‘SEBM005305 llOlP Is LAVINA IL KOMATSU DIDDA-3 MACHINE MODEL SERIAL NUMBER D155A-3 60001 and up © This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice. ‘* D155A-3 mounts the $6D140-1 and SA6D140-2 engine. For details of the engine, see the 6D140-1 Series and 6D140-2 Series Engine Shop Manual. © 1996 MOMATSU All Rights Reserved 00-1 Printed in Japan 02-96(03)01501 ®01 10 20 30 40 00-2 ® CONTENTS No. of page 1-1 GENERAL STRUCTURE AND FUNCTION...........cssccssesseseseetsseeseereeteee 10-1 TESTING AND ADJUSTING. DISASSEMBLY AND ASSEMBLY. .............ssssssssseseesesseneesess30-1 MAINTENANCE STANDARD.............ccsssssesseessesteensenteeseeneesee 40-1 01703017A03 ‘The affected pages are indicated by the use of the following marks. It is requested that necessary actions ‘must be taken to these pages according to the list below. Mark Indication Action required © | Page to be newly added Add © | Page to be replaced Replace (1 | Page to be deleted Discard Pages having no marks are not revised at this time, LIST OF REVISED PAGES Mark Pages Peso” | ark pages FSO | mark pages REVO" [an Pages Mark Pages Revision a) 10-12 1087 10-95 10-135 0-2 10-14 1058 10. 96 10-135. © 0-21 @ 10-15 1059 10. 97 10-138 @ 20226 | © 016 1061 10. 98 10-137 © 00 23 10-417 10-62 10. 9 10-138, 003 10-18 10-63 10-100 © 0139 © 00 10-18 10-68 10-101 Ow @ 00-5 10-20 1048, 10-102 201 0 00- 6 10-22 10-66 10-103, e@2w 26 00. 7 10-23 1067 10-108 © 2 216 00. 8 10-24 10-68 10-105, @2 3 © 00- 9 10-25 10-69 10-106, e220 4 @ 00-10 10-26, 10-70 10-107 20 5 © 00-11 10-27 10-71 @ 10-108 © 20 6 @ 00-12 10-28 e072 © | © 0109 6 2 7 © 00-13 10-29 © 07% © @ 10-110 © 2 8 © 00-14 10-30 @ 075 ® 10-111 ® 2 9 ® 00-15 10.31 076 @ 1112 @ 20.0 © 00-16 10-32 07 & 0.113 @ 20-101 © 00-17 10.33 1078 0-114 © 2102 © on 10-36 1079 10-115 20-103 © on 2 1035 10-80 10-116 20-108 or 3 10:36, 10-81 10-117 20-105 @ ens @ 10.37 1082 10-118 20-108. @ ens © 10.38 1083 10-119 20-107 © ens © ws @ | © we © 10-120 20-108 @ O17 © 10-40 10-85 10-121 | @ 20-109 © eons © 10-41 1086 10-122 © 20-1094 ers © 0-42 10-123 © 2010 © eo © 1043 10-124 © 2011 © on 10-46 ° 10-125, 12 o 2 1045 8 10-126 20.113 @ 10-1 10-46 9 10-127 20-114 © 10-2 10.47 ° 10-128 @ 20-115 @ 10-3 10-48 O 10895 © @ 10-129 ® 20-116 OD 10- 4 10-49 O 10896 © O 10-129-3@ 20-117 © 10-5 10.50 © 1090 © | o wi2946 20-118 @ 10-6 1051 1091 (10-130) 20-119 @ 10-8 wsz @ | ow @ |e wis © 20-120 @ e@09 © 10-53 O 1091-2 ® 10-132 20-121 @ 10-10 10-54 1093 10-133 20:12 © 10-11 10-56 10.96 @ wi @ |e 214 © 00-2-1ark Pages F812” Tarark pages POON | Mark Pages REVS | Mark Pages Reo” | Mark PAGES Heber 20-128 @ 20-402 20-812 @ 30-34 @ 30- 83-1 @ © 20-1251 20-403. © 20.813 © 3035 30-832 @ © 20:15 3) 20-404 284 © 3038 @ 30-8 @ 20.127 © 20-405 © 20-815 © 2037 @ 30-85 20-128 © 20-408 pss @ | © 3038 © 30-88 @ 20-19 © 20.407 © 20.817 © 3039 @ 30-87 @ 20-130 @ 20-408 @ 20-818 30-40 @ 30-88 @ 20131 © 20-409 20-820 © 3041 30-89 @ 20.12 © 20-410 @ 2081 @ | © 3042 © 30:99 @ 20-133 @ 20-411 @ 20-822 @ e@ 3043 © 30-91 @ 20138 20.412 © 20-823 @ | 0 30432 © 3092 @ 20-135 @ 20-413 @ 20-824 @ O 30433 © 30-93 @ 20.138 © 20-416 20-88 @ | 0 30434 © 20-94 20.137 © 20-415 © 20827 @ | 0 30435 © 30:95 @ 20.138 © 20-418 20-828 © | 0 30438 © 30-96 © 20.139 © 20.417 O 20-229 @ | 0 30437 © 3097 © 20-140 © 20-418 @ 20890 @ | 0 30438 © 30-98 @ 20-201 © 20-419 @ 20.631 © 3044 30-99 @ 20-202 @ 20-420 @ 20-832 @ 30-45 @ 30-100 @ 20-203 @ 20-421 @ 20-833 © 30-46 @ 30-101 @ 20-208 @ 20-422 @ 20-834 30-47 @ 30-102 @ 20-205 @ 20-423 @) 20-835 @ 30-48 30-103 @ 20-206 @ 20-701 OD 20-836 @ 3049 30-104 @ 20-207 @ 20-702 OD e232 16 3050 @ 30-105 @ 20-208 @ 20-703 @ 30-2 © 3051 @ 30-106 @ 20-209 @ 20.706 @ | @ 3 218 3052 @ 30107 @ 20.210 @ 20.705 @ | @ 20 3 © 3053 @ 30-108 @ 20.21 @ 20.706 © | @ 20 4 3054 30109 @ 2022 © 20.107 © 05 @ 3055 @ 3010 @ @ 20213 © 20-708 @ - 6 @ 30-56 @ 30-111 @ © 2024 © 20.710 © 7 @ 3057 @ a2 @ O 2021420 27 © 20 8 3058 @ 30-113 @ © 202430 vz @ |e x 9 ® 3059 @ 30114 @ O 202446) 20.713 © 30. 10 © 060 @ 20115 @ 20-215 274 @ |e on 2061 20116 @ 20.218 @ 20.715 @ | @ 20 2 @ 32062 @ 30117 @ 20.217 @ 20-716 ® | @ 20-13 © 3063 @ 30118 @ 20.218 @ 277 @ |e 0 4 © 3064 30.119 @ 20-219 @ 20-718 © 0-15 @ 3065 30-120 @ 20-220 20.119 © 20-18 @ 3068 20.11 @ 20.221 @ 20-720 © 20-17 @ 3067 @ 3012 @ 20-222 @ 20-721 @ 3018 @ 3068 @ 30-123 @ @ 20-223 © 20-722 @ 30 19 @ 30-69 © 30-124 @ 20-224 @ 20-723 @ 30- 20 @ 30-70 @ 30-125 @ 20-228 @ 20-724 @ 30- 21 @ 30-71 @ 30-126 @ 20-226 20-801 @ 30- 22 @ 30-72 @ 30-127 @ 20-227 @ @ 20-802 © 30- 23 @ 30-73 @ 30-128 @ 20-301 © O 20-802-1@ 30- 24 @ 30-74 @ 30-129 @ © 20902 © 20-803 © 30 25 @ 3075 @ 30130 @ 20-303 @ 20-804 @ 30- 26 @ 30-76 @ 30-131 @ © 20304 © 20-805 © 30- 27 @ 30-77 @ 30-132 @ © 20:204620 20-006 30 28 @ 2078 @ 30133 @ © 20-2043. 20-007 @ | @ 20-29 ® 3079 @ 30184 © © 20-304-4 ©) 20-808 D © 20-30 © 30-80 @ 30-135 @ 20.305 © 20-809 © 3031 @ 3081 @ 30.138 @ 20-308 © 20.80 © 30 32 @ 3082 @ 30137 @ 20-401 2081 20-33 @ 3083 30138_@ 00-2-2 017A03Mark Page® Kimber [Mor Pages Remsen | Mark Pages ROS lar Pages POON | rar, pages Revision 30139 @ 30.193 © 30288 ® 30298 W058 3038-1 @ 30-194 @ 30289 © 1 4055, 30-140 30-195 @ 30-250 @ 4 2 4056 30.141 30196 30-251 @ 40 3 4057 30-42 30197 @ 30252 2) wo 4 4058 30-43 30-198 @ 30253 @) 4 6 40-60 30-144 30-199 30-284 @ 07 4061 30-145 30200 @ 30-285 @ 40 8 30-148 30201 ® 30-256 @ “9 30-147 @ 30202 © 30257 @) 40-10 30148 2) 30203 @ 30258 @) on 30-149 @ 30-204 @ © 30259 © 40- 12 30-150 30205 @ | @ 30-260 © 40.13 30-152 @ 20206 2 | © 30261 © 40 14 30-183 @ 30207 @ | 0 3026-16 40. 16 30-154 30208 @ | 0 30.2612 017 ate 30-155 @ 30-209 @ @ 30262 © 40-18 30.158 © 3210 ® | © 30263 © 40. 19 30.157 @ got @ | 0 20-2616 40. 20 30-188 @ w22 © | 0 202026 40.21 30-189 @ w2210 | © 2026 © 40 2 30180 @ 302122 | @ 30265 « 40. 23, 30-161 @ 30-213 @ oO 40- 24 30-162 @ 30-214 @ ° 40- 25 30-163 @ 30-215 @ ° 40- 26 . 30-164 @ 30-216 @ . 40- 28 2 30-165 30-217 @ 40. 29 s 30-188 30218 © 30-288 ® 40. 30 5 30187 @ 30219 @ 30269 ® 40-31 30-188 @ 30.220 © 30270 ® 40. 32 30-169 30-221 @ 30-271 @ 40- 34 30-170 30-222 @ 30-272 @ 40-35 30.171 @ 30223 ® 30273 @ 40. 36 3017 @ 30224 © 3024 © 40-37 30173 @) 30225 © 30275 ® 40. 38 Ba 30-178 @ 30-226 @ 30-276 @ 40- 39 30.175 © 30227 @ 3027 @ 40. 40 30-176 @ 30-228 @ 30-278 @ 40- 41 30.17 @ 30228 © 027 ® |e 042 © 30-178 @ 30230 @ 30280 © | 0 4220 (30-179 @ 30-231 @ 30-281 @ OD 40- 423 © 30-180 @ 30-232 @ 30-282 @ @ 0-43 © 30181 ® 30.233 @ 30-283 © 40. 44 30-182 @ 30-234 30-28 © 40. 45 a0183 @ | @ 30235 30-285 © 40. 46 30-184 @ 30-236 3028 @ | @ 47 © 30-185 30-237 3027 @ | 0 4726 30-186 30-238 30-288 @ O 40- 47-3 @ 30-187 30-239 30-289 @ O 40-474 30-1871 @ 30-240 3029 @ | 0 «756 30-187-2 @ 30-241 30-291 @ O 40-476 @ 30-187-3 @ 30-242 30-292 @ 40-48 30.188 @ 30-248 30293 20. 49 30-189 © 30-244 30294 @ 40. 50 30-190 @ 30245, 30-295 @ 40-51 = 30.191 30-246 30298 @ 40.82 30.192 @ 30-247 30297 @ 40-53 00-2-3SAFETY SAFETY SAFETY NOTICE SAFETY NOTICE IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol i is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed care- fully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation, GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine, 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. * Always wear safety glasses when hitting parts with a hammer. « Always wear safety glasses when grind- ing parts with a grinder, etc. 3. If welding repairs are needed, always have a trained, experienced welder carry out the work, When carrying out welding work, al- ways wear welding gloves, apron, hand shield, cap and other clothes suited for weld- ing work. 4, When carrying out any operation with two ‘or more workers, always agree on the oper- ating procedure before starting. Always in- form your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them. 6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. ‘Smoke only in the areas provided for smok- ing. Never smoke while working. PREPARATIONS FOR WORK 7. Before adding oil or making any repairs, ark the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving, 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the contro! levers and hang warn- ing signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10. Remove all mud and oil from the steps or other places used to get on and off the ma- chine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. 00-3SAFETY SAFETY NOTICE PRECAUTIONS DURING WORK 19. Be sure to assemble all parts again in their original places. 11. When removing the oil filler cap, drain plug Replace any damaged parts with new parts. or hydraulic pressure measuring plugs, ‘« When installing hoses and wires, be sure loosen them slowly to prevent the oil from that they will not be damaged by contact spurting out. with other parts when the machine is be- Before disconnecting or removing compo- ing operated. nents of the oil, water or air circuits, first 99. When installing high pressure hoses, make remove the pressure completely from the sure that they are not twisted. Damaged aes tubes are dangerous, so be extremely care- 12. The water and oil in the circuits are hot ful when installing tubes for high pressure when the engine is stopped, so be careful circuits. Also, check that connecting parts not to get burned. are correctly installed. Wait for the oil and water to cool before 21, when assembling or installing parts, always carving out ern, Wone on the) OLY use the specified tightening torques. When eae installing protective parts such as guards, 13, Before starting work, remove the leads from or parts which vibrate violently or rotate at the battery. Always remove the lead from high speed, be particularly careful to check the negative (-) terminal first. that they are installed correctly. 14, When raising heavy components, use ahoist_ 22. When aligning two holes, never insert your or crane. fingers or hand. Be careful not to get your Check that the wire rope, chains and hooks fingers caught in a hole. ere (ree omicemeger 23. When measuring hydraulic pressure, check Always use lifting equipment which has that the measuring tool is correctly assem- Semple eeu bled before taking any measurements. Install the lifting equipment at the correct places. Use @ hoist or crane and operate 24, Take care when removing or installing the slowly to prevent the component from hit- ting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under in- ternal pressure or under pressure from a spring, always leave two bolts in position ‘on opposite sides. Slowly release the pres- sure, then slowly loosen the bolts to remove. 16, When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18, As a general rule, do not use gasoline to wash parts. In particular, use only the mini- mum of gasoline when washing electrical parts. 00-4 tracks of track-type machines. When removing the track, the track sepa- rates suddenly, so never let anyone stand at either end of the track.FOREWORD GENERAL FOREWORD GENERAL This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components. ‘STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating "Problems" to "Causes" are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. MAINTENANCE STANDARD This section gives the judgement standards when inspecting disassembled parts. NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Use the specifications given in the book with the latest date. 00-5FOREWORD HOW TO READ THE SHOP MANUAL VOLUMES ‘Shop manuals are issued as a guide to carrying ‘out repairs. They are divided as follows: Chassis volume: Issued for every machine mode! Engine volume: Issued for each engine series Electrical volume: Each issued as one ‘Attachments volume: | volume to cover all models These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is neces- sary that chassis, engine, electrical and attach- ment volumes be available. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work. FILING METHOD 1, See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume): 3 tH |—Item number (10. Structure and Function) |_____Consecutive page number for each item. Example 2 (Engine volume): 12-5 Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item 3. Additional pages: Additional pages are indi- cated by a hyphen (-) and number after the page number. File as in the example. Example: 10-4 12-203 10-41 12-203-1 10.421 Added pages —[12.293-2 105 12-204 00-6 HOW TO READ THE SHOP MANUAL REVISED EDITION MARK When a manual is revised, an edition mark (DG...) is recorded on the bottom of the pages. REVISIONS Revised pages are shown in the LIST OF RE- VISED PAGES next to the CONTENTS page. SYMBOLS So that the shop manual can be of ample prac- tical use, important safety and quality portions are marked with the following symbols. tem Remarks ‘Special safety precautions are Safety | necessary when performing the work. ‘Special technical precautions fr other precautions for pre: Caution | serving standards are neces: sary when performing the work. ‘Symbol Weight of parts of systems. AN Caution necessary when se- eo Weight | lecting hoisting wire, or when ‘SM | working posture is important, ete. Places that require special at- tention for the tightening torque during assembly. [Tightening] torque Places to be coated with ad- hesives and lubricants, etc. res Places where oll, water or fuel il, water| must be added, and the ca pacity. ’ 4 — Coat Places where oil or water Drain | must be drained, and quan- tity to be drained.FOREWORD HOISTING INSTRUCTIONS HOISTING Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISAS- SEMBLY AND ASSEMBLY section, every part weighing 25 kg or mor indicated clearly with the symbol Cai") * If 2 part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existence of another part caus- ing interference with the part to be re- moved. WIRE ROPES 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard *Z" or *S* twist ropes without galvanizing) Rope diameter Allowable load mm KN tons 10 98 10 112 137 14 125 167 16 4 216 22 16 278 28 1B 35.3 3.6 20 43.1 44 22.4 54.9 56 30 98.1 10.0 40 176.5 18.0 50 274.6 28.0 60 392.2 40.0 * The allowable load value is estimated to be one-sixth or one-seventh of the break- ing strength of the rope used. 2) Sling wire ropes from the middle portion of the hook. HOISTING INSTRUCTIONS Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can re- sult. Hooks have maximum strength at the middle portion. 100% = 88% 79% 71% 41% sooo 3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. Slinging with one rope may cause turning of the load during hoisting, tuntwisting of the rope, or slipping of the rope from its original winding Position on the load, which can re- sult in a dangerous accident. 4) Do not sling a heavy load with ropes form- ing @ wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allow- able load KN (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 KN (1000 kg) vertically, at various hanging angles. ‘When two ropes sling a load vertically, up to 19.6 KN (2000 kg) of total weight can be suspended. This weight becomes 9.8 KN (1000 kg) when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 39.2 KN (4000 kg) if they sling a 19.6 KN (2000 kg) load at a lifting angle of 150°, a ) shtoo4se 00-7FOREWORD COATING MATERIALS The recommended coating materials prescribed in Komatsu Shop Manuals are listed below. COATING MATERIALS Coxagory [Komateu code] PartNo. [Gry | Container ain applications, features TSS preven bbe estts,ubber Savion U-14__ | 790-129-9030] 1509 Tube land cork plugs from coming out woe TL pwme | tet paces reuing a ied ee : a | Pranic | tv, strong edheswe. Used for pists loxcopt on 700-13 0 | (x2) ‘container polyethylene, polypropylene, tetrafluoroethylene, Ending cnonae)rabber meta ana nan*met ame | Features Resistance to heat. chemicals x2 | os010-00030 ] soo | iste, |: Used‘or amtioosering and selon purposes for Adhesive pote 1d plugs. = i ive [Used as aches ors Tra os lie reo vene |e he Torta i, la Beat ache 73 facing] Madina] an oon - ea | veo. | 2e09 | Fie, [> Uae a mat Tor machined os = Foatras Reson Toa, do tects 648-0)| 700-129-8110] soe | — | Used at ait portions suet Yo gh tempers i Ua ae BARGRTE oF Sala TOF Gates nd ter | re0-1a0-s010| 2000 | tube |" psSags ctnona’ wan ane be Fostures: Resistance to best 1 UMLUSS eatat for ange surfaces and bolts at hightemperature locations, used 0 prevents ues | rso-r2o.s070| 19 | can | SPP " + BE a satan for hat esistant gasket fr hgh ‘epmtreonion suchas ng rocombusion ‘Samer shaun pe Fares: Ressonco to watr oT 1 Uita'ae estan for ange star, thre 190-128-902 1 Ao possi to us a0 Sealan for flanges with tu re oe Gasket sealant| ios o Sees ta rge clearance + Usb as tote for mating surfaces of frat cive coco, anamaion ca Used a Salant for vars HERG, pipe om us-s | 790-129-9080 Pract |. Ueda ~ bea! ‘container |* Used as sealant for tapered plugs, elbows, nip- ples of hydrate ising [Fetus Sion based, etane To Tea cad cs | ovsuoooors | 2509 | Tube |* Used a sealant for tage surface, thread {USS 8 Seat foro ganna deve case Features Sligo bivod quik hardening ype ve-7 | oooaoaniso | 1509 | tune |: Used nseatan or tyres! mousing make mnt foi al pan, memos nousng, ee. Raat reve 7"Used: as lubricant Tor siding pats To prevent tion lubricant eS = ea i squeaking) ‘Mahyenum Ud to prover sour or fing af Th Tad te | osero-ooo40 | 2009 | Tube | when pres iting or shrink iting - Unod Sctubrcan or kage, bearings eso Gene ures pe secu) Usumgren| —c2-u—|Sye-ao0ll-a | various | varius veto! Svea eocNu SSGE-0CK 7 Us To nara epee Ta Toad bean Sree places in contact win water or steam casumgrsse] Gz-ca|Svaz-oncA-a| Vorious | Vaio Svee-re0ca Sven t9oNcA aA 7 TST AS WA HOY TORT seo — | svaz-s00m | 122, Betows type 00-8FOREWORD STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUES OF BOLTS AND NUTS The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in section of DISASSEMBLY AND ASSEMBLY. 1 Kgm = 9.806 Nm Thread diameter Width of bolt across flats mm mm kgm 6 10 13.2214 1.3540.15 8 13 31.4429 3.2403 10 ” 65.7468 6.7207 2 19 112498 11.5210 “4 2 177419 18.0£2.0 16 24 279229 28.543 18 27 383439 3924 20 30 549458 5626 2 32 745478 7628 28 36 927498 94.510 2 a 1320140 135415 30 46 17204190 175420 33 50 | 2210240 225425 36 55 2750+290 28030 39 60 32804340 33535 * This torque table does not apply to the bolts with which nylon packings or other nonferrous metal washers are to be used, or which require tightening to otherwise specified torque.FOREWORD STANDARD TIGHTENING TORQUE TIGHTENING TORQUE OF SPLIT FLANGE BOLTS Use these torques for split flange bolts. Thread diameter Width Sse ‘of bolt across flats Tightening torque mm mm Nm kgm 10 4 65.7268 6.7407 R a 112298 11541 16 2 279429 28.543 Sealing surface TIGHTENING TORQUE FOR FLARED NUTS Use these torques for flared part of nut. Thread diameter | Width across flats a ‘of nut part of nut part Tightening torque mm mm Nm kgm 4 19 24.5449 2.5205 18 24 49419.6 522 22 27 78.54 19.6 B22 24 32 137.3429.4 1443 30 36 176.5+29.4 1843 33 a 196.1249 2045 36 46 245.2449 255 42 55 294.2449 305 00-10FOREWORD ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to in. This wire code table will help you understand WIRING DIAGRAMS. Example: SWB indicates a cable having a nominal number 5 and white coating with black stripe. CLASSIFICATION BY THICKNESS ELECTRIC WIRE CODE ate the thickness of wires. Nominal ene Cable 0.0. [current rating number | Numbey of [i of srandeCrons secon) “tin iar Applicable circuit 0.85 7 0.32 oa 24 12 | Starting, ighting, signal etc. 2 26 0.32 2.09 34 20 | Lighting, signal etc. 5 65 0.32 5.23 48 37 | Charging and signal 15 84 045 13.36 70 59 | Starting (Glow plug) “0 85 0.80 4273 4 135 | starting 60 127 0.280 e384 136 ve | staring 100 217 0.80 109.1 16 230 | starting CLASSIFICATION BY COLOR AND CODE Circus Pao" fowast | Charing | Ground | staring | toting | instrument | signet | other pi. [Code] W 8 8 R Y G t " [IM |coior! white | lock | Block Red Yellow | Green Blue Code] WR = ew RW YR ow Ww ‘ Color] White & Red] — [Black & White|Red & white [Yellow & Red|Green & White|Biu & White : Code] we = By Re ve GR La Color[ White & Black] — lack & Yellow] Red & Black [Yetow & Black [Green & Red Blue & Red « fame [eosel_we = BR RY YG cy wy Color|White & Bue] — __ | Black & Red [Red & VellowWeliow & Greenfereen & VeliowBlue & Vellow : Code] WG = = RG YL GB 1B Cotor|wnite & Green] — = ___ [fred & GreenfYetiow & BlueGreen & Black) Biue & Black : code] — 7 = RL ww cu 7 color] — 7 = _ | Fed & Biue fretow & whitelGreen & Blue] — 00-11FOREWORD CONVERSION TABLE CONVERSION TABLE METHOD OF USING THE CONVERSION TABLE The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. EXAMPLE ‘« Method of using the Conversion Table to convert from millimeters to inches 1. Convert 55 mm into inches. (1) Locate the number 50 in the vertical column at the left side, take this as @), then draw a horizontal line from @. (2) Locate the number 5 in the row across the top, take this as @, then draw a perpendicular line down from ®. (3) Take the point where the two lines cross as @. This point © gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. 2. Convert 50 mm into inches. (1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to convert it to 55 mm. (2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. (3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches. ‘mm = 0.03937 in 0 1 2 3 4 6 7 8 9 o jo 0.039 | 0.079 | 0.118 | 0.157 0.236 | 0.276 | 0.315 | 0.354 10 | 0.394 | 0.433 | 0.472 | 0.512 | 0.551 0.630 | 0.669 | 0.709 | 0.748 20 | 0.787 | 0.827 | 0.866 | 0.906 | 0.945 1,024 | 1.063 | 1.102 | 1.142 30 | 1.181 1.220) 1.260 1.339 1.417 | 1.457 | 1.496 | 1.536 40 | 1.575 | 1.614 | 1.654 1.732 1.811 | 1.850 | 1.890 | 1.929 2.205 | 2.244 | 2.283 | 2.323 2.598 | 2.638 | 2.677 | 2.717 2.992 | 3.032 | 3.071 | 3.110 3.386 | 3.425 | 3.465 | 3.504 3.780 | 3.819] 3.858 | 3.898 ® 2.520 2.913 3.307 3.701 00-12FOREWORD Millimeters to Inches CONVERSION TABLE ‘1mm = 0.03937 in 1 3 4 5 6 7 8 9 0 0 0.039 | 0.079 | 0.118 | 0.187 | 0.197 | 0.236 | 0.276 | 0.315 | 0.354 10 0.394 | 0.433 | 0.472 | 0.512 | 0.551 | 0.591 | 0.630 | 0.669 | 0.709 | 0.748. 20 0.787 | 0.827 | 0.866 | 0.906 | 0.945 | 0.984 | 1.024 | 1.063 | 1.102 | 1.142 30 1.181 | 1.220 | 1.260 | 1.299 | 1.339 | 1.378 | 1.417 | 1.457 | 1.496 | 1.536 40 1.875 | 1.614 | 1.654 | 1.693 | 1.732 | 1.772 | 1.811 | 1.850 | 1.890 | 1.929 50 1.969 | 2.008 | 2.047 | 2.087 | 2.126 | 2.165 | 2.205 | 2.244 | 2.283 | 2.323 60 2.362 | 2.402 | 2.441 | 2.480 | 2.520 | 2.559 | 2.598 | 2.638 | 2.677 | 2.717 70 2.756 | 2.795 | 2.835 | 2.874 | 2.913 | 2.953 | 2.992 | 3.032 | 3.071 | 3.110 80 3.150 | 3.189 | 3.228 | 3.268 | 3.307 | 3.346 | 3.386 | 3.425 | 3.465 | 3.504 90 3.543 | 3.583 | 3.622 | 3.661 | 3.701 | 3.740 | 3.780 | 3.819 | 3.858 | 3.898 Kilogram to Pound kg = 2.2066 Ib ° 1 2 3 4 5 6 7 8 9 0 0 220| 441! 661] 882| 11.02] 13.23| 15.43] 17.64| 19.84 10 22.05 | 24.25| 26.46 | 28.66] 30.86| 33.07) 35.27| 37.48| 39.68| 41.89 20 44.09 | 46.30] 48.50| 50.71) 51.91| 55.12] 57.32| 59.53] 61.73| 63.93 30 66.14] 68.34 70.55| 72.75] 74.96] 77.16) 79.37| 81.67| 83.78| 85.98 40 88.18 | 90.39] 92.59| 94.80] 97.00| 99.21/ 101.41 | 103.62 | 105.82 | 108.03 50 110.23 | 112.44 | 114.64 | 116.85 | 119.05 | 121.25 | 123.46 | 126.66 | 127.87 | 130.07 60 182.28 | 134.48 | 136.69 | 138.89 | 141.10 | 143.30 | 145.51 | 147.71 | 149.91 | 152.12 70 154.32 | 156.53 | 158.73 | 160.94 | 163.14 | 165.35 | 167.55 | 169.76 | 171.96 | 174.17 80 176.37 | 178.57 | 180.78 | 182.98 | 185.19 | 187.39 | 189.60 | 191.80 | 194.01 | 196.21 90 198.42 | 200.62 | 202.83 | 205.03 | 207.24 | 209.44 | 211.64 | 213.85 | 216.05 | 218.26 00-13FOREWORD CONVERSION TABLE Liter to U.S. Gallon 1¢ = 0.2642 US. Gal 0 1 2 3 4 5 6 7 8 9 0 0 0.264 | 0,628 | 0.793 | 1.057 | 1.321 | 1.585 | 1.849 | 2.113 | 2.378 10 2.642 | 2.906 | 3.170 | 3.434 | 3.698 | 3.963) 4.227 | 4.491 | 4.755 | 5.019 20 5.283 | 5.548 | 5.812 | 6.076 | 6.340 | 6.604 | 6.869 | 7.133 | 7.397 | 7.661 30 7.925 | 8.189 | 8.454 | 8.718 | 8.982 | 9.246 | 9.510 | 9.774 | 10.039 | 10.303, 40 10.567 | 10.831 | 11.095 | 11.369 | 11.624 | 11.888 | 12.152 | 12.416 | 12.680 | 12.944 50 13.209 | 13.473 | 13.737 | 14.001 | 14.265 | 14.529 | 14.795 | 15.058 | 15.322 | 15.586 60 15.850 | 16.115 | 16.379 | 16.643 | 16.907 | 17.171 | 17.435 | 17.700 | 17.964 | 18.228 70 18.492 | 18.756 | 19.020 | 19.285 | 19.549 | 19.813 | 20.077 | 20.341 | 20.605 | 20.870 80 21.134 | 21.398 | 21.662 | 21.926 | 22.190 | 22.455 | 22.719 | 22.983 | 23.247 | 23.511 90 23.775 | 24.040 | 24.304 | 24.568 | 24.832 | 25.096 | 25.361 | 25.625 | 25.889 | 26.153 Liter to U.K. Gallon 1 = 0.21997 UK. Gal 0 1 2 3 4 5 6 7 8 9 0 0 0.220 | 0.440 | 0.660 | 0.880] 1.100] 1.320} 1.540] 1.760) 1.980 10 2.200 | 2.420 | 2,640| 2.860 | 3.080] 3300| 3.520/| 3.740] 3.950] 4.179 20 4.399 | 4.619 | 4.839} 5.059 | 5.279| 5.499) 5.719] 5.939] 6.159] 6.379 30 6599 | 6819 | 7.039 | 7.259 | 7.479| 7.969| 7.919| 8.139] 8359 8.579 40 8.799 | 9.019 | 9.239 | 9.459 | 9.679 | 9.899 | 10.119 | 10.339 | 10.559 | 10.778 50 10.998 | 11.281 | 11.438 | 11.658 | 11.878 | 12.098 | 12.318 | 12.528 | 12.758 | 12.978 60 13.198 | 13.418 | 13.638 | 13.858 | 14.078 | 14.298 | 14.578 | 14.738 | 14.958 | 15.178 70 15.398 | 15.618 | 15.838 | 16.058 | 16.278 | 16.498 | 16.718 | 16.938 | 17.158 | 17.378 80 17.598 | 17.818 | 18.037 | 18.257 | 18.477 | 18.697 | 18.917 | 19.137 | 19.37 | 19.577 90 19.797 | 20.017 | 20.237 | 20.457 | 20.677 | 20.897 | 21.117 | 21.337 | 21.887 | 21.777FOREWORD CONVERSION TABLE kgm to ft. tb kgm = 7.233 ft. Ib I 0 1 2 3 4 5 6 7 8 9 0 o 72) 145) 217) 289] 362] 434] 506| 579| 65.1 10 723) 79.6] 868| 940} 1013} 1085 | 115.7 | 1230 | 130.2 | 137.4 20 144.7 | 151.9 | 159.1 | 166.4 | 1736 | 180.8 | 188.1 | 1953 | 2025 | 2098 30 217.0 | 224.2 | 231.5 | 238.7 | 245.9 | 263.2 | 260.4 | 267.6 | 2749 | 282.1 40 289.3 | 296.6 | 3038 | 311.0 | 3183 | 3255 | 332.7 | 340.0 | 347.2 | 3544 50 361.7 | 368.9 | 376.1 | 383.4] 3906 | 3978 | 405.1 | 4123 | 4195 | 4268 60 434.0 | 441.2 | 448.5 | 455.7 | 4629 | 470.2 | 477.4 | 484.6 | 491.8 | 499.1 70 806.3 | 513.5 | 5208 | 528.0 | 535.2 | 542.5 | 549.7 | 5569 | 564.2 | 571.4 80 578.6 | 585.9 | 593.1 | 600.3 | 607.6 | 6148 | 622.0 | 6293 | 636.5 | 643.7 90 651.0 | 658.2 | 665.4 | 672.7 | 679.9 694.4 | 701.6 | 708.8 | 716.1 100 723.3 | 730.5 | 737.8 | 745.0 | 7522 | 759.5 | 766.7 | 7739 | 781.2 | 788.4 110 795.6 | 8029 | 810.1 | 817.3 | 824.6} 831.8 | 839.0 | 8463 | 853.5 | 860.7 120 868.0 | 875.2 | 882.4 | 889.7 | 896.9 | 904.1 | 911.4 | 918.6 | 925.8 | 933.1 130 940.3 | 947.5 | 954.8 | 962.0 | 969.2 | 976.5 | 983.7 | 990.9 | 998.2 | 1005.4 140] 1012.6 | 1019.9 | 1027.1 | 1034.3 | 1041.5 | 1048.8 | 1056.0 | 1063.2 | 1070.5 | 1077.7 160 | 1084.9 | 1092.2 | 1099.4 | 1106.6 | 1113.9 | 1121.1 | 1128.3 | 1135.6 | 1142.8 | 1150.0 160 | 1167.3 | 1164.5 | 1171.7 | 1179.0 | 1186.2 | 1193.4 | 1200.7 | 1207.9 | 1215.1 | 1222.4 170 —|1129.6 | 1236.8 | 1244.1 | 1251.3 | 1258.5 | 1265.8 | 1273.0 | 1280.1 | 1287.5 | 1294.7 180 | 1301.9 | 1309.2 | 1316.4 | 1323.6 | 1330.9 | 1338.1 | 1345.3 | 1952.6 | 1359.8 | 1367.0 190 | 1374.3 | 1381.5 | 1388.7 | 1396.0 | 1403.2 | 1410.4 | 1417.7 | 1424.9 | 1432.1 | 1439.4 00-15FOREWORD kg/om? to Ib/in? CONVERSION TABLE tkglom? = 14.2233 Ibyin? 0 1 2 3 4 5 6 7 8 9 0 0 142| 284] 427| 569] 71.1] 853 99.6 | 1138] 128.0 10 1422 | 1565 | 170.7 | 1849 | 199.1 | 213.4 | 227.6 | 241.8 | 256.0 | 270.2 20 2845 | 298.7 | 3129 | 327.1| 341.4 | 3556 | 369.8 | 384.0 | 3983) 4125 30 426.7 | 440.9 | 455.1) 469.4 | 483.6 | 497.8] 512.0 | 526.3 | 540.5 | 554.7 40 5689 | 583.2 | 597.4| 611.6 | 625.8 | 640.1| 654.3 | 668.5 | 6827 | 696.9 50 7112 | 725.4 | 739.6 | 7538 | 768.1 | 782.3 | 7965 | 810.7 | 8250 ) 839.2 60 953.4 | 867.6 | 881.8 | 896.1 | 910.3] 924.5 | 938.7 | 953.0 | 967.2 | 981.4 70 995.6 | 1010 | 1024 | 1038 | 1053 | 1067 | 1081 | 1095 | 1109 | 1124 go 1138. | 1152 | 1166 «1181 | 1195 | 1209 | 1223, | 1237 | 1282 | 1266 90 {1280 | 1294 | 1309 | 1323 | 1337 | 1351 | 1365 | 1380 | 1394 | 1408 yoo 1422 | 1437 [1451 | 1465 | 1479 | 1493 | 1508 | 1522 | 1536 | 1550 v0 | 1565 | 1579 | 1593 | 1607 | 1621 | 1636 | 1650 | 1664 | 1678 | 1693 120 1707 [1721 | 1738 | 1749 | 1764 | 1778 | 1792 | 1806 | 1821 | 1835 130 | 1849 | 1863 | 1877 | 1892 |1906 | 1920 | 1934 | 1949 | 1963 | 1977 140} 1991 | 2008 | 2020 | 2034 | 2048 | 2062 | 2077 | 2091 | 2105 | 2119 150 2134 | 2148 2162 |2176 |2190 | 2205 |2219 | 2233 | 2247 | 2262 160 | 2276 | 2290 | 2304 | 2318 | 2333 | 2347 | 2361 | 2375 | 2389 | 2404 170 |2are | 2432 | 2446 | 2460 | 2475 | 2489 | 2503 | 2518 | 2532 | 2546 180 | 2560 | 2574 | 2589 | 2603 | 2617 | 2631 | 2646 | 2660 | 2674 | 2688 190 2702 [2717 | 2731 | 2745 2759 | 2773 | 2788 | 2802 | 2816 | 2830 200 | 2845 | 2859 | 2873 | 2887 |2901 | 2916 | 2930 | 2944 | 2958 | 2973 210 | 2987 |3001 | 3015 | 3030 | 3044 | 3058 | 3072 | 3086 | 3101 | 3115 220 |3129 | 3143 | 3158 |3172 | 3186 | 3200 |3214 | 3229 | 3243 | 3257 230 |3271 [3286 | 3300 |3314 | 3328 |3343 [3357 | 3371 | 3385 | 3399 240 | 3414 | 3428 | 3442 | 3456 | 3470 | 3485 | 3499 | 3513 | 3527 | 3542 00-16FOREWORD ‘Temperature Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature ture reading or vice versa is to enter the accompanying table in the center or boldface column of figures. ‘These figures refer to the temperature in either Fahrenheit or Centigrade degrees. CONVERSION TABLE ing into a Centigrade tempera: It it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column atthe left. titi desired to convert from Centigrade to Fahrenheit degrees, consider the center column a and read the corresponding Fahrenheit temperature on the right. table of Centigrade values, °C = 33.8F °C oF °C oF °C oF °C oF 40.4 | 40 | -400 | 11.7 | 19 | 518 | 78] 46 | 148] 272] 81 | a178 372 | -35 | 310 | 11.1 | 12 | 536] 83} 47 | 1166] 278 | 82 | 1796 -344 | -30 | -220 | -106 | 13 | 554] 89} 48 | 1184] 283 | 93 | 1014 317 | -2 | -130 | -100 | 1 | 572] 94] 49 | 1202] 289 | 86 | 1832 289 | -20 | -40 | -94 | 15 | 590 | 100 | 50 | 1220 | 294 | 95 | 1850 283) -19 | -22 | -9 | 16 | eos | to6 | 51 | 1238 | 300 | 86 | 1868 218 | -18 | -04 | -83} 7 | 626 | 11.1 | 52 | 1256 | 306] 87 | 1886 212 | 17 14 | -78 | 18 | 644 | 117 | 53 | 1274 | 311] 98 | t904 267 | 16 32 | -72| 19 | 662] 122] 56 | 1292 | 317 | 99 | 1922 26.1 | -15 50 | -67 | 20 | 680 | 128] 85 | 1310 | 322} 90 | i960 25.6 | 14 6s | -61| 21 | 698 | 133) 56 | 1928 | a28 | a1 | 958 -250 | -13 as | -56 | 22 | 716] 139 | 57 | 1946 | 333 | 92 | 1976 264) 12 | 104 | -50] 23 | 734 | 144 | 58 | 1364] 339 | 93 | 1904 239 | 11 122 | -44 | 24 | 752] 150 | 59 | 1382 | 344 | g4 | 2012 233) -10 | wo] -3s | 25 | 70] 156} 60 | 140.0] 250 | 95 | 2030 -28) -9 | 8] -33/} 26 | 788 | 161 | 6 | 18 | 356 | 96 | 2008 22) -# | 176] 28] 2 | 206 | 167 1436 | 361 | 97 | 2066 27 | 7 | 194] -22 | 28 | 24 | 172] 6 | 454] 367 | 98 | 208.4 nar | 6 | 212] 17 | 29 | a2 | 178 | 64 | 1472 | 372 | 99 | 2102 206 | 5 | 230] -11/ 30 | 60 | 183 | 65 | 1490 | 378 | 100 | 2120 -200 | -4 | 28 | 6 | 31 | e7e| a9 | 66 | 1508 | 406 | 105 | 2210 ~194 | -3 | 266] 0 | a2 | e936 | 194) 67 | 1526 | 433 | 110 | 2300 -1899 | -2 | 24] 06 | 33 | 914 | 200 | 68 | 1544 | 461 | 115 | 2390 -183 | -1 | 302 | 11] 34 | 932 | 206 | 69 | 1562 | 489 | 120 | 2480 -178 | 0 | 320] 17 | 35 | 950 | 211 | 70 | 1580 | 517 | 125 | 2570 -72) 1 | 338 | 22 | 36 | 968 | 217 | 71 | 1598 | sae | 130 | 2660 -167 | 2 | 356 | 28] 37 | 986 | 222 | 72 | 1616 | 572 | 135 | 2750 -161 | 3 | 374] 33} 38 | 1004 | 228 | 73 | 1634 | 600 | 140 | 2840 -156 | 4 | 392] 39 | 39 | 1022 | 233 | 7 | 1652 | 627 | 145 | 2930 150 | 5 | 410 | 44] 40 | 1040 | 239 | 75 | 1670 | 656 | 150 | 3020 44) 6 | 428 | 50 | 41 | 1058 | 244 | 76 | 1688 | 683 | 155 | 3110 -139) 7 | 446 | 56) 42 | 1076 | 250 | 77 | 1706 | 711 | 160 | 3200 ~133/ 8 | 464] 61 | 43 | 1094 | 256 | 78 | 1724 | 739 | 15 | 3290 “128 ) 9 | 482] 67 | as | 112 | 261 | 79 | 1742 | 767 | 170 | 3380 122) 10 | soo | 72 | 45 | 1130 | 267 | 80 | 1760 | 794 | 175 | 347.0 00-17017403, 01 GENERAL Specification drawing. Specifications Weight table. Table of fuel,GENERAL SPECIFICATION DRAWING Semi U-tiltdozer + giant ripper SPECIFICATION DRAWING Unit: 2695, U-tittdozer + giant ripper De, eee — 3 GL 5 01-2 017803017A03 GENERAL SPECIFICATION DRAWING + Semi U-tiltdozer + multi-shank ripper + U-tiltdozer + multi-shank ripper Unit: me 4265, 2080 2260 2695GENERAL SPECIFICATIONS SPECIFICATIONS Machine model D155A-3 Serial number ‘60001 - 60271 60272 and up _z | Bare tractor 27,900 £ . = ‘38,000 2 é Minimum turning radius (center of machine) m 1.05 Gradeability dog 30 ‘Stability (front, rear, left, right) deg 35 ol .| 37 3/8 5 |2| 2nd kn 67 gle B| | a 110 5 Ist 50 f/2\¢ £|5] 3| ana kev 82 giele e\r ard 139 | Bare tractor 76.48 (0.78) § | With semi U-dozer + variable mul-shankrp- 103.94 (1.06) § | por « ROPS + cab + air condone + side g | cover Pa § | With U-dozer + variable multi-shank ripper + Akg/orn’) 106.88 {1.09} | ROPS + eab + air conditioner + side cover $| Bare tractor 4975 | with semi U-dozer + variable mutt-shank rip- 8,185 = | per mm : With U-dozer + variable multi-shank ripper 8,550 «| & | Bare tractor 2,695, 2 | § | with semi U-dozr+ variable mult-shank ip- 3.955 #| S| per mm 3 | § | with U-dozer + variable multi-shank ripper 4265, E | To top of exhaust pipe 3,395 2 | To top of cab mm 2,580 § | (top of contol ever é 0170301703 GENERAL SPECIFICATIONS Machine model D155A-3 Serial number 60001 - 60271 | 60272 and up E | With cab installed 3,365 = | With ROPS canopy installed mm 3,500 4, | S| With canopy instated 3.500 # | Track gauge 2,100 E | Length of track on ground (mm) 3210 Track shoe width (standard) mm 560 Minimum ground clearance 485, (To bottom surface of undercover) Name $6D140-1 SA60140-2 , water-cooled, | 4oyde, water cooled, n- ‘Type of engine in-line, vertical type, | line, vertical type, direct Gireet ‘injection, with | injection, with turbo: turbocharger charger and altercooker No. of cylinders - Bore x Stroke mm 6-140x165 6140x165, Piston displacement ce 18.24 (15,240) 15.24 (15,240) Flywheel horsepower |kWirpm(HP/rpmi} 225/1,900 (608718007 — 3 © | 2 | Max. torque |Nevepetkgrvrpm) 1,482/1,250 (146/1,250) 2 | & | Max. speed at no toad rpm 2,050 aie] B | & | Min. speed at no toad tom = Min. fuel consumption ratio gkWhig/HPh} 205 (1) Starting motor 24v, TW Alternator 24V, 35 Battery 12V, 170An2 Radiator core type D7 3 3.element, single-stage, single phase _ | Toraue conver ieaiike i Planetary gear, multiple dise clutch, hy: 3 Graulicaly actuated, force-feed lubrication | transmission geer pump, forward 2speed, reverse 3 speed, manual mechanical typeGENERAL SPECIFICATIONS Machine model DI155A-3 Serial number 60001 - 60271 60272 and up Bevel gear shaft Spiral bevel gear, force-eed lubrication gear pump g ‘Wet type, multiple clutch disc, spring boosted, manual S & Steering clutch type, hydraulically actuated le Wet type, multiple clutch disc, spring boosted, intercon- 3 | B| steering brake rected with clutch, pedal operated, manually operated, alg hydraulically actuated i fia ‘Spur gear 1-stage, planetary gear 1-stage, splash type one lubrication Suspension Rigid, balancing beam type F corr rote 2 ach side 3 | Track roller 6 each side 5 Track sho (standrd shoe width: 56 mm) | ABSEMBIY pe single grower, 4T wah side, ph: 2286 Power train + lubrication pump (tandem) Gear type (SAL(3}80+100) ‘Scavenging pump Gear type (112) PPC charge pump (tandem with hydraulic pump (SAR(4)112)) Gear type (SAR(1)10) Max. delivery pressure : 3.7 MPa (38 kg/cm’) ‘Theoretical delivery : 22 &¢/min/2,223 rpm 5 cctype sant $ | Hydraulic pump (tandem) ‘Max. delivery pressure : 20.6 MPa (210 kglem’ 2 Theoretical delivery: 249 thminv2.223 rpm =| | te 21+ tandem spool type, hydraulically asisted type eo aoe Ripper tlt + ripper lift + blade lift + blade tit 2 | E| For age wn | 2] - For reper it 5 | 3) «For ripper tit 01-6 :01703 GENERAL SPECIFICATIONS Machine model DIS5A-3 Serial number soot 60271 60272 and up Tyee Reciprocal, piston type 8) cvinder toe 120 ‘© | Piston rod outer diameter 15 8) sox piston se a 130 Max. distance between pins 317 Min distance between pins 1398 8) cinder toe 120 e 5 © | Piston rod outer diameter 90 A st piston she [eee 160 5/21 | ax cistance betweon pins 1488 3 || © | min. distance between pins 1308 32 aa BJ evint tor 200 5] | ron od oer cameo 0 2 4 Max. piston stroke mm 160 2 5 | Max. nce between pins 1,468 i Min. distance between pins 1.308 B) cytnaer ore 160 £ | riston rod outer diameter oo | stax piston stroke — sto ; Max distance between pins ey i eae i 2) cinder bore | 160 © | Piston rod outer diameter 80 By sex ston ote 20 Max ditance between pins 1546 Min. distance between pins 1195 ° Oe NGENERAL SPECIFICATIONS Machine model D155A-3 Serial number 0001 - 60271 0272 and up Hydraulic tan Box type (control valve externally installed) Type Hydraulic smi Utitdozer, hydraulic Utitdozer Blade support method Brace type (right tit eyinder Blade iting height (rom ground tevel)_| rom 1.250 § | Blade lowering depth (from ground level) | mm ‘590 | 5 | Ma tae omen 1.000 8 | blade curing ange variation cog +6 2 |__| bine capacity m= a9 8 | 2) Blade with mm 3985 & | blade height mm 1720 _] JE ate cutine ance eg 2 E Blade iting height (from ground level) mm 1,250 |_| £ | ade lowering dest trom ground level | mm 590 B) | S| mex ocean mm 1.080 - |B | Blade cuting ensie variation deg +6 3] _| Blade capacity ™ 118 < SAE 13.2> 3 2] eiade wisth mm 4205 § | sae non mm 70 8 | piade outing angle og = & 2 |B] Max sit mm 1,000 8 | E] max. piten angle deg 6 3) 5 | ex. pch-beck anole to 6 = B al a|Noe mm 1.000 | 5 | Max pitch anole eg 6 BB Mex nent aa eg = 017803,017803, GENERAL ‘SPECIFICATIONS Machine mode! D155A-3 Serial number 60001 - 60271 60272 and up | Max. digging depth mm 870 | | Mos ttng height mm 5 2 € | ripping angle of point dog 345-60 ele & | | Max. beam width mm 2,260 3 | 8 | shank postions No. of holes 2 E 3 2 & é) |g AS a 3] |B] Max titing height mm 925 5 | E | Ripping angle of point deg (34.5 - 60 he : Baltes aan = 1s 8/5 | Shank positions No. of holes 3 E 6GENERAL WEIGHT TABLE WEIGHT TABLE A This weight table is a guide for use when transporting or handling components. Unit: kg Machine model D155A.3 Serial number 60001 ~ 60271 60272 and up Engine, damper assombly 1,340 11398) + Engine assembly 1220 1278 + Damper assembly 7 47 + Universal joint 18 18 + Engine mount parts (wiring) 3 3 Radiator assembly (including built-in oil cooler) 305 Hydraulic cooler 34 (15 as individual part) Fuel tank assembly (when empty) 235 Fuel tank assembly (when full) 660 Power train unit assembly 2,188 + Torque converter, PTO assembly 319 + Transmission assembly 645 + Steering clutch, brake assembly 995 + Steering valve assembly 5 + Transmission control valve assembly ” + Control valve cover assembly 3 + Main relief valve assembly 5 + PPC charge valve assembly 7 + Power train fiter assembly Fe + Scavenging pump ” + Power train, lubrication pump 2 + Hydraulic, PPC charge pump 25 Final drive assembly 13722 Sprocket teeth (22 Hull frame assembly 3,182 ‘Track group assembly (each side) 3,755 + Track frame 1228 + Idler assembly 410 + Recoil spring assembly 508 + Bogie, track roller assembly 4103 + Track roller assembly (single flange x1) 973 + Track roller assembly (double flange x1) 1093 + Cartier rolier assembly 452 01-10 ® 01703017A03, GENERAL WEIGHT TABLE Unit: kg Machine mode! D155A3 Serial number {60001 - 60271 60272 and up Track shoe assembly (860 mm, wet type) 25582 Pivot shaft assembly 162 Equalizer bar 229 Hydraulic tank assembly 102 Hydraulic fier assembly 19 Main control valve 99 (Blade tit + blade tit + ripper litt + ripper tilt) Engine underguard 163 Transmission underguard 228 Operator's seat 2 ‘Semi Ustitdozer assembly 74903 + Blode 2818 + Straight frame 690%2 + Tilt brace 981 + Center brace 922 + Tilt cylinder assembly 190 ‘Semi Ustit + pitch dozer assembly 5,007 + Blade 2818 + Straight frame 690.2 + Center brace 922 + Tilt cylinder assembly 190 + Pitch cylinder assembly 216 Blade lift cylinder assembly 1652 Multi-shank ripper assembly 3,600 + Bracket, beam 2014 + Shank 2663 + Lift cylinder assembly 1192 + Tilt cylinder assembly 1222 Giant ripper assembly 3,135 + Bracket, beam 1,728 + Shank 3331 + Lift eylinder assembly 1192 + Tilt cylinder assembly 1222 +_Pin puller cylinder assembly 1 ROPS assembly 480 Cab 285 ROPS canopy 698 Canopy 105 Dashboard 83 Floor frame 310 01-11 ®GENERAL TABLE OF FUEL, COOLANT AND LUBRICANTS: TABLE OF FUEL, COOLANT AND LUBRICANTS ae (OND OF AMBIENT TEMPERATURE | CAPACITY (0) ae ° ee} FLUID | “5 0 0 010 __20 _30_40'c| Specified | _ Refill — | | Engine oil pan — : a2 a | Power train case | ce 105 © Final drive case (each side) |Engine oil] | z M [eee 58 58, Damper case / Seer 15 15 Pivot shaft case (each side) Hea) i Ee 87 87 | 126 7 Hydraulic system | ae x : | en ae, en Idler (each) | 059 059 Track roller (each) | 0.45 045 Gear oil Cartier roller (each) 0.68, 068, Bogie (each) | | 021-023 | 021-023 Fuel tank [Diese fuel a a 500 - Ee [pee] Tooling system — (including reservoir tank) _| Coolant | Add antireeze 7 ‘* ASTM D975 No. 1 NOTE: (1) When fuel sulphur content is less than 0.5 %, change oil in the oil pan every periodic main- tenance hours described in this manual. Change oil according to the following table if, fuel sulphur content is above 0.5 %. Change interval of oil in engine oil pan 1/2 of regular interval Fuel sulphur content 05 to 1.0% Above 1.0 % 1/4 of regular interval ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers API: American Petroleum Institute (2) When starting the engine in an atmospheric, temperature of lower than 0°C, be sure to use engine oil of SAE10W, SAE 10W-30 and ‘SAE15W-40 even though an atmospheric tem- perature goes up to 10°C more or less in the day time. (3) Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to half. (4) There is no problem if single grade oil is mixed with muttigrade oil (GAE10W-30, 15W-40), but be sure to add single grade oil that matches the temperature in the table on the left. (5) We recommend Komatsu genuine oil which has been specifically formulated and ap- proved for use in engine and hydraulic work equipment applications. ‘Specified capacity: Total amount of oil including oil for components and oil in piping. Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance. 01-12 ® 017A03eee ears ren eran en en aaaaie ——————— ee 017A03, 10 STRUCTURE AND FUNCTION Radiator Oil cooler Power train system. Power train unit mount Overall drawing of power train unit Power train hydraulic piping diagram Power train hydraulic system drawing Power train hydraulic circuit diagram . Damper, universal joint Torque converter, PTO Transmission control Transmission . Transmission control valve Main relief valve Lubrication relief valve Steering, brake control Bevel gear shaft, steering clutch, steering brake Steering control valve... Reducing valve... Scavenging pump strainer Power train pump strainer Power train oil filter Final drive Radiator guard .. Main frame, underguard ... 10-61 Track frame 10-62 Recoil spring. 10-64 Track roller bogie 10-65 ‘Suspension : 10-66 Work equipment hycraule piping diagram . 10-68, PPC control piping diagram 210-71 Work equipment control .. -10- 72 Work equipment hydraulic system diagram ... 10-74 Work equipment hydraulic circ diagram 10- 75 Hydraulic tank and filter PPC charge valve Accumulator ... PPC lock valve... PPC valve Main control valve Operation of main control valve. Operation of work equipment control circuit. Piston valve Quick drop valve. Cylinder stay... Work equipment Pin puller switch ...... Pin puller solenoid valve Tilt/pitch selector switch Pitch solenoid valve. Cab mount Cab. Air conditioner Electrical wiring diagram. Electrical circuit diagram ... Machine monitor system Sensors. Engine starting system 10-1STRUCTURE AND FUNCTION RADIATOR RADIATOR 1 2 3 A A TN . | i I VEE ») | tl ie eS Vil | d sxc 1. Radiator core assembly 9. Fan 2. Fan guard 10. Outlet hose 3, Reservoir tank 11. Drain plug 4 Lower tank (power train oil cooler built-in) 12, Inlet hose (for circulating at low water 5. Overflow hose temperature) 6. Water filler cap 43, Cushion 7. Air bleed hose 14. Breather cap 8. Inlet hose 18. Valve 10-2 01703‘STRUCTURE AND FUNCTION RADIATOR Z S Outline + The radiator is provided with a reservoir tank to make it easier to check and maintain the radiator water level. + The power train oil cooler is built into the lower tank. Core wpe D7 Fin pitch oe Heat dissipation area tom | 02.42 rose] Ee Pa ten | 009 08 valve | Vacuum aa (fen?) | 0.005 (0.05) 10-3‘STRUCTURE AND FUNCTION OIL COOLER 1. Swing hinge 2. Hydraulic cooler 3. Power train oil cooler A, Power train oil cooler outlet port B. Power train oil cooler inlet port Outline + The power train oil cooler is built into the lower tank. The hydraulic cooler can be tilted, making it easy to clean. OIL COOLER — Power vain | Feutio Gteosier | "Yocter Corot F700. SACS GaP Inne fin type rec Cooling methos | aut 8 Tair cooted teat dsipaon awe [2473 me | 776m 017803,017A03 ‘STRUCTURE AND FUNCTION Hydraulic cooler titting procedure 1. Remove bolt (5) and nut (2) from mounting hole A and install them to B. * The diagram shows the condition of the pin bolt when tilted. 2. Remove 4 bolts (1). %* Be careful when doing this. Hydraulic cooler (6) will drop by the amount of clear- ance of lever (3) and bracket (4). 3. In this condition, use bolt (5) as the fulcrum and tilt hydraulic cooler (6) * When re-installing, carry out the removal Procedure in reverse, and return the pin bolt to its original position. OIL COOLER ‘skD00009 1. Bolt 2. Nut 3. Lever 4. Bracket 5. Pin bolt 6. Hydraulic cooler A. Hole used when installing (radiator side) B. Hole used when tilting (machine front) 10-5STRUCTURE AND FUNCTION ENGINE CONTROL ENGINE CONTROL 1. Decelerator pedal 2. Fuel control lever 3. Clutch 4. Stopper 5. Rod 6. Fuel injection pump Lever, pedal positions TOP, : LOW IDLING @: HIGH IDLING GH IDLING @: LOW IDLING 10-6 Outline ‘The engine speed is controlled by fuel control lever (2) or decelerator pedal (1). 01703‘STRUCTURE AND FUNCTION POWER TRAIN POWER TRAIN Outline + The power generated by engine (1) has its torsional vibration dampened by damper (2), and then passes through universal joint (3), and is transmitted to torque converter (10). + The power from the engine is transmitted through the oil by torque converter (10) to the transmission input shaft (turbine shaft) in ac- cordance with the change in load. + Transmission (11) uses a combination of a planetary gear system and hydraulic clutches to reduce the speed and shift the gears (for- ward 3 gears, reverse 3 gears). It connects two sets of clutches selected according to the change in load, and transmits the power to bevel gear (12) from the bevel pinion at the rear end of the transmission. + The power transmitted to the bevel gear shaft is used to steer the machine by engaging or disengaging steering clutch (13) and steering brake (14). 10-8 Steering clutch (13) on the side to which the joystick is operated is disengaged to turn the ‘machine. The size of the turning radius is con- trolled by steering brake (14). Steering clutch (13) and steering brake (14) are wet type, multiple disc clutch, spring boosted types. ‘The power sent from steering clutch and brake (13) and (14) is transmitted to final drive (18). Final drive (15) consists of a single stage spur gear and single stage planetary gear system. It reduces the speed and rotates sprocket (16) to drive track shoe (17) and move the ma- chine. 017A03017803, STRUCTURE AND FUNCTION POWER TRAIN SYSTEM POWER TRAIN SYSTEM S@NonreNns pad 16 15 Engine | Ser No $200 271 sepran 10. Torque converter . Damper 11. Transmission Universal join 12. Bevel gear Scavenging pump (112) 13. Steering clutch Power train lubrication pump (SAL(3)-100) 14, Steering brake Power train pump (SAL(3)-80) 15, Final drive PTO 16. Sprocket 3. Hydraulic pump (SAR(4)-112) 17, Track shoe }. PPC charge pump (SAR(1)-10) 10-9STRUCTURE AND FUNCTION POWER TRAIN UNIT MOUNT POWER TRAIN UNIT MOUNT 1. Cap (front) 5. Mount bolt 2. Mount bolt 6. Cap (rear) 3. Cushion 7. Front mount 4. Clamp 8. Rear mount 10-10 017403,017403 STRUCTURE AND FUNCTION OVERALL DRAWING OF POWER TRAIN UNIT OVERALL DRAWING OF POWER TRAIN UNIT PRI 9TRONS 10. 12. 3. Scavenging pump (112) Power train lubrication pump (SAL(3)-100) . Power train pump (SAL(3)-80) }. Hydraulic pump (SAR(4)-112) PPC charge pump (SAR(1)-10) Transmission control valve, cover . Steering control valve 3. Power train pump strainer Scavenging pump strainer Torque converter, PTO |. Main relief valve Transmission Steering clutch, brake Outline ‘The power train unit can be broadly divided into torque converter (with PTO) (10), trans- mission unit (12), and steering unit (13). So, after the power train unit has been re- ‘moved, it can be disassembled into the torque converter, transmission unit, and steering unit. The steering unit consists of the bevel pinion unit, bevel gear shaft, steering clutch and steer- ing brake. 10-11STRUCTURE AND FUNCTION POWER TRAIN HYDRAULIC PIPING DIAGRAM POWER TRAIN HYDRAULIC PIPING DIAGRAM Centralized pressure detection port ‘Scavenging pump (112) . Power train lubrication pump (SAL(3)-100) 3. Power train pump (SAL(3)-80) ‘Transmission control valve 3. Steering control valve . Main relief valve . Centralized pressure detection port Power train oil strainer Power train oil filter |. Power train oil cooler (built into radiator lower tank) Zeoprnogaene 10-12 moom> sxoo0018 RH. clutch pressure pickup port RH. brake pressure pickup port LH. clutch pressure pickup port LH. brake pressure pickup port Transmission modulating pressure pickup port Torque converter outlet port pressure pickup port Torque converter inlet port pressure pickup port 017A03,POWER TRAIN HYDRAULIC SYSTEM DRAWING STRUCTURE AND FUNCTION POWER TRAIN HYDRAULIC SYSTEM DRAWING {Engine started, joystick at neutral, gear shift lever at 1st) eowLto 10-14017A03 ‘STRUCTURE AND FUNCTION POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM P 1. Power train oil pan = ae ‘1A. Torque converter case wile — 1B. Transmission case L og ring case ‘pump (SAL(3}-80) oil fiter Main relief valve Transmission control valve rae 6A. Modulating vaive 6B. Quick return valve 6C. Speed valve 60. Directional valve 7. Ast clutch 8. 3d clutch 9. 2nd clutch 10. REVERSE clutch 11. FORWARD clutch 12, Torque converter relief valve 13, Torque converter 14, Oil cooler 15. Lubrication relief valve 16. Transmission lubrication 17. PTO lubrication 18. Reducing valve 48, Steering control valve 9A. Parking brake valve 198. RH. clutch valve 196. RH. brake valve 190. LH. brake valve 19E. LH, clutch valve 20. RH. brake 21. RH. clutch 22. LH. clutch 23. LH. brake 24, Power IV 25. Steering lubrication 25A. LH. brake disc lubrication cd za Zoe pi 20e |e cela ae come aoe 25B. LH. outer brake bearing lubrication 258 25D _25F 25H 25) 25L_25N_25P 28C. LH. torque shaft lubrication cV 25D. LH. bevel gear shaft lubrication 23 25E. LH. inner brake bearing lubrication 25F. LH. clutch dise lubrication } 25G. Bevel pinion bearing lubrication 25H. LH. bevel gear shaft bearing lubrication 251. ‘Bevel gear teeth lubrication 254. RA. bevel gear shaft bearing lubrication 25K. RH. clutch dise lubrication 254. RLH, inner brake bearing lubrication 25M. RAH. bevel gear shaft lubrication 25N. FLH. torque shaft lubrication 18 [Set pressure 28:0 MPa, (@5ztkglem) PTO aa) lubrication pump (SAL(3)-100) LT a \ + i I Fi | i | ! t Ld ! | i | 1 | 1 i y 1 | casing “OP i| | Me ! i steger eee { {|_| | | TI yy 1 1 i 1 1 I 1c i a ‘A. RH. clutch pressure pickup port 250. RH. outer brake bearing lubrication B. RH. brake pressure pickup port 25P. RH. brake disc lubrication LH. clutch pressure pickup port 26. Oil strainer D. LH. brake pressure pickup port 27. Scavenging pump (112) E. Transmission modulating pressure pickup port 28. Pin puller solenoid vaive (for giant ripper} F. Torque converter outlet port pressure pickup port —sADooot 29. Pin puller cylinder G. Torque converter inlet port pressure pickup port 30. Centralized pressure detection port 10-15STRUCTURE AND FUNCTION DAMPER, UNIVERSAL JOINT 4% 34.» Serial No. : 60272 and up DAMPER, UNIVERSAL JOINT soo002s 017803,017A03 ‘STRUCTURE AND FUNCTION DAMPER, UNIVERSAL JOINT |. Breather . Dipstick . Drain plug . Input shaft Flywheel . Outer body Coupling Universal joint Cover |. Rubber coupling Inner body SS eeanogsens Outline + The damper dampens the torsional vibration caused by the change in engine torque and the impact torque generated when ac- celerating suddenly or when carrying out heavy-duty digging. In this way it acts to pro- tect the torque converter, transmission, and other parts of the power train. + This damper has few component parts: it uses ‘a rubber coupling, so the vibration is ab- sorbed by the internal damping effect of the rubber material and by the damping effect provided by the deformation, fedion Operation + The motive force from the engine passes through flywheel (5) and is transmitted to outer body (6). The torsional vibration of the engine is ab- sorbed by rubber coupling (10), and the power is transmitted to inner body (11). It passes through universal joint (8), and is then transmitted to the torque converter and transmission.STRUCTURE AND FUNCTION TORQUE CONVERTER, PTO TORQUE CONVERTER, PTO TCS43-17A 1 10-18 01703,017403 ‘STRUCTURE AND FUNCTION no 13 4 15 10 16 "7 mo Power train, power train lubrication pump mount . Scavenging pump mount Power train oil strainer PTO lubrication tube Hydraulic, PPC charge pump mount . Input coupling . Input shaft . PTO drive gear (55 teeth) . Idler gear shaft . Idler gear (66 teeth) |. PTO case Drive case 3. Turbine |. Pump . Stator . Stator shaft ‘Transmission input shaft Pump drive gear (47 teeth) (Hydraulic, power train, power train lubrication pump) Scavenging pump drive gear (53 teeth) Torque converter oil inlet port To oil cooler To transmission case {from torque converter case) From transmission case (to power train pump) To transmission case (passage) ‘TORQUE CONVERTER, PTO Outline The torque converter is a 3-element, single stage, single phase type, and forms an inte- grated structure with the transmission. Pump (14) forms one unit with input coupling (6), input shaft (7), and drive case (12), and is rotated by the motive force from the engine. Turbine (13) forms one unit with transmission input shaft (17), and is rotated by the oil from the pump. Stator (15) forms one unit with stator shaft (16), and is held in position by PTO case (11). The scavenging pump is driven by PTO drive gear (8), and returns the oil accumulated in the transmission case to the steering case. 1019STRUCTURE AND FUNCTION TRANSMISSION CONTROL % For details of the operation of the joystick for the steering system, see STEERING, BRAKE CONTROL section. Lever positions @: NEUTRAL @: FORWARD @: REVERSE @; 1st 1. Safety lever 2. Joystick (directional, gear shift) 3. Limit switch (for safety lever) 4. Cable 5, Transmission control valve 10-20 ‘TRANSMISSION CONTROL Outline + The transmission is controlled by joystick (2). ‘The joystick is used to shift between forward and reverse, and to shift gears. + The transmission is equipped with a safety mechanism: if safety lever (1) is not placed at the LOCK position, limit switch (3) is not actu- ated and the engine cannot be started. 017003,STRUCTURE AND FUNCTION TRANSMISSION 10-22 TRANSMISSION ™moop> ErREHZO . To FORWARD clutch To REVERSE clutch To 3rd clutch . To 2nd clutch To ‘st clutch To torque converter case (from power train oil strainer) From torque converter case |. To scavenging pump To torque converter case From power train pump To steering valve . To steering case |. From steering case 0170301703 STRUCTURE AND FUNCTION TRANSMISSION |. Main relief valve . Transmission case . Transmission control valve, valve cover assembly .. Lubrication relief valve Input shaft REVERSE sun gear (34 teeth) Pinion shaft REVERSE ring gear (90 inner teeth, 1 i | || 105 outer teeth) iy 1) 9. REVERSE planet pinion (26 teeth) oS No.1 No.2 No.3 No.4 No.5 REVERSE | FORWARD 3rd 2nd 1st 5 6 2 @ 9 1911] 12 Ne 14 16 7 eterno) ero me o 10. Dise i] tH \ | [% 11. Plate H 12. Piston = 13, FORWARD planet pinion (27 teeth) 14, 3rd planet pinion (36 teeth) i 15. 3rd ring gear (91 inner teeth, 105 outer teeth) i 16. 2nd sun gear (39 teeth) i f 17. 1st planet pinion (21 teeth) a 18. 1st sun gear (49 teeth) S 19. Output shaft (20 teeth at 3rd sun gear I portion) 20. 1st ring gear (91 inner teeth, 105 outer teeth) 21. Ast carrier (90 teeth) | | | 22. 1st clutch housing 23, 2nd clutch housing 24. 2nd planet pinion (26 teeth) 2nd ring gear (90 inner teeth, 105 outer teeth) 3rd clutch housing 2nd, 3rd carrier . FORWARD clutch housing |. FORWARD sun gear (37 teeth) FORWARD ring gear (91 inner teeth, 105 outer teeth) |. FORWARD carrier (86 teeth) . REVERSE clutch housing |. Return spring REVERSE ring gear (86 teeth) . Pin 36. REVERSE carrier (90 teeth) SBBIBR Reese 36 35-34 3300«32 oD 28 (oa) 20 20 e249 ee 23) 222 20) 10-23STRUCTURE AND FUNCTION Outline + The transmission has three forward speeds and three reverse speeds, and uses a combi- nation of a planetary gear system and disc clutches. + In the transmission, two of the clutches of the 5 sets of planetary gears and disc clutches are controlled by the control valve and are held in position by hydraulic force to select one rota- tional direction and one speed. + The No. 1 clutch is held in position for re- verse, the No. 2 clutch for forward, the No. 3 clutch for 3rd, the No. 4 clutch for 2nd, and the No. 5 clutch for 1st. 10-24 TRANSMISSION ‘Speed range and clutches actuated ‘Speed range FORWARD 1st FORWARD 2nd FORWARD 3rd Neutral REVERSE 1st REVERSE 2nd REVERSE 3rd Clutches used (engaged) No. No. No. No. No. of plates and discs used 2, No. 5 2, No. 4 2, No. 3 5 1,.No. 5 1, No. 4 1, No. 3 Clutch No. No. of dises | No. of plates. No. 1 clutch 5 4 No. 2 clutch 6 5 No. 3 clutch 4 3 No. 4 clutch 4 3 No. 5 clutch 3 2 01703STRUCTURE AND FUNCTION ‘TRANSMISSION Overation Operation of disc clutch The disc clutch is installed in order to hold ring gear (8) in position. It consists of piston (12), plate (11), disc (10), pin (35), and piston return spring (33). The inside disc teeth are meshed with the outside teeth of the ring of The plate is meshed with pin (35), which is 8. fixed to housing (32) and the protruding notched portion on the plate outer diameter. Clutch engaged {held in position) 1 The oil from the control valve passes through the port of housing (32) and is forcibly sent to the back of piston (12). The piston pushes plate (11) against disc (10), and the friction stops the disc rotation. It also holds in position ring gear (8), which is meshed. ‘a with the inside teeth. . 32 pS 01703, sxoo018 — Clutch disengaged (released) + When the oil from the control valve is shut off, piston (12) is returned to its original posi- tion by piston return spring (33). The friction between plate (11) and disc (10) is released, and ring gear (8) is placed in neutral. 10-25STRUCTURE AND FUNCTION TRANSMISSION No.1 No.2 No.3 No.4 | No.5 Reverse | Forward ore and | tot 5 13 i 18 19 HT T iw ai ©) | L a ea 31 30 29 27 25 24 21° 20 aA sootres 2. Forward 1st + When the transmission is set to FORWARD ‘st, the No. 2 clutch and No. 5 clutch are engaged. The motive force from the torque converter transmitted to input shaft (5) is then transmitted to output shaft (19). + No. 2 clutch is actuated by the hydraulic pres- sure applied to the clutch piston, and holds ring gear (30) in position. No. 5 clutch is actu- ated by the hydraulic pressure applied to the clutch piston, and engages ring gear (20). + The motive force from the torque converter transmitted to input shaft (5), and the rota- tion of the input shaft passes through sun gear (29) and is transmitted to planet pinion (13). 10-26 + Ring gear (30) is held in position by No. 2 clutch, so the rotation of planet pinion (13) rotates carrier (31), which is on the inside of ring gear (30). + Cartier (31) and carrier (27) are joined by a spline, and rotate as one unit, so the rotation of cartier (31) passes through planet pinion (24) and is transmitted to ring gear (25). + Carrier (21) is meshed with ring gear (25), and rotates as one unit, so the rotation is trans- mitted to planet pinion (17). + _ Ring gear (20) is being held in position by No. 5 clutch, so the rotation of planet pinion (17) rotates sun gear (18), and this rotates output shaft (19). 01700301703 ‘STRUCTURE AND FUNCTION No.1 36 3431 3. Reverse 1st + When the transmission is set to REVERSE 1st, the No. 1 clutch and No. § clutch are engaged. The motive force from the torque converter transmitted to input shaft (5) is then transmit- ted to output shaft (19). + No. 1 clutch is actuated by the hydraulic pres- sure applied to the clutch piston, and holds carrier (36) in position. No. 5 clutch is actu- ated by the hydraulic pressure applied to the clutch piston, and engages ring gear (20). + The motive force from the torque converter is transmitted to input shaft (5), and the rotation of the input shaft passes through sun gear (6) and is transmitted to planet pinion (9). + Carrier (36) is held in position by No. 1 clutch, 80 the rotation of planet pinion (9) rotates ring gear (34). No.2 ‘TRANSMISSION No.3 No.4 | No.5 and | Ist WB 27 2 24 21 20 AA spoc0109 Ring gear (34) rotates in the opposite direc- tion from the input shaft, and rotates carrier gD. Carrier (31) and carrier (27) are joined by a spline, and rotate as one unit, so the rotation of carrier (31) passes through planet pinion (24) and is transmitted to ring gear (25). Cartier (21) is meshed with ring gear (25), and rotates as one unit, so the rotation is trans- mitted to planet pinion (17) Ring gear (20) is held in position by No. 5 clutch, so the rotation of planet pinion (17) rotates sun gear (18), and this rotates output shaft (19), 10-27STRUCTURE AND FUNCTION ‘TRANSMISSION CONTROL VALVE TRANSMISSION CONTROL VALVE O_O 0 6 | 5 10-28 017A03‘STRUCTURE AND FUNCTION GARR, s Vil 3 Yy Lei Cy | LM Lis po RR S AA 017A03, 21 20 19 18 17:16 1514 BB ‘TRANSMISSION CONTROL VALVE 1. Valve body 2. Spacer 3. Quick return valve sleeve 4, Quick return valve 5. Plug 6. Valve body 7. Stopper 8. Speed valve spool 9. Directional valve spool 10. Collar 11. Cover 12. Stopper 13, Piston 14. Piston spring 15. Modulating valve spool 16. Modulating vaive sleeve 17. Modulating vaive spring (large) 18. Modulating valve spring (small) 19. Modulating valve spring 20. Stopper 21. Cover 10-29‘STRUCTURE AND FUNCTION MODULATING VALVE Outline + The modulating valve assembly consists of the modulating valve and quick return valve, and has a pressure modulating function. + When the gear shift lever is operated to shift gear, the clutch is engaged by the piston, but if high oil pressure is suddenly applied, the piston will suddenly engage the clutch. This will cause the machine to start suddenly and will subject the machine to an excessive shock. To prevent this, the modulating valve is in- stalled to raise the pressure applied to the piston gradually to the set pressure when the gear shift lever is operated to shift gears. This engages the clutch smoothly and pre vents any starting shock. In this way, it not only improves the ride for the operator, but also improves the power train durabi + The graph on the right shows the amount of time elapsed and the rise in the oil pressure with the modulating valve. For example, when shifting from forward 1st to forward 2nd, the oil from the pump passes through the speed valve spool and flows to the 2nd clutch to fill the circuit to the clutch piston port. The time taken to fill the circuit to the clutch piston port is called the filling time. The oil pressure is 0 to 0.5 MPa (0 to 5 kg/cm’). The time taken for the oil pressure to rise to the set pressure after the circuit to the clutch piston port is filled is called the build-up time. ‘The combination of the filling time and build- Up time is called the modulating time. 10-30 TRANSMISSION CONTROL VALVE Oil pressure MPa Filling time Modulating time agiea) Build-up time 2.7 (28) 2.0(20) 1.0(10) 0 or 10 tse) Time sxooo11s 017403017A03 STRUCTURE AND FUNCTION Operation a Immediately after shifting gear ‘When the gear shift lever is operated and the clutch is engaged, the passage from the pump. to the clutch cylinder is opened, and oil flows, to the clutch cylinder. Using the power of this flow, quick return. valve (4) moves to the left in the arrow di tion, connects ports A to drain port B, and releases the back pressure of modulating valve sleeve (16). When this happens, modulating valve (15) and modulating valve sleeve (16) are pushed back to the right in the arrow direction by the reac- tion force of springs (17), (18), and (19). Oil pressure starting to rise, while rising When the oil sent from the pump fills the circuit to the clutch cylinder, the pressure starts to rise. The oil passing through orifice a of quick re- turn valve (4) moves quick return vaive (8) to the right in the arrow direction, and closes the passage between port A and drain port B. The oil also passes through orifice b of modu- lating valve (15), flows to port C, and pushes piston (13), When this happens, modulating valve (15) uses the reaction force to compress springs (17) and (18), and moves to. the left in the arrow direction The oil passing through the central port of quick return valve (4) passes through orifice ¢ and flows to port A. It forms the back pres- sure of valve sleeve (16), and moves valve sleeve (16) to the left in the arrow direction to ‘compress spring (19). ‘TRANSMISSION CONTROL VALVE Toclutcheylinger 4 1817 18 oak fom 18 pump svooom2 Toctucheyinder 9 kg nea 16a ee cs pump 10-31STRUCTURE AND FUNCTION ‘TRANSMISSION CONTROL VALVE 3. While oil pressure is rising, rise completion As the oil pressure in the circuit rises, the back pressure of valve sleeve (16) also rises, and valve sleeve (16) moves to the left in the arrow direction. In addition, as the oil pressure pushing piston (13) rises, modulating valve (15) moves to the. left in the arrow direction by reaction force. By continuous repetition of the above opera- tion, the load of springs (17), (18), and (19) increases, and the oil pressure gradually rises. Finally, vaive sleeve (16) contacts stopper (20) and cannot move any further, thus complet- ing the rise in oil pressure. 10-32 To clutch cylinder 18 4 | Hil, ue Py Drain 1716 oka tom 1513 pump svoomse 01703,01703 ‘STRUCTURE AND FUNCTION MAIN RELIEF VALVE MAIN RELIEF VALVE aA i t { U U 1, Body Outline 2. Torque converter relief valve 1, Main relief valve 3. Valve spring Main relief valve (6) sets the set pressure of 4. Piston the oil pressure for the transmission, steering 5. Piston spring clutch, and brake. 6. Main relief valve 2. Torque converter relief valve 7. Valve spring Torque converter relief valve (2) acts to pro- 8. Piston spring tect the torque converter from abnormally 9. Piston high pressure by relieving the circuit if the torque converter inlet port pressure rises A. Drain port (for torque converter relief) above the set pressure. B. Drain port Unit: MPa (kg/em*) C. From pump —— D. Drain por Tet reser E. To torque converter ‘Main relief pressure 2:7 (28.0) P1. Main relief oil pressure detection port Torque converter relief pressure | 0.86 (8.8) P2. Torque converter relief oil pressure detection port 10-33STRUCTURE AND FUNCTION Operation of main relief valve + The oil from the power train pump passes through the filter, enters port A of the main relief valve, then passes through orifice a and enters port B. Nw When the oil from the pump fills the circuit, the oil pressure starts to rise. + As the oil pressure in the circuit rises, the oil entering port B pushes piston (4). The reac- tion compresses spring (7), moves main relief valve (6) to the left in the arrow direction, and opens ports A and C. Then, the oil from the pump is relieved from port A to port G, then flows from port € to the torque converter. The oil pressure at port A at this point is 2.7 MPa (28 kg/om?). Operation of torque converter relief valve + The oil relieved by the main relief valve flows from port € to the torque converter, and at the same time, passes through orifice b and enters port D. ‘When the passage to the torque converter is filled with oil, the oil pressure starts to rise. + As the oil pressure to the torque converter rises, the oil entering port D pushes piston (9). The reaction compresses spring (3), moves relief valve (2) to the right in the arrow direc- tion, and opens ports C and E. Then, the oil from port C is relieved to port E and is drained to the oil tank. The oil pressure at port C at this point is 0.86 MPa (8.8 kg/cm’) 10-34 MAIN RELIEF VALVE To torque convener To ol tank From pump sroouzss To torque converter To oll tank ti From PUMP sypgqa07 01703017A03, STRUCTURE AND FUNCTION LUBRICATION RELIEF VALVE LUBRICATION RELIEF VALVE 1. Forward clutch housing 2. Spring 3. Piston A. From oil cooler B. Drain C. Drain Outline + The oil leaving the torque converter passes through the oil cooler built into the radiator lower tank. It then goes through the lubric tion relief valve and lubricates the transmis- sion and PTO. Unit: MPa (kg/cm*) * The lubrication relief valve fe Installed to the | TS preseure right side face of the forward clutch housing, —_Set preseure __ and prevents any abnormal pressure in the Te 05) lubricating oi Cracking pressu 03 (3.0) 10-35STRUCTURE AND FUNCTION STEERING BRAKE CONTROL STEERING, BRAKE CONTROL * For details of operation of the joystick for the transmission system, see TRANSMISSION CONTROL. Ox @ ® aos 2 10-36 017003,01703 STRUCTURE AND FUNCTION Out + Joystick (4) moves rods (11) and (8) to oper- ate the steering clutch and brake. (The steer- ing clutch and brake are interconnected.) + Brake pedal (1) moves rod (6) to operate only the brake. In this case, the brake is used for stopping the machine, so both the left and right brakes are applied at the same time. + If joystick (4) is moved slightly to the left, the left steering clutch is partially disengaged and the machine turns gradually to the left. + If joystick (4) is moved fully to the left, the left steering clutch is completely disengaged, and in addition, the left steering brake is applied, so the machine turns sharply to the left. + Safety lever (2) is interconnected with park- ing brake lever (9), and also acts as a parking brake. 1. Brake pedal 2. Safety lever 3. Rod (from joystick) 4, Joystick Lever, pedal positions (steering) @; NEUTRAL 5. Limit switch : STRAIGHT TRAVEL FORWARD 6. Rod (from brake STRAIGHT TRAVEL REVERSE LEFT CLUTCH DISENGAGED LEFT CLUTCH DISENGAGED LEFT BRAKE APPLIED RIGHT CLUTCH DISENGAGED RIGHT CLUTCH DISENGAGED RIGHT BRAKE APPLIED : BRAKE RELEASED pedal) 7. Steering control valve 8. Rod (for left steering) 9. Parking brake lever (from safety lever) 10. Cable BRAKE APPLIED 11. Rod (for right FREE steering) : LOCK STEERING BRAKE CONTROL 10-37STRUCTURE AND FUNCTION BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE 25 26 27 28 29 BB 10-38 01703,017A03 STRUCTURE AND FUNCTION BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE 1 a 3 5 6 10 011 12 13, 4 5 16 7 8 19 20 210 22 L, 7 f “TT ~ i | _ a a : es ( 1 L _ i \ f | A p an il 7 | 4] \X d : 1 | | \ Gi | A A eR J J iG B A ' ag | \ rt u ! 1 | ! ‘GZ 24 ‘ AA 3B soos Output shaft Brake hub Brake cage Spring Brake piston Brake plate (5 on each side) Brake disc (6 on each side) Brake inner drum Brake outer drum Bearing cage . Shim (for adjusting bearing preload) Bearing Bevel gear shaft Bevel gear (43 teeth) Clutch inner drum Clutch outer drum Clutch plate (5 on each side) Clutch disc (5 on each side) . Clutch piston Spring Clutch cage Bearing Clutch stopper Stopper ‘Shim (for adjusting bevel pinion gear) Bearing cage . Bearing Nut (for adjusting bearing preload) |. Bevel pinion gear (17 teeth) 10-39STRUCTURE AND FUNCTION Outline Bevel gear shaft +The bevel gear shaft system meshes the bevel pinion and bevel gear and sends the power output from the transmission at right angles to the left and right. At the same time, it also reduces the rotating speed. + The bevel gear shaft systern employs a spiral bevel gear for the bevel pinion and bevel gear, and lubrication is carried out by splash lubri- cation using the oil inside the case. + The bevel gear shaft system consists of bevel gear shaft (13), bearing (12), which supports the bevel gear shaft, and bevel gear (14), which is meshed with bevel pinion (28). Steering clutch + The steering clutches are interconnected with the bevel gear shaft at both ends by a spline. They act to connect and disconnect the power from the bevel gear shaft to the final drive to change the machine turning direction. + The steering clutch is a wet type, multiple disc clutch, spring boosted type. It is actuated hydraulically by the pressurized oil from the steering vaive, which is interconnected with the joystick, and is also interconnected with the brake, + The lubrication system is a forced-type one using the oil from the power train lubrication ‘pump circuit, which passes through the cover, hub, and cage, and is sent to the discs and plates. + The steering clutch consists of inner drum (15) (which is interconnected with the bevel gear shaft), disc (18), plate (17), clutch outer drum (16), piston (19), spring (20), and bear- ing (22), which supports all of these. In addition, clutch outer drum (16) and cage (21) are interconnected with brake inner drum (8), and the motive force from the bevel gear shaft passes through brake hub (2) and is transmitted to output shaft (1), 10-40 BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE ‘Steering brake The steering brakes are interconnected with the left and right steering clutches. They carry ‘out braking of the power from the steering clutch to the final drive and change the ma- chine turning direction or brake the machine. The steering brake is a wet type, multiple disc clutch, spring boosted type. It is hydraulically actuated by the oil pressure from the steering valve, which is interconnected with the brake pedal and joystick, and is also interconnected with the clutch. The lubrication is a forced lubrication system using the oil from the power train lubrication pump circuit, which passes through the brake ‘cover and cage, and is sent to the discs and plates. ‘The steering brake consists of clutch outer drum (16), clutch cage (21), inner drum (8), which is interconnected with brake hub (2), disc (7), plate (6), brake outer drum (9), piston (6), spring (6), bearing cage (3), which sup- Ports all of these, and output shaft (1). Brake ‘outer drum (9) is secured to the steering case. In addition, output shaft (1) is interconnected to brake hub (2) by a spline. When the engine stops and the back pressure of the brake piston drops, the brake is auto- ‘matically applied. However, it is dangerous if the oil pressure inside the circuit rises and the brake is released when the engine is started again, so when parking the machine, always place the parking brake at the LOCK position, In addition, output shaft (1) is interconnected to brake hub (2) by a spline and is stopped in the axial direction by stopper (24). 017A03017403, STRUCTURE AND FUNCTION BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE Operation of steering clutch fag @ 20 1. Steering clutch engaged When the joystick is at the neutral position, the steering valve is also at the neutral posi- tion, so there is no back pressure applied to piston (19). In this condition, the piston is pushed back to the right in the arrow direction by the tension of spring (20), and disc (18) and plate (17) are pushed into tight contact with stopper (23) of clutch outer drum (16). So, the power from bevel gear shaft (13) is transmitted to clutch outer drum (16) from inner drum (15) through the disc and plate, which are in tight contact. The power then asses through brake inner drum (8), which forms one unit with the clutch outer drum, and brake hub (2), and is transmitted to the final drive through output shaft (1), 19 1617 181513 2. Steering clutch disengaged ae 8 20 19 1617 181513 When the joystick is partially operated, the steering valve is switched and oil enters the back of piston (19). When the oil pressure rises, it pushes the piston to the left in the arrow direction, compresses spring (20), and releases the force pushing disc (18) and plate (17) together. When this happens, the power from bevel r gear shaft (13) rotates only inner drum (15) and the disc. The power is not transmitted to c clutch outer drum (16 or any other parts, so is e3 not transmitted to the final drive. y When the steering lever is released, the steer- i ing valve opens the drain circuit, and piston (19) is returned to its original position by the Ty tension of spring (20), so the condition be- comes the same as when the clutch is en- 7 Dates gaged in Item 1 above. If the left steering clutch is disengaged, power is transmitted only to the right steering clutch, 80 the machine turns left. - 10-41STRUCTURE AND FUNCTION BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE Operation of steering brake 1. Steering brake released When the joystick is at the neutral position and the brake pedal is released, the steering valve is also at the neutral position, so the steering clutch is engaged, and oil enters the back pressure port of piston (5) of the steer- ing brake. When the oll pressure rises, the oil pushes the piston to the left in the arrow direction, compresses spring (4), and releases the force pushing disc (7) and plate (6) together. When this happens, the power transmitted to brake inner drum (8) from bevel gear shaft (13) through the steering clutch is transmitted from brake hub (2) to output shaft (1), and is then transmitted to the final drive, 2. Steering brake applied (joystick operated) If the joystick is operated fully, the steering valve is switched and the steering clutch is disengaged. At the same time, the oil apply- ing the back pressure to piston (5) is con- nected to the drain circuit. In this condition, the piston is pushed to the right in the arrow direction by the tension of spring (4), and disc (7) and plate (6) are brought into tight contact with the stopper of brake outer drum (9). The brake outer drum is joined to the steer- ing case and is fixed in position. Therefore, even if the steering clutch is. dis- engaged, the rotation of brake inner drum (8), which is rotating under inertia (in other words, the rotation of output shaft (1)) is, stopped because the disc and plate are held in tight contact, By adjusting the amount the joystick is oper- ated, it is possible to control the hydraulic force applied to piston (5) to adjust the braking force. So, it is possible to control the turing radius and speed. 10-42 3 01703,01703 STRUCTURE AND FUNCTION 3. Brake applied (joystick at neutral, brake pedal depressed) When the brake pedal is depressed, the steer- ing valve is switched, and the oil applying back pressure to piston (5) is connected to the drain circuit. For this reason, the steering clutch is kept engaged, and only the brake is actuated to stop the rotation of output shaft a. 1245 6 7 8 9 BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE 13 10-43STRUCTURE AND FUNCTION STEERING CONTROL VALVE N ‘STEERING CONTROL VALVE 10-44 017A0301703 STRUCTURE AND FUNCTION STEERING CONTROL VALVE 2 3 4 1% 16 17 18 nn! 19 A. To right clutch 2 B. P port ©. To right brake D. To left brake E. Clutch valve drain F. Brake valve drain G. To left clutch a 2% 5 24 zane OL 20 1. Right steering lever 11. Right brake valve 20. Roller (left steering) 2. Brake lever 12. Valve spring (clutch valve) 21. Guide (brake valve) 3. Left steering lever 13. Piston (clutch valve) 22. Modulating spring (brake valve) 4, Parking brake lever 14, Right clutch valve 23. Bolt (brake valve) 5. Body 15. Bolt (clutch valve) 24, Left clutch valve 6. Cover 16. Modulating spring 25. Left brake valve 7. Cover {clutch valve) 26. Piston (brake valve} 8 Parking brake valve 17. Guide (clutch valve) 27. Valve spring (brake valve} 9. Check valve 18. Roller (right steering) 10. Roller (parking brake) _—_19. Roller (brake) Outline + The steering control valve is in the circuit The steering control valve sends oil from the between the power train pump (through the main relief valve) and the pistons of the steer- ing clutch and brake. It consists of two sets of steering valves and brake valves. If the joystick (steering, directional) is moved to the right or left, the steering clutch is disen- gaged. If the joystick is moved further, the brake is also applied. It is possible to adjust between gradual and sharp turning by the amount the joystick is operated. If the brake pedal is depressed, both the left and right brakes are applied, and the machine will stop. The above operations are carried out by switching the steering control valve, which is interconnected with the lever and pedal. power train pump to the steering clutch and brake, and operates each disc clutch. Valve control + The steering control valve is operated by left and right steering levers (1) and (3), which are interconnected with the joystick, and parking brake lever (4) and brake lever (2), which are interconnected with the brake pedal. Left and right steering levers (1) and (3) use a cam to interconnect the steering valve and brake valve inside the the steering control valve to carry out control 10-45STRUCTURE AND FUNCTION Operation 1. Joystick at neutral, brake pedal released {Clutch engaged, brake released, parking brake OFF) Joystick STEERING CONTROL VALVE Right brake Right clutch + When the joystick is at the NEUTRAL position and the brake pedal is released, levers (1), (2), and (3) are also at the NEUTRAL position. The oil ports of each valve are opened or closed by the spring tension. The oil from the power train pump passes through the main relief valve and enters port A of check valve (9). ‘Some of the oil entering port A flows to port B of left and right steering valves (24) and (14), and stops there. Then, the oil from the 10-46 vat teh vat bate ond Paving brake OFF —— back pressure port of the clutch piston returns from port C to drain port H, and the clutch is engaged by the tension of the clutch spring. The rest of the oil pushes open check valve (9), enters port E of left and right brake valves (25) and (11), and flows from port F to the back pressure port of the brake piston. When the oil pressure in the circuit rises, the piston moves to the left in the arrow direction, com- presses the brake spring, and releases the brake. 01703017403, ‘STRUCTURE AND FUNCTION ‘STEERING CONTROL VALVE 2. Joystick operated half way to left (left clutch disengaged, brake released, parking brake OFF) Ont Lt Left euten H. EEL Re Left clutch disengaged oe 3 ell iil t 13 Loft rake saretlh, i ore ors ork if on g Parking brake OFF vow When the joystick is operated half way to the left, roller (20) of lever (3) pushes bolt (15) to the left in the arrow direction, and compresses modulating spring (16). The reaction moves steering valve (24) to the left in the arrow direction. Then, port C and drain port H are closed, and ports B and C are opened. The oil from the power train pump enters port C from port B. Some of it flows to the clutch piston port to form the back pressure, and the rest passes through orifice “b* and enters port D. The oil entering port D pushes piston (13), and the reaction compresses spring (16) and moves valve (24) to the right in the arrow direction. This closes ports B and C, s0 no oil goes beyond port C, and the oil pressure is ‘maintained without rising any further. If the joystick is operated further to the left, the above operation is repeated, and when roller (20) of lever (3) reaches the position where it contacts bolt (23) of the brake valve, the oil pressure beyond port C rises to the set pressure 2.5 + 0.1 MPa (25 +1 kg/cm?) of the reducing valve and the clutch is completely disengaged. The oil pressure beyond port C is determined by the tension of modulating spring (16), which changes the load according to the amount the joystick is moved. Therefore, if the joystick is moved only slightly, the oil pressure beyond port C is set low and the clutch is partially disengaged. If the joy- stick is moved a greater distance, the oil pres- sure is set high and the clutch is completely disengaged. Port J is connected to port € and reduces the operating force of lever (3), pushing bolt (15) out to the left in the arrow direction. However, the oil pressure at port J (the booster pressure) follows the oil pressure of port C, which changes in accordance with the change in the amount of joystick movement, so the ‘operating force of the joystick also changes. 10-47STRUCTURE AND FUNCTION ‘STEERING CONTROL VALVE 3. Joystick operated fully to left (clutch disengaged, left brake applied, parking brake OFF) A2 9 E 22 k 23 26 a 2— ; ‘iit Left clutch S Left cluten disengaged F Loft brake oe applied CP ay Loft brake E Joystick + Ifthe joystick is operated fully to the left from the condition in item 2, roller (20) of lever (3) pushes bolt (23) to the left in the arrow direc- tion, and compresses modulating spring (22). The reaction to this moves brake valve (2) to the left in the arrow direction. Then, ports E and F close, and port F and drain port H open. + The oil from the power train pump goes from port A, pushes open check valve (8), and en- ters port E, where it stops. ‘Some of the oil which flows to the brake pis- ton port and acts as the back pressure is drained from port F to port H. The rest of the il passes from port F through orifice “e” and enters port G. However, when the oil beyond port F is drained to port H, the oil pressure drops. The oil entering port G pushes piston (26), and the reaction force pushing valve (25) to the left in the arrow direction becomes 10-48 oFF i ond . Parking brake OFF syowoa01 smaller, so valve (25) is moved to the right in the arrow direction by the tension of return spring (27). This closes ports F and H, and maintains the oil pressure beyond F so that it does not drop. If the joystick is operated further to the left, the above operation is repeated, and when it is operated fully, the brake is fully applied. The oil pressure beyond port F is determined by the tension of return spring (27), which changes the load according to the amount the joystick is moved. So, if the joystick is moved only slightly, the oil pressure beyond port F is set high and the brake is partially applied. If the joystick is moved a greater distance, the oil pressure is set low and the brake is fully apy Port K is connected to port E and reduces the ‘operating force of lever (3) pushing bolt (23) ‘out to the left in the arrow direction. 0170301703, STRUCTURE AND FUNCTION STEERING CONTROL VALVE 4. Brake pedal depressed (clutch engaged, brake applied, parking brake OFF) Joystick Brake pedal at neutr Right brake Right clutch Left clutch + When the brake pedal is depressed, two roll- ers (19) of lever (2) push left and right bolts (23) to the left in the arrow direction, and left and right brake valves (25) and (11) are actu- ated in the same way as in Item 3. Therefore, the oil pressure is set according to the amount the brake pedal is operated, and it is possible to adjust the braking force. The left and right steering levers are not oper- ated, so the clutch is engaged. ond Parking brake OFF svocooe2 10-49STRUCTURE AND FUNCTION ‘STEERING CONTROL VALVE 5. Parking brake ON (clutch engaged, brake applied, joystick at neutral, brake pedal released) Joystick at neutr pedal Right brake Right clutch Left clutch Left brake + When the joystick safety lever is placed at the LOCK position, roller (10) of lever (4) pushes parking brake valve (8) to the left in the arrow direction. Check valve (9) is pushed by parking brake valve (8), and moves to the left in the arrow direction in the same way, so port A and port E are closed. The oil flowing to the brake piston port and forming the back pressure passes from port F 10-50 ON Parking brake ON ‘svoona03 through port E, then passes through check valve (9) and parking brake valve (8) and is drained. Parking brake valve (8) remains pushed in by lever (4) and roller (10), so the back pressure of the brake piston port contin- ues to drop. As a result, the brake is fully applied and is held in this condition. Even if the engine is started again, check valve (9) remains closed, so the brake is kept ap- plied. 01780301703 STRUCTURE AND FUNCTION REDUCING VALVE REDUCING VALVE 1. Orifice 2. Plug 3. Body 4. Spring AA OB 5. Spool soooorse 6. Spring 7. Spool 8. Plug A. From main relief valve B. To steering control valve Outline + The reducing valve is installed between the main relief valve and the steering control valve. The set pressure of the main relief valve is a high 2.7 MPa (28 kg/cm?) at rated, so the re- Units MPa (kg/cm) ducing valve lowers the ol pressure tothe set Tse pressure pressure for the steering to protect the steer- pe eee ing: Cracking pressure 2.5 (25), 10-51