item Remedy
1 Standard size 1 Tolerance 1 Reoair limit I

1 Thickness of thrust plate +O.l
12.2 kO.1
-0.5

Clearance between hole size Shaft Hole clearance limit Replace
2 and shaft at front support
end -0.043 +0.550 0.093 -
150
-0.106 +0.050 0.656 -
Clearance between hole

3 and shaft at rear support 1 I50 1 --“d.?$j j 1;:;;; 1 “.““&, ~ -
end
Thickness of axle mount

4 0.2 (each)
shim
40-30
MAINTENANCE STANDARD CENTER HINGE PIN
CENTER HINGE PIN
,-’
/
,’
,’
I’
i
I
‘\
I\
\
\\
I
\\
/’ \ /’
*.
\
*. ,’ ,’
‘. -’ ‘- *’
--____--- --____---
7 8
kgm 65.7t6.9Nm
(6.7e0.7kgm)
B-B SKWO1009
40-32
MAINTENANCE STANDARD CENTER HINGE PIN
Unit: mm
Standard Toler, ante Standard Clearance

Clearance between upper
’ hinge pin and rear frame
-0.073 +0.05 0.023 -
66
-0.103 -0.05 0.153 -
-
2 Clearance
hinge pin and
between
rear frame
upper 50 -0.038
-0.068 +o.
0 100 0.0380.168 -
E Clearance between -
Z 3 hinge and bearing upper 50 -0.068
-0.038 -0.012
0 0.0260.068 -
-
4 Clearance
hinge pin and
between
spacerupper
(top) 50 -0.038
-0.068 +0.250
0 0.0380.318 -
Clearance between upper

-
5 ;b;roii,n and spacer 50 -0.038
-0.068 +0.250
0 0.0380.318 -
Clearance between front Replace

-
6 frame
bearing and upper hinge 105 -0.015
0 -0.02
-0.12 -0.120
-0.005 -
7 Clearance between lower -0.05 +0.05

69.85 -0.06 -0.05 o-0.11 -
hinge pin and rear frame
8 Clearance between front

frame and bearing 1 88.g 1 -Lo20 / “Kz 1 -“~050,7 1 - /
-
g Clearance
and hinge between
pin bearing 69.85 -0.050
-0.060 +0.050
+0.028 0.0780.113 -

Wear of oil seal contact
10 surface of upper hinge 0
spacer 63.45 -0.20
Height (top), (bottom) of

23 f0.1
upper hinge spacer I I
Standard size Standard clearance Clearance limit

12 Clearance when adjusting
shims at upper hinge 1.3 0.1 - 0.2 -
Adjust
Thickness of shim between
13 upper hinge and retainer 0.8 Max. 0.4 -
(rear frame portion)
40-33
0
MAINTENANCE STANDARD STEERING COLUMN
STEERING COLUMN
I-
-1
A-A
110.3+12.3Nm
(1 I.2521 25kgm)
iiII
II I
lb j
__-__-__-__.
nI --rmI.-==RF=-~
s=i== -.;-“‘;--;--;---,__-__-_i~__-~
P -%CC5,
SKWOlOlO
40-34
MAINTENANCE STANDARD PRIORITY VALVE
PRIORITY VALVE
44.1Nm
(4.5kgm)
SKWOlOll
Unit: mm

1 Return spring length length load length load Replace
218.7 N 175.5 N
63.4 45 62 ?I 1
(22.3 kg) (17.9 kg)
40-35
MAINTENANCE STANDARD STEERING CYLINDER MOUNT
STEERING CYLINDER MOUNT
A-A B-B
SKW01012
Unit: mm

I
Connection between
3 steering cylinder and
front frame
4 steering cylinder and

MAINTENANCE STANDARD BRAKE BOOSTER
BRAKE BOOSTER
26.5k12.8Nm 26.5+12.8Nm
‘8
32.4z2.ONm 10.8k2.ONm
(3.3t0.2kgm) (l.le0.2kgm)
sLw01013
8
b Unit: mm
7. -
is No. Check item Criteria Remedy
Clearance between primary

1
piston and bore
Clearance between second-

2
ary piston and bore
Clearance between power

3
piston and bore
-
Replace
4 Primary piston spring
85.3 T!Z12.7 N
129.4? 18.6 N
5 Secondary piston spring
Spring
Spring
8 Reaction spring
L
40-37
MAINTENANCE STANDARD BRAKE
BRAKE
SKWO1014
Unit: mm

1 Thickness of inner ring
6.6 0 5.8
-0.5
Thickness of brake disc

8.697 kO.063 7.4
Replace
2 Depth of lining groove 0.838 kO.2 0.4
Thickness of lining 1.08 0.89 (min.) -
3 Thickness of outer ring 19.5 kO.12 0.3
40-38
MAINTENANCE STANDARD PARKING BRAKE
PARKING BRAKE
. I
/
3
SKWOlOlS
Unit: mm
No
3
MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP (Hydraulic, steering pump)

(SAL(2140 + SAL(P) 141
x
/I I
SKWOlOlB
Unit: mm
I Model 1Standard clearance 1 Clearance limit 1

1 Side clearance
I*1 0.10 - 0.15 1 0.19 1
Clearance between inside dia- SAL(2)40

2 meter of plain bearing and out- 0.06 - 0.125 0.20
side of diameter of gear shaft SAL(2)14
Replace
Model Standard size Tolerance Repair limit
3 Depth for knocking in pin SAL(2)40 0
12 -
SAL(P)1 4 -0.5
-
Rotating torque of spline
4 5.9 - 13.7 N (0.6 - 1.4 kgm)
shaft
Discharge amount
Oil: EOIO-CD
Oil temperature:
45 - 55°C
20.6 MPa
SAL(2)14 3000 36 e/min
(210 kg/cm*) 3g e’min
40-40
MAINTENANCE STANDARD MAIN CONTROL VALVE
MAIN CONTROL VALVE

2-SPOOL VALVE
13.25k1.45Nm
40-42
68.6&.8Nm
(7+lkgm)
\
B-B
,l47+4.9Nm L
.5+0.5kgm)
D-D
Unit: mm

1 Relief valve spring length length load length load Replace
259 N 207 N
41.1 32.6 39.4
(26.4 kg) (21.1 kg)
40-43
3-SPOOL VALVE
13.24+1.47Nm
(17tlkgm)
UH
13.25t1.45Nm
(1.35k0.15kgm)
SDWOlOlS
40-44
I3
B-B
/ A-A
3.5kgm)
D-D /
Unit: mm

1 Relief valve spring length length load length load Replace
259.N 207 N
41.1 32.6 39.4
(26.4 kg) (21.1 kg)
40-45
MAINTENANCE STANDARD HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
/ I
_ m Boom : 93h93.2Nm m Bc)om : 17655176.5Nm

(9529.5kgm) (180?18kgm )
Bucket : 981?98.1Nm Bucket : 2599t259.9Nm
(100~10kgm) (265226.5kgm)
Steering : 785*78.5Nm Steering : 785=78.5Nm
(8028kgm) (80?8kgm) s0w01021
Unit: mm

+0.271 0.105 -
Boom 70 -0.030
-0.104 +0.075 0.375 0.675
Clearance
1 between piston Replace
rod and bushing -0.030 +0.27 1 0.105 -
Bucket 70 -0.104 +0.075 0.375 0.675
40-46
MAINTENANCE STANDARD WORK EQUIPMENT LINKAGE
WORK EQUIPMENT LINKAGE
D
E
11
2 1
A-A B-B c-c
8
17
16
5 6
F-F
D-D
13
3
G-G H-H J-J
40-48
MAINTENANCE STANDARD WORK EQUIPMENT LINKAGE
Unit: mm
l-
Standard Clearance
Clearance between pin clearance limit
1 and bushing at both ends
of bucket link 0.105 -
0.206 1.0
2 0.105 -
0.206 1.0
Clearance between pin

3 and bushing at connection -0.030 +0.142 0.110 -
60 0.218 1.0
of boom and frame -0.076 +0.080
-
Clearance between pin and
bushing at connection of -0.030 +0.142 0.110 -
4 0.218 1.0
bucket cylinder bottom and 6o -0.076 +0.080 Replace if
frame there is
Clearance between pin and scuffing
bushing at connection of -0.025 +0.142 0.105 - on pin
5 50 0.218 1.0
bucket cvlinder rod and -0.076 +0.080
bellcrank
Clearance between pin and
-0.030 +0.174 0.130 -
6 bushing at connection of 65 0.250 1.0
bellcrank and boom -0.076 +O.lOO
0.130 -
Ez
b
7 0.250 1.0
z, -
0
a 0.130 -
0.250 1.0
Width of boss Width of hinge Standard clearance

(Clearance a + b)
Connection of boom and
9
bucket
85 + 1.8 83+; 1.2 - 7.8 Insert shims
on both
sides so that
Connection of bucket link +2.2
10 88 f 1.5 1.3 - 7.1 clearance is
and bucket 83-0.6
less than 0.5
mm on both
Connection of bellcrank +2.2
11 88 + 1.5 0.7 - 4.5 left and right
and bucket link 83-0.6
Connection of bellcrank
12 200 f 0.5 204 i 1.5 2.0 - 6.0
and boom I
-
13 Connection of bucket +0.8

cylinder and frame 8o 0 I 83 f 1.5 I 0.7 - 4.5
Clearance
14 Connection of boom +0.8
88’,3 2.2 - 6.0 less than
cylinder and frame 85 0 1.5 mm
Connection of boom and

15 frame 85 f 1.8 88+03 1.2 - 7.8
Connection of boom and Clearance

16 boom cylinder 85 + 1.8 89 f 0.8 1.4 - 6.6 less than
2.0 mm
Connection of bucket +0.8

17 cylinder and bellcrank 85 0 88 + 1.5 0.7 - 4.5 Replace
40-49
MAINTENANCE STANDARD BUCKET
BUCKET
Unit: mm
I I I
1 Wear of cutting edge Replace

22 15.5
40-50
MAINTENANCE STANDARD BUCKET POSITIONER AND BOOM KICK-OUT
BUCKET POSITIONER AND BOOM KICK-OUT
*'/--
i .-/--
i _*/-’
/- L- I \
,’
i /-;*
,/
‘\
\
8 \.
\
i I’
__ _-r-- ,,’ , ,;5
.-- ,
i: :’\
I
~ /j
,’ /.“‘:,’
‘-__._ ---__,I I t 1
/i
Unit: mm
, Clearance at bucket
positioner switch
3 - 7 mm (There must be no interference)
2 Clearance at boom
Adjust
kick-out switch
3 Clearance between lever

0.5 - 2.0 mm
and guide
40-5 1
0
Komatsu America international Company
440 North Fairwav Drive I 1
Vernon Hills, IL 66061-8112 U.S.A.
Attn: Technical Publications PROPOSAL FOR MANUAL REVlslON
Fax No. (847) 970-4186
FOR INTERNAL USE ONLY -- No. PMR
2 NAME OF COMPANY: LOCATION:
: PHONE NO:
:
S DEPARTMENT: DATE:
E
R NAME:
MANUAL NAME:
MANUAL NO:
MACHINE MODEL:
S/N IF APPLICABLE:
PAGE NO:
PROBLEM:
Attach photo or sketch.

If more space is needed, use another sheet.
1 FOR INTERNAL USE ONLY

CORRECTIVE ACTION:
PFMRl 081696

WA180-3 Série 50001 e Acima

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WA180-3 Série 50001 e Acima

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SEBM005802

SERIAL NUMBERS VVA180-3 - 50001 andw

June 1997 Copyright 1997 Komatsu America International Company

WA1 80-3 50001 and up

. WA180-3 mount the S6D95L engine.

20 TESTING AND ADJUSTING .. .. .. .. .. . ... .. .. . .. .. ... .. .. .. .. .. .. .. .. . 20-I

30 DISASSEMBLY AND ASSEMBLY .................................. 30-I

40 MAINTENANCE STANDARD .......................................... 40-I

a Page to be replaced Replace

( ) Page to be deleted Discard

Pages having no marks are not revised at this time.

LIST OF REVISED PAGES

Revision Revision Revision Revision Revision

0 oo- 1 @ 10-15 IO-56 IO- 98 IO-141

20- 37 @ 20-138 @ 0 30- 45 @ 0 30-101 @ o 30-156

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to

2. When carrying out any operation, always PREPARATIONS FOR WORK

16. When removing components, be careful not

18. As a general rule, do not use gasoline to

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL

VOLUMES REVISED EDITION MARK

Example 1 (Chassis volume):

Special technical precautions

Example 2 (Engine volume):

Places that require special at-

. If a part cannot be smoothly removed from

Wire ropes 4) Do not sling a heavy load with ropes form-

* The allowable load value is estimated to

2) Sling wire ropes from the middle portion 30 60 90 120 150

l Used to prevent rubber gaskets, rubber

l Used in places requiring an immediately

I I I* Features: Resistance to heat and chemi-

790-129-9060 Adhesive: l Used as adhesive or sealant for metal, glass

Holtz l Used as heat-resisting sealant for repair-

l Quick hardening type adhesive

bers, plastics and woods.

Quick hardening type adhesive

Quick cure type (max. strength after 30 min-

I 1 tics and metals.

l Features: Resistance to heat, chemicals

l Used as adhesive or sealant for gaskets

l Features: Resistance to heat

l Features: Resistance to water, oil

l Used as sealant for various threads, pipe

/ LG-5 (190-129-90601 1 kg /‘;$;;:‘/ ‘,srr~~eft~;~~raulic piping.

l Features: Silicon based, resistance to heat,

l Features: Silicon based, quick hardening

Three bond l Used as heat-resisting sealant for repairing

l Used as lubricant for sliding portion (to pre-

SYG2-4OOLI l General purpose type

l Used for normal temperature, light load

Molybdenum 400 g l Used for places with heavy load

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUES OF BOLTS AND NUTS

Thread diameter Width

Thread diameter Width

TIGHTENING TORQUE OF HOSE NUTS

Thread diameter Width across flat Tightening torque

TIGHTENINGTORQUE OFSPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque