‘SEBM003801 SHOW IMTANINI OAL KOMATSU LW30-1 MACHINE MODEL SERIAL No. Lws0-1 H-shaped outrigger spec. 10001 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 + LW80-1 mount the S6D95L-1 engine, For details of the engine, see the 95 Series Engine Shop Manual. ©1993 MOmaTSU All Rights Reserved 00-1 Printed in Japan 10-93(02)0040101 10 20 30 CONTENTS No. of page GENERAI O11 STRUCTURE AND FUNCTION... a 10-1 TESTING AND ADJUSTING... DISASSEMBLY AND ASSEMBLY. ease 30-1 MAINTENANCE STANDARD 022701022701 The affected pages are indicated by the use of the following marks. It is requested that necessary ac- | Mark {ndication_ Action required | tions be taken to these pages according tothe table opener a © | Page to be replaced Replace (1 | Pago to be deleted Discard Pages having no marks are those previously re- vised or made aditions. LIST OF REVISED PAGES Mare Page Revision! wae page ROMS" wrk Page RESON wrk Page REVSIO“] ay Page Revision @ 10-62 10-104 10-147 10-170 1 10-63 © 10-05 «| 10-148 10.171 a 10-64 10-106 10-149 10-172 D 10-65 10-107 10-150 10-173 a 10-66 10-108 10-151 10-174 10-67 10-109 } 10-182 10-175 10-68 10-111 10-153 10-176 10-69 10-112 10-154 10-177 10-70 10-113 | 10-155 10-178 | 10-71 10-114 10-156 10-179 [eee G72 10-115 10-157 10-180 10-73 10-116 10-158 10-181 10-74 10-117 10-169 10-182 10-75 10-118 10-160 10-183 10-76 10-119 10-161 10-184 10-77 10-120 10-162 10-185 10-78 10-121 10-163 10-186 10-73 10-123 10-164 10-187 10-80 10-124 10-165 10-188 10-82 10-125 10-166 10-189 eon © 10-83 10-126 10-167 10-190 o12 10-84 10-127 10-168 10-191 013 10-85 10-129 10-168-1 10-192 oa 10-86 10-130 10-168-2 10-193 018 10-87 10-132 10-168-3 10-194 016 10-88 10-133 10-1684 =| 10-195 O13 10-89 10-134 10-1685 == 10-198 oD) 10-92 10-1361 10-168-6 10-197 os 10-93 10-135 10-168-7 10-198 oe 10-94 10-136 10-1688 == 10-199 10-95 10-137 10-168-9 10-200 eeiotaead 10-96 | 10-138 10-168-10 10-201 © 106 10-97 10-140 10-168-11 10-202 107 10-98 10-141 10-168-12 10-203 10-40 10-99 10-142 10-168-13 10-204 10-41 10-100 10-143 10-168-14 10-205 10-42 10-101 10-144 10-168-15 10-206 10-43 10-102 10-145 10-168-16 10-207 10-48 10-103 10-146 10-169 10-208 00-2-1 DMark Page —Fevision! mark Page RRVi8iOM| Mark Page REVIION ary Page Revision) ark Page Revition 10-209 20-142 20-253 20-404 20.462 © 10-210 20-143 5 20-254 20-405, 20-463) 10.211 20-144 © 20-255 20-408, o 20884 @ 10212 20-145 > 20.256 20-407 20-465 10.213, 20-146 » 20.287 20-408 © 20466 20-147 oO 20-258 20-409 o 20467 D @ 20-1 @Q 20-148 © 20-259 20-410 > 20-468 1) 20-2 20-149 20-260 (20-412 oO 20-469 203 20-150 © 20-261 20-413 o 20870 D 20-4 20-151 © 20-262 20-414 > 20-471 205 20-152 20-263 20-415, > 20472 206 20-153 © 20-264 20-416 o 20473 @ 20-101 20-184 20-265 20-417 o 20474 @ 20-102 20-155 ) 20-266 20-418 o 20-475 @ 20-103 20-156 20-267 20-420 o 20476 «D 20-104 20-157 » 20-268 20-421 o 20477 @ 20-105 20-201 © 20-269 20-422 o 20678 ® 20-106 © 20-202 © 20-301 20-423 o 20-479 OD 20-107 20-203 © 20-303 (20-424 © 20-480 20-108 © 20-204 20-304 20-425 > 20481 20-109 20-205 » 20-305 20-426 © 20482 © 20-110 © 20-206 > 20-306 20-427 20-483) 20-111 20-207 © 20-307 20-428 oO 20-484 «OD 20-112 © 20-208 © 20-308 20-430 > 20-485 20-113 > 20-209 > 20-310 20-431 © 20486 20-114 © 20-210 © 20-311 20-432 o 20487 OD 20-115 20-211 20-312 20-433 © 20-488 D 20-116 20-212 20.313 20-434 o 20889 20-117 oo 20214 20-314 20-435 o 20400 @ 20-118 > 20.218 20-315 20-436, o 20881 20-119 > 20-2151 © 20316 20-437 20-492 20-120 > 202162 @ | o 20317 20-438, > 20.493 a) 20-121 20-215-3 2 20-318 20-439 > 20501 OD 20-122 20-215-4 © 20-319 20-440 o 20-502 D 20-123 © 20-2155 11 > 20-320 (20-442 © 20503 20-124 20-2156 © 20321 20-443 © 20608 20-125 Oo 20-216 © 20-322 (20-444 o 20508 @ 20-126 © 20.217 © 20-323 20-445 © 20508 20-127 © 20-218 © 20-351 (20-446 o 20507 @ 20-128 © 20.219 > 20-352 20-447 © 20508 20-129 © 20-220 © 20-353 (20-448 20-509) 20-130 20-221 ) 20-354 20-449 20-510 @ 20-131 > 20-222 © 20-355 20-450 20511 20-132 20-223 © 20-356 20-451 > 20512 20-133 20-224 © 20-3857 20-482 © 20513 20-134 © 20-225 © 20-358 20-454 > 20514 20-135 > 20-226 © 20-359 20-455, © 20515 20-136 > 20-227 © 20-360 20-456 o 251 @ 20-137 20-228 © 20361 20-857 o 257 ® 20-138 20-229 © 20-362 20-888 o 2518 @ 20-139 20-230 © 20-801 20.859 © 20519 dD 20-140 20-251 © 20-402 20-460 o 20520 ® 20-141 20-252 © 20.403 20-461 > 20521 D o22T01022701 Mark Page FevisCnl stan Page —FeVSIO"! ak Page PESO“ Mag Page REVBIONI ay Page Revision 20-622 20-7184 () 30172 406 20523 20-7186 | > 30473 408 20-524 20-7187 30-174 409 20-525 20.7188 30-175) 40-10 20-526 20719 30-176) 40-11 20-527 20801) 30-177 40-12 20-528 20-803) 30-178 40-13 20529 20-804 30-179) 40-14 20-530 20-805) 30-180 <1) 40-15 20-531 20-808 4 30181 40-16 20-532 20-807 0 30182 40-17 20-533 20-808, 30-183 40-18 20-534 20-808 30-186) 40-19 | 20-601 20.810 30-185 40-20 | 20-602 20811 30-186 40-21 20.603 20812 » 30187 40-22 20-604 | © 20-813 30-188 40-23 20-605 | o 2846 @ 30-189) 40-24 20-606 20815 30-190 40-25 20-607 20-816) 30-191) 40-26 20-608 | o 2087 4 30-192 40-27 20-608 20818 30-193) 40-28 20-610 © 20819 4 30-194 4 40-29 20611 © 20-820 30-195) 40.30 | 20-612 20-821 30-196 4 40-31 | 20.613 © 20-822 30-197 40-32 20-614 © 20-823 30-198 4 40-33 20-615 30-199) 40-34 20-616 301 @ 30-200) 40-35 20-617 303 30-201 4 40-36 2618 30-4 D 30-202 40-37 20619) 3041 30-203) 40-38 20-620 30-5 30-208 Gh 40-39 20-701 30-6 > 30-208 40-40 20-703 30-153, 30-206) 40-41 20-704) 30-154) 30-207 40-42 20-705 30-155 30-208 40-43 20-706 30-166) | 0 30209 4 40-44 20-707 30157 30-210 4 40-45 20708) 301884 30211 a) | © 20-703 @ 30-159) 30-212) | 20710 30-160 30.213 | 2071 30-161 30-214) | 20-712 30-162) 30-215 i 20-713-1 (1) 30-164 30.217) | 20-713-2 30-165 30-218 4 | 20714 30-168 4 20717 30-168) 402 | 20-718 30-169 (1 40-3 | 20-7182 (1 30-170 40-4 | 20-718-3 1) 30171 40-5, I 00 -2-3A IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe methods of operation. Some of these operations re- quire the use of tools specially designed by Komatsu for the purpose. To prevent injury to workers, the symbol 4 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. A SAFETY 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 grinding parts with a grinder, ete. 3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work. 4.When carrying out any operation with two or more workers, always agree on the op- erating procedure before starting, Always inform 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 smoking. Never smoke while working. PREPARATIONS FOR WORK 7.Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the ‘machine from moving 8.Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them, 9.When disassembling or assembling, sup- port the machine with blocks, jacks or stands before starting work. 10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing, 00-3PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing compo- nents of the oil, water or air circuits, first remove the pressure completely from the circuit. 12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before car- rying out any work on the oil or water circuits, 13. Before starting work, remove the leads from the battery. Always remove the lead from the negative (—) terminal first. 14,When raising heavy components, use a hoist or crane Check that the wire rope, chains and hooks are free from damage Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from 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 pressure, then slowly loosen the bolts to remove. 16. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires 17.When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to 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 19. Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. « When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the ma- chine is being operated 20. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely care- ful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23.When measuring hydraulic pressure, check that the measuring tool is correctly assem- bled before taking any measurements. 24, Take care when removing or installing the 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: This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into chapters for each main group of components; these chapters are further divided into the following sections. 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. Contact your KOMATSU distributor for the latest information. 00-5HOW TO READ THE SHOP MANUAL HOW TO READ THE SHOP MANUAL VOLUMES Shop manuals are issued as a guide to carry- ing out repairs. They are divided as follows: Chassis volume: Issued for every machine model Issued for each engine series Each issued as fone volume to cover all models Engine volume: Electrical volume Attachments volume These various volumes are designed to avoid duplicating the same information. Therefore to deal with all repairs for any model, it is neces- sary that chassis, engine, electrical and attach- ment volumes are ready. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributers. 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 shows how to read the page number. Example 1 (Chassis volume) 10-3 Item number (10. Structure and Function} Consecutive page number for each item. Example 2 (Engine volume): 12-410 Unit number (1. Engine) Item number (2. Testing and Adjusting) Group No. (4. Fuel system) Consecutive page No. (Page 10 of Group 4) 3. Additional pages: Additional pages are in- dicated by a hyphen (-) and number after the page number. File as in the example. Example: 10-4 12-203 10-4-1 12-203-1 10-4.2 + Added pages — 1 9.203-2 10-5 12-204 00-6 REVISED EDITION MARK (DO@ When a manual is revised, an edition mark is recorded on the bottom outside corner of the pages. REVISIONS Revised pages are shown at the LIST OF REVISED PAGES on the between the title page and SAFETY page. SYMBOLS So that the shop manual can be of ample Practical use, important places for safety and quality are marked with the following symbols, Symbol | Item Remarks ‘Special safety precautions are necessary when performing the work. A | sate ‘Special technical precautions or other precautions for preserving standards are necessary when performing the work, | coution Weight of parts or systems. Caution necessary when 1] | Weight | selecting hoisting wire, or a wen working posture is important, ee ighten. | Places that require special iahter- | Stention forthe tightening '9 tordue| torque during assembly. Places tobe coated with - Coat | adhesives and lubricants, ete. A Paces where oll, water or Ger [oi water| fuel must be added, and the capacity. Places where oil or water Drain | must be drained, and quantity to be drained,HOISTING INSTRUCTIONS HOISTING INSTRUCTIONS Ay Heavy parts (25 kg or more) must be lifted with a hoist etc. In the Disassembly and Assembly section, every part weigh- ing 25 kg or more is indicated clearly with the symbol 1. If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made * Check for removal of all bolts fastening the part to the relative parts. © Check for existence of another part causing interference with the part to be removed 2. Wire ropes 1)Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below Wire ropes (Standard “2” or “S” twist ropes. without galvanizing) Rope diameter (mm) | Allowable load (tons) 10 1.0 112 14 125 16 14 22 16 28 18 36 20 44 224 56 30 10.0 40 18.0 50 28.0 60 40.0 The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength of the rope used. 2)Siing wire ropes from the middle portion of the hook Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion. 100% = 8B 78% 1% 50088 3) Do not sling @ heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load, B Singing with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result ina dangerous accident. 4)Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles, When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight becomes 1000 kg when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as. 4000 kg if they sling a 2000 kg load at a lifting angle of 150°. 2 & P 3 Load capacitySTANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE 1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections of “Disassembly and Assembly”. Thread diameter Width of bolt across flat (mm) (mm) kgm Nm 6 10 1,35+0.15 13.2214 8 13 3.2403 31.4429 10 7 67407 65.7468 12 19 115410 112498 14 22 18.0+20 177419 16 24 28543 279+29 18 27 3944 383439 20 30 56+6 549+58 22 32 76+8 745+78 24 36 94.510 92798 27 a 136415 1320+ 140 30 46 175+20 1720+ 190 33 50 225425 2210240 36 55 280+30 2750290 39 60 335+35 3280+340 —————___ 1 This torque table does not apply to the bolts with which nylon packings or other non- ferrous metal washers are to be used, or which require tightening to otherwise specified torque, + Nm (newton meter): 1Nm + 0.1 kgm 2. TIGHTENING TORQUE OF SPLIT FLANGE BOLTS Use these torques for split flange bolts. Width Tightening torque Thread diameter ‘of bolt across flats (mm) (mm) kgm Nm 10 14 67+07 65.7+68 12 7 11.51 112498 16 22 279429 00-8STANDARD TIGHTENING TORQUE Sealing sutoce 3. TIGHTENING TORQUE FOR NUTS OF FLARED — Use these torques for nut part of flared, CH. ae 0088 Thread diameter | Width across flats Tightening torque of nut part fof mut part | Pp (mm) (oom) kgm Nm 14 19 254058 245+49 18 24 642 494196 22 27 8+2 785+196 24 32 1443 | 13734294 30 36 1823 | 1765+29.4 33 a 2045 196.149 36 46 2548 245.2+49 42 58 305 | 294.2+49 COATING MATERIALS —_ The recommended coating materials prescribed in Komatsu Shop Manuals are listed below. Nomenciatre | Komalsucoge ‘Aptcatons UT-1& | Used; appr rubber pads rubber gaskets and cor plugs, fac ‘Used to apply resin, rubber, metallic and oe non-metallic parts when a fast, strong seal is Jed. Adhesives CT-2 | Preverting bots nuts and pos rom loosening end aking ol iz Provides an airtight, electrically insulating seal urs Used for aluminem surfaces ii ~ Used to coat plugs (plate shaped, bowl shaped) and holes, and te Uses with gaskets and packings to nreave sealing eteat TE Heat-resistant gasket for precombustion chambers sonnt gue tad erhovst pe peer ee ‘Used by itself on mounting surfaces on the final drive and transmission tee cases. (Thickness after tightening. OT = O08 mms Used by itself to seal grease fittings, tapared screw fittings and tapered to peeloft, fe screw fitings in hydraulic crcults of lass than 50 mm in diameter 6-6 Silicon base type used in combination with LG-1 and LG-4. 9 Has a shorter curing time thanUG-6, andis easier “Tnuiristion compound (Lubricant incluging ime Pounce en crane Prevent sticking, Burning or rusting ‘Applied to bearings and taper shafts to facilitate press-fiting and to Grease | Applied to bearings, siding parts and oll seals for wbrication Tus Iithium grease) 62-1 Drevention and faetitation of assembling work Vaseline — Used for protecting battery electrode terminals from corrosion *LT-2 isalso called LOCTITE in the shop manuals. 00-9ELECTRIC WIRE CODE ESAT In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. ELECTRIC WIRE CODE This wire code table will help you understand WIRING DIAGRAMS. ‘SWB indicates a cable having a nominal number 5 and white coating with black stripe. Example CLASSIFICATION BY THICKNESS — sores! T—Katar—Yoa tara Copaaeion] Md [EE] Antti cro strands (mm) (mum) 0.85 11 032 088 28 12 Starting lighting, signal ete. 2 26 iGrsaitaa | as209 31 20 Lighting, signal etc 5 65 032 5.23 46 37 Charging and signal 15 84 045 13.36 70 59 ‘Starting (Glow plug) 40 85 080 42.73 114 138 ‘Starting 60 127~| 080 6388 136 178 Starting 100 217 080 1091 176 230 Starting CLASSIFICATION BY COLOR AND CODE Ciruis rg" | eas carsioa | Ground | staring | Lighting | Instrument | Signal omer Tra. | S08 w 8 8 a Y 6 t mer Color] white Block Black Fed Yetiow Green Bie Coe] WR = aw Aw ow ow 2 Cotor| whitew ned | | Back&white | Rea& white | Yellow & ea | Green& White| Sive & White cose] we 7 ay Fe ve iF © | oac| Color] white &Bisck | — [Black Velow | Red & Black | Vetow & Black Blue & Rea tary "eoge] we = aR RY v6 wy : Color] wniedeive | | AlackaRed | Rod Vetow |Velow 8 Green [Groen & Yelow | Bive & Yeliow Coe] wa = 7 FG w 1a) cc] : Color] White & Green | — 7 Fed Green | Yetiow & Blue [Green & Black | (Blue & Bock) coe] S = a ww = = : cowrf — = = Reda Blue | Yelow & White] (Green & Bie) 7 00-10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 tine from @. (2) Locate the number § in the row across the top, take this as @, then draw a perpendicular line down trom ©). (3) Take the point where the two lines cross as ©. This point © gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.168 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 came procedure as above to convert §5 mm to 2.165 inches. (3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 {move the decimal Point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches, Millimeters to inches 1 mm = 0.03937 in 40, 1.875 | 1614 | 1.654 | 1.693 | 1.732 | 1.772;! 1811 | 1.850 | 1.890 | 1.929 f 2244 | 2.283 | 2.923 2480 | 2520 | 2559 | 2598 | 2638 | 2677 | 2.717 2756 | 2795 | 2895 | 2874 | 2913 | 2953 | 2992 | 3032 | 3071 | 3110 3150 | 3189 | 3228 | 3.268 | 3307 | 3.246 | 3386 | 3.425 | 3465 | 3504 | 3543 | 2503 | 2622 [3661 | 3701 | 3740 | 3790 | 3819 | 3a5e | ae08 00-11CONVERSION TABLE 1 mm » 0.03937 in ° 1 2 ee 8 9 [eee | ee en tat T ° | eave | on | one | ons | oxor | a2ae | oars | oa | oast 10 0.394 | 0.433 | 0472 0512 | 0551 | 0591 | 0.630 | 0.669 | 0.709 | 0.748 zo | o7er | os | o9es | ome | 09s | ovse | 1026 | 1.083 | v102 142 20 rast | 1220 | 1260 | 1290 1339 | 1978 | 1417 1457 | 1496 | 1536 wo | asye | coe | rose | vaso | 152 | a2 | si 1080 | 1900 | 220 | I ft 50 1969 | 2008 | 2047 | 2.087 2.126 | 2.165 | 2205 2.244 2.283 | 2.323 | eee ois |e oer | co |e |e 70 2786 | 2.795 | 2935 | 2874 | 2913 | 2063 | 2992 | 3032 | 3071 3.110 so | aso | aneo | 2220 | 3260 | 2307 | 3346 3986 3425 | 3405 aso4 20 asaa | 3583 | 3.622 | 2661 | 701 | 3740 | 3700 | sane | sess sess Kilogram to Pound 1g = 2.2086 T T T T T ee eee ee le ee | | ial 10 2205 | 2425 | 264s | 2060 | 2090 | s307 | 3527 | s748 | 3068 41.69 20 | asoa | asa0 | aso | 5071 | 5191 | 552 | sraz | e983 | 6173 | 6393 20 e614 | 6234 | 7055 | 7275 7496 | 7716 | 7037 | 8157 | 8378 a598 40, 88.18 | 90,39 | 92.59 | 94.80 97.00 | 99.21 | 101.41 | 103.62 | 105.82 108.03 50 11023 11244 | 114.64 | 11685 11905. 121.25 | 12346 125.66 | 127.87 13007 co |19028 19848 19660 | 19999 | 4130 14030 14551 | 14771 | 149.01 182.12 70 154,32 156.53 | 158.73 | 160.94 163.14 165.35 | 167.55 169.76 | 171.96 174.17 80 vyea7 | 7997 | 18078 | 18298 185.19 | 16739 18960 191.80 | 19401 19621 o» | 18042 | z00s2 20280 20509 20124 anes |anrs4 | aises 21605 21825 | | : L | 00-12CONVERSION TABLE Liter to U.S. Gallon 1&= 0.2642 U.S. Gal [ee T eee alos | ae | 8 8 ia Taw | ES wl | 0268 | 0.628 0.793 | 1057 | 1321 1588) 1849 2.113 | 2378 0 | 26%) 2506 | 9170] aaa se26 3065 | 4227 a4on| a7es| sor 20 s2ea| ssis| 5812| 6076) 6.2460 660s! 6.869) 7133 7.397] 7.661 20 | 7905] s1sa| 4s) a7e) aoe 9246 9510, 974 10030 10202 40 | 10807 | toast 11095 | r1.a59 14624 11886 12152 | 12416) 12680 | 12.084 50 | 13.209 13.473 | 13.737 | 14001 | 14.205 14.529 14.795 | 15.058 | 15.222 | 15586 : co | r5a60 | ra15 | toare) se6es | es07 17471 | 17495| 17700 7968 | 10228 7 | 18482 | 18756 | to0z0 | 19.295 | 9549 19019 | 20077 20381 | 20.005 | 20.870 eo | 21194 | 21398 21.662 21926 22.190 22.456 | 22719 22983 23207 | 23511 90 | 23275 | 24040 | 24306 | 20568 4 a22 25008 25.361 | 75625 75000 | 26.59 [ee | | | 1 Liter to U.K. Gallon 1 &= 0.21997 U.K. Gal eee T_T Ta2%0| oso | oseo| ose) 1100| 1920) 1s40| 1260| 1900 0 2.200 2420| 2640| 2860| 3090| 3200| 3520/ 3740) a950/ 4.179 20 4900 | 4619/4839 5050 5279) s400| s7i9| sow! e1s0| v9 30 6599 6819!) 7.039 7.259| 7479, 7.969| 7.919| 8139| 8359| 8.579 40 0799 9018 9258 9489 9.679 9850 | rax110/| 10220] r0580/ 10278 so | 099 11.281 11438 11658 11878 12098 12.918 | 12528 | 12.758 | 12978 60 13198 318 | ra696 | 12958 | 07e 14208 | 14518 | 14,738 sass | sare 70 | 18398 15.618 15.838 | 16058} 16.272 16.498 | 16.718 | 16938 | 17.158| 17.978 80 17.598 17.818 | 18037 | 18257 | 18477 18.697 18.917| 19.137] 19.357) 19.577 | r907 ron | | ae || nae ait? | 21.97 | 21ss7 | 21777 1 | i 00-13CONVERSION TABLE kam to ftlb 1 kgm =7.239 fb ee E | | 72| us| a7) 20| 362] «aa | sos | 579 5. 20 1447 1519 | 1691 | 1664 | 1736 } 1908 | tear | 1959 | 2025 2008 go | x70 | 202) ass | 2587) 250 | 2532 | 2604 | 2676 | 2749 | 2s 40 289.3 | 296.6 | 3038 | 311.0 | 3183 | 326.5 | 3327 | 340.0 | M72 | 3544 | | so | 617 | s6e9 | 3761 | aaa | s906 | aoe | 2051 | arza | aios 4268 60 agao | 442 | 4485 | 455.7 | 4629 | 4702 | 4774 | 4806 | 4918 | 499.1 70 5063 | 5135 | 5208 | 5280 | 5352 5425 | S197 | 5559 | 5642 5714 80 9786 | 585.9 | 593.1 | 600.3 | 6076 614.8 | 6220 | 629.3 636.5 643.7 ~ 6510 | 6582 | 6654 | 6727 | 6799 | 687.1 | 6944 | 7016 | 7088 | 7161 | | | oo | rsa} 7905) 7078) 1450 1522 | 7595 7667 | 7738 | 7812 | 7084 110 795.6 | 802.9 | 810.1 | 8173 | 824.6 | 831.8 | 8390 | 846.3 8535 | 860.7 120 eso | 275.2 9824 | 39.7 | aa69 | 904.1 | 9114 | 9186 | 9258 | 9331 130 9403 | 9475 | 9548 | 9620 | 9602 9765 | 983.7 | 9909 | 998.2 10054 jee sso | ota | oeaz /so004 | Hose snag /staus sia jess [i328 11500 reo | 11573. 14645 | 1971.7 | 11790 | 1186.2 | 11934 | 1200.7 | 12079 | 12151 12224 yo | t1286 | 12368 | 12481 | 12513 | 12585 | 1265.8 | 12730 | 1280.1 | 12875 12987 re0 | 1301.9 | 1909.2 | 13164 | 13236 | 1330.9 | 1338.1 | 1345.3 | 1962.6 a | 1367.0 190 | 19743 | 1381.5 | 9807 | 1396.0 | 1403.2 | 14104 [sea va2ag9 | 1432.1 | 14394 [i | ae 00-14CONVERSION TABLE kg/cm? to Ib/in? Tkg/em? = 14,2233 Ib/in? Cee [>]+[s]e]oe]> 1 H 10 1422 1565 | 1707 | 1849 | 1991 | 2134 | 2276 | 2418 | 2560 | 2702 2 | 204s | 2067 | 3120 | 271) are | ass6 | 2608 | se40 | 003 | a125 30 4267 | 4409 , 485.1 | 4604 | 4036 4978 | 5120 | 5263 | 5105 | 5547 40 568.9 | 583.2 | 597.4 | 611.6 | 625.8 640.1 | 6543 | 668.5 682.7 | 696.9 so | iz] 7254 | 7396 | 7508 | 7001 7923 | 2005 | a107 | e250 | se 60 asa4 | e676) ears 96.1 9103 9245 | 9387 | 9530 | 967.2 | 9814 70 9956 | 1010 | 1024 | 1028 | 1083. | 1067 | 1081 | 1095 | 1100 | s124 so fate tnsz | 166 | nner 95 | 1208 | 1223 | azar | 1252 | 1266 20 1280/1294 © 1309 | 1323 | 1337 j1951 | 1965 | 1380 1398 | 1408 100, 1422 1437 1451 1465 1479 1493 1508 1522 | 1836 1550 110 | 15651579 | 15091607 1621-1636 | 1650 | 1668 | 1678 | 1609 120 1707/1721 1735 17491764178 | 1792 1806 | 1821 | 1835 130 | 1949 | 18691877192 | 19061920 | 1904 | 1949 | 1969 | 1877 140, 1991 | 2005 2020 2034 2048 2062 2077 2091 2105 2119 150 [zis | 248 21622176 2100 2208 | 2219 | 2259 | 2247 | 2060 160, 2276 2290 | 2304 2318 (2333 2347 2361 2375 2389 2404 170} 2418 2432, | 2448 | 2460 | 2475 | 2489 | 2503 | 2518 | 2532 | 2546 reo | 25602574 2589-2609 | 2617, | 2631 | 2646 | 2650 | 2674 | 2088 sso 2102 arm army zrus | arso | arra | ran [na | 2018 a0 | | | 200 |aets | 2es0 27a 2007 | sor 210 | 2000 | ate | 2088 | 2578 210 | 2967 | 9001015 | 2090 | 3048 | 3058 | 3072 | 3086 | 101 | aris 220 312g /31a3 31883172 | 3186 3200 | 3214 | 3229 | 3243 | 3257 230 32713286 3300 | 3314 gaze | a343 3357 | 3371 | 3385 | 3300 20 [aaa ama | aase [2470 | 405 | 3450. | asia | asar_ | asco | 3028 00-15CONVERSION TABLE Temperature Fahrenheit-Centigrade Conversion. —A simple way to convert a Fahrenheit temperture reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures ‘These figures refer to the temperature in either Fahrenheit or Centigrade degrees, If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left If itis desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right. c + | + | |e . “aoa | 20 wag | | stu | ze | as | sme | ma |e | ama m2 | 38 cnr | a2 | sas | sa | a | tee | oe | a2 | ime ma | W0 cos | 12 | ssa] eo | ae | ree | mea | 9 | tere “ny | 28 Too | iw | sr2 | oa | a | vz0z | 259 | ox | sen 28.9 -20 94 15 590 100 | 50 122.0 20.4 85 185.0 as -22 | -a9 | w | cos | we | s1 | rz | 200 | 0 | 1060 ne je | cea | 7 | exe | ua | sz | t2s6 | aoe | or | t036 a2 ta | cre | te | eee | arr | so | azz | ata | oe | 000 csr |e | 32 | 72 | a | ez | rz | se | rzez | arr | oo | oz Ter | as | so | -s7 | 2 | eso | ize | ss | ss | azz | 0 | too ce) | 6a | -s1 | 21 | os | a | se | sxe | ee | or | tose -25.0 “13 86 8 | 2 ne 139 87 1346 B32 92 197.6 Tua | a2 | soa | cso | 2 | ra0 | ta | se | zee | ase | oo | 04 mo | wo | wo | 30) 2% | mo | se | eo | woo | aso | os | a0 228 9 158 a3 | 2 78.8 16.1 6 1418 356 6 204.8 ma | oe | w6 | -22 | 2 | we | v7 | 2 | 1s | 261 | 7 | mee Sareea 194 -22 2 824 1W72 os | 1454 36.7 98 208.4 cua | ce | aa | cee | os | ez | are | oe | tere | a2 | oo | 2102 oe |) mo] a4 jo) wo | wa | | oo | ae | a | 20 -m0 | 4 | ms | -o6 | 1 | os | 9 | 66 | 108 | we | 10s | 2210 Tbe 3) we | oo | ams | ee | or | ee | a | to | 20 wes | 2 | 24 | 06 | a3 | ore | zoo | op | res | a1 | tts | x00 3 | -1 | 202 1 | 34 | s32 | 206 | 69 | 1862 | 429 | 120 | 2420 sa | “| a0 fo | a | we [ns fw | so | any | om | ome 1 | 28} 22 | as | ose | az | 7 | rs | see | 130 | zee >| a6 | 28 a7 | 6s | x22 | 72 | ers | ara | ras | a0 3 | are | 3a | 38 | wom | 228 | 73 | 34 | ooo | vo | amo «| a2 | 39 | 39 | woz | 23 | 7 | sos2 | 627 | vs | m0 5 41.0 44 | 40 104.0 239 75 | 167.0 656 150 302.0 cus | 6 | aaa | 50 | a | ves | 2 | 2 | ree0 | sa | 155 | ans cas | 7 | as | 58 | a2 | tore | 20 | 2 | se | m1 | 190 | az00 cna) 8 | asa | 61 | a3 | toe | 26 | 7 | arze | rae | tes | 2200 Tae | 9 | a2 | 7 | a | mz | zr | 90 | sz | x67 | 170 | anno “22 | 10 | soo | 72 | «8 | mao | 27 | 2 | 10 | v4 | 76 | aero a neneensnalaneenennnnnelnsene 00-1601 GENERAL o22T01 Specifications : 01-2 Table of oil, coolant quantities 01-13SPECIFICATIONS Machine model a0. Serial No. 10001 and up ‘= ] Operating weight (excl operator) (to) 11,650 S| Gross woight (inc. one operaton tka) 11705 g| Max speed (hemi) 2° | Traction (N kg 54,880 (5,600) £]Gradeabitty tan 0) 9 60 S| Min. turning radius + 2wheel steering (™) 70 £ sAwheel steering (m) 39 Operating performance 80 : 80%251 45) z 4935178) 3 | with outiggers fully extended total cm denasiital 8 | cheumterence doceanan 2 4054011791 © | Over-front operations without outriggers (tx m) 1.0 x 5.04.5 —7.8] Boom length tm 45—177 sib length ) a7 | Wicth with outiggers (Front Rear) (rom 4970 8| extended 5 (oft- Right) (enemy aso S| Max. iting height (Boom only) im 189 a ot ib) im 23 3 | Rope speed of main winch é Tigh speedLow speed) (avin) 11186 é Hook speed of main winch (High speed/Low speed) (eodminy zane Rope speed of auxiliary winch (High speed/Low speed) (m/min) 042 | Hook speed of auxiliary winch ‘igh speedi.ow speed) ——_(mimin) 042 | Working range of boom (eg) 9589 Booming lift speed (see. 2 Boom telescope speed (sec. 40 {Boom length : 45 —17.7m) Swing speed wom) 25 Note:The valve with{ | are the values of boom length 01-2 o22T01o22To1 Reduction ratio Machine mode! Lweo-1 Serial No, 10001 and up Overall length (om) 6.820 Overall wiath (mm) 2,000 £ | overalt height (mm) 2,820 2 | Wheeibase (onmm) 2,750 & | Tread tooth tront and rear) (mm) 1,680 Ground clearance (mm) 308 Tail swing radius fom) 1,360 Model Komatsu S6095L-1 Type ‘A-cycle, water-cooled, inne, vertical, direct injection type with turbocharger No. of evinders - Bore x stroke (mm) 68-95% 115 Piston displacement (ce) 4,890 Flywhee! horsepower (kw HPP 110 (1481/,000 2) g| Mex torque (Nm tkgm/rprm) 435.1 (44.49/1,800 | 2] Max. speed under no load (rpm) 3,450 (during travel)) E 2,200 {in operation) Ein pce uncer no ood vom 280 Min. fuel consumption (g/kw-h (g/HP-h) 121.4 (162.7) Starting motor 24V, 4.5K Alternator 24V, 508 Battery 12V, 95641 x2 Torque converter Type TeAZ7-34 Structure 3-element, single-stage, 2-phase Lock-up clutch Hydraulically-operated, wet type, single disc clutch Transmission Constant mesh type, multi-shaft type, hydraulically- 5 ‘operated, force-feed lubricating type, 4forward and = Breverse speeds | Reduction gear Hypotd type, splash lubrication Dierentiat Straight bevel gear, splash lubrication 2.687 Final drive Reduction ratio Planetary gear, splash lubrication 4500 01-3Machine model Lwa0-1 Serial No. 10001 and up Steering system Front and rear wheels, hydraulically opera steering lock hydraulically operated (in the cab) + For transmission (SAL022) | | owvenne Front wheel dive (whoo : Front ona ween ft sie Suhel) © 2 | ano rype bot rot and oa) Fully flatng ante 2| § | suspension type (both front and roan Longitudinal serilipica ea peng type | ~ | tires (both front and rear) 118225 - 16PR el neers para pat 13 ae g | Service brake (both front and rear) Air-over-hydraulic type, dry type, disk type | Parking brake Spring boosted intornal expanding drum type en ate sat g | Dive ope Hyaraute moter 8 reduction gor Ptanetary gear type 2! Brake type ‘Wet, multiple disc type, spring boosted é (Hydraulic pressure release) Type Gear type Delivery (¢/min) ~ Sot presure (MPa ee For winch motor, outrigger and boom at snpine Speed 3350 pm ond Yor athons orange se of 3459 or «For wineh and outigger 607208210 Pees com and tandem) LOZ) §] £| -sortoom saLoan ea © | 8 | ror storing cooler and pilot (SAL025) 021720078) 8 | $ |“ intriple with those for swing and transmission) 5 &| «ror wing $A10061 27 — 1867070 3/2 78.5 —26 (27) Drive type + For winch motor, boom outrigger + For steering, cooler, pilot, swing, transmission Engine connected via clutch Engine connected directly 01-4 o22T01o22To1 Machine model uweo-1 Serial No. 10001 and up Vi Type xNo. + For main and auxiliary winches, boom iting, ‘elescopic and swing motions 5-spool valve + For clutch change of main and auxiliary winches 2-sp0o! valve (direct action) + For releasing brakes for unwinding main and 'g| auxiliary winches and boom lifting, telescopic 3 | and swing brake release 5-spoo! solenoid valve 3 | For outrigger, boom 1-spoo! solenoid valve § | + For outrigger jack, side 1-sp001 solenoid valve x4 + For steering mode, reverse steering, rear whe! Steering, low tension setting or winch rear Steering lock, PTO changeover, PTO setting 1-sp00! solenoid valve x7 + For unloading pilot pressure 1-poppet solenoid valve + For operating 6 spool valve PPC type x3 Boom lifting eylinder Type xNo. Double-acting piston type x1 $| | -orex outside diameter of rod stroke (mm) 150 110-1463 E | §) Boom telescopic cylinder Type x/No. Double-acting piston type x2 B| £| «Bore x outside diameter of rod — stroke (mm) 80 x 60 3,300 B3 2 3 | Outrigger jack evlinder Type x No. B | « soce x outside dlamatar of rod stroke en) Outrigger slide cylinder Type x No, + Borex outside diameter of rod stroke (mm) Steering cylinder Type xNo. Double-acting piston type x 4 + Bore x outside diameter of rod stroke (mm) 4525-2465 Winch motor ‘Swash plate piston type, fixed type x 2 ‘for main and austiary winches) Swing motor ‘Swash plate piston type, fixed type Hydraulic tank Hydraulic filter Box type, open Tank return side, 10 micron 01-5Machine model we0-1 Serial No. 10001 and up Type Box ype, stage E 8 | Telescope Hydraulically activated, nd and 3d, th and 2 Sth jibe svmultaneots telescoping type € ib Cxpansion/retraction selecting type) = | ie Pushed forward by cylinder 8 3| | type Boxtype, tstage 8 | Retract Builtin type Expansion Hydraulically operated Single top Equipped (when ibis retracted) Type + No Hydraulic drive type, 2-mator,2 | castor | sac roner ior ee eee cRD Hypoy B 7 Hypoy C te { @ | creveon | +beo 40 Uniaraa gear | Unr-dty grease 2 - 9 | conoco | stat motor oi Unveran gear | sunt ornse - Muttiperformanee 3C je Transelt EP | met ( ae Performance 3C Tranself EP type 2 eeu Exsoube 02 “Esso X03 exx0N Gear of GP n “estlube X03 Era Beacon £2 Al season cote aro GX eo *Esso heavy duty i exon heavy dy | Super duy meter at | Multipurpose gear | Gulrown EP2 Aniteot ana te "Super duty plus lubricant, Gulfcrown EP special coolant Dstvae 1300 Mobitn era 12 | Moan | "Demacsuper ee Mobigrease 77 : TOW-30, 15W-40 ret Mobilgrease special 01-15Engine Oi Ansitnaze {€0 or cel Coolant SAETOW, 90 40 oar Grease | supe . Ethylene Glycol m aa 10W30, 15W40 IGL-4 or GL-5] [Lithium-Base] 7 pea i (The 1540 oi Aco, 80, 140 UGI No 2 rent marked * is CE.) meats Multi-purpose white “supreme duty ntt-pumose cosa | grease 705 Anisreee and “ PENNZON. | feet motor oi Mult:purpose 4140 | 707L White - bearing | summer coolant orease FINA potonie N 15 | PETROFINA | FINA Kappa TO Fa prone N | FINA mason 12 | INA tomidor Spirax & ve | swe, | mimuta x SP Ey | Avia EP ease : : Sunoco uta presige | Sunoco antireere 7} sun : —— xP fd sree ba: ‘Sun prestige 742 coolant urs super plus MunifokEF2 Code 2098 state 18 | Texaco Mutigear eee Ursa premium bectee ‘Starplex 2 antifreeze coolant Tora €P 19 | TOTAL eusle: Total transmission Multis EP2 Antigel/antifreeze “rua x ™ 20 | union — | Guard we gear tube ts | Unoba €P i “Turbosr Mutigear nr | veeoo. | Diese sr Muitigoa 8 - Anuireere Moe Mutigoar¢ 01-16 ® o22T0110 STRUCTURE AND FUNCTION & Power train hydraulic circuit diagram. Power train hydraulic system diagram ... Rear steering lock system ‘Suspension Brake and air systems ... f= Brake and air circuit diagram... Brake and air piping diagram Hydraulic circuit diagram 7 Hydraulic equipment arrangement drawing Hydraulic tank ... Flow priority valve ... Center swivel joint Steering hydraulic system Priority valve Steering valve ... Steering mode selector valve . Reverse steering compensation valve Rear wheel steering valve Outrigger hydraulic system Outrigger selector valve Outrigger individual valve : Work equipment hydraulic system PPC valve. 10-6 10-7 10-40 10-41 10-42 10-43, 10-44 10-62 10-64 10-69 10-70 O71 10-72 10-75 10-76 10-78 10-79 10-80 10-82 10-84 10:86 10-87 10-92 Main control valve 10-98 5-spool solenoid valve .. sooo 10-100 Clutch vaive . ve 10-101 Travel(Operation selector solenoid valve .. 10-102 ‘Swing motor + 10-103, Cab cooler motor see 10-104 Winch motor o 110-105 Boom telescope cylinder. 110-108 Relief valve 10-107 BOOM wr soe 10-108 Hook... 110-123, Winch one 10-124 Winch brake . 10-126 Winch clutch. 10-127 Chassis outrigger: 110-129 Revolving frame : 10-130 Electric circuit diagram... sees 10-132, Location of electrical system component «10-135 Electric swivel joint 110-146 Multiple data transmission device. ses 10-148, Overload safety system. 110-157 Automatic gear sift system .... 10-167 Outline and operation of electric circuit ....... 10-168 10-1 @POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM §oen------ 0-10MFa I if pe Fe eae = [Wa ts 20MPs (85 kare’) - Y + zaro10%3 10-6 022701o2eTor POWER TRAIN HYDRAULIC SYSTEM DIAGRAM (ENGINE START, TRANSMISSION SHIFT LEVER "NEUTRAL") 5 16 v 2 bad zarF001 1. Strainer 2. Hydraulic pump (SAL(1)-22) 3. Oillfilter 4, PTO Clutch solenoid valve 5. PTO Set solenoid valve 6. Rear steering lock solenoid vaive 7. PTO Clutch 8. PTO Set and maximum speed control eylinder 9. Rear steering lock cylinder 10. Pilot vaive 11. Pilot fitter 12. Priority valve 13. ECMV 14. Main relief valve 15, Transmission solenoid valve 16. Transmission solenoid vaive 17, Transmission solenoid valve 18. Transmission solenoid valve 19. Torque converter lock-up solenoid valve 20. 2/4 drive changeover solenoid valve 21. Check valve 22. Manual selector 23. FR selector 24. HL selector 26. Range selector 26. Torque converter lock-up modulation valve 27. Relutch 28. FH clutch 29. FL clutch 30. Istclutch 31. 2nd-cluteh 32. Accumulator valve 33, 2/4 drive changeover cylinder 34. Torque control lock-up clutch 38. Torque converter 36. Torque converter outlet regulator valve 37. Oil cooler 38. PTO lubrication 38. Transmission lubrication 10-7REAR STEERING LOCK SYSTEM Bracket Cylinder | Lock-pin Knuckle arm Center detecting limit switch 10-40 zareoroas OUTLINE The rear steoring lock system is used to lock the rear steering at the time of front steering. To wark the system, the solenaid valve is oper- ated with the relevant ewitch at the operator's seat and the lock cylinder is extended and re- tracted by hydraulic pressure. 022T01o22To1 SUSPENSION 1. Shock absorber 2. Leaf spring zarFov049 OUTLINE + Leaf spring (both-end eye type) and automobile shock absorber are used to dampen shock from road surface. ‘The leaf spring is a semielliptical spring, 10-41BRAKE AND AIR SYSTEMS AIR SYSTEM + Compressed air from the air compressor is fed to the wet tank, where it is dehydrated before being fed to both the front and rear dry tanks. When the air circuit is filled with air generated by the air compressor and the air pressure in the wet tank comes up to the cut-out pressure of the air governor, the air governor is activat- ‘ed to open the unloader valve of the compres- sor. The compressor then becomes free of load and does not compress air. When air is supplied to the tank and the air pressure comes up to the cut-in pressure of the air governor, the air governor is activated to close the unloader valve and operate the com- pressor. If the air governor does not work well, the air pressure in the tank will increase. So, to protect the air circuit, a safety valve is activated to release the air into the atmosphere. BRAKE SYSTEM + When the brake pedal is depressed, the master cylinder generates hydraulic pressure corre- sponding to the depressing force. The pres- surized oil passes through the swivel joint and operates the brake valve. + When the brake valve is operated, air in the dry tank flows into the brake chamber, pressurizing the brake oil in the master cylinder. The pres surized oil pushes the caliper disk piston and operates the brake. 10-42 PARKING BRAKE + The parking brake is designed to operated by the spring of the parking brake cylinder and r leased by air pressure. So, when the air pres- sure is lower than the force of the parking brake cylinder spring, the brake is always ap- plied. When the air pressure increases to the specified level, the solenoid valve is activated to supply compressed air to the parking brake cylinder to release the parking brake. EXHAUST BRAKE + The exhaust brake switch at the operator's seat is turned on to operate the exhaust brake sole- noid valve, enabling compressed air to be sup- plied to the exhaust brake cylinder to operate the exhaust brake. o22To1022T01 BRAKE AND AIR CIRCUIT DIAGRAM |. Air compressor . Air tank (wet) . Safety vaive Air governor Check valve Airtank (dry) Brake valve Regulator valve Ot greuit B (for auxiliary brake) 8 9. Regulator valve (for front brake) 10. Regulator valve (for rear brake) 11. Solenoid valve } —T {for auxiliary brake) th 16 Double check valve Air master (front) 16 i " PMP MA YRo Air mastor (rear} Front bral Rear bral . Master cylinder Reserve tank . Reserve tank Parking brake solenoid valve Parking brake cylinder . Parking rake . Exhaust brake solenoid valve |. Exhaust brake . Drain valve . Hydraulic swivel joint Air coupler Air drier (OP) . Oi filter Desiccant Air pressure sensor Low pressure switch . Broke stop lamp switch . Overstroke switch Emergency brake limit switch Parking brake indicator switch Oi cicut 040.02 MPs ose a i® J a " 2 (ekgem ekgier) SRESSESBRSERESRYS Sass azos ag3MPa ! e5tgem! 2eTFONUsO 10-43BRAKE AND AIR PIPING DIAGRAM ( SS 10-44 1. Front brake 2. Master cylinder 3. Brake pedal 4. Swivel joint 5. Rear bi 6. Brake oll reservoir 7. Exhaust brake cylinder 17. Parking brake lamp switch solenoid valve 18. Parking brake s 49. Parking brake 20. Parking brake cylinder 29. Air compressor 022701HYDRAULIC CIRCUIT DIAGRAM UPPER SECTION 10-62 39 MPa okie Tap Pa ciep eer 463 MPa i187 kare O.61 M(t Agen as a 2 ae 0.21 Pe (21 kgier 2.8 MPa eo kgler) 2.2 MPaiz0kalcer Dah 3 Bagie 8 as MPa (Se Te ugien) a Kees Pe (0 glen) #13 20M 210 kale 22TFo10884 1. Air bleeder 2. Check valve for elutch 3, Rotary joint for winch clutch 4. Brake (Autor 5. Clutch 6. Brake (Pedal) 2. Piston motor for main winch 8, Piston motor for auxiliary winch 9, Main pedal brake 10. Auxiliary pedal brake 11. Clutch valve 12. Line filter 18. 6-spool solenoid valve 1A, Unloader valve for OSS (Main winch wind- ing) BB. Unloader valve for OSS (Auxili winding) 18C. Unloader valve for OSS (Boom lowering} 13D, Unlaader valve for OSS (Boom extending) 13E, Parking brake valve for swing 14, Main control valve 114A. Main winch spool ry winch my 148. Main winch spool 14D. Boom telescoping spool 14E, Swing spool 14F, Port relief valve 14G, Boom main relief valve 15, Shuttle valve 16. Shuttle valve 17. Pilot circuit relief valve 18. Travel/Operation selector solenoid valve 49. Safety and suction valves for cooler drive motor 20. Piston motor for cooler drive motor 21. PPC valve {for lever 22. PPC valve (for pedal and lever) 23. PPC valve (for lever) 24. Oil cooler unit (OP) 24A. Relief valve 248. Suction valve 24C. Solenoid 24D. Fan drive 24E, Oil cooler 24F. Cooler safety valve 28. Piston motor for swing 2A. Piston motor 25B. Brake valve 26. Swivel joint 27. Lift cylinder assembly 27A. Lift cylinder 278. Holding valve 28. Center swivel joint 29. Hook retract mode selector valve 29A. Hook retract low pressure relief valve 298. Hook retract mode selector solenoid valve 30. Book telescoping cylinder 30A. Counterbalancing valve 30B. 1st telescoping cylinder 30C. 2nd telescoping cylinder 31. Priority valve 31A, Relief valve 31B. Spool 32, Line strainer 33, Stoering valve 34. Check valve 38. Air breather oz2T01o2aTo1 LOWER SECTION Front side Right side | ‘Siigel sek 14 Hear side— 15, Tacs] [sige T1069 |. Slide cylinder . Jack cylinder Double pilot check valve Outrigger changeover solenoid valve . Steering cylinder Hydraulic pump (SAL(1)-25+6+22), . Hydraulic pump (SAL(1)-28+28) . Hydraulic tank . Breather . Return filter |. Swivel joint Flow priority valve Steering mode selector valve 134, Changeover solenoid valve for rear 2-wheel steering 138, Changeover solenoid valve for rear wheel and 4-wheel steering 18C. Changeover solenoid valve for reverse steering compensation Changeaver solenoid vaive for outrigger selector . Main rotiot valve 148. Spool 14C. Port relict valve Power train hydraulic system cir cuit 10-63HYDRAULIC EQUIPMENT ARRANGEMENT DRAWING LOWER SECTION 10-64 z2TF01070 022701o22T01 maroon a 10. n 12. 13. 4 ‘Steering mode selector vaive Solenoid selector valve for two rear wheel steering |. Solenoid selector valve for reverse steering cor- rection compensation Solenoid selector valve for rear/four wheel drive Flow priority valve Hydraulic pump (SAL(1}-28+28) Hydraulic pump (SAL(1}-25+6+22) Steering cylinder Outrigger individual valve Hydraulic oi! tank Outrigger selector valve Slide eylinder Double pilat check valve Jack cylinder 10-65UPPER SECTION (1/2) touzzo zerorare 10-66022701 . PPC valve (for pedal and lever) . Last chance filter . Pilot circuit reli valve Travel/Operation changeover solenoid valve PPC valve (for lever} Last chance fitter Cooler drive piston motor . Check valve Steering valve Relief valve |. Hook retract changeover solenoid valve . Clutch valve 1. Priority valve Shuttle valve Shuttle valve Safety valve and suction valve assembly for cooler drive motor Line filter . 5-spool solenoid valve Main control valve Center swivel joint ‘Swing piston motor 10-67UPPER SECTION (2/2) aareo07a 10-68 1. Boom lift cylinder 2. Courterbalance valve 3. Strainer 4, Rotary joint 5. Winch piston motor (for auxiliary winch) 6. Winch piston motor (for main winch) o2zT01o22T01 HYDRAULIC TANK => 4, 5. 6. 7 \. Return port Suction port Tank Return tube ap (with breather) Suction tube Drain plug Return filter Oil level gauge zarFo1078 OUTLINE + The hydraulic tank has a built-in return filter. 10-69FLOW PRIORITY VALVE Piston Body Stopper Spring Bee P port (from pump) PS port (to priority valve) OUT port (to tank) oe 10-70 z2rF01076 FUNCTION + When the hydraulic pump is rotating at high speed, only the necessary amount of oil is sup plied to the hydraulic circuit to prevent hydrau- lic pipe resistance loss, and any excess is re- turned to the tank. Controlled flow amount : 20 — 27 6/min. oz2T01022701 CENTER SWIVEL JOINT 1. Flange 2. Plate 3. Body 4. Slipper seal 5. Shaft 2aveonia7 A. Aport (Winch) 8. B port (Swing) ©. C port (Boom) D. Dport (Pilot) E. E port (Steering) F. F port (Steering) G. G port (Drain) H. H port (Return) |. Iport (Accelerator) 10-71STEERING HYDRAULIC SYSTEM CIRCUIT DIAGRAM OF HYDRAULIC SYSTEM tT" TH OUTLINE + The steering hydraulic circuit is intended to supply oil from the pump to the steering circuit via the priority valve. + The priority valve supplies the necessary amount of oil to the steering valve (orbit-roll valve) irrespective of the engine speed but ac- cording to the steering speed. + When the steering valve is not operated, the priority valve lets all the oll from the pump flow into the cab cooler motor. + The steering mode select switch at the opera- tor's seat is turned on to operate the steering mode selector valve (solenoid valve) for chang- ing the steering mode. + Four steering modes are available: "Front wheel", "Rear wheel", "Crab" and "Coordinated" + Reverse steering is also possible by using the reverse steering compensation switch at the operator's seat. + Only the rear wheels can be locked by pressing the hydraulic cylinder pin. 10-72 fh uy z1F0077 Solenoid valve operation table O: Excitation Mode Soe fer |eb | een iad Front 2-wheel Rear 2-wheel o}o 4-wheel coordinated ° 4-wheel crab ° Reverse front 2-wheel ° Reverse rear 2-wheel_ | © ° Reverse 4wheel coor S ° o22To1DIAGRAM OF STEERING HYDRAULIC SYSTEM a) 1 022701 OWE Tocab cover 2aTF01078 1. Hydraulic pump (SAL(1)-25+6+22) 8. Front right steering c 2. Flow priority valve 9. Front left steering cylinder 3. Line strainer 10. Rear right steering cylinder 4. Priority valve 11, Rear left steering cylinder 4A. Spool 12, Swivel joint 4B. Relief valve 5. Check valve Steering valve 7. Steering mode selector valve 7A. Changeover solenoid valve for rear 2- wheel steering 7B. Changeover solenoid valve for rear wheel & 4-wheel steering 7€. Changeover solenoid valve for reverse steering compensation 10-73