CEBDW19020

CEBMW19020
SHOP
MANUAL
KOMdkfSU
WA3204 Lc
WHEEL LOADER
MACHINE MODEL SERIAL NUMBERS
WA3204 Lc A25001 and up
to do so. We
It is our policy to improve our products whenever it is possible and practical
ents at any time without incurring any
reserve the right to make changes or add improvem
obligation to install such changes on products sold previous ly.
revisions may be
Due to this continuous program of research and development, periodic
ended that customers contact their distributor for
made to this publication. It is recomm
information on the latest revision.
NOV 91
PRODUCT PUBLICATIONS INFORMATION
VARIOUS PRODUCT PARTS & SERVICE PUBLICATIONS ARE AVAIlABLE TO ALL KOMATSU CONSTRUCTION
EQUIPMENT OWNERS, INCLUDING OPERATION & MAINTENANCE MANUALS, PARTS BOOKS AND SHOP
MANUALS.
SPECIAL PUBUCATIONS SUCH AS SERVICETOOL, AIR CONDITIONING, ANDTURBOCHARGER SHOP MANUALS

ARE ALSO AVAILABLE AS WELL AS SELECTED OPERATION & MAINTENANCE AND SHOP MANUALS IN FOREIGN
LANGUAGES.
THE PUBLICATIONS LISTED BELOW ARE AVAILABLE FOR THIS PARTICULAR MACHINE(S).
DESCRIPTION FORM NUMBER
PARTS BOOK - PAPER:
Engineand Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPBW19021
PARTS BOOK - MICROFICHE:
Engineand Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPMW19021
OPERATION & MAINTENANCE MANUAL:
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEAMW19020
SERVICE MANUAL:
Chassis ....................................................... CEBMW19020 .
Engine:
Trouble Shooting & Repair .................................... 1128 236 Hl
Service Manual ............................................. 1128 179 H2
Spec~ication ............................................... 1128 240 Hl
SAFETYMANUAL ................................................... 1085 883 R3
PARTS AND SERVICE PUBLICATIONS CAN ONLY BE ACQUIRED BY AN AUTHORIZED KOMATSU

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PUBINFO.KOM 092591
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CONTENTS
No. of page
IO ENGINE
12 TESTING AND ADJUSTING .................................................. 12-1

13 DISASSEMBLY AND ASSEMBLY .............................................. 13-1
14 MAINTENANCESTANDARD ................................................. 14-1
20 POWER TRAIN
21 STRUCTURE AND FUNCTION ................................................ 21-1

23 DISASSEMBLY AND ASSEMBLY .............................................. 23-l
24 MAINTENANCE STANDARD ................................................. 24-1
40 STEERING SYSTEM

42 TESTING AND ADJUSTING .................................................. 42-l
44 MAINTENANCE STANDARD ................................................. 44-l
50 BRAKE AND AIR SYSTEM

54 MAINTENANCESTANDARD ................................................. 54-l
60 WORK EQUIPMENT SYSTEM

64 MAINTENANCE STANDARD ................................................. 64-l
80 ELECTRIC AND ELECTRONIC SYSTEM

90 OTHERS
93 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93-l

97 GEAR PUMP 97-l
99 METRIC CONViiilbN %i_k’ : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 99-l
00-l
SAFETY
A WARNING! IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for the safe operation of your machine. The service and repair
techniques recommended and described in this manual are both effective and safe methods of operation. Some
of these operations require the use of tools specially designed for the purpose.
To prevent injury to workers, the symbol shown is used to mark safety precautions in this manual. The cautions
accompanying these symbols should always be followed carefully. If any dangerous situation arises or may
possibly arise, first consider safety, and take the necessary actions to deal with the situation.
A SAFETY
PREPARATIONS FOR WORK

GENERAL PRECAUTIONS
7. Before adding oil or making repairs, park the
Mistakes in operation are extremely dangerous. Read machine on hard, level ground, and block the
the Operation and Maintenance Manual carefully BE- wheels or tracks to prevent the machine from
FORE operating the machine. moving.
1. Before carrying out any greasing or repairs, read all 8. Before starting work, lower blade, ripper, bucket
the precautions given on the decals which are fixed or any other work equipment to the ground. If this
to the machine. is not possible, insert the safety pin or use blocks
to prevent the work equipment from falling. In
2. When carrying out any operation, always wear addition, be sure to lock all the control levers and
safety shoes and helmet. Do not wear loose work hang warning signs on them.
clothes, or clothes with buttons missing.
-Always wear safety glasses when hitting parts with 9. When disassembling or assembling, support the
a hammer. machine with blocks, jacks or stands before
-Always wear safety glasses when grinding parts starting work.
with a grinder, etc.
10. Remove all mud and oil from the steps or other
3. If welding repairs are needed, always have a places used to get on and off the machine.
trained, experienced welder carry out the work. Always use the handrails, ladders or steps when
When carrying out welding work, always wear getting on or off the machine. Never jump on or
welding gloves, apron, glasses, cap and other off the machine. If it is impossible to use the
clothes suited for welding work. handrails, ladders or steps, use a stand to provide
safe footing.
4. When carrying out any operation with two or more
workers, always agree on the operating procedure
before starting. Always inform your fellow workers PRECAUTIONS DURING WORK
before starting any step of the operation. Before
starting work, hang UNDER REPAIR signs on the 11. When removing the oil filler cap, drain plug or
controls in the operator’s compartment. hydraulic pressure measuring plugs, loosen them
slowly to prevent the oil from spurting out.
5. Keep all tools in good condition and learn the Before disconnecting or removing components of
correct way to use them. the oil, water or air circuits, first remove the
pressure completely from the circuit.
6. Decide a place in the repair workshop to keep tools
and removed parts. Always keep the tools and parts 12. The water and oil in the circuits are hot when the
in their correct places. Always keep the work area engine is stopped, so be careful not to get
clean and make sure that there is no dirt or oil on burned.
the floor. Smoke only in the areas provided for Wait for the oil and water to cool before carrying
smoking. Never smoke while working. out any work on the oil or water circuits.
00-2
SAFETY
13. Before starting work, remove the leads from the 19. Be sure to assemble all parts again in their origi-
battery. Always remove the lead from the negative nal places.
(-) terminal first. Replace any damaged part with new parts.
l When installing hoses and wires, be sure that
14. When raising heavy components, use a hoist or they will not be damaged by contact with
crane. other parts when the machine is being oper-
Check that the wire rope, chains and hooks are free ated.
from damage.
Always use lifting equipment which has ample 20. When installing high pressure hoses, make sure
capacity. that they are not twisted. Damaged tubes are
Install the lifting equipment at the correct places. dangerous, so be extremely careful when install-
Use a hoist or crane and operate slowly to prevent ing tubes for high pressure circuits. Also check
the component from hitting any other part. Do not that connecting parts are correctly installed.
work with any part still raised by the hoist or crane.
21. When assembling or installing parts, always use
15. When removing covers which are under internal the specified tightening torques. When installing
pressure or under pressure from a spring, always protective parts such as guards, or parts which
leave two bolts in position on opposite sides. Slowly vibrate violently or rotate at high speed, be partic-
release the pressure, then slowly loosen the bolts to ularly careful to check that they are installed
remove. correctly.
16. When removing components, be careful not to 22. When aligning two holes, never insert your fingers
break or damage the wiring, Damaged wiring may or hand. Be careful not to get your fingers caught
cause electrical fires. in a hole.
17. When removing piping, stop the fuel or oil from 23. When measuring hydraulic pressure, check that
spilling out. If any fuel or oil drips on to the floor, the measuring tool is correctly assembled before
wipe it up immediately. Fuel or oil on the floor can taking any measurements.
cause you to slip, or can even start fires.
24. Take care when removing or installing the tracks
18. As a general rule, do not use gasoline to wash of track-type machines.
parts. In particular, use only the minimum of gaso- When removing the track, the track separates
line when washing electrical parts. suddenly, so never let anyone stand at either end
of the track.
00-3
FOREWORD
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 chapters for each main group of components; these
chapters are further divided into the following sections.
STRUCTUREANDFUNCTION
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.
00-4
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SERVICE MANUAL
VOLUMES REVISIONS
Service manuals are issued as a guide to carrying Revised pages are shown at the LIST OF RE-
out repairs. They are two manuals for each machine, VISED PAGES on the between the title page and
Chassis volume and Engine volume. SAFETY page.
These volumes are designed to avoid duplication

of information. Therefore to deal with all repairs for
any model, both chassis and engine volumes are SYMBOLS
needed.
So that the shop manual can be of ample practi-
DISTRIBUTION AND UPDATING cal use, important places for safety and quality are
marked with the following symbols.
Any additions, amendments or other changes will
be sent to your distributors. Get the most up-to-date
information before you start any work.
Symbol Item Remarks
FILING METHOD
Special safety precautions
1. See the page number on the bottom of the page. are necessary when perform-
A ing the work
File the pages in correct order.
Safety Extra special safety precau-
2. Following examples show how to read the page %b? tions are necessary when
number: 4 performing the work because
it is under internal pressure.
Example 1 (Chassis volume):
Special technical precautions
or other precautions for pre-
Caution serving standards are neces-
* sary when performing the
Item number (21. Structure
and Function) work.
‘t Consecutive page number Weight of parts or systems.
for each item Caution necessary when
kn Weight selecting hoisting wire or
r??l
when working posture is
Example 2 (Engine volume): important, etc.
Refer to the pertinent engine manual. Places that require special
Tightening
attention for tightening
3. Additional pages: Additional pages are indicated torque
torque during assembly.
by a hyphen (-) and numbered after the page
number. File as in the example. Places to be coated with
& Coat
adhesives and lubricants etc.
Example: Places where oil, water or
Oil, water fuel water must be added,
21-4 Q1
and the capacity.
21-4-l Added pages Places where oil or water
21-4-2
Drain must be drained, and quan-
21-5
tity to be drained.
REVISED EDITION MARK ([l] [2] [3] ....)
When a manual is revised, an edition mark is

recorded on the bottom outside corner of the pages.
00-5
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
u
m
Hooks have maximum strength at the middle
portion.
Heavy parts (25 kg or more) must be
lifted with a hoist etc. In the Disas-
sembly and Assembly section, every
part weighing 25 kg or more is indi-
cated clearly with the symbol A
L!a
I 100% 88% 79% 71% 41%
FSOO64
1. If a part cannot be smoothly removed from the

machine by hoisting, the following checks should 3) Do not sling a heavy load with one rope
be made: alone, but sling with two or more ropes sym-
metrically wound on to the load.
A
0 Check for removal of all bolts fastening the
part to the relative parts. Slinging with one rope may cause turning
of the load during hoisting, untwisting of
0 Check for existence of another part causing the rope, or slipping of the rope from its
interface with the part to be removed. original winding position on the load,
which can result in a dangerous accident.
2. Wire ropes
4) Do not sling a heavy load with ropes forming
1) Use adequate ropes depending on the weight a wide hanging angle from the hook.
of parts to be hoisted, referring to the table When hoisting a load with two or more ropes,
below: the force subjected to each rope will increase
with the hanging angles. The table below
shows the variation of allowable load (kg)
Wire ropes
when hoisting is made with two ropes, each
(Standard “2” or “s” twist ropes without galvaniz-
of which is allowed to sling up to 1000 kg
ing) vertically, at various hanging angles.
Rope diameter (mm) 1 Allowable load (tons) When two ropes sling a load vertically, up to
2000 kg of total weight can be suspended.
10.0 1.0
This weight becomes 1000 kg when two
11.2 1.4
ropes make a 120” hanging angle. On the
12.5 1.6
other hand, two ropes are subject to an
14.0 2.2
excessive force as large as 4000 kg if they
16.0 2.8
sling a 2000 kg load at a lifting angle of 150”.
18.0 3.6
20.0 4.4
22.4 5.6
30.0 10.0
40.0 18.0
50.0 28.0
60.0 40.0 A
The allowable load value is estimated to be

one-sixth or one-seventh of the breaking
strength of the rope used.
2) Sling wire ropes from the middle portion of

the hook. Lifting angle : a
Slinging near the edge of the hook may

cause the rope to slip off the hook during
hoisting, and a serious accident can result.
00-6
STANDARD TIGHTENING TORQUE
1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS
The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections of
“Disassembly and Assembly”.
Thread diameter Width

of bolt across flat
(mm) (mm)
km I Nm
6 10 1.35kO.15 13.2k1.4
8 13 3.2k0.3 31.4k2.9
10 17 6.720.7 65.7k6.8
12 19 11.5kl.O 112k9.8
14 22 18.Ok2.0 177&19
16 24 28.5 +3 279 + 29
18 27 3924 383?39
20 30 5626 549*58
22 32 7628 745 -c78
24 36 94.5+10 927298
27 41 135*15 1320*140
30 46 175&20 1720+190
33 50 225225 2210+240
36 55 288-c30 2750 + 290
39 60 335*35 3280 + 340
This torque table does not apply to the bolts with which nylon packings or other non-ferrous metal washers are
to be used, or which require tightening to otherwise specified torque.
+ Nm (newton meter): 1Nm + 0.1 kgm
2. TIGHTENING TORQUE OF SPLIT FLANGE BOLTS
Use these torques for split flange bolts.
Thread diameter Width Tightening torque

of bolt across flats
(mm) (mm) kgm Nm
10 14 6.720.7 65.7k6.8
12 17 11.521 11229.8
16 22 28.5+3 279229
00-7
STANDARD TIGHTENING TORQUE
3. TIGHTENING TORQUE FOR NUTS OF FLARED FITTINGS
Use these torques for nut part of flared.
Width across flats

T Tighteni I torque
Thread diameter I
of nut part of nut part
(mm) kgm Nm
(mm)
14 19 2.5205 24524.9
18 24 522 49219.6
22 27 8+2 78.5 + 19.6
24 32 14*3 137.3k29.4
30 36 18?3 176.5 f 29.4
33 41 2025 196.1249
36 46 25?5 245.2 *49
42 55 30?5 294.2 &49
COATING MATERIALS
The recommended coating materials prescribed in the shop manuals are listed below.
m
Applications
Used to apply rubber pads, rubber gaskets, and cork plugs.
Used to apply resin, rubber, metallic and non-metallic parts when a
F
fast, strong seal is needed.
LT-2* Preventing bolts, nuts, and plugs from loosening and leaking oil.
LT-3 Provides an airtight, electrically insulating seal.
Used for aluminum surfaces.
I LG-1 Used with aaskets and oackinas to increase sealina effect.

Heat-resistant gasket for precombustion chambers and exhaust
Liquid gasket Used by itself on mounting surfaces on the final drive and trans-
mission cases. (Thickness after tightening: 0.07 - 0.08 mm).
Used by itself to seal grease fittings, tapered screw fittings and

tapered screw fittings in hydraulic circuits of less than 50 mm in
diameter.
Applied to bearings and taper shafts to facilitate press-fitting and to

prevent sticking, burning or rusting.
Applied to bearings, sliding parts and oils seals for lubrication, rust
orevention and facilitation of assemblina work.
Vaseline Used for orotectina batterv electrode terminals from corrosion.
*LT-2 is also called LOCTITE in the shop manuals.
00-8
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: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Applicable circuit
CLASSIFICATION BY COLOR AND CODE
Classification Circuits Starting Charging Lighting Signal Instrument Other

Code B W R G Y L
Primary
Color Black White Red Green Yellow Blue
White & Yel- Green & Yellow & Blue &

Color -- Red & Green
low Black Blue Black
Code -- WG RL GL YW
6 White & Green & Yellow &
Color -- Red & Blue
Green Blue White
00-9
GENERAL WEIGHT TABLE
WEIGHT TABLE
A This weight table is a guide for use when transporting or handling components.
Unit: kg
Engine assembly 587

Radiator assembly 105
Torque converter assembly 40
Transmission (with torque converter) 520
Front drive shaft 45
Rear drive shaft 11
Front axle assembly (dry) 690
Rear axle assembly (dry) 675
Rear axle pivot 120
Wheel (1 piece) 115
Tire (1 piece) 110
Hydraulic tank (dry) 137
Main control valve 76
Lift cylinder (1 piece) 108
Dump cylinder 105
Engine hood 105
Front frame 1,100
Rear frame 875
Bucket link 30
Tilt lever 235
Lift arm (with bushing) 850
Bucket (with teeth) 1,180
Counterweight 1,130
Fuel tank (empty) 130
Battery (1 piece) (wet) 40
Operator’s seat 40
Floor plate 115
Rops cab 480
00-l0
GENERAL
LUBRICANTS, FUEL AND COOLANT

PROPER SELECTION TABLE
AMBIENT TEMPERATURE CAPACITY

RESERVOIR FLUID (Top line aF, Bottom line “C)
TYPE -22 -4 14 32 50 68 86 104 122 Specified Refill
-30 -20 -10 0 10 20 30 48 50
Engine oil
Engine with filter See
NOTE 1
Torque converter
Transmission & 35 4 25 Q
Service brakes Engine oil
See
NOTE 2
Hydraulic system 130 4 75 e
Drive axles - Axle oil See NOTE 3 24 4 24 P

Front & rear each each
All lubrication Grease See NOTE 4 Fill as in- --
fittings strutted
Fuel tank Diesel fuel See NOTE 5 200 P --
Cooling system Coolant See NOTE 6 484 __
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
API: American Petroleum Institute

ASTM: American Society of Testing and Material
SAE: Society of Automotive Engineers
SAE 15W-40 multi-viscosity oil meeting the Ameri-
NOTES: can Petroleum Institute (API) Classification of
CE/SF is recommended. CD/SF oil may be used in
1. ENGINE OIL areas where CE/SF oil is not available.
Normal Operation A sulfated ash limit of 1.O mass percent is suggest-

ed for optimum valve and piston deposit and oil
Oil performance recommendations are as follows: consumption control. The sulfated ash must not
exceed 1.85 mass percent. The sulfated ash limit of
The use of a quality engine lubricating oil combined 1.85 mass percent has been placed on all engine
with appropriate oil and filter change intervals are lubricating oils recommended for use in the engine.
critical factors in maintaining engine performance Higher ash oils can cause valve and/or piston
and durability. damage and lead to excessive oil consumption.
00-l1
The API service symbol displays the following 2. ENGINE OIL
information. The upper half of the symbol displays
the appropriate oil categories; the lower half may Use API classification CE engine oil. If API classifi-
contain words to describe oil energy conserving cation CD is used, reduce the oil change interval to
features. The center section identifies the SAE oil half.
viscosity grade.
3. AXLE OIL
Oil viscosity recommendations are as follows:
For axle oil, use only the recommended oil as
The use of a multi-graded lubricating oil has been follows:
found to improve oil consumption control and
improve engine cranking in cold temperatures while SHELL: DONAX ll or TD
maintaining lubrication at high operating tempera- CALTEX: RPM TRACTOR HYDRAULIC FLUID
tures. CHEVRON: TRACTOR HYDRAULIC FLUID
TEXACO: TDH OIL
While SAE 15W-40 multi-viscosity oil is recom- MOBIL: MOBIL AND SUPER UNIVERSAL
mended for most operating climates, refer to the
previous chart for oil viscosity recommendations for * It is possible to substitute engine oil SAE 30W API
extreme climates. classification CD for axle oil. If noise comes from
the brake, it is no problem of durability.
Limited use of low viscosity oils, such as SAE 1OW-
30 may be used for easier starting and providing 4. GREASE
sufficient oil flow at ambient temperatures below
+23”F (-5°C). However, continuous use of low The recommended lubricating grease is No. 2 multi-
viscosity oils can decrease engine life due to wear. purpose lithium grease with 3% molybdenum disulfide.
Do not use special “break-in” lubricating oils for a 5. DIESEL FUEL

new or rebuilt engine. Use the same type of oil
A
during the “break-in” as specified for normal opera- WARNING! Do not mix gasoline or
tion. alcohol with diesel fuel. This mixture
can cause an explosion.
Arctic Operation
IMPORTANT: Due to the precise tolerances of
If an engine is operated in ambient temperatures diesel injection systems, it is extremely important
consistently below -10” F (-23” C) and there are no that the fuel be kept clean and free of dirt or water.
provisions to keep the engine warm when it is not Dirt or water in the system can cause severe
in operation, use a synthetic CE/SF or CD/SF damage to both the injection pump and nozzles.
engine oil with adequate low temperature properties
such as SAE 5W-20 or 5W-30. The use of ASTM No. 2-D diesel fuel with a mini-
mum Cetane number of 40 is recommended. The
The oil supplier must be responsible for meeting use of No. 2-D diesel fuel will result in optimum
the performance service specifications. engine performance under most operating condi-
tions. Fuels with Cetane numbers higher than 40
IMPORTANT: The use of a synthetic base oil does may be needed in high altitudes or extremely low
not justify extended oil change intervals. Extended ambient temperatures to prevent misfires and
oil change intervals can decrease engine life due to excessive smoke.
factors such as; corrosion, deposits and wear.
At operating temperatures below +32” F (O”C),
Additional information regarding lubricating oil acceptable performance can be obtained by using
availability throughout the world is available in the a blend of No. 2-D and No. 1-D fuels. The use of
“E.M.A. Lubricating Oils Data Book for Heavy Duty lighter fuels can reduce fuel economy.
Automotive and Industrial Engines.” The data book
may be ordered from the Engine Manufacturers Use a low sulfur content fuel having a cloud point
Association, One Illinois Center, 111 East Wacker that is at least 10 degrees below the lowest expect-
Drive, Chicago, IL U.S.A. 60601. The telephone ed fuel temperature. Cloud point is the temperature
number is (312) 644-6610. at which crystals begin to form in the fuel.
The viscosity of the fuel must be kept above 1.3

cSt to provide adequate fuel system lubrication.
00-12
GENERAL
6. COOLANT Total Hardness - Not to exceed 170 parts per

million (10 grains/gallon maximum) to prevent
Heavy duty diesel engines require a balanced scale deposits. Water containing dissolved
coolant mixture of water, antifreeze, and supple- magnesium and calcium (the usual reason for
mental coolant additives. Supplemental coolant water hardness) above the specified amount will
additive recommendations are included in the cause scale deposits to develop in the engine.
section entitled “CHANGE THE COOLANT AND
FLUSH THE COOLING SYSTEM”. The coolant Chlorides - Not to exceed 40 parts per million
should be changed at the specified service interval (2.5 grains/gallon maximum) to prevent corro-
shown in the “MAINTENANCE TABLE”. sion.
DCA4 is recommended to inhibit corrosion in the Sulfites - Not to exceed 100 parts per million
cooling system. (5.8 grains/gallon maximum) to prevent corro-
sion.
In climates where the temperature is above -34°F
(-37°C) use a coolant mixture that contains 50 Dissolved Solids - Not to exceed 340 parts per
percent antifreeze. Antifreeze is essential in any million (20 grains/gallon maximum) to minimize
climate. It broadens the operating temperature sludge deposits, scale deposits, corrosion or a
range by lowering the coolant freezing point and by combination of these.
raising its boiling point. Do not use more than 50
percent antifreeze in the mixture unless additional If any of the above requirements cannot be met,
freeze protection is required. Never use more than use distilled, de-ionized, or de-mineralized water.
68 percent antifreeze under any condition. To determine if local water supplies meet these
standards, water samples can be tested by water
Low silicate ethylene glycol antifreeze is recom- treatment laboratories. “Softened” water that is
mended. The antifreeze should contain no more prepared using common salt (sodium chloride)
than 0.1% anhydrous alkali metasilicate. Low contains excessive amounts of chlorides and
silicate antifreeze is recommended to avoid the should not be used.
formation of silica-gel (hydro-gel). This gel forma-
tion can occur when the cooling system contains NOTE: Never use water alone in the cooling
an over concentration of high silicate antifreeze system because corrosion will occur.
and/or supplemental coolant additive. DO NOT use
methanol or alcohol as an antifreeze because of its Maintain supplemental coolant additive levels at 1
low boiling point. unit DCA4 per 1 U.S. gal (3.8 liters) of coolant.
Antifreeze may retain its freeze protection for more Use antifreeze during all seasons to protect the
than one season but coolant conditioners must be cooling system from corrosion as well as freezing
added to maintain corrosion protection. damage.
Antifreeze formulated with methoxy propanol, or A mixture of 50% water and 50% ethylene glycol
propylene glycol, is not recommended for this base antifreeze is required for operation of the
system. engine in temperature environments above -34.8” F
(-37°C). A mixture of 40% water and 60% anti-
NOTE: Do not mix types of antifreeze solutions. freeze is recommended for temperatures below -
Mixed solutions make it impossible to 34.6” F (-37” C).
determine the protection against freezing.
Antifreeze containing sealer or anti-leak In tropical climates where antifreeze availability may
additives should NOT be used in this be limited, use a corrosion inhibitor (Cummins
system. Sealer or anti-leak additives will liquid DCA), or an equivalent to protect the engine
cause plugging problems in the cooling cooling system.
system.
Do not operate the engine without a thermostat.
Check the solution periodically and at normal
operating temperature, to be sure the cooling
system has sufficient protection against freezing.
Use water which has a low mineral content. Water

used in conjunction with antifreeze, coolant filters
and inhibited water must meet the following stan-
dards:
00-l 3
ENGINE
12 TESTING AND ADJUSTING
STANDARDVALUETABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
TOOL LIST FOR TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
VALVE CLEARANCE . . . . .._._.................................................... 7
FUELINJECTIONTIMING ......................................................... 8
ENGINE OIL PRESSURE AND TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
BLOW-BYPRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
EXHAUSTGAS COLOR .._........................................................ 12
ACCELERATOR PEDAL, OPERATING FORCE AND OPERATING ANGLE ...................... 13
* The following precautions are necessary when using the Standard Value Tables to make judgements during
troubleshooting or during testing and adjusting.
1. The values in these tables are based on the values for new machines leaving the plant, so they should
be used as target values when repairing or when estimating wear after a period of use.
2. The information in the Standard Value Tables are estimates, based on standards from the production
plant when the machines were shipped. Therefore, when troubleshooting they should be used as
reference in combination with repair and operating records when making judgements.
3. These standard value tables must not be used for standard values when judging claims. In addition, do
not use these values alone to make simple judgements.
12-I
TESTING AND ADJUSTING STANDARD VALUE TABLE
STANDARD VALUE TABLE

. FOR ENGINE ON TEST BENCH
Engine T 614T
Standard Permissible
Category Item Condition, etc. Unit
value value
Engine speed
High idling speed vm 2585?50
Low idling speed rpm 85o-t50
Performance 0°C
Necessary starting
-20” C (Using starting rpm Min 150
speed
aid) rpm Min 120
Intake resistance All speed mmH 0 Max 381 Max 635

Exhaust pressure At rated output mm t?g Max 76
Exhaust temperature All speed (Intake air “C 576 (Turbine
temp.: 20” C) Outlet)
Intake and
Sudden acceleration Max 6.0 Max 6.0
exhaust system Bosch
Exhaust gas color At high idling Max 1.0 Max 2.0
Scale
At rated speed Max 1.0 Max 2.5
Valve clearance Intake valve mm 0.30

(Engine cold) Exhaust valve mm 0.61
Oil temperature 40-60” C

Compression
(Engine speed: kg/cm”
pressure
320-360 rpm)
BUY
At rated output, oil 457
Blow-by pressure
orifice size 7.67mm
temperature min. 70” C
SAE 15W-40
mmHs0 (:w
engine)
(Used
engine)
Oil pressure
(SAE 15W-40 At rated speed kg/cm2 2.1-3.5
Oil temp.: 80°C At low idling kg/cm2 0.7-2.2
min.)
Lubrication All speed

Oil temperature “C 80-110 Max 120
system (Oil in oil pan)
At continuous rated
horsepower
Oil consumption ratio % Max 0.3 Max 0.5
(Proportion of fuel
consumption)
Fuel injection
Nozzle tester kg/cm2 209
Fuel system pressure
Fuel injection timing Before top dead center Degree 22
Radiator pressure Opening pressure

Cooling system kg/cm2 0.720.1
valve function (Differential pressure)
12-2
Engine 614T
I I I I
Category Item Condition, etc. Unit
value value
Fan speed
At rated speed rpm 2045
Cooling system (o*87 ratio)
(Continued) Deflect when pushed
Fan belt tension kg 80-110 80
with a force of 6 kg
NOTE: The values given in the Testing and Adjusting data are NOT for adjustment of the output.
Do not use these values as a guide to change the setting of the fuel injection pump.
12-3
l FOR ENGINE ON CHASSIS
Er ne T 6’ T
Category Check item Conditions Unit
value value
Performance Engine speed

High idling speed rpm 2410550 2410?50
Low idling speed rpm 845250 845250
At abrupt acceleration Bosch Max 6.0 Max 6.0

index
Exhaust gas color Bosch Max 1.0 Max 2.0
At high idling
Intake and
index
exhaust system
Intake valve (20” C) mm 0.30
Valve clearance mm 0.61
Exhaust valve (20°C)
Blow-by pressure Max 89 Max 457

At high idling (Water temp.
(Orifice size of mmH,O
inside operating range) (New limit) (Worn limit)
7.67 mm)
Oil pressure (Water temperature inside

operating range)
(SAE 15W-40, oil
Lubrication temp.: min. 80°C) At rated speed kg/cm2 2.1-3.5
system At low idling kg/cm’ 0.7-2.1
Whole speed range (Inside

Oil temp. “C 80-110 Max 120
oil pan)
Fuel injection Degree 22

Fuel system Compression B.T.D.C.
timing
Cooling system Fan belt tension Belt tension gauge kg 80-110 80
Operating force kg 4-8.5 Max 10.5
OL1 45
Operating
Acceleration Degree
angle 32
pedal t Q2
Stopper mm 43-53
height
To
U41901002
12-4
TESTING AND ADJUSTING TOOL LIST FOR TESTING AND ADJUSTING
TOOL LIST FOR TESTING AND ADJUSTING
No. Testing and measuring item Tool name Part number Remarks
1 Enaine speed Tachometer 799-203-8000 Digital display 60-19999 rpm
2 Battery specific gravity I 1.1 - 1.3

Battery coolant tester 795-500-l 000 -5 - -50°C
3 Coolant freezing
temperature
0 - 200°C
790-500-l 300
799-Yu1-6000 0 - 1ooo”c
5
6 0 - 10 kg/cm2
7 0 - 20 kg/cm2
8 intake pressure, exhaust Engine pressure 0 - 1500 mmHg

799-203-2002
pressure measuring kit
9 Blow-by pressure I 0 - 1000 mmHs0
10 Intake resistance I -1000 - 0 mmH*O
11 Compression pressure I Compression gauge 795-502-l 204 0 - 70 kg/cm2
Blow-by pressure Blow-by checker 799-20 l-l 503 0 - 500 mmHs0
Valve clearance Feeler gauge 795-l 25-1330
14 Exhaust gas color Smoke meter Commercially Discoloration 0 to 70%

available standard color (Discoloration
% x 1/lO k Bosch index)
15 Fuel on water mixed in oil Engine oil checker 799-20 l-6000 Water content 0.1%, 0.2% in
standard sample
16 Coolant quality Water quality tester 799-202-7001 PH, nitrous acid ion
concentration
17 Leakage from cooling Cap tester 799-202-9001 0 - 2 kg/cm2

system I
18 Fuel injection pressure Nozzle tester Commercially 0 - 300 kg/cm2

Nozzle injection condition available
Electrical circuit Tester Commercially Current, voltage,

available resistance
Accelerator pedal force Push-pull scale 7AO-262-0020 Commercially available

0 - 25 kg
Belt tension Belt tension gauge ST-l 293

(Cummins)
Fuel injection timing Injector timing tool 3375522

(Cummins)
12-5
A When carrying out testing, adjusting or trou-

bleshooting, stop machine on level ground, A When checking the water level in the radiator,
wait for the water to cool. Do not remove the
insert the safety pins and block the tracks. radiator cap while the water is hot. Boiling
water may spurt out.
A When working in groups, use agreed signals

and do not allow unauthorized persons near the A Be careful not to get caught in rotating parts.
machine.
12-6
TESTING AND ADJUSTING VALVE CLEARANCE
VALVE CLEARANCE
+ Adjust clearance between valve and rocker lever as
follows.
Unit: mm
Intake valve Exhaust valve
Cold 0.30 0.61
Special tool
Part number . Part name Q’ty
A 1 7951251330 1 Feeler gauge I 1
1. Loosen band (1) of air cleaner assembly (2), dis-

connect from turbocharger (3), then remove air
cleaner (2).
+ When removing the air cleaner, remove the
intake hose first.
2. Loosen band (4) and remove bolt (5) of exhaust

muffler (6). Disconnect turbocharger (3) then
remove exhaust muffler (6).
3. Remove bracket (7 and 8) of air cleaner and ex-

haust muffler.
4. Remove air connector (9).
5. Adjusting valve clearance

t For details of the engine, see the Troubleshoot-
ing and Repair Manual, CEBM 614TR0.
12-7
TESTING AND ADJUSTING FUEL INJECTION TIMING
FUEL INJECTION TIMING

* Measurement condition
+ Coolant temperature: Inside operating range.
Unit: mm
Item
value value
Fuel injection timing 22
Special tool
Part number Part name Q’ty
Injection time tool
1. Remove the cable (1) from injection pump.
2. Testing and adjusting fuel injection timing

* For details of the engine, see the Troubleshoot-
ing and Repair Manual, CEBM 614TR0.
12-8
TESTING AND ADJUSTING ENGINE OIL PRESSURE AND TEMPERATURE
ENGINE OIL PRESSURE AND

TEMPERATURE
1. Measuring engine oil pressure.
+ Measurement condition
Coolant temperature: Inside operating range.
l
Unit: ka/cmz
Item
value value
Oil pressure 2.1-3.5

rated speed r-m_ I
Low idling I 0.7-2.1 I
Special tool
A 799-203-2002 Engine pressure 1

measuring kit
A When measuring, be careful not to get caught

in rotating parts.
A Install and remove the plug and oil pressure

gauge with the engine stopped.
+ Measure the engine oil pressure when the oil

temperature is at the specified temperature.
1) Remove plug (1).

2) Install oil pressure gauge A (25 kg/cm2).
+ Install the oil pressure gauge so that it is
affected as little as possible by the engine
vibration.
3) Start engine and measure oil pressure.
12-9
TESTING AND ADJUSTING ENGINE OIL PRESSURE AND TEMPERATURE
2. Measuring oil temperature.

l Coolant temperature: Inside operating range.
Item
value value
Oil temperature 30-110°C 120°c
Special tool
A 790-500-l 300 Thermistor 1

or Thermistor temp.
799-l 01-6000 gauge
1) Remove dipstick (1).

2) Insert sensor of thermistor temperature gauge
in dipstick guide.
Connect sensor to thermistor temperature
gauge A and measure temperature of oil in oil
pan.
12-10
TESTING AND ADJUSTING BLOW-BY PRESSURE
BLOW-BY PRESSURE
l Engine valve clearance: Standard valve.
l Engine speed: Rated speed.
Unit: mmHs0
Blow-by a9 457
pressure
Soecial tools
A When taking measurements, be careful not to

touch the exhaust manifold, muffler, or to get
caught in rotating parts.
1. Measuring blow-by
1) When measuring the blow-by, warm the engine
up thoroughly. (oil temp: min. 60°C)
2) Stop engine and install engine pipe tee of blow-
by checker on engine breather hose.
3) Connect adapter and blow-by A (O-1000
mmHs0) to hose.
4) Run the engine at rated idling and measure the
blow-by pressure.
Manometer
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 valve can
be obtained at stall speed.
l If it is impossible to check at rated output or
stall speed, measure at high idling. --- In this
case, the, blow-by valve will be about 30% of
the value at rated output.
+ Blow-by may vary greatly according to the
condition of the engine, so if there is any abnor-
mality in the reading, check for any problem
related to defective blow-by, such as excessive
oil consumption, defective exhaust gas color, or
early deterioration or contamination of the oil.
12-11
TESTING AND ADJUSTING EXHAUST GAS COLOR
EXHAUST GAS COLOR

l Valve clearance: Standard value.
Unit: Bosch index
Item
Exhaust Acceleration Max 6.0 Max 6.0

color High idling Max 1.0 Max 2.0
Special tool
A 799-201-9001 Smoke meter 1
A When measuring the exhaust color, be careful

not to touch the exhaust pipe.
+ When measuring the exhaust gas color, warm the

engine up thoroughly (oil temp. min. 6O’C).
1. Insert probe @ in outlet of exhaust pipe and secure

to exhaust pipe with clip.
2. Connect probe hose, connector hose of accelerator

switch and air hose @ to smoke meter A.
+ The pressure of the air supply should be under
15 kg/cm*.
3. Connect power cord to AC 1OOVsocket.

+ Check that the power switch is OFF before
connecting the cord.
4. Loosen cap nut of suction pump and insert filter

paper.
t Insert filter paper securely to prevent exhaust
gas leakage.
5. Turn power switch ON.
6. Accelerate engine suddenly. At the same time,

depress accelerator pedal, operate relief valve and
catch exhaust gas color on filter paper.
7. Lay filter paper used to catch exhaust gas color on

top of unused filter papers (10 sheets or more)
inside filter paper holder, and read indicated value.
12-12
TESTING AND ADJUSTING ACCELERATOR PEDAL
ACCELERATOR PEDAL, OPERATING

FORCE AND OPERATING ANGLE
Unit: ka
Item
value value
Operating force of
4-7 13.5
accelerator pedal
Special tools
Part number Part name CYty
A 1 7AO-262-0020 1 Push-pull scale I 1
Commercially
B Angle gauge 1
available
Floor upper
OPERATING FORCE
1. Measuring procedure
1) Put push-pull scale A in contact with the accel-
erator pedal at point 150 mm from pedal ful-
crum “a”.
t The center of push-pull scale A must be in
contact with a point 150 mm from the pedal
fulcrum.
2) Start the engine, push the pedal in the direction
of operation and measure the maximum value
when pushing from idling to the end of the
pedal travel (high idling).
2. Testing and adjusting

1) Stop the engine.
2) Disconnect cable (1) at the bottom of the
accelerator pedal, and check that the ball joint
at the bottom of the pedal moves smoothly.
L12BV024
12-13
3) Connect the cable at the bottom of the pedal,

then disconnect at the connection for the injec-
tion pump, and check that the cable (1) moves
smoothly.
u Cable joint nut: 1.420.1 kgm
a Cable joint nut: Thread tightener (LT-2)
+ When carrying out this inspection, adjust or

replace parts as necessary.
+ Measure the operating force again and
check that it is within the standard range.
12-14
OPERATING ANGLE OF ACCELERATOR PEDAL
Unit: mm
Item
value value
Operating angle of al 45”

accelerator pedal a2 32”
Installed height of
accelerator pedal L 48
stopper U41901004
1. Measuring
1) Stop the engine.
2) Put angle gauge @in contact with the accelera-
tor pedal and measure the angle of movement
a = a, - a2 from low idling (a,) to high idling
(a&-
Angle of depression: L = a, - a2
2. Adjusting
1) Remove the cover at the bottom of the cab,
open the engine hood and apply the safety
lock.
2) Loosen nut (1) and adjust with bolt (2) so that
installed height L of the accelerator pedal
stopper is 47 mm.
3) Loosen locknut (3) and adjust the length of the
cable so that the injection pump governor lever
contacts the high idling stopper when the
accelerator pedal is fully depressed (high
idling).
* Check that the injection pump governor
lever contacts the low idling stopper when
the accelerator pedal is released (low
idling).
t Adjust the travel of the governor lever at
joint (4).
Iz=] Cable joint nut: 1.4kO.l kgm
& Cable joint nut: Thread tightener (LT-2)
+ After completing the above adjustments,

measure each part again to check that it is
within the standard value.
ENGINE
13 DISASSEMBLY AND ASSEMBLY
STARTING MOTOR.. ................................................................ 3

REMOVAL ..................................................................... 3
INSTALLATION .................................................................. 3
ALTERNATOR ..................................................................... 4
REMOVAL ..................................................................... 4
INSTALLATION .................................................................. 4
OILCOOLER ...................................................................... 5
REMOVAL ..................................................................... 5
INSTALLATION.. ................................................................ 5
FUELINJECTION PUMP.. ............................................................ 6

REMOVAL ........... ..i ....................................................... 6
INSTALLATION .................................................................. 6
WATER PUMP ..................................................................... 7

REMOVAL ..................................................................... 7
INSTALLATION.. ................................................................ 7
INJECTORS ....................................................................... a
REMOVAL ..................................................................... a
INSTALLATION.. ................................................................ 9
TURBOCHARGER ................................................................... 10
REMOVAL ..................................................................... 10
INSTALLATION .................................................................. 11
CYLINDER HEAD 12
REMOVAL ... . . . . . . . . . . . . . . . . . ::::::::::::::::::::::::::::::::::::::::::::::::: 12
INSTALLATION .................................................................. 13
RADIATOR ........................................................................ 14
REMOVAL ..................................................................... 14
INSTALLATION .................................................................. 16
ENGINE .......................................................................... ia
REMOVAL ..................................................................... ia
INSTALLATION .................................................................. 23
FUELTANK ....................................................................... 28
REMOVAL ..................................................................... 28
INSTALLATION .................................................................. 29
13-1
* Take the following method for air bleeding when you start to operate hydraulic cylinders after reassembling
cylinders, pumps and pipings.
1. Start engine, keep idling.

2. Operate hydraulic cylinder 4. - 5 cycles, but do not exceed beyond 100 mm of stroke end.
3. Continue to operate cylinder 3 - 4 cycles until stroke end.
4. After finishing above steps, keep normal engine speed.
NOTE: After long storage, same procedure is required.
13-2
DISASSEMBLY AND ASSEMBLY STARTING MOTOR
STARTING MOTOR
REMOVAL
A Disconnect the cable

terminal of the battery.
from the negative (-)
1. Remove catch, then open hood.
2. Disconnect wire (1) and connector (2).
3. Remove the starting motor (3) from flywheel hous-

ing.
STARTING MOTOR
INSTALLATION
1. Install the starter motor (3) to flywheel housing.

Tighten the mounting bolts.
Bolts 77 Nom
+ For details of the starting motor, see the Engine

Shop Manual CEBM 614SM0.
2. Connect connector (2) and wire (1).
3. Close hood, then lock with catch.
4. Connect cable to negative (-) terminal battery.
13-3
DISASSEMBLY AND ASSEMBLY ALTERNATOR
ALTERNATOR
REMOVAL
A Disconnect the cable from the negative (-)

2. Disconnect wires (1, 2, and 3).
3. Remove the alternator assembly (4).

t For details of the alternator see the Engine
ALTERNATOR
INSTALLATION
1. Install alternator assembly (4), then partially tighten

mounting bolt and nut.
+ For details of the alternator, see the Engine
2. Fit belt in pulley groove and install.

+ For details of the drive belt, see the Engine
3. Connect wires (3, 2, and 1).
5. Connect cable to negative (-) terminal of battery.
13-4
DISASSEMBLY AND ASSEMBLY OIL COOLER
OIL COOLER
REMOVAL
2. Remove the oil filter (1).

* Use filter wrench 118 to 131 mm.
3. Disconnect hose (2).
4. Remove the oil cooler (3).

+ Removing the oil cooler, see the Engine Shop
Manual CEBM 614SM0.
OIL COOLER
INSTALLATION
1. Install the oil cooler (3).

+ For details of the oil cooler, see the Engine
2. Connect hose (2).
3. Install the oil filter (1).

+ For details of the oil filter, see the Engine Shop
Manual CEBM 614SMO.
13-5
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
FUEL INJECTION PUMP

REMOVAL
2. Disconnect control cable rod (1).
3. Remove the fuel filter (2) and disconnect fuel tube

(4).
+ For details of the fuel injection pump, see the
Engine Shop Manual CEBM 614SM0.
4. Disconnect fuel return hose (3). Remove injection

pump side.
5. Remove the fuel injection pump (5).

A- For details of the fuel injection pump, see the
FUEL INJECTION PUMP

INSTAUTION
1. Install the fuel injection pump (5).

2. Connect fuel return hose (3).
3. Install the fuel filter (2) and connect fuel tube (4).
4. Connect control cable rod (1).
13-6
DISASSEMBLY AND ASSEMBLY WATER PUMP
WATER PUMP
REMOVAL

1. Remove catch, then open hood. Loosen drain valve

(1) and drain cooling water.
+ If the coolant contains antifreeze, dispose of it
correctly.
Cooling water: 484
2. Disconnect wires (2, 3, and 4) from the alternator.
3. Remove the fan guard (5) from the radiator.
4. Remove the fan belt (6) and the alternator (7).

+ For details on the fan belt and alternator, see
the Engine Shop Manual CEBM 614SM0.
5. Remove the water pump (8) from engine.

+ For details of the water pump, see the Engine
WATER PUMP
INSTALLATION
1. Install the water pump (8) to engine.

* For details of the water pump, see the Engine
2. Install the alternator (7) and the fan belt (6) to

engine.
+ For details of the alternator and fan belt, see
the Engine Shop Manual CEBM 614SM0.
3. Install the fan guard (5) to radiator.
4. Connect wires (4, 3, and 2) to the alternator.
5. Tighten drain valve (1) and add water through water

filter to specified level.
Cooling water: 484

Q
t Run the engine to circulate the water through

the system. Then check the water level again.
7. Connect cable to negative (-) terminal of the bat-

tery.
13-7
DISASSEMBLY AND ASSEMBLY INJECTORS
INJECTORS
REMOVAL
A Stop the machine on level ground and install

the safetv 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.
2. Loosen band (1) of air cleaner assembly (2). Dis-

cleaner(2).
t When removing the air cleaner, remove the
intake hose first.

muffler (6). Disconnect from turbocharger (3), then
4. Remove brackets (7 and 8) of air cleaner and ex-

haust muffler.
5. Remove air connector (9) from engine.
6. Remove the injector (10) from the engine.

t For details of the injector, see the Engine Shop
Manual CEBM 614SM0.
13-8
DISASSEMBLY AND ASSEMBLY INJECTORS
INJECTORS
INSTALIATION
1. Install the injectors (10) to the engine cylinder head.

t For details of the injector, see the Engine Shop
Manual CEBM 614SMO.
2. Install air connector (9) to the engine.
3. Install brackets (7 and 8) to the air cleaner and the

exhaust muffler.
4. Tighten band (4) and install bolt (5) to exhaust

muffler (6). Connect to turbocharger (3), then install
exhaust muffler.
5. Tighten band (1) to air cleaner (2). Connect hose to

turbocharger (3), then install air cleaner.
13-9
DISASSEMBLY AND ASSEMBLY TURBOCHARGER
TURBOCHARGER
REMOVAL

the safety bar on the frame. Lower the work
moving.

cleaner (2).
intake hose first.

remove exhaust muffler.

haust muffler.
6. Remove the turbocharger (3) from engine.

+ For details of the turbocharger, see the Engine
13-10
DISASSEMBLY AND ASSEMBLY TURBOCHARGER
TURBOCHARGER
INSTALIATION
1. Install the turbocharger (3) to engine.

t For details of the turbocharger, see the Engine
2. Install air connector (9) to engine.
3. install brackets (7 and 8) to air cleaner and exhaust

muffler.

exhaust muffler.

turbocharger (3), then install air cleaner.
13-11
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
CYLINDER HEAD
REMOVAL

moving.

cleaner (2).
intake hose first.


haust muffler.
6. Remove the engine head cover (10) and cylinder

head (11).
+ For details of the engine head cover and cylin-
der head, see the Engine Shop Manual CEBM
614SM0.
13-12
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
CYLINDER HEAD
INSTALIATION
1. Install the engine cylinder head (11).

+ For details of the engine cylinder head, see the
2. Install the engine head cover (10).

+ For details of the engine head cover, see the
3. Install brackets (7 and 8) to air cleaner and exhaust

muffler.

exhaust muffler.

turbocharger (3), then install air cleaner (2).
13-13
DISASSEMBLY AND ASSEMBLY RADIATOR
RADIATOR
REMOVAL

the 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.
Y Y Loosen the oil filler cap slowly to release the

A
*
pressure inside the hydraulic tank. Then operate
the control levers several times to release the
remaining pressure in the hydraulic piping.
1. Draining water, oil

1) Loosen drain valve (1) and drain cooling water.
t If the coolant contains antifreeze, dispose
of it correctly.
Coolant water: 484
2) Loosen the radiator filler cap (12) slowly to

release the pressure inside the radiator.
2. Hood
1) Open hood and remove cable (2) then close
hood and install safety bolt (3).
2) Remove radiator grille (4) and exhaust pipe (5).
3) Remove mounting bolts, then remove hood (6).
+ Screw eyebolts into the holes for the
mounting bolts of the exhaust pipe, and be
careful of the balance when removing the
hood.
Hood: 110 kg
3. Fan Guard
Remove fan guard (7) and radiator support (8).
13-14
4. Electric wiring
Disconnect wiring (9) of radiator water lever sensor
from connector.
5. Radiator hoses
1) Disconnect radiator hoses (10, 11, and 12) from
engine.
2) Disconnect radiator sub-tank hoses from radia-
tor.
6. Cooler piping
1) Sling radiator (13), then remove mounting bolts.
t Remove the cooler hose clamp.
2) Raise radiator about 20 cm, then disconnect
cooler hoses (14 and 15).
t Be careful not to raise the radiator too high.
* Do not let the fan interfere with the radiator
shroud when raising the radiator.
7. Radiator
Remove radiator (13).
sr When removing the radiator, move it toward the
counterweight to prevent the radiator core from
coming near the fan.
Radiator: 105 kg
RADIATOR
INSTALIATION
1. Radiator
Raise radiator (13) and stop 20 cm above mounting
position.
+ Be careful not to damage the radiator core.
t Insert the radiator carefully from the counter-
weight side.
2. Cooler piping
1) Keep radiator 20 cm above mounting position
and connect cooler hoses (14 and 15).
t Install the hoses without twisting or interfer-
ence.
+ After connecting the hoses, install the
clamps.
D Hose nut: 2025 kgm
2) Set radiator (13) in mounting position, then

tighten mounting bolts.
+ Install the cooler hose clamp.
+ Install so that the clearance from the fan is
uniform.
D Mounting bolt (13A): 2531.5 kgm
3. Radiator hoses
1) Connect radiator hoses (10, 11, and 12) to
engine.
2) Connect sub-tank hoses to radiator.
4. Electric wiring
Connect wiring (9) of radiator water level sensor to
connector.
13-16
5. Fan guard
Install fan guard (7) and radiator support (8).
+ Install so that the clearance between the fan
guard and fan is uniform.
Radiator support mounting bolt:

1121.0 kgm
6. Hood
1) Raise hood (6), set in mounting position, then
t Stop the hood about 10 cm above the
mounting position and install cable (2).
2) Install exhaust pipe and radiator grille.
3) Remove safety bolt.
7. Refilling with water

Tighten drain valve (1) and add water through water
filler to the specified level.
+ Run the engine to circulate the water through
Qi# Coolant: 484
* Check the transmission oil level and add oil if

necessary.
DISASSEMBLY AND ASSEMBLY ENGINE
ENGINE
REMOVAL

A Disconnect the lead from the (-) battery termi-

nal.
A
m & Loosen the oil filler cap slowly to release the
4
pressure inside the hydraulic tank. Then operate
the control levers several times to release the
1. Draining water, oil

1) Loosen drain valve (1) and drain cooling water.
+ If the coolant contains antifreeze, dispose
of it correctly.
Cooling water: 484
2) Loosen the radiator filler cap (12) slowly to

release the pressure inside the radiator.
2. Hood
1) Open hood and remove cable (2), then close
hood and install safety bolt (3).
2) Remove radiator grille (4) and exhaust pipe (5).
3) Remove mounting bolts, then remove hood (6).
* Screw eyebolts into the holes for the
mounting bolts of the exhaust pipe, and be
careful of the balance when removing the
hood.
Hood: 110 kg
3. Fan guard
Remove fan guard (7) and radiator support (8).
13-18 -’
4. Electric wiring
Disconnect wiring (9) of radiator water level sensor
from connector.
5. Radiator hoses
1) Disconnect radiator hoses (10, 11, and 12) from
engine.
2) Disconnect radiator sub-tank hoses from radia-
tor.
6. Cooler piping
1) Sling radiator (13), then remove mounting bolts.
+ Remove the cooler hose clamp.
2) Raise radiator about 20 cm, then disconnect
cooler hoses (14 and 15).
t Be careful not to raise the radiator too high.
* Do not let the fan interfere with the radiator
shroud when raising the radiator.
7. Radiator
Remove radiator (13).
+ When removing the radiator, move it toward the
counterweight to prevent the radiator core from
coming near the fan.
Radiator: 105 kg
8. Electric wiring
Disconnect the following electric wiring.
l Disconnect cable (16) between starting motor
to battery relay.
0 Disconnect connector (17) of safety relay.
l Disconnect wire (18, 19, and 20) from the alter-
nator.
l Disconnect connector (21) of water temperature
sensor.
l Disconnect connector of fuel cut-off solenoid
and engine oil level sensor, and engine oil
pressure sensor.
+ After removing the wiring, mark each wire
with a tag to distinguish when installing.
9. Fuel hoses
1) Disconnect hose (22) between fuel tank and
fuel injection pump from fuel tank.
2) Disconnect hose (23) between fuel tank and
water filter from fuel tank.
10. Fuel control cable

Remove lock nut (24), then remove fuel control
cable (25).
+ Make matchmarks before removing the lock
nut.
13-20
11. Drive shaft

Remove rear drive shaft (26).
* Make matchmarks on the coupling before
removing.
12. Transmission support

Set support @ under transmission.
+ Set the support securely so that it does not slip
out of position.
+ Adjust the support to the correct height.
13. Torque Converter

Sling engine then remove bolts (27) connecting
engine and torque converter.
14. Muffler, air cleaner

Remove the muffler (28) and the air cleaner (29).
Muffler: 23.0 kg
Air cleaner: 16.0 kg
13-21
15. Engine
1) Remove engine oil drain valve (30).
2) Remove mounting bolts (31). Lii off engine

(32).
+ Be careful not to damage the fuel tank
breather tube and engine oil drain hose
when removing.
Engine: 587 kg
13-22
ENGINE
INSTALLATION
1. Engine
1) Sling engine (32), set in mounting position and
tighten mounting bolts (27) of engine and
torque converter uniformly.
+ Confirm that o-ring fitted to the torque
converter contact surface.
0 O-ring circumference: Soapy water.
+ When connecting the engine to the torque

converter, adjust the height so that the
torque converter pilot goes in smoothly. Do
not try to force it in.
2) Tighten rear mounting bolts.

t Fit the rubber cushion securely in the
bracket groove.
+ Position the engine correctly.
D Mounting bolt: 76.Ok8.5 kgm

Mounting bolt: 32 mm
L12AD040
3) Install engine oil drain valve (30).
13-23
2. Muffler, air cleaner

Set muffler (28) and air cleaner (29) in InorUIitin ‘g
position, then tighten mounting bolts.
3. Transmission sup ort

Remove support 8I from under transmission.
+ Remove the support carefully.
4. Drive shaft
Align matchmarks and install rear drive shaft (26).
Mounting bolt: 7.0+0.5 kgm

Install fuel control cable (25) align matchmarks, then
tighten lock nut (24).
* For details of adjusting the length of the fuel
control cable, see Testing and Adjusting.
Rod end: 1.2-1.5 kgm
13-24
ASSEMBLY AND ASSEMBLY ENGINE
6. Fuel hose
1) Connect hose (23) between fuel tank and water
filter to fuel tank.
2) Connect hose (22) between fuel tank and
injection pump to fuel tank.
7. Electric wiring
Connect the following electric wiring.
0 Connect connector of fuel cut-off solenoid and
engine oil level sensor, and engine oil pressure
sensor.
l Connect connector (21) of water temperature
sensor.
0 Connect wires (18,19, and 20) to the alternator.
0 Connect connector (17) of safety relay.
0 Connect cable (16) between starting motor to
battery relay.
Radiator
Raise radiator (13) and stop 20 cm above mounting
position.
+ Be careful not to damage the radiator core.
+ Insert the radiator carefully from the counter-
weight side.
13-25
9. Cooler piping
1) Keep radiator 20 cm above mounting position
and connect cooler hoses (14 to 15).
t Install the hoses without twisting or interfer-
ence.
+ After connecting the hoses, install the
clamp.
D Tightening torque of hose nut: 2025 kgm
2) Set radiator (13) in mounting position, then

+ Install the cooler hose clamp.
+ Install so that the clearance from the fan is
uniform.
Mounting bolt: 25.0 -31.5 kgm
10. Radiator hoses

1) Connect radiator hoses (10, 11, and 12) to
engine.
2) Connect sub-tank hoses to radiator.
11. Electric wiring

Connect wiring (9) of radiator water level sensor to
connector.
12. Fan guard

Install fan guard (7) and radiator support (8).
* Install so that the clearance between the fan
guard and fan is uniform.
Radiator support mounting bolt: 11 t 1.O

D kgm
13-26
13. Hood
1) Raise hood (6), set in mounting position, then
l Stop the hood about 10 cm above the
mounting position and install cable.
2) Install exhaust pipe and radiator grille.
3) Remove safety bolt.
14. Refilling with water

Tighten drain valve and add water through water
filler (29) to the specified level.
+ Run the engine to circulate the water through
%P Coolant: 484
13-27
DISASSEMBLY AND ASSEMBLY FUEL TANK
FUEL TANK
REMOVAL

1. Radiator grille
Remove radiator grille (1).
A Open the hood and apply the lock.
2. Draining fuel
Loosen drain valve (2) and drain fuel.
Fuel: 2004
3. Drain valve
Remove engine oil drain valve (3) from fuel tank.
4. Fuel tubes, wiring

1) Disconnect fuel hoses (4 and 5) from fuel tank.
2) Disconnect wiring (6) for fuel unit from connec-
tor.
5. Fuel tank
1) Sling fuel tank (7), remove mounting bolts, then
lift off fuel tank.
+ Lay a pallet below the fuel tank, keep the
tank balanced and lower slowly.
Fuel tank: 130 kg
2) Pull fuel tank out from under machine.

+ Be careful not to let the breather tube hit
the machine body.
13-28
DISASSEMBLY AND ASSEMBLY FUEL TANK
FUEL TANK
INSTALLATION
1; Fuel tank
1) Set fuel tank on pallet, then pull in to below
mounting position.
+ Be careful not to let the breather tube hit
the machine body.
2) Raise fuel tank (7) set in mounting position,
then tighten mounting bolts.
+ When raising the fuel tank, keep it horizon-
tal and set in the mounting position.
t Tighten the mounting bolts in the following
order: Left, Rear, Right.
Mounting bolt: 95 2 10 kgm

2. Fuel tubes, wiring, clamp

1) Connect wiring (6) for fuel unit to connector.
2) Connect fuel hoses (4 and 5) to fuel tank.
3. Drain valve
Install engine oil drain valve (3) to fuel tank.
4. Hood
Release lock and close hood.
5. Grille
Install grille (1).
6. Refilling with fuel

Tighten drain valve and add fuel through fuel filler
(6).
%b Fuel: 2004
ENGINE
14 MAINTENANCE STANDARD
ENGINEMOUNT . . . . . . . . . . .. . . . .. . .. .. . . . . .. . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . 2
RADIATOR AND TORQUE CONVERTER OIL COOLER . . . . . . . . . . . . . . . . .. . . , . . . . . . . . . . . .. . .. 3
14-1
MAINTENANCE STANDARD ENGINE MOUNT
ENGINE MOUNT
OUTLINE
l The engine, torque converter, and transmission are 1. Transmission mount
joined together. 2. Engine mount
l There are rubber mounts at the engine end and
transmission end.
A-A
L12AD039
MAINTENANCE STANDARD RADIATOR & OIL COOLER
RADIATOR AND TORQUE CONVERTER OIL COOLER

1. Radiator
2. Fan Guard Specifications
3. Torque converter oil cooler Core type: G6 type
4. Sub tank Total heat dissipating area: 45.44 m*
5. Filler cap Cross-sectional area of water tubes: 110 cm*
6. Coolant level sensor
F2
._ 3
____
yi:
IL i\, __A--
;;I” L
I
c
--- ._- __-
3
L06AH030
14-3
POWER TRAIN
21 STRUCTURE AND FUNCTION
GENERAL
HYDRAljili=‘CiRCUITFOk’POWEdikkir;l’:::::::::::::::::::::::::::::::::::::::::::::: :
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN ...................................... 7
TORQUE CONVERTER AND TRANSMISSION PIPING ......................................... 8
TORQUE CONVERTER CHARGING PUMP. ................................................. 9
TORQUE CONVERTER . . .. . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TORQUE CONVERTER OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
TRANSMISSION .................................................................... 12
CLUTCHPACK .................................................................. 14
FORWARD AND REVERSE CLUTCH ............................................... 14
lST,3RDCLUTCH ............................................................ 14
2ND,4THCLUTCH ............................................................ 15
CONTROLVALVE ................................................................ 16
SOLENOIDVALVE ............................................................... 17
UPPERVALVE .................................................................. 18
LOWER VALVE.. ................................................................ 19
PRIORITY AND MAIN REGULATOR VALVE ............................................. 20
MAIN REGULATORVALVE ......................................................... 21
TORQUE CONVERTER OIL OUTLET VALVE ............................................ 22
PILOTREDUCINGVALVE .......................................................... 23
SOLENOIDVALVE ............................................................... 24
FILLVALVE .................................................................... 25
MODULATING RELIEF VALVE, ACCUMULATOR VALVE, QUICK RETURN VALVE ................. 27
DIRECTIONALSPOOL ............................................................ 31
EMERGENCYMANUALSPOOL ..................................................... 32
PILOTOILFILTER ............................................................... 33
AXLE MOUNT...................................................................... 34
AXLE ............................................................................ 36
FRONT ........................................................................ 36
REAR.. ....................................................................... 37
DIFFERENTIAL . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . .. 38
FINALDRIVE . . . . . . . . .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
TIREANDWHEEL _................................................................. 40
21-1
STRUCTURE AND FUNCTION GENERAL
GENERAL
419FOO3
Outline
l The power from engine (1) passes from the flywheel l The power from the transmission output shaft is
through the ring gear and is transmitted to torque then sent to the front and rear axle.
converter (2). The torque converter uses oil to The power for the front axle passes through center
convert the transmitted torque to correspond to drive shaft (12) and front drive shaft (10) and is
changes in the load. It transmits the power to the transmitted to front axle (7); the power for the rear
transmission input shaft. In addition, the power from axle passes through rear drive shaft (14) and is sent
the engine passes through the pump drive gear of to rear axle (18).
the torque converter and is sent to the hydraulic 0 The power transmitted to front axle (7) and rear axle
and steering pump (3), and torque converter charg- (18) is reduced by the pinion gear and ring gear of
ing pump (4) to drive these pumps. differential (8). It then passes from the differential to
l Transmission (5) has six clutches which are ac- the sun gear shaft (axle shaft) of final drive (15).
tuated hydraulically by operating the solenoid valve l The power of the sun gear is reduced by a plane-
to move the directional spool and range spool of tary mechanism and is transmitted through the
the control valve. The transmission has a speed planetary hub to the wheel.
selection of four FORWARD and four REVERSE
speeds. The speeds are selected manually.
21-2
This page is blank.
21-3
3 4
\ \
1419FOO4
21-4
1. Engine 8. Differential (Front) 15. Final drive

2. Torque converter 9. Brake (Front) 16. Brake (Rear)
3. Hydraulic pump and steering pump 10. Front drive shaft 17. Differential (Rear)
4. Torque converter charging pump 11. Flanged bearing 18. Rear axle
5. Transmission 12. Center drive shaft 19. Rear wheel
6. Front wheel 13. Parking brake
7. Front axle 14. Rear drive shaft
21-5
HYDRAULIC CIRCUIT FOR POWER TRAIN
(Engine low idling, F-R lever at neutral, speed lever at 4th)
27
4
1(
UmI
28
)(
29
uII0
)(
r
p 30
L
L
Y” )(
77 18
L
i” )(
31
mn
- ! 4 I9F504
21-6
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN
Lb
L)(@ 1.6
IYA rl X
3.25 t 0.25 kg/cm*
L L1ouol3
1
1. Transmission case 12. Torque converter 23. 3rd, 4th solenoid valve
2. Strainer 13. Torque converter oil outlet valve 24. 1st 4th solenoid valve
3. Torque converter charging pump 14. Oil cooler 25. REVERSE solenoid valve
4. Lubricating pump 15. Transmission clutch lubricating 26.’ FORWARD clutch
5. Torque converter oil filter 16. Brake valve 27. REVERSE clutch
6. Direction clutch lubricating 17. Accumulator 28. 4th clutch
7. Priority valve 18. Charge valve 29. 3rd clutch
8. Pilot reducing valve 19. Emergency manual spool 30. 2nd clutch
9. Quick return valve 20. Directional spool 31. 1st clutch
10. Main regulator valve 21. Speed spool 32. Pilot oil filter
11. Fill valve 22. FORWARD solenoid valve 33. Accumulator valve
21-7
STRUCTURE AND FUNCTION TORQUE CONVERTER AND TRANSMISSION PIPING
L07CM003
1. Transmission 5. Torque converter charging pump

2. Torque converter oil filter 6. Transmission control valve
3. Torque converter 7. Charging valve
4. Torque converter oil cooler
21-8
STRUCTURE AND FUNCTION TORQUE CONVERTER CHARGING PUMP
TORQUE CONVERTER CHARGING PUMP

Outline
l The torque converter charging pump is installed l The torque converter charging pump sucks in oil
to the torque converter case. It is driven by power through a strainer from the bottom of the trans-
from the engine and supplies oil to the torque mission. The oil from the front pump is sent to the
converter and transmission system. torque converter oil filter. The oil from the rear
pump enters the lubrication ports through the
charge valve for brake valve, and lubricates the
FORWARD and REVERSE clutches of the trans-
mission.
(1
Section A-A 419FOOS

Torque converter Directional clutch
charging pump lubrication pump
I
i
SAL(2)-040 SAL(2)-020
1. Front cover Specifications:

2. Drive gear (12 teeth) Type: Sal(2)-040 (Front pump)
3. Gear case Theoretical delivery: 40.2 cc/rev
4. Rear cover Max. delivery pressure: 210 kg/cm2
5. Front cover Max. speed 3000 rpm
6. Gear case
7. Drive gear (12 teeth) Type: SAL(2)-020 (Rear pump)
8. Rear cover Theoretical delivery: 20.2 cc/rev
9. Driven gear (12 teeth) Max. delivery pressure: 210 kg/cm2
10. Driven gear (12 teeth) Max. speed: 3000 rpm
21-9
STRUCTURE AND FUNCTION TORQUE CONVERTER
TORQUE CONVERTER
E419F012
1. Turbine
2. Drive case 6. Housing Specifications:
7. P.T.O. gear (Drive) Model: TCA32-2A
3. Stator
8. Pump Type: 3-element, single stage, single phase
4. Pilot
5. Stator shaft 9. Transmission input shaft Stall torque ratio: 2.7
21-10
STRUCTURE AND FUNCTION TORQUE CONVERTER
TORQUE CONVERTER OIL FILTER

1. Relief valve
2. Element
3. Center bolt
4. Drain plug
Filtration area: 8,900 cm2

Relief pressure: 3.25 kg/cm2
To transmission
419FOO9 control valve
Operation
0 The oil from the torque converter charging pump
(5) enters the filter inlet port A and passes from
the outside of element (2) to the inside. It then
flows to the outlet port B.
419FOlO
l If the element (2) is clogged with dirt, or the oil e To transmission

control valve
temperature is low, the pressure at the inlet port
rises. When this happens, the oil from the inlet
port A opens relief valve (1) and flows directly to
the outlet port. This prevents damage to the pump
or filter element (2).
- 419FOll
21-11
STRUCTURE AND FUNCTION TRANSMISSION
TRANSMISSION
SectionB-B
1. TOROUE CONVERTER CHA?GING PUMP

2. TRANSNISSION VALVE
3. OIL FILLER
4. TORQUE CONVERTER OIL FILTER
5. STRAINER
6. PP.RKING BRAKE CALIFER
7 OIJTFUT COlJPLlhG
21-12
L07CR027
Outline
8. Reverse clutch 16. 4th clutch
l The transmission consists of a 4-FORWARD, 4-
9. Forward clutch 17. Rear coupling
REVERSE speed transmission and transmission
10. Torque converter 18. Output shaft valve.
11. Input shaft 19. Reverse idle gear l In the transmission, the power of the input shaft is
12. 1st - 3rd shaft 20. Parking brake
changed by the combination of No. 1 or No. 2
13. 1st clutch disc
clutch with No. 3, 4, 5 or 6 clutch to give FOR-
14. 3rd clutch 21. Front coupling WARD 1 - 4 or REVERSE 1 - 4 speed, and is tran-
15. 2nd - 4th shaft 22. 2nd clutch
smiyted to the output shaft.
21-13
CLUTCH PACK
FORWARD AND REVERSE CLUTCH
1 2 3 4 5 6 7 8
1. Thrust washer 5. Forward and reverse cylinder a. Forward clutch oil port
2. Thrust bearing 6. Forward clutch b. Reverse clutch oil port
3. Reverse gear 7. Forward gear c. Lubricating oil port
4. Reverse clutch 8. Input shaft
lST, 3RD CLUTCH
u41901070
L.__J
1. 1st, 3rd shaft 6. 3rd clutch 1st clutch oil port

2. Idler gear 7. 3rd gear ;::3rd clutch oil port
3. 1st gear 8. Thrust bearing C. Lubricating oil port
4. 1st clutch 9. Thrust washer
5. lst, 3rd cylinder
21-14
2ND, 4TH CLUTCH
u41901071
1. Idler gear 6. 2nd, 4th shaft 2nd clutch oil port

2. 2nd gear 7. 4th gear :: 4th clutch oil port
3. 2nd clutch 6. Thrust bearing C. Lubricating oil port
4. 2nd and 4th cylinder 9. Idler gear
5. 4th clutch
21-15
CONTROL VALVE
-I!
h
U41901008
1. Emergency manual valve a. To cooler

2. Solenoid valve b. From pump
3. Pilot pressure check plug
4. Upper valve
5. Lower valve
6. Pump pressure check plug
7. Clutch pressure check plug
21-16
SOLENOID VALVE
Section B-B u41901009

Section A-A
1. Connector 5. Reverse solenoid valve

2. Valve body 6. Forward solenoid valve
3. lst, 4th solenoid valve 7. Emergency manual spool
4. 3rd solenoid valve 8. Lock plate
STRUCTURE
l The transmission solenoid valve is installed to the is operated, the solenoid valve is actuated and moves
transmission together with the transmission valve. the spool inside the transmission valve.
When the directional lever or speed control lever
21-17
UPPER VALVE
Section A-A
1. Upper valve body 9. Check valve

2. Main regulator valve 10. Lower valve body
3. Pilot reducing valve 11. Torque converter oil outlet valve
4. Priority relief valve 12. FORWARD and REVERSE spool
5. Fill valve pressure adjusting screw 13. HIGH and LOW spool
6. Modulation fill valve 14. Speed range spool
7. Accumulator valve 15. Solenoid valve
8. Quick return valve 16. Emergency manual spool
21-18
LOWER VALVE
,lO
,11
lb--
.12
15\ .13
14
Section B-B
Outline
The oil from the pump passes through the torque l The pressure of the oil which flows to the circuit is
converter oil filter, enters the transmission valve, adjusted by the pilot reducing valve. During gear
and is divided into the pilot circuit and the clutch shifting, the oil flows in accordance with ON-OFF
actuation circuit. position of the solenoid valves and actuates the
The priority valve gives priority to the oil sent to FORWARD, REVERSE and speed spools.
the pilot circuit, so the pilot pressure is always 0 By switching the FORWARD, REVERSE, and
kept the same. speed spools, the oil regulated by the modulating
The pressure of the oil flowing to the clutch actua- valve is sent to the selected clutch to obtain the
tion circuit is adjusted by the modulation valve necessary gear combination.
and actuates the clutch. The oil which is relieved
is sent to the torque converter.
The quick return and modulating valve are inter-
connected 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.
21-19
PRIORITY AND MAIN REGULATOR

VALVE To lower valve To torque
*
converter
1 B
Function
l The priority valve gives priority to the oil sent to
the pilot circuit of the lower valve. It also acts as a
main relief valve to maintain the maximum pres-
sure at the specified level.
Operation
l The oil from the pump enters port “a”. It passes
through pilot reducing valve (1) and is divided into
oil which flows to the pilot circuit of the lower
valve and oil which flows to priority valve (2).
~~:~ u41901019
To lower valve To torque converter

l The oil which flows to priority valve (2) passes t 6
though orifice (3) and flows to port “b”.
As a result, it pushes spring (4) and moves priori-
ty valve (2) in the direction of the left, so the oil
flows to port “c”.
I I 8 I I
To accumulator valve
U41901020
To lower valve TO torque converter
t _Q
l When the hydraulic pressure at port “b” goes

above the specified pressure, priority valve (2)
moves further to the left. The oil is drained from
port “d” to protect the circuit.
(Main relief function)
From
cooler
To accumulator valve
U41901021
21-20
Function To torque
To lower valve converier
l The main regulator valve controls the amount of
t 0
oil that flows to the clutch circuit. It sends any
excess oil to the torque converter circuit.
a
Operation
0 The oil from the pump enters priority valve (1). It
then flows from port “a” through main orifice (2)
and fills the clutch circuit.
XJ 181
TO accumulator valve
u41901022
5 4b
To lower vatw / /
l The oil which passes through orifice (4) and en-

ters port “b” acts against spring (5) and moves
the spool to the left. It then passes through port
“c” and flows to the torque converter circuit.
&l&&q 11 To accumulator
l valve
’ ’
21-21
TORQUE CONVERTER OIL OUTLET

VALVE
Function
l The torque converter oil outlet valve is installed at
the outlet side of the oil flow from the torque con-
verter and functions to limit the maximum pres-
sure of the oil inside the torque converter.
TO cooler
From torque
converter
c
Operation
l The oil, flowing out the torque converter and en-
tering chamber “c” through the orifice in spool (1)
acts against spool (1).
l When the pressure at port “a” becomes high, the

oil pressure in chamber “c” also becomes high.
Spool (1) moves in the direction left as the oil
pressure becomes high enough to overcome the
force of the spring, and the oil then flows from
port “a” to port “b”.
TO cooler
0 When the increasing pressure at port “a”, spool

(1) moves further in the direction of left and oil
port “a” opens to drain port “d” through port “b”
(this is called a “cold relief”).
21-22
PILOT REDUCING VALVE
Function
l The pilot reducing valve regulates the pressure
use to actuate the transmission spools.
Operation
l The oil from the pump enters port “a”. It passes
through port “b” bf piiot reducing valve (l), and
enters transmission spool (2) of the lower valve to
fill the pilot circuit. The oil at port “b” passes Lower valve
b
Pilot filter
through orifice (3) and goes to port “c”. 3 1
//
From pump
u41901015
l As the pressure in the pilot circuit rises, the hy-

draulic pressure at port “c” also rises. It pushes Lower valve
against spring (4) and moves pilot reducing spool
(2) in the direction of the right. Port “a’ and port
“b” are shut off, so the pressure at port “c” is mai-
ntained at the same level.
From pump
U41901016
21-23
SOLENOID VALVE
Pilot filter
Function
l There are four solenoid valves installed to the fl
transmission control valve. When the gear shift
lever in the operator’s compartment is operated,
the solenoid valves are switched ON/OFF. This
drains the oil and actuates the speed spool.
Operation
1) Solenoid valve OFF
The oil at ports “a” and “b” of speed spools (1 and
2) is sealed by solenoid valves (4 and 5). Pilot
reducing valve (3) is closed, so the condition is
maintained. As a result, the oil flows only to the
second clutch.
2nd clutch
Pilot
filter
2) Solenoid valve ON
When the gear shift lever is operated, the drain
ports of solenoid valves (4 and 5) open. 4
The oil at ports “a” and “b” of speed spools (1 and
2) flows from ports “c” and “d” to the drain circuit.
Therefore, ports “a” and “b” become the low pres-
sure circuit, and spring (6) moves the speed
spool to the left.
As a result, the oil at port “e” flows to the 4th
clutch and the clutch is engaged.
I
:.:
:::
d
hl&all
4th clutch
:::
::: .I;!.
>:
U41901018
21-24
FILL VALVE
Function
l The fill valves adjust the pressure of the oil enter-
ing the accumulator and the flow of the oil, and
allows the clutch pressure to rise.
C
I I I I
O 0 0.5 1.0 1.5 (set)
u41901502
Operation
1. Clutch fully engaged (point “a”)
To F-R spool To torque converter
rom torque
Onverter
et valve
rom 2nd
rifice
rom 3rd
rifice
To F-R spool To torque converter

2. When shifting from FORWARD to REVERSE t Q
(point “b”)
l The oil inside the accumulator is drained by
the quick return valve and moves accumulator
piston (1) to the left.
When this happens, the pressure in chamber
“c” and chamber “d” drops, so the force of
spring (2) moves fill valve (3) to the right and
opens port “a”.
u41901034
i
21-25
3. Start of rise in clutch pressure (point “c”- point ToF-R spool TO torque converter
“d”) * f
l When the oil from the pump fills the clutch
piston, the pressure in the clutch circuit start
to rise. As a result, 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 the pressure P3 in
chamber “d” start to rise. When this happens,
the relationship between PI and P2 is PO > Pi
+ P3 (tension of spring [2]). The fill valve
moves to the left, and port “a” is shut off, so
this prevents any sudden rise in the clutch
pressure.
To F-R spool To toraue converter
l The oil from port “b” flows to the directional spool,

and at the same time, because of the condition Pp
> PI, the oil also passes through the orifice in the
quick return valve and flows to chamber “c”. PI
and P3 both rise, and the relationship is P3 = P1
+ P3 (tension of spring [2]). This action is repeat-
ed to raise the clutch pressure.
l The oil from the oil cooler circuit is sent to the fill
valve and flows to port “e”. The pressure at port
“e’ changes according to the engine speed. Ther-
efore because of the relationship P3 = PI + P3 f
P4 (changed according to engine speed), the
pressure of Pp changes also by the same amount
as the change in pressure of P4. Therefore, the
pressure of P3 rises by the same amount as the
change in the pressure of P4 at the same time, so
it is possible to create pressure characteristics
corresponding to the engine speed.
21-26
MODULATING RELIEF VALVE,

ACCUMULATOR VALVE,
QUICK RETURN VALVE
Function
l The modulating relief valve and quick return valve
act together to raise the transmission clutch pres-
sure smoothly. This reduces shock when shifting
gear, and prevents the generation of peak torque in
the power train. Therefore, operator fatigue is
reduced to give better operating comfort, and at the
same time, the durability of the power train is
increased.
Operation 01
1) FORWARD clutch completely engaged (clutch 0 0.5 1.0 1.5 kec)
pressure point A on Fig. U41901501) u41901501
Torque converter
I n I
Forward clutch
...:...:
,.... ........:.::..::.
To speed spool
......_........
......._.................. (. ., ,(,,:,
,.,..............:.:.:..,.,.....
::.
:::
.:.
:.:
.:.
.................................................:.:
..
=Fl
er
1
u41901024
21-27
2) Immediately after from FORWARD to REVERSE

(clutch pressure point B on Fig. U41901501).
Torque converter
_,
...............&i
F:c L
...................~........................................................................
9
Oil cooler r
u41901025
When the directional lever is moved from FOR- l Accumulator (8) returns to the left end under the
WARD to REVERSE, FORWARD solenoid valve (1) force of spring (9).
closes and REVERSE solenoid valve (2) opens. To make the shock small when shifting gear, the oil
Directional spool (3) moves to the right, and the oil pressure in the clutch circuit drops, and accumula-
at FORWARD clutch (4) is drained to the drain tor (8) must be at the left end.
circuit.
At the same time, the oil from the pump flows to
REVERSE clutch (5), but while the clutch is filling
with oil, the pressure at the clutch is low.
For this reason, the pressure at port “a” of quick
return valve (6) is low, check valve (7) opens, and
the oil at port “b” flows to port “a”. At the same time,
the accumulator pressure moves quick return valve
(6) to the left, so the oil in accumulator (8) is sud-
denly drained from port “c”.
21-28
3) Clutch pressure rising (clutch pressure point C on

Fig. U41901501).
Torque converter
Forward clutch
U41901026
l 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, quick return
valve (6) moves to the right and drain port “c” is
closed.
21-29
4) Clutch engaged (clutch pressure point D .on Fig.

u41901501).
Torque converter
Forward clutch
u41901027
l Because of the differential pressure created by fill l When accumulator piston (8) moves to the end of
valve (1 l), the oil passing through 1st orifice (10) its stroke, the rise in pressure at port “d” stops. The
flows to accumulator piston (8) at a constant flow. specified pressure is maintained and the REVERSE
As this oil flows in, the accumulator moves gradual- clutch is fully engaged. This action is the same
ly to the right and compresses spring (9). As a action as when the speed spool is operated.
result, the accumulator pressure rises. At the same
time, the clutch pressure also rises.
l For speeds other than 1st speed, oil flows into the
accumulator from 1st orifice plus 2nd and 3rd
orifices, so the modulation time is shorter than for
1st speed.
21-30
DIRECTIONAL SPOOL
From pilot circuit
Operation
1) At neutral A!
l Solenoid valves (4 and 5) are OFF, and the
drain port is closed. The oil from the pilot circuit
passes through the oil hole in the emergency
manual spool, and fills ports “a” and “b” of the
directional spool.
l In this condition, P1 + spring force (1) = Ps +
spring force (2), so the balance is maintained.
Therefore, the oil at port “c” does not go to the
FORWARD or REVERSE clutches.
From pilot circuit
1
2) At FORWARD
l When the directional lever is placed at FOR-
WARD, solenoid valve (4) is switched ON, drain
port “d” opens and the oil which was filling port
“a” is drained. As a result, PI + spring force (1)
c Pp + spring force (2), so the directional
4,
spool moves to the left. The oil from port “c”
flows to port “d” and is supplied to the FOR-
WARD clutch. CL
p&J U41901032
21-31
EMERGENCY MANUAL SPOOL
Function From pilot reducing valve

l If there is a failure in the electrical system, and the
FORWARD and REVERSE solenoid valves cannot
be actuated, the emergency manual spool actuates
the FORWARD or REVERSE clutches manually.
Operation
1) Neutral
l The oil from the upper valve (pilot reducing
valve) passes around emergency manual spool
(1) and is sealed by solenoid valves (2 and 3).
l For normal operations, the emergency manual
spool is in the neutral position.
ch
ch
2) Emergency spool actuated (FORWARD)
When emergency manual spool (1) is pushed, port
“a’ and the drain port are connected, so the oil from
chamber “b” is drained. As a result, directional spool
(4) moves to the left, so the oil flows to the FOR-
WARD clutch and the clutch is engaged.
21-32
PILOT OIL FILTER
1. Head
2. Element
3. Case
a. Oil suction port
b. Oil delivery port
Specifications
l Particle size: 105 microns (150 mesh)
l Filtering area: 370 cm*
419FO53
Function
l The pilot oil filter is installed between the upper
valve and lower valve of the transmission control
valve. It removes dirt from the oil flowing to the pilot
circuit.
21-33
STRUCTURE AND FUNCTION AXLE MOUNT
AXLE MOUNT
ir
CY
Section A-A
4 I9F505
21-34
STRUCTURE AND FUNCTION AXLE MOUNT
k-
::
v--
View Z
View Y
4 I SF506
Front axle
1. Front axle l The front axle (1) receives the force directly during
2. Front frame operations, so it is fixed directly to the front frame
3. Rear frame (2) by axle mounting bolts (5).
4. Rear axle
5. Axle mounting bolt Rear axle
6. Pivot l 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.
21-35
STRUCTURE AND FUNCTION AXLE
AXLE
FRONT
u41901303
View Z Outline
1. Filler plug 6. Final drive l The power from the engine passes through the
2. Level plug 7. Axle housing torque converter transmission and drive shaft and is
3. Coupling 8. Axle shaft transmitted to the front and rear axles.
4. Differential 9. Drain plug 0 Inside the axle, the power is transmitted from the
5. Brake pinion gear to the ring gear, and is sent at right
angles. The speed is reduced and it passes through
the differential and is transmitted to the sun gear
shaft.
l The power of the sun gear is further reduced by the
planetary-type final drive, and is transmitted to the
axle shaft and wheel.
21-36
STRUCTURE AND FUNCTION AXLE
REAR
ur-/ -i I
I
I
1. Filler plug
2. Level plug
3. Coupling
4. Differential
5. Brake
6. Final drive
u41901304 7. Axle housing
8. Axle shaft
View 2
9. Drain plug
21-37
STRUCTURE AND FUNCTION DIFFERENTIAL
DIFFERENTIAL
* Illustration shows for front axle.
1. Side gear (Differential)

2. Pinion (Differential)
3. Spider
4. Bevel gear
5. Sun gear shaft
6. Pinion gear
21-38
STRUCTURE AND FUNCTION TIRE AND WHEEL
TIRE AND WHEEL

The tire acts to absorb the shock from the ground
surface to the machine, and at the same time they
must rotate in contact with the ground to gain the
power which drives the machine.
Various types of tires are available to suit the
purpose. Therefore it is very important to select the
correct tires for the type of work and bucket
capacity.
E423F070
1. Tire Specifications
2. Side ring Tire size: 17.5 x 25 - 12PR
3. Lock ring TRA code: L2
4. Rim Wheel size: 14.00 x 24
5. Air valve Air pressure: 2.8 kg/cm*
21-40
POWER TRAIN
STANDARDVALUETABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
TOOL LIST FOR TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINESTALLSPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 6
SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TIREANDWHEEL .................................................................. 12
TROUBLESHOOTING ................................................................ 13
PRECAUTIONS WHEN TROUBLESHOOTING ............................................ 14
METHOD OF READING TROUBLESHOOTING TABLES ..................................... 16
PREVENTING RECURRENCE OF TROUBLE 18
CHECKSBEFORETROUBLESHOOTING. ..:::::::::::::::::::::::::::::::::::::::::::: 19
JUDGEMENT ON POWER TRAIN .................................................... 20
TROUBLESHOOTINGTABLE ........................................................ 22
1. Machinedoesnotmove ......................................................... 22
2. Machine speed is low, thrust is weak, gradeability falls off. ............................... 24
3. Large shock when moving off or changing gear. ....................................... 26
4. large time lag when moving off or changing gear. ..................................... 27
5. Oil temperature in torque converter is high. .......................................... 28
+ The following precautions are necessary when using the Standard Value Table to make judgements during
1. The values in these tables are based on the values for new machines leaving the plant, so they should be
used as target values when repairing or when estimating wear after a period of use.
2. The standard values in these tables for judgement when troubleshooting are estimated values based on the
standard values for the machine when shipped from the plant, and on the results of various tests. Therefore,
they should be used as reference in combination with repair and operating records when making
judgements.
3. These standard value tables must not be used for standard values when judging claims. In addition, do not
use these values alone to make simple judgements.
22-1
Classifi-
cation
Item
N-F
I Condition
Dnit Standard
value
Permissible
value
Operating
FORWARD- force I- N-R ti
REVERSE
control lever N-F
Stroke
N-R
1st-2n l Torque converter oil
temperature: 80 - 80°C
I 0.3-0.9 I Max. 1.4
Operating
2nd3r l Engine speed: Low idling
force t
Speed
control lever
I 32-42 I 27-47
mm 1 32-42 1 27-47
I 32-42 2747
rpm~
I
Torque converter stall

0 Coolant temperature:
Inside operating range
Engine speed Hydraulic stall
l Hydraulic temperature:
45-55” c
Full stall
Main regulator pressure

Priority oil pressure I 23?2 I 23&2
Oil
pressure
Pilot reducing pressure l Engine speed: High idling
I lo?1 I 1o+l
-2
of torque All clutch oil pressure Inside operating range
converter
l Torque converter oil
and
Lubrication oil pressure temperature: 80-80” C
transmission
Torque converter outlet
port oil pressure (T/C
stall)
l Tire inflation pressure:
Fitting of
wheel lock
A Specified pressure
I Max. 2.5
I
Tire and ring

B mm Max. 4.5
wheel
I
I I
I
Clearance of
wheel lock C 1 2-12 1
ring L15AR007
22-2
TOOL LIST FOR TESTING AND ADJUSTING

For er fine
No. Check item Tool Part number Remarks
Digital display
Multi-tachometer 799-203-8000
Engine speed L: 60 - 20,000 rpm
Drive, mech tach El 9014 (Cummins part)
H: 60 - 19,999 rpm
Water, oil and

Thermistor kit 799-l 016000 0 - 200°C
intake temperature
Oil pressure Hydraulic tester D 799-l 01-5000 0 - 25 kg/cm2
Compression 795-502-l 590 0 - 70 kg/cm2

Compression pressure
gauge, adapter 795-502-l 330 KIT NO. 795-502-l 205
Blow-by checker 799-201-l 503

Blow-by pressure 0 - 1000 mmH20
Pipe tee 3375788 (Cummins part)
Valve clearance Feeler gauge Commerciallv available 0.30, 0.61 mm
Discoloration 0 - 70% with

standard color
Exhaust gas color Smoke checker 799-201-9001
(Discoloration % x 1/lO =
Bosch index)
For chassis
No. Testing and measuring item Tool Part number Remarks
Digital display
1 Engine speed Tachometer 799-203-8000
60 - 19,999 rpm
2 Oil temperature Thermistor kii 799-l 016000 0 - l,ooo”c
0 - 25 kg/cm2
3 Oil pressure Hydraulic tester 799-l 01-5000 0 - 300 kg/cm2
0 - 50 kg/cm2
4 Operating force Push-pull gauge 7AO-262-0020 0 - 25 kg

I I I I
5 Measuring clearance Feeler gauge Commercially available 0.1-3.0 mm
6 Brake pedal operating force Push gauge 799-101-1001 O-110 kg
7 Brake oil pressure Hydraulic tester 793-605-l 001 O-100 kg
8 Thickness of pad Vernier calipers Commerciallv available 150-200 mm
9 Brake distance Tape measure Commercially available 30 m

- 10 Operating time Stop watch Commercially available 1/l 0 second
11 Measuring travel Convex scale Commercially available O-2 m
22-3
TESTING AND ADJUSTING ENGINE STALL SPEED
l Coolant temperature: Inside operating range
l Hydraulic oil temperature: 45 - 55°C
l Torque converter oil temperature: 60 - 80°C
Unit: rom
Item
value value
Engine speed
Low idling 740840
High idling 2485-2585
Torque con-
2290-2490 2190-2590
verter stall
Hydraulic stall 2320-2520 2220-2620
Full stall 1680-2080 1580-2180
Soecial tools
Part number Part name Q’tY
A 799-203-8000 Tachometer 1
B 799-l 01-6000 Thermistor kit 1
Drive, mech
El 9014 (Cummins) 1
tach
03907455 Hub 1
03903475 Seal 1
0 3918215 Cover 1
1 l 3914132 Adapter 1
I 0 62392 I Washer I 2
I 0 3027685 I Screw I 2
.3915800 Gasket 1
t Check that the low idling and high idling speeds are
within the standard value.
a Before measuring the stall speeds, install adapter
(1) and other parts on the engine speed output
portion of engine rear side, then connect tacho-
meter A.
22-4
TESTING AND ADJUSTING ENGINE STALL SPEED
t Check that the engine speeds are within the stan-

dard value. If any item is outside the permitted
range, check for any looseness for play in the
linkage.
A Apply the parking brake and block the tires.
1. Measuring torque converter stall

1) Start engine and run at low idling.
2) Put the directional lever (2) in FORWARD or
REVERSE, and speed control lever in the
highest speed range.
3) Using the brake, stop the machine and measure
the engine speed when the engine reaches high
idling.
+ Turn the transmission cut-off valve switch
(3) to OFF and use the left brake. (Check
that the pilot lamp is OFF)
+ Do not run at stall speed for more than 20
seconds, and do not let the torque convert-
er oil temperature rise above 120°C.
2. Measuring hydraulic stall

1) Start engine and run at high idling.
2) Operate the dump (4) or lift lever (5) to move
the cylinder to the end of its stroke and actuate
the relief valve of the main control valve.
3) Measure the engine speed at this point.
+ Do not run the engine at stall speed for
more than 20 seconds, and operate the
control lever quickly
3. Measuring full stall

Measure the engine speed when torque converter
stall and hydraulic stall are reached at the same
time.
+ Measure full stall when both the torque
converter and hydraulic stall speeds are normal.
If either stall speed is abnormal, remove the
abnormality and measure the stall speed again.
22-5
TESTING AND ADJUSTING TORQUE CONVERTER AND TRANSMISSION
MEASURING OIL PRESSURE OF

TORQUE CONVERTER AND
TRANSMISSION
t Measurement condition
l Torque converter oil temperature: 60 - 80°C
nit: kg/cm2
Standard Permissi-
Item
value ble value
Priority oil pressure 23+2 23-t2
Main regulator pressure 25-c2 25&2
Pilot reducing pressure 1021 1o+l

-2
All clutch oil pressure 23+2 23+2

-4
Lubrication valve oil

1.2kO.3 1.2kO.3
pressure
Torque converter outlet oil 4 2+0.4

4.220.2
pressure . -0.5
Special tool
Part number Part name QW
A 799-l 01-5000 Hydraulic tester 1
AY
w Apply the parking brake and block the tires.
4
Preparatory work
* The following operations are necessary preparatory
work for all measurements of the hydraulic system.
l Open left inspection cover (1) of the rear frame.
l Turn transmission cut-off selector switch (9) to
the OFF position, and use the left brake.
(Check that the pilot lamp is OFF.)
l Remove the plug from the measuring port of
the transmission valve.
l Install hydraulic test kit A to the measurement
port, pull the gauge to the operators
compartment, then start the engine and mea-
sure the pressure.
22-6
* Check that there is no leakage of oil from any

joints.
* After removing the measurement plug, always coat
the plug with adhesive.
& Plug: Sealing agent &G-l)
agent coating part
2-3mm
1. Measuring main regulator pressure 416F251

1) Measuring port 2.
2) Start the engine and measure the pressure at
IW idling and high idling.
2. Measuring pilot pressure

low idling and high idling.
3. Measuring pressure of all clutches

law idling and high idling.
4. Measuring torque converter outlet port pressure

torque converter stall.
22-7
5. Adjusting modulating time

The modulating time can be made longer or shorter
by adjusting screw (A).
1) Tighten the screw.
2) Loosen the screw. - - -
+ Adjustment range: Within al turn
- -
I
'ns ,
Tome -
u41901038
_
+ Standard length: 6.75 mm

(Turn back to end, then tighten 4-l/2
turns.)
t Do not adjust needlessly, and check the
pressure alter adjusting to confirm that
there is no abnormality
22-8
TESTING AND ADJUSTING SHIFT LEVER
SHIFT LEVER
Unit: kg/cm*
Stan- Permis-
Item dard sible
value value
Oper-
ating 1st-2nd 0.3-0.9 M,;
force I I
Speed
2nd-3rd 0.3-0.9 M,y
lever
364th 0.3-0.9 M,y
Neutral- 32-42 27-47

Direc- Forward mm mm
tional
lever Neutral- 32-42 27-47
Reverse mm mm
Travel
Special tools
Part number Part name 1 Qtv
A 1 79A-264-0020 1 Push-pull scale I 1
799-l 01-6000 Thermistor kii 1
A Be sure to set chocks firmly against the tires.
1. Measuring the lever operating force

1) Stop the engine.
2) Attach push-pull scale A or a spring balancer to
the lever knob at the center and measure the
operating effort required to pull it in the operat-
ing direction.
+ The measurement should be made in each
speed range.
2. Measuring the lever travel

1) Stop the engine.
2) Put mark “1” on the center on the control lever
knob and measure the travel when the lever is
moved in the operating direction.
TESTING AND ADJUSTING EMERGENCY MANUAL SPOOL
METHOD FOR OPERATION OF

EMERGENCY MANUAL SPOOL
Outline
l The transmission valve is controlled electrically but
if there should be any failure in the electrical sys-
tem, or failure in the solenoid valve and spool which
prevents the machine from maving, the emergency
manual spool can be operated to move the ma-
chine.
A This spool if designed to allm the machine to

be mo& from a dangerous jobsite location to
a safe place where it can be repaired in cases
where the machine is unable to move because
of failure in the transmission control. This spool
must not be operated unless 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 Lower the bucket to the ground to prevent the

machine from moving, then apply the parking
brake and block the wheels.
1. Remove inspection panel (1) for checking the

transmission oil level.
A Always stop the engine before operating the

spool.
2. Remove lock plate (2) of the emergency manual

spool of the transmission valve.
3. Move to the operating position of emergency

manual spool (3) according to the direction in which
the machine is to be moved (FORWARD or RE-
VERSE).
l For FORWARD: Push the spool until it
catches in the detent.
(Approx. 8 mm)
l For REVERSE: Pull the spool until it
catches in the detent.
(Approx. 8 mm)
22-10
TESTING AND ADJUSTING EMERGENCY MANUAL SPOOL
4. Check that the area around the machine is safe,

then remove the blocks from under the wheels.
5. Sit in the operators seat, and depress the left brake

pedal fully
6. Start the engine, release the parking brake, then

gradually release the brake pedal to start machine
movement.
A When the engine is started and the trans-

mission is engaged, the MACHINE WILL
MOVE !!!!! Therefore, before starting the
engine, always check that the direction of travel
is safe, and always keep the brake pedal
depressed.
7. After moving the machine, stop the engine, apply

the parking brake, and block the wheels.
8. Return the manual spool to the neutral position,

then install the lock plate.
22-11
TESTING AND ADJUSTING TIRE AND WHEEL
TIRE AND WHEEL

l Tire inflation pressure: Specified pressure
Unit: mm
Item No.
value value
Fitting of wheel Max. 2.5 Max. 2.5

*
lock ring B Max. 4.5 Max. 4.5
Clearance of
C 2-12 2-12
wheel lock ring
Measuring procedure
Tire inflation pressure:
1. Fitting of wheel lock ring Specified pressure
Measure dimensions A and B with a feeler gauge.
2. Clearance of wheel lock ring

Measure dimension C.
L15AR007
22-12
TROUBLESHOOTING
22-13
TROUBLESHOOTING PRECAUTIONS WHEN TROUBLESHOOTING
PRECAUTIONS WHEN TROUBLESHOOTING
1. SAFETY 2) Check the following items which can be

checked simply by visual checks etc.
A l Stop the machine on level ground, and check

that the safety pins and parking brake are
a. Check oil level.
b. Check for leakage of oil from piping or
correctly applied, and that the tires are blocked. hydraulic equipment.
l When working in groups, use agreed signals c. Check travel of control levers.
and do not allw unauthorized persons near the d. Check stroke of spool in control valves.
machine.
l Be careful not to get burned by hot parts or get 3) Reenact the failure and check the condition
caught in rotating parts. of the machine (particular conditions at the
l Always disconnect the cable from the negative time of failure).
(-) terminal of the battery before disconnecting a. Ask the user or operator if the decision
any wiring. about the failure was made based on mea-
sured values, or by comparison, or by
Y & l Always release the pressure before re- feeling.
4 moving the plugs or caps of any place b. Compare extent of failure with standard
under hydraulic or air pressure, and con- values.
nect all measuring tools correctly Elh~i;F safety before carrying out any
2. METHODS FOR TROUBLESHOOTING Do not make any check or measure-

ment that will make the condition
+ Just because a failure occurs, do not im- worse.
mediately start to disassemble the machine.
If the machine is disassembled before making 4) Try to locate the possible causes for the
the proper checks, failure.
l The machine may be disassembled in such The transmission system consists of the trans-
a way that the problem cannot be located, mission itself, the transmission control valve,
so the cause of the problem will be un- and the transmission electric control.
known. In particular, when trouble occurs in the trans-
mission system, the probable location of the
As a result, failure can be divided as follows:
l The customer and operator will lose confidence l Transmission itself, or transmission control
in you. valve,
l Time will be wasted, and unnecessary costs will l Transmission electric control.
be incurred for excess parts and greasing. To decide which of the two is the location of
the failure, go to page 22 - 19.
To avoid these problems, use the following pro-
cedure when troubleshooting. 5) Carry out troubleshooting using the trouble-
shooting charts.
1) Ask the customer and operator the following There are the following two types of trouble-
questions about the breakdown. shooting charts.
a. Have there been any other problems apart
from the one reported? 1. TROUBLESHOOTING TABLE . . . . . . . .
b. Was there anything unusual before the
machine broke down? . . . . . 22 POWER TRAIN
C. Did the breakdown occur suddenly, or had 42 STEERING SYSTEM
there been signs of trouble before? 52 BRAKE AND AIR SYSTEM
d. What was the machine doing when break- 62 WORK EQUIPMENT SYSTEM
down occurred? 82 ELECTRIC AND ELECTRONIC
e. Had the machine been repaired before the SYSTEM
breakdown? If so, who carried out the re-
pair, and when? 2. TROUBLESHOOTING FLOW CHART. . .
f. Had the same kind of failure occurred be- The troubleshooting charts consist of:
fore? 1) Items which can be checked easily
2) Items which are likely to be the cause
of such failures.
22-14
TROUBLESHOOTING PRECAUTIONS WHEN TROUBLESHOOTING
Follw these charts to carry out trouble- 3. PRECAUTIONS WHEN REMOVING, INSTALLING,
shooting. At the same time, do not forget DISASSEMBLING OR ASSEMBLING PARTS
the following points. DURING TROUBLESHOOTING
l Check related items. If it is necessary to remove, install, disassemble
l Check that there are no other failures or assemble parts for troubleshooting, remem-
or breakdowns. ber the following points.
+ For details of troubleshooting tables, Carry out the various testing and adjusting
see page 22 - 16. while observing the items on quality control
given in “Testing and Adjusting”.
6) Investigate causes of breakdown. When removing parts, check their condition of
l Even if the breakdmn is repaired, if the mounting, and distinguish between front and
original cause of the problem is not re- rear, left and right, and top and bottom.
moved, the same breakdwn will occur Check the match marks, or make match marks
again. To investigate and remove the origi- to prevent mistakes when installing.
nal cause, see %tions to take to prevent If a part cannot be removed even when the
failures from occurring again”. nuts and bolts have been removed, do not use
excessive force to remove it. Check the part to
see if there is any problem with it, and remwe
the problem before trying to disassemble the
part.
When installing or assembling, clean off all dust
and dirt and repair any scratches or dents.
Remove all grease or oil before coating with
gasket sealant.
22-15
TROUBLESHOOTING METHOD OF READING TABLES
METHOD OF READING
TROUBLESHOOTING TABLES
DESCRIPTION OF SYMBOLS USED IN TROUBLE-

SHOOTING TABLES
The following symbols are used in the “Remedy” column
to indicate the method of eliminating the cause of a
fault.
X: Replace A: Repair
A: Adjusting C: Clean
METHOD OF READING TROUBLESHOOTING

TABLES
The symbol o in the table is inserted only for
causes which can be diagnosed. If a cause cannot
be diagnosed, the corresponding box is left blank.
If the result of problem 1 using the troubleshooting
table shown at right is abnormal, the cause of the
trouble can be assumed to lie between “a” and “d”.
Because it is not possible to make a problem
regarding “e”, it is necessary to perform the next
problem (owing to the possibility of a multiple fault).
If the result of problem 1 is normal, the cause of the
fault does not lie between “a” and “d”. In such a
case, before diagnosing the cause as “e”, however,
carry out a check by means of problem 2 or 5.
If now the result of problem 1 is abnormal and the
result of problem 2 normal, the cause is one of “a”,
“b” or “d”. In addition, if the result of problem 3 is
abnormal, the cause will be narrowed down to one
of “b” or “d”. To determine which of “b” or “d” is the
actual cause, perform problem 4.
If the result of problem is abnormal, blacken out the
corresponding o in the table and then perform the
next problem on these causes in order to narrow
the likely causes.
Unnecessary
Example 1: problem
Problem 1 - Abnormal From the table
Problem 2 - Normal of example 1,
Problem 3 - Abnormal the cause of the
Problem 4 - Normal fault is “b”.
Example 2: From the table of

Problem 1 - Normal example 2, the cause
Problem 2 - Abnormal of the fault is “e”.
+ In example 2, it is evident that the cause is “e”
without carrying out problem 2, however pro-
blem 2 is performed by way of an additional Unnecessary
check. problem
22-16
TROUBLESHOOTING METHOD OF READING TABLES
Example 3: From the table of

Problem 1 4 Abnormal example 3, the cause
Problem 2 4 Abnormal is one of “a”, “c”
Problem 3 - Normal and “e”.
Continue problems
From the table of

Problem 4 - Normal example 3-1, the
Problem 5 - Normal cause is “c”.
Example 4:
From the table of
Problem 1 - Abnormal example 4, the cause
Problem 2 - Normal is one of “a”, “b”
or “d”.
Continue problems
Problem 3 - Abnormal From the table of

Problem 4 - Abnormal example 4-1, the
Problem 5 - Normal cause is “a” or “d”.
As can be seen from the above examples, it is not

necessary to perform all the problems.
Also, looking at a particular cause, no matter how many
0 marks there are in the column corresponding to that Example 4-1
cause, it will cause to be an actual cause if there is even
one o mark in the same column.
22-17
TROUBLESHOOTING PREVENTING RECURRENCE OF TROUBLE
PREVENTING RECURRENCE OF TROUBLE
l The troubleshooting table is used to establish the direct cause of damage or breakdown of a part or piece of
equipment. It is not able to establish the root cause of the damage or failure, however.
l Also, this table only describes the action to be taken with the particular part or piece of equipment. It does not
mention what action should be taken to pment a recurrence of the root cause.
l In order to remove the root cause of a fault so as to prevent a recurrence, carefully investigate the real cause
while referring to the foll&ng items.
l Regarding the method of checking and adjusting each part or piece of equipment, refer to “Testing and
Adjusting” in the Shop Manual.
HYDRAULIC EQUIPMENT
1. Oil checks 3) Oil cleaning and replacement

l The fundamental cause of almost all faults occurring l If a large amount of metal particles or other
in hydraulic equipment is the inclusion of water, air foreign matter is discovered in the oil, either
or other foreign matter in the oil. Accordingly, it is wash the oil using an oil refresher or replace it.
necessary to check the oil to see whether or not it + If the oil is contaminated by water, it is not
contains any of the above substances, and then possible to remove the water by means of
take aoorooriate action. an oil refresher.
1) Oii checks + When washing the oil, also wash or replace
0 Check for water contamination. the strainer and replace the filter.
Check the oil for possible water contamination
by means of a diesel engine oil checker or a 2. Cleaning fragments of damaged parts
hot plate. l If a part becomes damaged, fragments may pass
0 Check for contamination of other foreign mat- into the oil line. It is thus necessary to wash the oil.
ter. Remove the drain plug and filter, then l In addition, disassemble and wash such parts as
check the bottom of the tank and also the filter valves and cylinders which are liable to collect
to see if any foreign matter has collected there. metal fragments and other foreign matter, thus
Check the degree of contamination by means helping to prevent a recurrence of faults due to
of a contamination checker. such fragments becoming lodged in various parts of
0 Viscosity check the engine or hydraulic equipment.
Check the viscosity of the oil using a viscome-
ter in order to confirm whether or not the oil is
satisfactory
2) Check of contamination point
If, as a result of the above checks, it is dis-
covered that the oil is contaminated by water or
other foreign matter, it is necessary to find out
where the contamination is occurring and also
to take steps to prevent it.
Water: Oil storage tank, breather, etc.

Sand: Oil replenishing or replacing
method, etc.
Rubber: Cylinder packing, etc.
Metal: Wear or damage to hydraulic
equipment such as pump and
motor, as well as transmission
and torque converter, etc.
22-18
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
Standard
Item Remedy
value
Lubricating oil, cooling water

1. Check fuel Iwel Add fuel
2. Check for dirt or water in fuel Clean, drain
Checks 3. Check hydraulic oil level Add oil
before 4. Check hydraulic oil strainer Clean, drain
starting 5. Check brake oil level Add oil
6. Check engine oil level (Level of oil in oil pan) Add oil
7. Check cooling water level Add water
8. Check condition of dust indicator Clean or replace
Electrical equipment
9. Check for loose or corroded battery terminals Tighten or replace
Item 10. Check for loose or corroded alternator terminals Tighten or replace
11. Check for loose or corroded starting motor Tighten or replace
terminals
Hydraulic, mechanical component

12. Check for abnormal noise or smell Repair
13. Check for oil leakage Repair
14. Bleed air from system Bleed air
Electrical components
15. Check battery voltage (engine stopped) Replace
20-30V
Other 16. Check level of battery electrolyte Add or replace
check 17. Check for discolored, burnt, or bare wiring Replace
items 18. Check for missing wiring clamps, hanging wires Repair
19. Check for water leaking onto wiring (check care- Disconnect connector
fully for water leakage at connectors and and dry connection
terminals)
20. Check for broken or corroded fuses Replace
21. Check alternator voltage (engine running at over Replace
27.529.W
half throttle)
22. Noise when battery relay is operated (switch Replace
starting switch from on to off)
22-l 9
TROUBLESHOOTING JUDGEMENT ON POWER TRAIN
Use the following method to judge if the abnormality in the p-r train is in the electrical system of the transmission,
or in the power train itself. If the abnormality in the electrical system, go to troubleshooting items E-8; if the
abnormality is not in the electrical system, go to troubleshooting items T-l - T-4.
Judgement flow
YES
2 + Defective ~nsmissm solenoid valve
when emergency
YES scmw Of Spool Of
1 -pmbbmsW
- rmpe is bosemd.
Caw out test for dces machine move?
pm&m
tranomirrim Co to tmubbahooting for tmnsmbsion,
sobmid. y IternsT- -T-4
Is cmditicm normal?
to trwbbshooting
GO for transmission
NO ) ebcbical sysWm. Item E-8
Testing and inspection of transmission solenoid
A Stop the machine on level ground and put

blocks under the tires.
+ Air tank at specified pressure
1. Install a T-adapter (or socket adapter) to connector

CN75, and check the voltage between the con-
nector pin and the chassis ground.
2. Turn the starting switch ON.

+ Do not start the engine.
3. Turn the parking brake switch ON - OFF (release). Result of inspection
4. When depressing the foot brake, depress the R.H. Normal Go to T-l - T-4
brake so that the transmission is not cut off.
0 (continuous) at two places
Checking directional solenoid circuit Go to troubleshooting E-8 (d)
Standard condition No o (continuous)

Go to troubleshooting E-8 (b), (c)
Lever Connector 5-
ower No l(battery voltage)
position pin pin p?l i;;)
Go to troubleshooting E-8 (a)
0: 0 - 0.5V (continuous)
0: 20 - 30V(battery voltage)
22-20
TROUBLESHOOTING JUDGEMENT ON POWER TRAIN
Checking speed solenoid circuit
Standard condition
7-pin
Lever Connector
1-pin 2-pin 3-pin 4-pin (Power
position pin
source)
1st 0 l 0 0 0
2nd 0 0 0 0 l
3rd 0 0 0 0 0
4th 0 0 0 0 0
0: 0 - 0.5V (continuous)
0: 20 - 30V (battery voltage)
Result of inspection:
Normal Go to T-l - T-4
0 (continuous) at two places or more

Go to troubleshooting E-8 (9
No o (continuous)
Go to troubleshooting E-8 (e)
No l (battery voltage)
Go to troubleshooting E-8 (e)
22-21
TROUBLESHOOTING TROUBLESHOOTING TABLE
TROUBLESHOOTING TABLE
TORQUE CONVERTER AND TRANSMISSION
1. Machine does not move.
Ask the operator the following questions.

l Did the machine suddenly stop moving?
Yes = Seizure or damage to internal parts.
l Was an unusual noise emitted from the ma-
chine?
Yes = Damaged parts.
Checks before troubleshooting.

Is the machine monitor functioning normally4
Is quantity and type of oil in transmission
correct?
Is the transmission filter or strainer clogged?
Has oil in transmission deteriorated or does it
emit a burnt smell?
Is there any damage or oil leakage which can
be discerned by viewing the exterior of the
machine?
l Is the transmission drive shaft broken?
l Is wheel brake (including emergency brake) or
parking brake locked?
oesnotmove0 en01temperature 1s high.
Note: Disassemble the solenoid valve only in a clean

and dry workshop because dust and moisture
can cause the solenoid valve to fail. Replace
the solenoid valve as an assembled unit when
making the repair in the field.
22-22
The following symbols are used to indicate the

action to be taken when a cause of failure is
located:
X: Replace A: kq_Xiir
A: Adjust C: Clean
22-23
2. Machine speed is low, thrust is weak, grade-

ability falls off.
Fault check
l Measure the machine speed during excavation
work and also when it is on flat and sloping
ground, respectively, in order to determine
whether the machine is actually faulty or wheth-
er the operator simply feels that the machine
lacks power.

o Is quantity and type of oil in transmission
correct?
l Is the transmission filter or strainer clogged?
l Is there any leakage of oil from pipe or valve
connections?
l Is wheel brake or parking brake dragging?
l Are tire pressure and tread satisfactory?
l Is the method of performing work correct?
Problem
1 Machine is faulty I” all speed positlons. 00000 000
2 MachIne IS faulty in a particular speed posltlon. 0

Charging pump emits an unusual noise when the 011
3
temperature is low. 0
4 011 I” torque converter overheats. 0 0 0 0
No-load maximum and mnmum speeds of engine are

5 abnormal. 0
6 Each stall engine speed IS abnormal. 0000
I
,2 Metal particles adhere to the transmlsslon strainer or
torque converter filter. 0 0
LO7zzOO3
22-24

located:
A: Adjust C: Clean
22-25
3. Large shock when moving off or changing gear.
Fault check.
Because it is difficult to determine whether shock is
abnormally large or normal, consider it large in the
follawing cases.
l When a shock occurs which is clearly larger
than any that has occurred so far.
o When the shock is large compared to that
occurring on other machines of the same type.

o Is the lo&-idling speed of the engine too high?
l Is there excessive play in each drive shaft?
NO
Problem
1 Large shock 111

all speed posltlons 0 0
2 Large shock in a partrxiar speed posmon. 0
3 Clutch pressure excessively high. 0
L07zz005

located:
A: Adjust C: Clean
22-26
4. Large time lag when moving off or changing

gear.
Check the following items with the operator.

l If the time lag is large and also the machine
speed, thrust force and gradeability are abnor-
mal, refer to item 2. “Machine speed is low,
thrust is weak, gtadeability falls off’.

l Is quantity and type of oil in transmission
correct?
l Is there any leakage of oil from valve or pipe
connections?
Fault check
l Determine whether or not the time lag is large
by means of the judgement criterion table.
1 Large time lag at all speed positions. 0 0 0
2 Large timg lag at a particular speed position 0

3 Low clutch pressure at all speed posItIons 0 0
Clutch oil pressure IS large at speed stages having a large
4 0 0
time lag.
~07zZO06

located:
X: Replace A: &pair
A: Adjust C: Clean
22-27
5. Oil temperature in torque converter is high.

l If the oil temperature rises when the torque
converter stalls and fails when it is unloaded.
Select the correct speed position.
e If the oil temperature rises only when pushing
soil uphill.
Yes = improve the working method.

l Radiator water level and fan belt tension.
l Is quantity and type of oil in transmission
correct?
l Is the transmission filter or strainer clogged?
Fault check
l Measure the temperature of the oil in the torque
converter and compare the measured value
with the judgement criterion table to see wheth-
er or not it is high.
Yes = Faulty oil temperature gauge.
‘.-’ I Problem
II / / 111 I / I / I
Chargkng pump emlts unusual Norse when oil temperature O
1
IS low.
No-load mawnum and mr~mum engine speeds are
.2
abnormal. 0 0 0 0
3 1 Each stall engine speed IS abnormal.

I lolololol I I I I IO1
Machlne speed, thrust force and gradeabIlIty are abnormal
4 000000000 0
at all speed posltlons.
MachIne speed, thrust force and gradeabllity are abnormal
5
at a partlcualr speed posItIon.
0
Transmlwon
I
Metal particles adhere to the transmlsslon strainer or
11
torque converter filter. 0 0 0
LO7zzOO7

located:
A: Adjust C: Clean
22-28
POWER TRAIN
TORQUE CONVERTER CHARGING PUMP ................................................. 3

REMOVAL ..................................................................... 3
INSTALLATION .................................................................. 3
TRANSMISSION, TORQUE CONVERTER .................................................. 4

REMOVAL ..................................................................... 4
INSTALLATION .................................................................. 10
TORQUECONVERTER ............................................................... 16
DISASSEMBLY.. ................................................................ 16
ASSEMBLY .................................................................... 19
TRANSMISSION .................................................................... 22
DISASSEMBLY.. ................................................................ 22
ASSEMBLY .................................................................... 29
CLUTCH PACK ..................................................................... 40

DISASSEMBLY.. ................................................................ 40
FORWARD-REVERSE CLUTCH PACK .............................................. 40
lST-3RDSPEEDCLUTCHPACK .................................................. 42
2ND-4TH SPEED CLUTCH PACK 44
ASSEMBLY ................... . . . . . . . . . . . . . . . . . . . . . . . .. .. . . . . . . . . . . . . . . . . . . . . . . 46
FORWARD-REVERSE CLUTCH PACK .............................................. 47
lST-3RDSPEEDCLUTCHPACK .................................................. 52
2ND-4TH SPEED CLUTCH PACK ................................................. 56
TRANSMISSION CONTROL VALVE ...................................................... 60

REMOVAL ..................................................................... 60
INSTALLATION .................................................................. 61
TRANSMISSION SOLENOID VALVE 67

DISASSEMBLY.............:::::::::::::::::::::::::::::::::::::::::::::::::::: : 67
ASSEMBLY .................................................................... 67
.
DIFFERENTIAL.. ................................................................... 68
DISASSEMBLY .................................................................. 68
ASSEMBLY .................................................................... 72
FRONT AXLE ...................................................................... 83

REMOVAL ..................................................................... 83
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
REAR AXLE ....................................................................... 87
REMOVAL ..................................................................... 87
INSTALLATION .................................................................. 90
DRIVE SHAFT ...................................................................... 93

DISASSEMBLY.. ................................................................ 93
ASSEMBLY .................................................................... 95
AXLEHOUSING .................................................................... 97
DISASSEMBLY.................................................................. 97
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
* For details of disassembly of the gear pump, see SECTION 97.
* Take the following method for air bleeding when you start to operate hydraulic cylinders after reassembling

2. Operate hydraulic cylinder 4 - 5 cycles, but do not exceed beyond 100 mm of stroke end.
23-2
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER CHARGING PUMP

REMOVAL

1. Covers
Remove cover under cab, transmission inspection
cover, and side cover of hydraulic tank.
2. Hydraulic piping
Disconnect the following hydraulic piping.
0 Disconnect hose (1) between filter and pump
from pump.
l Disconnect tube (2) of hose between pump and
torque converter regulator valve from pump.
0 Disconnect tube (3) between transmission
strainer and pump from pump.
3. Torque converter charging pump

Remove mounting bolts, then remove torque con-
verter charging pump (4).
* This operation should be carried out by two
workers.
Torque converter charging pump: 13 kg
INSTALLATION

Set torque converter charging pump (4) in mounting
+ Check that there is an O-ring on the face in
contact with the housing.
2. Hydraulic piping
Connect the following hydraulic piping.
l Connect tube (3) between transmission strainer
and pump at pump end.
l Connect tube (2) of hose between pump and
torque converter regulator valve to pump.
l Connect hose (1) between filter and pump to
pump.
3. Cover
Install all covers.
23-3
DISASSEMBLY AND ASSEMBLY TRANSMISSION, TORQUE CONVERTER
TRANSMISSION,
TORQUE CONVERTER
REMOVAL

A Open the hood and fit the lock.
e Loosen plug (1) at the top of the hydraulic tank

filter, and plugs (2 and 3) of the pump piping to
prevent the oil inside the tank from flowing out.
l Disconnect the cable from the negative (-) terminal
of the battery.
1. Draining oil
Remove drain plug (4) and drain oil from transmis-
sion case.
+ After loosening the drain valve, pull out gradual-
ly to drain the oil.
Qi# Transmission oil: 35P
2. Cover
Remove cover under cab.
3. Ladder
Using eye bolts, lift off ladder (5).
+ The ladder is difficult to balance, so be careful
of the center of gravity when removing.
Ladder: 50 kg
23-4
4. Brake hose
1) Disconnect hoses between the charge valve to
brake valve, and the brake valve to transmis-
sion, in the brake side.
* Remove the hose clamps from the floor
support.
2) Disconnect hoses between the brake valve to
front brake, and the brake valve to rear brake,
in the brake valve side.
5. Electric wiring
Disconnect the following wiring from the connector.
0 Wires (10 and 11) for front frame.
l Wire (12, 13, and 14) for rear frame.
0 Wire (15 and 16) for transmission.
l Wire (17) for cab.
o Ground connection (18).
+ After removing the harness, mark with a tag to
distinguish when installing.
6. Main control valve linkage

Disconnect main control valve linkage (19) at main
control valve end.
+ Remove the washer liquid hose from the tank.
7. Steering hydraulic pipings

Disconnect the following hydraulic pipings from
steering valve.
* Hoses (68 and 69) between the steering valve
to steering cylinder.
+ Hoses (70 and 71) between the steering valve
to priority valve.
+ Hoses (72) between the steering valve to hy-
draulic tank.
23-5

Remove lock nut of fuel control cable (20) then
disconnect from fuel injection pump.
+ Remove the clamp at the bottom of the floor.
Parking brake cable

1) Remove clevis pin (21) then disconnect from
caliper lever.
2) Remove cable bracket (22).
10. Cab, floor plate

Sling cab and floor support (23) remove mounting
bolts, then lift off.
+ If shims are installed between floor support and
frame, check numbers of shims.
+ Check that no hoses or electric wires are
caught, and lift off slowly.
+ The work, equipment linkage contacts the
hydraulic tank, so push the work equipment
control lever forward.
+ Be careful not to damage the cab windows
during the operation.
t After removing, put blocks under the floor
support and lower to the ground.
el kg
Cab, floor support: 530 kg
23-6
11. Hydraulic piping

Disconnect tube (24) between hydraulic tank
and main control valve at main control valve
end.
Disconnect hoses (25 and 26) between main
control valve and lift cylinder at main control
valve end.
Disconnect hoses (27 and 28) between main
control valve and dump cylinder at main control
valve end.
Disconnect hose (29) between steering valve
and main control valve at main control valve
end.
Disconnect hose (30) between steering valve
and hydraulic tank from manifold.
Loosen clamp of hose (31) between hydraulic
tank and pump at pump end.
12. Hvdraulic tank

Uiing eye bolts, remove hydraulic tank (32).
Hydraulic tank: 160 kg
13. Drive shafts

Disconnect center drive shaft (33) and rear drive
shaft (34) from transmission.
t When disconnecting the center drive shaft,
insert blocks between the frames.
23-7
14. Transmission piping

1) Disconnect cooler hoses (35 and 36) from
transmission valve.
2) Disconnect brake hose (37) from transmission,
then remove together with accumulator (38).
3) Disconnect hose (39) between torque converter
charging pump and torque converter filter at
torque converter filter end.
4) Remove tube (40) between transmission strain-
er and torque converter charging pump.
15. Hydraulic, steering pump

1) Remove hose (30) between steering valve and
hydraulic tank.
2) Remove hydraulic and steering pump (41).
* Remove the O-ring from the housing con-
tact surface.
+ Move hose (29) between the steering valve
and the main control valve towards the
front of the machine.
16. Torque converter, transmission

1) Using eye bolts, sling torque converter and
transmission, remove front mounting bolts, then
remove bracket (42).
2) Set supporting bar @ to the engine mounting

bracket, and adjust height.
4 I SP664
23-8
3) Remove mounting bolts holding engine, then lift

off torque converter and transmission (43).
+ Be careful of the fitting of the pilot cover,
and lift off slowly.
+ Check that the piping does not interfere
with other parts when lifting off the assem-
bly.
Torque converter, transmission: 520 kg
23-9
INSTALLATION
1. Torque converter, transmission

1) Raise torque converter and transmission (43)
set in mounting position, then tighten mounting
bolts holding to engine.
t Check that there is an O-ring fitted to the
torque converter housing.
+ Adjust the height of the pilot cover so that
it enters the hole in the flywheel smoothly.
Do not force it when installing.
2) Remove supporting bar @that is seated to the

engine mounting bracket.
t Check that there is no abnormality with the
brake tube.
3) Install front bracket (42), then partially tighten

mounting bolts.
D Mounting bolt of bracket: 28.5+3.0 kgm
4) Use adjustment screw to set transmission in

position, then tighten mounting bolts fully so
that clearance ‘a’ is the specified value.
0 Clearance ‘a’: 1 - 2 mm
D Mounting bolt: 76.Ok8.5 kgm

__ ,_ Tunting bolt: 3qI__ _
Clearance ‘a’
4 I SF402
23-10
2. Hydraulic, steering pump

1) Set hydraulic and steering pump (41) in mount-
ing position, then tighten mounting bolts.
+ Check that there is an O-ring fitted to the
housing contact face, and be careful not to
get it caught.
2) Install hose and tube (30) between steering
valve and hydraulic tank.
+ Return hose (29) between the steering
valve and the main control valve to its
mounting position.
3. Transmission piping
1) Install tube (40) between transmission strainer
and torque converter charging pump.
2) Connect hose (39) between torque converter
charging pump and torque converter filter at
torque converter filter end.
3) Install brake hose (37) to transmission valve
together with accumulator (38).
D Hose nut: 1423 kgm

Hose nut: 32 mm
+ Be careful not to tighten the accumulator

U-bolt too much.
4) Connect cooler hoses (35 and 36) to transmis-
sion valve.
Iz_7 Hose nut: 20+5 kgm

Hose nut: 41 mm
4. Drive shafts
Connect center drive shaft (33) and rear drive shaft
(34) to transmission.
+ Be careful to install the coupling facing in the
correct direction.
D Mounting bolt: 7.0 +0.5 kgm
23-11
Hydraulic tank
1) Using eye bolts, raise hydraulic tank (32) set in
mounting position, then tighten mounting bolts.
* Move the hoses and electric wiring in the
mounting direction.
+ Tighten the bolts fully after fixing the posi-
tion of the hydraulic tank.
+ Insert the hose between the hydraulic tank
and the pump before starting the operation.
6. Hydraulic piping
l Tighten clamp of hose (31) between hydraulic
tank and pump.
l Connect hose (30) between steering valve and
hydraulic tank to manifold.
main control valve at main control valve end.
0 Connect hoses (27 and 28) between main
control valve and dump cylinder at main control
valve end.
l Connect hoses (25 and 26) between main
control valve and lift cylinder at main control
valve end.
l Connect tube (24) between hydraulic tank and
+ Fit the O-ring securely in the groove.
+ Move the mounting position of the clamp of
hose (31) 90”.
7. Cab, floor support

Raise cab and floor support (23), set in mounting
Insert shims between floor support and frame
and check that there is no clearance between
rubber and frame, and between rubber and
floor support. After adjusting, check that cab
door can be opened and closed smoothly.
The work equipment linkage contacts the
hydraulic tank, so push the work equipment
control lever forward.
Move the parking brake and fuel control cable
towards the mounting position.
Be careful not to catch the electric wiring.
23-12
8. Parking brake cable

1) Install cable bracket (22).
2) Connect clevis pin (21) to caliper lever.
t If the operation of the brake is poor, see
SECTION 52, TESTING AND ADJUSTING.

Set fuel control cable (20) in mounting position,
then secure with lock nut.
+ Install the clamp at the bottom of the floor.
+ For details of adjusting the fuel control cable,
see SECTION 12, TESTING AND ADJUSTING.
10. Steering hydraulic piping

0 Hoses (68 and 69) between steering valve and
steering cylinder.
l Hoses (70 and 71) between steering valve and
priority valve.
l Hose (72) between steering valve and hydraulic
tank.
23-13
11. Main control valve linkage

Connect main control valve linkage (19) to main
control valve.
+ Connect the washer liquid hose to the tank.
12. Electric wiring

Connect the following wiring to the connector.
l Ground connection (18).
0 Wire (17) for cab.
8 Wires (15 and 16) for transmission.
0 Wires (12, 13, and 14) for rear frame.
0 Wires (10 and 11) for front frame.
Floor surface
ab
For trans
For front frame For rear frame
419FOI 101
13. Brake hose

1) Connect tubes (8 and 9) between brake valve
and front and rear axles at brake valve end.
D Tube nut: 1.220.3 kgm
2) Connect hoses (6 and 7) between charge valve

and brake valve at brake valve end.
+ Install the hose clamp to the floor support.
23-14
14. Ladder
Using eye bolts, raise ladder (5) set in mounting
+ Tighten the mounting bolts after fixing the
ladder in position.
15. Cover
Install cover under cab.
16. Refilling with oil

1) Tighten drain valve and add oil through oil filler
(44) to fill transmission to the specified level.
+ Run the engine to circulate the oil through
the system. Then check the oil level again.
Q Transmission oil: 35P
2) Tighten plug at top of hydraulic tank filter, and

plugs of pump piping, then add hydraulic oil
through oil filler (45) to the specified level.
17. Bleeding air, for brake line

For details of bleeding air, see SECTION 52, TEST-
ING AND ADJUSTING.
1, SPp t-1 39
23-15
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
TORQUE CONVERTER
DISASSEMBLY
SDecial tools
Part number Part name Q?y
Unit repair stand 1
Bracket 1
Plate 1
Plate 1
1. Torque converter assembly

Remove torque converter assembly (1) from hous-
ing (2).
2. Turbine, case assembly

1) Set torque converter assembly (1) in tool A.
2) Remove mounting bolts (3) of case, then

remove turbine and case assembly (4).
+ When removing the mounting bolts, leave
two mounting bolts on opposite sides, then
turn over the assembly (pilot side at the
top) and remove the remaining two mount-
ing bolts.
23-16
3) Disassemble turbine and case assembly as

follows:
i) Remove pilot (5).
ii) Remove snap ring (6).
iii) Push boss of turbine (7) and remove from
case (8).
3. Stator
Remove snap ring (1 l), then remove stator (12).
4. Pump
1) Remove mounting bolts (13).
2) Remove pump (14) together with guide.
23-17
5. Gear, retainer
1) Push stator shaft (15), and remove bearing (20)
on gear (16).
2) Remove retainer (17).
419Pi 132
23-18
ASSEMBLY
Special tools
A 790-50 l-5000 Unit repair stand 1
Al 790-901-2110 Bracket 1
A2 1 793-31O-2140 1 Plate I 1
A3 I 793-310-2131 I Plate I 1
1. Retainer, gear
1) Install seal ring (18) to stator shaft (15).
+ Coat the seal ring with grease, and make
the protrusion from the stator shaft uniform.
2) Install retainer (17).
3) Install bearing (20) on gear (16).

4) Push inner race side of bearing (20) (I.D.: 85
mm), and install on stator shaft.
2. Pump
1) Set stator shaft (15) in tool A.
2) Install pump (14).
3) Coat ball with grease, then assemble to shaft.
4) Install guide (19).
5) Tighten mounting bolts (13).
D Mounting bolt: 7+0.5 kgm
3. Stator
1) Install stator (12).
2) install snap ring (11).
4. Turbine, case assembly

1) Assemble turbine and case assembly as fol-
lows.
i) Assemble snap ring (lo), then install bear-
ing (9) (O.D.: 90 mm) in case (8).
ii) Support inner race (I.D.: 55 mm) of bearing,
and install turbine (7) in case (8).
iii) Install snap ring (6).

iv) Install pilot (5).
4b Mounting bolt: 7.OkO.5 kgm
23-20
2) Align bolt holes, install turbine and case assem-

bly (4), then install 24 mounting bolts (3).
D Mounting bolt: 3.2kO.3 kgm
5. Torque converter assembly

Install torque converter assembly (1) in housing (2).
23-21
DISASSEMBLY AND ASSEMBLY TRANSMISSION
TRANSMISSION
DISASSEMBLY
Special tools
Part number Part name
1. Hydraulic piping
l Tube between transmission control valve and
torque converter regulator valve.
l Hose (1) between filter and transmission valve.
l Tube (2) between pump and filter.
l Hose (3) between transmission and brake
booster.
+ After removing the tubes, fit covers to
protect the threads.
2. Filter
1) Remove filter (4) then remove bracket (5).
2) Remove oil filler (6).
+ Remove the rear coupling.
3. Transmission control valve

Remove transmission control valve (7).
23-22
4. Pump, regulator valve

1) Remove regulator valve (8).
2) Remove pump (9), then remove O-ring.
5. Parking brake
Remove cover (lo), then remove parking brake
(11).
6. 2nd-4th speed shaft, emergency pump covers

1) Remove emergency pump cover (12), then
remove O-ring.
2) Remove cover (13) of 2nd and 4th speed shaft,
then remove O-ring.
7. Rear housing
Using
__.. forcing._ screw, raise rear housing (15), then lift
off with tool A.
* Lift off slowly and be careful not to damage the
seal ring.
Rear housing: 135 kg
23-23
8. Torque converter
Lii off torque converter (16) from rear housing.
+ Make match marks on the contact faces of the
housing and torque converter before removing.
4 J9P687
9. Pump gear
1) Remove ring (17), then remove gear (18).
2) Remove ring (19) from rear cover, then remove
shaft and bearing (20). Remove bearing (22)
from shaft (21).
4 I SF405
10. Seal ring

Remove seal ring (23) from each clutch shaft.
23-24
11. 2nd-4th speed, lst9rd speed clutches

1) Pull out 2nd and 4th speed clutch (24) together
with 1st and 3rd clutch (25) from bearing of
housing, then remove towards output shaft of
2nd and 4th speed clutch.
t Pull out the 1st and 3rd speed clutch from
the bearing, then move towards the FOR-
WARD-REVERSE side.
2) Using tool B, lift off 1st and 3rd speed clutch

(25).
+ Remove slowly and be careful not to hit the
other gears.
lst3rd speed clutch: 40 kg
3) Using tool B, lift off 2nd and 4th speed clutch

(24).
2nd-4th speed clutch: 49 kg
12. FORWARD-REVERSE clutch

1) Remove ring (26) and leave gear (27) free.
23-25
2) Using tool C, pull out FORWARD-REVERSE

clutch (28).
+ When pulling out the FORWARD-REVERSE
clutch, gear (27) will contact the bearing,
so raise the gear about half way.
A Be careful not to get your fingers caught be-

tween gear (27) and the housing.
FORWARD-REVERSEclutch: 42 kg
lr I
13. Idler gear

1) Remove gear (29) from housing.
+ Remove bearing (30) for the 1st and 3rd
clutch.
2) Remove ring from gear (29), then remove

bearing (31).
14. Rear retainer

Remove mounting bolts, then remove retainer (32)
and oil seal.
23-26
15. F%ont retainer

1) Remove mounting bolts, then using forcing
screw, remove retainer (33) and shim.
t Check the number and thickness of the
shims, and keep in a safe place.
2) Remove O-ring (34), oil seal (35) and bearing
cup (36) from retainer.
-.
4 I9F406
16. Output shaft gear

1) Remove lock plate (37), then remove shroud
(36).
t Be careful not to cut your hand with the edge
of the shroud.
2) Remove ring (39) from groove, move it to

center, then move gear (40) to same position
as ring.
23-27
SEMBLY AND ASSEMBLY TRANSMISSION
3) Push shaft (41) to rear, then pull shaft out past

front housing.
A Be careful not to get your fingers caught be-

tween the gear and the housing.
+ Be careful not to damage the spline groove

of the shaft.
4) Remove gear (40), ring (39), and bearings (42

and 43) from shaft.
17. Gear of emergency steering pump

1) Remove ring (44), then remove gear (45).
Remove ring (46), then remove bearing (47).
4 I9F407
23-28
ASSEMBLY
Soecial tools
Lifting tool 2
* Lifting tool 1
C 793-520-2900 Liiing tool 1
D 790-415-l 020 Expander 1
E 1 790-415-1030 installer 1
1. Gear of emergency steering pump (if equipped)

1) Press fit bearing (47) in housing, then secure
with ring (46).
2) Insert gear (45) on bearing, then secure with
ring (44).
4 I9F408
2. Output shaft gear

1) Press fit bearing cup (48) in housing (49) and
retainer (50).
2) Press fit bearing cone (43) on shaft (41), as-

semble ring (39) and gear (40) then press fit
cone (42).
t Press fit the cone correctly up to the shoul-
der of the shaft to prevent incorrect adjust-
ment of the end play.
t Do not fit the ring into the groove. Move it
to the center, then remove gear (40) from
the spline groove and set in the same
position as the snap ring.
3) Assemble shaft (41) in housing.

* Insert the shaft at an angle as shown in the
photograph.
4) Partially tighten mounting bolts of shaft retainer

(33).
5) Insert gear (40) in shaft spline, then set shroud

(38) in mounting position.
‘3) Secure with ring (39).
7) Fit lock plate (37) and install shroud.
+ Bend the lock plate securely.
* Check that the gear does not contact the
shroud.
3 Mounting bolt: 11.5? 1 kgm
,, Make a curve
0 // “d,“,“tT”plate is x
face of bolt
Good No good
4 I9F409
23-30
3. Adjusting rotating torque of bearing

1) Assemble desired thickness of shim to retainer
(33), then install without O-ring. Tighten mount-
ing bolts uniformly.
+ Rotate the shaft when tightening to settle
the bearing. After tightening, tap the end
face of the shaft several times to settle the
bearing again.
+ Coat the bearing well with oil.
t Standard shim thickness: 0.9 mm
a Bearing: Transmission oil
m Mounting bolt: 11.32 1.3 kgm
2) Tighten mounting bolts of coupling on shaft

(41), then measure rotating torque.
+ Rotating torque: 0.01-0.1 kgm
+ If no small torque wrench is available,
measure as follows.
+ Install measuring plate (50) and retainer
plate on shaft (41) then tighten the mount-
ing bolts of the coupling. Install a push-pull
scale to the tip of plate (50) and measure
the torque.
Length of plate (4): 100 mm
Reading of push-pull scale: 0.1-l .O kgm
* Do not measure the torque when the rotat-
ing starts; measure the torque during the
rotation.
t If the rotating torque is not within the stan-
dard value, adjust by changing the thick-
ness of the shim.
t When the rotating torque is within the
standard value, check that the end play is
I0.I
3) Install selected shim (51) and O-ring (34) to
retainer (33) then assemble retainer.
t Put the thin shim in the middle and the
thick shim on the outside.
+ Coat the retainer mount and inside circum- 419F410
ference of the housing with soapy water.
e Retainer mount, inside circumference of

housing: Soapy water
D Mounting bolt: 11.3+ 1.3 kgm
23-31
4. Oil seal
1) Press fit rear oil seal (52).
+ Press fitting distance ‘a’: 12.52 1.O mm
& Lip of seal: Grease (G2-Ll)
2) Press fit rear dust seal (70).

+ Press fitting distance ‘c’: 3.52 1.O mm
6 Lip of seal: Grease (G2-Ll)
:411-1
3) Press fit front oil seal (35).

t Press fitting distance ‘b’: 22.4kl.O mm
e Lip of seal: Grease (G2-Ll)
4) Press fit front dust seal (71).

t Press fitting distance ‘d’: 13.5+ 1.O mm
419F412.1
5. Idler gear
1) Press fit bearing (31) on gear (29).
23-32
2) Press fit gear and bearing (29) on shaft (53).

l Insert the gear and bearing up to the mid-
dle.
t Assemble bearing (30) for the 1st and 3rd
clutch.
6. FORWARD-REVERSE clutch
1) Using tool C, insert FORWARD-REVERSEclutch
(28) in housing, mesh FORWARD-REVERSE
gear with back idler gear (27) and assemble.
A Be careful not to get your fingers caught by the

gear.
2) Press fit idler gear (27) completely, then secure

with ring (26).
t Always assemble the ring and fit it securely
in the groove.
7. lst3rd speed, 2nd-4th speed clutches

1) Using tool B, insert 2nd and 4th speed clutch
(24) in housing, then move to output shaft side.
+ Do not fit the bearing at the bottom of the
clutch.
23-33
2) Using tool B, insert 1st and 3rdI speed clutch

(25) in housing.
+ Do not fii the bearing at the bottom of the
clutch completely.
3) When 1st speed gear (55) passes gear (56) of

2nd and 4th speed clutch, insert bearing of 2nd
and 4th speed clutch in housing.
56
419F413B
4) Insert 1st and 3rd speed clutch (25) in bearing.

* Be careful that all gears are meshed when
inserting in the bearing.
* Be careful that gear (24) of the 2nd and 4th
clutch is meshed with the emergency drive
gear when assembling.
* If the gears do not mesh properly, do not
try to force them in. Rotate the gears slight-
ly to mesh.
8. Seal ring (23)
23-34
1) Coat seal ring (61) and external circumference

of tool D with oil, and fii the seal ring with force
on tool D to the depth of dimension “x”.
t “x” = 110mm
t Exercise care not to fit the seal ring deeper
than dimension “x”. The seal ring will be
expanded excessively otherwise. Dimension “X”
+ The expanded seal ring (61) should be
removed from the upper side of tool D. It 61
should never be removed from the lower
I
side.
1
-
e Seal ring: Transmission oil D------
2) Quickly fit seal rings (61 and 62) removed from U41901801
tool D on shaft (63).
t Fit a seal ring in the lower groove in the
shaft first.
+ Be sure to use new seal rings.
,--- ._\ 63
U41901802
3) Coat the internal periphery of tool E with oil,
and cause seal rings to fit it by moving it up
and down.
+ After the seal rings are fitted, assure that
they are free of flaws.
I I
& Seal rings: Transmission oil
U41901803
23-35
9. Pump gear
1) Press fit bearing (22) on shaft (21).
+ Press fit the bearing completely.
4 I9P689
2) Press fit shaft and bearing (20) in housing.

+ Insert the shaft until it is level with the
surface of the housing.
+ If the bearing is fixed, the gear cannot be
inserted, so fix the bearing after inserting
the gear.
3) Insert gear (18) on shaft, then secure with ring
(17).
10. Torque converter

Using eye bolts, raise rear housing (16) set in
mounting position on torque converter, then tighten
mounting bolts.
t Align the holes of the mounting bolts and mesh
with the pump accessory gear properly when
installing.
t Blow in air to check that the oil holes are
aligned properly.
D Mounting bolt: 11.5+1.0 kgm
23-36
11. Rear housing

1) Using tool A, raise housing (15) and assemble
to front housing (57).
Be careful so that fluid sealant is not forced
out in the case, and install the case within
five minutes aiter applying.
Supply with oil more than one hour later
alter assembling.
Remove pilot cap (58) of the torque con-
verter, and mesh the spline of the input
shaft correctly.
Be careful not to damage the seal rings of
the shafts.
Housing contact face: Gasket sealant

(liquid type) Part Number: 419-l 518131
Housing mounting bolt: 11.5 20.5 kgm
2) Install pilot
D Mounting bolt of pilot cap: 6.8-t0.8 kgm
12. 2nd-4th speed shaft, emergency pump covers

1) Fit O-ring (59) and install cover (13) of 2nd and
4th speed shaft.
2) Fit O-ring (60) and install emergency pump
cover (12).
* Be careful not to let the O-ring come out of
place.
G O-ring: Transmission oil
13. Pump, regulator valve

1) Set pump (9) in mounting position, then tighten
mounting bolts.
2) Set regulator valve (8) in mounting position,
m Mounting bolt: 7.OkO.5 kgm

14. Parking brake

Set parking brake (11) in mounting position, then
tighten mounting bolts of coupling and install cover
(1%
t Be careful not to damage the oil seal.
s Outside circumference of coupling: Trans-

mission oil
1 Mounting bolt of coupling: 2823.5 kgm

1) Install guide pin in mount.
2) Raise transmission control valve (7), set in
mounting position, then tighten mounting bolts.
* For the tightening torque and order of the
mounting bolts, see page 2362 the section
under the bolts installing the transmission
valve.
16. Filter
1) Install oil filler (6).
t Install the rear coupling.
2) Install bracket (5), then install filter (4) to
bracket.
i Mounting bolt of bracket: 11.321.3 kgm
17. Hydraulic piping

l Hose (3) between transmission and brake
booster.
l Tube (2) between pump and filter.
l Hose (1) between filter and transmission valve.
l Tube between transmission control valve and
torque converter regulator valve.
t Install the hose without twisting or interfer-
ence.
23-38
18. Adjustment of speedometer sensor

Transmission case
1) Screw sensor (1A) until touching with outer
surrounding surface of gear (1B).
* Confirm that gear faces outer surrounding
surface against clamp face, before installing
sensor.
2) After confirming that sensor (1A) contacts with
gear (1B), restore the thread within the range of
3/4 to 1 revolution and fix it with a lock nut.
1B-.
t Be careful so that sensor harness output
direction does not become opposite direc-
tion with connector clamp.
423FO1108
_“,
e Sensor thread portion: Adhesive (LT-2)
D Sensor lock nut: 4?1 kgm
23-39
DISASSEMBLY AND ASSEMBLY CLUTCH PACK
CLUTCH PACK
DISASSEMBLY
Special tools
I Part number I Part name I Q’ty
A 793-31o-1300 Stand 1
Al 793-31o-1370 Guide pin 5
A2 793-31o-1330 Plate 1
A3 01541-1260 Nut 2
A41793-31o-1360 Bar 2
FORWARD-REVERSE CLUTCH PACK
A When setting the clutch

wipe off all oil to prevent
pack on the stand,
the pack from slip-
ping, and be careful not to get your fingers
caught between the stand and the clutch pack.
* Set the pack on stand A with the FORWARD side at

the top.
1. Bearing
Using puller, remove bearing (1).
2. Spacer, FORWARD gear

Remove spacer (2), thrust bearing (3) needle
bearing (4), FORWARD gear (5) and thrust bearing
(6).
3. End plate
1) Install tool Aa, tighten tool As, and remove ring
(7).
t After removing the ring, remove tool Aa.
23-40
DIS ASSEMBLY AND ASSEMBLY CLUTCH PACK
2) Remove end plate (8).
Clutch plate
Remove plate (9), disc (10) and spring (11) from
housing.
Piston
Blow in air through oil hole on FORWARD side of
shaft, and remove piston (12).
+ If the piston is at an angle and cannot be
removed, push the piston in and try again.
+ Do not force the piston out. This will damage
the inside of the cylinder.
6. Bearing
t Set the pack with the REVERSE side at the top.
Using puller, remove gear (13) and bearing
(14).
7. Shaft, cylinder
1) Remove shaft (74).
2) Remove snap ring (75) and remove cylinder
(76) from housing (77).
t Suitably mark the cylinder for identification
of forward side or reverse side.
+ Carry out disassembly there after in the
manner equal to what is described in steps
3 - 5 of the procedure on the forward side.
U41901804
23-41
lST-3RD SPEED CLUTCH PACK
t Set the pack on stand A with the 1st speed side at

the top.
1. Idler gear
Fit puller on idler gear (20), then remove bearing
(21) and spacer (22) together with idler gear.
2. 1st gear
Remove thrust washer (23) 1st gear (24) and
needle bearing (25).
3. End plate
1) Install tool As, tighten tool As, and remove ring
(26).
* After removing the ring, remove tool AZ.
23-42
4. Clutch plate
1) Remove plate (28), disc (29) and spring (30)
from housing.
2) Remove thrust washer (31).
5. Piston
Blow in air through oil hole on REVERSE side of
+ If the piston is at an angle and cannot be
A Do not force the piston out. This will damage
6. Bearing
Set the pack with the 3rd speed side at the top.
Using puller, remove bearing (33).
7. 3rd gear
Remove washer (34), thrust bearing (35), needle
bearing (36) 3rd gear (37) and thrust bearing (38).
+ Repeat steps 3 to 5 used for the 1st clutch to
disassemble the 3rd clutch.
2NII-4TH SPEED CLUTCH PACK
* Set the pack on stand A with the 4th speed side at

the top.
1. idler gear
Fit puller on idler gear (39) then remove bearing
(40) together with idler gear.
* Set a block between the housing and stand,
and adjust the height of the stand.
2. 4th gear
Remove thrust bearing (41) 4th gear (42) and
needle bearing (43).
3. End plate
1) Install tool AZ, tighten tool As, and remove ring
(44).
t After removing the ring, remove tool AZ.
23-44
Clutch plate
Remove plate (46) disc (47) and spring (48) from
housing.
5. Piston
Blow in air through oil hole on 4th speed side of
t If the piston is at an angle and cannot be
t Do not force the piston out. This will damage
6. Idler gear
+ Set the pack on stand A with the 2nd speed
side at the top fit puller on idler gear (50), then
remove bearing (51) together with idler gear.
t When fitting the puller, put the plate in contact
with the center.
7. 2nd gear
Remove thrust bearing (52) needle bearing (53),
2nd gear (54) and thrust bearing (55).
+ Repeat steps 3 to 5 used for the 4th clutch to
disassemble the 2nd clutch.
23-45
ASSEMBLY
1. Shaft, cylinder
1) Fit cylinder (76) in housing (77) and fix with
snap ring (75).
2) Fit shaft (74).
* Assure that the snap ring is positively fitted
in the groove.
+ Match marking for forward side or reverse
side.
i
0 0
i
U41901804
23-46
Special tools
A 793-31o-1300 Stand 1
A< 793-31o-1370 Guide Din 5
FORWARD-REVERSE CLUTCH PACK
A When setting the clutch pack on the stand,

wipe off all oil to prevent the pack from slip-
+ Set the shaft and housing on stand A with

the REVERSE side at the top.
1. REVERSE piston
Install REVERSE piston (56).
+ Be careful not to damage the piston seal.
l Check that the spring pin is not protruding from
the circumference of the shaft.
& Eliding surface of piston seal: Transmission
2. Clutch plate
Insert tool A1 in housing, then assemble plate (57),
disc (58) and spring (59) in turn.
* Soak plate (57) in clean transmission oil for at
least two minutes before assembling.
+ Be careful not to let spring (59) and plate (57)
catch on each other.
t Do not let the plate or spring catch in the ring
groove of the clutch housing when assembling.
23-47
3. End plate
1) Install tool A2 and tighten tool As to push in end
plate (69).
2) Assemble ring (61) then remove tool As.
+ Check that ring (61) is fitted securely in the
groove.
+ Check that disc rotates smoothly by hand.
4. Thrust bearing
Install thrust bearing (19).
5. REVERSE gear
Using a screwdriver, align spline groove inside plate
and install gear (13).
+ If the spline of the gear cannot be aligned,
rotate the gear lightly. Never try to force the
gear into position.
6. Bearings
Install needle bearing (17) and thrust bearing (16).
* Check that the end face of the thrust bearing is
level with or below the stepped part of the
shaft.
23-48
7. Bearing
Assemble washer (15), then press fii bearing (14).
+ Press fii completely so that washer (15) is in
close contact with the stepped part of the shaft,
and bearing (14).
t After press fitting the bearing, check that clear-

ance ‘a’ is within the standard range.
‘a’ = 0.072 - 0.742 mm
419F414
8. FORWARD piston
1) Turn over clutch pack.
A 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 RE-

VERSE piston.
& E;;ding surface of piston seal: Transmission
9. Clutch plate
insert tool A1 in housing, then assemble plate (9),
and disc (10) and spring (11).
+ Assemble in the same way as for the REVERSE
side.
10. End plate

1) install tool As and tighten tool & to push in end
plate (8).
2) Assemble ring (7), then remove tool Aa.
+ Assemble in the same way as for the RE-
VERSE side.
11. Thrust bearing

12. FORWARD gear

Install FORWARD gear (5).
+ Assemble in the same way as for the REVERSE
side.
13. Bearing
Install needle bearing (4).
14. Spacer
Assemble thrust bearing (3), then assemble spacer
(2).
+ Check that the end face of the thrust race of
the thrust bearing is level with or below the
stepped part of the shaft.
23-50
15. Bearing
Press fit bearing (1).
t Press fit completely so that spacer is in close
contact with the stepped part of the shaft, and
bearing (1).

ance ‘b’ between the thrust bearing and the
spacer is within the standard range.
‘b’ = 0.042 - 1.172 mm
419F415
16. Clutch pack operation test

Blow in compressed air through the oil hole in the
shaft and check the operation of each clutch.
t If the gear on the side where the air is blown in
is held in place, the clutch is working normally.
23-51
lST-3RD SPEED CLUTCH PACK

pack on the stand,
the pack from slip-
+ Set the shaft and housing on tool A with

the 3rd speed side at the top.
1. 3rd speed piston

Install 3rd speed piston (62).
t Be careful not to damage the piston seal.
t Check that the spring pin is not protruding from
& ziiding surface of piston seal: Transmission
2. Clutch plate
Assemble plate (63), disc (64) and spring (65) in
turn.
t Soak plate (63) in clean transmission oil for at
+ Be careful not to let spring (66) and plate (63)
+ Do not let plate (63) or spring catch in the ring
3. End plate
1) Install tool As and tighten tool As to push in end
plate (66).
2) Assemble ring (67), then remove tool As.
+ Check that ring (67) is fitted securely in the
groove.
+ Check that the disc rotates smoothly by
hand.
3) Install thrust bearing (38).
23-52
4. 3rd gear
Install 3rd gear (37), then install needle bearing (36).
gear into position.
+ Assemble the lower needle bearing first.
5. Bearings
Install thrust bearing (35) and washer (34), then
press fit bearing (33).
+ Check that the end face of the thrust bearing is
shaft.
+ Press fit completely so that the washer is in
and bearing (33).
+ After press fitting the bearing, check that clear-
ance ‘d’ between the thrust bearing and the
washer is within the standard range.
‘d’ = 0.031 - 0.701 mm I
419F416
6. 1st speed piston


2) Assemble piston (32) in same way as for 3rd

speed piston.
e Siding surface of piston seal: Transmission
3) Install thrust washer (31).
23-53
7. Clutch plate
Assemble plate (28), disc (29) and spring (30).
t Assemble in the same way as for the 3rd speed
side.
8. End plate
1) Install tool A2 and tighten tool Aa to push in end
plate (27).
2) Assemble ring (26) then remove tool AZ.
t Assemble in the same way as for the 3rd
speed side.
9. 1st gear
Install 1st gear (24), then assemble needle bearing
(25)*
+ Assemble in the same way as for the 3rd speed
side.
10. Idler gear

Assemble thrust washer (23), then assemble idler
gear (20).
23-54
11. Bearing
Assemble spacer (22), then assemble bearing (21).
+ Assemble the spacer with the spline side at the
bottom.
+ Press fitting inner race (21) only (separate inner
race and outer race when press fitting).
+ After press fitting the bearing, check that clear-
ance ‘c’ between the washer and the gear is
within the standard range.
‘c’ = 0.04 - 1.04 mm
419F417

+ If the gear on the side where the air is blown in
23-55
2ND-4TH SPEED CLUTCH PACK

pack on the stand,
the pack from slip-
* Set the shaft and housing on tool A with

the 2nd speed side at the top.
1. 2nd speed piston

Install 2nd speed piston (66).
+ Be careful not to damage the piston seal.
t Check that the spring pin is not protruding from
e $ding surface of piston seal: Transmission
2. Clutch plate
Assemble plate (69), disc (70) and spring (71) in
turn.
+ Soak plate (69) in clean transmission oil for at
t Be careful not to let spring (71) and plate (69)
t Do not let plate or spring catch in the ring
3. End plate
1) Install tool As and tighten tool As to push in end
plate (72).
2) Assemble ring (73), then remove tool AZ.
t Check that ring (73) is fitted securely in the
groove.
+ rhhtx;k that the disc rotates smoothly by
23-56
4. Thrust bearing
5. 2nd speed gear

Install 2nd gear (54), then assemble needle bearing
(53).
gear into position.
6. Bearing
t Check that the end face of the thrust bearing is
shaft.
7. Bearing
Assemble idler gear (50), then press fit bearing (51).
ance ‘e’ between the thrust bearing and the
idler gear is within the standard range.
‘e’ = 0.04 - 0.71 mm
419F418
23-57
8. 4th speed piston


+ Put a block on top of the stand.

2) Assemble piston (49) in same way as for 4th
speed piston.
e $iding surface of piston seal: Transmission
9. Clutch plate
Assemble plate (46), disc (47) and spring (48).
sr Assemble in the same way as for the 2nd speed
side.
10. End plate

1) Install tool A2 and tighten tool As to push in end
plate (45).
2) Assemble ring (44), then remove tool AZ.
+ Assemble in the same way as for the 2nd
speed side.
11. Thrust bearing

23-58
12. 4th aear

1) &semble in same way as for 2nd speed side.
2) Install 4th gear (42), then assemble needle
bearing (43).
+ Assemble the needle bearing at the bottom
first.
13. Thrust bearing

Assemble thrust bearing (41).
+ Check that the end face of the thrust bearing is
shaft.
.
14. Bearing
Install idler gear (39), then press fit bearing (40).
+ Press fit completely so that the idler gear is in
and bearing (40).

ance ‘f’ between the thrust bearing and the
spacer is within the standard range.
‘f’ = 0.101 - 1.231 mm
4lSF419

t If the gear on the side where the air is blown in
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
TRANSMISSION CONTROL VALVE

REMOVAL
A Park the machine on level ground, set the

safety bar on the frame, ground the bucket,
shut down the engine, apply the parking brake
and place blocks under the tires.
A Open the engine hood and lock it.
l Remove hydraulic tank side cover and transmission

oil filler cover.
1. Draining oil
Remove drain plug (1) and drain oil from transmis-
sion case.
Transmission oil: 304
2. Hydraulic piping
1) Remove transmission oil supply tube (2).
2) Remove tube (3) between transmission and
torque converter charging pump.
3) Disconnect the following hydraulic piping from
transmission control valve.
l Tube (4) between transmission control
valve and torque converter regulator valve.
l Hose (5) between transmission control
valve and accumulator.
0 Hose (6) between torque converter oil filter
and transmission control valve.
o Hose (7) between transmission control
valve and oil cooler.
t Remove the elbow of hose (5).
3. Electric wiring
Disconnect wiring (8) of transmission solenoid valve
from connector.

Sling transmission control valve (9) remove mount-
ing bolts, then lower and remove from under the
machine.
A There is little space, so be careful when work-

ing.
t When installing the lifting tool, avoid the con-

nectors and fit securely to the valve itself.
Transmission control valve: 48 kg
23-60
INSTALLATION

Set transmission control valve (9) in mounting
+ For the tightening torque and order of the
mounting bolts, see page 23-62, the section
under the bolts installing the transmission valve.
2. Electric wiring
Connect wiring (8) of transmission solenoid valve to
connector.
t When installing the wiring connector be careful
not to deform the thread case.
3. Hydraulic piping
1) Connect the following hydraulic piping to trans-
mission control valve.
valve and oil cooler.
0 Hose (6) between torque converter oil filter
and transmission control valve.
valve and accumulator.
l Tube (4) between transmission control
valve and torque converter charging pump.
2) Install tube (3) between transmission and
torque converter charging pump.
3) Install transmission oil supply tube (2).

Tighten drain plug and add engine oil through oil
Transmission oil: 3OP
+ Run the engine to circulate the oil through the

system. Then check the oil level again.
l Install the hydraulic tank side cover and trans-
mission oil filler cover.
23-61
t Tighten the bolts installing the transmission

valve in the order indicated in the picture below
to avoid the valve body from being distorted.
+ Torque down by two steps.
D First step 1.5kO.5 kgm

Second step 3.5kO.5 kgm
U41901808A
23-62
Disassembly of Transmission Control Valve
'J41901805
23-63
1. Separating
Remove the mounting bolts, separate the unit into
upper valve (1) and lower valve (2) and remove
gasket (3).
2. Disassembly of upper valve

1) Remove- coverV (4) with its mounting bolts
removed, and then remove gasket (5) pilot
valve (6) priority spring (7), quick return valve
ass’y (8), accumulator piston (9) and spring
(10).
2) Remove sleeve (11) from the quick return valve
ass’y and then remove spring (12) and ball (13).
3) Remove plug (14) from sleeve (11).
4) Remove cover (15) with its mounting bolts
removed, and then remove gasket (16) (main
regulator valve (17), spring (18) priority valve
(19) modulating valve ass’y (20), accumulator
shaft (21) and springs (22 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 ass’y
(20) and then remove retainer (27), springs (28
and 29), sleeve (30) and O-ring (31).
7) Remove nut (32) and washer (33) from cover
(15) and then remove adjust screw (34) and
O-ring (35).
8) Remove plug (36) and main orifice (37) from
upper valve (1).
3. Disassemblv of lower valve

1) Remove- solenoid valve ass’y (38) with its
mounting bolts removed, and then remove
gasket, spring (39), retainer (40), spring (41)
and sleeve (42).
2) Remove cover (43) with its mounting bolts
removed, and then remove gasket (44), torque
converter regulator valve (45), shim (46), spring
(41A), sleeve (42A), forward-reverse selector
valve (47), H-L selector valve (48), range selec-
tor valve (49) spring (50) and spacer (51).
3) Remove pilot filter (52) and O-ring (53) with the
mounting bolt removed.
4) Remove plug (54) from forward-reverse selector
valve (47).
5) Remove plug (55) from lower valve (2) and
cover (43).
6) Remove orifice (56) from lower valve (2).
23-64
Assembly of Transmission Control Valve
v
c9
41A
OO-53
23-65
1. Assembly of lower valve + See “Testing and Adjusting Volume” for the
1) Fit orifice (56) to lower valve (2). adjusting procedure.
+ Turn in the orifice until it clears the body by 3) Fit plug (26) to modulating valve ass’y (20); fii
2 mm or longer. O-ring (31) to sleeve (30) and then fit springs
2) Fit plug (55) to lower valve (2) and cover (43). (28 and 29) and retainer (27).
4) Fit load pistons (24 and 25) to main regulator
e Plug: Sealer (LG-1 or LG-5) valve (17) and priority valve (19).
5) Fit springs (22 and 23), accumulator shaft (21)
modulating valve ass’y (20) priority valve (19)
spring (18) and main regulator valve (17) to
Area to be coated
cover (15); and then mount cover (15) with
gasket (16) suitably fitted in position.
D Mounting bolts: 7.OkO.5 kgm
416F251
6) Fit plug (14) to sleeve (1l), set ball (13) and
spring (12) to quick return valve (8) and then
3) Fit plug (54) to forward-reverse selector valve mount sleeve (11).
(47)3 7) Fii spring (lo), accumulator piston (9), quick
4) Fit O-ring (53) to pilot filter (52) and mount the return valve ass’y (8), priority spring (7) and
pilot filter in position by tightening its mounting pilot valve (6) to cover (4). Then mount cover
bolt. (4) with gasket (5) suitably fitted in position.
D Mounting bolt: 7.020.5 kgm D Mounting bolts: 7.OkO.5 kgm
5) Fit H-L selector valve (48), range selector valve

(49) spacer (51) spring (50) forward-reverse 3. Connecting
selector valve (47), sleeve (42A), spring (41A), Connect lower valve (2) and upper valve (1) togeth-
shim (46) and torque converter regulator valve er with gasket (3) suitably fitted in position.
(45), and then mount cover (43) with gasket
(44) suitably fitted in position. a Mounting bolts: 3.220.3 kgm
D Mounting bolts: 7.OkO.5 kgm
6) Fit sleeve (42), spring (41), retainer (40) and

spring (39), and mount solenoid valve ass’y (38)
to lower valve (2) with gasket suitably fitted in
position.
D Mounting bolts: 7.0205 kgm
2. Assembly of upper valve

1) Fit plug (36) and main orifice (37) to upper
valve (1).
* Turn in the orifice until it clears the body by
2 mm or longer.
Plug: Sealer (LG-1 or LG-5)
2) Fit adjusting screw (34) together with O-ring

(35) to cover (15) and also fit washer (33) and
nut (32) to cover (15).
23-66
DISASSEMBLY AND ASSEMBLY TRANSMISSION SOLENOID VALVE
U41901806
DISASSEMBLY ASSEMBLY
1. Remove mounting bolts from solenoid valve body 1. Fit plug (10) to solenoid valve body (1).
[;I and then remove solenoid (2), plate (3) and clip
a Plug: Sealer (LG-1 or LG-5)
2. Remove lock plate (5) and then remove emergency

manual spool (6) and O-ring (7). 2. Fit orifice (8) and O-ring (7) to emergency manual
1) Remove orifice (8) from emergency manual spool (6), and fix them up by lock plate (5).
spool (6). 1) Mount plate (9).
2) Remove plate (9).
3. Fit plate (3) and clip (4) to solenoid (2), and mount
3. Remove plug (10) from solenoid valve body (1). solenoid (2) to valve body (1) by bolts.
a Mounting bolts: 7.020.5 kgm
Area to be coated
6-7
416F251
23-67
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
DIFFERENTIAL
2 1
DISASSEMBLY
1. Differential cover
Remove bleeder screw (l), then remove differential
cover (2).
Install the axle to a stand.
+ Remove the axle housing.
4 I9P846
Cage
1) Screw in forcing screw, remove mounting bolt,
then remove cage (3).
+ Check the number and thickness of the
t Loosen the mounting bolts of the coupling.
Cage: 17 kg
2) Remove O-ring from cage.
3. Brake piston
Screw in forcing screws at three places, raise
uniformly and remove piston (4).
t If the piston O-ring is not damaged, it is also
possible to install the bleeder screw and blow
in air to remove the piston.
4. Bearing carrier
Screw in forcing screws, raise uniformly and remove
bearing carrier (5).
+ Check the number and thickness of the shims,
and keep in a safe place.
+ Keep the left and right bearing carriers sepa-
rately in sets.
23-68
5. Differential carrier
1) Lii off differential carrier (6) from housing.
+ Be careful not to let the lifting tool slip out
of place when removing.
Differential carrier: 85 kg
I
2) Remove bearing cone (7) from differential

carrier, remove mounting bolts, then remove
differential case (8).
3) Remove thrust washer (9) then remove side

gear (10).
4) Remove cross shaft (ll), pinion gear (12) and

washer (13).
23-69
5) Remove gear (14), then remove thrust washer

(16).
6) Remove mounting bolts from bevel gear case

(16), then remove bevel gear (17).
7) Remove bearing cone (18) from bevel gear

case.
6. Coupling
Remove mounting bolts, then remove coupling (19),
retainer (20) and O-ring (21).
7. Bevel gear
1) Remove retainer (22), then remove oil seal (23),
O-ring (24) and retainer (25).
4 I SF427
419P857 ?.I
23-70
2) Using a press, pull out bevel pinion gear (26),

then remove bearing cone (27) and spacer (28).
+
I
\ 1 I,
26’ 4 I SF428
3) Remove bearing cups (30 and 31) from cage

(28). ,30
,31
4 I SF429
4) Using a press, remove bearing cone (32) from

bevel pinion gear (26).
t When removing sleeve (35) from the pivot
portion of reardifferential housing (36),
remove sleeve (35) with chisel after provid- 32.
ing slits (a) in the sleeve by using a sand-
ing machine.
4 I SF430
4lSFOI 104
23-71
ASSEMBLY
Special tools
Part number Part name 1 Q’tv
A 1 793-520-2150 1 Mandrel I 1
B1793-520:2200 1 Installer 1 3
1. Bevel pinion gear

1) Press fit bearing cone (32) on bevel pinion gear
(26), then install spacer (28).
+ Check that there is no clearance at the
contact face of any part.
2) Press fit bearing cups (30 and 31) in cage (29). 29 -30
3) Assemble bevel pinion gear (26) in cage (29),
then press fit bearing cone (27).
t Apply the specified load to the bearing with
the press, and rotate the case to settle the
031
bearing.
Load of press: 5 tons
&& Bearing: Axle oil

4 I SF429
+ When rotating the case with the specified

load, rotate lightly by hand. If the case
does not rotate smoothly, replace the
bearing and spacer, and try again. The
case must rotate smoothly.
4) Press fit oil seal (23) on retainer (22), then
install O-ring (24).
t Press fit oil seal (23) uniformly so that
depth ‘t’ is within the specified range.
Depth ‘t’ = 16 - 19 mm
& Lip of oil seal, O-ring: Axle oil
23-72
5) Install retainer (25) on top of bearing cone.

+ Do not forget the retainer.
6) Install retainer (22) in cage.
+ Tighten the mounting bolts partially, and
tighten them fully after installing the cou-
pling.
2. Coupling
Install coupling (19), O-ring (21) and retainer (20) to
pinion cage (29) then tighten mounting bolts.
+ Tighten the mounting bolts partially, and tighten
them fully after completing the assembly.
+ Be careful not to damage the seal when insert-
ing the coupling.
+ After installing the coupling, tighten the retainer
mounting bolts fully.
e Coupling, oil seal lip: Axle oil

4 l9P863
._
e Mounting bolt: Thread tightener (LT-2)
a Mounting bolt: 23.5k3.0 kgm
3. Differential carrier
1) Press fii bearing cone (18) in case.
+ After inserting the bearing, check that there
is no clearance at the end face.
2) Align with pin of bevel gear (17), set differential

case (16) in mounting position, then tighten
mounting bolts.
e Contact surface of bevel gear and differen-

tial case: Thread tightener (LT-2)
Iz_7 Mounting bolt: 11.521.0 kgm
23-73
3) install thrust washer (15) and side gear (14) in

differential case.
t Be careful to install the thrust washer facing
in the correct direction.
b Sliding face of thrust washer: Axle oil
4) Install pinion gear (12) on cross shaft (1l), then

install washer (13).
+ Be careful to install the washer stopper in
the correct position.
b Gear, shaft: Axle oil
5) Press fit bearing cone (7) in differential case (8).

+ After inserting the bearing, check that there
is no clearance at the end face.
6) Set side gear (10) in mounting position.

7) Align with pin of differential case and thrust
washer (9) in place with grease.
23-74
8) Set differential case (8) in mounting position,

+ Be careful not to let the washer fall out.
D Mounting bolt: 11.5? 1.O kgm
4. Adjusting cage with shims

1) install cage (3) to differential housing (33) with
no shim.
2) Insert measuring tool A in differential housing

(33) and measure distance between end face
of bevel pinion gear and tool A.
t Measure with an inside micrometer or a
cylinder gauge.
t When inserting tool A in the differential
housing, coat with oil and insert uniformly
without twisting.
23-75
3) Selection shim
’ t=c- (L + D/2)
t: Thickness of shim
c: (A + a) - (B + b)
L: Actual measured value
D: Diameter of tool A
A: 189
B: 62.5
a: Deviation from value A
b: Deviation from value B
+ For diameter D, use the actual measure- T
ment.
t Shim thickness Y’ should be within 0.5 -
1.9 mm.
The following values are written with elec-
tric pen on the end face of the pinion gear.
MD +O.lO (-0.01)
I
L- Distance ‘b’ (mm)

L Distance ‘a’ (mm)
I- Set No. for bevel pinion gear and bevel
gear.
4) Remove cage.
5. Bearing carriers
Press fit bearing cups (36 and 37) on bearing
carriers (34 and 35).
& Press fitting portion of bearing cup: Axle oil
6. Adjusting bearing carrier with shims

1) Raise differential carrier (6), set in mounting
position, then temporarily install left and right
bearing carriers (34 and 35).
t Install the differential carrier with the bevel
gear on the right as seen from the cage
mount side.
+ Install the bearing carrier with no O-ring or
shim, and adjust.
a Bearing: Axle oil
23-76
2) Tighten carrier (34) on differential case side to

standard torque.
+ Tighten 8 bolts, and check that they are
tightened to the specified torque.
D Mounting bolt: 11.3k1.2 kgm
3) Tighten carrier (35) on bevel gear side with 4

mounting bolts.
+ Rotate the bevel gear when tightening to
settle all the parts.
m Mounting bolt: 2.7kO.3 kgm
4) Loosen 4 mounting bolts at bevel gear end until

bearing has end play.
5) Tighten 4 mounting bolts again uniformly.
IZI] Mounting bolt: 0.37kO.03 kgm
* Confirm that the bearing has end play at

this time.
6) Using a feeler gauge, measure clearances T1

and T2 at two places in groove of bearing
carrier (35) on bevel gear side.
7) Selecting shims
Shim thickness = (Tl + T2/2)+0.005 mm
+ Use a combination of the following shims to
give the required shim thickness.
0.07 mm, 0.20 mm, 0.30 mm, 0.80 mm
23-77
8) Remove left and right bearing carrier, then

assemble selected shims (36).
+ Rotate the bevel gear and tighten the
mounting bolts of the bearing carrier uni-
formly.
c-7 Mounting bolt: 11.32 1.2 kgm
9) Using spring balance (37), measure preload of

bevel gear, and check that it is within the
specified range.
+ Preload: 0.64 - 2.15 kg
t If the preload is not within the specified
range, change the shim thickness to adjust.
7. Cage
1) Fit O-ring (38) to cage.
e O-ring: Axle oil
4 Install guide bolts, assemble shims (39) select-

ed in step 4 then install cage (3).
23-78
8. Adjusting backlash
1) Measure backlash of bevel gear with dial
gauge.
+ Measure first with all the shims installed on
the bevel gear side.
+ Measure the backlash at three places
around the circumference of the bevel gear.
The variation between measurements must
be within 0.1 mm.
Backlash of bevel gear: 0.3 - 0.41 mm
2) To make backlash within specified range, move

some of shims from bevel gear side to opposite
side.
+ When moving the shims, do not change the
total shim thickness.
+ If the backlash is too large, move shims
from B to A.
+ If the backlash is too small, move shims
from A to B.
4 I9F433
23-79
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 adjustment
The tooth contact pattern Adjust the pinion gear by adjusting the shims at the cage.
should start from about 5 Adjust the bevel gear in the same way as when adjusting
mm from the toe of the backlash.
bevel gear and cover about
50% of the length of the
tooth. It should be in the
20BF5 I4
center of the tooth height.
Bevel pinion gear is too far 1. Reduce shims at pinion gear to bring closer to bevel
from bevel gear. gear.
2. Move bevel gear further away from pinion gear and
adjust backlash correctly.
2OBF5 I5
- 2OBF519
Bevel pinion gear is too 1. Increase shims at pinion gear to move away from
close to bevel gear. bevel gear.
2. Move bevel gear closer to pinion gear and adiust
backlash correctly. /l
2OBF5 I6
2OBF520
Bevel gear is too close to 1. Reduce shims at pinion gear to bring closer to bevel
pinion gear. gear.
2. Move bevel gear further away from pinion gear and
adjust backlash correctly. II
2OBF5 I7
2OBF5 I9
Bevel gear is too far from 1. Increase shims at pinion gear to move away from
pinion gear. bevel gear.
2. Move bevel gear closer to pinion gear and adjust
backlash correctly.
2
c n
2OBF5 IB
? 2OBF520
t 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.
23-80
10. Bearing carrier

Remove bearing carrier (34), assemble angled ring
(40), then install together with adjusted shims (36).
t Coat the angled ring with grease, and be care-
ful not to let it fall when assembling.
t When installing bearing carrier (34) the angled
ring may fall out, so do not use a hammer to
install.
a Angled ring: Grease (G2-Ll)
D Mounting bolt: 11.5+ 1.O kgm
11. Brake piston

1) Fii O-rings (41 and 42) securely in grooves of
brake piston (4) and bearing carrier (34).
t Coat the brake piston and piston mount
lightly with grease to prevent the O-ring
from twisting or breaking.
e Piston and piston mount surface: Axle oil
2) Install piston press fitting tool B to differential

housing, then tighten screws (43) uniformly to
press fit.
t Press fit the piston until it contacts the
housing.
t If using a plastic hammer to tap in, be
careful not to damage the O-ring and pis-
ton.
12. Checking for leakage of brake oil

1) Install bleeder screw.
2) Tighten all screws (43) of piston press fitting
tool B completely, then turn back one turn.
3) Install hydraulic test kit @to brake tube mount,
then operator pump to bleed air from inside
cylinder.
4) Operate pump and raise pressure to 14
Hydraulic test kit
kg/cm*.
* After raising the pressure to 14 kg/cm*,
leave for 5 minutes and check that the drop
in pressure is less than 3.5 kg/cm*.
4 I9F434
23-81
5) If the test shows that there is no leakage of oil,

raise pressure to 42 kg/cm2.
t After raising the pressure to 42 kg/cm2,
leave for 5 minutes and check that the drop
in pressure is less than 3.5 kg/cm2.
t If there is any leakage of oil, remove the
brake piston and check the O-ring for
damage.
+ After checking for leakage of brake oil,
insert piston fully.

1) Install differential cover (2) on differential hous-
ing.
+ Install a guide bolt in the mount hole of the
bleeder screw to prevent gasket from enter-
ing the hole.
e C$;r contact face: Gasket sealant (Loctite
D Mounting bolt: 11.52 1.O kgm 4 f 9P846
2) Remove guide bolt and install bleeder screw

(1).
+ Check that there is no gasket sealant in the
screw hole when installing.
+ Tighten the mounting bolts of the coupling
fully.
t After holding sleeve (35) to the pivot end
face of rear differential housing, be careful
not to incline sleeve (35) and press fit it.
+ Press fit sleeve (35) so that the end face of
sleeve becomes as same as that of pivot
portion.
419FOI 106
23-82
DISASSEMBLY AND ASSEMBLY FRONT AXLE
FRONT AXLE
REMOVAL

moving.
1. Jack up machine, and put blocks @ under front

frame.
+ Use the bucket to raise the front frame, and
insert the block when the tires are slightly off
the ground. If the machine is not equipped with
a bucket, put blocks under the tips of the lift
arms, and raise the front frame.
2. Front drive shaft

Disconnect front drive shaft (1).
Front drive shaft: 20 kg
3. Brake tube
Disconnect brake tube (2).
4. Tire, wheel
Sling tire and wheel (3), remove mounting bolts,
then lift off.
Tire, wheel: 335 kg
23-83
5. Axle
1) Using jack and hoist, sling axle (4), then re-
move mounting bolts and lower axle.
+ Use the jack to adjust the height when
removing the mounting bolt.
Axle: 690 kg
f+ kg
2) Pull out axle assembly from machine.
23-84
INSTALlATlON
1. Axle
1) Insert axle under machine body.
+ Use a hoist and jack to insert the axle.
2) Raise axle (4) with jack and hoist, set in mount-

ing position, then tighten mounting bolts.
+ Use the bolts as guides to align with the
mounting position.
a Mounting bolt: 8058 kgm
2. Tire, wheel
Raise tire and wheel (3) set in mounting position,
then tighten the mounting bolts.
3. Brake tube
Connect brake tube (2).
+ Careful not to tighten the tube too much.
D Tightening torque of tube nut: 1.2kO.3 kgm
23-85

Connect front drive shaft (1).
5. Lowering machine to ground

Remove block I from under front frame, and lower
machine to ground.
t Raise the front frame slightly with the bucket
and remove the block.
6. Bleeding air from brakes

+ For details of bleeding air, see SECTION 52,
TESTING AND ADJUSTING.
23-86
DISASSEMBLY AND ASSEMBLY REAR AXLE
REAR AXLE
REMOVAL

+ Before removing the rear axle, remove the
fuel tank. See the section of “Removal of
fuel tank”.
1. Jack up machine, and put blocks @ under rear

frame.
t Use the jack to raise the rear frame, and insert
the block when the tires are slightly off the
ground.
2. Tire, wheel
Sling tire and wheel (1) remove mounting bolts,
then lift off.
Tire, wheel: 335 kg
3. Rear drive shaft

Remove rear drive shaft (2).
t Make match marks to show the mounting
position.
4. Brake hose, grease tubes

1) Disconnect brake hose (3).
2) Remove grease tubes (4 and 5).
t Remove the tube clamp.
23-87
5. Axle
1) Secure pivot to axle with wire.
+ Fit the wire securely so that the pivot can-
not move.
2) Fii garage jack under axle (6) then remove
mounting bolts.
+ Adjust the height of the jack when remov-
ing the mounting bolts.
Rear axle: 800 kg
3) Pull out rear axle from machine.

+ Use a hoist and jack to remove the axle.
+ After pulling the axle out from the machine
body, remove wire.
t Remove the fuel tank before removing the
axle.
See the section of “Removal of fuel tank” in
Chapter 13.
6. Front pivot
1) Lift off front pivot (7).
+ Be careful not to let the lifting tool slip
when lifting off the pivot.
Front pivot: 55 kg
& kg
t Carry out the work of item 2) only, as the

front pivot is welded.
2) Remove O-ring (8) and bushing (9) from pivot

(7).
23-88
7. Rear pivot
1) Remove thrust cap (lo), then remove wear
plate (11).
+ If there is shim (12) between the thrust cap
and the pivot, check the number and thick-
ness of the shim, and keep in a safe place.
11 4 I9F423
2) Remove thrust plate (13), then remove wear

plate.
3) Lift off rear pivot (14).

+ Be careful not to let the lifting tool slip
when lifting off the pivot.
Rear pivot: 120 kg
4) Remove O-ring (15) and bushing (16) from

pivot (14).
23-89
INSTALIATION
1. Front pivot
1) Install O-ring (8) and bushing (9) to pivot (7).
t Check that the clearance of bushing con-
tact faces is within 0 to 3.15 mm.
t Assemble the bushing with the chamfered
edge on the axle housing side.
* Install with the joint of the bushing at the
side.
a O-ring, bushing: Grease (G2-Ll)

419FOI
2) Raise pivot and insert in axle mount.

t Check that the O-ring is not caught.
+ After installing the pivot, tie it to the axle
with wire to prevent the pivot from coming
out.
t Remove the fuel tank before removing the
axle.
See the section of “Removal of fuel tank” in
Chapter 13.
2. Rear pivot
1) Install O-ring (15) and bushing (16) to pivot
(14).
t Check that the clearance of bushing con-
tact faces is within 0 to 3.15 mm.
* Assemble the bushing with the chamfered
edge on the axle housing side.
t Install with the joint of the bushing at the
side.
& O-ring, bushing: Grease (G2-Ll)
419Fl21
2) Raise pivot, insert in axle mount, then install

wear plate (17) and thrust plate (13).
Mounting location Of
t Check that the O-ring is not caught.
thrust plate
&
I_
Mountina bolt: Thread tiahtener (Loctite
262) -
Mounting bolt: 28.523.0 kgm
t Remove all grease from the mounting bolts

and mount holes.
419FOI 103
23-90
3) To make axle and pivot parallel, turn thrust cap

(10) back to front, and tighten 4 bolts uniformly.
m Mounting bolt: 721 kgm
+ Check that the clearance between the pivot

and thrust cap is uniform.
t Set in the mounting position on the ma-
chine with the thrust cap turned back to
front.
3. Axle
Raise axle (6) with jack and hoist, set in mounting
+ Use the bolts as guides to align with the mount-
ing position.
+ Tighten the mounting bolts from the rear pivot
end, and tighten in three stages.
* After installing the axle, remove the wire.
D Mounting bolt: 80~8 kgm
+ Mounting the fuel tank after the axle is mount-

ed. See the section of “Installation of fuel tank”
in Chapter 13.
4. Adjusting shims at rear pivot

1) Tighten 4 mounting bolts of thrust plate to the
specified-tightening torque.
+ Tighten with the wear plate installed.
2) Using a feeler gauge, measure greatest clear-

ance between thrust plate and pivot, and select
shims.
+ Select the number of shims as follows:
0 -0.1: 1 shim
0.1 l-0.3: 2 shims
0.31-0.5: 3 shims
--I-- Clearance
4 l9F426
23-91
3) Install selected shims (12) wear plate (11) and

thrust cap (10).
D Mounting bolt: 28523.0 kgm
5. Brake hose, grease tubes

1) Install grease tubes (4 and 5).
+ Install the tube clamp.
2) Connect brake hose (3).
+ Do not tighten the brake tube too much.
D Hose nut: 1.2kO.3 kgm
6. Rear drive shaft

Install rear drive shaft (2).
+ Align match marks and be careful to install with
the coupling facing in the correct direction.
D Mounting bolt: 7.OkO.5 kgm
+ Install the fuel tank.

See the section of “Installation of fuel tank” in
Chapter 13. 26
,.
7. Tire, wheel I
-- .,
-1
Sling tire and wheel (l), set in mounting position,
8. Lowering machine to ground

Remove block 0 from under rear frame, and lower
machine to ground.
+ Raise the rear frame slightly with a jack and
remove the block.

* For details of bleeding
air, see SECTION 52,
TESTING AND ADJUSTING.
23-92
DISASSEMBLY AND ASSEMBLY DRIVE SHAFT
DRIVE SHAFT
DISASSEMBLY

1) Remove coupling and tube (1).
+ Make match marks “a” before removing so
that the direction of the coupling does not
change.
2) Loosen bolt (2), then remove coupling (3) and

retainer.
+ Make match marks before removing so that
direction of the coupling does not change.
3) Using a press, remove flange bearing (4).
2. Center drive shaft, rear drive shaft

+ Follow the procedure in 1. Front drive shaft
Step 1).
23-93
3. Spider, bearing
1) Remove seal and bearing caps (5).
2) Remove ring (7) of spider (10) and bearing (6),

then tap with plastic hammer to remove spider
and bearing.
+ Repeat the same procedure for the front,
center and rear drive shafts.
6
419F422B
23-94
ASSEMBLY
1. Spider, bearing
1) Set spider (10) and bearing (6) in mounting
position, assemble ring (7), then install.
+ Assemble so that the grease nipples face in
the same direction.
t Repeat the same procedure for the front,
center and rear drive shafts.
419F422E
2) Install bearing (5).

t Check that there is a bearing and Derling
washer inside the bearing cap.
& Bearing cap: Grease (G2-Ll)
t If the spider and bearing cap are worn,

replace the spider and bearing.
+ Heat will damage the bearing, so do not
weld strap (8) of the cap.

1) Press fit flange bearing (4).
t Do not hit the flange bearing directly with a
hammer.
2) Align match marks, install coupling (3) and

retainer (9)‘ then tighten mounting bolt (2).
+ Tighten the bolts to the specified tightening
torque aiter installing on the machine.
6 Spline: Grease (G2-Ll)
m Mounting bolt : 28523.0 kgm

3) Align match marks and install coupling and

tube (1).
t Check that the couplings are facing in the
same direction.
+ If the spline is worn, replace the whole
drive shaft assembly.
a Spline: Grease (G2-Ll)
3. Center drive shaft, rear drive shaft

+ Follow the procedure in 2. Front drive shaft
Step 1) to 3).
23-96
DISASSEMBLY AND ASSEMBLY AXLE HOUSING
AXLE HOUSING
DISASSEMBLY
1. Draining oil
Remove drain plug (1) and drain oil from axle.
Axle: 244
Special tools
No. Part number Part name Q’ty
4 f 9P882
A 790-101-3100 Puller Ass’v 1
A1 1 790-101-3110 1 Puller I 1 set
A2 790-101-3120 Bolt 2
As 790-101-3130 Nut 2
1) Remove bleeder screw (2), then remove differ-
ential cover (3).
2) Install axle on stand.
4 I SF883
3. Axle housing
1) Sling axle housing (4), remove mounting bolts,
then lift off.
t Mark the housings to distinguish the left
and right axle housings.
2) Disconnect axle housing, then remove sun gear

(5), brake disc (6) and brake inner ring (7).
t Be careful not to damage the face of the
brake disc.
Axle housing: 247 kg

4. Brake outer ring

Remove brake outer ring (8).
l Be careful not do damage the surface in con-
tact with the brake disc.
5. Planet carrier
1) Remove snap ring (10) from axle shaft (9), then
pull out planet carrier (11).
+ When removing the planet carrier, be care-
ful not to get your fingers caught between
the pinion gears.
10
,,,,
,, 1
9’ 4 I9F435
2) Extend tab of lock washer (12), remove lock nut

(13), then remove washer (14).
4 I9F436
6. Axle shaft
1) Stand housing (4) on end, and raise about 20
mm.
2) Tap end face of axle shaft (9) with copper
hammer to remove shaft, then remove bearing.
* Pull the axle shaft out a short distance,
then remove part ‘a’ of oil seal (15) with
a screwdriver. This is to prevent bearing
(16) from damaging the oil seal.
23-98
3) Remove bearing (16) and seal (15) from axle

shaft (9).
4 I9F437
Remove the bearing as follows.

When removing bearing (16) of shaft (9) push
in portion “a” of oil seal and sleeve (15) towards
flange uniformly with screwdriver evenly around
circumference.
Make clearance “c” at contact of bearing (16)
and sleeve (15A) to enable fitting of the tip of
the puller.
6) Fit bolt (30)(5/8-18UNF, length = approx. 60

mm) to bearing puller Al, and install to portion
“d”.
+ Screw in the threaded portion of the bolt
fully.
7) Set bearing puller Al at clearance C between

bearing (16) and sleeve (15A), and assemble
bolt A2 and nut A3.
* When doing this, fix the bearing puller
securely so that there is no play.
416F01005A
A3
A3
Al
A2 ‘A2
416FO1 QQ7A
23-99
8) Insert washer between bolt (30) and flange

surface, then turn bolt (30) to loosen, and
remove bearing (16).
+ There is only a small amount of room to fii
the puller to the bearing, so be careful that
r-T 9
it does not come off.

t If the length of the threaded portion of bolt
(30) is too short, use more washer on the
flange surface to adjust the height of bolt
(30), then remove bearing (16).
+ Replace the oil seal and sleeve assembly
with a new port. 416F01008n
7. Ring gear
Using a puller, raise ring gear (17) uniformly, then
remove.
I- Axle housing
4 I9F438
8. Axle housing
Remove bearing cups (18 and 19) from axle hous-
ing (4).
4 I9F439
23-100
9. Planet carrier
1) Knock in spring pin (20).
* Be careful not to knock the spring pins in
too far.
Carrier
4 I SF440
,,.~.. ~~
2) Using a press, remove shaft (21).
3) Remove spring pin (20) from shaft (21).
4) Remove planetary gear (22) from planetary

carrier (ll), then remove bearing cone (23),
shim (24) and ring (25).
+ Repeat the above steps to remove pinion
gears.
23-101
ASSEMBLY
Special tools
A I 793-520-l 551 1 Seal support I 1
B 1 793-520-2720 1 Nut wrench 1 1
1. Planet carrier
1) Install bearing cone (23) on planetary gear (22),
then set in carrier (11).
t Insert ring (25) inside the planetary carrier
before starting.
2) Using a feeler gauge, measure clearance be-

tween carrier (11) and bearing cone (23) and
select shims to bring clearance within standard
value.
Clearance: 0.112 - 0.450 mm
+ Decide the shim (24) thickness for each
gear separately.
3) Assemble selected shims and press fit shaft

(21).
* Align the holes of the shaft and spring pin,
then knock in the spring pin until it is level
with the carrier.
Press fitting force: 5 tons
& Shaft: Axle oil
23-102
4) Tap end face of shaft and differential end of

gear (22) to push back bearing so that gear
can rotate smoothly.
l The gear must rotate smoothly,
2. Axle housing
Press fit bearings (18 and 19) in axle housing (4).
* After press fitting cup, check that there is no
clearance at area ‘a’.
& Press fitting portion of cup: Axle oil
419F441
3. Ring gear
Press fit ring gear (17) in axle housing (4), then
knock in pin (26).
t Align the pin hole when installing the ring gear.
t Cool ring gear (17) with dry ice at about -30” C
before press fitting.
4. Axle shaft Press

1) Assemble outer oil seal (28) to inner oil seal (-ygSi&
(27).
2) Using a press, press fit oil seal on axle shaft
(9).
+ Do not hit the seal with a hammer as the
seal may be deformed.
Q Lip of outer oil seal: Axle oil
I I 4 I9F442
23-103
3) Set bearing (16) on press stand, and press fii

axle shaft (9).
+ Be careful not to let the bearing slip out of
position.
/9
6 Press fitting portion of bearing: Axle oil
‘16
4 I9F443
--
5. Housing
1) Stand shaft (9) on end, and install tool A.
+ Adjust the height with the adjustment bolt
so that the top of tool A touches seal (15)
lightly with a uniform clearance.
t Secure tool A firmly so that it does not slip
out of position.
4 I9P900
2) Raise housing (4) horizontally and insert care-

fully on shaft.
+ Stop housing (4) before press fitting the oil
seal.
e Press fitting portion of oil seal: Axle oil
3) Align housing (4) with press fitting portion of oil

seal and lower housing slowly.
t Use the weight of the housing to insert it.
+ After installing the housing, seal surfaces
(a) and (A) must be level. In addition, if
there is any clearance at ‘a’, the clear-
ance must be uniform.
4) Remove tool A.
/ 4 I9F444
23-104
5) Assemble bearing (29) on shaft, and Ipotate

housing tzby hand to settle bearing.
+ Press fit until the end play is 0.5 mm.
b Press fitting portion of bearing cone: :Axle

oil
6. Adjusting end play

1) Install washer (14) lock washer (12), and nut
(13) on shaft.
+ Align washer (14) with the groove of the
shaft when installing.
2) Rotate housing (4) by hand, and use tool B to

tighten lock nut (13) until shaft can no longer
be rotated by hand.
3) Loosen ,lock nut (13) until housing can be

rotated easily by hand.
23-105
4) Rotate shaft and tighten lock nut until standard

value is reached for end play.
End play: 0.025 - 0.200 mm
+ Put the axle housing on its side. Install a
dial gauge to the housing and put the
probe in contact with the WIheel Inounting
surface.
5) After deciding the end play, bend tap of lock

washer (12) and fit in groove of lock nut (13).
+ Bend the tab of the lock washer and fit it
securely in the groove of the lock nut.
7. Planetary carrier
Align spline of axle shaft, install planetary carrier
(1l), then secure with ring.
* Clean the shaft and planetary carrier spline
before assembling.
+ Install the ring securely in the groove of the
shaft.
A When assembling the planetary carrier, be

careful not to get your fingers caught in the
gear.
8. Brake outer ring

Install brake outer ring (8) in axle housing.
+ Align the pin and the outer ring pin hole when
installing.
+ Be careful not to damage the surface of the
brake outer ring.
23-106
9. Axle housina
1) Install brake inner ring (7), brake disc (6) and
sun gear shaft (5) in differential housing.
+ Check that there is no damage to the sur-
face of the brake ring.
+ Soak the brake disc for at least two min-
utes in clean axle oil before installing.
2) Raise axle housing (4) horizontally, align hole of

spline groove pin (30), and install carefully.
+ When installing, be careful not to let the
brake ring and disc slip out of position.
+ Clean all grease and oil from the surface of
the axle housing and differential housing,
and coat with a continuous film of gasket
sealant.
& Housing contact surface: Gasket sealant

(Loctite 515)
D Mounting bolt of housing: 28.523.0 kgm

1) Knock pin into differential housing, then install
differential cover (3).
* Coat with a continuous film of gasket seal-
ant.
t Be careful not to get any gasket sealant in
the mounting hole of the bleeder screw
when installing.
& Cover contact surface: Gasket sealant

(Loctite 515)
D Mounting bolt of cover: 28.523.0 kgm
2) Install bleeder screw (2)

Tighten drain plug and add engine oil through oil
Q Axle oil: 24P
23-107
POWER TRAIN
ENGINE AND TRANSMISSION MOUNT ................................................ 2
TORQUE CONVERTER CHARGING PUMP .............................................. 4
TORQUE CONVERTER ............................................................ 5
TRANSMISSION .................................................................. 6
TRANSMISSION CONTROL VALVE .................................................... 9

UPPERVALVE ................................................................ 9
LOWERVALVE ................................................................ 11
SOLENOIDVALVE ............................................................... 12
TRANSMISSION CLUTCH ......................................................... 13
DIFFERENTIAL ................................................................. 16
FINALDRIVE ................................................................... 18
DRIVESHAFT ................................................................... 20
AXLEMOUNT .................................................................. 21
AXLE . . . . . . . . . . . .._........................................................... 23
24-1
MAINTENANCE STANDARD TRANSMISSION AND ENGINE MOUNT
ENGINE AND TRANSMISSION MOUNT
B-B
.__
.
__-.. L12AD042
3
24-2
MAINTENANCE STANDARD TRANSMISSION AND ENGINE MOUNT
Unit: mm
No. Check item Criteria Remedy
1 Clearance between transmission bracket and adjustment bolt l-2 Adjust

Tightening torque of mounting bolt 76.0 + 8.5 kgm
Tightening torque of bracket mounting bolt 28.5 23.0 kgm

Retighten
Tightening torque of mounting bolt 76.0 f 8.5 kgm
Tightening torque of clearance adjustment bolt 23.5 28.0 kgm
24-3
MAINTENANCE STANDARD TORQUE CONVERTER CHARGING PUMP

SAL(2)-040 + 020
/
2
Section A-A
419F126
Torque converter
charging pump Direction clutch lubricating pump
I
SAL(2)-040 ’ SAL(S)-020
Unit: mm
Standard Clearance
Model
clearance limit
Clearance between gear
1
case and side plate gear SAL(2)-040
0.10-0.15 0.19
SAL(2)-020 I
Clearance between inside Replace

diameter of plain bearing SAL(2)-040
2 0.06-o. 125 0.20
and outside diameter of SAL(2)-020
gear shaft
3 Insertion depth of pin 12+O

I I -0.5
-iline 1
0.5-l .5 kgm
5 Tightening torque of bolt 11.5kl.O kgm Retighten
Revo- Discharge Standard Repair limit

Model lution pressure discharge discharge
Discharge (rpm) (kg/cm2) (P/min) @/min)
(EOl O-CD, 45-55” C)
SAL(2)-040 3000 30 115 106
SAL(2)-020 3000 30 59 53
24-4
MAINTENANCE STANDARD TORQUE CONVERTER
TORQUE CONVERTER
419F127
Unit: mm
Standard size Repair limit

1 Outside diameter of pilot Repair
52 51.75 chrome
100 100.5 plating or
2 Inside diameter of retainer (Seal ring contact surface)
1 replace
3 Inside diameter of sleeve (Seal ring contact surface) 50 50.1
4 Backlash between PTO drive gear and driven gear 0.169-0.393 Replace
Width 3 2.7
5 Wear of seal ring
Thickness 4 3.6
Replace
6 Tightening torque of pump mounting bolt 3.2~0.3 kgm
7 Tightening torque of pilot mounting bolt 7.0 20.5 kgm

Retighten
8 Tightening torque of gear retainer mounting bolt 7.0 kO.5 kgm
24-5
MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION
1 2
LO7CRO2a
24-6
Unit : mm
Tolerance
Standard . Standard
size clearance
1 Shaft Hole
Clearance between idle shaft and bearing
60 0 0 -0.015-
-6.012 -0.015 0.012
2 Clearance between idle gear and bearing
between pump drive shaft and
between pump drive gear bearing

I 85 I l.015 I +l:K I -iiE-
Clearance between pump drive shaft and 45 +0.013 0 -0.025-

bearing + 0.002 -0.012 -0.002
Clearance between pump drive gear bearing 0 +0.022 -0.013-

and housing 100 -0.015 -0.013 0.037
Clearance between output shaft oil seal and 100 + 0.400 + 0.054 -0.400-
housing +0.200 0 -0.146
Clearance between output shaft oil seal and 100 +0.400 + 0.054 -0.400-
housing +0.200 0 -0.146
Clearance between output shaft bearing and 110 0 -0.015 -0.04- Replace
housing -0.015 -0.040 0
10 Clearance between output shaft and bearing
Clearance between output shaft bearing and

11
housing
12 Clearance between output shaft and bearing
13 Clearance between Forward-Reverse clutch 90 0 + 0.022 -0.013-

bearing and housing (R) -0.015 -0.013 0.037
14 Clearance between Forward-Reverse clutch 90 0 + 0.022 -0.013-

bearing and housing (F) -0.015 -0.013 0.037
15 Clearance between lst3rd clutch bearing and 100 0 + 0.022 -0.013-

housing (R) -0.015 -0.013 0.037
16 Clearance between lst3rd clutch bearing and 100 0 + 0.022 -0.013-

housing (F) -0.015 -0.013 0.037
17 Clearance between 2nd-4th clutch bearing and 90 0 + 0.022 -0.013-

housing (R) -0.015 -0.013 0.037
Clearance between 2nd-4th clutch bearing and

18
housing (F) 1 13’ 1 l.018 1 +-ii:: 1 -ii::-
24-7
Unit: mm
Standard
Tolerance Repair limit
Wear of diameter size
19A (Seal ring contact surface)
+0.05
50 49.95
0
Wear of seal ring groove width 1 3.2 1 +;*076 ( 3.5
19C Wear of seal ring width

I 3-14 I IO2 I 2-7
Replace
19D Wear of seal ring thickness 2.3 20.1 2.1
20 Outside diameter of coupling 75 0 74.95

(Oil seal contact surface) (R) -0.074
Outside diameter of coupling

21
(Oil seal contact surface) (F) 1 75 1 IO74 1 74*g5
22 Clearance between output shaft cover and housing
23 1 Rotating torque of output shaft 0.01-0.1 kgm
24 Tightening torque of coupling mounting bolts 27.5 54.0 kgm

Retighten
25 Tightening torque of strainer mounting bolts 30.6 + 9.2 kgm
26 Torque convertor assembly mounting bolt 11.521.0 kgm
24-8
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
TRANSMISSION CONTROL VALVE

UPPER VALVE
u41901045
24-9
Unit: mm
Tolerance
Standard Standard Clearance
size clearance limit
Clearance between pilot Shaft Hole
1
reducing valve spool and body
19 -0.02 +0.013 0.020- 0.050
-0.03 0 0.043
Clearance between main -0.02 +0.013 0.020-
2 19 -0.03 0 0.043 0.050
regulator valve and body
Clearance between main

3 regulator valve and load
piston
Clearance between priority -0.02 +0.013 0.020-

4 valve and body 19 -0.03 0 0.043 0.050
Clearance between priority -0.02 +0.018 0.020-

5 valve and load piston 12.5 -0.03 0 0.048 0.055
Clearance between quick return -0.020 +0.013 0.020-

6 valve and body 28 -0.028 0 0.041 0.044
Clearance between fill valve -0.02 +0.013 0.020-

7 and body 28 -0.03 0 0.043 0.050
Clearance between fill valve -0.02 + 0.033 0.040-

8 and sleeve 28 -0.03 + 0.020 0.066 0.070
Replace
Clearance between fill valve
9
and sleeve
Clearance between sleeve and

10
body
Clearance between accumula-
11 tor valve and body 1 28 1 ;:;; 1 +;*‘13 1 ;:$;- 1 0.050
Main regulator valve and pilot

12
valve spring
13 Priority valve spring 69.5 52.6 25.92+ 1.30 66.7 23.3
14 Quick return spring 48.0 41 .o 0.08 f 0.004 46.1 0.072
15 Fill valve spring (inner) 41.8 40.0 2.4620.12 40.1 2.21
16 Fill valve spring (outer) 43.6 24.3 14.07+0.70 41.9 12.7
17 Accumulator spring (outer) 99.6 99.6 0 95.6
18 Accumulator spring (inner-l) 35.6 35.6 0 34.2
19 Accumulator spring (inner-2) 40.8 40.8 0 39.2
24-10
6 5
Unit: mm
No. Check item I Criteria Remedy
Tolerance
Clearance between torque size clearance limit
Shaft Hole
1 converter regulator valve and
body -0.02 +0.013 0.020-
19 0.050
-0.03 0 0.043
Clearance between Forward-

-0.02 +;.“‘a 1 ;:E- 1 0.050
2 Reverse selector spool and 19
-0.03
bodv
Clearance between High-Low -0.02
3 19
selector spool and body -0.03
Clearance between range Replace

4 19
selector spool and body
:e Repair limit
Torque converter regulator Installation Free Installation

5 load (kg) length load (kg)
spring
56820.28 67.5 5.1
Forward-Reverse selector spool 8.5kO.43 46.8 7.7

6 48.8 36
spring I I I I
High-Low and speed range

7 48.0 36.7 7.1220.36 46.1 6.4
selector spool spring II I
I
24-11
MAINTENANCE STANDARD SOLENOID VALVE
SOLENOID VALVE
w 1.275 t 0.475 kgm

m 0.165 + 0.015 kgm
\ w 3.15 ?Z 0.35 kgm \ /
Section A-A Section B-B

u41901047
Unit: mm
Tolerance
Standard . Standard Clearance
Clearance between emergency Shaft Hole
1 Replace
manual valve spool and body
-0.02 +0.013 0.020-
14 0.050
-0.03 0 0.043
24-12
MAINTENANCE STANDARD TRANSMISSION CLUTCH
TRANSMISSION CLUTCH
Forward, Reverse Clutch Assembly
(F) 1
\
419F153
i5 9’ il
lst, 3rd Clutch Assembly

-tt--12
419F154
2nd, 4th Clutch Assembly
419F155
24-13
Unit: mm
No. Check item
-
Criteria
- r Remedy
Clearance between piston and

Standard
size
r Tolerance T Standard
clearance
Clearance
limit
Shaft Hole
cylinder
1 -0.27 +0.06
(F-R) Inside 110
-0.32 -0.07
(F-R) Outside -0.27 +0.06
139
-0.32 -0.07
Clearance between piston and -0.27 +0.06 0.20-

110 0.43
cylinder (lst, 2nd, 3rd, 4th) Inside -0.32 -0.07 0.38
2
6.27 +0.06 0.20-
(lst, 2nd, 3rd, 4th) Outside 165 0.43
-0.32 -0.07 0.38
bearing
Clearance between F-R clutch shaft +0.013 X1.025-
3 50 0
and bearing inner race (R) -0.002 -0.002
-0.012
bearing
Clearance between F-R clutch shaft + 0.030 -0.042-
4 50 0
and bearing inner race (F) +0.015 -0.015
-0.012
bearing
Clearance between lst, 3rd clutch +0.015 -0.030-
5 55
shaft and bearing inner race (R) +0.002 -0.002
i.015
bearing Replace
Clearance between 1st 3rd clutch + 0.030 -0.045-
6 55 0
shaft and bearing inner race (F) +0.015 -0.015
-0.015
bearing
Clearance between 2nd, 4th clutch +0.013 -0.025
7 50 0
shaft and bearing inner race (R) + 0.002 -0.002
-0.012
bearing
Clearance between 2nd, 4th clutch +0.015 -0.030-
8 60 0
shaft and bearing inner race (F) + 0.002 -0.002
-0.015 I
I
Repair
Standard size Tolerance
I limit
Thickness of separator plate
9 1.7 50.05 I 1.5
Deformation of wear surface of

0.08 0.15
separator plate
Thickness of friction plate 2.2 20.08 I 1.9

10 Deformation of wear surface of
0.13 0.25
friction plate I
Load of wave spring (at height

11
2.2 mm) 103 (kg) +lO.O (kg) 83 (kg)
Thickness of 1st clutch thrust

12 3.18 2.7
washer
24-14
F-R clutch spacer length
End play of forward gear
24-15
DIFFERENTIAL
DIFFERENTIAL
/ i ..l I ‘\ II , ):
:’ Ii / I \ i
View Z
24-16
MAINTENANCE STANDARD DIFFERENTIAL
Unit: mm
1 Free turning torque of bevel gear 0.64-2.15 kg
I Differential side bearing preload I 210-730 kg I
Thickness shim of differential side bearing carrier Adjust

Standard shim 0.59-l .47
Thickness shim of differential housing and cage

3 Standard shim 0.7-l .8
assembly
4 Height of jut out pin 12

Replace
5 Height of jut out pin 11
Tightening torque of left carrier differential

6 (1St) w/o shim 11.5 + 1.O kgm
side bearing mounting 8 bolts
Tightening torque of right carrier differential

7Lsideiing mounting 4 bolts 1 (1st)w/oshim11.5+1-Okgm 1
8
Tightening torque of left carrier differential
side bearing mounting 8 bolts I (2nd) w/o shim 2.720.3 kgm
Tightening torque of right carrier differential

9 (3rd) w/o shim 0.37+0.03 kgm
side bearing mounting 4 bolts
Tightening torque of left and right carrier differential

10 Final torque 11.5 f 1.O kgm
side bearing mounting bolt I
11 1 Tightening torque of bevel gear mounting bolts 11.5kl.O kgm I Retiahten

12 1 Tightening torque of case mounting bolts I 11.5 +l.O kgm I
13 Tightening torque of seal retainer mounting bolts 9.0 k3.5 kgm
14 Tightening torque of cage mounting bolts 18.Ok2.0 kgm
15 Tightening torque of coupling mounting bolts 28.5 23.0 kgm
16 Tightening torque of drain plug 18.5k5.5 kgm
17 Tightening torque of brake disc checking plug 13.5t4.0 kgm
18 Tightening torque of breather 0.6kO.l kgm
19 Tightening torque of differential cover 11.5kl.O kgm
24-17
MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
.‘.‘.‘.~.~.~.~.~.~.I~.~.I~.~.~,~.\~.~.~.~.~.~.~.~.~.~.~.~.~.~.~.
~::::. : :::.
.~.~.~.~,~,~.\~.~.\~.~.~.~.~.~.~.~.~,~.~.~.~.~.~.~.~,..~ ::::, :;::.
.‘.‘.‘.‘.‘.‘.‘.‘.‘.‘.‘.‘.~.~.‘.~.~.~.~.~,~.~,~,~.~,~,~.~.~.~.~.~.~.~.~.~.~.~.
;, .;, .; ,., .,.,.,.,., .,., .,. .,., ., .,., ., .,., .,.,., .,., .,..., .; .,.,., ..
Detail P
419Fl35
24-18
MAINTENANCE STANDARD FINAL DRIVE
Unit: mm
No. Check item I Criteria Remedy
Tole
Standard
1
size
1 Clearance between axle housing Shaft
and ring gear
+O.lO +0.10 -O.lO-
t 340
+0.03 0 +0.07 I
+ 0.025 +0.187 O.lO-

2 Clearance of guide pin 12
+ 0.007 +0.125 0.18
0 -0.028 -0.068
Clearance of axle (Outer race) 145
housing bearing -0.018 -0.068 -0.010
3
of differential side 0 0 -0.020-
95
(Inner race) -0.022 -0.020 + 0.022
Replace
+ 0.025
Clearance of axle (Outer race) 157.162
housing bearing 0
4
of tire side +0.076 +0.025 -0.076-
101.600
(Inner race) + 0.050 0 -0.025
(Housing) +0.21
160
+O.ll
Diameter of axle shaft oil seal
5
mounting place 0
(Shaft) 126
-0.063
6
Clearance between pinion gear
33.338
+ 0.025
+0.013
L
bearing and shaft
7 End play of axle shaft ( .025-0.200 mm
Clearance between oil seal and

8 0.162-2.062 mm
housing
Tightening torque of axle oil filler

9 13.5k4.0 kgm
plug
Tightening torque of mounting
10 94.5 + 10.5 kgm Retighten
bolts
Tightening torque of mounting 28.5k3.0 kgm

11
bolts
24-19
MAINTENANCE STANDARD DRIVE SHAFT
DRIVE SHAFT
6 E419F132
1 Tightening torque of bolt 7.OkO.5 kgm
2 Tightening torque of bolt 28.5k3.0 kgm
4 Tightening torque of bolt 7.OkO.5 kgm Retighten
7 Tightening torque of bolt 28.5 +3.0 kgm
24-20
MAINTENANCE STANDARD AXLE MOUNT
AXLE MOUNT
69.0 f 7.0 kgm
w 28.5 f 3.0 kgm
m 28.5 f 3.0 kgm

u41901340
Section A-A 1
24-21
MAINTENANCE STANDARD AXLE MOUNT
Unit: mm
No. I Check item Criteria Remedy
Standard size Tolerance Repair limit
1 Thickness of thrust plate

12
i.15
0
2 Thickness of wear plate
-0.1
Tolerance Standard Clearance

clearance limit Replace
Clearance between shaft Shaft Hole
3 and hole at front support
side -0.050 +0.565 O.lOO-
-0.122 + 0.050 0.667
4 Clearance between shaft 170 -0.043 + 0.550 0.093-

and hole at rear support -0.106 +0.050 0.656
side
5 Thickness of axle mount 0.2 (Standard shim thickness)

shim
24-22
MAINTENANCE STANDARD AXLE
AXLE
View 2
24-23
Unit: mm
No. Check item Criteria Remedv
Standard
size
Clearance of bearing at Outer race

1
differential side 120 I l.020 I:::: I,:Fz I
Inner race
75 I rE: I:.015 I ii:E- I
Outer race
140 I IO18 I:::z I,z- I
Clearance of bearing of
2
pinion shaft at pinion side Inner race +0.039 0 --.054-
65 +0.020 -0.015 -0.020
Outer race 0 -0.041 --.076- Replace

120 -0.015 -0.076 -0.026
Clearance of bearing of
3
pinion shaft at coupling side Inner race +0.039 0 --.054-
55 +0.020 -0.015 -0.020
12 t 0.025 t 0.027 --.025-

4 Clearance of bevel gear pin
to.007 0 t 0.020
Clearance between pinion

5 25.4 -0.05 to.10 O.lO- 0.3
gear and spider -0.10 to.05 0.20
Clearance between differen- 302 -0.25 to.05 0.20-

6
tial housing and piston -0.10 -0.05 0.50
Clearance between bearing

7
carrier and piston
Standard size I Standard clearance I Clearance limit
8 Backlash of bevel gear Adjust
0.30-0.41
9 Backlash of differential gear 0.1O-O.25
10 End play of pinion gear (Max) 0.15

Thickness of side gear
11
washer
12
Thickness of pinion gear
washer
-q$+-j Rep’a
Height of spacer between
Replace at
13 pinion shaft bearing and 52.02 + 0.025
disassembly
bearing
Outside diameter of axle to.142

14 mount mounting place 180 179.8 Replace
t 0.077
(Rear differential)
24-24

Outside diameter of axle
15 mount mounting place Replace
-0.050
(Rear differential) 190 189.6
-0.122
24-25
STEERING SYSTEM
HYDRAULIC PIPING . . . . . . . . . . . . . .. . . . . .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
HYDRAULIC CIRCUIT SCHEMATICS . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
HYDRAULIC CIRCUIT DIAGRAM . . . ................................................... 4

2-SPOOL . . . . . . . . . . . . . . . . . . ................................................... 4
3-SPOOL (WITH GROUND DRIVEN STEERING) ........................................ 5
3-SPOOL (WITH GROUND DRIVEN STEERING, SECURITY VALVE) .......................... 6
STEERING CONTROLSYSTEM ...................................................... 7

STEERING VALVE (ORBITROL VALVE) ............................................... 7
PRIORITYVALVE .............................................................. 14
HANDPUMPANDSLEEVE ...................................................... 17
CUSHIONVALVE .............................................................. 19
GROUND DRIVEN STEERING PUMP 20
DIVERTERVALVE...............:::::::::::::::::::::::::::::::::::::::::::::: : 21
STEERING COLUMN ............................................................. 24
STEERING CYLINDER MOUNT AND CENTER HINGE PIN .................................. 25
41-1
STRUCTURE AND FUNCTION HYDRAULIC PIPING
See foldout #1 at end of book.
HYDRAULIC CIRCUIT SCHEMATICS

(Engine running, work equipment control valve in “HOLD”, steering valve in “NEUTRAL”)
3
L’
J
u41901319
-
41-2
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT SCHEMATICS
1. Hydraulic tank 8. Steering cylinder 10. Lift cylinder

2. Hydraulic and steering pump 9. Main control valve 11. Dump cylinder
3. Priority valve 9A Lift spool 12. Oil filter
4. Steering valve 9B Dump spool 13. Breather
5. Overload relief valve 9C Relief valve
6. Cushion valve 9D Safety valve (With suction)
7. Restrictor valve
41-3
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC CIRCUIT DIAGRAM

P-SPOOL
,L_____Mi 4 i
Tr
2
M
.
r
7
“I
l--7
r-7
91 9B 1
12 -- 1
1 21 Okg/cmi U41901320
_.~
1. Hydraulic tank 8. Steering cylinder 10. Lift cylinder

2. Hydraulic and steering pump 9. Main control valve 11. Dump cylinder
3. Priority valve 9A Lii spool 12. Oil filter
4. Steering valve 9B Dump spool 13. Breather
5. Overload relief valve 9C Relief valve
6. Cushion valve 9D Safety valve (With suction)
7. Restrictor valve
41-4
STRUCTUREANDFUNCTION HYDRAULIC CIRCUIT DIAGRAM
3-SPOOL (WY GROUND DRJEN STEERING)
1.
1’ 8
r-- l3
i_ -1’
@-
I !
21 Okgicm” r 90 u41901321
LE
1. Hydraulic tank 9. Main control valve 10. Lift cylinder
2. Hydraulic and steering pump 9A Lift spool 11. Dump cylinder
3. Priority valve 9B Dump spool 12. Oil filter
4. Steering valve 9C Attachment spool 13. Breather
5. Overload relief valve 9D Relief valve 14. Attachment cylinder
6. Cushion valve 9E Safety valve (With suction) 15. Diverter valve
7. Restrictor valve 9F Safety valve (With suction) 16. Ground driven steer-
8. Steering cylinder ing pump
41-5
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM
3-SPOOL (WITH GROUND DRIVEN STEERING, SECURITY VALVE)
I
&.a . .
-i
I
14
!
- I--
t I u41901322
IL
1. Hydlraulic tank 9. Main control valve 11. Dump cylinder
2. Hydlraulic and steering pump 9A Lii spool 12. Oil filter
3. Prior:ity valve 9B Dump spool 13. Breather
4. Steering valve 9C Attachment spool 14. Attachment cylinder
5. Overload relief valve 9D Relief valve 15. Diverter valve
6. Cushion valve 9E Safety valve (With suction) 16. Ground driven steer-
7. Restrictor valve 9F Safety valve (With suction) ing pump
a. Steering cylinder 10. Lii cylinder 17. Security valve
la. Float valve
41-6
STRUCTURE AND FUNCTION STEERING CONTROL SYSTEM
STEERING CONTROL SYSTEM

STEERING VALVE (ORBITROL VALVE)
Section X-X
t f-
X X
22WF045A
1. Gland 7.
Spacer A. Load sensing port
2. Valve body 8. Rotor B. To left steering cylinder
3. Spool 9. Stator C. To right steering cylinder
4. Center pin 10. Spacer D. To hydraulic tank
5. Sleeve 11. Cover E. To steering pump
6. Drive shaft 12. Centering spring
41-7
Outline
l The steering valve is connected directly to the
steering wheel. It acts to switch the oil from the
steering pump to the right and left steering
cylinders to decide the direction of travel of the
machine.
l The steering valve consists basically of spool
(3) sleeve (5), rotor (8) and stator (9). Spool (3)
and sleeve (5) have a rotary type direction
selecting function. Rotor (8) and stator (9)
operate as a hydraulic motor during normal
steering operation, and as a hand pump when
the supply of oil stops due to a breakdown in
the steering pump or engine.
Structure
l Spool (3) is connected directly to the drive shaft of
the steering wheel. It is connected to sleeve (5) by 406F411
center pin (4) (not in contact with the spool when
the steering wheel is at NEUTRAL) and centering
spring (12).
0 Drive shaft (6) is meshed at the top with center pin
(4) and forms one unit with sleeve (5). At the same
time, it is meshed with rotor (8) of the Girotor set by
a spline.
l There are four ports in valve body (2). They are
connected to the pump circuit, tank circuit, and the
head, and front and rear steering cylinders. In
addition, the pump port and tank port are connect-
ed inside the body by the check valve. Therefore, if
there is any failure in the pump or engine, oil can
be sucked in directly from the tank through the
check valve.
Groove to mesh
with center pin
41-8
This page is blank.
41-9
STRUCTURE AND FUNCTION . STEERING CONTROL SYSTEM
Operation
1. Steerina wheel at NEUTRAL
[7 Groove, hole in
spool
Hole in sleeve
22WP953
G F b
Valve body
Sleeve Spool
Sleeve \ I
=$gig --) Drain
pool
Section X-X Section Y-Y Section t-2

41-10 22WP954
22WF039A
STRUCTUREANDFUNCTION STEERING CONTROL SYSTEM
l When the steering wheel is not being used, center

pin (4) is held by centering spring (12) in the center
of the oblong hole of spool (3). Spool (3) and
sleeve (5) do not move.
When this happens, pump port A in the sleeve,
ports E, F and G leading to the cylinder and Giro-
tor, and vertical grooves B, C and D in the spool
are shut off.
However, orifice a of pump port A and orifice d
(connected to drain port H) of the spool are con-
nected.
In addition, orifice b of port J from the priority valve
is connected with the vertical groove B of the spool.
Port K of the sleeve connects drain port L of the
spool to vertical groove B.
l By connecting and disconnecting these ports and
grooves, the oil from the pump passes through
orifices a and d of port A and is drained to the
hydraulic tank.
The oil which forms the pilot pressure of the priority
valve passes from port J through orifice b. It then
goes through vertical groove B and port K, and
returns to the hydraulic tank from port L.
For details of the operation of the priority valve, see
section for priority valve.
41-11
2. Steering wheel turned to the left
Priority valve
TI
I -
-
~~~ u41901353
D Groove,hole in
spool
@ Hole in sleeve
22WF833
41-12
l When the steering wheel is turned to the left, spool

(3), which is connected by the spline of the steering
shaft, turns to the left. However, sleeve (5) and the
spool are interconnected by centering spring (12),
so the spool compresses the centering spring.
As a result, there is a difference (angle variation) in
the angle of rotation of the spool and the sleeve.
This difference corresponds to the amount by which
the centering spring is compressed.
When this happens, first, port A and vertical groove
B are connected, then vertical groove B and port E
leading to the Girotor. Next, port E leading from the
Girotor and vertical groove C are connected, and
finally, vertical groove C and port G leading to the
front right cylinder head are connected.
At the same time, vertical groove B and orifice b of
port J leading to the priority valve are kept connect-
ed, but the connection between port K of the sleeve
and vertical groove B and port L gradually closes.
Port F from the front left cylinder head is connected
to vertical groove D (leading to drain port H) at the
same time as port A and vertical groove B are
connected.
l By connecting and disconnecting these ports and
grooves, the oil from the pump goes from port A to
vertical groove B, then flows to port E of the Girotor
to rotate the Girotor. The oil delivered from the
Girotor goes from port E and enters vertical groove
C, then from port G to the head end of the front
right cylinder.
The oil entering vertical groove B passes through
orifice b and flows to port J. From port J it be-
comes the pilot pressure of the priority valve.
The oil from the head end of the front left cylinder
goes from port F and enters vertical groove D, and
is drained to the hydraulic tank.
l For details of the operation of the Girotor, see the
next page.
3. Steering wheel not operated

When the operation of the steering wheel is
stopped, the difference in rotation of the spoof and
spring is returned to the NEUTRAL position by the
reaction of centering spring (12).
For details of the function of center pin, see func-
tion of center pin.
41-13
PRIORITY VALVE
1. Plug
2. Valve body
3. Spool
4. Return spring
5. Plug
6. Relief valve body
7. Spring seat
8. Valve spring
9. Holder
10. Relief valve ball
11. Screen
A. To steering valve
To main control valve
:. From steering valve
D: Drain
E. From pump
Outline
l The priority valve is in the circuit from the steering
E’ pump to the steering valve and main control valve.
Section X -X
E22WF046A It acts to divide the oil from the steering pump to
the steering valve or main control valve circuit.
It protects the circuit by setting the hydraulic pres-
sure in the circuit from the priority valve to the
steering valve at 200 kg/cm*.
41-14
Operation
1. Steering wheel at NEUTRAL

When the engine is stopped, the force of spring (4)
pushes spool (3) to the left in the direction of the
arrow. The circuit between port M and port N is
FULLY OPEN, and the circuit between port M and
port Q is FULLY CLOSED.
In this condition, when the engine is started and the
steering pump is rotated, the oil from the pump
goes from port M to port N, and then flows to port
A of the steering valve. The oil entering port A, is
restricted by orifice a, so the pressure in the circuit
rises.
When this happens, the oil which passes through
orifice m of spool (3) and enters port P, compress-
es spring (4) and moves spool (3) to the right in the
direction of the arrow. The circuit between M and
port Q becomes almost FULLY OPEN, and the
circuit between port M and port N becomes almost
FULLY CLOSED. The circuits are stabilized in this
condition, and most of the oil from the pump goes
to the main control circuit.
2. Steering wheel turned to the left

When the steering wheel is turned to the left, an
angle variation between the spool and the sleeve of
the steering valve is created, and the Row of oil is E22WF834
10
switched. (See explanation of “Steering valve”.) The
oil from the pump flows from port M to port N and To front right cylinder
enters port A. Because of the opening of the sleeve

(port A) and spool (port B), a difference in pressure
is generated between the circuit up to port A and
the circuit beyond port B. Some of the oil from port
B flows to the Girotor and enters the front right
cylinder; the rest of the oil passes through orifice b,
flows to port J and enters port R. When this hap-
pens, spool (3) is stabilized in a position where the
load of spring (4) is in balance with the difference in
pressure between the circuit up to port A and the
circuit beyond port B (pressure at port P - pressure
at port R). The opening of the circuit from port M to
port N and port Q is adjusted to divide the flow of @ Hole in sleeve
oil to both circuits.
The ratio of this flow is determined by the opening
of port A and port B, that is, the angle variation
between the sleeve and spool of the steering valve.
The opening is adjusted steplessly by the number
of turns of the steering wheel.
E22WF835
3. Steering cylinder at end of stroke From girotor To front right cylinder

If the steering wheel is turned after the steering
cylinder has reached the end of its stroke, the
circuit from port M through port N to S is kept
open, so the hydraulic pressure rises.
When this pressure reaches 200 kg/cm2, relief valve
(10) opens and the oil is relieved to the hydraulic
tank. This flow of oil generates a difference in
pressure on either side of orifice r. The balance
between the load of spring (4) and the circuit up to
port A and the circuit beyond port B is lost, and the
pressure on the circuit up to port A becomes
higher.
For this reason, the pressure at port P moves spool
(3) further to the right in the direction of the arrow
than in Section 2. The circuit between port M and
port N is stabilized at almost FULLY CLOSED, and
the circuit between port M and port Q is stabilized
at almost FULLY OPEN.
From pump
10
E22WF836
41-16
HAND PUMP AND SLEEVE
2OBFO60 2OBFO61
[Fig. 1 I [Fig. 21
The connections between the sleeve ports and the

suction and drain ports of the Girotor, which are
joined by the sleeve, are as shown in the above
diagram.
If the steering wheel is turned to the right, ports a,
c, e, g, i and k are connected to the pump by the
vertical grooves of the spool. Ports b, d, f, h, j and
I are connected in the same way to the head of the
front left steering cylinder.
In the situation shown in Fig. 1, ports 1, 2 and 3 are
the delivery ports of the Girotor set. They are
connected with ports 1, b and d, so oil is sent to
the cylinder. At the same time, ports 5, 6 and 7 are
connected, so oil flows in from the pump.
If the steering wheel is turned 90” from this posi-
tion, the condition changes to that in Fig. 2. In this
case, ports 1,2 and 3 are the suction ports and are
connected with ports i, k and a. Ports 5, 6 and 7
are the delivery ports and are connected with ports
d, f and h.
l In this way, the ports of the Girotor acting as

delivery ports are connected to ports which are
connected to the steering cylinder. The ports acting
as suction ports are connected to the pump circuit.
l Adjusting delivery in accordance with angle of
steering wheel:
For every l/7 turn of the steering wheel, the inner
teeth of the Girotor gear advance one position, so
the oil flow from the pump is adjusted by this
movement. In this way, the oil delivered from the
pump is directly proportional to the amount the
steering wheel is turned.
Function of Center Pin

0 Centering pin (12) consists of four layers of leaf
springs crossed to form an X shape. The springs
are assembled in spool (3) and sleeve (5) as shown
in the diagram on the right.
When the steering wheel is turned, the spring is
compressed and a difference in rotation (angle
variation) arises between the spool and the sleeve.
Because of this, the ports in the spool and sleeve
are connected and oil is sent to the cylinder. When
the turning of the steering wheel is stopped, the
Girotor also stops turning, 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
Angie
the sleeve and spool, so the steering wheel returns variation
to the NEUTRAL position.
li 20BF062
41-18
CUSHION VALVE
Section X-X
Section Y-Y u41901323
1. Valve seat Function

2. Body The cushion valve is installed to reduce the hydraulic
3. Poppet pulse in the steering circuit caused by the switchback
4. Orifice action coming from the machine body at the end of the
5. Spool steering stroke.
6. Poppet
A: From steering valve
B: From steering valve
41-19
STRUCTUREANDFUNCTION STEERING CONTROL SYSTEM
GROUND DRNEN STEERING PUMP
I Section A-A
4 I9F479
View 2
1. Drive gear (Teeth 12)

2. Front cover
3. Gear case
4. Rear cover
5. Driven gear (Teeth 12)
Specifications
0 Model: SAM(2)-28
0 Theoretical delivery: 28 cc/rev.
l Max. delivery pressure: 210 kg/cm2
l Max. rotational speed: 3000 rpm
41-20
-!L
\
F
Section X-X
Section Y-Y
4 I9F480
1. Diverter valve A. From steering pump
2. Valve body To steering pump
3. Check valve k To hydraulic tank
4. Check valve
z: Sensor mounting port
Ground driven steering pump
Port
Function F. Round driven steering pump
l If the engine stops or the pump seizes during Port
machine traveling, and it becomes impossible to G. From hydraulic tank
steer, the rotation of the transmission is used to
turn the emergency steering pump to make steering
possible.
41-21
Operation
l Pump and engine are working normally.
To oriority valve
1 To main control valve
S&or c I 3
1
Steering pump
’_ Emergency pug
m j‘.
Xl
Hydraulic tank
l When the engine is working normally, the hydraulic

pump and steering pump are rotated by the engine.
Therefore, oil is sent to the steering valve, and the
machine can be steered.
In addition, the emergency steering pump is rotated
by the transmission, so oil from port A of the
diverter valve pushes open check valve (2) and
enters port B.
Pressure oil from the steering pump is flowing to
port D, so it pushes spool (3) in the direction of the
arrow.
As a result, the oil from port B flows to port C and
is drained to the hydraulic tank.
41-22
l Failure in pump or engine when machine is

traveling.
Ittr-
To priority valve
it
i
To main control valve
Se&or 4 d
! -
Steering pump
m
I -
7’. T/M
Emergency pump
Hydraulic tank
U41901325
l If there is a failure in the pump or engine when the

machine is traveling, the rotation of the wheels is
transmitted through the transfer to rotate the emer-
gency steering pump.
The steering pump is not rotating, so no pressure
oil is formed at port D. As a result, spool (3) is
pushed in the direction of the arrow by spring (4).
The oil from the emergency steering pump passes
from port A through port B and flows to the steering
valve to make steering possible.
t The emergency steering pump is designed so
that it can rotate both directions.
41-23
STRUCTURE AND FUNCTION STEERING COLUMN
STEERING COLUMN
Section A-A
1. Steering wheel
2. Steering column
3. Center shaft
4. Steering valve (Orbitrol)
5. Tilt lever
Section B-B
41-24
STRUCTURE AND FUNCTION STEERING CYLINDER MOUNT AND CENTER HINGE PIN
STEERING CYLINDER MOUNT AND CENTER HINGE PIN

Outline
l The front frame and rear frame are connected front and rear frames, so when the cylinders are
through a bearing by the center hinge pin. The operated, the frame bends at the middle to give the
steering cylinders are connected to the left and right desired angle, that is the desired turning radius.

1. Front frame
2. Steering cylinder
3. Rear frame
4. Upper hinge pin
5. Lower hinge pin
6. Steering cylinder bottom pin
7. Steering cylinder rod pin
4 I9F530
Section D-D
Section C-C
41-25
STEERING SYSTEM
STANDARDVALUETABLE FOR CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
TOOLLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
STEERING WHEEL.. ................................................................. 3

PLAY.. ........................................................................ 3
OPERATING FORCE ............................................................... 4
OPERATING TIME - LOCK TO LOCK ................................................... 5
STEERINGOILPRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TROUBLESHOOTING ................................................................. 7
STEERING SYSTEM ............................................................... 8
1. Steering wheel does not turn. ..................................................... 8
2. Steering wheel is sluggish. ....................................................... 9
3. Steering wheel moves unsteadily or is subjected to large shock. ........................... 10
* The following precautions are necessary when using the Standard Value Tables to make judgements during
2. The information in the Standard Value Tables are estimates, based on standards from the production plant
when the machines were shipped. Therefore, when troubleshooting they should be used as reference in
combination with repair and operating records when making judgements.
42-1
STANDARD VALUE TABLE FOR CHASSIS
Testing and measuring item Measurement condition Unit
value value
Steering wheel Road surface: Flat, horizontal, mm O-40 Max. 60

l Steering wheel play dry, paved surface: kg 1.1-l .6 Max. 2.4
l Steering wheel operating force 0 Hydraulic temperature:
l Operating time of steering wheel 45-55” c
(Low idling) 0 Machine posture: Sec. 4.5 Max. 5.0
(High idling) Facing straight 3.2 Max. 3.7
Hydraulic temperature:
Steering oil pressure 200+;
45-55” c kg/cm” 200 f 20
l Main relief oil pressure
Engine speed: High idling
TOOL LIST
No. Testing and measuring item Tool name Part number Remark
O-25 kg/cm2
1 Oil pressure Hydraulic tester 799-l 01-5000 O-50 kg/cm2
O-300 kg/cm2
2 Operating force Push-pull gauge 7AO-262-0020 O-25 kg
42-2
STEERING WHEEL
PLAY
l Engine speed: Low idling
l Machine posture: Facing straight
Item
value value
Steering wheel play O-40 Max. 60
1. Measuring procedure
1) Turn the steering wheel lightly clockwise and
counterclockwise two or three times and con-
firm the neutral position of the steering mech-
anism. Put mark “1” on the outer frame of the
vehicle monitor or instrument panel.
2) Turn the steering wheel clockwise. Align the po-

sition where the tires begin to move with mark
“l”, then put mark “2” on the steering wheel.
3) Turn the steering wheel counterclockwise. Align

the position where the tires begin to move with
419F302
mark “l”, then put mark “3” on the steering
wheel. Measure the distance of a straight line
between mark “3” and mark “2”.
42-3
TESTING AND ADJUSTING STEERING WHEEL
OPERATING FORCE
l Road surface: Flat, horizontal, dry, paved surface
l Engine speed: Low idling (bucket unload)
Item
value value
Force of steering wheel 1.0-l .6 Max. 2.4
Soecial tool
A 79A-264-0020 Push-pull scale 1
Measuring procedure
1. Hook push-pull scale A to the knob of the steering
wheel.
+ Hook push-pull scale to center of knob.
2. Start the engine.

+ After starting the engine, raise the bucket about
400 mm and remove the safety bar.
3. Pull push-pull scale A at a tangent, and read the

value when the steering wheel is moving smoothly.
+ Do not read the value at the time the steering
wheel starts to move.
42-4
TESTING AND ADJUSTING STEERING WHEEL
OPERATING TIME - LOCK TO LOCK
Measuring procedure
1.
TESTING AND ADJUSTING STEERING OIL PRESSURE
STEERING OIL PRESSURE
l Engine speed: High idling
Unit: mm
Main relief oil pressure 1 200+07 1 200220
Soecial tool
1. Measuring main relief pressure
%& Loosen the oil filler cap slowly to release the

A
4 pressure inside the hydraulic tank. Then operate
the steering wheel several times to release the
1) Pii safety bar (6) on the frame.

2) Remove plug (1) for measuring the right turn
steering circuit.
3) Install hydraulic tester A to the measuring port.
4) Start the engine and run at high idling. Turn the
steering wheel to the right and measure the
pressure when the relief valve is actuated.
+ When removing the plug (2) for the left turn
steering circuit, turn the steering wheel to
the left and measure.
42-6
TROUBLESHOOTING
+ Before carrying out the troubleshooting in this section, read “PRECAUTIONS WHEN TROUBLESHOOTING”,
“METHOD OF READING TROUBLESHOOTING TABLES”, and “PREVENTING RECURRENCEOFTROUBLE” listed
in SECTION 22.
42-7
STEERING SYSTEM
1. Steering wheel does not turn.

l Did the steering system suddenly cease to
turn? 4 Damage to equipment in steering
circuit.
l Did steering wheel show signs of being sluggish
for some time? - Worn parts in steering circuit
or faulty seal.

e Is oil level and type of oil in the hydraulic tank
correct?
l Has the safety bar been removed from the
frame?
l Is the steering linkage properly adjusted?
No.
Problems
1 Steering wheel cannot turn left or right. 0 000
Fault of item 1 and also work equipment does not

’ I ooerate normallv. I O 101 I I
3 Steering wheel can only turn to either left or right. 0
4 Steering wheel is sluggish and does not turn properly. 0 0 0
5 Oil pressure in steering circuit does not rise at all. 0
6 Steering wheel turns, but steering does not move. 0
L07zz011
t Because the steering circuit and the work equip-

ment circuit are intimately related to each other, The following symbols are used to indicate the
check the operation of the work equipment if the action to be taken when a cause of failure is
steering behaves abnormally. located:
X: Replace A: k?pidr
A: Adjust C: Clean
42-8
2. Steering wheel is sluggish.

l Did the steering wheel suddenly become slug-
gish? - Damage to equipment in steering cir-
Wit.
l Did the steering wheel show signs of being
sluggish for some time? - Worn parts in steer-
ing circuit or faulty seal.

l Is oil level and type of oil in the hydraulic tank
correct?
l Is there any oil leakage from the oil pressure
hose, valves, cylinders, etc?
l Is there any seizure between the pin and bush-
ing of the center hinge bearing and the steering
cylinder pin and bushing?
l Check tire pressure.
Fault check.
l Measure the operating force of the steering
wheel and also the operating time of steering
wheel, then check the results against the stan-
dard value table to see whether or not there is
any abnormality.
Steering wheel is sluggish and jerky.
eermg cmult pressure IS low.
LO7ZZO12

located:
A: Adjust C: Clean
42-9
3. Steering wheel moves unsteadily or is subjected

to large shock.

l Is the oil level and type of oil in the hydraulic
tank correct?
l Is there any play in the center pin hinge bearing
or steering cylinder pin bushing?
l Does tire pressure fluctuate?
Fault check.
Operate the wheel loader in a safe place and check
the conditions under which the steering wheel
becomes unsteady.
+ If, in addition to the steering wheel being un-
steady, there are other faults such as sluggish-
ness, etc., refer to item 2. “Steering wheel is
sluggish.”

located:
A: Adjust C: Clean
42-10
STEERING SYSTEM
STEERINGVALVE ................................................................... 2
REMOVAL ...................................................................... 2
INSTALLATION.. ................................................................. 4
DISASSEMBLY.. ................................................................. 7
ASSEMBLY .................................................................... 10
PRIORITYVALVE ................................................................... 15
REMOVAL ..................................................................... 15
INSTALLATION.. ................................................................ 17
STEERING CYLINDER ............................................................... 19

REMOVAL ..................................................................... 19
INSTALLATION .................................................................. 20
DISASSEMBLY.. ................................................................ 21
ASSEMBLY .................................................................... 23
CENTER HINGE PIN.. ............................................................... 26

REMOVAL ..................................................................... 26
INSTALlATION .................................................................. 31
* For details of disassembly and assembly of the gear pump, see SECTION 97.
+ Take the following method for air bleeding when you start to operate hydraulic cylinders after reassembling

43-1
DISASSEMBLY AND ASSEMBLY STEERING VALVE
STEERING VALVE
REMOVAL

%& Loosen the oil filler cap to relieve the pressure

A
4 in the hydraulic oil tank, then operate the con-
trol lever 2 or 3 times to eliminate the residual
pressure in the piping.
0 Loosen plug (1) at the top of the hydraulic tank

1. Cover
2. Hydraulic wiping
Disconnect’ the-following hydraulic hoses from
steering valve.
l Hose (4) between the steering valve and priority
valve.
l Hose (5) between the steering valve and hy-
draulic tank.
l Hoses (6 and 7) between the steering valve and
steering cylinder.
0 Hose (8) between the steering valve and priority
valve.
43-2
3. Steering column linkage

Disconnect steering column (9) from steering valve.
4. Steering valve
Remove steering valve (10) after removing mounting
bolts.
43-3
...-
INSTALLATION
1. Steering valve
1) Assemble seal (19) to shaft (18) and coat top
surface of seal well with grease.
t Be careful of the direction of the seal when
assembling.
6 Top surface of seal: Grease (G2-Ll)
F42101029 F42101030
2) Coat internal part of spline (c) of steering valve

(9) and circumference (b) of plate (17) well with
grease.
a Internal part of spline (c): Grease (G2-Ll)
& Circumference of plate (b): Grease (G2-Ll)
3) Insert splined part of shaft (18) fully into splined

part of steering valve (9).
+ Insert the longer spline into the steering
valve.
F42101130
F42101131
4) Set bracket (16) on steering valve (9), assemble

plate (17) on left and right of shaft, then tighten
together with bracket with mounting bolts.
t When doing this, install so that the clear-
ance between the shaft and plate is uni-
form.
43-4
5) Align spline of joint (14) at tip of steering col-

umn with shaft of steering valve (9) then fix
bracket (16) temporarily.
+ When doing this, install so that the clear-
ance between the ‘shaft and plate is stan-
dard dimension (a).
Standard value: 1-2 mm
t Set block on the top surface of the front
frame to prevent the steering valve from a
falling.
6) Assemble remaining mounting bolt to bracket
(16) and secure bracket.
F42101132'
7) Align joint (14) of tip of steering column with

shaft groove, then install, taking care not to
tighten lock bolt (15) excessively.
* When tightening the lock bolt, be careful
not to twist the shaft with a screwdriver, or
to force it up.
l When screwing in the lock bolt, do not use
impact, screw in by hand.
D Lock bolt: 11.25k1.25 kgm

i
F42101128
2. Hydraulic piping
Connect the following hydraulic piping to steering
valve.
0 Hose (8) between steering valve and priority
valve.
l Hoses (6 and 7) between steering valve and
steering cylinder.
0 Hose (5) between steering valve and hydraulic
tank.
0 Hose (4) between steering valve and priority
valve.
.
3. Cover
Install cover under cab.
4. Supply of oil
Tighten plug (1) at top of hydraulic tank filter, and
plugs (2 and 3) of pump piping, and supply hydrau-
lic oil from oil filler port to the specified level.
43-6
DISASSEMBLY
+ Use a wire brush to remove all the dirt and dust

stuck to the joint around the outside circumference
of the unit.
t Carry out the operation in a clean place to prevent
dirt or dust from sticking to the valve.
t 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 (l), then remove end cap (2).
3. Remove O-ring (3) from end cap (2).
23EFOI 108
4. Pull out rotor set (4), then remove O-ring (5).

+ Be careful not to drop the star inside the rotor
set.
5. Remove spacer (6).
23EFOI 109 _
6. Remove drive shaft (7).
7. Remove spacer plate (8).
8. Remove O-ring (9) from housing (10).
23EFOI I IO
..
Disassembly of control side

9. Remove housing (10) from vice, and place on a
clean cloth. Be careful not to damage the finished
surface.
10. Raise tip of snap ring (11) with screwdriver, and

remove from housing.
23EFOIIII
11. Turn spool and sleeve to place pin in a horizontal

position, then push in spool and sleeve with your
thumb, and remove bushing (12) from housing.
23EFOI I I?.
12. Remove X-ring seal (13) from bushing (12).
13. Remove dust seal (14) from bushing (12) with

screwdriver.
t Be careful not to damage the bushing.
23EFOI I I3
43-8
14. Remove 2 bearing races (15) and thrust needle (16)

from spool and sleeve.
15
15. Pull out spool and sleeve assembly (17) from

housing (10) in the direction of the arrow.
t 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 it out from the housing.
16. Pull out pin (18) from spool and sleeve assembly
(17).
16
\h. 23EFOI I I5 ’
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).
23EFOI II6
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).
23. Tap housing, and remove ball (27) and retainer (28).
23EFOI I I7
43-9
ASSEMBLY
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.
t Check that the retainer is not inserted at an
angle.
2. Insert ball (27).
3. Fit O-rings (26 and 25) in check sheet (24), and

push check sheet (24) into housing.
+ Be careful to set the top and bottom of the
check sheet facing in the correct direction.
23EFOI I lCJ
4. Install set screw (23).

+ Check that the set screw is set in slightly from
the end face of the housing.
a Set screw: 1.2 kgm
a Set screw: Adhesive (LT-2)
5. Assemble spool (20) and sleeve (19) so that spring

groove is on same side.
t Rotate the spool and slide it in.
t Grip the splined portion of the spool lightly and
check that the spool rotates smoothly inside the
sleeve. Spri
+ If there are match marks, check that the match
marks are aligned.
23EFOI I IS
43-10
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.
23EFO I I 20i
7. Insert pin (18) in spool and sleeve assembly (17).
23EFOI 121
-.
8. Insert spool and sleeve assembly (17) in housing

(10) in the direction of the arrow.
1) Keep pin horizontal and rotate to left and right
a little at a time to insert.
+ 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 rotates smoothly
inside housing.
23EFOI 122
9. Install O-ring (22) to housing (10).
10. Fit 2 bearing races (15) and thrust needle (16) in

case (10).
I ,
23EFOI I23
43-11
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 install.

l Tap with a plastic hammer to assemble to the
specified position.
l It must be in contact horizontally with the
bearing race.
14. Fit snap ring (11) in housing.
23EF0 I I24
-
14,Screwdriver_
23EF0 1125:
Assembly of rotor
15. Hold flange of housing lightly in vice.
+ Be careful not to tighten the vice too hard.
+ Check that the spool and sleeve are set in
slightly from the housing surface with fourteen
holes.
16. Insert O-ring (9) in housing.
17. Put on spacer plate (8), and align positions of bolt

hole and tap hole of housing.
23EFOI 127
43-12
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.
23EFO I 128;
19. Insert O-ring (5) in rotor set (4).
23EFOI I29
20. Make O-ring (5) end of rotor set to spacer plate Inset portion of star of rotor set
end, then align inset portion of star of rotor (4) with
drive.
1) Check that lines A, B, C, and D are all parallel.
2) Without removing joint of drive (7), position bolt
holes of rotor set.
t This procedure is very important for determin-
ing the valve timing of unit.
Pin Port surface 23EF0, , 3.
21. Insert spacer (6) inside rotor set.
22. Set end cap (2) on rotor set, and align bolt hole.
23EFOI 131
_”
23. Coat thread of screw with grease, and tighten end Order for tightening of end cap
cap*
+ install the handle to the spool, and check that
the spool rotates.
D End cap mounting screw

First step: 1.5 kgm
Second step: 2.75+0.15 kgm
23EFOI 132
43-14
DISASSEMBLY AND ASSEMBLY PRIORITY VALVE
PRIORITY VALVE
REMOVAL

M & Loosen the oil filler cap to relieve the pressure

A
l Loosen plug (1) at the top of the hydraulic tank

1. Cover
2. Hydraulic piping
l Disconnect hose (4) between steering valve and
priority valve from priority valve side.
l Disconnect tube (5) between priority valve and
manifold from the manifold side.
0 Disconnect hose (6) between steering valve and

priority valve from the priority valve side.
l Disconnect the return hose (7) between steer-
ing valve and hydraulic tank from the priority
valve side.
l Disconnect hose (9) between steering pump

and priority valve from the tube of priority valve
side.
t After disconnecting hose (9), remove clamp
from bracket (10).
3. Priority valve
Remove mounting bolts and remove priority valve
(8).
43-16
INSTALLATION
1. Priority valve
After placing priority valve on the fixing portion,
tighten the mounting bolts.
+ Tube is tightening temporarily on manifold.
2. Hydraulic pipings
Connect the following hydraulic pipings.
l Connect hose (9) between steering pump and
priority valve on priority side tube.
t After connecting hose (9) secure the clamp to
bracket (10).
l Connect return hose (7) between steering valve

and hydraulic tank on priority valve.
priority valve on the priority valve.
l Connect tube (5) between priority valve and
manifold on the manifold.
priority valve on the priority valve.
43-17
3. Cover
install cover under cab.
4. Supply of oil
Tighten plug (1) at top of hydraulic tank filler, and
plug (2 and 3) of pump piping, and supply hydraulic
oil from oil filler port to the specified level.
43-18
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER
STEERING CYLINDER
REMOVAL

safety bar on the ground, ground the bucket,
i A
k Loosen the oil filler cap to relieve the pressure
1. Hydraulic piping
1) Disconnect hoses (2 and 3) from cylinder.
1) Remove bolt at rod end, then remove pin (4).
+ Check the number and thickness of the
2) Remove bolt at bottom end, then remove pin
3) Remove steering cylinder (6).

+ This operation should be carried out by two
workers.
+ Be careful not to damage the cylinder rod.
Steering cylinder: 20 kg
INSTALIATION
1) Set steering cylinder (6) in mounting position.
2) Install pin (5) at bottom end, then install bolt.
3) Install pin (4) at rod end, then install bolt.
A Use a bar to align the pin holes. Never use your

fingers.
* Adjust with shims to give specified value for

clearance ‘a’:
Clearance ‘a’ = 0 - 0.5 mm
4 l9F448
2. Hydraulic piping
1) Connect hoses (2 and 3) to cylinder.
D Hose nut: 8.0?2 kgm
3. Greasing
Grease cylinder pins well.
+ Wipe off any grease which comes out.
43-20
DISASSEMBLY
Special tools
Part number Part name 1 Q’ty
A 1 790-502-1001 1 Cylinder repair stand 1 1
B 1 790-100-1200 I Wrench I 1
1. Set cylinder assembly (1) in tool A.
2. Straighten lock tab of cylinder head (2), then using

tool B, remove cylinder head (2) from cylinder.
3. Pull cylinder head and piston rod assembly (3) from

cylinder (4) then lift off.
+ Oil will come out when the piston rod assembly
is removed from the cylinder, so have a
container ready.
4. Remove cylinder (4) from tool A.
5. Set cylinder head and piston rod assembly on tool

A, and loosen nut (5) with power wrench @ and
socket 0.
+ Power wrench: 16 times
+ Width across flats of socket 0: 46 mm
6. Remove nut (5), then remove piston assembly (6)

and cylinder head assembly (7) from rod (8).
43-21
7. Disassemble of oiston assemblv as follows:

0 For piston ring type _
1) Remove wear ring (9).
2) Remove piston ring (10) from piston (11).
125P387A
17
8. Disassemble cylinder head assembly as follows:
1) Remove snap ring (16), then remove dust seal
(17). JP,“S _ /”
2) Remove rod packing (18).
3) Remove bushing (19) from cylinder head (20). $ f1
2U
125P388A 125P389A
4) Remove O-ring (21) and back-up ring (22).
125P390A
43-22
Soecial tools
A 790-502-1001 Winder repair stand 1
+ Coat the sliding surface of all parts with engine oil.

Take care not to damage rod packings, dust seals
or assembly (6) on rod, then install nut (5).
1. Assemble cvlinder head assemblv as follows:

1) Using push tool, press fit ‘bushing (19) on
cylinder head (20).
t Be careful not to deform the bushing when
pressing it in.
2) Assemble rod packing (18).
+ Be careful to install the rod packing facing
Rod packing
-_ -’
4 I SF449
3) Using a~ push tool, install dust seal (17) on
head (20).
4) Install snap ring (16). -
20
125P388A 125P389A
6) Install back-up ring (22) and O-ring (21).

* Do not force back-up ring. Heat in hot
water (50 - 60°C) before inserting.
125P390A
43-23
STEERING CYLINDER
2. Assemble piston assembly as follows:

l For piston ring type
1) Using tool C, expand piston ring (10).
+ After setting the piston ring in tool C, rotate
the handle 8 to 10 times to expand.
2) Remove piston ring (10) from tool C, and
assemble on piston (11).
3) Fit tool D on piston ring, and compress piston

ring with clamp 0.
t Part No. of clamp @
07281-00909
4) Assemble wear ring (9).
3. Set piston rod (8) in tool A.
4. Assemble cylinder head assembly (7) and piston

assembly (6) on rod, then install nut (5).
5. Using power wrench @ and socket 0, tighten nut

(5) to the following specified torque:
+ Power wrench: 16 times
+ Width across flats of nut (5): 46 mm
u Tightening torque of nut (5): 80+8 kgm
43-24
6. Remove piston rod and cylinder head assembly

from tool A.
7. Set cylinder (4) in tool A.
8. Sling piston rod and cylinder head assembly (3),

and install in cylinder (4).
9. Using tool B, tighten cylinder head nut (2).
D Cylinder head nut: 5525.5 kgm
10. Bend lock into notch on cylinder.
11. Remove cylinder assembly from tool A.
43-25
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
CENTER HINGE PIN

REMOVAL
Special tools
A 793-840-l 410 Push tool 1
B 790-l 01-5221 Grip 1
C 793-840-l 310 Push tool 1
D 790-l 01-5281 Push tool 1
+ Remove the bucket before starting the operation.

stop the engine, apply the parking brake and
place blocks under the tires.
i A
& Loosen the oil filler cap slowly to relieve the
4 pressure in the hydraulic oil tank, then operate
the control lever 2 or 3 times to eliminate the
residual pressure in the piping.

Remove left and right rod pins (4) of steering
cylinder.
+ If there are any shims, check the number and
thickness of the shims, and keep in a safe
place.
2. Drive shaft
Disconnect center drive shaft (5) at flange bearing
end.
* Set a block under the drive shaft and discon-
nect.
Center drive shaft: 55 kg
43-26
3. Electric wiring
Disconnect wires (6 and 7) for front frame from
connector.
+ Remove the wiring clamps and move towards
the front frame.
4. Hydraulic piping
Disconnect the following hydraulic piping and brake
hose.
l Disconnect lilt cylinder hose (9) from joint
inside rear frame.
0 Disconnect dump cylinder hose (10) from joint
inside rear frame.
0 Disconnect steering cylinder hose (11) from
tube connector.
0 Disconnect front axle brake hose (12) from
joint.
+ Carry out hose disconnection at the joint in the
front frame.
5. Tire
Set jack under axle, raise frame, and remove front
tire (13).
Tire: 335 kg
6. Frame support
1) Adjust height of rear frame and insert block 0.
t Insert blocks on the left and right sides of
the frame.
2) Insert stands @ under counterweight.
t Block left and right rear tires securely to
prevent them from rotating.
43-27
7. Lower hinge pin

1) Remove mounting bolt, then remove retainer
(14).
+ If there are shims between the retainer and
rear frame, check the number and thick-
ness of the shims, and keep in a safe
place.
2) Set jack under front frame, adjust height, and

remove lower hinge pin (15).
t Adjust the height carefully so that the pin
can be removed easily by hand.
3) Remove spacer (16).
8. Upper hinge pin

Remove lock bolt, then remove upper hinge pin
(17).
+ Bring the steering linkage closer and remove
the upper hinge pin.
43-28
9. Disconnecting frame
Remove safety bar, pull front frame to front and
disconnect frame.
+ Be careful not to let the spacer at the top of the
lower hinge get caught on the rear frame.
+ Carry out the operation carefully and be sure to
keep the parts in balance.
+ Move the frame about 100 mm at a time.
10. Lower hinge

1) Remove mounting bolts, then remove retainer
(13).
* If there are shims between the retainer and
front frame, check the number and thick-
ness of the shims, and keep in a safe
place.
2) Remove dust seal (19) from retainer (18).
18 19
4 I9F460
3) Remove spacer (20) and dust seal (21) from

front frame.
4) Using tools A and B, remove bearing (22) and

spacer (23).
Front
frame
4lSF461
11. Upper hinge

1) Remove dust seal (24).
419FOI 121
2) Using tools B and C, remove bearing (26).
419FOI 120
43-30
INSTALlATlON
Special tools
A 793-640-l 410 Push tool 1
B 790-l 01-5221 Grip 1
C 790-l 01-5341 Plate 1
D 793-640-l 430 Guide 1
E 793-640-l 420 Push tool 1 4lSFOI 122
F Guide 1
+7-f&z
G Push tool 1
1. Upper hinge
1) Press fii bearing (26), spacer (26-l) to front
frame by using tools @, 0.
+ The clearance of the bearing (26) and
spacer (26-l) is adjusted, so do not change 419FOI 124
the combination.
When replacing the bearing and spacer,
replace as a set.
+ Be careful not to fii the bearing at an angle.
2) Assemble seal (24) into retainer (24-l).

* Assemble seal lip carefully paying attention
to the direction.
a Seal lip portion: Grease (G2-Ll)
+ Seal assembling method is as follows.

1 Dustseal 0.25-0,. 4lSFOI 125
___x 419FOI 123
3) Tighten retainer with three mounting bolts, then

insert shims so that the max. clearance (a) be-
tween retainer and hinge becomes 0.1 mm and
below.
D Mounting bolt: 2.020.2 kgm

(When adjusting shims)
D Mounting bolt: 11.5? 1.O kgm
43-31
-
4) Install seal (24) into front frame.
+ Assemble seal lip carefully paying attention
to the direction.
a Seal lip portion: Grease (G2-Ll)
+ Seal assembling method refers to item 2.

\
Front flame
419FOI 126
2. Lower hinge
1) Using tools D and E, press fii bearing (22) and
spacer (23) on front frame.
+ The clearance of bearing (22) is adjusted,
so do not change the combination with
spacer (23). If the bearing or spacer is
replaced, change both parts as a set.
+ Be careful to install the bearing straight.
+ Do not forget to install the spacer.
e gsi$ circumference of bearing: Grease D
4 I9F464
_.
2) Assemble seal (19) on retainer (18).

+ Be careful to install the seal lip facing in the
correct direction.
a Lip of seal: Grease (G2-Ll)
43-32
3) Tighten 3 mounting bolts of retainer, then select

shims to bring clearance ‘a’ between retainer
and hinge to within 0.1 mm. Install selected
shims.
D Mounting bolt: 2.020.2 kgm

(When adjusting with shims)
D Mounting bolt: 11.5?1.0 kgm
4 I9F465
4) Install dust seal (21) and spacer (20).

+ Be careful to install the seal lip facing in the
correct direction.
a Lip of dust seal: Grease (G2-Ll)
a g;dfl )circumference of spacer: Grease
3. Connecting frame
Move front frame towards rear frame, and align pin
holes.

fingers.
+ Align the pin holes correctly.

4. Upper hinge pin

Insert upper hinge pin (17), then secure with lock
bolt.
& gutsiki; circumference of hinge pin: Grease
5. Lower hinge pin

1) Insert lower hinge pin (15), then install spacer
(16).
a gus!; circumference of hinge pin: Grease
2) Install retainer (14) on lower hinge pin, tighten

3 mounting bolts, then select shims to bring
clearance ‘b’ between retainer and hinge to
within 0.1 mm. Install selected shims.
+ Tighten the retainer mounting bolts partially
to act as stoppers when adjusting the
shims.
D Mounting bolt of pin: 11Zr0.2 kgm

(When adjusting with shims)
e Mounting bolt of pin: Thread tightener

(Loctite 262)
D Mounting bolt of pin: 11.5 + 1.O kgm
D Mounting bolt of retainer: 11St- 1.O kgm
+ Tighten the mounting bolts of the retainer

to the specified tightening torque, then
tighten the mounting bolts of the pin.
43-34
4 I SF467
3) Install safety bar.
6. Tire
Set tire (13) in mounting position, then tighten
mounting bolts.
1 Mounting bolt: 94.52 10.5 kgm

5
7. Frame support
1) Remove stands @ from under counterweight.
2) Jack up rear frame and remove block 0.
8. Hydraulic piping
Connect the following hydraulic piping and brake
hose.
l Connect front axle brake hose (12) to joint.
D Hose nut: 1.4kO.l kgm
l Connect steering cylinder hose (11) to tube.

l Connect dump cylinder hose (10) to joint inside
rear frame.
l Connect lift cylinder hose (9) to joint inside rear
frame.
t Carry out hose disconnection at the joint in the
front frame.
9. Electric wiring
Connect wires (6 and 7) for front frame to connec-
tor.
+ After connecting the connector, install the
clamp.
10. Drive shaft

Install center drive shaft (5).
+ Be careful to install the coupling facing in the
correct direction.
m Mounting bolt: 7.OkO.5 kgm

Install left and right pins (4) at steering cylinder rod .4
end.
t Adjust with shims so that the total clearance
‘a’ is within the specified range.
Clearance: O-O.5mm
4 I9F448

Tighten plug at top of hydraulic tank filter, and plug
of pump piping, then add hydraulic oil through oil ‘2
ei
.I)
+ Run the engine to circulate the oil through the

For details of bleeding air, see SECTION 52, TEST-
ING AND ADJUSTING.
419PlO50
, 1
STEERING SYSTEM
STEERINGCOLUMN .............................................................. 2
STEERING CYLINDER MOUNT. ...................................................... 3
CENTERHINGEPIN .............................................................. 3
STEERING PUMP ................................................................ 6
PRIORITYVALVE ................................................................. 7
GROUND DRIVEN STEERING PUMP .................................................. 8
44-1
MAINTENANCE STANDARD STEERING COLUMN & ORBIT-ROLL
STEERING COLUMN
3.OeO.3 kgm
m 1.220.4 kgm
u41901345
Tolerance Stan-
Standard dard Clearance
size clear- limit
Clearancebetween steering shaft and Shaft Hole
1 ante Replace
column bearing
0 +0.15 0.05-
19 0.4
-0.08 -0.05 0.23
44-2
STEERING CYLINDER MOUNT
CENTER HINGE PIN
m 11 i 1 .Okgm
,17
21
Section A-A
Section D-D
Section B-B U41901346
44-3
Unit: mm
No. T Check item Criteria Remedy
3
Clearance between mounting pin
1 and bushing at connection of
steering cylinder rod and frame 0.050-
0.167 I I
Clearance between mounting pin

0 +0.150 0.050-
2 and bushing at connection of 40
-0.025 + 0.050 0.175
steering cylinder bottom and frame
Width of Standard clearance
Width of boss
hinge (clearance a + b) I
Connection of steering cylinder
3
and front frame 50+0.8 After adjusting with
0 shim: Less than 0.5
Connection of steering cylinder After adjusting with

4 54+0.8
and rear frame shim: Less than 0.5
Standard Clearance
clearance limit
Clearance between lower hinge pin I I
5
and rear frame
+ 0.030-
+0.122 I I
i-4
Clearance between lower hinge pin + 0.030-
6
and soacer (Small) + 0.326 Replace
Clearance between lower hinge pin +0.015-
7
and bearina 75 I :::z! I l.015 + 0.076
Clearance between lower hinge pin -0.030 + 0.026 +O.OlO-

8 75
and space (Large) I -0.076 I -0.020 +0.102 I I
9
Clearance between rear frame and
space (Large)
90
I -0.010
-0.040 I + 0.054
0
+O.OlO-
+0.094 I I
Clearance between front frame and +0.010-

10
lower hinge bearing 120 I i.020 I Z:E + 0.076 I I
Clearance between upper hinge + 0.030-

11
pin and rear frame +0.122 I I
Clearance between upper hinge +0.015-
12
pin and bearing + 0.076 I I
Clearance between front frame and -0.041 -0.076-
13 115 O
uooer hinge pin I -0.015 I -0.076 -0.026 I I
Clearance between upper hinge

pin and rear frame
+0.280 + 0.054 + 0.280-
14 90
Clearance between upper hinge +0.180 0 +0.360
pin oil seal and front frame boss
No. Check item Remedy
Tolerance
Height of lower hinge pin space size clearance limit
15 Shaft Hole
(Small)
24.5 Replace
Height of lower hinge pin space

16 66.5
(Large)
Tightening torque of lower hinge When adjusting with shim: 2+0.2 kgm
17
retainer mounting bolts Final value: 11.5 + 1.O kgm
Retighten
Tightening torque of lower hinge
18 Final value: 11.5? 1.O kgm
retainer mounting bolts I
Clearance between lower hinge pin

19 Max. 0.1
bearing retainer and front frame
Clearance between lower hinge pin

20 Max. 0.1
bearing retainer and rear frame Adjust
Clearance between upper hinge

21 pin bearing retainer and front Max. 0.1
frame
44-5
MAINTENANCE STANDARD STEERING PUMP
STEERING PUMP
l Model SAL(3)-63 +32
l-A
Ir Typical pump schematic

Section A-A
419F142
SAL(3)-63 SAL(3)-32
Unit: mm
No. I Check item I Criteria 1 Remedv
Model Standard clearance Clearance limit

Clearance between gear
1 case and side plate,
SAL(3)-63
gear 0.10-0.15 0.19
SAL(3)-32
Clearance between in-

side diameter of plain SAL(3)-63 Replace
2 0.06-O.149 0.20
bearing and outside SAL(3)32
diameter of gear shaft
3 Insertion depth of pin 14.0 0

-0.5
Rotating torque of spline

4 SAL(3)-63 +32 1.4-2.4 kgm
shaft
5 Tightening torque of bolt 25231.5 kgm Retighten

Discharge Standard Repair limit
pressure discharge discharge
(kg/cm2) (PJmin) (elmin)
Discharge
Oil: EO-CD 210 145 134
Temperature: 45-55” C
(Rear)
2500 210 70 66
SAL(3)-32 I i
MAINTENANCE STANDARD PRIORITY VALVE
PRIORITY VALVE
E416F415
Unit: mm
Free Installation Installation Free Installation

1 Control spring length length load (kg) length load (kg)
Replace
63.4 45 22.3 63.421 22.3 + 1.8
2 Relief spring 31 27.5 9.3 3120.4 9.3 f 0.9
44-7
MAINTENANCE STANDARD GROUND DRIVEN STEERING PUMP
GROUND DRIVEN STEERING PUMP

l Model SAM(2)40
A
t-
4 I SF492
Unit: mm
Standard clearance Clearance limit

Clearance between gear case and side
1
plate, gear 0.10-0.15 0.19
Clearance between inside diameter of

2 needle bearing and outside diameter of 0.020-0.043 0.075 Replace
near shaft
0
3 Insertion depth of pin
12-o.5
4 1 Rotating torque of spline shaft I 0.3 +0.7 kgm
5 Tightening torque of bolt 16.5? 1.5 kgm Retighten

Standard Repair limit
Revolution Pressure
Discharge discharge discharge
(rpm) (kg/cm*)
Oil: EOl O-CD (elmin) (elmin)
3000 210 73 58
44-8
BRAKE SYSTEM
BRAKECONTROLSYSTEM ............................................................ 2
SYSTEM DIAGRAM.. .............................................................. 2
BRAKE CIRCUIT DIAGRAM .......................................................... 3
BRAKE CIRCUIT SCHEMATICS ....................................................... 4
CHARGEVALVE.. ................................................................... 5
ACCUMULATOR.. ................................................................... 9
BRAKEVALVE ..................................................................... 10
PRESSURECONTROLVALVE ....................................................... 11
SAFETYVALVE ................................................................. 12
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
PARKING BRAKE . . . . . . . . . . . . . . . . . . .. . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
51-1
STRUCTURE AND FUNCTION BRAKE CONTROL SYSTEM
BRAKE CONTROL SYSTEM

SYSTEM DIAGRAM
10
U41901308
Outline
1. Front brake
When the brake pedal is depressed, the brake
2. Brake pedal
valve, which is connected to the pedal by a link, is
3. Brake valve
actuated, and actuates the front and rear brakes.
4. Differential pressure warning switch
A safety valve (spool actuated by differential pres-
5. Accumulator
sure) is built into the brake valve, and if there is
leakage of oil in the front or rear brake systems,
7. Rear brake
and the differential pressure between the front and
8. Pressure switch
rear drops below the specified pressure, the port on
9. Charge valve
the side where there is leakage is closed. In addi-
10. Transmission
tion, an alarm buzzer and warning lamp are
actuated.
The charge valve acts to keep the pressure of the
oil from the pump within the specified pressure, and
stores it inside the accumulator.
51-2
BRAKE CIRCUIT DIAGRAM
5A
t
----~
I
I
pJ i
1 cut-out Y-t 3A
8
I I
I I
I A-_ I 1
I I
u41901309
1. Transmission oil pan 5. Brake valve
2. Torque converter charging pump 5A. Safety valve
3. Charge valve 5B. Pressure control valve
3A. Relief valve 6. Brake
3B. Flow divider valve 7. Brake
3C. Check valve 8. Transmission, F-R lubrication
4. Accumulator 9. Differential pressure warning switch
10. Pressure switch
51-3
BRAKE CIRCUIT SCHEMATICS
(Engine running, brake pedal is released, oil is being

supplied to accumulator)
:.>.
.;:j:;:
.._
..\
.1
i...
r
8
STRUCTURE AND FUNCTION CHARGE VALVE
CHARGE VALVE
.T
419F518
Hydraulic circuit diagram
Function
1. Body A. To transmission lubrication l The charge valve acts to keep the pressurized oil
2. Screw B. To brake valve (ACC port) from the pump at the specified pressure, and stores
3. Spring P. From pump it in the accumulator.
4. Poppet T. To oil pan (Dr port) When the hydraulic pressure reaches the specified
(Rl relief pressure, the oil from the pump is connected to the
valve) drain circuit to reduce the load on the pump.
5. Valve seat
6. Piston
7. Retainer
8. Check valve
9. Orifice
10. Orifice
11. Spool
12. Spring
13. Orifice
51-5
STRUCTURE AND FUNCTION
CHARGE VALVE
Section X-X
Section Z-Z
111 i2 13
419F519
Section Y-Y Section W-W
51-6
Operation
r
1. When no oil is being supplied to accumulator 3
(cut-out)
The oressure at port B is higher than the set
pressure of Rl relief valve (4j, so piston (6) is
pushed up forcibly by the pressure at port B.
Rl relief valve (4) is opened, so port C and port f
T are connected.
The spring chamber at the right end of spool
(11) is connected to port C of Rl relief valve (4)
through orifice (13), so it becomes the tank
pressure.
The oil from the pump enters port P, and at a
low pressure equivalent to the load of spring
(12), it pushes spool (11) to the right, and flows I I
to port A. A\ In
At the same time, it passes through orifices (10
and 13) and flows to the tank.
4 I9F520
2. When oil is being supplied to accumulator

1) Cut-in condition
l If the pressure at port B goes below the set
pressure of Rl relief valve (4), piston (6) is
0
pushed back down by spring (3), valve seat
(5) and poppet (4A) are brought into tight
contact, and the passage between port C
and port T is shut off.
l The spring chamber at the right end of
spool (11) is also shut off from port T, so
the pressure rises, and the pressure at port I Irl hlri h I
P also rises in the same way.
l When the pressure at port-P rises above
the pressure at port B (accumulator pres-
sure), supply of oil to the accumulator
starts. In this case, a fixed flow is supplied
regardless of the engine speed, the flow is
determined by the size (area) of orifice (10)
and the differential pressure created on
both sides of it (equivalent to the load of
spring [12]). The remaining oil flows to port
A.
/ I I \ \
- 1
I \
P 10 11 12
419F521
51-7
2) When cut-off pressure is reached

When the- pressure at port B (accumulator
pressure) reaches the set pressure of Rl
relief valve (4), poppet (4A) moves away 0
from valve seat (5), and the oil flows to
relieve the circuit.
Because of this relief action, a differential
pressure is created above and below piston
(6). Piston (6) is moved up and poppet (4A)
is forcibly opened, so port C and port T are
connected.
The spring chamber at the right end of
spool (11) is also connected to port C of
Rl relief valve (4) through orifice (13), so it
becomes the tank pressure.
The pressure at port P also drops in the
same way to a pressure equivalent to the
load on spring (12), so the supply of oil to
port B is stopped.
4 I9F522
51-8
STRUCTURE AND FUNCTION ACCUMULATOR
ACCUMULATOR 1. Cap
2. Core
3. Top cover assembly
4. Cylinder
5. Piston
6. Bottom cover
7. Nut
8. Lead switch
Specifications
Gas used: Nitrogen gas
Charge amount: 3000 cc
Charge pressure: 20+0.5 kg/cm2 (at 80” z%‘C)
-__
Agf@+ijq
Power sorce GND 419F512
Lead switch circuit
Function
l The accumulator is installed between the charge
valve and brake valve. It is charged with nitrogen
gas between the cylinder and free piston, and uses
the compression of the gas to ensure braking force
and control when the engine is stopped.
51-9
STRUCTURE AND FUNCTION BRAKE VALVE
BRAKE VALVE
I--
I- X
\
T ’ P
Section Y-Y
1. Spring A. To rear brake Function

2. Spring B. To front brake l The brake valve acts to control the brake oil pres-
3. Spool P. From pump sure, and controls the hydraulic pressure sent to the
(Safety valve) T. To transmission oil pan brake circuit according to the amount the brake
4. Spring pedal is depressed.
5. Orifice The oil at the inlet port of the brake valve is sup-
6. Piston plied pressurized oil kept at the specified pressure
7. Sleeve by the charge valve.
8. Spring l The brake valve has a built-in safety valve (spool
9. Piston actuated by differential pressure), and if there is
10. Spool (Pressure leakage of oil in the front or rear brake lines, and
control valve) the differential pressure between the front and rear
11. Retainer brakes becomes 15 - 17 kg/cm2, the safety valve
12. Push rod spool moves and closes the port on the side where
13. Warning switch leakage of oil has occurred. It also actuates the
alarm buzzer and warning lamp.
51-10
PRESSURE CONTROL VALVE To brake To brake 13

3
Operation
1. When brake pedal is depressed

When the brake pedal is depressed, push rod (12),
which is connected to the brake pedal by a linkage,
is pushed in. When this happens, spool (10) is
pushed to the right in the direction of the arrow by
spring (2). When spool (10) moves, the circuit
between port P and port C opens, and the circuit
between port T and port C closes.
The oil from the pump passes from port C through
spool (3), is divided to port A and port B, and flows
to the brake chamber.
2. When brake pedal is being held in position To brake To brake

(balanced)
The oil at port C passes through orifice (5) and
actuates piston (9).
When the brake pressure rises, piston (9) pushes
back spool (10) against the resistance of spring (2)
until port P is closed. When port P closes, port T is
also closed, so the brake pressure is maintained.
If the pedal is further depressed from this position,
port P again opens, and pressurized oil flows to the
brake, so the brake pressure rises.
On the other hand, if the pedal pressure is reduced,
port T opens and the brake pressure goes down.
Therefore, the brake pressure can be adjusted
according to the amount the pedal is depressed.
To brake To brake
3. When brake pedal is fully depressed
When push rod (12) contacts the stopper, it cannot
push spring (2) in any further. The brake pressure
at this point is the maximum output pressure and it
balances the load of spring (2). (Max. output pres-
sure: 50 kg/cm2. However, when the input pressure
on the brake valve is less than 50 kg/cm2, that
pressure becomes the maximum output pressure.)
51-11
4. When brake pedal is released From brake From brake

When the brake pedal is released, push rod (12) is
returned by return spring (l), and spool (10) is also
pushed back by piston spring (8). Because of the
movement of spool (10). the circuit between port P
and port C is closed, and the circuit between C and
port T is opened. As a result, the brake oil is
drained, so the brake oil pressure drops and the
brake is released.
SAFETY VALVE
Operation
When the brake is being operated, if there should be oil
leakage in either of the circuits, a difference in pressure
is created between chamber A and chamber B. This
Warning
differential pressure moves the spool, and the spool 3
A switch 4 B
closes the port to stop the supply of oil to the side \ To brake \ \ \ To brake
where there is the leak. At the same time, the alarm
buzzer sounds and the warning lamp lights up. The
diagram on the right shows the condition when there is
leakage of oil from the front brake, and in this condition,
the pressure in chamber A is higher than the pressure
in chamber B. Therefore, the pressure in chamber A
pushing spool (3) to the right becomes stronger than
the pressure in chamber B pushing the spool to the left.
When this pressure difference reaches 15 - 17 kg/cm2,
the pressure in chamber A compresses spring (4),
moves spool (3), and this closes the port to chamber B.
At the same time, the movement of spool (3) actuates
the warning switch.
1 I
U41901316
51-12
STRUCTURE AND FUNCTION BRAKE
__ __ \ \
j--T !
__ -_
-A
i_ _,_ \’
\_ __ /
\ \
8 8
U41901306
* Illustration shows for front axle.
1. Differential housing 4. Disc

7. Axle housing
2. Piston 5. Outer ring
8. Sun gear shaft
3. Inner ring 6. Bearing carrier
Function
l The brake is a wet-type, single disc brake. It con- Inner ring (3) is installed to the notched part of
sists of piston (2), inner ring (3), disc (4), and outer bearing carrier (6). Outer ring (5) is secured to axle
ring (5). housing (7) by pin.
l The brake cylinder consists of differential housing l Disc (4) has a lining stuck on both faces. It is
(1) and bearing carrier (6). Piston (2) is assembled assembled between inner ring (3) and outer ring (5).
inside the brake cylinder. It is connected by the spline of the sun gear shaft.
51-13
STRUCTURE AND FUNCTION PARKING BRAKE
PARKING BRAKE
,Function
0 The parking brake is a disc-type brake and is 1. Caliper
2. Caliper IE?ver
installed to the transmission output coupling (6) at
the front. 3. Cable
4 Pad
0 The lever (2) and caliper (1) are connected bv wire _. _.
cable (3). ?he force bf brake can be controlled by 5. USC
the amount of lever pulled. 6. Coupling
51-14
STRUCTURE AND FUNCTION BRAKE CALIPER
BRAKE CALIPER 1
Outline
l The parking brake caliper is fixed to the transmis-
sion case.
The disc is installed to the transmission output shaft
coupling and rotates together with the coupling.
‘ansmission
\
419FO92
1. Hand lever
2. Cable
3. Caliper lever
4. Caliper
5. Disc
6. Pad
7. Adjustment bolt
423Fl23A
51-15
BRAKE SYSTEM
STANDARDVALUETABLE ............................................................. 2
TOOL LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BRAKE PEDALUNKAGE............................................................... 5
BRAKEPERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BRAKE PISTON LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
AIRBLEEDING.. .................................................................... 9
ACCUMULATOR CIRCUIT ........................................................... 9
FRONT AXLE BRAKE CIRCUIT ...................................................... 10
REAR AXLE BRAKE CIRCUIT ....................................................... 10
PARKINGBRAKE ................................................................... 11
PERFORMANCE ................................................................. 11
CHECKING AND ADJUSTING ....................................................... 12
CLEARANCE ................................................................... 14
+ The following precautions are necessary when using the Standard Value Tables to make judgements during
2. The standard values in these tables are used when troubleshooting. They are estimated values based on
the standard values for the machine when shipped from the plant, and on the results of various tests.
Therefore, they should be used as reference in combination with repair and operating records when making
judgements.
* Before carrying out the troubleshooting in this section, read “PRECAUTIONS WHEN TROUBLESHOOTING”,
“METHOD OF READING TROUBLESHOOTING TABLE” and “PREVENTING RECURRENCE OF TROUBLE” in
SECTION 22 TROUBLESHOOTING.
52-1
value value
Brake pedal 0 Coolant temperature: kg 25-35 46

0 Operating force Inside operating range
l Angle l Engine speed: Low idling degree 20+2 29
l Road surface: Flat, horizontal,

dry, paved surface
l Speed when applying brakes:
35 km/h
Brake performance l Time lag when pressing the m Max. 14.0 Max. 14.0
pedal: 0.1 sec.
Specified pressure
l Pedal operating force: 38 kg
Drop in brake oil pressure kg/cm* Max. 3.5 Max. 3.5
l Test pressure:
42 kg/cm*/5 min.
Wear of brake disc mm 1.02-1.14 0.7

Specified pressure
0 Road surface:
Flat, dry, paved surface
Parking brake Machine Machine
with l/5 (11’20’) gradient
performance 0 stopped stopped
Machine: In operating condi-
tion
l Brake lever operating force:
Max. 25 kg
11.7 (a)
Thickness of pad Min. 7.0
11.3 (b,c,d)
419F315
Clearance between mm 0.1-0.4 Max. 2.6
disc and pad
0 Brake lever operating force: 170-210 170-210
Lever travel (9-11 clicks)
25 kg (9-11 clicks)
52-2
TESTING AND ADJUSTING TOOL LIST
TOOL LIST
No. 1 Testing and measuring item Tool name Part number Remark
O-25 kg/cm2,
1 Oil pressure Hydraulic tester 799-l 01-5000 O-50 kg/cm2
O-300 kg/cm’
2 Operating force Push-pull gauge 7AO-262-0020 O-25 kg
3 Measuring clearance Feeler gauge Commercially available 0.1-3.0 mm
4 Brake pedal operating force Push gauge 799-l 01-l 001 O-110 kg
5 Brake oil pressure Hvdraulic tester 793-605-l 001 O-100 kg
6 Thickness of pad Vernier calipers 150-200 mm
7 Brake distance Tape measure 30 mm

Commercially available
8 1 Operating time I Stop watch 1/l0 second
Convex scale O-2 m
A When carrying out testing, adjusting or troubleshooting, stop the machine on level ground, install the safety
bar on the frame, lower the bucket to the ground, and stop the engine.
Then apply the parking brake and block the tires.
A When taking measurements, do not allow unauthorized persons near the machine.
52-3
TESTING AND ADJUSTING BRAKEPEDAL
BRAKE PEDAL
item
I Standard
value I
Pemissible
value
Special tool
A 799-101-1001 Push gauge 1
1. Measuring operating force of pedal

1) Fit push gauge A to the operator’s foot.
+ Align the center of the push gauge with the
center of the pedal.
2) Start the engine and run at low idling, then de-
press the pedal and measure the operating
force.
2. Measuring travel of pedal

1) Fit push gauge A to the operator’s foot.
+ Align the center of the push gauge with the
center of the pedal.
2) Start the engine and run at low idling. Measure
the travel of the pedal when it is operated with
an operating force of 30 kg.
3. Measuring play of pedal

1) Start the engine and run at low idling. Measure
the travel of pedal when it becomes too heavy
when forced by hand.
4. Adjustment of transmission cut-off switch

1) Pull up brake arm (1) and check that it is fully
returned.
2) Push lever (a) of transmission cut-off switch (2)
lightly, and adjust mounting screw (3) of the
switch so that the clearance between the switch
itself and switch lever (a) is 0.5 mm.
52-4
TESTING AND ADJUSTING BRAKE PEDAL LINKAGE
BRAKE PEDAL LINKAGE
A Put blocks securely under the wheels.
Measurement condition
Transmission oil temperature: 2040” C
Engine stopped
Preparation
Clinometer
Adjust the .length of rod (2) so that the angle of

brake pedal (1) is 45” to the floor. (Both left and Al9FOIOI”
right)
Standard length of rod: 153 mm
When adjusting push rod (5) installed between

bellcrank (3) and brake valve (4), loosen nut (6),
bring the push rod into light contact with rod socket
(7) of the brake valve, then turn the rod back 3/4
turns (1.0-l .25 mm).
* Length of push rod: 254.3 mm (before adjust-
ing)
5 7
I
Stroke
\ I
7 254.3 mm
4lSFOIOI I
52-5
TESTING AND ADJUSTING BRAKE PERFORMANCE
BRAKE PERFORMANCE
+ Measurement condition Standard Permissible
l Time lag when pressing the pedal: 0.1 sec. Item
value value
0 Pedal force: 38 kg
l Road surface: Flat, horizontal, straight, dry, paved Brake
surface Max. 14 m Max. 14 m
performance
l Machine speed: Speed when applying brakes: 35
km/h
Measuring procedure Special tool

Start the engine and then start the machine. Part number Part name Q’ty
Place the speed control lever in the highest speed Commercially Tape
range and drive the machine. 1
available measure
When the machine is traveling at 35 km/h, depress
the left brake pedal with the specified operating
force.
+ Decide the run-up road and point to apply the
brakes, then apply the brakes when the braking
point is reached.
t Turn transmission cut-off selector switch ON.
Measure the distance from the braking point to the

point where the machine stops.
+ Carry out the test three times and take the aver-
age value.
A
Stoppmg point Brake take effect Brake pedal depressed
I (brake applied)
Run-up road
Brake distance
423F319
52-6
TESTING AND ADJUSTING BRAKE PISTON LEAKAGE
BRAKE PISTON LEAKAGE

l Test pressure: 42 kg/cm*
Item
I value I value
Drop in
Max. 3.5 kg/cm* Max. 3.5 kg/cm*
pressure
i
4 19P0501
..
Special tools
A 793-605-l 001 Hydraulic tester 1
B 790-101-l 102 Pump assembly 1
Measuring procedure
1. Stop the engine.
2. Remove brake tube (1) on the side to be measured,

then remove adapter (2).
3. Install hydraulic tester A after removing the adapter.

t Connect the quick coupler 0 of hydraulic
tester A.
4. Loosen bleeder screw (3) and bleed the air.

+ To bleed the air, operate pump.
5. Tighten the bleeder screw and operate pump to

raise the pressure to 42 kg/cm*, then tighten the
stop valve.
6. Leave for 5 minutes with the pressure applied, then

check the drop in pressure.
t Do not move the hose when measuring the
pressure. If the hose is moved, the pressure will
change.
t When removing hydraulic tester A after testing,
operate pump to lower the pressure in the
hydraulic tester A before removing.
t After completing inspection, install the brake
tube and bleed the air from the brake circuit.
52-7
TESTING AND ADJUSTING BRAKE DISC
BFIAKE DISC
l Coolant temperature: inside operating range
Unit: mm
Item value
value
Disc wear Min. 0.7

1.02-1.14
(one side) I I
Soecial tool
Part number Part name cxty
Commercially
Feeler gauge 1
available
Measurina Drocedure
1. Loose; brain plug (1) and drain the axle oil.
Axle oil: 24P
2. Remove measuring plug (2).
3. Depress the brake pedal lightly.

* Check that the piston is in close contact with
the disc.
4. Insert a feeler gauge between disc (4) and plate (3),

and measure the clearance.
5. Tighten the drain plug and add axle oil through the
oil filler to the specified level.
Gz Axle oil: 244 419F308
52-8
TESTING AND ADJUSTING AIR BLEEDING
AIR BLEEDING
A Put block securely under the wheels.
A Pii the support securely to prevent the boom

from falling.
* Condition
l Transmission oil temperature: 2040” C
t Preparatory work
l Prepare the following tools.
1) Vinyl hose
(inside diameter: 7-8 mm, length: 2 m)
2) Bar thermometer
3) Oil container (clean, 5 liters)
4) Working lamp
ACCUMUlATOR CIRCUIT
1. Bleeding air
1) Start the engine and check the transmission oil
level.
t When doing this, check that the brake
pressure warning lamp on the machine
monitor in the operator’s compartment is
not flashing, then stop the engine.
2) Insert vinyl hose @into bleeder screw (1) of the
brake valve, and put the other end in a
container.
3) Depress the brake pedal, loosen bleeder screw
(l), until the oil comes out. When no more oil
comes out, tighten bleeder screw (1) and
release the brake pedal.
* While the oil is coming out, even if no air
comes out, do not stop, but drain all the
oil.
4) Return the drained oil to the transmission oil
filler port, start the engine again, and charge
the accumulator.
+ When this is done, the brake pressure
warning lamp on the machine monitor in
the operator’s compartment must not flash.
5) Repeat the procedure in Item 2) - 4) at least
three times.
+ If air still comes out even after three times,
start the engine again, charge the accumu-
lator, and bleed the air from the brake
valve.
52-9
TESTING AND ADJUSTING AIR BLEEDING
FR;ONT AXLE BRAKE CIRCUIT
2. Bleeding air
1) After charging the accumulator, stop the en-
gine, insert vinyl hose @ into bleeder screw (2)
on the right side of the front axle, and put the
other end in a container.
2) Depress the brake pedal with half stroke, loos-
en bleeder screw (2), and drain the oil.
+ Drain approx. 0.5 liters each time.
+ Even if the air does not come out, do not
stop. Always drain approx. 0.5 liter of oil.
t Depress the brake pedal with half stroke
while bleeding air from the brake circuit in
the axle not to actuate the safety spool built
in the brake valve.
3) When the oil stops coming out, tighten bleeder
screw (2) and release the brake pedal.
4) Carry out the same procedure on both the left
and right sides, and repeat the air bleeding
procedure three times each.
+ If air still comes out from the bleeder on
either the left or right side even after three
times, repeat the air bleeding procedure for
both the left and right bleeders.
REiAR AXLE BRAKE CIRCUIT
3. Bleeding air
Repeat the same procedure as for “Bleeding air
from front axle brake circuit”.
+ After completion of the air bleeding operation,
run the engine at low idling and check the oil
level in the transmission. If necessary, add
more oil.
52-I 0
TESTING AND ADJUSTING PARKING BRAKE
PARKING BRAKE
PERFORMANCE
l Road surface: Flat, dry, paved surface with l/5
(1l”20’) gradient.
l Machine: In operating condition
l Parking lever operating force: Max. 25 kg
Unit: kg/cm2
423F321
Item
value value
Parking brake Machine stopped on

performance l/5 (1 l”20’) gradient
Measuring procedure
1. Start the engine and drive the machine straight up
a l/5 gradient with bucket unloaded.
2. Depress the brake, place the directional lever in

neutral, then stop the engine. 423F322
3. Pull the parking brake lever, then slowly release the

brake pedal and the machine must not move at all.
l The measurement must be made with the ma-
chine facing either up or down the slope.
52-11
CHECKJNG AND ADJUSTING
Unit: mm
item
I value I value
11.7 (a) Min. 7.0

Thickness of pad
11.3 (b,c,d)
Special tool
w
Part number Part name Q’ty 419F309
Commercially Vernier calipers 1

available I I
A Block the tires securely.
1. Measuring pad
1) Stop the engine and operate the parking brake
lever to release the brake.
2) Remove pad (1) from the caliper, and measure
the thickness of the pad to the backing plate.
If the measurement is not within the standard
value, replace the two pads as a set.
For details of replacing the pads, see DISAS-
SEMBLY AND ASSEMBLY.
2. Measuring lever
t Lower operating force: 25 kg
Unit: mm
I 1
Item value
I value I
Travel 170-210 mm (9-11 clicks)
Special tool
Push-pull scale 1
Commercially
available Convex scale 1
1) Install a push-pull scale 50 mm from the tip of

lever (2) and measure operating force.
2) Measure the movement of the lever tooth when
the lever is operated at the standard value.
52-12
3. Adjusting procedure
+ If the operating force is not within the standard
value, check the linkage and cable.
1) Insert the lever tooth at the bottom.
2) Loosen lock nut (3) and pull out clevis pin (4).
3) Screw in clevis (5) to remove the lever play.
4) Assemble clevis pin (4) and tighten lock nut (3).
+ The caliper should be completely released
when the lever tooth is in the bottom
groove.
52-13
CLEARANCE
Unit: mm
Item
value value
Clearance between
0.1-0.4 Max. 2.6
disc and pad
Special tool
Part number I Part name I Q’tv
u 419F310
Commercially
Feeler gauge 1
available
1. Measuring Drocedure
1) Move’ihe parking brake back and release the
brake.
2) Insert a feeler gauge between disc (6) and pad
(l), and measure the clearance (S) and (T).
+ Measure the clearance at 4 points on the
pad.
1) Move the parking brake lever back to release
the brake.
2) ;Irove clevis pin (4) and leave caliper lever (7)
3) Tighten adjustment bolt (8) and adjust the

clearance to within the standard value.
t Be careful not to tighten the adjustment
bolt too far.
+ After adjusting, there should be no play of
the adjustment bolt in the axial direction.
t After adjusting, there should be clearance
S and T.
4) Align the hole of caliper lever (7) and assemble
clevis pin (4).
* After making the adjustment, measure the
operating force and travel of the parking
brake lever. If it is not within the standard
value, adjust the lever.
52-14
BRAKE SYSTEM
BRAKEVALVE ...................................................................... 2
REMOVAL ...................................................................... 2
INSTALLATION ................................................................... 3
DISASSEMBLY ................................................................... 4
ASSEMBLY ..................................................................... 5
PARKING BRAKE .................................................................... 6

REMOVAL ...................................................................... 6
INSTALLATION.. ................................................................. 8
PARKING BRAKE PAD ............................................................... 10

REMOVAL ..................................................................... 10
INSTALLATION .................................................................. 10
ACCUMULATOR.. .................................................................. 11
REMOVAL ..................................................................... 11
INSTALLATION .................................................................. 11
DISASSEMBLY.. ................................................................ 12
ASSEMBLY .................................................................... 12
53-1
DISASSEMBLY AND ASSEMBLY BRAKE VALVE
BRAKE VALVE
REMOVAL

1. Relief pressure out of accumulator circuit

Remove brake valve breather screw cap (1) and
install vinyl hose. Drain brake oil until oil does not
come out, after stepping on brake pedal slightly
(about one fourth).
+ Don’t step on brake pedal strongly, or oil
draining stops.
2. Hydraulic hoses and tubes

1) Disconnect hose (6) between charge valve and
brake valve, and hose (7) between brake valve
and transmission, from brake valve side.
2) Disconnect hose (8) between brake valve and
front brake, and hose (9) between brake valve
and rear brake, from brake valve side.
3. Brake valve
1) Pull out rod linkage cotter pin (7), and remove
pin (8).
2) Remove mounting bolts, and remove brake
valve (6).
Brake valve: 10 kg
53-2
1. Brake valve
1) After placing brake valve (6) on the fixing
portion, fix it with mounting bolts.
2) Install rod linkage yoke portion on bellcrank, fii
it with cotter pin (7) after mounting pin (8).
2. Hydraulic hose
1) Connect brake hoses (8 and 9) on brake valve.
+ Be careful not to tighten tube nut too
much.
a Tube nut: 1.7550.75 kgm
2) Connect hose (7) between brake valve and

transmission, and hose (6) between charge
valve and brake valve, on the brake valve.
a Base nut: 5.052 kgm (Width across flat 24

mm)
3) Letting air out of brake system

See Inspection and Adjustment volume about
relieving air method.
53-3
DISASSEMBLY
1. Plug and adapter

1) Remove plugs and adapter from brake valve.
2. Removing of cover
1) Remove mounting bolts (3 and 13) of covers (1
and 12).
+ Remove O-rings (5 and 6) of the mating
face.
2) Remove rod (4) from cover.
3. Removing of spool
1) Remove springs (7,8, and 18) from housing (2).
2) Remove spring retainers (10 and 19).
3) Remove spools (11, 9, 14, and 15).
t Don’t damage spool when removing spool.
t Be careful not to enter dust in housing after
disassembling.
4IQPOt170.
4 3 5 7 10 8 9 14 15 16 17
4lQFOI 107
._
53-4
ASSEMBLY
1. Spool
1) After assembling spool (11) into housing safety
valve fixing portion, install retainer (19) and
spring (18) in both sides.
2) Assemble spools (14, 15, 16, and 17) from rear
portion of housing pressure control valve fixing
portion, and install housing.
419FOIlO8
3) Assemble spool (9) from front portion of hous-

ing, and install retainer (10) and springs (7 and
6).
+ Confirm whether there are flows or cracks
on the springs.
2. Cover
1) Install O-rings (5 and 6) on the both sides of
assembling portion for housing safety valve and
pressure control valve.
+ Confirm whether there are flows setting,
wear, degradation on the O-ring.
2) Assemble piston (4) in cover (1) and install
cover (1) and cover (12) on the housing.
a Mounting bolt: 6-7.5 kgm
3. Plug and Adapters

Install plugs and adapters on the brake valve.
1 19 19 2 11 12 13
4 i lb 14 lb 1'6 1
419FOIlO7 i
DISASSEMBLY AND ASSEMBLY PARKING BRAKE
PARKING BRAKE
REMOVAL

1. Draining oil
Loosen drain plug (1) and drain oil from transmis-
sion case.
b
Transmission oil: 3OP
.(.
+ After loosening the drain plug, gradually pull it
out and drain the oil.
2. Linkage
Remove lever pin (2).
+ Check that the parking brake is in the RE-
LEASED position.
3. Center drive shaft

Disconnect drive shaft (3) from transmission.
4. Caliper assembly
Remove mounting bolts, then remove caliper
assembly (5) together with spacer.
5. Cover
Remove mounting bolts, then remove cover (4).
6. Disc
1) Remove mounting bolts, then remove coupling
and disc (6).
+ There is an O-ring installed, so be careful
not to damage it.
+ Pull the coupling and disc out straight to
prevent damage to the seal of the transmis-
sion case.
53-6
2) Remove mounting bolts, then disconnect cou-

pling (7) and disc (6).
7. Disassembly of caliper
1) Remove support (8) from caliper assembly.
+ Support (8) is unitized with the caliper
ass’y. Therefore, no removal is required.
2) Remove adjustment screw (9).
3) Extend lock plate (10) with a chisel, remove

bolts, then disconnect calipers (11 and 12).
4) Remove nut from caliper, then remove pads (13
and 14).
5) Remove spring (15) and pin (16) from caliper.
4 I9F4.53
INSTALLATION
1. Assembly of caliper
1) Install pin (16) and spring (15) on caliper (11).
4 I9F453
2) Install pads (13 and 14) to caliper, then secure

with nut.
3) Set calipers (11 and 12) in mounting position,

install retraction plate (17) and lock plate (lo),
t Knock the tip of the retraction plate into the
caliper mount hole up to the root.
D Mounting bolt: 1.2kO.l kgm
4) Bend lock plate with a chisel to lock bolt.

A- Bend the lock plate securely.
5) Install adjustment screw (9).

6) Install support (8) on caliper assembly.
a Mounting bolt: 18a2 kgm
t Support (8) is unitized with the caliper ass’y.

Therefore, no removal is required.
53-8
2. Disc
1) Set disc (6) in position on mount of coupling
(7) then tighten mounting bolt.
D Mounting bolt: 11.5 + 1.O kgm
2) Set coupling and disc (6) in mounting position,

+ Install straight to prevent damage to the
transmission seal.
& zsertion portion of coupling: Transmission
3. Caliper assembly
Set caliper assembly (4) in mounting position, then
install together with spacer (18).
D Mounting bolt: 11.5r 1.O kgm
4. Cover
Set cover (5) in mounting position, and install.
5. Center drive shaft

Connect center drive shaft (3) at transmission end.
D Mounting bolt: 7.0*0.5 kgm
6. Linkage
Install lever pin (2).
+ Bend the cotter pin securely.
+ For details of adjusting the disc and pad clear-
ance, see SECTION 52, TESTING AND
ADJUSTING.

Install drain plug and add gear oil through oil filter
to the specified level.
Q Transmission oil: 3OP

DISASSEMBLY AND ASSEMBLY PARKING BRAKE PAD
PARKING BRAKE PAD

REMOVAL

1. Linkage
Remove pin (1).
+ Check that the parking brake is in the RE-
LEASED position.
2. Pads
1) Extend lock plate (2) with a chisel, and remove
bolts (3).
2) Remove calipers (4 and 5).
3) Remove nut from calipers (4 and 5), then
remove pads (6 and 7).
L-l 4 I9F454
INSTALLATION
1. Pads
1) Set pads (6 and 7) in mounting position, then
secure with nut.
2) Set calipers (4 and 5) in mounting position,
install lock plate (2), then tighten mounting
bolts.
t Knock the tip of the lock plate into the cali-
per mount hole up to the root.
a Mounting bolt: 1.2kO.l kgm
3) Bend lock plate (2) with a chisel to lock bolt (3).
2. Linkage
Install pin (1).
+ Bend the cotter pin securely.
3. Adjusting linkage
* For details of adjusting the linkage, see SEC-
TION 52, TESTING AND ADJUSTING.
53-10
DISASSEMBLY AND ASSEMBLY ACCUMULATOR
ACCUMULATOR
REMOVAL

1. Relieve pressure out of the accumulator circuit

Remove brake valve breather screw cap (1) and
install vinyl hose. Drain brake oil until oil does not
come out, after stepping on brake pedal slightly
(about one fourth of the way).
+ Do not step heavily on the brake pedal or the
oil draining stops.
2. Disconnect accumulator with joint

Remove accumulator (4) from joint (2).
* Plug joint opening to prevent oil contamination.
3. Mounting clamps
Remove mounting clamps (3) and take accumulator
(4) out of machine.
INSTALLATION
1. Accumulator mounting
Set the accumulator with its lower end laid on the
locating plate welded to the mount plate.
2. Clamping down
Install lower “U”clamp and hand tighten nuts. Install
upper “U” clamp and hand tighten nuts. Tighten
down lower “U” clamp, then the upper “U” clamp.
Torque to the specified value.
L04AH023
D Tightening torque: 3.Ok1.5 kgm
53-11
DISASSEMBLY AND ASSEMBLY ACCUMULATOR
DISASSEMBLY
+ Before accumulator is disassembled, the nitrogen

charge pressure must first be released.
NOTE: Refer to exploded view at right.
1. Relieve nitrogen pressure

Remove cap from gas valve. Loosen valve and
allow gas to completely drain.
2. Internal disassembly
Remove nut (3), covers (4, 5) and plates (7). Tap
cylinder (1) on a wood block and remove piston (2).
Remove O-rings (7, 12), slider seal (13) and backup
rings (14).
+ Discard all seals and replace with new.
+ Clean all parts using a non-flammable solvent.

Immerse parts in solvent and move up and
down slowly until all old lubricant and foreign
material is dissolved.
t Dry all parts thoroughly using compressed air.
t Check all parts for wear, cracks, breakage,

scratches, scoring or out of round.
ASSEMBLY Air tightness: Apply 70 kg/cm2 for 10 minutes to

check that no gas or oil leak devel-
NOTE: Refer to exploded view at right. ops.
1. Internal assembly t Recheck ?hat the body, piston and seal are sound
Replace the old O-rings, seals etc. with new ones after durability tests.
from a spare parts kit (419-43-12700).
+ Gas pressure drop: Maximum of 20%.
1) Assemble the piston (2) and gently slide it into
the cylinder (1). Follow up with plate (7), bot- 5. Nitrogen gas (N2)
tom cover (4) and nut (3). Tighten the nut (3), Charge with nitrogen gas (N2) to 20+.5 kg/cm2 at
then line up the holes for the spring pin (11) 80+5”C.
and insert pin.
Specifications:
2) Assemble the top cover@), O-ring (7), plate (6), Max operating Pressure: 70 kg/cm2
core (8) seal washer (9) and cap (10). Tighten Gas capacity: 3000 cc
nut (3) then line up the holes for the spring pin Nitrogen gas seal pressure: 20 f .5 kg/cm2(at
(11) and insert pin. 8025°C)
Operating conditions:
2. Durability test Operating pressure: 20-70 kg/cm2
Accomplish durability test on a bench with accumu- Normal pressure: 50-70 kg/cm2
lator inside protective cage. (Accumulator charge valve control pressure)
Operating temperature: -30” C to + 120” C
Pressure resistance: Apply 105 kg/cm2 for 10 Normal temperature: + 50” C to + 120” C (fluid)
minutes and check to see Effective discharge, oil: 1700 cc Minute
that no cracks developed.
53-12
ACCUMULATOR
I
l-
ll-
14-
/)
I
I 1
a
\
3
:;--8 ,I
I/
1. Cylinder 5. Top cover 9. Seal washer 13. Slider seal
2. Piston 6. Plate 10. Cap 14. Back-up ring
3. Nut 7. O-ring 11. Spring pin 15. Position sensor
4. Bottom cover 8. Core 12. O-ring
53-13
BRAKE SYSTEM
BRAKE ........................................................................ 2
PARKINGBRAKE ................................................................. 3
BRAKEVALVE ................................................................... 4
54-I
MAINTENANCE STANDARD BRAKE
BRAKE
_- __
-._ l __ __
Ii
_J
-_
\
Ii
Unit: mm
0
9.6 8.8
-0.5
Thickness of brake disc 8.197 + 0.063 7.4

2 Groove depth of brake disc 0.838 kO.2 0.4 Replace
Thickness of brake disc lining 1.08 Min. 0.89
Thickness of brake outer ring surface

3 19 +0.13 0.3
of disc
54-2
MAINTENANCE STANDARD PARKING BRAKE
PARKING
/7-l
a 3 b6
\ 423F226
Unit: mm
Wear of pad Standard size

I Repair limit
(Remaining thickness of friction
1 material) 10.5 (a, b, c), 8.5 (d) 1 Replace
(Including backing plate) 13.7 (a, c), 11.7 1 7.0
2 Face runout of disc

Rebuild
,,
3 Thickness of disc plate
Replace
Clearance between pad and

4 Adjust
disc
5 Tightening torque of nut 0.27kO.5 kgm

Retighten
6 Tightening torque of bolt 1.220.1 kgm
54-3
MAINTENANCE STANDARD BRAKE VALVE
BRAKE VALVE
Unit: mm
Free Installation Installation Free Installation

1 Spring length length load (kg) length load (kg) Replace
55.1 46.1 46.7 53.3 37.3

WORK EQUIPMENT SYSTEM
HYDRAULIC PIPING . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . 2
HYDRAULIC CIRCUIT DIAGRAMS .. . . . . . . . . . . . . . . . . . . . . . . . .. .. . . . . . . . . . . . . . . . . .. . . . . . . . . . 3
HYDRAULICTANK ................................................................... 5
OILFILTER BYPASSVALVE ......................................................... 6
BREATHER ..: .................................................................. 7
HYDRAULICANDSTEERINGPUMPS . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
HYDRAULICVALVES ................................................................. 9
SECURITYVALVE ................................................................. 9
PRIORITYVALVE ................................................................ 10 ,
RELIEFVALVE .................................................................. 11
SAFETY VALVE (WITH SUCTION VALVE) .............................................. 12
SUCTION VALVE ................................................................ 13
MAIN CONTROLVALVE ........................................................... 14
2-SPOOL ................................................................... 14
3-SPOOL ................................................................... 16
OPERATION.. ............................................................... 18
HYDRAULICCYLINDER .............................................................. 24
LIFTCYLINDER ................................................................. 24
DUMPCYLINDER ................................................................ 24
STEERING CYLINDER ............................................................ 24
BUCKETLlNKAGE . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 25
WORK EQUIPMENT LEVER LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . 27
61-1
STRUCTURE AND FUNCTION HYDRAULIC PIPING
HYDRAULIC PIPING
See Foldout #1 at end of book.
Rest of page is blank.
61-2
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAMS
HYDRAULIC CIRCUIT DIAGRAMS

Operation
1) When work equipment circuit is normal. (Hydraulic
tank oil level is correct.)
From
orbitrol
valve
b 1
\ /
To main
control
valve
Priority valve
Drain
Steering pump
U41901326
l Oil from steering pump enters port “a”, and it

pushes spool (1) in the direction of arrow, and also
it reaches to float valve (2) chamber A.
0 Oil from hydraulic pump flows to work equipment
control valve through port “b”.
61-3
STRUCTUREANDFUNCTION HYDRAULIC CIRCUIT DIAGRAMS
2) When work equipment circuit is abnormal.

(Hydraulic tank oil level is too low).
From
orbitrol
valve
To main
control 0
valve I I
I Priority valve
I
Drain
Steering pump Hydraulic pump

>>>>>:
....................
$$$gf
:.:.:.:.:.:
.:.:.:.>:_
......
....._..._.
.Q..\..... .:.:.:.:.:.:.:.:(.:.:.:.:.:.:.:.:.:.~:.:.:
....._.....
I.........
u41901327
Hydraulic tank
0 When oil in the hydraulic tank is decreased, float (3)

goes down and oil from the pump circuit flow to the
hydraulic tank. The pressure of port “a” goes down
and spool (1) moves to direction of arrows then oil
from hydraulic pump flows to tank circuit to prevent
the leak from the damaged part.
61-4
STRUCTURE AND FUNCTION HYDRAULIC TANK
HYDRAULIC TANK
Section A-A
Section B-B
4 I SF527
1. Cap
2. Breather
3. Oil level gauge
4. Drain valve
5. Catch
6. Filter bypass valve
7. Oil filter
61-5
STRUCTUREANDFUNCTION HYDRAULIC TANK
OIL FILTER BYPASS VALVE
When the filter is clogged

Bypass valve (1) opens and the oil returns directly to
the tank without passing through the filter.
From main
Bypass valve set pressure: 1.27 kg/cm* control valve
I 423F131
_ To main
Control valve
When negative pressure is formed in the return

circuit
Valve (2) moves up and acts as a check valve.
Check valve set pressure: 0.26 kg/cm*
423F132
61-6
STRUCTURE AND FUNCTION HYDRAULIC TANK
BREATHER .
Preventing negative pressure inside the tank

The tank is a pressurized, sealed type, so negative
pressure is formed inside the hydraulic tank when the oil
level drops during operations. When this happens, the
difference in pressure between the tank and the outside
atmospheric pressure opens the poppet (3) and air
from the outside is let into the tank to prevent negative
pressure.
Preventing rise in pressure inside the tank

When the hydraulic cylinders are being used, the oil
level in the hydraulic circuit changes and the tempera-
ture rises. If the hydraulic pressure rises above the set
pressure, the breather is actuated to release the hydrau-
lic pressure inside the tank.
1. Body
2. Filter element
3. Poppet
4. Sleeve
61-7
STRUCTURE AND FUNCTION HYDRAULIC AND STEERING PUMPS
HYDRAULIC AND STEERING PUMPS
! ? 3 4 5 6 7 8
* Typical pump schematic
Section A-A 419FO96
I Steering pump I Hydraulic pump I

I SAL(3)-63
I SAL(3)-32 I
Specifications:
1. Front cover Steering pump
2. Gear case Model SAL(3)-63 (Front pump)
3. Drive gear (Teeth 12) Theoretical discharge 63.1 cc/rev
4. Rear cover Max. pressure 210 kg/cm2
5. Front cover Max. pump speed 2,500 rpm
6. Gear case
7. Drive gear (Teeth 12) Hydraulic pump
a. Rear cover Model SAL(3)-32 (Rear Pump)
9. Driven gear (Teeth 12) Theoretical discharge 32.0 cc/rev
10. Driven gear (Teeth 12) Max. pressure 210 kg/cm2
Max. pump speed 2,500 rpm
61-8
STRUCTURE AND FUNCTION HYDRAULIC VALVES
HYDRAULIC VALVES
SECURITY VALVE
Section A-A
4 I SF484
Function
1. Valve body
l If hoses between security valve (including work
2. Spool
equipment control valve) and each cylinder are
3. Spring
broken, security valve prevents oil flowing out.
When lower oil level until float valve actuating point,
security valve actuates to return all oil flows to work
equipment control valve to hydraulic tank.
61-9
PRIORITY VALVE
li lb
Section X-X
~22WF046A
Outline
l The priority valve
REUEF VALVE
1. Main valve
2. Valve seat
3. Pilot poppet
4. Pilot poppet spring
5. Adjustment screw
423Fl37
1
I f /3
Function
l The safety valve (with suction valve) is in the dump
cylinder circuit in the main valve. If shock causes
any abnormally high pressure in the cylinder when
the main valve is at neutral, the safety valve (with
suction valve) releases the abnormal pressure and
protects the cylinder and cylinder circuit from
damage.
56OBFO70
Operation
Port A is connected to the pump circuit and port C
is connected to the drain circuit. The oil passes
through the orifice of main valve (1) and flows to
port B. Pilot poppet (3) is in close contact with
valve seat (2).
When the hydraulic pressure in the circuit inside
port A and port B reaches the set pressure of the
pilot poppet spring (4) pilot poppet (3) opens, and
56OBF071
the pressurized oil from port B flows from port D to
port C, so the pressure at port B drops.
When the pressure at port B drops, the orifice effect

of main valve (1) generates a difference in pressure
between port A and port B. The main valve is
pushed open and the oil from port A passes
through port C and flows to the drain circuit to
release the abnormal pressure.
The set pressure can be varied by changing the
tension of pilot poppet spring (4). To change the set
pressure, remove cap nut, loosen lock nut and turn 560BF072
adjustment screw (5) as follows.
61-11
SAFETY VALVE (WITH SUCTION VALVE)
1. Valve body
2. Suction valve
3. Main valve
4. Main valve spring
5. Pilot piston
6. Suction valve spring
I
423F138
Functioh
l The safety valve (with suction valve) is in the dump
cylinder circuit in the main valve. If shock causes
any abnormally high pressure in the cylinder when
the main valve is at neutral, the safety valve (with
suction valve) releases the abnormal pressure and
protects the cylinder and cylinder circuit from
damage.
Operation
As a safety valve
l Port A is the cylinder circuit and port B is the drain
circuit.
The oil pressure in port A flows to port D through a
hole in the pilot piston. It also flows to port C
through an orifice consisting of the main valve (3)
and the pilot piston (5).
The pilot piston is secured to the safety valve by a
lock nut. The diameter of the cross section (cross-
sectional area) gives a relationship of de > dl > ds
423F140
> dq.
l If abnormally high oil pressure occurs in port A, the
suction valve (2) is not actuated because of the
relationship dp > dl.
However, because of the relationship ds > d4 in
ports A and C, the hydraulic pressure on the main
valve (3) is equivalent to the area difference be-
tween ds and dq. If this pressure goes up to the
poppet spring force (set pressure), the poppet is
actuated, and the oil in port A flows into port B.
. ,
423F139
61-12
As a suction valve
l If negative pressure is generated in port A, port D
also has negative pressure, because ports D and A
are connected with each other. .The tank pressure
in port B is applied to port E.
Hydraulic pressure “a” equivalent to the area differ-
ence between dp and dl is applied to the safety
valve because of the tank pressure in port E.
Therefore, hydraulic pressure “e” acts to open the
valve and hydraulic pressure “a” acts to close the
suction valve (2).
l If the pressure in port A drops, (approaching nega-
tive pressure) hydraulic pressure “a” becomes
smaller than oil pressure “e”.
423F141
When oil pressure “e” becomes larger than oil
pressure “a” + valve spring (6) force, the suction
valve (2) opens, causing the oil to flow from port B
into port A. This prevents negative pressure from
building up in port A.
SUCTION VALVE
Function
l Suction valve prevent from generating the negative
pressure in circuit.
1. Main poppet
2. Sleeve
3. Spring
423F142
Operation
l If negative pressure is generated in port A (lift
cylinder rod end) (if the pressure is lower than in
port B in the tank circuit), the main poppet (1)
opens because of the difference in area between dl
and ds. Oil then flows from port C at the tank end 423F143
to port A at the cylinder port end.
61-13
MAIN CONTROL VALVE
2-SPOOL
. 419FO97
A. From pump
B. To dump cylinder rod side
C. To dump cylinder bottom side
D. To lift cylinder rod side
E. To lift cylinder bottom side
F. Drain port (To tank)
G. Drain port
H. Drain port
61-14
Section W-W Section U-U
Section X-X Section V-V

419FO98
1. Valve body
2. Lift spool 5. Suction valve
3. Dump spool 6. Check valve
4. Main relief valve 7. Safety valve (With suction)
Outline
0 The main control valve controls the actuation of the
attachments and the bucket in the hydraulic system. However, the circuit gives priority to the bucket, so
It has a tandem circuit which gives priority to the when the dump spool is being operated, even if the
bucket circuit. lift spool is operated, the lift arm will not move.
l The oil from the pump enters port A. The maximum There are two safety valves (with suction valves) (7)
pressure is set by the relief valve. The oil passes to protect the circuit if abnormal pressure is gener-
through the bypass circuit of dump spool (3) and lift ated in the bucket circuit. If one of the two safety
spool (2). It then flows from port B to the drain valves is acting as a relief valve, the other valve acts
circuit, passes through the filter and returns to the as a suction valve to make up for any lack of oil.
tank. If the dump and lift spools are actuated, the oil
flows to the dump and lift cylinders.
61-15
3-SPOOL
4 I 9F489
1. Main relief valve 5. Suction valve A. Pump port

2. Valve body 6. Check valve B. To dump cylinder rod end
3. Dump spool 7. Safety valve (With suction) C. To dump cylinder bottom end
4. Lift spool 8. Attachment spool D. To lift cylinder rod end
E. To lift cylinder bottom end
F. Drain port (To hydraulic tank)
G. Drain port
H. Drain port
I. Attachment port
J. Attachment port
61-16
3 8 I
Section X-X
Section Y-Y
Section Z-t Section V-V

Section W-W 4 I SF490
Outline
l The main control valve controls the actuation of the However, the circuit gives priority to the attachment
attachments and the buckets in the hydraulic and the bucket, so when the dump spools are
system. It has a tandem circuit which gives priority being operated, even if the lift spoof is operated, the
to the attachment and the bucket circuit. lift arm will not move. The attachment and the dump
l The oil from the pump enters port A. The maximum spools can be operated at the same time.
pressure is set by the main relief valve (1). The oil l There are two safety valves (with suction valves) (7)
passes through the bypass circuit of attachment to protect the circuit if abnormal pressure is gener-
spool (8), dump spool (3) and lift spool (5). It then ated in the attachment and the bucket circuit. If one
flows from port F to the drain circuit, passes of the two safety valves is acting as a relief valve,
through the filter and returns to the tank. If the the other valve acts as a suction valve to make up
attachment, dump and lift spools are actuated, the any lack of oil.
oil flows to the dump and lift cylinders.
61-17
OPERATION
Lift and dump spools at “HOLD position”
F41 SOOd5B
l The oil from pump (1) enters port A. The lift spool (3) is also at hold, so the bypass
l Dump spool (2) is at neutral, so the bypass circuit circuit is open. The oil from port B passes around
is open and the oil from port A passes around the the spool, flows from the drain circuit through the
spool and flows to port B. filter, and goes back to the tank.
61-18
Lift spool at “RAISE position”
DL
F4190006A
l When lift control lever (4) is pulled, lift spool (3) is At the same time, the oil from the cylinder rod end
pulled out to the RAISE position. flows from port D to drain port F and returns to the
l The oil flows from pump (l), then passes through tank. When this happens, the lift arm goes up.
the bypass circuit of dump spool (2) and flows to
the bypass circuit of lift spool (3). The bypass
circuit is closed by dump spool (3), so the oil
pushes open check valve (5).
The oil from check valve (5) flows to port E and
enters the cylinder bottom.
61-19
Lift spool at “LOWER position”
F4190007A
l When lift control lever (4) is pushed, lift spool (3) is The oil then flows from check valve (5) to port D
pushed into the LOWER position. and enters the rod end of cylinder.
l The oil flows from pump (1) then passes through l At the same time, the oil from the cylinder bottom
the bypass circuit of dump spool (2) and flows to flows from port E and enters drain port F. It then
the bypass circuit of lift spool (3). The bypass returns to the tank. When this happens, the lift arm
circuit is closed by lift spool (3), so the oil pushes goes down.
open check valve (5).
61-20
Lift spool at “FLOAT position”
4” Lift lever 3
\ ‘\
F4190008A
l When lift control lever (4) is pushed down further In addition, RAISE circuit E and LOWER circuit D of
from the LOWER position, lift spool (3) is pushed the lift cylinder are connected to the drain circuit, so
into the FLOAT position. the lift arm goes down under its own weight.
l The oil flows from pump (1) then flows around the l When the bucket is in contact with the ground, it
bypass circuit of dump spool (2) to the lift spool can move up and down in accordance with the
bypass circuit. The oil in the bypass circuit flows to shape of the ground.
the drain circuit because of the spool, but it cannot
push open check valve (5).
61-21
Dump spool at “TILT back position”
Lift lever
F4190009A
l When dump lever (6) is pulled, dump spool (2) is l At the same time, the oil at the cylinder rod end
pulled out to the TILT position. flows from port G to drain port F, and flows back to
l The bypass circuit is closed by dump spool (2), so the tank. When this happens, the bucket tilts.
oil from port A pushes open check valve (7).
The oil from port A flows from check valve (7)
through port H to the cylinder bottom.
61-22
Dump spool at “DUMP”
F4190010A
l When the dump lever (6) is pushed, dump spool (2) l At the same time, the oil at the cylinder bottom end
is pushed into the DUMP position. flows from port H to drain port F and then returns
l The bypass circuit is closed by the dump spool (6), to the tank. As a result, the bucket is dumped.
so the oil from port A pushes up check valve (7).
The oil from check valve flows from port G into the
spool. It then flows to the cylinder rod end.
61-23
STRUCTURE AND FUNCTION HYDRAULIC CYLINDER
LIW CYLINDER
1. Cylinder head
2. Cylinder
3. Rod
4. Piston
5. Lock ring
6. Lock ring bolt
U41901328
DUMP CYLINDER
1. Cylinder head
2. Cylinder
3. Rod
4. Piston
5. Lock ring
u41901339 6. Lock ring bolt
STEERING CYLINDER
1. Cylinder head
2. Cylinder
3. Piston rod
4. Piston
5. Lock nut
61-24
STRUCTURE AND FUNCTION BUCKET LINKAGE
BUCKET LINKAGE
H
\J
419F531
1. Lift arm
2. Dump cylinder
3. Lift cylinder
4. Bucket
5. Bucket link
6. Tilt lever
61-25
STRUCTURE AND FUNCTION BUCKET LINKAGE
Section C-C
Section F-F
Section D-D
Section E-E
Section G-G
Section H-H Section J-J
419F532
61-26
STRUCTURE AND FUNCTION WORK EQUIPMENT LEVER LINKAGE
WORK EQUIPMENT LEVER LINKAGE
4 I9F626
1. Lift lever
2. Kick-down switch
3. Dump lever
4. Lift lever magnet switch
5. Main control valve
6. Dump lever magnet switch
61-27
STANDARDVALUETABLE ............................................................. 3
TOOLLIST ......................................................................... 4
DUMP AND LIFT CONTROL LEVERS ...................................................... 5
HYDRAULIC CIRCUIT ........................................................ 7
HYDRAULICPRESSURE.. ............................................................ 10
LIFTARMAND BUCKET .............................................................. 12
HYDRAULIC DRIFT OF LIFT ARM AND BUCKET ............................................ 14
BUCKET POSITIONER ...............................................................
Lift arm does not rise. .......................................................... 20

2. Lift arm moves slowly or does not have sufficient lifting power. 21
Lift arm movement becomes slow after it reaches certain height. 22
4. Bucket cannot be held down with lift arm cylinder. ..................................... 22
5. Lift arm has large hydraulic drift. .................................................. 22
6. Lift arm movement is unsteady during work. ......................................... 22
7. Lift arm descends momentarily when control lever is shifted from “Hold” to “Raise”. ............. 22
8. Bucket does nottilt back. ....................................................... 23
9. Bucket moves slowly or has insufficient tilt back power. 24
10. Bucket movement becomes tilt 25
11. Bucket cannot held down by the dump cylinder. .................................... 25
12. Bucket
25
14. Bucket dumps momentarily is shifted to “Tilt back”. ............. 25
Control levers lift arm and bucket and sluggishly. ........................... 26
* The following precautions are necessary when using Standard Value Tables to make judgements during
62-1
judgements.
“METHOD OF READING TROUBLESHOOTING TABLES” and “PREVENTING RECURRENCE OF TROUBLE” in
SECTION 22.
62-2
value value
Dump and lift levers

0 Lift lever operating force
Hold - Raise 1.5-4.5 Max. 6.8
Raise - Hold 1.7-4.7 Max. 7.1
Hold - Lower l Hydraulic temperature: 45-55°C 1.5-4.5 Max. 6.8
Lower - Hold 0 Engine speed: Low idling 1.5-4.5 Max. 6.8
Lower - Float kg 2.1-5.1 Max. 7.7
Float - Hold 1.7-4.7 Max. 7.1
l Dump lever operating force

Hold - Dump 1.5-4.5 Max. 6.8
Hold + Tilt 1.5-4.5 Max. 6.8
Tilt - Hold 2.1-5.1 Max. 7.7
0 Lift lever travel
Hold - Raise 79-93 63-l 03
Hold - Lower 60-80 50-90
Hold - Float 107-l 27 97-137
mm
l Dump lever travel
Hold - Dump 71-91 61-101
Hold - Tilt 77-97 67-l 07
Main valve 0 Hydraulic temperature: 45-55°C

kg/cm2 210+10 210?20
l Main relief oil pressure l Engine speed: High idling
Lift arm and bucket operating l Hydraulic temperature: 45-55°C

speed 0 Engine speed: High idling
0 Lift arm lifting time l Steering position: Neutral 5.56.1 Max. 7.4
0 Lift arm lowering time l Coolant temperature: Inside 2.5-3.5 Max. 4.2
l Bucket dumping time operating range. 1.0-l .6 Max. 1.9
sec.
l Bucket tilt back time (Full l Bucket: unloaded 2.1-2.7 Max. 3.2
stroke) 0.9-l .5 Max. 1.8
l Bucket tilt back time
(Horizontal position of
bucket)
Hydraulic drift of lift arm l Hydraulic temperature: 4555°C

and bucket l Coolant temperature: Inside
l Retraction of lift cylinder rod operating range
l Retraction of dump cylinder 0 Stop engine, leave for 5 minutes, Max. 4.0 Max. 2.0
rod then measure for next 15 mm Max. 4.0 Max. 2.0
minutes.
l Lift arm horizontal
0 Bucket horizontal
l Unloaded
Bucket positioner l Hydraulic temperature: 4555°C

l Clearance of switch 3-5
mm
Boom kick-out 3-5
l Clearance of switch
62-3
TESTING AND ADJUSTING TOOL LIST
No. I Tool name I Part number Remark

-
1 Oil temperature Thermistor kit 799-l 0 l-6000 o-1,000” c
O-25 kg/cm’
Oil pressure Hydraulic tester 799-l 01-5000 O-50 kg/cm*
0300 kg/cm*
Measuring clearance Feeler gauge Commercially available 0.1-3.0 mm
Brake pedal operating force Push gauge 79A-264-0020 o-110 kg
Brake oil pressure Hydraulic tester 793-605-l 001 O-100 kg
Thickness of pad Vernier calipers Commercially available 150-200 mm
Brake distance I Tape measure I Commercially available 30 m
Operating time Stop watch Commercially available 1/l 0 second
Measuring travel Convex scale Commercially available O-2 m
62-4
TESTING AND ADJUSTING DUMP AND LIFT CONTROL LEVERS
DUMP AND LIFI- CONTROL LEVERS

Item
value value
Operating force (kg)

0 Lift control lever
Hold - Raise 1.5-4.5 Max. 6.8
Raise - Hold 1.7-4.7 Max. 7.1
Hold - Lower 1.5-4.5 Max. 6.8
Lower 4 Hold 1.5-4.5 Max. 6.8
Lower - Float 2.1-5.1 Max. 7.7
Float - Hold 1.7-4.7 Max. 7.1
l Dump control lever

Hold - Dump - 1.5-4.5 Max. 6.8
Hold - Tilt 1.5-4.5 Max. 6.8
Tilt - Hold 2.1-5.1 Max. 7.7
Travel (mm)
0 Lift control lever
Hold - Raise 79-93 63-l 03
Hold - Lower 60-80 50-90
Hold - Float 107-l 27 97-l 37
l Dump control lever

Hold - Dump 71-91 61-101
Hold 4 Tilt 77-97 67-l 07
Special tool
I Part number I Part name I Q’ty
A 1 79A-264-0020 1 Push-pull scale 1 1
A Install the safety bar on the frame.
Measuring procedure
1. Operating force of dump and lift control levers

l Fit push-pull scale A on dump and lift control
levers and measure operating force.
+ Hook the push-pull scale A on the center of
the knob.
* Operate at the same speed as normal and
measure the minimum force needed to
operate the knob.
62-5
TESTING AND ADJUSTING DUMP AND LIFT CONTROL LEVERS
2. Travel of dump and lift control levers

l Measure the travel of the control levers at each
position.
+ Mark the knob of the lever and use a scale
to measure.
+ If the level travel is not within the specified
value, check the linkage for play and the
bushing for wear.
Adjusting procedure
+ If the travel of each lever is outside the standard
value at every position.
1. Open the engine hood and the inspection cover

of the hydraulic tank, and loosen lock nut (1).
+ Remove the washer liquid container, and fix
on top of the ladder.
2. Disconnect ball joint (2) from the main control

valve.
3. Turn the ball joint in or out to adjust the length

of the rod.
419F311
62-6
TESTING AND ADJUSTING HYDRAULIC CIRCUIT FLUSHING
HYDRAULIC CIRCUIT FLUSHING

l This procedure is to be used if components have
broken metal pieces or wear powder can get into
the hydraulic circuit.
A Park the machine on flat level ground, install a

safety bar to the frame, lower the bucket to the
ground, stop the engine, apply the parking
brake, and then put chocks under the tires.
* Remove all dirt and debris from around the com-

ponent that is to be removed. This is prevent dirt
from getting into the hydraulic circuit.
* At any time that a component is removed from the

hydraulic system, all connecting tubes will be
properly cleaned and masked with tape to prevent
dirt from getting into the system before reassembly
is accomplished.
1. BEFORE FLUSHING
1) Drain the hydraulic oil.
A When draining the oil, turn the oil filler cap

slowly to release the remaining pressure.
2) Remove the troubled pump, then repair or

obtain a new pump.
3) Cleaning the hydraulic tank.
A. Remove and check the filter cover.

B. Clean the tank inside with detergent, light
oil or kerosene.
C. Blow dry with air to remove dirt.
t When cleaning, take care to completely

remove the dirt from the tank bottom.
D. Remove dirt from the element case bottom.

E. Remove dirt and clean the suction tube in
the hydraulic tank.
F. Remove the tubes from the tank to the
pump and from pump to valve, then thor-
oughly clean the tubes inside.
4) Cleaning the hydraulic cylinder.

1. Hydraulic tank 5. Cover plate
A. Disassemble the hydraulic cylinder as 2. Sight gauge 6. Oil filler cap
described in the this manual. 3. Filter element 7. Breather assembly
B. Clean with a detergent the inside of the 4. Valve assembly 8. Control valve
cylinder tube and the inside of the cylinder
head.
62-7
t On disassembly, if damage is found on

cylinder tube inside wall or the piston
packing replace with new one.
5) Cleaning the work equipment control valve and

the steering valve.
A. Disassemble per instructions in this manual.

B. Fill a container with detergent.
C. Deposit valve into the container to clean.
* Use a nylon brush to clean the hole

and recessed portion on the valve
body and spool.
t When removing the relief valve and

overload relief valve, do them as as-
semblies. Put them into a detergent-
filled container to clean the check valve
and poppet inside the assemblies. Do
this by manually operating the check
valve and poppet and seeing how they
operate.
6) Remove the steering tube and work equipment

tube separately and clean with detergent, then
blow dry with air.
7) Install the tubes and valves that were removed

and cleaned.
8) Replace the breather element on the hydraulic

tank with a new one.
9) Install a new hydraulic filter element.
+ Make sure that the element is seated prop-

erly when installing. If the element is not
seated properly, no effect can be expected
from the element.
10) Add oil to the hydraulic tank up to the specified

oil level.
2. WORK STEPS FOR FLUSHING
1) Start the engine and run at low idling for 10

minutes without operating the work equipment
and without utilizing the steering.
2) Run the engine at the high idling setting for 10

minutes without operating the work equipment 1. Hydraulic tank 5. Cover plate
and without utilizing the steering. 2. Sight gauge 6. Oil filler cap
3. Filter element 7. Breather assembly
+ Check the oil level at the hydraulic tank. If 4. Valve assembly 8. Control valve
the oil level became lower, add oil up to the
specified fluid level.
62-8
3) Release air from the bucket cylinder, work

equipment and the steering cylinders circuit as
Follows:
A Operate components only in this sequence to

release the air: Boom cylinder, Bucket
cylinder and then Steering cylinder.
A Completely release air from the cylinders de-

scribed above, because if not done so, the air
that has mixed in the cylinders can cause a
piston packing to brake.
A. Run the engine at low idle and slowly oper-

ate the cylinder by stopping the cylinder
about 100 mm before the stroke end. Re-
peat extending and retracting the cylinder
in this manner for four or five cycles.
A Avoid operating the cylinder up to the maxi-

mum stroke end at the beginning of this opera-
tion. Doing maximum stroke operation will
cause mixed air-oil compression and result in
damage to the piston packing.
B. Only after completion of item A. above,

now aently operate the cylinder up to the
stroke end, three or four times to release
air from the cylinder.
+ Check the oil level at the hydraulic

tank; if low, service to proper fluid level.
4) Measure the hydraulic pressure.
l Measure the pressures on the work equip-

ment and the steering system. If pressures
are out of specifications, adjust them to
with in specifications.
5) Drain the hydraulic oil, then;
A. Recheck for dirt at the bottom of the hy-

draulic tank. If found, remove.
B. Remove hydraulic oil filter element, recheck

case inside and remove dirt, then install a
new filter element.
6) Add oil to the hydraulic tank up to the required

fluid level.
7). Release air from the hydraulic circuit by repeat-

ing the above procedural steps.
8). Check the oil level at the hydraulic tank. If oil

level is low, add oil to the specified fluid level.
62-9
TESTING AND ADJUSTING HYDRAULIC PRESSURE
HYDRAULIC PRESSURE
l Hydraulic oil temperature: 45-55°C
Unit: ka/cm*
Item
value value
Main relief pressure 21OrtlO 210+20
Soecial tool
1. Measuring procedure (Main relief valve)

% Y
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) Remove plug (1) for measuring pressure of

dump cylinder circuit.
2) Install hydraulic tester A to measuring port.
l Check that there is no oil leakage from any
connection.
t Use a hose which is long enough to reach
the operator’s compartment.
3) Start the engine, raise the lift arm 400 mm from
the ground and operate the dump control lever
(TILT). Measure the pressure when the relief
valve is actuated.
+ Be careful not to apply any sudden pres-
sure to the pressure gauge.
When removing the hydraulic pressure

Y Y
A gauge, release the pressure inside the
4 circuit
62-10
TESTING AND ADJUSTING HYDRAULIC PRESSURE
A Always stop the engine before adjusting the

hydraulic pressure.
1) Stop the engine, open the engine hood and

inspection cover, then remove the side cover.
2) Remove cap nut (1) of the relief valve.

3) Loosen lock nut (2), then turn adjustment screw
(3) to adjust.
+ Amount of adjustment for 1 turn of screw:
1 turn: Approx. 35.7 kg/cm*
+ Turn the adjustment screw as follows:
To INCREASE pressure, TIGHTEN screw.
To DECREASE pressure, LOOSEN screw.
t If the relief pressure cannot be measured i
accurately, do not try to adjust the pres-
sure. 419F312
.--
62-11
TESTING AND ADJUSTING LIFT ARM AND BUCKET
LIFI- ARM AND BUCKET

l Coolant temperature: inside operating range
l Steering position: Neutral
l Hydraulic temperature: 45 - 55°C
l Bucket: Unloaded
Unit: sec.
Item
value value
Lifting time of lift arm 5.5-6.1 Max. 7.4
Lowering time of lift arm 2.5-3.5 Max. 4.2
Tilt back time of bucket

(From horizontal 0.9-l .5 Max. 1.8
position of bucket)
Soecial tool
I Part number I Part name I CYty h-4 Lifting time of lift arm
IA 7AO-262-0550 I Stop watch I 1
Measuring procedure
1. Lifting time of lift arm

Set the bucket near the maximum tilt back position
and at the lowest position on the ground. Raise the
bucket and measure the time taken for bucket to
reach the maximum height of the lift arm.
423F327 i
-.’
Lowering time of lift arm
2. Lowering time of lift arm

Set the bucket horizontal with the lift arm at the
maximum height, lower the bucket and measure the
time taken for the bucket to reach the lowest
position on the ground.
423F328
62-12
TESTING AND ADJUSTING LIFT ARM AND BUCKET
3. Dumping time of bucket Dumping time of bucket

Raise the lift arm to the maximum height and
measure the time taken for the bucket to move from
the maximum tilt back position to the maximum
dump position.
Tilt back time of bucket

4. Tilt back time of bucket
1) Raise the lift arm to the maximum height and
measure the time taken for the bucket to reach
the maximum tilt back position.
2) Set the bucket horizontal and measure the time
taken for the bucket to move from the horizon-
tal position to the maximum tilt back position.
423F330
62-13
TESTING AND ADJUSTING HYDRAULIC DRIFT
HYDRAULIC DRIFT OF LIW ARM

AND BUCKET
l Hydraulic temperature: 45 - 55°C
l Stop engine, leave for 5 minutes, then measure for
next 15 minutes.
l Lift arm horizontal
l Bucket horizontal
l Unloaded
Unit: mm
ltem
1St;;gd 1 Permitble
Retraction of lift
( Max. 4.0 1 Max. 20
cylinder rod
Retraction of dump
Max. 4.0 Max. 20
cylinder rod
Special tool
Commercially available Convex scale 1
A Fit the safety locks on the control levers.
A Do not go under the work equipment.
Measuring procedure
1. Set the lift arm and bucket horizontal, then stop the
engine. 423F33 I
2. Stop the engine, wait for 5 minutes, then start

measuring.
3. Measure the amount the lift and dump cylinder rods

retract during 15 minutes.
A. Retraction of dump cylinder rod

B. Retraction of lift cylinder rod
423F332
62-14
TESTING AND ADJUSTING BUCKET POSITIONER
BUCKET POSITIONER
+ Measurement conditions
Unit: mm
I I
Item
Clearance “b” between

proximity switch and 3-5
angle
1. Inspection procedure
1) -With the engine stopped, check that the clear-
ance between switch (1) and angle (2) is within
the standard value.
2) Start the engine, run at high idling, and check
the actuation position. (Measure three times
and take the average.)
2. Adjusting procedure a
I
1) Lower the bucket to the ground and set the

bucket to the desired digging angle. Return the
control lever to the HOLD position and stop the
engine.
2) Adjust nut (4) of the proximity switch so that
clearance “a” between the tip of protector (3) of
proximity switch (1) and the face of the proximi-
ty switch sensor is the standard value, then lock
in position.
* Clearance “a”: 0.5-1.0 mm
w Nut: 1.820.2 kgm
62-15
TESTING AND ADJUSTING BOOM KICK-OUT
3) Using shims, adjust so that the clearance “b”

between the response surface of switch (1) and
angle (2) is within the specified value, then lock
in position.
Check that protector and angle are not in f-l
contact.
Using shims, adjust the angle so that the
clearance between the response surface of
the switch and the angle is within the speci-
fied value over the whole stroke of the
angle, then lock in position.
Check that the centers of the sensing sur- b
face of the proximity switch and angle (2)
2 1
are in line, then lock in position. U42301010A-
After adjusting, operate the bucket lever

and check that the bucket positioner is
actuated at the desired position.
Clearance “b”: 3-5 mm
62-16
TESTING AND ADJUSTING BOOM KICK-OUT
BOOM KICK-OUT
Unit: mm
Item
value value
Clearance between
3-5
proximity switch and bar
1. Inspection procedure
1) With the engine stopped, check that the clear-
ance between switch (1) and plate (2) is within
the standard value.
2) Start the engine, run at high idling, and check
the actuation position. (Check three times and
take the average.)
1) Raise the lift arm to the desired position. Return
the control lever to the HOLD position, and
stop the engine.
A Always apply the safety lock to the control

lever.
2) Lower the lift arm and stop the engine.

3) Align the marking with the switch center and
adjust the plate (2) position so that the switch
center and the plate lower end are in line
%h each other.
a Switch mounting nut: 1.8kO.2 kgm
4) Fix the switch so that the clearance between

the sensing surface of the switch and plate (2)
is 3-5 mm.
* After adjusting, operate the lift lever and
check that the kick-out is actuated at the
desired position.
I I
419F314
62-17
This page is blank.
62-18
TROUBLESHOOTING
62-19
TROUBLESHOOTING TROUBLESHOOTING TABLES
1. Lift arm does not rise.

l Did the lift arm suddenly fail to raise? - Seizure
or damage to various units.
l Was an unusual noise produced? (Where did it
emanate from?)
l Were there previous signs of the lift arm slow-
ing down? - Wear of parts or flattening of
spring.

l Is oil level in hydraulic tank correct?
l Is stroke of lift arm control lever and spool
correct?
No’ 1 Problem
i-i I I I .I I /
1 Bucket cannot operate and lift arm IS unable to ascend. 00000
The machlne body can be llfted up by the lift arm

2 however the lift arm IS unable to ascend. Alternatively, 00
the bucket operates but the lift arm is unable to ascend.
I
The lift arm can ascend under no load but cannot
3 0 0
ascend under load.
4 The hydraulic pump produces an unusual noise. 0 0
5 Lift cylinder has large amount of hydraulic drift. 0 0

When the engine IS at high idling, steering action is
6
light and excessively fast.
When the engine IS at high Idling, steering actlon 1s
7
heavy and slow. 0 0 0
L1022017
The following symbols are used to indicate the action to

be taken when a cause of failure is located.
X: Replace A: k?pair
A: Adjust C: Clean
62-20
2. Lift arm moves slowly or does not have sufficient

lifting power.

l Is the amount and type of oil in the hydraulic
tank correct?
l Is the stroke of the lift arm control lever and
also the spool of the main control valve cor-
rect?
l Seizure of work equipment linkage bushing.
Fault check.
There is a strong relationship between faults involv-
ing lifting force and lifting speed. Such faults appear
initially in the form of insufficient lifting speed.
Measure the lifting speed of the lift arm when
loaded and refer to the judgement criterion table to
determine whether or not there is a fault.
When the engine is at high idling, steering action is

5
light and excessively fast. 0
When the engine is at high idling, steering action is
6 0 0
heavv and slow.
7 Lift cylinder has a large amount of hydraulic drift. I I I 10101

- -
I I I I I
The relief pressure of maine relief valve is low when hh_
8 1 pppl
the engine is at high idling.
LlOZZO18

A: Adjust C: Clean
62-21
3. Lift arm movement becomes slow after it reaches 6. Lift arm movement is unsteady during work.
a certain height. During excavation or ground leveling when the lift
arm control lever is in the “Hold” position, the
Check before troubleshooting. bucket and lift arm move up and down in accor-
l Visible deformation of lift cylinder. dance with the terrain.
Cause Problem and cause

l Swollen or internally damaged lift cylinder tube. Check the amount of hydraulic drift and whether or
t Regarding other faults occurring during lift arm not the machine body can be lifted up by the lift
ascent, refer to item “2. Lift arm moves slowly cylinder.
or does not have sufficient lifting power.”
1. If the amount of hydraulic drift is greater than
4. Bucket cannot be held down with lift arm the standard value, refer to item “5. Lift arm has
cylinder. large hydraulic drift.”
If the relief pressure in the circuit at the bottom of
the lift cylinder is insufficient, refer to item “2. Lift 2. If the machine body can be lifted up by the lift
arm moves slowly or does not have sufficient lifting cylinder, refer to item “4. Bucket cannot be held
power.” down with lift arm cylinder.”
Checks before troubleshooting. 3. If the amount of hydraulic drift is normal and

l Is level of oil in the hydraulic tank correct? the machine body can be lifted up by the lift
l Is stroke of main control valve and lift arm cylinder after the lift arm is moved several times
spool correct? to cause the lift cylinder to move through its
entire stroke -the trouble is due to the genera-
Cause tion of a vacuum in the cylinder.
l Faulty main control valve or suction valve seat * If a vacuum is generated frequently, -faulty
on lift cylinder rod side. suction valve on lift cylinder rod side.
l Oil leakage from lift cylinder piston seal.
7. Lift arm descends momentarily when control
5. Lift arm has large hydraulic drift. lever is shifted from “Hold” to “Raise”.
The lift arm descends momentarily under its own
Ask the operator the following questions. weight when the lift arm control lever is gradually
l Did the hydraulic drift suddenly become large? shifted from the “Hold” position to the “Raise”
- Dirt lodged in valve or damaged parts. position while the engine is at low idling. When the
l Did the hydraulic drift gradually become large? control lever is put completely into the “Raise”
- Worn parts. position, the lift arm behaves normally.
Checks before troubleshooting. Cause

l Is the type and temperature of the oil in the l Faulty seating of main control valve or lift arm
hydraulic tank correct? load check valve.
l Is the lift arm spool in the “Hold” position? -
Seized link bushing, faulty spool detent.
Problem and cause

l When measuring hydraulic drift, internal of lift
cylinder produces oil leak noise - Damaged
piston packing.
62-22
8. Bucket does not tilt back.

l Did the bucket suddenly cease to move? -
Seized or damaged equipment.
Was any unusual noise emitted? Where did it
emanate from?
l Were there previous signs of the bucket slowing
down? - Worn parts or flattened spring.

l Is amount of oil in hydraulic tank satisfactory?
l Is the stroke of the bucket control lever and
spool correct?
Steering action is light and excessively fast when the

6
engine is at full throttle. 0
Steering action is heavy and slow when the engine is at o
7
full throttle.
L10zz019

A: Adjust C: Clean
62-23
9. Bucket moves slowly or has insufficient tilt back

power.

l Is the quantity and type of oil in the hydraulic
tank satisfactory?
l Is the stroke of the bucket control lever and the
main control valve spool correct?
l Seizure of bushing in bucket linkage.
l Was an unusual noise produced?
Fault checks.
l Check the amount of deficient tilt back force by
performing actual work.
l Measure the operating speed of the bucket and
check it against the judgement criterion table to
determine whether or not it is normal.
No.
Lrft arm kfting force and lifting speed are abnormal and
1 also bucket tilt back force and tilt back speed are ab- 00000
normal.
Lift arm kfting force and lifting speed are normal but
2
bucket tilt back force and tilt back speed are abnormal.
Phenomena of item 1 become particularly bad when the
Steering action is light and excessively fast when the
Steering action is heavy and slow when the engine is at

6
full throttle.
7 The dump cylinder has a large amount of hydraulic drift.
The relief pressure of main relief valve is low when

8
the engine is at full throttle.
9 The drscharge volume of the hydraulrc pump is low.

A: Adjust C: Clean
62-24
10. Bucket movement becomes slow during tilt back. 13. Bucket moves unsteadily when machine travels
under load. (Main control valve in “Hold”).
Check before troubleshooting.
l External deformation of dump cylinder. Checks before troubleshooting.
l Is oil level and type of oil in the hydraulic tank
Cause correct?
l Swollen or internally damaged dump cylinder l Excessive play in pin and bushing of work
tube. equipment linkage.
l Regarding other faults which occur when the 0 Was an unusual noise produced?
bucket operates, refer to item “9. Bucket moves
slowly or has insufficient tilt back power.” Cause
l Faulty piston seal of dump cylinder.
11. Bucket cannot be held down by the dump l Faulty safety valve with suction valve for the
cylinder. bottom side of dump cylinder.
Refer to item “9. Bucket moves slowly or has insuffi- If the above symptoms occur together with
cient tilt back power.” other symptoms, refer to the problem items
corresponding to each fault.
l Is oil level in the hydraulic tank satisfactory? 14. Bucket dumps momentarily when control lever is
l Is the stroke of the main control valve dump shifted from “Hold” to “Tilt back”.
spool correct? The bucket dumps momentarily under its own
weight when the dump control lever is gradually
Cause shifted from the “Hold” position to the ‘Tilt back”
l Faulty seat of safety valve with suction valve of position while the engine is at low idling. When the
control valve for the rod side of dump cylinder. control lever is put completely into the “Tilt back”
l Oil leakage from seal of dump cylinder piston. position, the bucket behaves normally.
12. Bucket has large hydraulic drift. Cause

l Faulty seating of main control valve dump spool
Ask the operator the following questions. check valve.
l Did the hydraulic drift suddenly become large?
- Dirt lodged in valve or damaged parts.
l Did the hydraulic drift gradually become large?
- Worn parts.

l Is the type and temperature of the oil in the
hydraulic tank correct?
l Is the dump spool in the neutral position? -
Seized link bushing, faulty spool detent.
Fault checks.
l Use the judgement criterion table to check
whether or not the hydraulic drift of the bucket
is actually large.
l If hydraulic drift is large,
Cause: Oil leakage in dump cylinder.
l If hydraulic drift returns to normal,
Cause: Faulty seating of overload relief valve
or suction valve on rod side.
Faulty oil sealing on spool of dump
control valve.
62-25
15. Control levers of lift arm and bucket move stiffly

and sluggishly.
Fault check.
Using the judgement criterion table, check whether
or not the operating force of the lever is large.
Main control valve
No.
Problem
Movement of lift arm and bucket becomes sluggish when

1
losd is applied and oil pressure increases.
Movement of lift arm and bucket becomes sluggish along
2
with change in oil temperature. 0 0
Movement of lift arm and bucket becomes partially
3
sluggish irrespective of oil pressure and temperature.
0
Movement of lift arm and bucket becomes generally
4
sluggish irrespective of oil pressure and temperature. 0 0 0 0
Movement of lift arm and bucket does not become light
5 even when the link of the control lever is disconnected 0
at the valve connection part and the lever operated.
L1022021

A: Adjust C: Clean
62-26
HYDRAULICTANK ................................................................... 2
REMOVAL ...................................................................... 2
INSTALLATION ................................................................... 5
HYDRAULIC FILTER .................................................................. 7

REMOVAL ...................................................................... 7
INSTALLATION ................................................................... 7
HYDRAULIC & STEERING PUMP ........................................................ 8

REMOVAL ...................................................................... 8
INSTALLATION.. ................................................................. 9
MAIN CONTROLVALVE .............................................................. 10

REMOVAL ..................................................................... 10
INSTALLATION .................................................................. 12
DISASSEMBLY .................................................................. 13
ASSEMBLY .................................................................... 15
DUMPCYLINDER ................................................................... 17
REMOVAL ..................................................................... 17
INSTALLATION .................................................................. 19
LIFTCYLINDER .................................................................... 20
REMOVAL ..................................................................... 20
INSTALLATION .................................................................. 21
HYDRAULICCYLINDER .............................. ............................... 22

DISASSEMBLY.. ........ . ....................... ............................... 22
ASSEMBLY ................................. . .. ............................... 24
WORK EQUIPMENT ................................. ............................... 27

REMOVAL ..................................... ............................... 27
INSTALLATION .................................. ............................... 30
COUNTERWEIGHT .................................. ............................... 33

REMOVAL ..................................... ............................... 33
INSTALLATION .................................. ............................... 33
* For details of disassembly and assembly of the gear pump, see SECTION 97.
63-1
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
HYDRAULIC TANK
REMOVAL

*~e Loosen the oil filler cap slowly to relieve the

4 pressure inside the hydraulic oil tank, then
operate the control lever 2 or 3 times to elimi-
nate the residual pressure in the piping.

1. Brake oil level sensor, washer liquid container

1) Remove washer liquid container, then discon-
nect vinyl hose (4).
2) Disconnect connector (5) of washer liquid
container.
3) Disconnect hose (6) of radiator sub tank.
63-2
2. Hydraulic piping
l Disconnect tube (7) between main control valve
and hydraulic tank at main control valve end.
0 Disconnect lift cylinder hoses (8 and 9) from
main control valve.
0 Disconnect dump cylinder hoses (10 and 11)
from main control valve.
l Disconnect steering valve hose (12) from main
control valve.
e Loosen clamps of hoses (13 and 14) between

hydraulic tank and hydraulic and steering pump
at pump end.
l Remove return hose and tube (18) of steering
valve and main control valve.
3. Air cleaner
Disconnect air cleaner (15) from turbocharger, and
remove.
4. Hydraulic tank
1) Disconnect work equipment control linkage (16)
at main control valve end.
2) Using eye bolts, sling hydraulic tank (17),

remove mounting bolts, then lift off.
+ Be careful not to hit the window of the cab
when lifting off the hydraulic tank.
Hydraulic tank: 160 kg
63-4
INSTALLATION
1. Hydraulic tank
1) Using eye bolts, raise hydraulic tank (17), set in
mounting position, then install mounting bolts.
+ Tighten the mounting bolts partially, then
tighten them fully after fixing the tank in
position.
2) Connect work equipment control linkage (16) at

main control valve end.
2. Air cleaner
Connect air cleaner (15) at turbocharger end and
install.
3. Hydraulic piping
l Install return hose and tube (18) of steering
valve and main control valve.
l Insert hoses (13 and 14) between hydraulic tank
and hydraulic and steering pump at pump end,
then tighten clamps.
+ Set the mounting direction of the clamps
90” apart.
l Connect steering valve hose (12) to main

control valve.
0 Connect dump cylinder hoses (10 and 11) to
main control valve.
l Connect lift cylinder hoses (8 and 9) to main
control valve.
l Connect tube (7) between main control valve
4. Brake oil level sensor, washer liquid container

1) Connect connector (5) of washer liquid tank.
2) Install washer liquid tank, then connect vinyl
hose (4).
3) Connect hose (6) of radiator sub tank.

Tighten plug at top of hydraulic tank filter, and plug
of pump piping, then add hydraulic oil through oil
t Run the engine to circulate the oil through the
63-6
DISASSEMBLY AND ASSEMBLY HYDRAULIC FILTER
HYDRAULIC FILTER
REMOVAL
9 Y
Loosen the oil filler cap slowly to release
A the pressure inside the hydraulic tank.
4
1. Cover
Remove mounting bolts, then remove cover (1).
The tension of the spring is pushing the

*
AY cover, so be careful when removing.
4
t Be careful not to damage O-ring and the con-

tact faces of the cover and tank.
2. Filter
Remove spring (3) and bypass valve (4), then
remove filter (5).
419P985/
.--
INSTALLATION
1. Filter
Install filter (5), then install bypass valve (4) and
spring (3).
\ 419P986
2. Cover
Fit O-ring (2) in groove of cover, then install cover
(1) to tank.
+ Replace the O-ring with a new part.
+ Fit the O-ring securely in the groove, and make
sure that it is not caught when installing.
63-7
DISASSEMBLY AND ASSEMBLY HYDRAULIC & STEERING PUMP
HYDRAULIC & STEERING PUMP

REMOVAL

Loosen the oil filler cap to relieve the pres-

Y &
A sure in the hydraulic oil tank, then operate
+ the control lever 2 or 3 times to eliminate
the residual pressure in the piping.

NOTE: l To gain access to the hydraulic & steering

pump, REMOVE the hydraulic control valve
per this section first.
l The right entry ladder must be removed.
l The engine hood must be opened and
safety lock installed.
1. Hydraulic piping
1) Disconnect tubes (4 and 5) between hydraulic
tank and hydraulic and steering pump at pump
end.
2) Disconnect hoses (6 and 7) between hydraulic
and steering pump and steering valve at pump
end.
2. Steering, hydraulic pump

Remove mounting bolts, then lift off pump (8).
workers.
+ There is little space to work, so be careful.
\7 -
A ka Steering and hydraulic pump: 14 kg
4 I9P9.98
DISASSEMBLY AND ASSEMBLY HYDRAULIC & STEERING PUMP
INSTALLATION
1. Steering and hydraulic pump

Set pump (8) in mounting position, then tighten
mounting bolts.
+ Check that there is an O-ring installed between
the pump and housing.
workers.
+ There is little space, so be careful when work-
ing.
2. Hydraulic piping
1) Connect hoses (6 and 7) between hydraulic and
steering pump and steering valve at pump end.
2) Connect tubes (4 and 5) between hydraulic

tank and hydraulic and steering pump at pump
end.
63-9
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
MAIN CONTROL VALVE

REMOVAL

* &
Loosen the oil filler cap to relieve the pres-
A sure in the hydraulic oil tank, then operate
4 the control lever 2 or 3 times to eliminate
the residual pressure in the piping.

1. Hydraulic piping
l Disconnect tube (4) between main control valve
l Disconnect lift cylinder hose (5) from main
control valve.
l Disconnect dump cylinder hose (6) from main
control valve.
l Disconnect hose (7) between steering valve and
63-10

1) Disconnect main control valve linkage (8) at
main control valve end.
2) Disconnect hose (9) between hydraulic tank
and main control valve at hydraulic tank end.
3) Remove the washer liquid tank (12).
4) Remove mounting bolts, then lift off main

control valve (13).
el k0
Main control valve: 55 kg
t Be careful not to let the lifting tool slip

when raising the main control valve.
63-11
INSTALLATION

1) Set main control valve (13) in mounting posi-
tion, then tighten mounting bolts.
t Tighten the mounting bolts on diagonally
opposite sides and be careful not to deform
the valve.
2) Connect main control valve linkage (8) at main

control valve end.
3) Connect hose (9) between hydraulic tank and
main control valve at hydraulic tank end.
4) Install the washer liquid tank (12).
2. Hydraulic piping
0 Connect dump cylinder hose (6) to main con-
trol valve.
0 Connect lift cylinder hose (5) to main control
valve.
0 Connect tube (4) between main control valve

Tightening plug at top of hydraulic tank filter, and
plug of pump piping, then add hydraulic oil through
oil filler (19) to the specified level.
t Run the engine to circulate the oil through the
63-12
DISASSEMBLY
419F455
63-13
1. Case assembly
1) Remove bolts (1) then remove case assembly
(2).
2) Remove plate (3), then loosen bolt (5) of lever
(4).
3) Remove shaft (6) from lever (4).
4) Remove oil seal (7) and bearings (8 and 9).
0
w-27
B-26
2. Spool assembly
1) Remove case (lo), then remove spool assembly
(11).
2) Remove bolt (12), then remove retainer (13),
spring (14), and retainer (13) from spool (15).
+ Remove bolt (12) with the spool still assem-
bled in the valve body.
3. Main relief valve assembly

1) Remove main relief valve assembly (17).
2) Loosen nut (18), then remove holder (19).
3) Remove poppet (20), spring (21) and retainer
(22).
4) Remove seat (23) from sleeve (25), then re-
move spring (24).
+ If there is any abnormality in sleeve (25),
valve (26) or plug (27), replace the whole
assembly. These parts are not available
individually.
4. Safety valve with suction valve assembly

Remove safety valve assembly (28).
5. Suction valve assembly 419F456

Remove suction valve assembly (29).
6. Check valve
Remove plug (30), then remove spring (31) and
valve (32).
63-14
ASSEMBLY
0
0
@%3
419F455
63-15
1. Check valve
Assemble valve (32) and spring (31) in body (33), fit
O-ring, then tighten plug (30).
D Plug: 47.5a2.5 kgm
2. Suction valve assembly

Fit O-ring and back-up ring, then install suction
valve assembly (29).
D Suction valve: 14kl kgm
3. Safety valve with suction valve assembly

Fit O-ring and back-up ring, then install safety valve
assembly (28).
D Safety valve: 142 1 kgm
4. Main relief valve assembly

1) Assemble spring (24) in sleeve (25), then install
seat (23).
2) Assemble poppet (20) spring (21) and retainer
(23) in sleeve (25).
3) Screw nut into holder (19), .fit O-ring, install
sleeve (25), then tighten nut (18).
4) Fit O-ring and back-up ring, then install main
relief valve (17).
D Main relief valve: 15.5k2.5 kgm
5. Spool assembly
1) Assemble retainer (13), spring (14) and retainer
(13) in spool (15), then tighten bolt (12). B-l,,
Iz_7 Bolt: 7+0.5 kgm
* When tightening bolt (12), tighten with the

spool assembled in the valve body.
2) Assemble spool assembly (11) in body, fit
O-ring, then install case (10).
6. Case assembly
1) Install bearings (9 and 8), and oil seal (7) in case.
2) Assemble lever (4) inside case, fit key, then
install shaft (6) to lever (4) inside case. 419F456
3) Tighten bolt (5).
4) Fit O-ring, align lever (4) with spool, then install
case assembly (2).
63-16
DISASSEMBLY AND ASSEMBLY DUMP CYLINDER
DUMP CYLINDER
REMOVAL

safety bar on the
A Loosen the oil filler cap slowly to relieve the

pressure in the hydraulic oil tank, then operate
4
the control levers 2 or 3 times to eliminate the
residual pressure in the piping.
1. Bucket positioner
Disconnect connector (1).
+ Remove the wiring clamps and brackets.
2. Hydraulic piping
1) Disconnect hose (2) at rod end from cylinder.
2) Disconnect tube (3) and hose (4) at bottom end
from connector.
3. Rod pin
Sling cylinder, remove lock bolt, then remove pin
(5).
t When raising the cylinder, sling at two places
and be careful to maintain the balance.
4. Dump cylinder
1) Remove lock bolt, then remove pin (6) at bot-
tom end.
+ There are shims installed, so check the
number and thickness of the shims, and
keep in a safe place.
2) Lift off dump cylinder (7).

Dump cylinder: 120 kg
419PLOO3
63-18
INSTALIATION
1. Dump cylinder
1) Raise dump cylinder (7) and set in mounting
position.
2) Align pin hole at bottom end, assemble shim so
that total clearance ‘a’ between cylinder and
frame is within specified range, then install pin
(6) and lock with bolt.
Clearance ‘a’: Max. 1.5 mm
a a
419PiOO4
-
4 I SF457
3) Align pin hole at rod end, then install pin (5) 4lSP1005
and lock with bolt.

fingers.
2. Hydraulic piping
1) Connect tube and hose (4) at bottom end.
2) Connect tube and hose (2) at rod end.
* Fit the O-rings securely in the grooves.
+ Install the hose without twisting or interfer-
ence.
3. Bucket positioner
Connect connector (1).
+ For details of adjusting bucket positioner, see
SECTION 62, TESTING AND ADJUSTING.
* Install wiring clamps and brackets.
LlFr CYLINDER
REMOVAL

shut down engine, apply the parking brake and
place blocks under the tires.
Y Y Loosen the oil filler cap to relieve the pressure

A
1. Rod pin
1) Sling lift cylinder (1) remove lock bolt, then
remove pin (2).
2) Start engine, and operate control levers to
retract cylinder rod on side where pin has been
removed.
+ Do not retract the rod fully. Stop about 20
mm from the end of the stroke.
2. Hydraulic piping
1) Disconnect tube (3) and hose (4) at rod end
from connector.
2) Disconnect tube (5) and hose (6) at bottom end
from connector.
t Fit covers to prevent dirt or dust from
entering the hoses or connections.
3. Lift cylinder
1) Remove lock bolt, then remove pin (7) at bot-
tom end.
+ There are shims installed, so check the
number and thickness of the shims, and
keep in a safe place.
2) Remove lift cylinder (1).
* Be careful of the center of gravity, and
remove slowly.
Lift cylinder: 115 kg
63-20
DISASSEMBLY AND ASSEMBLY LIFT CYLINDER
INSTALLATION
1. Lift cylinder
1) Raise lift cylinder (1) and set in mounting posi-
tion.
2) Align pin hole at bottom end, assemble shim so

that total clearance ‘a’ between cylinder and
frame is within specified range, then install pin
(7) and lock with bolt.
Use bar to align the pin holes. Never use your

A fingers.
Clearance ‘a’: Max. 1.5 mm

4 I9F496
2. Hydraulic piping
1) Connect tube and hose (6) at bottom end.
2) Connect tube and hose (4) at rod end.
t Fit the O-rings securely in the grooves.
+ Install the hoses without twisting or interfer-
ence.
3. Rod pin
Start engine, operate control levers to extend rod.
Align pin hole, install pin (2), then lock with bolt.
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
DISASSEMBLY
Special tool
A 790-502-1003 Cylinder repair stand 1
1. Set cylinder assembly (1) on tool A. IUI

419FOI II2
2. Remove mounting bolts (2) of cylinder head.
3. Pull cylinder head and piston rod assembly (3) out

of cylinder (4) and lift off.
t Oil will come out when the piston rod assembly
is removed from the cylinder, so place a con-
tainer in position to catch the oil.
419FOI I I3
4. Remove piston bolts (5), then remove spacer (6),

piston assembly (7) and cylinder head assembly (8)
from rod (9).
419FOI I
5. Remove O-ring (10) and back-up ring (11) from

piston rod (9).
419PI255
63-22
6. Disassemble piston assembly as follows:

Remove wear ring (12) and piston ring (13) from
piston (14).
7. Disassemble cylinder head assembly as follows:

1) Remove O-ring (15) and back-up ring (16).
2) Remove snap ring, then remove dust seal (17).
3) Remove rod packing (18).

4) Remove bushing (19).
63-23
Special tools
A 1 790-502-1003 1 Cylinder repair stand I 1
B 790-702-l 000 Expander 1
C 796-720-l 680 Ring 1
+ Clean all parts, and check for dirt or damage. Coat

the sliding surfaces of all parts with engine oil
before installing. Be careful not to damage the
packings, dust seals or O-rings when installing.
1. Assemble cylinder head assembly as follows:

1) Using push tool 0, press fit bushing (19) on
cylinder head (20).
+ Be careful not to deform the bushing when
press fitting.
2) Assemble rod packing (18).
+ Be careful to install the rod packing facing
19 419FOI I I6
4lSFOI II7
4lSFOI I I8
3) Install back-up ring (16) and O-ring (15).

* Do not try to force the back-up ring into
position. Warm it in warm water (50 -
6O’C) before fitting it.
4) Using push tool @, install dust seal (17) on
head (16), then secure with snap ring.
419FOI I IS
63-24
2. Assemble piston assembly as follows:

1) Using tool B, expand piston ring (13).
* Set the piston ring on the tool C and turn
the handle 8 to 11 times to expand the ring.
2) Remove piston ring (13) from tool B and as-
semble on piston (14).
3) Fit tool C on piston ring and compress piston
ring with clamp 0.
+ Clamp parts No.: 07281-01919
4) Assemble wear ring (8) on piston.
13
t07P502A:
3. Assemble O-ring (10) and back-up ring (11) on

piston rod (9).
207P503 207P504
,~“_
4. Assemble cylinder head assembly (8) and piston

assembly (7) on piston rod.
419P1255
5. Assemble spacer (6) then tighten piston bolts (5)

on piston.
m Tightening torque of bolts (5): 11 ?l kgm
4lSFOI II4
53-25
6. Set cylinder (4) in tool A, then raise cylinder assem-

bly and piston rod assembly (3) and install in
cylinder.
419FOI II3
l Tighten mounting bolt (2) of cylinder head.
l Remove cylinder assembly (1) from tool A.
419FOI II2
63-26
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
WORK EQUIPMENT
REMOVAL

1. Bucket link
1) Remove mounting pin (1) of bucket link.
t Tie the bucket link to the tilt lever with wire.
2) Remove mounting pins (2) of bucket hinge.
A Do not put your fingers in the pin hole.
3) Drive machine in reverse to disconnect bucket.
Bucket: 1,030 kg
419P1052
2. Dump cylinder pin

Sling dump cylinder (3) remove pin (4), then
disconnect cylinder rod and tilt lever.
+ Insert a block between the cylinder bottom and
frame.
Dump cylinder: 120 kg
3. Lift cylinder pin

Sling lift cylinder (5), then remove pin (6).
* If shims are inserted, check numbers of shims.
t Place a support under the tip of the lift arm.
+ Place a block on top of the axle, and lower the
cylinder onto it.
Lift cylinder: 115 kg
63-27
4. Lift arm, tilt lever, bucket link

1) Remove boom kickout switch (7).
2) Sling lift arm, tilt lever and bucket link (8),

remove mounting pin of lift arm, then lift off lift
arm.
el kg
Lift arm, tilt lever, bucket link assembly:
1,065 kg
+ If there are any shims, check the number

and thickness of the shims, and keep in a
safe place.
5. Tilt lever, bucket link

1) Sling bucket link (9), remove mounting pin (lo),
then remove bucket link from tilt lever.
Bucket link: 30 kg
2) Sling tilt lever (1l), remove mounting pin (12),

then lift off from lift arm.
Tilt lever: 205 kg
63-28
6. Dust seal, bushing

1) Remove dust seal (14) and bushing (15) from
lift arm (13).
4 I9F466

tilt lever (11).
11
16
16
4 I9F469

bucket link (9).
18
18
19
4 I 9F470
63-29
INSTALLATION

fingers.
1. Dust seal, bushing

Press fit bushings (15) in bucket link, tilt lever, and
lift arm, then assemble dust seal (14).
& Bushing: Grease (G2-Ll)
Lift arm Bushing Hydraulic cylinder

\
419F471
2. Tilt lever, bucket link

1) Align holes of tilt lever (11) and lift arm (13),
then install mounting pin (12) and lock with
bolt.
_ 419PE065
2) Assemble cord ring on bucket link (9), align

holes of tilt lever (1l), then install pin (10) and
lock with bolt.
+ Tie the bucket link to the tilt lever with wire.
+ Be careful not to let the cord ring get
caught when installing.
63-30
3. Lift arm, tilt lever, bucket link assembly

1) Raise lift arm, tilt lever, and bucket link (8), and
set in mounting position. Align holes at mount
of front frame and lift arm, assemble shim so
that clearance ‘a’ on left and right is equal,
then install mounting pin and lock with bolt.
t Clearance ‘a’: Max. 1.5 mm
+ After installing the pin, set a support under
the tip of the boom.
-P- Y!-+ 4 I9F472
2) Install boom kickout switch (7).
4. Lift cylinder
Sling lift cylinder (5) start engine and align cylinder
rod with lift arm mounting hole. Install pin, then lock
with bolt.
A Before starting the engine, check that the

directional lever is locked, and the parking
brake engaged.
5. Dump cylinder
Sling dump cylinder (3) and operate control lever to
align pin holes. Install pin, then lock with bolt.
+ After installing the pin, remove the block.
6. Bucket
1) Operate control lever to align hole of bucket
mounting pin (2). Install cord ring (20) and
assemble shim so that clearance ‘b’ on left
and right is equal, then install mounting pin and
lock with bolt.
t Be careful not to let the cord ring get
+ Clearance ‘b’: Max. 1.5 mm
20
\
20
4 I9F473
7. Bucket link
1) Raise bucket link (9), align hole of mounting pin
(1). Install cord ring (21) and assemble shim so
that clearance ‘c’ on left and right is equal,
then install mounting pin, and lock with bolt.
t Be careful not to let the cord ring get
t Clearance ‘c’: Max. 1.5 mm
21
8. Greasing
Grease all pins.
63-32
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
COUNTERWEIGHT
REMOVAL

1. Sling counterweight (l), remove mounting bolts,

then lift off counterweight.
+ Be careful to maintain the balance when remov-
ing the counterweight.
el kg
Counterweight: 1,130 kg
+ Be careful not to damage the lamps when

removing the counterweight.
INSTALLATION
1. Counterweight
Raise counterweight (2), set in mounting position,
+ When setting in the mounting position, be
careful not to damage the lamps.
a Mounting bolt: 36 mm
This page is intentionally blank.
63-34
HYDRAULIC AND STEERING PUMPS .................................................. 2
GROUND DRIVEN STEERING PUMP .................................................. 3
PRIORITYVALVE ................................................................. 4
MAINCONTROLVALVE ............................................................ 6
2-SPOOL ..................................................................... 6
3-SPOOL ..................................................................... 8
CYLINDER ..................................................................... 10
STEERINGCYLINDER .......................................................... 10
LIFTCYLINDER ............................................................... 10
DUMPCYLlNDER .............................................................. 10
BUCKET LINKAGE.. ............................................................. 12
BUCKET ...................................................................... 16
WITHTOOTH.. ............................................................... 16
WlTHB.0.C. ................................................................. 16
BUCKET POSITIONER AND BOOM KICK-OUT .......................................... 17
64-1
MAINTENANCE STANDARD HYDRAULIC AND STEERING PUMPS
HYDRAULIC AND STEERING PUMPS

. SAL(3)-63+32
Section A-A
419F142
Unit: mm
Model Standard clearance Clearance limit
Clearance between gear I
1 SAL(3)-63
case and side plate, gear 0.10-0.15 0.19
SAL(3)-32 I I
Clearance between
inside diameter of plain SAL(3)-63 Replace
2 0.06-0.149 0.20
bearing and outside SAL(3)-32
0
l 4*04.5
Rotating torque of spline
4 SAL(3)-63 + 32 1.4-2.4 kgm
shaft I
5 Tightening torque of bolt 25231.5 kgm Retiahten

discharge discharge
(elmin) (elmin)
Discharge
Oil: EO-CD
(Rear)
2500 210
SAL(3)-32
64-2
MAINTENANCE STANDARD GROUND DRIVEN STEERING PUMP
GROUND DRIVEN STEERING PUMP

. SAM(2)-40
4 l9F492
Unit: mm
Standard clearance Clearance limit

Clearance between gear case and
1
side plate, gear 0.10-0.15 0.19
Clearance between inside diameter of

2 needle bearing and outside 0.020-0.043 0.075 Replace
0
12-0.5
4 Rotating torque of spline shaft 0.3kO.7 kgm
5 Tightening torque of bolt 16.5k1.5 kgm Retighten

Revolution Pressure
Discharge discharge discharge
Oil: EOl O-CD (rpm) (kg/cW (elmin) (elmin)
3000 210 73 58
64-3
MAINTENANCE STANDARD PRIORITY VALVE
PRIORITY VALVE
E416F415
Unit: mm
Free installation Installation Free Installation

1 Control spring length length load (kg) length load (kg)
Replace
63.4 45 22.3 63.4+1 22.32 1.6
2 Relief spring 31 27.5 9.3 31+0.4 9.3 f 0.9
64-4
This page is blank.
64-5
MAINTENANCE STANDARD MAIN CONTROL VALVE
MAIN CONTROL VALVE

P-SPOOL
ii 5 i
64-6 419F143
Unit: mm
Spool return spring

1
(For Dump, Lit?)
6.75kO.75 kgm
7
Tightening torque of joint at

8 6.75 +0.75 kgm
end of spool
Tightening torque of adjust-

9 3.1520.35 kgm
ment lever lock bolt I
Tightening torque of cover

10 3.15kO.35 kgm
mounting bolt I
Tightening torque of main

11 15.522.5 kgm
relief valve
Tightening torque of adjust- Retighten

12 3.15kO.35 kgm
ment screw lock nut
Tightening torque of safety

13 14.Okl.O kgm
valve with suction valve
Tightening torque of suction

14 14.0+1.0 kgm
valve
15 Tightening torque of plug 15.522.5 kgm
16 Tightening torque of plug 7.0 f 1.O kgm
Tightening torque of case

17 3.220.3 kgm
mounting bolt
18 Tightening torque of plug 47.5 22.5 kgm
19 Tightening torque of plug 37.5 f 2.5 kgm
64-7
3-sPOOL
17
\
/ / \
13
4 I SF495
64-8
Unit: mm
,
No. Check item I Remedy
Standard size I ReDair limit I

Free Free Installation
Spool return spring installation Installation
length length load (kg)
length load (kg)
1 (For Dump, Lift, x O.D.
Attachment) Replace
76.3x
39.2 49 9
Possible to
use again
Main valve spring of main 39.5x if no
2 11.2 25 3
relief valve damage or
32.6 x 4.5
3 Check valve spring 10.9 24.5
27.9 x
Suction valve spring 13 18 0.7
49.3 x 26.4 47.8 21.2 Replace

Poppet spring of relief valve 12.2 41.9
Tightening torque of plug at

end of spool 6.75 k 0.75 kgm
(Dump, Attachment)
Tightening torque of plug at 6.75 20.75 kgm

7
end of spool (Lift)
Tightening torque of joint at 6.75kO.75 kgm

8
end of spool
Tightening torque of adjust- 3.1520.35 kgm

9
ment lever lock bolt
Tightening torque of cover 3.1520.35 kgm

10
mounting bolt
Tightening torque of main 15.5k2.5 kgm

11
relief valve
Retighten
Tightening torque of adjust- 3.15kO.35 kgm
12
ment screw lock nut
Tightening torque of safety 14.Okl.O kgm

13 valve with suction valve
Tightening torque of 14.021.0 kgm

14
suction valve
15 Tightening torque of plug
16 Tightening torque of plug
Tightening torque of case

17
mounting bolt
18 Tightening torque of plug 47.5 a25 kgm
19 Tightening torque of plug 37.5k2.5 kgm
64-9
MAINTENANCE STANDARD CYLINDER
CYLINDER
STEERING CYLINDER
/
m 55 ? 5.5kgm
LIFT CYLINDER
m 11.5 f l.Okgm
I :
U41901348
/
m 14.3 f 5.7kgm
DUMP CYLINDER
2 1 m 11.5 f l.Okgm
u41901349
/
w 25.5 2 2.5kgm
64-10
MAINTENANCE STANDARD CYLINDER
STEERING CYLINDER
Unit: mm
Tolerance
Shaft Hole
1 Clearance between rod and bushing ,
-0.025 +0.132 0.031-
40 0.519
-0.067 +0.006 0.219 I Replace
=F
Clearance between piston rod mount- 0 +0.112 0.050-
-0.025 +0.050 0.137
Clearance between cylinder bottom 0 +0.160 0.042-

-0.025 +0.042 0.205
LIFT CYLINDER
Unit: mm
No. 1 Check item I Criteria I Remedy
Tolerance
Shaft Hole
1 Clearance between rod and bushing Replace
60 -0.030 t 0.291 0.107-

0.395
0.695
-0.104 to.77
Clearance between piston rod mount- to.219

2 75 Replace
ing pin and inside diameter of hole to.145
Clearance between cylinder bottom t 0.227 Replace

3 75
mounting pin and bushing t 0.047 bushing
DUMP CYLINDER
Unit: mm
Tolerance
Standard , Standard Clearance
Shaft Hole
1 Clearance between rod and bushing
I
60 -0.030 to.271 0.091- 0.675
-0.104 to.061 0.375 Replace
bushing
Clearance between piston rod mount- t 0.207
2 95
ing pin and bushing to.120
Clearance between cylinder bottom t 0.207

3 95
mounting pin and bushing to.120
64-11
MAINTENANCE STANDARD BUCKET LINKAGE
BUCKET LINKAGE
64-12
ab ,
5-
11 li 14
I
Section B-B Section C-C

Section A-A
a b
b 8 a
a
! I
b 5
T 15
7
Section F-F
Section D-D Section E-E
7, ‘,3
a b
Section G-G Section H-H

Section J-J
419F571
64-13
MAINTENANCESTANDARD BUCKETLINKAGE
Unit: mm
- -
Standard
T Tolerance
Standard Clearance
Clearance between pin and size
Shaft Hole
clearance limit
1 bushing at boss ends of
bucket link -0.030 +0.174 0.130-
75 1.0
-0.076 +O.lOO 0.250
Clearance between pin and

-0.030 +0.174 0.130-
2 bushing at joint of lift arm and 75 1.0
-0.076 +O.lOO 0.250
bucket
Clearance between pin and +0.207 0.156-

-0.036
3 bushing at joint of lift arm and a5 1.0
-0.090 +0.120 0.297
frame
Clearance between pin and Replace

-0.036 +0.207 0.156- also if
4 bushing at joint of bucket 95 1.0
-0.090 +0.120 0.297 other parts
cylinder bottom and frame
are biting
Clearance between pin and into pin
-0.036 +0.207 0.156-
5 bushing at joint of bucket 95 1.0
-0.090 +0.120 0.297
cylinder rod and lever

-0.036 +0.207 0.156-
6 bushing at joint of tilt lever 95 1.0
-0.090 +0.120 0.297
and lift arm

-0.030 +0.174 0.130-
7 bushing at joint of lift 75 1.0
-0.076 +O.lOO 0.250
cylinder bottom and frame
Clearance between pin and +0.174

-0.030 0.130-
8 bushing at joint of lift cylinder 75 1.0
-0.076 +O.lOO 0.250
rod and lift arm
I I
Width between Standard clearance
Width of hinge
bosses I (Clearance a + b1
Joint of bucket cylinder and Insert
9
frame gO+O.a shims on
9321.5 0.745
0 I I both sides
to make
+1.5 clearance
10 Joint of lift arm and frame 101 +l.l 104 o 1.9-5.6
on both
left and
11 Joint of lift arm and bucket 105kl.l loa+1*5 1.9-5.6 right sides
I 1 I less than
+2.8
1.5 mm
Joint of bucket link and 109+1.5
12 2.2-6.0
bucket lo4 -0.5 1
64-14
No. Check item T Criteria T Remedy
Width between Standard clearance

Width of hinge
bosses (Clearance a + b)
13 Joint of lift cylinder and frame
85+0.8
8921.5 1.7-5.5
0
Joint of tilt lever and bucket +2.8 Replace

14 109+ls5 0.7-7.0
link lo4 -0.5 0
15 Joint of tilt leverand lift

arm 25OkO.5 253 50.5 2.540
Joint of tilt lever and dump go+0.8

16 93k1.5 0.7-4.5
cylinder 0
Insert
shims on
both sides
to make
Joint of lift cylinder and lift clearance
17 85kl.l 8921.5 0.4-5.6
arm on both left
and right
sides less
than
1.5 mm
64-15
MAINTENANCE STANDARD BUCKET
BUCKET
WITH TOOTH
Q$q 129f7kgm
m 88 it 5 kgm

Section C-C
m 90 - 112kgm
1 419F572
Section K-K
2 Unit: mm
Standard size II ReDair limit

1 Wear of cutting edge (thickness)
I 31.8 19 1
. Replace
2 Wear of cutting edge (length) 90 5
3 Wear of bucket tooth 37 21
4 Clearance of bucket tooth mounting part Less than 0.54 Replace or adjust
64-16
MAINTENANCE STANDARD BUCKET POSITIONER AND BOOM KICK-OUT
BUCKET POSITIONER AND BOOM KICK-OUT
Section A-A
u41901351
Unit: mm
1 Clearance of bucket positioner switch 3-5

Adjust
2 Clearance of boom kick-out switch 3-5
64-17
ELECTRIC AND
ELECTRONIC SYSTEM
ELECTRICALFOLDOUT . . . . . . . . .. . .. . . . .. . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 2
ENGINE STARTING CIRCUIT . . . . . . . .. . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . 3
SAFETYRELAY . . . . . . . . . . . . . . . . . . . . .. . . . . . . .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ENGINE STOP CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ELECTRICAL TRANSMISSION CONTROL ............................................... 6

COMBINATION SWITCH.. ........................................................ 7
TRANSMISSION CUT-OFF SELECTOR SWITCH ........................................ 8
NEUTRALIZER RELAY ........................................................... 9
KICK-DOWN SWITCH . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . 10
KICK-DOWN ELECTRICAL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . . . 11
BUCKET POSITIONER AND BOOM KICK-OUT . . . .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . 19
PROXIMITYSWITCH . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . 21
ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS) ................................... 25

MONITOR PANEL ............................................................. 26
INDICATION ON MONITOR PANEL. ................................................ 27
SENSORS,SWlTCHES .......................................................... 29
SENSOR, SWITCH ACTUATION TABLE ............................................ 29
BRAKE PRESSURESWITCH .................................................... 30
BRAKE DIFFERENTIAL PRESSURE WARNING SWITCH ................................ 30
COOLANTLEVELSENSOR ..................................................... 31
TORQUE CONVERTER OIL TEMPERATURE SENSOR ................................. 31
ROTATIONAL SPEED SENSOR .................................................. 32
FUELLEVELSENSOR ........................................................ 33
81-l
STRUCTURE AND FUNCTION ELECTRICAL FOLDOUT
ELECTRICAL FOLDOUT
See Foldout #‘s 2, 3 & 4 at end of book
81-2
STRUCTURE AND FUNCTION ENGINE STARTING CIRCUIT
ENGINE STARTING CIRCUIT
FROM 5A FUSE
Function @ Battery (+) - starting switch terminal B - starting

l To ensure safety when starting the engine, the switch terminal C - safety relay terminal - safety relay
system is equipped with a neutral safety circuit. This terminal B 4 directional lever switch terminal N -
makes it impossible for the engine to start if the ground, so the safety relay switch is closed.
directional lever is not at the N (Neutral) position. In addition, current flows from starting switch terminal
BR - battery relay coil - ground, so the battery relay
Operation switch is closed. This forms the following circuit.
l When the directional lever is placed at the N (Neu- @ Battery (+) 4 battery relay - starting motor terminal
tral) position, the neutral contacts of the directional B - safety relay terminal B - safety relay terminal C -
lever switch are closed. In this condition, if the starting motor terminal, and the engine starts.
starting switch is turned to the START position, If the directional lever is at any position other than N
current flows in the following circuit. (Neutral), circuit @ is not formed, and the engine does
not start.
STRUCTURE AND FUNCTION SAFETY RELAY
SAFETY RELAY
TERMINAL B n
TERMINAL C
CONNECTOR
TERMINAL B
TERMINAL C
SAFETY RELAY CONNECTION CHART
L08CD007
81-4
STRUCTURE AND FUNCTION ENGINE STOP CIRCUIT
ENGINE STOP CIRCUIT

Operation
l When the starting is turned ON, electric current l When the starting switch is turned OFF, circuit (1)
flows in the following circuit. is shut off, but the engine is rotating, so there is still
@ Battery (+) - starting switch terminal B - starting voltage at terminal R of the alternator. For this
switch terminal BR - fuel cut solenoid - ground reason, the following circuit is formed.
connection. @ Alternator terminal R 4 battery relay terminal BR
When electric current flows to the fuel cut solenoid, 4 ground connection.
the fuel governor is put in the FREE position by the The battery relay is maintained, but because of the
fuel control linkage. diode inserted into the circuit, no electric current
Fuel flows to the fuel injection pump and the engine flows to the fuel cut solenoid, so the engine stops.
starts.
STARTING SWITCH
TO STARTING RELAY
TO STARTING MOTOR
BAll-ERY
I 1
L08DDOO2
81-5
STRUCTURE AND FUNCTION ELECTRICAL TRANSMISSION CONTROL
ELECTRICAL TRANSMISSION CONTROL
Kick-down switch
I’ (Lift control lever)
ombination switch
FORWARD-REVERSE lever
Speed control lev
Transmission c
Transmission
Transmission control valve
4 I9F556
Function
Selection of FORWARD,
1 FORWARD-REVERSElever
REVERSE and NEUTRAL
gl-
Selection of travel speed range Speed control lever
When traveling in F2 it is possible to use this switch to shift down to

Fl regardless of the position of the speed control lever.
If the directional lever is placed in R or N, the transmission
automatically returns to 2nd.
Transmission returned to neutral when left brake pedal is operated.
Selects if transmission cut-off function is used or not used.

With this function, the left brake pedal can be used to get even better
performance than conventional loaders in digging operations or ease
of steering when loading on to trailers.
To prevent the operator from driving off when the parking brake is
6 Neutralizer function still applied and causing seizure of the parking brake, the transmis-
sion is returned to neutral when the parking brake is applied.
The engine can only be started if the FORWARD-REVERSElever is in

neutral. In any other position the engine will not start.
7 Neutral safety function
This prevents the machine from starting suddenly. (For details, see
STARTING CIRCUIT.)
When the machine is driven in reverse, a back-up lamp lights up and

a Warning function
a back-up horn sounds to warn people standing near the machine.
81-6
COMBINATION SWITCH
423F188
Outline
l The FORWARD-REVERSElever has three contacts; When the lever is moved to the desired position, the
the speed control lever switch has four contacts. switch, which is connected by a shaft, moves and
The switch alone has no detent mechanism. The electric current flows in only that circuit to move the
detent mechanism is in the combination switch machine.
itself. Each switch is held at two places by pins. In
addition, each switch is secured to the base by
three screws.
Function
1 1 FORWARD-REVERSElever switch I Selecting FORWARD, REVERSE, or NEUTRAL
2 1 Speed control lever switch I Selecting machine speed range
Prevents speed control lever from going into 3rd or 4th speed
3 Speed control lever stopper
during operations
4 Direction indicator lamp Indicates direction when turning left or right
Returns direction indicator lamp lever to neutral automatically after

5 Self cancel
turning left or right
6 1 Lamp switch I Selects clearance lamps, headlamps, parking lamps

7 I Dimmer switch I Selects travel beam, low beam
8 I Emergency flasher switch I Makes left and right turn signal lamps operate at the same time
9 I Emergency flasher pilot lamp I Flashes when emergency flasher lamp is ON
81-7
TRANSMISSION CUT-OFF SELECTOR SWITCH
Outline
l The transmission cut-off selector switch is a 2-circuit
waterproof toggle switch. It is installed in series with
the transmission cut-off switch at the power supply
side of the transmission FORWARD-REVERSE
circuit.
Operation
OFF ON
l If the transmission cut-off selector switch is put to l If the transmission cut-off selector switch is put to
CLOSED, there is always the (+) 24V in the circuit OPEN, there comes the (+) 24V in the FORWARD-
of the FORWARD-REVERSEclutch solenoid valve REVERSE clutch solenoid valve only through this
passing through this switch. Therefore, although the transmission cut-off selector switch. Therefore,
left brake is operated and the transmission cut-off when the left brake is operated and oil pressure of
switch is moved to OPEN, electric current will flow brake booster reaches to specified pressure and the
to the solenoid valve through the transmission cut- transmission cut-off switch is moved to OPEN, no
off switch, and the transmission will not be placed electric current will flow to the solenoid valve, and
in neutral. the transmission will be placed in neutral.
SWITCH OFF
SWITCH ON AND LEFT BRAKE IS OPERATED
TFIANSMISSION
CUT-F TbNSMISSION CUT-OFF
SELECTOR SWlTCH(MANUAL) SELECTOR SWTTCH(MANUAL)
LO8DDO03
81-8
NEUTRALIZER RELAY
o When the parking brake is being used, no electric For this reason, no electric current flows to the
current flows to the relay coil. The input terminal is FORWARD-REVERSE circuit of the transmission
connected to output terminal “6”. which is connected to output terminal “5”. When the
parking brake is being used, the transmission is
kept in neutral.
TO UACHW lRANsMIssloN -lmNsJAsstoN

MoNrroA aJT-oPPswrai aJl--y
IH
T
I I I I
I ON OPP
81-9
STRUCTURE AND FUNCTION KICK-DOWN SWITCH
KICK-DOWN SWITCH
4 1. Switch
2. Washer
3. Screw
4. Cover
5. Body
5 6. Cable
6
fe
Circuit structure
0 421FO1053
Operation The kick-down is canceled (or will not operate)

l The kick-down (shift down from 2nd to 1st) oper- under the following conditions.
ates only when the transmission is in FORWARD 2. l When the directional lever is at N.
l When traveling in FORWARD 2, if it is desired to l When the directional lever is at R.
shift down to 1st without operating the speed l When the speed control lever is at any position
control lever, it is possible to shift down to 1st by other than 2.
pushing the kick-down switch at the top of the left l When the parking brake is applied.
lever. l When the starting switch is at OFF.
l After this, even if the kick-down switch is pressed,
the transmission remains in FORWARD 1.
81-10
STRUCTURE AND FUNCTION KICK-DOWN ELECTRICAL CIRCUIT
KICK-DOWN ELECTRICAL CIRCUIT

Normal lever operation for FORWARD/REVERSE and speed lever (FORWARD)
Operation
l If the transmission control lever is shifted to FOR- 2) Battery (+) - neutralizer terminal (3) - neutral-
WARD 2nd, the current flows as follows. izer terminal (5) - transmission cut-off relay
1) With the FORWARD solenoid, current flows in terminal (3) - transmission cut-off relay terminal
the following circuit. (6) - FORWARD solenoid 4 FORWARD solenoid
Battery (+) - neutralizer terminal (3) - neutraliz- relay terminal (2) - FORWARD solenoid relay
er terminal (5) 4 FORWARD solenoid relay (KDS terminal (1) - ground.
relay 0) terminal (6) - FORWARDsolenoid relay The FORWARD solenoid is actuated, and the
terminal (5) - Forward-Reverse lever switch FORWARD clutch is engaged.
terminal F - ground. 3) When the Forward-Reverse lever switch is at
Because of this, the FORWARD solenoid relay position 2, both sides of transmission solenoid
is actuated, and the circuits between terminals (1st 3rd) are non-continuous, so the transmis-
(1 and 2), and between terminals (3 and 4) are sion clutch at this point is 2nd speed.
closed. Unless the kick-down switch is pressed, there is
Next, current flows in the following circuit. no electricity in the coil of KDS relay 0, so KDS
relay @ does not work.
With the above steps l), 2), and 3), the trans-
mission is set to FORWARD 2nd.
BATTERY sAllERY REIAY NE-R RELAY TO MACHINE l.RNSMISSlCN l-Fw43MlsslcN

MctmcR CLcT-oFF SWlK4-l CUTOFF RELAY
TERwNu.
-I
81-11
Normal lever operation for FORWARD/REVERSE and speed lever (REVERSE)
Operation
When transmission control lever is set to Rl 3) When the speed control lever is set to 1st speed,
1) When the Forward-Reverse lever switch is at the R the following circuit is formed.
position, following circuit is formed. Battery (+) - 1st solenoid - speed control lever
Battery (+) - REVERSE solenoid relay terminal (6) switch 1st terminal 4 ground, so current flows to the
- terminal (5) - Forward-Reverse lever switch 1st solenoid. The 1st solenoid is actuated, so the
terminal R - ground. Current flows to the REVERSE speed range is set at 1st.
solenoid relay coil terminals (6 and 5), and actuates
the REVERSE solenoid relay.
2) When the REVERSEsolenoid relay (KDS relay 0) is
actuated, terminals (1 and 2) and terminals (3 and
4) are closed. Current then flows in the following
circuit.
Battery (+) - neutralizer relay terminal (3) 4 terminal
(5) - transmission cut-off relay terminal (3) - trans-
mission cut-off relay terminal (6) 4 REVERSE sole-
noid - REVERSE solenoid relay terminal (2) -
terminal (1) - ground.
The REVERSE solenoid is actuated and the RE-
VERSE clutch is engaged.
TFtbNSMISSlcN lRaNSMlSSloN
I3 l-a” EAlTERY FIELAY NELJTRALIZER RELAY Fm’F CUT-CFFSWKH CUT-CFFREUY
----
T
SPEEDCONTROL
LO6DD006
81-12
When kick-down switch is operated (When operating or traveling with F2)
~0 ~M,NE TRANSMISSIONTRANSMISSION
NEUTRAUZER-Y MONITOR ClJ-f-CFFSWITCH CUTGFF RELAY
MAIN BRAKER
L.. ..A L.. ..J

FORWARDREVERSE
L&R SWKCH
I.f I
J, t +
7iJ? 47’ SPEED -
SWKCH
L08DD007
Operation kick-down relay terminal (6) - kickdown relay

If the kickdown switch is pushed ON, the current flows terminal (5) - speed control lever switch 2nd termi-
to the kickdown relay coil through the following circuit. nal - ground. Even if the kick-down switch is re-
1) Battery (+) - neutralizer terminals (3) - neutralizer turned and the switch goes OFF, the kick-down
terminal (5) - kick-down switch - FORWARD relay continues to be actuated.
solenoid relay terminal (4) - FORWARD solenoid
relay terminal (3) - kickdown relay terminal (6) - Shifting from 2nd to 1st
kick-down relay terminal (5) - speed control lever 3) When the kick-down relay is actuated, the following
switch 2nd terminal - ground. The kick-down relay circuit is formed.
coil is then actuated, and kick-down relay terminals Battery (+) - 1st solenoid - kick-down relay termi-
(1 and 2) and terminals (3 and 4) are closed. nal (4) - kick-down relay terminal (3) 4 ground.
The speed range is then changed to 1st.
Self hold circuit of kick-down relay
2) When the kick-down relay is actuated, the following As explained above, if the kick-down switch is pressed
circuit is formed. at F2, the transmission is shifted down to Fl, and even
Battery (+) - neutralizer relay terminal (3) - neutral- if the kick-down switch is released or pressed again, the
izer relay terminal (5) - kick-down relay terminal (2) transmission continued in Fl.
- kick-down relay terminal (1) - FORWARDsolenoid The kick-down can be canceled in the following cases.
relay terminal (4) - kick-down relay terminal (3) -
81-13
STRUCTUREANDFUNCTION KICK-DOWN ELECTRICAL CIRCUIT
1) When the Forward-Reverse lever is moved to a

position other than F.
2) When the speed control lever is moved to a position
other than 2nd.
3) When the parking brake is applied.
4) When the starting switch is turned OFF.
Details of the actions of 1) - 4) are given on the follow-
ing pages.
TO MACHINE TRAuSMISSloN TRANSMISSION

BAl-rERY wrrERY RELAY NEUTRALIZERRELAY MoNFToR CUTd=F SWiTCH Cura=F RELAY
R
T
STARTING
EWlTUi
I
‘
ALTERNATOR
MAINBRAKER TERMINAL
+ PARKJNGBRAKESWTXH
t It
SPEED CONTFiOL
SWmCH
LO8DD007
81-14
Operation for canceling kick-down I

(When Forward-Reverse lever is placed at N or R)
Operation
1) When the Forward-Reverse lever switch is at a 3) When the kickdown relay is reset, kickdown relav
position other than F, the F terminal contact is OFF, ’ terminals (3 and 4) are bpened, so current stops
so the current stops flowing in the following circuit. flowing in the following circuit.
Battery (+) - neutralizer relay terminal (3) - neutral- Bettery (+) - 1st solenoid 4 kickdown relay termi-
izer relay terminal (5) - FORWARD solenoid relay nal (4) - kick-down relay terminal (3) - ground.
terminal (6) - FORWARD solenoid relay terminal (5) 1st is canceled, and the transmission is reset to 2nd
- Forward-Reverse lever switch terminal F - ground. (the position of the speed control lever).
When the current stops flowing, the FORWARD
solenoid relay is reset.
2) When this is done, FORWARD solenoid relay
terminals (3 and 4) are opened, so the current stops
flowing to terminals (6 and 5) of the kick-down relay
coil. The kickdown relay is reset and the self-hold
is canceled.
TF7ANsMissioN
BAlTERY BAnEFlY RELAY NEUTWUER RELAY TO MACHINE -SM’SS’oN
MoNrrOf3 Cl.W.OFF !M’lTCH CCTT-OFFRELAY
STARTINQ SWKH
MAIN SRAKER
PAFlKlNGBRME
FORWARD433ERSE
LEvEuswrrC+l
81-15
Operation for canceling kick-down II

(When speed control lever is at a position other than 2nd)
Operation
1) When the speed control lever switch is at a position 2) At the same time, kick-down relay terminals (3 and
other than 2nd, speed control lever switch 2nd 4) are also opened, so current stops flowing in the
terminal - ground is opened, so the current stops following circuit.
flowing in the following circuit. Bettery (+) - 1st solenoid - kickdown relay termi-
Battery (+) - neutralizer relay terminal (3) - neutral- nal (4) 4 kick-down relay terminal (3) - ground.
izer relay terminal (5) 4 kick-down relay terminal (2) 1st is canceled, and the transmission is set to the
- kickdown relay terminal (1) - FORWARDsolenoid speed range selected by the speed control lever.
relay terminal (4) - FORWARD solenoid relay
terminal (3) - kick-down relay terminal (6) - kick-
down relay terminal (5) - speed control lever switch
2nd terminal - ground.
When the current stops flowing, the kick-down relay
is reset.
Kick-down relay terminals (1 and 2) are opened and
the self-hold is canceled, so even if the speed
control lever switch is again set in 2nd, the kick-
down switch is not actuated.
81-16
Operation for canceling kick-down Ill

(When parking brake is applied)
Operation
1) When the parking brake is applied, the parking 2) FORWARD solenoid relay terminals (3 and 4) are
switch is opened, and current stops flowing to the opened, so current stops flowing to kickdown relay
neutralizer relay coil. Neutralizer relay terminals (3 terminal (6). The kick-down relay is reset, and kick-
and 5) are opened, current stops flowing to the F down relay terminals (3 and 4) and terminals (1 and
and R solenoid and FORWARD solenoid relay 2) are opened. As a result, current stops flowing in
terminal (6) so the FORWARD solenoid relay is the following circuit.
reset. Battery (+) 4 1st solenoid - kick-down relay termi-
nal (4) - kickdown terminal (3) - ground.
1st is canceled, and the speed range is set to the
position indicated by the speed control lever.
*
:
NEUTRALIZER REIAY
sKrrERY BwrERY~Y
+I
:
d7 PARKlNG
SFWE
swrrc+l
FCRWARD*EVERSE
LEVERSWITCH
LOSDDOI 0
81-17
Operation for canceling kick-down IV

(When starting switch is turned OFF)
Operation
l When the starting switch is turned OFF, the battery
relay is opened, so current stops flowing to the
transmission Forward-Reverse circuit and trans-
mission speed circuit, and the kickdown switch
operation is canceled. If the starting switch is at
OFF, even if the kick-down switch is ON (actuated),
the kick-down switch will not work.
NEUTRALIZER RELAY TO MACHINE T~S~~SS~ON TRANSMlSSlON

BAlTERY BAlTERY RELAY aTa=F swlTci CUTG=F RELAY
7--y _--_
STAMINQ
SWITCH
1 1 -BACK-UPLAMP
L.. _.A
FORWARD-REVERSE
LBvERswrrui
m
SPEED CONTROL SWITCH
Ul8DDO11
81-18
STRUCTURE AND FUNCTION BUCKET POSITIONER & BOOM KICK-OUT
BUCKET POSITIONER AND BOOM KICK-OUT
1. Bucket positioner proximity switch

2. Boom kick-out proximity switch
3. Lever
4. Dump cylinder
5. Lift arm
6. Plate Section A-A
U41901332
81-19
STRUCTURE AND FUNCTION BUCKET POSITIONER & BOOM KICK-OUT
Operation
Boom kick-out
l The boom kick-out is electrically operated and acts
to stop the lift arm. When the lift arm reaches the
desired position before the maximum height, the lift
arm lever is returned to neutral.
0 Plate (6) is secured to the lift arm (5). A proximity
switch (2) is fixed to the frame. When the lift arm is
moved from the LOWER position to the RAISE
position, the lift arm rises. When it reaches the
desired position, the proximity switch and lever
come into contact and the lift arm lever is returned
to neutral.
Bucket Dositioner
The bucket positioner is electrically actuated and is
used to automatically obtain the optimum digging
angle for the bucket.
When the bucket is moved from the DUMP position
to the TILT position, and it reaches the desired
angle, the dump lever is automatically moved from
the TILT position to the neutral.
Lever (3) is secured by bolts to dump cylinder rod.
A proximity switch (1) is fixed by bolts to the cylin-
der (4).
When the bucket is moved from the DUMP position
to the TILT position, the dump cylinder rod moves
to the left. At the same time, lever (3) also moves to
the left. When it reaches the desired position, lever
(3) separates from proximity switch (l), and the
421FI I I
bucket lever returns to neutral.
81-20
STRUCTURE AND FUNCTION PROXIMITY SWITCH
Proximity switch for
boom kick-out
PROXIMITY SWITCH To battery relay
Operation of proximity switch
Lift arm RAISE Kick-out relay

l When the lift arm is lower than the set position for
the boom kick-out, the detection unit (steel plate) is
on the sensing surface of the proximity switch. The
relay switch is at OFF and the electric current of the
solenoid coil is shut off.
Cam Roller
iii====A /
Proximity switch
Lift a
‘Detection unit
u41901333

boom kick-out
l When the lift control lever is moved to the RAISE
position, the lever cam and the cam follower keep ; ery relay
the lift spool in the RAISE position, so the lift arm
goes up.
Solenoid for kick-out

II Kick-out relay
n _ Lift lever
--- Cam
\
Roller
u41901334
81-21
l When the lift arm goes up and reaches the set

position for the kick-out (that is, the detection unit
[steel plate] is separated from the sensing surface
of the proximity switch), the proximity switch and
relay circuit act to send electric current to the
solenoid. This actuates the solenoid, the cam is
pulled out of the cam detent, and the lift spool is
returned to the neutral position by the return spring.
boom kick-out
To battery relay
I *-
Kick-out relay
Solenoid for kick-out
*> Lift lever
Cam Roller Solenoid
Return spring
Movement of proximity switch

Sensing surface of proximity switch Sensing surface of proximity switch
Position is in contact with detection unit is separated from detection unit
Operation display of proximity

switch
ON OFF
Proximity switch load circuit

Current flows Current shut off
(Relay switch circuit)
Relay switch load circuit

Current shuts off Current flows
(Solenoid circuit)
81-22
bucket kick-out
2
:I
Bucket TILT To battery relay
l When the bucket is lower than the set position for

the bucket leveler, the detection unit (steel plate) is
on the sensing surface of the proximity switch. No
electricity flows through the proximity switch. The
relay switch is at ON and the electric current from
Solenoid for positioner
the battery flows through the solenoid coil.
Bucket lever
-;iB Cam Roller
I
Detection unit
\
Proximity switch U41901336
l When the bucket control lever is moved to the TILT Proximity switch for
position, the lever cam and the cam follower keep bucket kick-out
the dump spool in the TILT position, so the bucket
tilts. To battery relay
Positioner relay
=- Cam
Detection unit Proximity switch
81-23
l When the bucket tilts and reaches the set position

for the bucket leveler (that is, the detection unit
[steel plate] is separated from the sensing surface
of the proximity switch), the proximity switch and
relay circuit act to send electric current to the
solenoid coil. This actuates the solenoid, the cam is
pulled out of the cam detent, and the dump spool
is returned to the neutral position by the return
spring.

bucket kick-out
y relay
Positioner relay
fr=====:= Cam Roller
Detection unit Proximity switch =: u41901338
Movement of proximity switch

Sensing surface of proximity switch Sensing surface of proximity switch
Position is in contact with detection unit is separated from detection unit
Operation display of proximity

ON OFF
switch
Proximity switch load circuit

Current flows Current shut off
(Relay switch circuit)
Relay switch load circuit

Current shut off Current flows
(Solenoid circuit)
81-24
STRUCTURE AND FUNCTION ELECTRONIC VEHICLE MONITORING SYSTEM
ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS)

Outline
l The electronic vehicle monitoring system is a l The electronic vehicle monitoring system consists of
system to inform the operator of the condition of the monitor panel, sensors, controller, warning
the machine. It consists of sensors installed in buzzer, warning lamp and power source.
various parts of the machine, which observe the l The displays can be broadly divided into CHECK
condition of the machine and process the informa- items (1) and CAUTION items (2 and 3), which
tion speedily, and display the situation on the display warnings if any abnormality arises in the
monitor panel. machine; and gauges (5), speedometer (7), and
service meter (9) which always display the condi-
tion of the machine.
Warning lamp Warning buzzer
Battery
81-25
l The monitor consists of the following components. own microcomputer which processes the signals
CHECK module (l), CAUTION module (2), CAU- from the sensor and gives a display.
TION module (3) gauge module (5) speedometer The panel uses a liquid crystal display.
module (including service meter), the case, and l CHECK (I), and CAUTION (2 and 3) modules all
various other components. use common partsThe microcomputer judges
l Each module (excluding the service meter) has its which module it is from the wiring harness to which
it is connected.
1A 5f
\
‘48
/ I \ \\
SC/ 4 ;‘o hl h
U41901060
1. Check (Before starting) 3C. Coolant level 5. Gauge

1A. Brake oil level 3D. Coolant temperature 5A. Coolant temperature
1B. Engine oil level 3E. Torque converter oil 58. Torque converter oil
1C. Coolant level temperature temperature
2. Caution (Warning) 4. Pilot indicator 5C. Fuel
2A. Battery charge 4A. 6. Signal lamp
28. Fuel level 4B. Parking brake 7. Speedometer
3. Caution (Emergency warning) 4C. Work lamp 8. Head lamp (High beam)
3A. Brake oil level 4D. Transmission cut off 9. Service meter
3B. Engine oil pressure selector 10. Service meter indicator
81-26
INDICATION ON MONITOR PANEL
Category Symbol 1 Indication item Indication range Description

I I
Brake oil level Below low mark
Displayed when starting switch is turned

Checks
to ON with engine stopped.
before Engine oil level Below low mark
Display goes out when normal
starting
Display flashes when abnormal
Coolant level Below low mark
When charging
I- Battery charge
is defective Displays when engine is running.
Caution 1
Display flashes when abnormal and
Ia Fuel level Below low mark lamps flash at the same time
Brake oil level Below low mark
Below specified
Engine oil pressure
pressure
Display when engine is running.
Caution 2 Coolant level Below low mark
Display flashes when abnormal;
buzzer and lamp actuated
Coolant temperature Above 105°C
61
4 Torque converter oil
temperature
Above 130” C
Parking brake When operated
Display when starting switch is

turned ON;
Lights up when operated
Pilot
Transmission cut-off When operated
Displays when starting switch is

turned ON:
Lights ‘up during preheating
81-27
Category Svmbol Indication item Indication range Description
O-100 km/h
Travel speed Digital display
O-100 MoprH
--
Speed-
--
- 0 High beam When operated
Displays when starting switch is
turned ON;
ometer Lights up when operated
Signal lamp
4D (right, left)
When operated
Hazard When operated Lights up when operated
Actuated when engine oil pressure is

0-99999/h
Service meter normal.
displayed
Advances 1 for every hour of operation
Service
meter
0
Service meter
Flashes when service meter is operating
indicator
Red
I
105°C
10213~
$
97°C
Coolant temperature 90°C One lamp lights up to indicate level
Green 80°C
67°C
Nhite
C
El
Red 130°C
120°C
110°C
Torque converter oil
Gauge 90°C One lamp lights up to indicate level
temperature
70°C
Green
50°C
F
Full
617
517
Green
Fuel level 417
All lamps light up below indicated level
317
217
Red Emtv
E
81-28
SENSORS, SWITCHES
Function
l The signals from the sensors or switches are
directly input to the monitor panel. With contact
type sensors or switches, one side is always
grounded to the chassis. When the contacts are
closed, the panel recognizes the signal as a normal
signal. (The sensor signal for the engine oil pressure
is reversed by relay.)
SENSOR, SWITCH ACTUATION TABLE
Check item I Sensor type I When normal I When abnormal
Brake oil pressure switch I Contact I ON I OFF
Brake differential pressure warning switch Contact ON OFF
Engine oil level sensor (Cummins part)
Coolant level sensor Contact ON OFF
Fuel level sensor Resistor
Engine oil pressure switch (Cummins part)
Coolant temperature sensor (Cummins part)
Torque converter oil temperature sensor Resistor
Rotational speed sensor Magnet
81-29
BRAKE PRESSURE SWITCH
Circuit structure
4 I9F544
4 I9F543
Function
l This sensor is installed at the bottom of the accu-
mulator in the brake line, and when the pressure in 1. Connector
the brake line drops below the specified pressure 2. Cover
(40 kg/cm2), the switch goes OFF and the ma- 3. Spring
chine monitor lamp flashes to warn of the abnormal- 4. Switch
ity.
BRAKE DIFFERENTIAL PRESSURE WARNING SWITCH
rL2kg-J
Circuit structure
4 I9FS44
Function
l This brake differential pressure warning switch is
installed to the brake valve safety valve that is 1. Shaft
actuated if there is any abnormality in one of the 2. Body
two brake lines. If there is any abnormality in the 3. Spring
brake line, the safety valve is actuated, and this 4. Connector
switch goes OFF, and the machine monitor lamp
flashes to warn of the abnormality.
81-30
COOLANT LEVEL SENSOR
U41901062
e Circuit structure
Function
l The coolant level sensor is installed on top of the 1. Connector
radiator. When the coolant level goes down, the 2. Wire
float goes down and the electric current is shut off. 3. Plug
The machine monitor lamp then lights up to indicate 4. Float
the abnormality. 5. Switch
TORQUE CONVERTER OIL TEMPERATURE SENSOR
U41901063A
2
%
Circuit structure
Function
l These sensors are installed on the engine thermo-
stat housing and transmission case. They use a 1. Connector
thermistor to detect the temperature, and when the 2. Wire
temperature goes above the specified temperature, 3. Tube
the machine monitor lamp lights up to indicate the 4. Plug
abnormality. 5. Thermistor (Beat type)
81-31
ROTATIONAL SPEED SENSOR
eCircuit structure
I28
423F178
Function
l The speedometer sensor is installed on the trans- 1. Connector
mission output gear. A pulse voltage is generated 2. Magnet
by the rotation of the gear teeth, a signal is then 3. Case
sent to the machine monitor, and this displays the 4. Core
travel speed. 5. Wiring
6. Boot
81-32
FUEL LEVEL SENSOR
&
Circuit structure
U41901065
“y2
1
4 I9F553
Function
o The fuel level sensor is installed on side of the fuel
tank. The float moves up and down according to 1. Connector
the fuel level. The movement of the float is sent 2. Float
through a lever to actuate a variable resistor. This 3. Arm
sends a signal to the machine monitor to display
the fuel level.
When the display on the machine monitor drops to
a certain level, a signal is generated between the
modules inside the machine monitor, and the
warning lamp lights up.
81-33
ELECTRIC AND
ELECTRONIC SYSTEM
SPEEDOMETER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING ................................................................. 5
PRECAUTION WHEN HANDLING CONNECTOR .......................................... 6
CONNECTOR TERMINAL NUMBERS ................................................... 8
POSITION OF CONNECTORS FOR TROUBLESHOOTING ............................... 13
ELECTRICALCIRCUITSYSTEM ..................................................... 18
ENGINE STARTING CIRCUIT SYSTEM ............................................. 18
ENGINE STOP CIRCUIT SYSTEM ................................................. 19
TRANSMISSION CONTROL AND PARKING BRAKE SYSTEM ............................. 20
ELECTRICAL CN AND THREE DIMENSIONAL VIEW DIAGRAM ............................... 21
METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART ........................... 22
TROUBLESHOOTING TABLES 25
E-l ENGINEDOESNOTS~A~T~‘:::::::::::::::::::::::::::::::::::::::::::::::: 26
E-2 ENGINE DOES NOT STOP. ................................................. 27
E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING. ................................ 27
E-4 TRANSMISSION DOES NOT RETURN TO NEUTRAL. .............................. 28
E-5 TRANSMISSION DOES NOT WORK NORMALLY. 29
E-6 KICK-DOWN SWITCH DOES NOT WORK. ...... : : : : : : : : : : : : : : : : : : : : : : : : : : : : : :: :: 48
E-7 KICK-DOWN ONLY WORKS WHEN KICK-DOWN SWITCH IS ON. ..................... 50
E-8 KICK-DOWN OPERATION IS NOT CANCELED. ................................... 51
E-9 KICK-DOWN WORKS BY MISTAKE WHEN TRAVELING IN F2. ........................ 52
t The following precautions are necessary when using the Standard Value Tables to make judgements during
judgements.
use these values alone to make simple judgement calls.
82-1
“METHOD OF READING TROUBLESHOOTING TABLES” and “PREVENTING RECURRENCE OF TROUBLE” -all
in SECTION 22.
t When carrying out troubleshooting of the power train, it is necessary to distinguish if the breakdown is in the
power train itself or in the electrical system. See “JUDGEMENT ON POWER TRAIN” in SECTION 22.
+ When disconnecting or connecting the T-adapter (or socket adapter) or short socket adapter or when
disconnecting the connector for checking, turn the starting switch OFF to prevent accidents.
+ When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN o A( )).
* When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after
checking, then go to the next check.
82-2
TESTING AND ADJUSTING SPEEDOMETER MODULE
SPEEDOMETER MODULE
How to adjust the speedometer
Remove the vehicle monitor from the vehicle and make
the adjustment on the back of the speedometer.
t Adjustment to be done when power supply is off!
Adjustment
1) Remove rubber caps “1” and “2” on the rear side of
the speedometer module.
+ Turn starting switch OFF.
2) When the rubber cap is removed, rotary switches
can be seen inside. Then, make the adjustment by
turning this switch with a screwdriver as shown
below.
Rotary switch
+ Switch “3” has no relation to the speedometer
adjustment. Rotate
/
Per kilometer
Switch position
Tire size
1 2
20.5 x 25 - 12PR (L-3) STD 1 7 or 8
20.5 x 25 - 12PR (L-2) OP 1 7 or 8
17.5 x 25 - 12PR (L-3) OP 1 D
17.5 x 25 - 12PR (L-2) OP 1 D

f-7 F41E01113
3) After completing adjustment, restore rubber cap to

its original position and install the vehicle monitor.
Reference: Correction factor (%) of switch (2)
z 01234567
+14 +12 +lO +6 +6 t4 +2 0

=
1 I
0 00
$ 0
$
u41901770
89ABC D E F
gg$ 0 -2 -4 6 -6 -10 -12 -14
- ._
82-3
82-4
TROUBLESHOOTING
82-5
TROUBLESHOOTING PRECAUTION WHEN HANDLING CONNECTOR
PRECAUTION WHEN HANDLING

CONNECTOR
When connecting, align
1. If the connector has a lock, always release the lock the guide inside the
before disconnecting the connector. connector and push in. /
When connecting, align

this arrow and push in.
Be sure to fit rubber When removing, press
cover tightly. this part in and pull
the connector out.
/ When removing, press in

on both sides and pull
the connector out. F I42A093
F142AOSZ
______
2. Never pull the cord to disconnect the connector.
F142A095
F I42A094
_-
3. If the connector is difficult to disconnect, do not try

to pull it out.
(If it is difficult to reach by hand, remove the clamp
and move the wiring harness.)
This must be removed.
82-6
TROUBLESHOOTING PRECAUTION WHEN HANDLING CONNECTOR
4. After pulling out the connector, cover with a vinyl

bag to protect the contacts from dirt or oil.
F I42A097
5. When cleaning the connector, never use cleaning

agents such as trichloroethane or trichloroethylene.
If the connector is very dirty, use a neutral cleaning
agent. After cleaning, wash well and dry completely
immediately. (Do not use any connector which has
deposits left on it after drying.)
Coat with contact restorer.
(When drying, be particularly careful to dry the gaps
in the rubber.)
F I42A098
6. When assembling the connector, be sure to fit it

correctly.
(For connectors with locks, it should be possible to
hear the locks click as they fit completely into posi-
tion.)
F142AlOO
F I42A099
l Correct any protrusion of the boots.
82-7
TROUBLESHOOTING CONNECTOR TERMINAL NUMBERS
CONNECTOR TERMINAL NUMBERS
No. of T ECONOSEAL CONNECTOR

pins Female terminal (Socket) Male terminal (Pin)
142F400A
142F401A
1’
142F403A 142F402A
142F405A 142F404A
5’ i ‘1
142F407A 142F406A
12
142F408A
82-8
No. of T DLI CONNECTOR (For monitor panel)

5 6 1 4
1 4 5
142F418 142F419
1 6
12
142F420 142F421
16
142F422 142F423
82-9
No. of T N-SLC CONNECTOR

423F349 423F350
i ‘2 423F352
1 2
4
c
LG
423F353
4 3 423F354
1 3
I?!?
423F355 4 6 6 ‘4 423F356
5 423F358
423F357
82-10
No. of T MIC CONNECTOR

3 1
5 5 4
142F410 I3 142F411
13
142F412 142F413
17
142F414 142F415
-1
‘12
r
21
142F416 1 ( ) 423F417
82-11
No. of
RELAY CONNECTOR
pins
--____
?
aB
5
5
0
0
m ;
_______
0
423F348
82-12
TROUBLESHOOTING POSITION OF CONNECTORS
POSITION OF CONNECTORS FOR TROUBLESHOOTING
CN14 (For starting switch)

ECONOSEAL connector 4 pins
CN16 (Speed lever, directional lever)

CN53 (Neutralizer relay)

RELAY connector 5 pins
CN54 (Back-up lamp relay)

CN64
CN75
CN79 (Diode)
N-SLC connector 2 pins
82-13
CN95 (Diode)
CN102 (For safety relay)

CN104 (For battery relay)

STARTER MOTOR -
CN304 (For fuse box)



82-14
CN316 (Parking brake switch)

CN318 (Diode)
CN389 (Diode)
CN390 (For transmission control valve)



82-15

CN435 (FORWARD solenoid relay)

CN437 (Kick-down switch relay)

CN438 (Kick-down switch inlet)

CN441 (REVERSE solenoid relay)

CN442 (Diode)
CN443 (Engine stop relay)

82-16
CN444
CN446 (For engine stop motor)

CN454 (Transmission cut-off relay)

CN455 (Transmission cut-off switch)

Connector 1 pin
CN456 (Transmission cut-off switch)

Connector 1 pin
82-17
TROUBLESHOOTING ELECTRICAL CIRCUIT SYSTEM
ELECTRICAL CIRCUIT SYSTEM
ENGINE STARTING CIRCUIT SYSTEM
-I---
L08DDo43
82-18
ENGINE STOP CIRCUIT SYSTEM
LC8DW44
82-19
TRANSMISSION CONTROL AND PARKING BRAKE SYSTEM
82-20
ELECTRICAL CN AND THREE

DIMENSIONAL VIEW DIAGRAM
See Foldout #5 at end of book.
82-21
TROUBLESHOOTING METHOD, TROUBLESHOOTING FLOW CHART
METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART
The electrical system can be broadly divided into the following two parts.
1. Starting system, transmission electrical control system, and brake system.

2. ELECTRONIC VEHICLE MONITORING SYSTEM.
The charts for these systems are marked as E-xx, and M-xx respectively.
Troubleshooting Item
chart No.
Troubleshooting of starting system, transmission electrical control system, and brake

E-XX
system.
M-xx Troubleshooting of electronic vehicle monitoring system.
YES
1. Method for troubleshooting
l Check or measure the items inside the rectangle I HNO 1
According to the result, follow the YES arrow or the NO arrow and proceed to the next rectangle. (Note:
The number given at the top right of the rectangle is a reference number. It does not indicate the order for
troubleshooting.)
l If the result of the check or measurement leads directly to the CAUSE column, note the cause and take the
action given in the REMEDY column.
l The value for the check and the measurement method is given inside the rectangle. If the value is correct,
or the answer is yes, follow the YES arrow; if the value is not correct or the answer is no, follow the NO
arrow.
l Below the rectangle, there is a list given preparatory work, methods of operating and handling, and
judgement values needed for checking and measuring. If the preparatory work is ignored, or the wrong
method of operating or handling is used, or the judgement is wrong, this could result in damage to the
equipment. Therefore, always read the procedure carefully before starting the check or measurement, and
carry out the operation in the order given.
2. Precautions when carrying out troubleshooting

The precautions to be followed when carrying out troubleshooting for each failure is marked * under the
description of the failure. Always follow these precautions when making measurements.
3. Tools needed for troubleshooting

The tools needed for troubleshooting for each problem are listed as follows.
Prepare these tools before starting troubleshooting.
4. Place to install connectors, connector pin numbers

When troubleshooting some problems, measurements have to be made of continuity, voltage and resistance
at each step during the troubleshooting procedures. The location for measurement at each step (location of
connector, connector pin number) is shown in a photograph or diagram. For this reason, use these photographs
together with the YES-NO type troubleshooting flow charts to carry out troubleshooting quickly and accurately.
82-22
TROUBLESHOOTING METHOD. TROUBLESHOOTING FLOW CHART
Example
t When disconnecting or connecting the T-adapter (or socket adapter) or short socket adapter, or when
disconnecting the connector for checking, turn the starting switch OFF to prevent accidents.
+ When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNxx ( ))
+ When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after
Cause Remedy
a) /8 lights up.
Defectwe transmlwon cut-off

leplace
switch
J
Defective CHECKS BEFORE 7eplace
1 STARTING module
Is there contlnwty
between CNP4
(fernale) and
chaws ground?
Disconnection III wring 4fter Irlspectlorr.
1) Transmiss!on cut-off
NO L
harness, ordefective contact ‘epalr (clean) or
1) Short-clrcult CN18 _.
swtch ON between CN18 Ifemale)(3) and ,eplace
(female)(3) and (41
2) Connect T-adapter to CNP4 (fernale)
2) Turn startng switch
ON CNP4 (female)
3) Turn starting swtch
OFF
betwew CN 18
NO
(male)(4) and chassts
D,scowectlorr ,I> wr!ng After nnspectlon,

NO harness, or defectwe COntaCt repair (clean) or
Turn starting switch m between CN18 (femaleI(4) and replace
OFF
chassis ground
Tester
Troubleshooting
tools T-adapter or socket adapter
T-adapter (for DLI)
(for Econoseal)
CN18
82-23
TROUBLESHOOTING METHOD, TROUBLESHOOTING FLOW CHART
82-24
82-25
TROUBLESHOOTING E-l
E-l ENGINE DOES NOT START.
t When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting
the connector for checking, turn the starting switch OFF to prevent accidents.
+ When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN o A( ))
t When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after
t If the head lamps and other electrical parts are not working normally, check battery - battery relay - starting
switch first.
(a) Starting motor does not rotate. I Cause
1) Checking starting circuit. YES Defectwe startmg motor I eplace

I assemblv
Defective contact, or
YES disconnection in wiring harness
fter checking,
YE: between CN 102 (31 Ifemale) -
between CN102 ?pair or replace
CN97 (7) - CN64 (4) - CN16
(female) (31 and NO 3 (91 (female).
Is there continuity
Defective F-R switch. or
between CN16 (9)
defective contact or
(starting motor
- (male) and chassis - NO disconnection in wiring harness fter checkmg.
ground! between F-R switch and
inlet). tpair or replace
4 Chassis ground.
2) Place F-R lever at N. I
1 Place F-R lever at N.
3) Turn starting switch 21 Connect T-adapter
OFF. (or socket adapter) to CN16.
3) Turn starting switch OFF. Defective contact, or
Disconnect CN 102 NO 4 YES disconnection in wiring harness
.fter checking.
(starting motor inlet). between CN102 I11 (female) -
Measure with CN97 (4) - CN64 (7) ,pair or replace
Is voltage between
starting switch at CN14 (3) (female) - CN14 131.
START. and chassis ground
20 - 3OV?
leplace
2) Checking battery - battery relay - starting switch. Defective contact, or

n \,?C I disconnection 8” wiring harness
rfter checking.
epair or replace
rfter checking,
epair or replace
way.
1) Turn starting switch If NO for
one terminal
ON. Defective battery relay
Is there sound of 2) Measure voltage
between two
terminals connected YES Defective contact. or
disconnection in wiring harness ifter checking
by thick insulated between CN 104 (3) - battery epair or replace
cable. relay - chassis ground
1)
ON - OFF.
Defective contact. or
.. YES disconnection in wiring harness
between CN14 (21 ffemalel - After checking,
3 YES 5- CN64 (21 - CN95 (2) -CN95 epair or replace
(1) - CN104 (31, or
Is voltage between Is voltage between defectwe battery relay.
CN14 (2) (female) _
NO and chassis ground and chassis ground
20 - 3OV? Is voltage between
(CN14 (1)) (female)
1) Connect T-adapter
and chassis ground (p;;;,k;,t adapter) No
2) Turn starting Defective starting switch ?eplace
20 - 3OV?
switch ON.
2) Turn starting switch Defective contact, or
1 I Connect T-adapter ON. disconnectionin wiring harries! \fter checking,
(or socket adapter) to NO between CN14 (1) (ferde) -
epair or replace
CN14
CN306 (21 - CN306 (11 -
CN64 (81 - CN104 (2).
T-adapter or socket adapter

I .!! (for Econoseal)
2x2
Fe 8 L08DD017
+ *-
82-26
TROUBLESHOOTING E-2, E-3
E-2 ENGINE DOES NOT STOP. Cause Remedy
Defective adjustment of linkage Adjust

between fuel cut solenoid and
.governor.
YES
Does spool of fuel cut Defective fuel Cut solenoid. Replace
solenoid work? 2
Turn starting switch

ON - OFF and check
visually.
I Is voltage between
CN97 (male)(ll) and
chassis ground OV?
1) Connect T-adapter
(socket) to CN97.
YES
B Wrong wiring or contact
between +24V wiring harness
and BR terminal of starting
switch - CN64 (2) - CN97 (11).
After inspection,
repair or replace.
2) Turn starting
switch OFF.
1) Turn starting
switch OFF. Defective starting switch. Replace
E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING.

YES
l Defective adjustment of fuel cut Adjustment
solenoid.
YES
3---, Defective contact or r\fter inspection,
disconnection in wiring harness .epair or replace.
Is voltage between between CN14 (female)(2) -CN64
BR terminal of (2) - CN97 (11).
YES
1 2 - startingswitchand -
chassis ground 20
-3OV?
Is there continuity
Does spool of fuel cut between CN97 - 1) Turn starting
solenoid move?
NO
(male)(l
1)and switch ON.
--_,
NO
Defective starting switch, Replace
chassis ground?
Turn starting switch 1) Turn starting

ON-OFF and check switch OFF.
sound of fuel cut
solenoid working.
Defective fuel cut solenoid. Replace

NO
T-adapter or socket adapter (for

Troubleshooting Econoseal).
tools.
L07DD016
82-27
TROUBLESHOOTING E-4
E-4 TRANSMISSION DOES NOT RETURN TO NEUTRAL.

WHEN PARKING BRAKE IS APPLIED (TRANSMISSION CUT-OFF NORMAL)
+ When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting
checking, then go the next check.
.
Cause Remedy
YES Defective neutralizer

1. relay.
Replace
t
Is problem removed
when relay is Defective parking
- NO 2 YES After inspection,
replaced? 2 brake switch, or
repair or replace
- Is there continuity defective mounting
1) Interchange _ betweenCN316 _ position of switch
neutralizer (female) and
relay (CN53) CN317 (male)? NO Contact.of chassis
with backup ,L with wiring harness After inspection.
lamp relay ICN54) 1) Pull parking between CN53 (2) repair or replace
2) Turn startmg brake lever. (female) - CN318
switch ON. 2) Turn starting (2) - CN318 (1)
switch OFF. -CN317 (female).
L08DD018
82-28
TROUBLESHOOTING E-5
E-5 TRANSMISSION DOES NOT WORK NORMALLY.
* When carrying out troubleshooting of the brake system, stop the machine on level ground.
4 When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting
* When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN o A( ))
* When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after
1. Judgment on power train

Use the following method to judge if the abnormality in the power train is in the electrical system of the
transmission, or in the power train itself. If the abnormality in the electrical system, go to troubleshooting items
E-5; if the abnormality is not in the electrical system, go to troubleshooting items T-l - T-4.
Judgment flow
YES
- Defective transmission solenoid valve
2
‘When emergency
YES screw of spool of
1 - problem speed
- range is loosened,
Carry out test for does machine move?
problem
transmission ) Go to troubleshooting for transmission,
solenoid. Items T-l - T-4
NO
Is condition normal?
Go to troubleshooting for transmission

k electrical system. Item E-5
NO
L08DD019
82-29
TROUBLESHOOTING E-5
2. Testing and inspection of transmission solenoid control circuit
A Stop the machine on level ground and put blocks under the tires.
1. Install a T-adapter (or socket adapter) to connector CN75, and check the voltage between the connector pin
and the chassis ground.
2. Turn the starting switch ON.
+ Do not start the engine.
3. Turn the parking brake switch ON - OFF (release).
4. When depressing the foot brake, depress the R.H. brake so that the transmission is not cut off.
5. Check the normal actuation table shown below. If there is any abnormality, go to the troubleshooting table on
the right according to the results of the check below.
CN75 pins - Pin No.
Lever position 1 2 3 4 5 6 7 8
1st 2nd 3rd 4th F R power source
F-R lever FORWARD 0 0 0
REVERSE a 0 0
Speed 1st 0 0 0 0
lever
2nd l 0 0 0
3rd l 0 l l
4th 0 0 0 l
Normal actuation table

0 : 0 - 0.5V (continuous)
l : 20 - 30V (battery voltage)
Result of inspection (abnormality) Cause Troubleshooting
l No battery voltage at all Problem in transmission cut-off switch, E-5 (a)

Parking brake, neutralizer relay circuit
o No continuous (F) Problem in F circuit E-5 (b)
o No continuous (R) Problem in R circuit E-5 (c)
0 Continuous at two places Contact in F and R circuits E-5 (d)
l No battery voltage at all Problem in power circuit E-5 (e)
o No continuous Problem in speed circuit E-5 (e)
0 Continuous at two places or more Contact in speed circuit E-5 (9
82-30
TROUBLESHOOTING E-5
82-31
TROUBLESHOOTING E-5
(a) Problem in parking brake, transmission cut-off, neutralizer relay circuit.
transmission
1
YES
removed when
removed when
and CN456.
L
relay is replaced?
I
,
NO
Is there continuity
1) Start engine. 1) Interchange transmission YES
between CN454(2)
cut-off relay (CN4541
with backup lamp
(female) and H NC-I F.r
relay KN54).
2) Start engine.
switch OFF.
I
1) Disconnect CN454
21 Turn starting
switch ON. NO
IES
Is problem I YES
1) Interchange neutralizer YES

relay (CN53) with
backup lamp CN316 (female)
relay (CN541.
2) Start engine. Is there lack of I) Disconnect parking Is there ContinuiW
continuity between brake switch between CN316
CN53 (2) (female)
2) Release parking
brake.
1) Disconnect CN53 1-1
3) Turn starting
2) Release parking 2) Turn starting
switch OFF.
brake. switch OFF. NO
31 Turn starting
switch OFF.
YES
(female) and
chassis20 - 3OV? n
I I
1) Disconnect CN53. NO
2) Turn starting
switch ON.
1 m T-adapter or socket adapter

25 (for Econoseall
=i;z
$zg
+G?- L08DD020
82-32
TROUBLESHOOTING E-5
Cause Remedy
Defective transmission
cut-off switch teplace
Ieplace
Abnormal contact of
ground connection or \fter mspectlor
chassis with wring ‘epaw or replact
harness between CN454
(2) and CN455.
1 Defective contact, or After inspectior

disconnection in wiring repair or replace
(6) (female1 - CN390
(2) and CN391 (21.
Defectwe contact, or
disconnection in wiring After mspectiol
harness between CN454 repair or replacl
(1) and CN305 (12).
Replace
Replace
disconnection m wiring After mspectiol
harness between CN53 repair or replac
(21 and CN317.
dlsconnection in wring 4fter mspectior
harness between CN3 16 ,epair or replam
and chassis ground
disconnection in wiring Prfter inspectior
- harness between CN53 .epair or replace
(5) and CN454 (3).
dlsconnection in wmng After inspectiol
harness between CN53 repair or replacl
(1). (3) - CN305 (121
- fuse - CN305 I1 1)
L08DD021
82-33
TROUBLESHOOTING E-5
(b) Defective continuity in FORWARD solenoid circuit.

+ Carry out check according to E-5 Transmission does not work normally, then go to troubleshooting.
YES
‘ES
IS there continuity
between CN390 I1
1 Disconnect CN39C
) Turn starting
switch OFF. 3
) Place directional
lever at FORWARD. IS problem removed
YE
Interchange FORWARC 5 1) Disconnect CN435.

solenoid relay (CN4351 I 1
Is voltage between 2) Turn starting
with REVERSE solenoic switch OFF.
CN390 (2) (female) relay (CN441). YES CN435 (6) (female)
and cnasw 3) Place directional
Start engine. lever at FORWARD.
20 - 3OV?
Turn parking NO 4 _
switch ON - OFF.
- 1) Disconnect CN435
1) Disconnect CN390. Place directional ISthere continuity 2) Turn starting
2) Turn starting lever at FORWARD. between CN16 _ switch ON.
switch ON. (male) (1) and (2)? 3) Turn parking
3) Turn parking switch ON _ OFF. uo
switch ON - OFF
(released). 1) Disconnect CN 16
4) Turn transmission 2) Turn starting
cut-off selector switch OFF.
switch OFF. 3) Place directional NO
lever at FORWARD.
NO

h .E (for Econoseal)
25%
228
+ v)- L08DD022
82-34
TROUBLESHOOTING E-5
I Cause Remedy
Ieplace
YES Defective contact, or

7 disconnection in wiring After inspection
Is there continuity harness between CN435 epair or replacl
YES between CN435 (1) (2) and CN390 I1 ).
- (female) and
chassis’ Defective contact, or
disconnection in wiring ifter inspectlor
harness between CN435 epair or replacl
(1) and chassis ground.
_ 2) Turn starting
switch OFF. Defectwe contact, or
0 YES
disconnection in wiring after inspectior
harness between CN435 epair or replacl
Is there continuity
between CN16 (1 j (5) and CN16 (2).
NO- (female) and
chassis, Defective contact, or
disconnection in wiring after inspectior
harness between CN16 epan or replace
1) Disconnect CN16.1N0 (1) and chassis ground.
2) Turn starting
switch OFF. Defective contact, or
_disconnection in wiring rfter inspectior
harness between CN435 apair or replace
(6) and CN53 (5).
leolace
L08DD023
82-35
TROUBLESHOOTING E-5
(c) Defective continuity in REVERSE solenoid circuit.

YES
ES
) Disconnect CN391
!I Turn starting
switch OFF. 3
I) Place directional
lever at REVERSE. Is problem removed
when relay is
NO replaced’ between CN441 15)
I (female) and chassis)
1) Interchange REVERSE
solenoid relay (CN4411
~8th FORWARD s&no
relay (CN435) YE switch OFF.
21 start eng,ne. 3) Place directional
3) Turn park,ng lever at REVERSE.
switch ON - OFF.
I I
1) Disconnect CN39’ I. 1) Disconnect CN441
2) Turn starting 2) Turn starting
between CNl6 (malt?) switch ON.
switch ON.
3) Turn parking
switch ON - OFF
4) Turn transmlsslon 1) Disconnect CN16
cut-off selector 2) Turn starting
switch OFF. switch OFF.
3) Place directional NO
lever at REVERSE.
NO

L& .P (for Econoseal)
96
e_z8
+ v)- L08DD024
82-36
TROUBLESHOOTING E-5
Cause Remedy
Defective REVERSE
solenoid. eplace
Defective REVERSE
solenoid relay. eplace
7 YES disconnection in wiring fter inspection
harness between CN441 !pair or replace
Y ES Is there continuity (2) and CN391 (1)
- between CN441 (1) -
(femalel and chaws Defectwe contact, or
disconnection in wiring fter inspection
harness between CN441 :pair or replace
1) Disconnect CN441. NO (1) and chassis ground.
2) Turn starting
switch OFF. Defectwe contact, or
8 YES disconnection in wiring fter inspection
! harness between CN44 !pair or replace
I
there contmu~ty
Is
II (5) and CN16 (3)
betweenCN16 11) -
ND Ifemale) and chassis’ Defective contact, or
disconnection in wiring fter inspection
harness between CN16 :paw or replace
1) Disconnect CN16. ND (1) and chassis ground.
2) Turn starting Defectwe contact. or
switch OFF. disconnection in &ring
harness between CN44 fter inspection
(6) and CN304 (6) - ?par or replace
fuse - CN304 (5) -
main breaker.
Defective directlonal
lever switch. eplace
See Troubleshooting E-5 (a)
L08DD025
82-37
TROUBLESHOOTING E-5
(d) Contact in F-R circuit.

(1) When F (FORWARD) is continuous.
Is there continuity
I
1)
between CN390
(male) and chassis?
Disconnect
(1)
CN390.
t
NO 2
2) Turn starting I I
switch OFF.
Y‘ES
1I Disconnect CN39C NO 3
2) Disconnect CN75. I 1
3) Turn starting
swrtch OFF. betweenCN75 (5)
(male) and (1) (3) YES
1) Disconnect CN75.
NO 4
H
21 Disconnect CN390.
3) Turn starting Is there continwty
switch OFF. betweenCN75 (51
(female) and chaws? YES
Disconnect CN75.
NO 5 r
Disconnect CN16.
betweenCNl6 121
r-t
Disconnect CN435.
(malei and 11) (3)
Turn starting
(41 15) 16) (7) (61, 6
switch OFF.
1) Disconnect CN16 Is there contwity

between CN16 (2)
2) Turn starting
imale) and chassis’
switch OFF.
3) Place directional
lever at N or Fi.
1) Disconnect CN 16.
21 Turn starting
switch OFF.
1 m T-adapter or socket adapter

“C (for Econoseal)
2x2
9::
)_ v)- L08DD026
82-38
TROUBLESHOOTING
E-5
Cause Remedy
Defective insulation
between CN390 (11 (male)
and connector body, or
abnormal contact of chassis rfter inspection
ground with wiring harness epair or replace
of CN390 (1) inside control
valve.
Abnormal contact of chassi

ground with wiring harness ifter inspection
between CN390 (1) (female epair or replace
and CN75 (51 (male).
Abnormal contact of wiring

harness between CN75 (5)
(male) - CN390 (1) with
wiring harness between rfter inspectnon
CN75 (1) (3) (4) (6) epair or replace
- CN393 (1). CN392 (1).
CN391 (1).
Abnormal contact of
chassis or ground
connection with
tfter inspection
wiring harness
epair or replace
between CN75 (51
(female) a’nd CN435
(2) (female).
Defective transmission
control switch leolace
YES Defective transmission

control switch leplace
Abnormal contact of
NO 7 YES chassis or ground
connection with rfter inspection
wiring harness between epair or replace
CN16 (2) and CN435 (5).
Short circuit between
terminals (1) - (2) after inspection
of FORWARD solenord epair or replace
Disconnect CN16. No relay CN435 (male1
Disconnect CN435.
Turn starting
switch OFF.
L08DD027
82-39
E-5
TROUBLESHOOTING
(2) When R (REVERSE) is continuous.
YES
Is there continuity
between CN391
i
(1)
I V
‘I
s?
1) Disconnect CN3 91. NO 2

2) Turn starting
switch OFF.
between CN391 (1
1
1) Disconnect CN391. NO 3
2) Disconnect CN75.
3) Turn starting Is there contmu~ty
switch OFF. between CN75 (61
(male1 and (11 (31 14) YES
(5J?
4 J
1) Disconnect CN75
2) Disconnect CN39 ‘i
Is there cont,n~,ty YFS
3) Turn starting
between CN75 (61
switch OFF.
1) Disconnect CN75.
2) Disconnect CN16.
3) Disconnect CN441
4) Turn starting
switch OFF. Is there cont,n~,ty
between CN16 (3)
2) Turn starting
imale) and chaws’
swtch OFF. I-
3) Place directional u
lever at N or R. 1) Disconnect CN16.
21 Turn starting
switch OFF.

i .: (for Econoseall
%Z;_
Z.z8
I- VI- _ L08DD028
82-40
TROUBLESHOOTING E-5
Cause Remedy
between CN391 (1 I (male)
and connector body, or
hfter lnspectio
abnormal contact of chassis
‘epair or replac
ground with wiring harness
of CN391 (11 inside control
valve.
Abnormal contact of chassis

ground with wiring harness 4fter inspectio
between CN391 (1) (female) .epair or replac
and CN75 (6) (male).
Abnormal contact of wiring

harness between CN75 (61
(male) - CN391 (1) with
4fter Inspect10
wiring harness between
.epair or replac
CN75 (1) (3) (4) (5)
- CN393 (1). CN392 (1).
CN390 (1 I
4fter inspectio
,epair or replac
qeolace

control swtch qeolace
Abnormal contact of
NO 7 YES chassis or ground
connection with Ifter inspectio’
wiring harness between epair or replac
Is there continuity CN16 (3) and CN441 (5)
-between CN16 (3) -
(male) and chassis? Short circuit between
terminals (1) - (2)
of REVERSE solenoid qeolace
1) Disconnect CN16. NO relay CN441 knale).
2) Disconnect CN441.
3) Turn starting
switch OFF.
L08DD029
82-41
TROUBLESHOOTING E-5
(e) Problem with transmission solenoid, or speed always stays in 2nd.

t Carry out check according to E-5 Transmission does not work normally, then go to troubleshooting.
(1) No continuity YES

in 1 St. 3 I
-
Is there continuity
. between CN393 (l),
(female) and NO 4 YES
-
chassis?
- Is there continuity
1) Disconnect CN393.b b+veenCNl6 (4) _
2) Put speed lever (male1 and CN16 (8)
imale) 7
at 1 St. NO
3) Turn starting
switch OFF. 1) Disconnect CN16.
21 Put speed lever
at 1 St.
3) Turn starting
switch OFF.
(2) p3czt7tinuity YES

5 I
switch OFF. 1) Disconnect CN 16.

2) Put speed lever
at 3rd.
3) Turn starting
switch OFF.
YES
YES 1
(3) No continuity
Is there CO”tl”“lfy in 4th. 7
between CN16 (8)
ifemale) and chassis)
Is there continuity
between CN393 (1)
(fern&l or CN392 (1)
1) Disconnect Ccl 6 (female) - chassis? YES
2) Turn starting NO 87
switch OFF.
21 Put speed lever

at 4th.
1) Disconnect CN392
3) Turn starting
and CN393.
switch OFF.
2) Turn starting
switch ON.
NO

A .g (for Econoseall
gzL5
ez 8
+ Y)-
L08DD030
82-42
TROUBLESHOOTING E-5
Cause Remedy
. Defective speed solenoid Replace
disconnection in wiring After inspectior
harness between CN393 (1) repair or replacf
- CN75 (1) -CN16 (4).
rve speed lever Rep,ace
31 Defective H.L solenoid replace
/ =::;6, After inspectior

harness between CN392 (1) repair or replace
rive speed lever Rep,ace
Replace
After inspection,
repair or replace.
Replace
disconnection in wiring After inspection.
harness between CN 16 (8) repair or replace.
and chassis ground.
disconnection in wiring After inspection.
harness between CN392 (2) repair or replace.
and CN393 (2) - CN75 (7)
- CN305 (12) - fuse -
CN305 (1 1) - main breaker
L08DD031
82-43
TROUBLESHOOTING E-5
(f) Contact in speed circuit.

(1) 1st (speed) solenoid is continuous.
1) Disconnect CN393
2) Turn starting NO 2
swtch OFF.
Disconnect CN393
NO 3
Disconnect CN75.
Turn starting
Is there continuity
switch OFF. between CN75 (1)
;;;“a$\,and 13)(41
4
I I
1) Disconnect CN75.
2) Disconnect CN393
3) Turn starting
switch OFF. Isthere contuuty
between CN75 11) YES
(femalei and chasms?
1) Disconnect CN75. 5
2)
31
4)
Disconnect CN16.
Disconnect CN437
Turn starting
switch OFF. r-l
1)
Is there contmu~ty
between CN75 (1 j
Ifge)rm;q) and (31 14)
Disconnect CN75. 6NO

~!jsiJq
2) Disconnect CN16.
3) Disconnect CN437
4) Turn starting {
switch OFF.
2) Put speed lever
at 2nd.
3) Turn starting
switch OFF.
1 0) T-adapter or socket adapter
us (for Econoseal)
nz?
$2:
+ m-
L08DD032
82-44
TROUBLESHOOTING
Cause Remedy
between CN393 (1) and
connector body, or
abnormal contact of 4fter mspectio
chassis ground with repair or replac
wiring harness of CN393
(1) inside control valve.
Abnormal contact of
chassis ground with
4fter inspectio
.epair or replac
CN393 (1) (female) and
CN75 (1) (male).
Abnormal contact of
4fter inspectio
CN75 (1) (male) - CN393
‘epair or replac
(1) with wiring harness
between CN75 (3) (4) (5) (6)
- CN392 (1). CN390 (1).
CN391 (1)
Abnormal contact of chasslr
Or ground connection with
wiring harness between 4fter inspectio
CN75(1) (female) - CN16 .epair or replac
(4) - CN437 (4).
Abnormal contact of
CN75 (3) - 16) hne with after inspectio
wiring harness between ,epair orteplac
CN75 (1) (female) - CNl 6
(4) -CN437 (4).
YES Defective transmission ieplace

control switch

7eplace
NO 7 control switch
Is there contnuty
- between CN16 (41 -
Imale) and chaws’ NO 0 YES Defective kickdown teolace
relay.
- Isthere cont,nulty
1 I Disconnect CN16. - between CN437 ‘3) -
Imale) and CN437
21 Turn starting Abnormal contact of
(41 hnalel? NO
switch OFF. After Inspect101
wirina harness of CN437
epair or replac
’ 1) Disconnect CN437. (3) wyth wiring harness
2) Turn starting of CN437 (4). or abnormal
switch OFF. contact of chassis or ground
connection with wiring
harness between CN16 (4)
and CN75 (1)
L08DD033
82-45
TROUBLESHOOTING E-5
(2) 3rd (H.L.) solenoid is continuous.
YES
H
Is there continuity
between CN392 (1) YES
(male) and chassis?
I
2
2) Turn starting
switch OFF. s there continuitv
between CN392 (1)
YES
(female) and
‘I--h chassis ground? I
1) Disconnect CN392. NO 3
2) Disconnect CN75.
3) Turn startina I Is there continuitv
switch OFF.- 4 betyen?h
I ,
I 1
1) Disconnect CN75.
2) Disconnect CN392 Is there
continuity
3) Turn starting between CN75 (3)
switch OFF.
NO d
Is there continuity
2) Disconnect CN16. between CN75 (3)
3) Turn starting (female) and (1 I (4
1(5) (6)? NO 6
switch OFF.
1) Disconnect CN75.
3) Turn starting
switch OFF.
1) Disconnect CN16.
2) Put speed lever
at 2nd.
3) Turn starting
switch OFF.

; .z (for Econoseal)
gi;l?
228
I-Y)- L08DD034
82-46
TROUBLESHOOTING E-5
Cause Remedy
between CN392 11) (male)
and connector body. or
abnormal contact of Ifter inspectiol n.
chassis ground with epair or replac e.
wiring harness of CN392
(1) inside control valve.
4bnormal contact of
:hassis ground with ifter inspectiol II.
epair or replacl a.
:N392 (11 (female) and
ZN75 (31 (male).
rbnormal contact of
viring harness between
:N75 (3) (male) - CN392 ifter inspectiol 1.
1)with wiring harness epair or replao e.
letween CN75 (1) (41 (5)
5) - CN393 (1). CN390 (1)
:N391 (1).
.bnormal contact of chassis

r ground connection with
firing harness between CN7 rfter inspectior 1.
$1(female) - CN16 (61. epair or replace?.
hbnormal contact of
(iring harness between
:N75 (31 (female) and rfter inspectior 1.
:N16 (6) with wiring epair or replace?.
arness between CN75
I) (4) (5) (6) line
YES Nefective transmission
leplace
ontrol switch
NO 7 YES lefective transmission

leplace
ontrol switch
Is there continuity
- between CN16 (6) -
(male) and chassis? rbnormal contact of chassis
NO orground connection with ifter inspectior 1.
1) Disconnect CNl6. wiring harness between epair or replace?.
2) Turn starting :N16 (6) and CN75 (31.
switch OFF.
L08DD035
82-47
TROUBLESHOOTING E-6
E-6 KICK-DOWN SWITCH DOES NOT WORK.

(NORMAL Fl - F4 SWITCHES CORRECTLY)
* When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN 0 A( ))
w
ES
YES
YES 2
Is problem removed
1 Interchange klckdowr
relay (CN437l with
REVERSE solenoid
relay (CN441)
!I start engne
NO 3
Is problem removed
when relay IS
replaced,
YES
1
11 Interchange FORW/: ARD
solenoid relay ICN4 351 j$!z$q
w,th REVERSE soler rold
relay (CN441).
21 start engIna.
between CN438 (1) YES 5 1) Disconnect CN435
and CN437.
Is there co”tw,ty
2) Turn starting
between CN438 12)
11 Disconnect CN438 switch OFF.
Ifemalel and CN435
2) Press klckdown swm
31 Turn startng swtch
OFF
between CN438 (1) 2lTurn starting swtch OFf

(female) and CN435 NO
(61 Ifemale)’
1 Disconnect CN438 ‘I
and CN435.
2) Turn starting NO
switch OFF.

A .E (for Econoseal)
r:z;i?
?,“8
+ Y)-
L08DD036
82-48
TROUBLESHOOTING E-6
Cause Remedy
Defective kickdown relay. Fqeolace
Defective FORWARD solenoid

relay.
YES 8 YES disconnection in wiring Frfter inspectlor
harness between CN437 1:3) r,epair or replacf
Is voltage between and chassis ground.
_ CN437 (4) (female) _
a&y,hassis 20 -
NO disconnection in wiring Pifter inspectior
YES 7 harness between CN437 (L1) r,spair or replace
- 1) Disconnect CN437.
and CN393 (1).
2) Turn starting
Is there co”U”“lty switch ON.
- betweenCN437 (5) -
Ifemale) and chassis?
2 Defective contact, or
1) Disconnect CN437. NO 9 YES disconnection in wiring Pifter inspectior
2) Put speed lever harness between CN437 (Ei) r,spa? or replacf
at 2nd. Is therecontinuity and CN16 (5).
L betweenCNl6 151 _
3) Turn starting
Imaleliand CN16 (8)
switch OFF.
hllalei? NO
Defective speed switch
1) Disconnect CN16.
2) Put speed lever
at 2nd.
3) Turn starting
switch OFF.
NO disconnection in wmng A fter inspection
harness between CN435 (2I) r( ?pair or replace
and CN437 (6).
disconnection in wiring A fter Inspection
harness between CN438 (2!) rf tpair or replace
- CN437 (1) -CN435 (4)
disconnection in wiring ,fter inspectior
harness between CN438 (1 1 t:?pair or replacf
and CN435 16).
Defective klckdown switch F
L08DD037
82-49
TROUBLESHOOTING E-7
E-7 KICK-DOWN ONLY WORKS WHEN KICK-DOWN SWITCH IS ON.

(KICK-DOWN SWITCH RELAY DOES NOT CARRY OUT SELF-HOLD OPERATION.)
Cause Remedy
1 YES
1 Defective kickdown relay. Replace
Is problem removed
when relay 1s
replaced? Defective contact, or
NO disconnection in wiring After inspection,
harness between CN437 repair or replace
1) Interchange kickdown (2) and CN53 (5).
relay (CN437) with
REVERSE solenoid relay
(CN441).
2) Start engine.
L08DD038
82-50
TROUBLESHOOTING E-8
E-8 KICK-DOWN OPERATION IS NOT CANCELED.
* When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN o A( ))
t When disconnecting connectors or connecting T-adapters, return them to the original condition immediatelyafter
Cause Remedv
(1) Is not
canceled when directional lever is moved from
FORWARD to NEUTRAL or REVERSE.
1 YES Defective FORWARD

solenoid relay.
Is problem removed
when relay is
replaced,
NO Contact of wiring
After inspectio
repair or replac
1) Interchange FORWARD (female) (3) and (41.
solenoid relay lCN4351
with REVERSE solenoid
relay lCN441).
21 Start engine
(2) Is not canceled when parking brake is applied.
YES Defective parking

1 brake switch.
I I
Is there contlnulty
between CN316
(female) and CN317 - NO
Defective neutralizer
(maleI’
relay
1) Dwxxvv?ct parking
brake switch
ICN316.CN317).
2) Pull parking Contact between CN53 4fter inspectio
brake.
1) Interchange neutralizer (2) and chassis. .epair or replac
3) Turn startmg
relay (CN53) wth backup
watch OFF.
lamp relay (CN54)
2) Startengine.
(3) Is not canceled when speed lever is moved

from 2nd to other speed position.
YES
Defective kickdown leolace
relay.
1
Isproblem removed
YES Zontact of wiring
when relay is
harness between CN438 ifter inspectiol
replaced? NO 2 (female) (1) and (2). epair or replacl
Is there continuity
1 I Interchange klckdow”
relay ICN4371 with - between CN438 Contact of chassis or
REVERSE solenoid relay ground connection with After inspectio
(CN441 I wiring harness between repair or replac
2) Startengine. Is there continuity CN437 (51 and CN16 (5)
1) Disconnect CN438. - betweenCN437 (51 _
2) Turn starting (female) and chassis)
swtch OFF. Contact of wiring harness
IN0 4fter inspectio
I I
between CN437 (3) and .epair or replac
1) Disconnect CN437. CN437 (4). or contact of
21 Turn starting chassis or around connectior
switch OFF.
with wiring-harness between
31 Put speed lever on
position other than
CN437 (4) and CN393 (1).
2nd.
L08DD039
82-51
TROUBLESHOOTING E-9
E-9 KICK-DOWN WORKS BY MISTAKE WHEN TRAVELING IN F2.
t When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN o A( ))
t When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after
Cause Remedy
YES
Defective kickdown switch Replace
1
Is there continuitv
between CN438 IFS
(1) (male1 and Defective kickdown relay Replace
CN438 (2) (male)? NO 2
1) Disconnect CN438 Is there continuity

2) Turn starting _ betweenCN437 _ YES Contact of wiring
switch OFF. (male) (1) - (2) harness between CN438 After inspectiol
3) Do not press and (3) - (4)? (female) (1) and (2). epair or replac
NO3
kickdown switch.
1) Disconnect kick-
down relay YEE Contact of wiring
NO 4
ifter inspectiol
CN437. harness between CN43J
epair or replacm
2) Turn starting
switch OFF. 1) Disconnect CN438
2) Turn starting
/pFzz&%;H (female) (1) and (2).
switch OFF. Contact of wring harness

After inspectiol
between CN437 (female)
epair or replac
1) Disconnect CN437. NC (3) and (4)
L08DD040
82-52
ELECTRIC AND
ELECTRONIC SYSTEM
MACHINE MONITOR .............................................................. 2

REMOVAL .................................................................... 2
INSTALLATION ................................................................. 3
83-1
DISASSEMBLY AND ASSEMBLY MACHINE MONITOR
MACHINE MONITOR
REMOVAL

moving.

+ After disconnecting the connectors, mark

with a tag to distinguish when installing.
+ When removing the machine monitor, be

careful not to give it any sudden shock.
1. Covers
Remove covers (1 and 2) of machine monitor.
2. Electric wiring
Disconnect the wiring from the following connec-
tors.
l Connectors (3 and 4) of CAUTION 2 module.
l Connector (7) of speedometer module.
0 Connector (8) of service meter.
0 Connectors (9 and 10) of gauge module.
l Connectors (11 and 12) of CHECK module.
3. Machine monitor
Remove mounting bolts, then remove machine
monitor (13).
+ When removing the machine monitor, be careful
to protect it from any shock.
419PlO96
83-2
DISASSEMBLY AND ASSEMBLY MACHINE MONITOR
MACHINE MONITOR
INSTALLATION
sr After inserting the connectors, apply the connector
lock securely. Assemble so that there is no strain
on the wiring.
1. Machine monitor
Set machine monitor (13) in mounting position and
install.
+ Do not tighten the screws to tight.
2. Electric wiring
Connect the wiring to the following connectors.
0 Connectors (11 and 12) of CHECK module.
0 Connectors (9 and 10) of gauge module.
0 Connector (8) of service meter.
0 Connector (7) of speedometer module.
0 Connectors (5 and 6) of CAUTION 1 module.
+ After inserting the connectors, apply the con-

nector locks securely. Install the wiring so that
there is no strain on the wires.
3. Cover
Install covers (1 and 2) of the machine monitor.
83-3
OTHER
CAB .......................................................................... 2
REMOVAL .................................................................... 2
INSTALLATION ................................................................ 2
CAB . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .. . . . . . . . . . . . . . . . . . . . . . . . . . 3
93-1
DISASSEMBLY AND ASSEMBLY CAB
CAB
REMOVAL

* Remove mounting bolts on rear side of cab (4

bolts).
l Disconnect wiring for cab.
* Lii off the cab evenly.
Cab: 310 kg
CAB
INSTALLATION
* Coat the seal evenly with adhesive compound.
Adhesive compound (Cemedine

366E)
93-2
DISASSEMBLY AND ASSEMBLY CAB
CAB
1. Front wiper
2. Front glass
3. Door
4. Rear wiper
View Z
GEAR PUMP
97 SA SERIES
GENERAL ...................................................................... 2
PRINCIPLE OF OPERATION ....................................................... 3
PRESSURELOADEDTYPEGEARPUMP ............................................. 6
FIXEDSIDEPLATETYPE GEARPUMP.. ............................................. 8
SASERIES ..................................................................... 9
STRUCTURE .................................................................. 9
TESTINGANDADJUSTING ...................................................... 13
DISASSEMBLY ................................................................ 16
ASSEMBLY .................................................................. 20
MAINTENANCE STANDARD ...................................................... 25
97-1
GEAR PUMP GENERAL
GENERAL
The hydraulic pump is a device which receives me- The hydraulic pumps used in construction machinery
chanical energy from a prime mover such as an engine, are external gear pumps and are classified as fixed
converts the energy into fluid energy, and functions as displacement rotary pumps.
the source of energy in a hydraulic system.
External gear pumps employ involute spur gears, and
The fluid energy can be divided into the energy of can be structurally classified into the following types.
velocity, pressure, and potential. Almost all of the fluid
0 Type of side plate adjustment
energy used for hydraulic pressure is pressure energy.
Fixed side plate type
(FAL, FAR, GAL, GAR)
The hydraulic pump receives and transmits the energy
through the static pressure of a fluid, and easily produc-
es a high pressure since its delivery is determined by Pressure loaded type
the transfer of volumetric displacement enclosed by the (PAL, PAR, KAL, KAR)
fixed walls. Therefore, the pump delivery is not changed
significantly with variations in the load. Pressure plate type
It follows that the pump itself is a device which makes

a Type of bearing
the oil flow, rather than a device to produce pressure.
The pump pressure is generated by the resistance (the Ball or roller bearing type
load) against the oil flow. Therefore, when there is no
resistance, no pressure is produced. Plain bearing type
Structurally, hydraulic pumps can be broadly classified

into rotary pumps and reciprocating pumps. Function- Gear pumps installed on installed on the machines are
ally, They can be classified into fixed displacement called standard pumps. They are designed as follows:
pumps and variable displacement pumps.
“PAL 160”
r PAL 160 1
P= A= L= 160=
s: For high pres- A: Flange type mount L: Counter-clockwise Theoretical pump deliv-
sure: 210 kg/cm- section rotation ery at 1,000 rpm
2, pressure load- (liters/min)
ed type
K: For high pres- B: Foot type mount R: Clockwise rotation
sure: 175 kg/cm- section
2, (210 kg/cm2
for some pumps)
pressure loaded
type
P: For medium pres-
sure: 140 kg/c-
m2 (155 kg/cm2
for some pumps)
pressure loaded
type
c: For medium pres-
sure: 125 kg/-
cm2, fixed side
plate type
F: For low pressure:

30 kg/cm2, fixed
side plate type
97-2
GEAR PUMP GENERAL
PRINCIPLE OF OPERATION
l MECHANISM FOR DELIVERING OIL
The drawing at right shows the operational principle

of an external gear pump in which two gears are
rotating in mesh. Suction Discharge
The oil entering through the suction port is trapped

in the space between two gear teeth, and is deliv-
ered to the discharge port as the gear rotates.
Except for the oil at the bottom of the gear teeth, 23OF137
the oil trapped between the gear teeth is prevented
from returning to the suction side with the gears in
mesh.
Since the gears are constantly delivering oil, the oil

delivered to the discharge port is forced out of the
port.
The amount of discharge increases with the speed

of rotation of the gear.
If there is no resistance in the oil passage into

which the discharged oil flows, the oil merely flows 23OF138
through the passage, producing no increase in
pressure.
If, however, the oil passage is blocked with some

thing like a hydraulic cylinder, there will be no other
place for the oil to flow, so the oil pressure will rise.
But the pressure which rises in this way will never
go higher, once the hydraulic cylinder piston starts
moving because of the oil pressure.
As described earlier, the pump produces the oil

flow, but not the oil pressure. We can therefore 23OF139
conclude that pressure is a consequence of load. In
other words, the pressure depends on a counter-
part
23OF140
97-3
GEAR PUMP PRINCIPLE OF OPERATION
placing an overload on the bearings, and resulting in a

l INTERNAL OIL LEAKAGE shortened service life of the bearing or interference of
the gear with the case.
Oil leaks from a place under higher pressure to a
place under lower pressure, provided that a gap or
a clearance exists in between,
In the gear pump, small clearances are provided

between the gear and the case and between the
gear and the side plate to allow the oil to leak out
and to serve as a lubricant so that the pump will be
protected from seizure and binding.
The drawing at right shows how the leaked oil

flows in the pump. As such, there is always oil
leakage in the pump from the discharge side (under
higher pressure) to the suction side. The delivery of
the pump is reduced by an amount equal to the
pump discharge.
In addition, the delivery of the pump will also de-

crease as the amount of oil leakage increases
because of expanded radial clearance resulting ZXlF141
from the wear of pump parts, the lower oil viscosity
resulting from increases in the oil temperature, and
the initial use of low viscosity oil.
l FORCES ACTING ON THE GEAR
The gear, whose outer surface is subjected to oil

pressure, receives forces pointing towards its
center.
Due to the action of the delivery pressure, the oil

pressure is higher on the delivery side of the pump,
and due to suction pressure, is lower on the suction
side. In the intermediate section, the pressure will
gradually lower as the position moves from the schsrge side
delivery side to the suction side. This phenomenon
is shown in the drawing at right.
In addition, the gears in mesh will receive interact-

ing forces.
These forces pushing the gears toward the suction

side are received by the bearings. Since the gears sure distribution
are pressed toward the suction side by theses
forces, the radial clearance becomes smaller on the
suction side in the case. In some pumps (PAL, PAR, 23OF142
KAL, KAR), the clearance may become zero, thus
allowing the gear teeth and the case to come into
light contact.
For this reason, an excessive increase in the deliv-

ery pressure must be avoided, since it will produce
a large force which will act on the gears,
97-4
GEAR PUMP PRINCIPLE OF OPERATION
l “TRAPPING” PHENOMENON OF THE OIL
When a gear pump is rotating with the gears in

mesh as shown in the drawing at right, in some
instances two sets of gear teeth are in mesh while
in other instances only one set of the gear teeth is
in mesh. Delivery*
When two sets of the teeth are in mesh simulta-

neously, the oil in the space between the meshed
gear teeth will be trapped inside - the front and rear
exits will be completely shut.
This is called the “trapping” phenomenon of oil.
The space in which the oil is trapped moves from

the suction side to the delivery side as the gears The pace reaches
rotate. The volume of the space gradually decreas- the minimum
es from the start of trapping until the space reach-

es the center section, and then gradually increases
after leaving the center section until the end of
trapping.
Since the oil itself is non-shrinkable, a reduction of

the volume of space will greatly increase the oil
pressure, unless some provision is made to relieve
oil pressure. The high pressure oil will cause the
pump to make noise and vibrate.
To prevent this, relief notches are provided on the

side plates to release the oil to the delivery side.
As shown in the drawing below, the relief notches

are provided in such a way that the oil can be
relieved from the trapping space tot he delivery side
when the volume of the space is reduced.
Relief notches are also provided on the suction side

to prevent the formation of a vacuum in the space
by allowing the oil to enter the space from the
suction side when the space is expanded.
23OF144 23lF145
97-5
GEAR PUMP PRESSURE LOADED TYPE GEAR PUMP
PRESSURE LOADED TYPE GEAR PUMP
19
23OF146
GENERAL
DESCRIPTION 1. Drive gear
2. Bracket
Hydraulic pumps used for the work equipment hydraulic 3. Bushing
units on construction machinery are pressure loaded 4. Gear case
type gear pumps. Some gear pumps of this type have 5. Cover
a maximum delivery pressure of 210 6. Seal plate
kg/cm* or higher. 7. Collar
8. Bach-up ring
The pressure loaded type gear pump is designed so 9. Driven gear
that the clearance between the gear and the side plate
can be automatically adjusted according to the delivery
pressure. Therefore, the oil leakage from the side plate
is less than in the case of the fixed side plate type
under a high discharge pressure. Consequently, no
significant reduction of the pump delivery occurs, even
when the pump is operated under high pressure.
97-6
STRUCTURE AND OPERATION
In a pressure loaded type pump, two bushings acting as

side plates are inserted into the pump case, and are
pressed toward the sides of the gears. The oil leakage
from the gear sides is thus minimized.
Since the bushings are constantly pressed toward the

gears by the oil pressure, there is no fear of an increase
on oil leakage, even when the bushings are worn out
and the clearances are expanded many hours of
operation.
The bushings are pushed towards the gears from the

cover side by the oil pressure, and they are pushed
from the gear side by the pressure of oil trapped
between the gear teeth and that which has leaked out
from the clearance between the gear and the bushing.
Since the oil pressure in the gears is higher on the

pump delivery side and is lower on the suction side,
provisions are made so that the pressing force acting
on the bushings from the cover side is regulated in such
a way that the delivery side is pressed harder and the
suction side weaker to match the counter pressure.
More specifically, the area of the bushing on the dis-

charge side is made larger than that on the suction side
by partitioning the area of the bushing subjected to
pressure on the cover side, with a back-up ring installed
to the seal plate as shown in the drawing at right.
When the pump is operated at high speed, the pressure

on the suction side is lowered and the distribution of
pressure around the periphery of the gear will change
into the state shown in the drawing at right below.
‘th blwa groow
Pressure balance grooves are therefore provided on the \
bushings to keep the balance of the force on the cover Discharge
side against the pressure acting on the bushing from without belance groove
\ (high speed)
the gear side that varies with the pump rotation and the
pressure distribution. Thus the delivery pressure is led
as shown in the drawing and the pressure distribution is
stabilized at any rotational speed. OW140
97-7
FIXED SIDE PLATE NPE GEAR PUMP
-5
Ll 0AVO18
1. Drive gear
GENERAL DESCRIPTION 2. Bracket
Hydraulic pumps used for the main clutch, transmission, 3. Gear case
and steering system on bulldozers are fiied side plate 4. Cover
type gear pumps which can be classified as follows: 5. Driven gear
pumps generally called FAL or FAR pumps having a
maximum delivery pressure of 30 kg/cm2 and pumps
generally called GAL or GAR pumps having a maximum
delivery pressure of 125 kg/cm2.
Since the bracket and the case cover serve as the side
plates and the gear teeth bottom land is closer to the
outer race of the bearing in the case of the fixed side
plate type gear pump, oil leakage is liable to occur at
the clearance between the gear and the side plate.
However, this is only a small problem, as the pump is
used for steering icontrol which is operated at a low
service pressure. ;
97-8
STRUCTURE
SA SERIES
SA SERIES Side date
FEATURES
The gear pump is a high quality, reliable product that is

specially designed for use in construction equipment
which works under severe conditions.
l The side plate, given surfaces treatment to improve
its matching characteristics with the special copper
alloy, ensures minimum torque loss and excellent
wear resistance.
l With the improved hydraulic balance mechanism,
the pump offers stable performance and high
durability.
2OOF132
STRUCTURE
1. Drive gear
8 10 8 2. Driven gear
i. ziA:g
\_\ I
5: Plate
6. Bracket
7. O-ring
8. Side plate
9. Back-up ring
10. Seal ring
11. Gear case
12. Side plate
13. Back-up ring
14. Seal ring
15. Cover
8 16. O-ring
17. Bolt
18. Dowel pin
4 6 1 11 2 18 16 13’14
21FO23
97-9
SA SERIES STRUCTURE
SA-1 Series single pump
LlOAVOlB
(The drawing above shows a pump of the counter-clock-

wise rotation type. In a clockwise rotation pump, the
positions of the suction and delivery ports are reversed.)
l Side port type
LloAVO20

97-10
SA SERIES STRUCTURE
Rear poti type


l Side port type
Deliwry port
-
I: F
LlQhVB22

97-11
SA SERIES STRUCTURE
0 Rear port type
:
- Ii

Daliwry port
Depth: - F
LlEcIVE24

NOTE: Dimensions A through H in the drawings vary with pump capacity.
97-12
SA SERIES STRUCTURE

Measure the pump delivery with a bench or flow meter kit (790-303-1001).
For SA pumps operating at a service pressure of 50 kg/cm2 or less, see the standard and the repair limit in Table
No. 2. (Examples: Pumps for power trains and servo-hydraulic pumps for excavators)
* See Notes on pat followir table 1 81 The capacity codes marked + are for triple pumps.
No Check item Series Wpa&y Delivery T Standard Repair limit
No pressure Rotation Delivery Rotation Delivery

(kg/cm*) (rpm) (liters/min) (rpm)
(%’
1 Performance 008 25 23
Hydraulic 010 32 29
oil: 012 38 34
EOlO- 1 014 210 3500 47 3500 43
CD 016 52 46
020 66 61
Oil temper- 025 83 76
ture:
50” c 416 44 40
+020 55 50
425 67 62
028 77 71
2 032 210 3000 88 3000 82
036 100 92
040 111 103
045 121 111
050 138 128
420 45 42
+025 55 51
&IO 90 82
+050 112 102
056 210 2500 129 2500 119
063 145 134
3 071 158 146
080 184 170
100 231 214
112 140 2000 212 2000 192
125 236 213
112 233 215

125 2200 253 2200 234
140 287 266
4 160 210 328 303
_______________
____________
______________
180 336 310
200 2000 373 2000 345
224 411 385
250 460 425
97-13
SA SERIES STRUCTURE
St; ndard Repair limit

~
No Check item Series Delivery
I
No pressure Rotation ~ Delivery Rotation Delivery
(kg/cm? (rpm) (liters/min) (rpm)
(I:;’
2 Performance 008 27 25
010 33 30
Hydraulic 012 40 37
oil: 1 014 30 3500 48 3500 44
EOlO- 016 54 50
CD 020 68 63
025 86 79
Oil Tempera
-ture: MO8 23 21
50” c 416 43
420 :: 53
+025 72 66
2 028 30 3000 80 I 3000 74
032 92 84
036 ~ 104 95
040 115 106
045 126 115
050 144 132
+020 49 44
+025 60 55
+040 96 88
+050 119 109
056 30 2500 134 ~ 2500 123
063 151 138
3 071 164 150
080 192 176
100 241 221
112 30 2000 217 2000 198

125 240 220
112 242 222

125 2200 254 242
140 300 2200 275
160 342 314
4 30 ___________--___-___-___
180 350 321
200 2000 389 2000 257
224 434 398
250 480 440
For SA pumps operating at a service pressure of 50 kg/cm” or less, see the standard and the repair limit in table,
No. 2. (Examples: Pumps for power trains and servo-hydraulic pumps for excavators).
97-14
SA SERIES STRUCTURE
Note 1.) If it is impossible to raise the pump speed

to the value shown in the table because of
limitations of the test bench, calculate the
allowance for the delivery from the follow-
ing formula:
Q = Qo - /No - N) Qth
1000
however, NX 1000 rpm

where, RPM of test bench
;: Repair limit for delivery at N rpm
(liters/min)
RPM in the table
::1 Repair limit for delivery in the table
(liters/min)
Qth: Capacity code
Note 2.) If the test bench allows the pump to raise

its delivery pressure above 140 kg/cm2 but
not above 210 kg/cm*, use the repair limit
for delivery given in Table, No 1
Note 3.) For pumps whose service pressure ex-

ceeds 50 kg/cm’ in operation, use Table,
No 1. (do not use Table, No 2)
Note 4.) The volumetric efficiency of a pump de-

creases after the pump is reassembled.
After reassembly, therefore, perform the
following tests with a test bench or flow-
meter kii (790-303-l 001).
(1) Shock test

20 times
252 kg/cmX max
I--- t- -t )
Time
LlOAVO25
(2) Performance test (measure thedelivery)
97-15
SA SERIES DISASSEMBLY
1. Single pump
+ Cautions before disassembly
To avoid confusion in the reassembly, stamp
match marks on connecting sections of bracket
(6) to gear case (11) and gear case (11) to
cover (15).
6
UOAVO31
1) Put the pump assembly on a work bench with

the bracket side facing down, and loosen
mounting bolts (17) for cover (15).
+ Use the bracket mounting bolt holes to secure

the pump assembly.
L10AV032
2) Remove cover assembly (15).

t Place the internal parts in line in the order of
removal, taking care not to damage the con-
tacting surfaces or sliding surfaces of the parts.
+ Pull out cover assembly (15), taking care not to
damage the hole for the dowel pin. Do not pry
the cover.
L10AV033
3) Remove O-ring (16) from the cover.
- LlOAVO34
97-16
4) Pull out side plate (12) on the cover side.
LlOAV036
5) Remove backup ring (13) and seal ring (14).
6) Remove drive gear (1) and driven gear (2).

+ Pull out the gears by hand. Do not use a ham-
mer.
+ If the oil seal is not replaced, tape the drive
gear and the spline section to protect the oil
seal from damage. 1
7) Remove bracket (6) from gear case (11).

t When removing bracket (6) from gear case
(11) take care not to let side plate (8) on the
bracket side fall down and leave the side plate-
installed as is to the gear case.
it Do not hit the side plate surface.
LlOAVO38
97-17
8) Pull outside side plate (8) from gear case (11).
LlOAVO39
9) Remove backup ring (13) and seal ring (14).
10) Remove O-ring (7) from bracket.
LlOAVO41
97-18
2. Tandem pump
1) Stamp match marks.
2) Put the pump on a work bench with the front

pump bracket surface facing down, and remove
the four bolts that connect the front pump to
the rear pump.
Match
3) Disconnect the front pump from the rear pump.
4) For the disassembly of single pumps, see the

section on single pumps.
3. Triple pump
Follow the same procedure for tandem pumps. LlOAVOSS
L10AV066
97-19
SA SERIES ASSEMBLY
ASSEMBLY
1. Single pump
+ When a used gear case is assembled, remove
the burrs from the case and make sure that the
side plate can be sided smoothly.
t Make sure that the dowel pin on the case has
specified length (4).
L10AV042
P k Lenoth of dowel pin
2
1) Put cover (15) on a work bench.
MOAV043
2) Install side plate (12) into gear case (11) with

the seal groove facing outside.
+ Do not install the backup ring and the seal to
side plate (12) at this stage.
l Do not confuse the suction side of the side
plate with the delivery side.
* Do not damage the periphery of the side plate,
especially around the seal section. Discharge port
LlOAVO44
Measurement of side clearance

Temporarily assemble bracket (6) and gear case (11)
as shown in the drawing at right. Place the assembly on
a work bench and measure the difference between the
stack height including drive gear (l), side plates (8) and
(12) and the height of gear case (11).
Measure with a depth dial gauge or depth micrometer.
Judgement criteria
Confirm that the measurements conform to the standard
clearance given in the Maintenance Standard Table.
23OF222
97-20
SA SERIES ASSEMBLY
3) Install gear case (11) to cover (15) with the

match marks aligned.
4) install drive gear (1) and driven gear (2).
LlOAVO46
5) install side plate (8) with the backup and seal

ring grooves facing upward.
LlOAVO47
6) Install backup ring (9) and seal ring (10).

+ Install them with care to prevent gaps between DiFcharge port
the ring and the gear case.
+ If it is impossible to eliminate the gap, replace
the seal ring and the backup ring.
-Gap
23OF223
97-21
SA SERIES ASSEMBLY
7) Apply some hydraulic oil to the shafts of gears

(1 and 2) and also to the sliding section of the
side plate.
+ Take care to keep gear case free from oil.
L10AV048
8) Install O-ring (7) to bracket (6).
L10AV049
9) Install bracket (6).

+ Align the match marks when installing the
bracket.
+ Before installing the bracket, make sure that the
seal and backup rings are properly installed
according to the precautions in item 6.
t Make sure O-ring (7) is fit properly.
+ Confirm that the contact surface is free from
dirt and dust.
LlOAVO60
10) Carefully turn the gear pump assembly

upside down so that the bracket side will
face downward, and put the gear pump
assembly on a work bench.
t When turning the pump upside down, take care
not to let the contact surfaces open out and not
to let the O-ring and seal come off.
LlOAVOSl
97-22
SA SERIES ASSEMBLY
11)Remove the cover (15) and install O-ring (16).

12)Install backup ring and seal ring to side plate
(12) in the manner described in item 6.
13) Install cover (15).
* Align the match marks when installing the
cover.
* Before installing the cover, make sure backup
ring and seal ring are properly installed ac-
cording to the precautions given in item 6.
* Make sure O-ring (16) is fii properly.
L10AV036
14) Tighten mounting bolts (17).

* Use a torque wrench and tighten the bolts to
the specified torque in the order shown in the
drawing.
For the tightening torque, see the Mainte-
nance Standard Table, this section.
sx!l
1
4
lightening
2
order
LiOAVO26
L10AV032
Series I Rotational toraue
1 0.2 - 0.5 kgm

15) After assembly, check the rotational torque of
the pump shaft to see if it conforms to the value
2 0.3 - 0.7 kgm
given in the table.
* After the pump is assembled, carry out the 3 0.7 - 1.2 kgm
performance test (measure the pump delivery)
with a test bench or flow meter kit (790-303- 4 1.0 - 1.5 kgm
1001). Confirm that the performance is with the
repair limits.
2. Tandem pump
1) For the assembly of individual units of the front
and rear pump, follow the same assembly
procedure as for the single pump.
2) Put the front pump on a work bench.
97-23
SA SERIES ASSEMBLY
3) Install the coupling to the front pump.
L10AV063
4) Fii the O-ring to the rear pump bracket.

5) Put the rear pump on top of the front pump.
+ Take care not to let the O-ring come off.
+ Align the match marks.
.x
r
Series I lightening torque 1

1-2
3 I 4-7 kw
16-20 kgm
4
lightening order
L10AV027
6) Tighten four mounting bolts.

+ Tighten the bolts with a torque wrench to the
specified torque in the order shown in the
drawing below.
Match
+ After the pump is assembled, carry out the

performance test (measure the pump delivery)
with a test bench or flow-meter kit (790303-
1001). Confirm that the performance is within
the repair limits.
3. Triple pump
Follow the same assembly procedure as for the
tandem pump.
97-24
SA SERIES MAINTENANCE STANDARD
LlOAVO28
Unit: mm
No Check item Series

Criteria T
Remedy
No Standard clearance Clearance
limit
1
0.10 - 0.15 0.19
2
SAL & SAR

0.10 - 0.15 0.19
1 Clearance between 0=20- 080
the gear case and 3
SAL & SAR
the gear plus the Replace the side
0.13 - 0.18 0.20
side plate plate or the
700-125
pump assembly
SAL i? SAR
0.11 - 0.16 0.19
1=12- 180
4
SAL & SAR
0.14 - 0.19 0.22
2=00- 250
SAL & SAR
0.06 - 0.144
0=08- 014
2 Clearance between 1
the I.D. of the plain SAL & SAR
bearing and the 0.06 - 0.119
O.D. of the gear o=lS-025
shaft 0.22 Replace
2 0.06 - 0.125
3 0.06 - 0.149
4 0.06 - 0.140
97-25
SA SERIES MAINTENANCE STANDARD
No Check item Series

No +
1 10 - 12.5 kgm
A
Clearance
limit
Remedy
3 Tightening torque 2 10 - 12.5 kgm

for the case mount- 3 23.5 - 27 kgm
ing bolts
4 15 - 18 kgm
97-26
OTHER
99 METRIC CONVERSIONS
99-1
METRIC CONVERSIONS
UNIT MULTIPLY BY TO GET MULTIPLY BY TO GET
acre
DENSITY (Mass Density)
pound per cubic yard kilogram per cubic meter

0.5932763 1685555 Ob/yd3)
(lb/yd3) (kg/m3)
/ ;;;;;y per cubic meter 1 0.06242797 / (lb/ft3)
pound3 per cubic inch gram per cubic centimeter

27.67990 0.03612730 (lb/in3)
(lb/in ) Wcm3)
I
pound per US gallon 8.345406
0.1198264 (lb/US gal)
(lb/US gal)
I
pound per UK gallon kilo ram per liter 10.02242
0.09977633
(lb/UK gal) (kgfl)
FORCE
4.448222 newton (N) 0.2248089 pound-force

pound, pound-force
(lbf)
0.004448222 kilonewton (kN) 224.8089 pound-force
I I I I
ounce-ounce-force (ozf) 0.2780139 newton (N) 3.596942 ounce force
99-2
METRIC CONVERSIONS
FORCE PER LENGTH
0.1751268 newton per millimeter (N/mm) 5.710148 pound-force per inch

pound, force per inch
(Ibf/in)
175.1268 newton per meter (N/m) 0.005710148 pound-force per inch
pound-force per foot) newton per meter (N/m)

14.5939 0.06852178 pound-force per foot
(lbf/ft)
1.055056 kilojoule (kj) 0.9478170 (Btu)

British thermal unit
(Btu)
1055.056 joule (J) O.COOQ478170 (Btu)
Btu per hour* (Btu/h) 0.2930711 watt (W) 3.412141 (Btu/h)
Btu per minute*

17.58427 watt (w) 0.05686902 (Btu/min)
(Btu/min)
Btu per gallon (Btu/gal) 0.2787163 kilojoule per liter (kJ/I) 3.5878777 (Btu/gal)
*Heat flow rate. Also see POWER.
LENGTH
mil
1.609344 kilometer (km) 0.6213712 mile

mile
1609.344 meter (m) 0.0006213712 mile
rod 5.0292 meter (m) 0.1988388 rod

METRIC CONVERSIONS
MASS (WEIGHT)
ounce
short ton (2000 lb)
megagram (Mg) 0.9642064 long ton
0.7456999 kilowatt (kW) 1.341022 (hp)

horsepower (hp)
745.6999 watt (W) 0.001341022 (hp)
Btu per hour* (Btu/h) 0.2930711 watt (W) 3.412141 (Btu/h)
Btu per minute* 17.56427 watt (W) (Btu/min)

0.05666902
(Btu/min)
*Also heat flow rate. See HEAT.
PRESSURE
6.894757 kilopascal (kPa) 0.1456377 (psi)

pound force per square
inch (psi)
0.006694757 megapascal (Mpa) 145.0377 (psi)
inch of mercury (in Hg) 3.37665 kilopascal (kPa) 0.296134 (in Hg)
inch of water (in H20) 0.24664 kilopascal (kPa) 4.0166 (in H20)
bar 100.0 kilopascal (kPa) 0.01 bar
99-4
METRIC CONVERSIONS
TEMPERATURE
degree Fahrenheit (‘F) (” F-32) + 1.8 degree Celsius (“C) (1.8x%) + 32 (“F)
TEMPERATURE INTERVAL OR TOLERANCE
degree Fahrenheit (OF) divide by 1.8 degree Celsius (“C) 1.8 (‘F)
VOLUME
cubic yard (yd3) 0.7645549 cubic meter (m3) 1.307951 (yd3)

I
cubic foot (ft3)

-1 0.02831685 cubic meter (m3) 35.31466 (ft3)
16.38706 cubic centimeter (cm3) 0.06102376 (in3)

cubic inch (in3)
0.01638706 liter (I) 61.02376 (in3)
3.785412 liter (I) 0.2641720 (US gal)

U&l~u$ gallon
0.003785412 cubic meter (m3) 264.1720 (US gal)
US liquid quart (US qt) 0.9463529 liter (I) 1.066688 (US qt)
US liquid pint (US pt) 0.4731765 liter (I) 2.113376 (US Pt)
I 0.2365882 liter (I)

I 4.226753 cup
0.02957353 liter (I) 33.81402 (US fl 02)

US fluid ounce
(US fl 02)
29.57353 cubic centimeter (cm3) 0.03381402 (US fl oz)
tablespoon 14.78676 milliliter (ml) 0.06762807 tablespoon
teaspoon 4.928922 milliliter (ml) 0.2028841 teaspoon
4.546092 liter (I) 0.2199692 (UK gal)

lJJKli$)d gallon
a
0.004546092 cubic meter (m3) 219.9692 (UK gal)
0.02841307 liter (I) 35.19507 (UK fl oz)

UK fluid ounce
(UK fl oz)
28.41307 cubic centimeter (cm3) 0.03519507 (UK fl oz)
99-5
METRIC CONVERSIONS
TORQUE
pound-force foot
1.355818 newton meter (N-m) 0.7375621 (ft lb)
(Ibf ft) (ft lb)
pound-force inch
0.1129848 newton meter (Nom) 8.850748 (in lb)
(Ibf in) (in lb)
ounce force inch (ozf in) 0.007061552 newton meter (N-m) 141.6119 (ozf in)
VELOCITY
mile per hour (mph) 1 HI9344 kilometer per hour (km/h) 0.8213712 (mph)
0.3048 meter per minute (m/min) 3.280840 (ft/min)

foot per minute (ft/min)
0.00508 meter per second (m/s) 196.8504 (ft/min)
foot per second (ft/s) 0.3048 meter per second (m/s) 3.280840 We)
25.4 millimeter per second 0.03937008 (in/s)

(mm/s)
inch per second (in/s)
0.0254 meter per second (m/s) 39.37008 (in/s)

FOLDOUTS
FOLDOUTS #‘S:
1. Hydraulic Piping Diagram.
2. Electrical Wiring & Electronic Vehicle Monitoring System Diagrams, pg. 1.
5. Electrical Wiring Circuit & Connectors (CN) Diagrams.

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

CEBDW19020

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CEBMW19020

MACHINE MODEL SERIAL NUMBERS

WA3204 Lc A25001 and up

SPECIAL PUBUCATIONS SUCH AS SERVICETOOL, AIR CONDITIONING, ANDTURBOCHARGER SHOP MANUALS

DESCRIPTION FORM NUMBER

PARTS BOOK - PAPER:

Engineand Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPBW19021

PARTS BOOK - MICROFICHE:

Engineand Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPMW19021

OPERATION & MAINTENANCE MANUAL:

Chassis ....................................................... CEBMW19020 .

SAFETYMANUAL ................................................... 1085 883 R3

PARTS AND SERVICE PUBLICATIONS CAN ONLY BE ACQUIRED BY AN AUTHORIZED KOMATSU

PHONE NO. FAX NO. SHIPPING METHOD DISTR/BRANCH CODE

MODEL NUMBER SERIAL NUMBER

KDC91 D 081696 CURRENT PRICES WILL BE CHARGED

12 TESTING AND ADJUSTING .................................................. 12-1

21 STRUCTURE AND FUNCTION ................................................ 21-1

41 STRUCTURE AND FUNCTION ................................................ 41-1

50 BRAKE AND AIR SYSTEM

51 STRUCTURE AND FUNCTION ................................................ 51-1

60 WORK EQUIPMENT SYSTEM

61 STRUCTURE AND FUNCTION ................................................ 61-1

80 ELECTRIC AND ELECTRONIC SYSTEM

81 STRUCTURE AND FUNCTION ................................................ 81-1

93 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93-l

A WARNING! IMPORTANT SAFETY NOTICE

PREPARATIONS FOR WORK

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SERVICE MANUAL

These volumes are designed to avoid duplication

When a manual is revised, an edition mark is

1. If a part cannot be smoothly removed from the

The allowable load value is estimated to be

2) Sling wire ropes from the middle portion of

Slinging near the edge of the hook may

1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS

Thread diameter Width

+ Nm (newton meter): 1Nm + 0.1 kgm

2. TIGHTENING TORQUE OF SPLIT FLANGE BOLTS

Use these torques for split flange bolts.

Thread diameter Width Tightening torque

3. TIGHTENING TORQUE FOR NUTS OF FLARED FITTINGS

Use these torques for nut part of flared.

Width across flats

I LG-1 Used with aaskets and oackinas to increase sealina effect.

Used by itself to seal grease fittings, tapered screw fittings and

Applied to bearings and taper shafts to facilitate press-fitting and to

Vaseline Used for orotectina batterv electrode terminals from corrosion.

*LT-2 is also called LOCTITE in the shop manuals.

ELECTRIC WIRE CODE

CLASSIFICATION BY COLOR AND CODE

Classification Circuits Starting Charging Lighting Signal Instrument Other

White & Yel- Green & Yellow & Blue &

Engine assembly 587

LUBRICANTS, FUEL AND COOLANT

AMBIENT TEMPERATURE CAPACITY

Hydraulic system 130 4 75 e

Drive axles - Axle oil See NOTE 3 24 4 24 P

API: American Petroleum Institute

Normal Operation A sulfated ash limit of 1.O mass percent is suggest-

Do not use special “break-in” lubricating oils for a 5. DIESEL FUEL

The viscosity of the fuel must be kept above 1.3