Professional Documents
Culture Documents
Shop
Manual
WA380=
SERIAL NUMBERS
VVA380-3 - 50001
andw
This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or
disclosed except in accordance with written authorization from Komatsu America International Company.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or add improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication.
It is recommended that customers contact their distributor for information on the latest revision.
April 1998
Copyright
International
Company
No. of page
01
GENERAL . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..~.......
01-I
10
STRUCTURE
10-l
20
TESTING
30
DISASSEMBLY
40
MAINTENANCE
00-2
0
AND FUNCTfON
AND ADJUSTING
.. . . . .. . . . . . . . . . . . . . ..*..............*.
. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .
AND ASSEMBLY
STANDARD
20-I
. . . .. . . . . . . . . . . . . . . . . . . . . . . . .. . . . .
30-l
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20-129
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20-130
20-282
20-387
10-186
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20-131
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20-132
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20-133
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20-134
20-303
20-392
10-190
20- 40
20-201
20-304
20-401
10-191
20- 41
20-202
20-305
20-402
10-192
20- 42
20-203
20-306
20-403
10-193
20-43
20-204
20-307
20-404
IO-194
20- 44
20-205
20-308
20-405
10-195
20- 45
20-206
20-309
20-406
70-196
20- 46
20-207
20-310
20-407
10-197
20- 47
20-208
20-311
20-408
IO-198
20- 48
20-209
20-312
20-409
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20-210
20-313
20-410
10-200
20- 50
20-211
20-314
20-411
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20-212
20-315
20-412
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20- 52
20-213
20-316
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20-214
20-317
20-414
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20-215
20-318
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20-216
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20-217
20-320
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20-
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20-252
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20-355
20-422
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20-356
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20-255
20-357
20-451
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20-103
20-256
20-358
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20-104
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20-258
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20-i59
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20-107
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20-108
20-261
20-364
20-457
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20-109
20-262
20-365
0
@
20-458
20- 16
20-110
20-263
20-366
20-459
20- 17
20-111
g)
20-264
20-367
13
20-460
20- 18
20-112
20-265
20-368
20-461
20- 19
20-114
20-266
20-369
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20-115
20-267
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20-269
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20-525
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30-157
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20-526
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30-103
30-158
30-213
20-527
30- 48
30-104
30-159
30-214
20-528
30- 49
30-105
30-160
30-215
20-529
30- 50
30-106
30-161
30-216
20-530
Q)
30- 51
30-107
30-162
30-217
20-531
30- 52
30-108
30-163
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30-109
30-164
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30-110
30-165
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30-
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30-111
30-166
30-221
30-
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30-112
30-167
30-222
30-
30- 57
30-113
30-168
30-223
30-
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30-114
30-169
30-224
30-
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30-115
30-170
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SAFETY NOTICE
SAFETY
SAFETY
SAFETY NOTICE
operation.
The
are both effective and safe. Some of these techniques require the use of tools specially
designed by Komatsu for the specific purpose.
To prevent injury to workers, the symbol A
manual. The cautions accompanying
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,
00-3
SAFETY
SAFETY NOTICE
00-4
original places.
Replace any damaged parts with new parts.
. When installing hoses and wires, be sure
that they will not be damaged by contact
with other parts when the machine is being operated.
20. When installing high pressure hoses, make
sure that they are not twisted. Damaged
tubes are dangerous, so be extremely careful when installing tubes for high pressure
circuits. Also, check that connecting parts
are correctly installed.
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 assembled before taking any measurements.
24. Take care when removing or installing the
tracks of track-type machines.
When removing the track, the track separates suddenly, so never let anyone stand at
either end of the track.
GENERAL
FOREWORD
FOREWORD
GENERAL
This shop manual has been prepared
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.
or
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
When
AND UPDATlNG
a manual
(@@@....I
pages.
is revised,
an edition
mark
of the
REVISIONS
Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.
SYMBOLS
So that the shop manual can be of ample practical use, important safety and quality portions
are marked with the following symbols.
FlLlNG 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):
J
Special technical precautions
10 -3
Yz
Tightening
torque
;I
coatpEgbJfF%fjf~y
Oil.
3. Additional pages: Additional pages are indicated by a hyphen (-1 and number after the
page number. File as in the example.
Example:
10-4
12-203
IO-5
12-204
00-6
:
w
Water
T-
Drain
HOISTING
FOREWORD
INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Heavy parts (25 kg or more) must be
lifted with a hoist, etc. In the DISASSEMBLY AND ASSEMBLY
section,
every part weighing 25 kg or more is
indicated clearly with the symbol &
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
-r
Allowable
load
mm
kN
tons
10
9.8
1.0
11.2
13.7
1.4
12.5
15.7
1.6
74
21.6
2.2
16
27.5
2.8
18
35.3
3.6
20
43.1
4.4
22.4
54.9
5.6
30
98.1
10.0
40
176.5
18.0
50
274.6
28.0
60
392.2
40.0
100%
88%
f!f
79%
71%
41%
sADoo479
30
Lifting
60
mole
90
(deoreel
120
150
SA0004e.0
00-7
COATING MATERIALS
FOREWORD
COATING MATERIALS
j, The recommended coating materials such as adhesives, gasket sealants and greases used for
disassembly and assembly are listed below.
* For coating materials not listed below, use the equivalent of products shown in this list.
Category
<omatsu code
LT-IA
Part No.
Qw
Container
790-I 29-9030
150 g
Tube
790-I 29-9050
20 g
(2 pes.)
olyethylenc
container
LT-2
09940-00030
50 g
LT-3
790-129-9060
(Set of adhesive and
hardening
agent)
Adhesive:
1 kg
iardening
agent:
500 g
Can
LT-4
790-129-9040
250 g
olyethylen
container
Holtz
MH 705
790-126-9120
75 g
Tube
Adhesives
Three bond
1735
Aron-alpha
201
Loctite
646-50
LG-1
50 g
29
79A-129-9110
50 cc
790-129-9010
200 g
790-129-9140
790-129-9130
Tube
Gasket
sealant
00-8
LG3
790-129-9070
1 kg
Can
COATING
FOREWORD
Category
Komatsu code
Part No.
Container
Qtv
LG-4
790-129-9020
Tube
200 g
LG-5
~790-129-9060 1
1 kg
MATERIALS
/ p~$~;e/
.3b,;;;;;raulic
piping_ plugs, elbows,
Used as sealant for tapered
Gasket
sealant
790-129-9090
Molybde_
num
disulphide
lubricant
L-G
/ ogg40-ooo51 /
Can
09940-00040
200 g
G2-Ll
SYG2-4OOLI
SYG2-35OLI
SYG2-4OOLI-A
SYG2-160LI
SYGA-16OCNLI
GZ-CA
SYG2-400CA
SYG2-350CA
SYG2-4OOCA-A Various
SYG2-16OCA
SYGA-16OCNCA
Various
Molybdenum
disulphide
lubricant
SYG2-400M
400 g
(10 per
case)
Tube
Various
Grease
LM-P
Various
Belows type
00-9
FOREWORD
STANDARD
TlGHTENlNG
TORQUE
Width
across flats
I
mm
mm
Nm
6
8
10
12
14
10
13
17
13.2+1.4
31+3
66+7
113+10
177+19
1.35kO.15
3.2kO.3
6.7f0.7
11.5+1
18+2
z;
28.5+3
39f4
56+6
76F8.5
94.51 10.5
kw
16
18
20
22
24
30
32
36
279+30
382539
549f59
745&83
927+103
z
33
36
39
41
46
50
55
60
1320+140
172Otl90
2210+240
2750f290
3290f340
Thread diameter
of bolt
Width
across flats
mm
mm
Nm
kgm
6
8
10
12
10
13
14
27
7.85f1.95
18.6k4.9
40.2k5.9
82.35f7.85
0.8kO.2
1.9+0.5
4.1CO.6
8.4kO.8
135+_15
175+20
225+25
280&30
335f35
Thread diameter
Tightening
torque
mm
mm
Nm
kgm
02
::
14
22
18
19
24
27
24.5k4.9
78.5k19.6
49k19.6
2.5kO.5
8&2
5-+2
05
06
10
12
14
24
30
33
36
42
32
36
41
46
55
137.3k29.4
176.5f29.4
196.1+49
245.2f 49
294.2f.49
14+3
18+3
20+5
25+5
30+5
Thread diameter
mm
mm
Nm
kgm
10
12
16
14
17
22
65.7k6.8
112k9.8
279+29
6.7kO.7
11.5+1
28.5+3
00-10
STANDARD TIGHTENING
FOREWORD
TORQUE
Thread diameter
mm
mm
::
24
33
42
Tightening
torque
Nm
Varies depending on
type of connector.
kgm
34.3+ 4.9
93.1f9.8
142.lf 19.6
421.4k58.8
877.1k 132.3
3.5kO.5
9.5fl
14.5+2
43f6
89.5f13.5
No.
08
10
12
14
76
18
20
24
30
33
36
42
52
Tightenil
1 torque
Thread diameter
mm
mm
Nm
kgm
8
10
12
14
16
14
17
19
22
24
27
30
32
32
-
7.35f 1.47
11.27kl.47
17.6421.96
22.54fl.96
29.4k4.9
39.2f 4.9
49f4.9
68.6f9.8
107.8+ 14.7
127.4k19.6
151.9k24.5
2>0.7+29.4
323.4144.1
0.75kO.15
1.15f0.15
1.8f.0.2
2.3kO.2
3kO.5
4kO.5
5+0.5
7+1
llk1.5
13+2
15.5k2.5
21.5k3
33+4.5
::
24
30
33
36
42
52
-I
36
-
Tightening torque
mm
mm
Nm
kgm
14
19
24.5f 4.9
2.5kO.5
18
22
24
27
49+ 19.6
78.5f19.6
24
30
32
36
137.3k29.4
176.5k29.4
14f3
18f3
33
36
42
41
46
55
196.1+49
245.2+49
294.2F 49
20f5
25f5
30+5
5+2
8f2
00-l 1
FOREWORD
STANDARD TIGHTENING
TIGHTENING
Use these torques for metric bolts and nuts of 102 Series Engine.
Thread diameter
TIGHTENING
Tightening torque
mm
Nm
6
8
10
12
lo+2
24 + 4
43 + 6
77 zk 12
kgm
1.02
2.45
4.38
7.85
+
+
f
+
0.20
0.41
0.61
1.22
Use these torques for metric eye joints of 102 Series Engine.
Thread diameter
Tightening torque
mm
Nm
6
8
10
12
14
8+2
lo+2
12&Z
24 k 4
36 + 5
kgm
0.81
1.02
1.22
2.45
3.67
f
+
*
f
+
0.20
0.20
0.20
0.41
0.51
112
314
1
00-12
Tightening torque
Nm
3&l
8+2
12 rt:2
15f2
24+4
36 f 5
60 f 9
kgm
0.31
0.81
I.22
1.53
2.45
3.67
6.12
+ 0.10
f 0.20
f 0.20
f 0.41
f 0.41
zk0.51
+ 0.92
TORQUE
FOREWORD
CLASSIFICATION
BY THICKNESS
Applicable circuit
60
127
0.80
100
217
0.80
CLASSIFICATION
Priority
63.84
109.1
13.6
178
Starting
17.6
230
Starting
Charging
Ground
Starting
Lighting
Instrument
Signal
Other
>ri_ Code
narY Color
White
Black
Black
Red
Yellow
Green
Blue
BW
RW
YR
GW
LW
Code
WR
2
Color White & Red
Black &White Red & White Yellow & Red Green & White-Blue & White
bciiary
5
/Code1
Color
RL
GL
llow & White Green & Blue
00-13
CONVERSION TABLE
FOREWORD
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE
The Conversion Table in this section is provided to enable simple conversion of figures.
details of the method of using the Conversion Table, see the example given below.
For
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 @I, then draw a perpendicular line
down from 0.
(3) Take the point where the two lines cross as 0. This point @ gives the value when converting
from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2.
Millimeters
@--
00-14
to inches
1 mm = 0.03937 in
0
10
0
0.394
20
30
40
0.787
1.181
1.575
0.039
0.433
0.827
1.220
1.614
0.079
0.472
0.866
1.260
1.654
0.118
0.512
0.906
1.299
1.693
0.157
0.551
0.945
1.339
1.732
0.276
0.669
1.063
1.457
1.850
0.315
0.709
1.102
1.496
1.890
0.354
0.748
1.142
1.536
1.929
2.244
2.638
3.032
3.425
3.819
2.283
2.677
3.07 1
3.465
3.858
2.323
2.717
3.110
3.504
3.898
1.969 . ,.2.008
.... .....G
. .. 50
....... . ,..........
2.362
2.402
60
2.756
2.795
70
3.150
3.189
80
3.543
3.583
90
.2.047
...... .... I..2.087
......._I
... .. .... ..2.126
2.441
2.480
2.520
2.913
2.835
2.874
3.307
3.228
3.268
-3.622
3.661
3.701
2.953
3.346
3.740
2.992
3.386
3.780
CONVERSIONTABLE
FOREWORD
Millimeters
to Inches
mm = 0.03937
in
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
IO
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
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
50
1.969
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
2.323
60
2.362
2.402
2.441
2.480
2.520
2.559
2.598
2.638
2.677
2.717
70
2.756
2.795
2.835
2.874
2.913
2.953
2.992
3.032
3.071
3.110
80
3.150
3.189
3.228
3.268
3.307
3.346
3.386
3.425
3.465
3.504
90
3.543
3.583
3.622
3.661
3.701
3.740
3.780
3.819
3.858
3.898
Kilogram to Pound
1 ka = 2.2046
/I2 I 3
\
0
lb
I5 16I7 I8 I g
i4
2.20
4.41
6.61
8.82
11.02
13.23
15.43
17.64
19.84
IO
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
81.57
83.78
85.98
40
88.18
90.39
92.59
94.80
97.00
50
60
70
80
90
00-15
FOREWORD
CONVERSIONTABLE
0.264
0.528
0.793
1.057
1.321
1.585
10
2.642
2.906
3.170
3.434
3.698
3.963
20
5.283
5.548
5.812.
6.076
6.340
30
7.925
8.189
8.454
8.718
40
10.567
10.831
11.095
50
13.209
13.473
13.737
60
15.850
70
1.849
2.113
2.378
4.227
4.491
4.755
5.019
6.604
6.869
7.133
7.397
7.661
8.982
9.246
9.510
9.774
10.039
10.303
11.359
11.624
11.888
12.152
12.416
12.680
12.944
14.001
14.265
14.529
14.795
15.058
15.322
15.586
16.115
16.379' 16.643
16.907
17.171
17.435
17.700
17.964
18.228
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
\
0
titer to U.K.Gallon
Y-
0.220
0.440
0.660
0.880
1.100
1.320
1.540
1.760
1.980
70
2.200
2.420
2.640
2.860
3.080
3.300
3.520
3.740
3.950
4.179
20
4.399
4.619
4.839
5.059
5.279
5.499
5.719
5.939
6.159
6.379
30
6.599
6.819
7.039
7.259
7.479
7.969
7.919
8.139
8.359
8.579
40
8.799
9.019
9.239
9.459
9.679
9.899
10.119
10.339
10.559
10.778
50
lo.?98
11.281
11.438
11.658
11.878
12.098
12.318
12.528
12.758
12.978
60
13.198
13.418
13.638
13.858
14.078
14.298
14.518
14.738
14.958
15.178
70
15.398
15.618
15.838
16.058
16.278
16.498
16.718
16.938
17.158
17.378
80
17.598
17.818
18.037
18.257
18.477
18.697
18.917
19.137
19.357
19.577
90
19.797
20.017
20.237
20.457
20.677
20.897
21.117
21.337
21.557
21.777
00-M
CONVERSIONTABLE
FOREWORD
kgm to ft. lb
1 kgm = 7.233
7.2
14.5
21.7
28.9
ft. lb
36.2
43.4
50.6
57.9
65.1
\
0
10
72.3
79.6
86.8
94.0
101.3
108.5
115.7
123.0
130.2
137.4
20
144.7
151.9
159.1
166.4
173.6
180.8
188.1
195.3
202.5
209.8
30
217.0
224.2
231.5
238.7
245.9
253.2
260.4
267.6
274.9
282.1
40
289.3
296.6
303.8
311.0
318.3
325.5
332.7
340.0
347.2
354.4
50
361.7
368.9
376.1
383.4
390.6
397.8
405.1
412.3
419.5
426.8
60
434.0
441.2
448.5
455.7
462.9
470.2
477.4
484.6
491.8
499.1
70
506.3
513.5
520.8
528.0
535.2
542.5
549.7
556.9
564.2
571.4
80
578.6
585.9
593.1
600.3
607.6
614.8
622.0
629.3
636.5
643.7
90
651.0
658.2
665.4
672.7
679.9
687.1
694.4
701.6
708.8
716.1
100
723.3
730.5
737.8
745.0
752.2
759.5
766.7
773.9
781.2
788.4
110
795.6
802.9
810.1
817.3
824.6
831.8
839.0
846.3
853.5
860.7
120
868.0
875.2
882.4
889.7
896.9
904.1
911.4
918.6
925.8
933.1
130
940.3
947.5
954.8
962.0
969.2
976.5
983.7
990.9
998.2
1005.4
140
1012.6
1019.9
1027.1
1034.3
1041.5
1048.8
1056.0
1063.2
1070.5
1077.7
150
1084.9
1092.2
1099.4
1106.6
1113.9
1121.1
1128.3
1135.6
1142.8
1150.0
160
1157.3
1164.5
1171.7
1179.0
1186.2
1193.4
1200.7
1207.9
1215.1
1222.4
170
1129.6
1236.8
1244.1
1251.3
1258.5
1265.8
1273.0
1280.1
1287.5
1294.7
180
1301.9
1309.2
1316.4
1323.6
1330.9
1338.1
1345.3
1352.6
1359.8
1367.0
190
1374.3
1381.5
1388.7
1396.0
1403.2
1410.4
1417.7
1424.9
1432.1
1439.4
00-17
FOREWORD
CONVERSiONTABLE
kg/cm*to lb/in*
lkg/cm* = 14.2233 lb/in*
\
0
14.2
28.4
42.7
56.9
71.1
85.3
99.6
113.8
128.0
10
142.2
156.5
170.7
184.9
199.1
213.4
227.6
241.8
256.0
270.2
20
284.5
298.7
312.9
327.1
341.4
355.6
369.8
384.0
398.3
412.5
30
426.7
440.9
455.1
469.4
483.6
497.8
512.0
526.3
540.5
554.7
40
568.9
583.2
597.4
611.6
625.8
640.1
654.3
668.5
682.7
696.9
50
711.2
725.4
739.6
753.8
768.1
782.3
796.5
810.7
825.0
839.2
60
853.4
867.6
881.8
896.1
910.3
914.5
938.7
953.0
967.2
981.4
70
995.6
1010
1024
1038
1053
1067
1081
1095
1109
1124
80
1138
1152
1166
118-I
1195
1209
1223
1237
1252
1266
90
1280
1294
1309
1323
1337
1351
1365
1380
1394
1408
100
1422
1437
1451
1465
1479
1493
1508
1522
1536
1550
110
1565
1579
1593
1607
1621
1636
1650
1664
1678
1693
120
1707
1721
1735
1749
1764
1778
1792
1806
1821
1835
130
1849
1863
1877
1892
'I906
1920
1934
1949
1963
1977
140
1991
2005
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
2418
2432
2446
2460
2475
2489
2503
2518
2532
2546
180
2560
2574
2589
2603
2617
2631
2646
2660
2674
2688
190
2702
2717
2731
2745
2759
2773
2788
2802
2816
2830
200
2845
2859
2873
2887
2901
2916
2930
2944
2958
2973
210
2987
3001
3015
3030
3044
3058
3072
3086
3101
3115
220
3129
3143
3158
3172
3186
3200
3214
3229
3243
3257
230
3271
3286
3300
3314
3328
3343
3357
3371
3385
3399
240
3414
3428
3442
3456
3470
3485
3499
3513
3527
3542
00-18
CONVERSION
FOREWORD
TABLE
Temperature
Fahrenheit-Centigrade
ture reading
Conversion
a simple
way to convert
These figures
If it is desired
temperatures
from
in either
Fahrenheit
If it is desired to convert
from Centigrade
Fahrenheit
Fahrenheit
to Centigrade
Centigrade
or Centigrade
degrees,
degrees,
temperature
reading
temperature
to Fahrenheit
temperature
a Fahrenheit
table
into a Centigrade
column
tempera-
of figures.
degrees.
consider
the
in the column
center
column
as a table
of Fahrenheit
at the left.
as a table of Centigrade
values,
on the right.
1C = 33.8F
OF
OF
-40.4
-40
-40.0
-11.7
11
51.8
7.8
46
114.8
27.2
81
117.8
-37.2
-35
-31.0
-11.1
12
53.6
8.3
47
116.6
27.8
82
179.6
-34.4
-30
-22.0
-10.6
13
55.4
8.9
46
118.4
28.3
83
181.4
-31.7
-25
-13.0
-10.0
14
57.2
9.4
49
120.2
28.9
84
183.2
-28.9
-20
-4.0
-9.4
15
59.0
10.0
50
122.0
29.4
85
785.0
-28.3
-19
-2.2
-8.9
16
60.8
,10.6
51
123.8
30.0
66
186.8
-27.8
-18
-0.4
-8.3
17
62.6
11.1
52
125.6
30.6
87
168.6
-27.2
-17
1.4
-7.8
18
64.4
11.7
53
127.4
31.1
88
190.4
-26.7
-16
3.2
-7.2
19
66.2
12.2
54
129.2
31.7
89
192.2
-26.1
-15
5.0
-6.7
20
68.0
12.8
55
131.0
32.2
90
194.0
-25.6
-14
6.8
-6.1
21
69.8
13.3
56
132.8
32.8
91
195.8
-25.0
-13
8.6
-5.6
22
71.6
13.9
57
134.6
33.3
92
197.6
-24.4
-12
10.4
-5.0
23
73.4
14.4
58
136.4
33.9
93
199.4
-23.9
-11
12.2
-4.4
24
75.2
15.0
59
138.2
34.4
94
201.2
-23.3
-10
14.0
-3.9
25
77.0
15.6
60
140.0
35.0
95
203.0
-22.8
-9
15.8
-3.3
26
78.8
16.1
61
141.8
35.6
96
204.8
-22.2
-6
17.6
-2.8
27
80.6
16.7
62
143.6
36.1
97
206.6
-21.7
-7
19.4
-2.2
28
82.4
17.2
63
145.4
36.7
98
208.4
-21.1
-6
21.2
-1.7
29
84.2
17.8
64
147.2
37.2
99
210.2
-20.6
-5
23.0
-1.1
30
86.0
18.3
65
149.0
37.8
100
212.0
-20.0
-4
24.8
-0.6
31
87.8
18.9
66
150.8
40.6
105
221.0
-19.4
-3
26.6
32
89.6
19.4
67
152.6
43.3
110
230.0
-18.9
-2
28.4
0.6
33
91.4
20.0
69
154.4
46.1
115
239.0
-18.3
-1
30.2
1.1
34
93.2
20.6
69
156.2
48.9
120
248.0
32.0
1.7
35
95.0
21.1
70
158.0
51.7
125
257.0
-17.2
33.8
2.2
36
96.8
21.7
71
159.8
54.4
130
266.0
-16.7
35.6
2.8
37
98.6
22.2
72
161.6
57.2
135
275.0
-16.1
37.4
3.3
38
100.4
22.8
73
163.4
60.0
140
284.0
39.2
3.9
39
102.2
23.3
74
165.2
62.7
145
293.0
-15.0
41.0
4.4
40
104.0
23.9
75
167.0
65.6
150
302.0
-14.4
42.8
5.0
41
105.8
24.4
76
168.8
68.3
155
311.0
-13.9
44.6
5.6
42
107.6
25.0
77
170.6
71.1
160
320.0
-13.3
46.4
6.1
43
109.4
25.6
78
172.4
73.9
165
329.0
-12.8
48.2
6.7
44
111.2
26.1
79
174.2
76.7
170
338.0
-12.2
10
50.0
7.2
45
113.0
26.7
80
176.0
79.4
175
347.0
-17.8
-15.6
00-l 9
01 GENERAL
OlOlOlOl-
2
4
7
9
01-l
0
GENERAL
1.8) 392 W
(.L.L) 08LZ
01-2
0
II=
GENERAL
GENERAL
SPECIFICATIONS
SPECIFICATIONS
Machine model
WA380-3
Serial No.
5000 l-52999
53001 and up
Operating weight
kg
16,140
16,440
Distribution (front)
kg
7,960
7,965
Distribution (rear)
kg
8,180
8,475
m3
3.1
3.2
kN (kg)
48.64 (4,960)
50.2 (5,120)
FORWARD 1st
km/h
7.1
7.1
FORWARD 2nd
km/h
11.4
11.4
FORWARD 3rd
km/h
20.2
20.2
FORWARD 4th
km/h
31.5
31.5
REVERSE 1st
km/h
7.4
7.4
REVERSE 2nd
km/h
11.8
11.8
REVERSE 3rd
km/h
21.0
21.0
REVERSE 4th
km/h
32.5
32.5
Max. rimpull
kN {kg)
159.85 {16,300)
159.85 (16,300)
Gradeability
deg
25
25
mm
5,475
5,475
mm
6,370
6,430
Overall length
mm
7,750
7,965
mm
2,695
2,695
mm
2,905
2,905
mm
3,395
3,315
(Bucket raised)
mm
5,345
5,455
Wheelbase
mm
3,200
3,200
Tread
mm
2,160
2,160
mm
390
390
mm
3,915
4,030
mm
2,850
2,925
mm
1,120
1,170
deg
49
49
deg
48
50
mm
340
345
Rated load
Travel speed
Mb:;:8
Overall height
01-4
0
SPECIFICATIONS
GENERAL
WA380-3
Machine model
I
50001-52999
Serial No.
53001 and up
Komatsu S6D108
Model
Type
mm
6 - 108 x 130
e {cd
7.15 {7,1501
Flywheel horsepower
kW {HPYrpm
140 {1871/2,200
Maximum torque
Nm IkgmYrpm
g/kWh {g/HPhI
218 (162)
rpm
2,450
rpm
760
24 V
Starting motor
7.5 kW
24 V
Alternator
12V
Battery
35A
150Ahx2
Torque converter
Transmission
Reduction gear
Differential
Final drive
Drive type
Front/rear-wheel drive
Front axle
Fixed-frame, semi-floating
Rear axle
Tire
20.5-25-16PR (L3)
Wheei rim
17.00 x 25-1.7TlL
inflation pressure
Front tire
kPa {kg/cm*1
343 13.51
Rear tire
kPa Ikg/cm*I
343 13.51
Main brake
Parking brake
01-5
0
GENERAL
SPECIFICATIONS
Machine model
Serial No.
Type
Structure
53001 and up
Articulated tipe
Gear type
(SAL(3)100+50+36+(1)25)
pump)
Delivery
(/min.
224+112+81+57
MPa kg/cm3
Spool type
20.6 (2101
MPa If@cm3
Spool type
20.6 (2 101
Boom cylinder
No. - bore x stroke
mm
Reciprocating piston
2 - 160 x 713
Bucket cylinder
No. - bore x stroke
mm
Reciprocating piston
1 - 180 x 503
Steering cylinder
No. - bore x stroke
mm
Reciprocating piston
2 - 80 x 442
Link type
Bucket edge type
01-6
0
5000 l-52999
WA380-3
Single link
Flat edge with BOC
r?
GENERAL
WEIGHT TABLE
WEIGHT TABLE
A This weight
Unit: kg
Serial No.
Engine
Radiator
Torque converter
Transmission
WA3803
Machine model
50001
- 52999
Serial No.
WA380-3
50001
- 52999
730
165
Bucket cylinder
166
54
191
700
Front frame
1,406
25
Rear frame
1,199
22
Bucket link
56
Bellcrank
309
164
1,020
1,583
Axle pivot
Counten,veight
Wheel (each)
Fuel tank
179
Battery (each)
44
Hydraulic tank
Hydraulic, Steering, Switch, PPC pump
1,170
670
Cab
295
193
14
46
Operators seat
38
01-7
0
GENERAL
WEIGHT TABLE
Unit: kg
Machine model
WA380-3
Machine model
Serial No.
5300 1
and up
Serial No.
Engine
Radiator
730
Bucket cylinder
165
Torque converter
Wheel (each)
Battery (each)
01-8
0
191
1,230
Rear frame
207
53001
and up
1,465
Bellcrank
WA380-3
Front frame
Bucket link
Tire (each)
I
I
56
309
677
375
14
46
Operators seat
38
71
ROPS canopy
164
ROPS cab
398
635
GENERAL
LIST OF LUBRICANT
RESERVOIR
KIND OF
FLUID
AND WATER
AMBIENT TEMPERATURE
-22 -4
-30 -20
14
-10
32
0
50
10
68
20
86
30
CAPACITY
104122'1
40 5OY
Specified
Refill
31 e
28 e
-I-
Engine oil
42 Q
Transmission case
40 e
190 L
Hydraulic system
Axle
(Front and rear)
(Each)
See
Note
138 e
Pins
Grease
=r
Cooling
system
Diesel fuel
Water
287 Q
53 Q
Add antifreeze
I
% ASTM
D975 No. 1
*:
NLGI No. 0
When operating a machine with the auto-greasing
system (if equipped) at temperatures
-2OC, set the greasing time to 20 minutes. See the Operation & Maintenance
Manual.
Note 1: For axle oil, use only recommended
oil as follows.
DONAX lT or TD
SHELL:
RPM TRACTOR HYDRAULIC FLUID
CALTEX:
CHEVRON: TRACTOR HYDRAULIC FLUID
TEXACO:
TDH OIL
MOBILAND SUPER UNIVERSAL
MOBIL:
It is possible to substitute engine oil CLASS-CD SAE30 for axle oil.
If noise comes from the brake, it is no problem of durability.
below
01-9
0
GENERAL
REMARK
When fuel sulphur content is less than 0.5%, change oil in the oil pan every periodic maintenance
hours described in this manual.
Change oil according to the following table if fuel sulphur content is above 0.5%.
0.5 to 1.0%
Above 1.0%
When starting the engine in an atmospheric temperature of lower than OC, be sure to use engine
oil of SAEIOW, SAElOW-30 and SAE15W-40, even though an atmospheric temperature goes up to
IOC more or less in the day time.
Use API classification CD as engine oil and if API classification
interval to half.
There is no problem if single grade oil is mixed with multigrade oil :SAE!OW-30,
sure to add single grade oil that matches the temperature in the table.
15W-401, but be
We recommend Komatsu genuine oil which has been specifically formulated and approved 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.
ASTM: American Society of Testing and Material
SAE: Society of Automotive Engineers
API: American Petroleum Institute
01-10
0
G
3
10
3
2
3
IOIO-
3
4
IO-
IO-
IO-
IOIOIOIOIOIOIOIOloIOIOIOloIO-
IO
12
14
24
46
47
49
53
54
56
57
58
72
76
IO- 77
IO- 78
IO- 82
IO- 83
IO- 84
IO- 89
lo- 93
IO- 95
IO- 97
lo- 98
IO- 99
IO-100
10-101
10-l
0
POWER TRAIN
POWER TRAIN
1. Transmission
2. Torque converter
3. Engine (S6D108)
4.
5.
6.
Front axle
Front drive shaft
Center drive shaft
7.
8.
Outline
l
1o-3
-8
20
8
-9
-10
5
0
1o-4
5
5
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Front tire
Final drive
Wet type multiple disc brake
Differential
Front axle
Front drive shaft
Flange bearing
Center drive shaft
Parking brake
Transmission
Rear drive shaft
Final drive
Wet type multiple disc brake
Differential
Rear axle
Rear tire
Engine (S6D108)
Torque converter
Hydraulic, steering switch, PPC Pump
Torque converter charging pump
Outline
l
1o-5
8
1. Transmission
2. Torque converter
3. Radiator
4. Oil cooler
1 O-6
PIPING
%woo422
5. Torque
6.
7.
8.
TRANSMISSION
(Engine
TRANSMISSION
stopped)
rI
J
1
14
B
13
:
-
1 O-8
--A2
STRUCTURE
AND FUNCTION
TRANSMISSION
TRANSMISSION
HYDRAULIC
HYDRAULIC
CIRCUIT
DIAGRAM
CIRCUIT DIAGRAM
22
23
I O-23MPa
p
24
p
25
J?
i@=
26
t#
28
sLww424
1.
2.
J.
I
4.
5.
6.
7.
8.
9.
10.
11.
12.
Transmission
case
Strainer
Hydraulic pump (SAL45+20)
Oil filter
Pilot reducing valve
Modulation valve
Quick return valve
Maih relief valve
Emergency manual spool
Pilot oil filter
Priority valve
Solenoid valve (Ist, 4th)
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
1st clutch
2nd clutch
3rd clutch
4th clutch
REVERSE clutch
FORWARD clutch
Parking brake
Torque converter
Oil cooler
Transmission
lubrication
Torque
converter
outlet
valve
1o-9
TORQUE CONVERTER
TORQUE CONVERTER
1.
2.
3.
4.
5.
Turbine
Drive case
Stator
Pilot
Stator shaft
10-10
6.
7.
8.
9.
Housing
PTO gear (drive)
Pump
Output shaft (Transmission
input shaft)
Specifications
Model: TCA37-2A
Type: 3 element,1 stage,1
Stall torque ratio: 3.37
phase
STRUCTURE
AND
FUNCTION
TORQUE
CONVERTER
(11).
The motive force of drive case (4) is used as
the motive force to drive the gear pump
through PTO gear (drive) (6).
Flow of oil
The oil supplied from the torque converter
charging pump enters inlet port A, passes
through the oil passage of stator shaft (81,
and flows to pump (5).
The oil is given centrifugal force by pump
(51, enters turbine (21, and transmits the energy of the oil to the turbine. Turbine (2) is
fixed to transmission input shaft (1 I), so the
motive force is transmitted to the transmission input shaft.
The oil from turbine (2) is sent to stator (31,
and enters the pump again. However,
part
of the oil is sent from the stator through
outlet port B to the cooler.
l
10-l1
TORQUE
CONVERTER
OIL FILTER
1.
2.
3.
4.
Relief valve
Element
Center bolt
Drain plug
Specifications
SEW00014
0
To Transmission
control valve
Operation
.
The oil from the torque converter charging
LLU
lA_
.
IO-12
SEW00015
B
To Transmission
control valve
TRANSMISSION
TRANSMISSION
E4
A ---I
.6
10-14
TRANSMISSION
1.
2.
3.
4.
5.
6.
7.
8.
9.
a.
b.
c.
3rd clutch
3rd gear
Thrust washer
Spacer
1.
2.
3.
4.
5.
2
_
Idler gear
2nd gear
2nd clutch
2nd, 4th cylinder
4th clutch
6.
7.
8.
9.
a.
b.
c.
10-17
TRANSMISSION
Operation of clutch
When operated
.
The oil sent from
the transmission
valve
passes through the oil passage inside shaft
(I), and goes to the rear face of piston (6) to
actuate the piston.
When piston (6) is actuated, separator plate
(2) is pressed against clutch disc (3) and
forms shaft (I) and clutch gear (4) into one
unit to transmit the motive force.
Oil is drained from oil drain hole (5) at this
time, but this does not affect clutch operation since less oil is drained than supplied.
valve is shut
off, the pressure of the oil acting on the rear
face of piston (6) drops.
The piston is returned to its original position
by wave spring (71, so shaft (I) and clutch
gear (4) are separated.
When the clutch is disengaged, the oil at the
rear face of the piston is drained by centrifugal force through oil drain hole (5). preventing the clutch from remaining
partially engaged.
lo-18
STRUCTURE
AND FUNCTION
TRANSMISSION
23
FORWARD 1ST
3k
Operation
.
In forward
Ist,
clutch (20) are
from the torque
put shaft (9) is
i
14
(14).
The clutch discs of forward clutch (8) and
1st clutch (20) are held by the hydraulic pressure applied to the piston.
The motive force from the torque converter
is transmitted
from input shaft (9) via forward clutch (8) to forward gear (23), then
transmitted to 1st and 3rd cylinder gear (32).
SAW@3439
10-19
TRANSMISSION
FORWARD 2ND
34
Operation
In forward 2nd,
clutch (18) are
from the torque
put shaft (9) is
14
(14).
The clutch discs of forward clutch (8) and
2nd clutch (18) are held by the hydraulic
pressure applied to the clutch piston.
The motive force from the torque converter
is transmitted
from input shaft (9) via forward clutch (8) to forward gear (231, then
transmitted via 1st and 3rd cylinder gear (321,
1st and 3rd shaft (191, and idler gear (29) to
1O-20
SAWOWO
FORWARD 3RD
TRANSMISSION
8
\
32
30
34
Operation
.
In forward
3rd,
clutch (11) are
from the torque
put shaft (9) is
14
(14).
The clutch discs of foward
clutch (8) and
3rd clutch (11) are held by the hydraulic pressure applied to the clutch piston.
The motive force from the torque converter
is transmitted
from input shaft (9) via forward clutch (8) to foward
gear (231, then to
1st and 3rd cylinder gear (32).
SAW00441
10-21
STRUCTURE
AND
FUNCTiON
TRANSMISSION
FORWARD 4TH
32
Operation
In forward 4th,
clutch (12) are
from the torque
put shaft (9) is
sAbvox42
(14).
The clutch discs of forward clutch (8) and
4th clutch (12) are held by the hydraulic pressure applied to the clutch piston.
The motive force from the torque converter
is transmitted
from input shaft (9) via forward clutch (8) to forward gear (231, then
transmitted via 1st and 3rd cylinder gear (32)
to 4th gear (28).
1o-22
REVERSE 1ST
TRANSMISSION
24
25
34
Operation
.
In reverse
Ist,
clutch (20) are
from the torque
put shaft (9) is
14
(14).
The clutch discs of reverse clutch (7) and 1st
clutch (20) are held by the hydraulic pressure applied to the piston.
The motive force from the torque converter
is transmitted
from input shaft (9) via reverse clutch (7) to reverse gear (24). The
direction of rotation is reversed by idler gear
SAWCOW
(211, and the motive force is then transmitted to 1st and 3rd cylinder gear (32) via idler
gear (29) and 1st and 3rd shaft (19). Since
the 1st clutch is engaged, the motive force
transmitted
to 1st and 3rd cylinder gear (32)
is transmitted
from 1st gear (25) via the 1st
clutch to 2nd and 4th cylinder gear (331, then
transmitted
to output shaft (14) via the 2nd
and 4th shaft, idler gear (31) and output gear
(34).
1 O-23
TRANSMISSION
TRANSMISSION
CONTROL VALVE
CONTROL VALVE
SBWIXWA
a.
b.
C.
d.
e.
f.
1.
2.
3.
4.
5.
Lower valve
Upper valve
Emergency
manual
Pilot oil filter
Modulation
valve
9.
spool
h.
From pump
To oil cooler
Clutch oil pressure measurement port
Main oil pressure measurement port
Torque converter
inlet port
oil pressure
measurement
Pan
Torque converter outlet port
oil pressure
measurement
Pan
Parking brake oil pressure
measurement
port (priority
measurement
port)
Pilot oil pressure measurement port
Outline
l
1o-24
STRUCTURE
AND FUNCTION
TRANSMISSION
CONTROL VALVE
UPPER VALVE
.2
.3
4
A-A
2.
3.
z36wcma
4.
spool
5.
6.
1o-25
TRANSMISSION
CONTROL VALVE
LOWER VALVE
1.
2.
3.
4.
5.
6.
7.
1O-26
A-A
8. Priority valve
9. Solenoid
valve
(Parking
brake)
IO. Solenoid
valve (Range selector)
11. Solenoid valve (H-L selector)
sAwowl
a.
b.
STRUCTURE
AND
TRANSMISSION
FUNCTION
From pump
TRANSMISSION
CONTROL
VALVE
SOLENOID VALVE
Lower valve
Function
l
When the gear shift lever is operated to move
in forward
or reverse, electric signals are
sent to four solenoid valves mounted on the
transmission valve, activating the FORWARD/
REVERSE, H-L or range spool, according to
the combination
of solenoid valves which
are opened and closed.
.
For the parking brake solenoid valve, refer
to the section Parking Brake Solenoid Valve.
Operation
1. Solenoid valve OFF
The oil from pilot reducing valve (1) flows to
ports a and b of H-L selector spool (2) and
range selector spool (3). The oil at a and b is
blocked by solenoid valves (4) and (51, so
selector spools (2) and (3) are moved to the
right in the direction of arrow.
As a result, the oil from the pump flows to
the 2nd clutch.
8
2
From pump
a-
2.
Solenoid valve ON
When the speed lever is operated, the drain
ports of solenoid valves (4) and (5) open.
The oil at ports a and b of selector spools (2)
and (3) flows from ports c and d to the drain
circuit. Therefore,
the pressure in the circuits at ports a and b drops, and the spools
are moved to the left in the direction of the
arrow by return springs (6) and (7).
As a result, the oil .at port e flows to the 4th
clutch and switches from 2nd to 4th.
Actuation
From pump
SWW
1 O-27
TRANSMISSION
CONTROL VALVE
From pump
/ Lower valve
Function
The pilot reducing valve controls the pressure used to actuate the directional selector
spool, H-L selector spool, range selector
spool, and parking brake spool.
l
Operation
The oil from the pump enters port a, passes
through port ,b of pilot reducing spool (11,
enters spools (2) and (3) in the lower valve,
and fills the pilot circuit.
The oil at port b passes through the orifice
and flows to port c.
l
sBwoo451
From pump
Frompump
l
Solenoid valve
From pump
1 O-28
STRUCTURE
AND FUNCTION
TRANSMISSION
CONTROL
VALVE
To clutch
To torqueconverter
circuit
%
Operation
1. The oil from the pump passes through the
priority valve, then through ports A and B of
until the main relief valve (1) specified pressure is reached, and flows to the clutch valve.
2.
0
z!
4
To clutch
circuit
To torqueconvert&
From&iority valve
SBWCO456
lo-29
TRANSMISSION
CONTROL VALVE
converter outlet port valve is installed in the outlet line of the torque converter and adjusts the maximum
pressure of
the torque converter.
Ooeration
.
The oil at port a passes through
the orifice
To cooler
When the pressure at port a rises, the pressure at port c also rises. This overcomes the
tension of spring (2) and moves spool (I) to
the left in the direction of the arrow to allow
oil to flow from port a to port b.
To cooler
If the pressure
at port a becomes
even
higher, spool (1) is moved further to the left
in the direction
of the arrow, and the oil
flows from port a to port b and drain port d.
(Cold relief)
To cooler
SEW00060
1O-30
STRUCTURE
AND
FUNCTION
TRANSMISSION
CONTROL
VALVE
PRIORITY VALVE
Function
The priority valve regulates the pumps discharge pressure and provides the pilot oil
pressure and parking brake release oil pressure.
.
If the pressure in the circuit reaches a level
above the measured oil pressure, the priority valve acts as a relief valve, releasing the
pressure to protect the hydraulic circuitry.
Operation
1. The oil from the pump enters port a and
separates
into the oil flowing
to parking
brake valve (I), priority valve (2) and the
pilot circuit.
2.
3.
From
pump
To pilot
To main
relief valve valve
sAwoo457
sAimJ458
Tor!!n
- pilot
To
relief valve valve
s~w~)459
10-31
STRUCTURE
AND
FUNCTION
TRANSMISSION
CONTROL
VALVE
Operation
1. After engine is started, clutch completely
engaged (clutch pressure at point A)
(FORWARD
(Clutchfully engaged)
1st)
or
1st clutch
A
T
P
2nd clutch
S
Torque converter
3rd clutch
Oil filter
Accumulator
1 O-32
4th clutch
SAW00460
TRANSMISSION
CONTROL VALVE
or
2nd clutch
S
Torque converter
3rd clutch
Oil filter
4th clutch
FORWARD clutch
.4
REVERSE clutch
e
From accumulator
+
6
H
C
SAWCO463
1o-33
3.
TRANSMISSION
CONTROL VALVE
to rise (clutch
/ m
2ndclutch
roque converter
Oil filter
Accumulator
FORWARD
clutch
REVERSE
clLltch
Parking
brake
From accumcAstor
l
1o-34
STRUCTURE
4.
AND
FUNCTION
TRANSMISSION
CONTROL
VALVE
Start of accumulator
operation, clutch completely engaged (clutch pressure at point DI
: clutch
2nd clutch
3rd clutch
4th clutch
FORWARD
clutch
RMRSE
clutch
Parking
10 To accumulator
SAW00467
1o-35
TRANSMISSION
CONTROL VALVE
2.
.
When at FORWARD
the directional lever is placed at the
FORWARD position, solenoid valve (4) is
switched ON and drain port d opens. The oil
which is filling port a is drained, so PI +
spring force (I) < P2+ spring force (2). When
When
REVERSE clutch
b
pi
2
IFrom
1O-36
TRANSMISSION
CONTROL VALVE
Function
When the gear shift lever is operated, electric signals are sent to the solenoid valves
paired with the H-L selector valve and range
selector valve.
Operation
3rd clutch
2nd clutch
1stclutch
4th clutch
From
modulation valve
From pilot
valve
SBWWA70
1.
l
2nd speed
When solenoid valves (I) and (2) are OFF,
the drain port is closed. The oil PI from the
pilot circuit overcomes the force of the H-L
selector spool (4) and range selector spool
(5) springs (3) and moves spools (4) and (5)
to the left. The oil in the clutch circuit passes
from H-L selector spool (4) port a through
range selector spool (5) port b and is supplied to the 2nd clutch.
10-37
STRUCTURE
AND FUNCTION
TRANSMISSION
2ndclutch
,/
CONTROL VALVE
3rdclutch
itBI\
From
From
blot valve
modulationvalve
swm471
2.
.
4th speed
When solenoid
valves (I) and (2) are ON,
the drain port is open. The oil from the pilot
circuit passes through solenoid valves (I)
and (2) and is drained, so H-L selector spool
(4) and range selector spool 6) are moved
to the right by the force of springs (3). The
oil in the clutch circuit passes from H-L selector spool (4) port c through range selector spool (5) port d and is supplied to the
4th clutch.
1 O-38
3.
l
TRANSMISSION
CONTROL ,VALVE
3=f,B
From pilot 553
&B
valve
Operation
1. When the emergency manual spool is at
neutral (during normal operation)
.
The oil from the pilot valve passes through
emergency
manual
spool (I), enters the
lower valve directional
spool (2) ports a
and b and is sealed by forward solenoid
valve (4) and reverse solenoid valve (3).
3-
SBWCG472
2.
.
When the emergency manual spool is actuated (to the forward side)
When emergency manual spool (I) is pulled
out, the oil from the pilot valve passes
through emergency
manual spool (1) and
flows only into directional spool (2) port a,
not into port b. This generates a pressure
difference between ports a and b, directional spool (2) moves to the left, oil flows
into the forward clutch and the clutch is engaged.
From pilot
valve
ARD clutch
SBWW473
1o-39
TRANSMISSION
MODULATION
VALVE
A-A
1.
2.
3.
Valve body
Fill valve
Accumulator
1O-40
valve
CONTROL VALVE
STRUCTURE
TRANSMISSION
AND FUNCTION
CONTROL
VALVE
Function
.
The modulation valve consists of a fill valve
and an accumulator.
It controls the pressure
and flow of the oil flowing to the clutch and
increases the clutch pressure.
sec.
(Clutchfully engaged)
Operation
1. The diagram shows the clutch fully engaged (point A).
SAwoodM
Fill valve
From priority
valve
Acc&wlator
From torgue
converter outlet
valve
sBww475
2.
l
To clutch
10-41
STRUCTURE
3.
.
AND
FUNCTION
1 O-42
TRANSMISSION
CONTROL
VALVE
To clutch
From priority
valve
Pk
From priority
valve
TRANSMISSION
CONTROL VALVE
1.
2.
3.
A.
6.
Inlet port
Outlet port
Specifications
170 cm*
Filtering area:
Filter mesh size: 105 p
Outline
l
The pilot oil filter is mounted on the transmission lower valve, and filters dirt from the
oil flowing to the pilot circuit.
1o-43
STRUCTURE
AND
TRANSMISSION
FUNCTION
CONTROL VALVE
ACCUMULATOR VALVE
13
6
11
10
A-A
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
10-44
Outline
.
The accumulator
TRANSMISSION
Operation
1. Shifting down when digging (kick-down F2
+ Fl)
When the transmission
is in F2, oil pressure
is. stored
in the 2nd clutch accumulator.
When the kick-down
is operated,
the Fl
clutch is engaged, but the oil pressure in the
accumulator
is maintained for the 2nd clutch
until the torque
is transmitted
to the 1st
clutch. In this way, it is possible to shift gear
smoothly without losing the torque.
CONTROL VALVE
maintained so
remains of torque
Tze
SDWOOO40
11
?
2
Oil pressure
maintained so
torqe is lowered
0
k
g
I
U
0
SDW00041
1o-45
DRIVE SHAFT
DRIVE SHAFT
1.
2.
3.
4.
Outline
.
The -.motive force
1O-46
STRUCTURE
AND FUNCTION
AXLE
AXLE
FRONT AXLE
/1
A-A
1.
Oil
2.
3.
4.
5.
6.
7.
8.
plug
Coupling
Differential
Wet-type multi-disc
Final drive
Axle housing
Axle shaft
Drain plug
supply
port
and
level
brake
1o-47
AXLE
REAR AXLE
SAW03487
1. Oil
A-A
1 O-48
2.
3.
4.
5.
6.
7.
8.
supply
port
and
plug
Coupling
Differential
Wet-type multi-disc
Final drive
Axle housing
Axle shaft
Drain plug
level
brake
DIFFERENTIAL
DIFFERENTIAL
FRONT DIFFERENTIAL
SAW00488
1.
2.
3.
4.
5.
6.
1o-49
REAR DIFFERENTIAL
Shaft
Bevel gear (Teeth 41)
Sun gear shaft
Bevel pinion (Teeth 9)
1O-50
DIFFERENTIAL
STRUCTURE
AND FUNCTlON
DIFFERENTIAL
Outline
The motive force from the engine is transmitted to the front and rear axles via the
torque converter, the transmission
and the
propeller shaft.
.
In the axle, the motive force, is transmitted
from bevel pinion (I) to bevel gear (5). shifted
90 and reduced, and transmitted to sun gear
shaft (2) via pinion gear (4).
The motive force of the sun gear is further
reduced by planetary gear-type final drive,
and transmitted to the axle shaft and wheel.
l
SEW00077
E3
:
2
SEW00078
When slewing
When slewing, the speed of rotation of the
left and right wheels is unequal, so pinion
gear (4) and side gear (3) in the differential
assembly rotate according to the difference
in the left and right rotation speeds, and the
motive force of carrier (6) is transmitted
to
the sun gear shafts (2).
l
SEW00079
1O-51
DIFFERENTIAL
Ordinary differential
SEW00080
Operation
When traveling straight (equal resistance from road
surface to left and right tires)
.
If the resistance from the road surface to the
left and right wheels is the same, the distance
between pinion gear (4) and meshing point
a of left side gear (7) is the same as the
distance between pinion gear (4) and meshing
point b of right side gear (3).
.
Therefore the left side traction TL and the right
side traction TR are balanced.
When traveling on soft ground (resistance from
road surface to left and right tires is different)
.
On soft ground, if the tire on one side slips,
the side gear of the tire on the side which has
least resistance from the road surface tries to
rotate forward. Because of this rotation, the
meshing
of pinion gear (4) and side gear
changes.
.
If left side gear (7) rotates slightly forward, the
distance between the pinion gear and the
meshing point a of the left side gear becomes longer than the distance between the
pinion gear and the meshing port b of the
right side gear. The position is balanced as
follows.
,axTL=bxTR
The ratio between the distances to a and
b can change to 1 : 1.38.
.
Therefore when the ratio of the distances to
a and b is less than 1 : 1.38 (that is, the
difference between the resistance from the road
surface to the left and right tires is less than
38%), the pinion gear will not rotate freely, so
drive force will be given to both side gears,
and the tires will not slip.
Because of this effect, the tire life can be increased by 20 - 30%, and at the same the
operating efficiency is also increased.
1 O-52
FINAL DRIVE
FINAL DRIVE
SAW00493
:
9
1
1.
2.
3.
4.
5.
Planetary
Planetary
Axle shaft
Ring gear
Sun gear
18)
Outline
As the final function the final drive operates
to reduce the rotative speed of the motive
force from the engine and increases the driving force.
.
Ring gear (4) is press-fitted in the axle housing and fixed in place by a pin.
.
The motive force transmitted
from the differential to the sun gear shaft (5) is reduced
using a planetary gear mechanism,
increasing the driving force.
The increased driving force is transmitted to
the tires via planetary gear (2) and axle shaft
l
(3).
SAW00494
AXLE MOUNT,
AXLE MOUNT,
6
I
A-A
B-B
sEwccl495
1o-54
1.
2.
3.
4.
5.
6.
Front axle
Rear axle
Front frame
Rear frame
Upper hinge pin
Lower hinge pin
AXLE MOUNT,
c-c
SLWO0496
FRONT AXLE
.
Front axle (1) is fixed directly to front frame
(3) by tension bolts so that it receives
force during operations directly.
REAR AXLE
.
Rear axle (2) has a structure
the
which allows
the center of rear frame (4) to float so that
all the tires are in contact with the ground
surface, even when traveling on soft ground.
1o-55
STEERING PIPING
STEERING PIPING
6
sEw01220
1.
2.
3.
4.
5.
6.
7.
8.
Steering cylinder
Steering valve
Orbit-roll valve
Hydraulic pump
Hydraulic tank
Oil filter
Oil cooler
Stop valve
1O-56
STEERING COLUMN
STEERING COLUMN
3
=z-_-__
-..-_ ::.tJ
-Ii-
-__-_--------------__-_--__
- ---_---_
__ -_-_----__
--_----__-__ -*_-_________
1.
2.
3.
4.
Steering wheel
Steering column
Joint
Orbit-roll
1o-57
STEERING VALVE
STEERING VALVE
D-D
sLwo1zzz
1 O-58
A: To steering cylinder
6: To steering cylinder
Pa: From orbit-roll
Pb:
From orbit-roll
PI: From steering pump
P2: From switch pump
PB:To main control valve
T: Drain (to oil cooler)
STEERING VALVE
To Orbit-roll
valve
To Orbit-roll
valve
To cut-off valve
(Main cotrol valve)
pump-1
I
sLw01223
1o-59
0
STEERING VALVE
Engine
at low speed
From Orbit-roll
valve
I)
_, To cut-off valve
(Main control valve)
SLwo1224
1 O-60
0
STEERING VALVE
From Orbit-roll
valve I,
Orbit-roll
valve
B
k
SLWO1225
1O-61
0
STRUCTURE
FLOW
AND
STEERING
FUNCTION
AMP
li
1.
2.
3.
4.
Steering spool
Valve housing (body)
Spring seat
Return spring
1.
5.
6.
7.
A:
B:
c:
Cap
Capscrew
Flow amp notch
ki
Orbit-roll
/\
Relief
valve
I
sLwmz7
VALVE
I O-62
SLWO1226
STRUCTURE
2.
STEERING
AND FUNCTION
Spool actuated
Relief
valve
pump
VALVE
When oil flows to port PiA, the pressure inside the cap at end A rises and moves steering spool (1) in the direction of the arrow.
The oil entering
from port PiA passes
through the hole in spring seat (3), through
flow amp notch (7) in steering spool (I), and
then flows to the opposite end (B end).
sLwo1z28
1O-63
STEERING VALVE
3.
wheel
stopped,
flow
PiB
AA
stop valve
Stop valve
Ii
Orb&roll
1O-64
STRUCTURE
AND
FUNCTION
STEERING
VALVE
_ To Orbit-roll
To Orb&roll
valve
*
valve
To cut-off valve
(Main control valve)
1O-65
0
TURNING
STEERING VALVE
RIGHT
From CkbJ;roll
To cut-off
valve
(Main control valve)
SLvm1231
1O-66
0
STEERING VALVE
TURNING LEFT
To Orbit-roll
valve
From
I)
To cut-off valve
(Main control valve)
sLw01232
1O-67
0
STEERING VALVE
SEWOOG97
Function
.
The steering
relief valve is inside the steering valve, and sets the maximum circuit pressure of the steering circuit when the steering valve is actuated.
When the steering
valve is being actuated, if the steering circuit goes above the set pressure of this valve,
oil is relieved from this valve. When the oil
is relieved, the flow control spool of the demand valve is actuated, and the oil is drained
to the steering circuit.
1O-68
Adjustment
screw
Spring
Plug
Pilot poppet
Valve seat
STEERING VALVE
*To
From Orbit-roll r,
valve
Orbit-roll
valve
1O-69
0
STRUCTURE
AND
STEERING
FUNCTION
1.
2.
3.
4.
5.
Function
.
The overload relief valve is installed to the
steering valve. It has the following two functions: When the steering valve is at neutral,
if any shock is applied to the cylinder, and
an abnormal
pressure is generated,
the oil
is relieved from this valve. In this way, it
functions as a safety valve to prevent damage to the cylinder or hydraulic piping. On
the other hand, if negative pressure is generated at cylinder end, it functions as a suction valve to prevent a vacuum from forming.
Operation
Acting as relief valve
.
Port A is connected to the cylinder circuit
and port B is connected to the drain circuit.
Oil passes through the hole in poppet (I)
and acts on the different areas of diameters
dl and d2, so check valve poppet (3) and
relief valve poppet (2) are firmly seated in
position.
l
1O-70
A
\
Poppet
Relief valve poppet
Check valve poppet
Pilot poppet
Spring
VALVE
STEERING VALVE
SEW00095
SEW00096
1o-71
ORBIT-ROLL VALVE
ORBIT-ROLL VALVE
A-A
11
B-B
SFbVOl234
1.
2.
3.
4.
Needle bearing
Center spring
Drive shaft
Valve body
1 O-72
5.
6.
7.
8.
Rotor
Cover
Center pin
Sleeve
9. Spool
10. Stator
11. Lower cover
12. Check valve
ORBIT-ROLL VALVE
Outline
.
The steering
valve is connected
directly to
the shaft of the steering wheel.
It switches
the flow of oil from the steering pump to the
left and right steering cylinders to determine
the direction of travel of the machine.
The steering valve, broadly speaking, consists of the following
components:
rotary
type spool (3) and sleeve (51, which have the
function of selecting the direction, and the
Girotor set (a combination
of rotor (8) and
stator (911, which acts as a hydrauiic motor
during normal steering operations, and as a
hand pump (in fact, the operating force of
the steering wheel is too high, so it cannot
be operated)
when the steering pump or
engine have failed and the supply of oil has
stopped.
\,I
Structure
.
Spool (3) is directly connected
to the drive
shaft of the steering wheel, and is connected
to sleeve (5) by center pin (4) (it does not
contact the spool when the steering wheel
is at neutral) and centering spring (12).
The top of drive shaft (6) is meshed with
center pin (41, and forms one unit with sleeve
(5), while the bottom of the drive shaft is
meshed with the spline of rotor (8) of the
Girotor.
There are four ports in valve body (21, and
they are connected to the pump circuit, tank
circuit, and the circuits at the head end and
bottom end of the steering cylinders.
The
pump port and tank port are connected by
the check valve inside the body. If the pump
or engine fail, the oil can be sucked in directly from the tank by this check valve.
sswm715
+
Connected to
steering
wheel shafi
SBww718
1o-73
ORBIT-ROLL VALVE
SSWW725
1o-74
SSWCO726
Suctiion /
discharge port
SBWCO727
STRUCTURE
ORBIT-ROLL VALVE
AND FUNCTION
2
2
5
fQ
4
+%Q$+
SDwo1236
3
Angle
Variation
12
SDWO123-l
1o-75
STOP VALVE
STOP VALVE
Circuit diagram
1.
2.
3.
4.
5.
6.
7.
Boot
Wiper
Seal
-Poppet
Spring
Spool
Spring
1O-76
A: From orbit-roll
B: To steering valve
DR: To drain
STRUCTURE
AND
EMERGENCY
EMERGENCY
FUNCTION
STEERING
STEERING
PUMP
PUMP
A-A
1.
2.
3.
4.
5.
Specifications
.
Model: SUM(2)-050
.
Direction
of revolution:
Theoretical
delivery:
.
Max. delivery
pressure:
l
direction
1o-77
STRUCTURE
AND FUNCTION
DIVERTER
DIVERTER VALVE
VALVE
x-x
1.
2.
3.
4.
Diverter valve
Valve body
Check valve
Check valve
FUNCTION
.
If the engine stops or the pump seizes during machine traveiing,
and it becomes impossible to steer, the rotation of the transmission is used to turn the emergency steering pump to make steering possible.
1 O-78
A.
B.
C.
D.
E.
F.
G.
SEW01240
STRUCTURE
AND
FUNCTION
DIVERTER
VALVE
OPERATION
.
are working
normally.
To st.eerino
CYI inder
From
steerino
cylinder
Hvdraui
ic
tank
To stewing
cylinder
1o-79
Co
STRUCTURE
AND
FUNCTION
DIVERTER
VALVE
To steering
cylinder
Hydraulic
From
steering
cylinder
tank
svwo2909
1 O-80
0
Emergency
steering
pump
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
1 O-82
BRAKE PIPING
brake)
Outline
.
When
four pumps)
brake)
valve
STRUCTURE
AND FUNCTION
BRAKE HYDRAULIC
BRAKE HYDRAULIC
CIRCUIT
DIAGRAM
CIRCUIT DIAGRAM
6
22
\
23
From
pilot
circuit
---.
__-_I-_---
----j
r---;s_lc_.Aly
f
I
IA
IB
1.
IA.
IB.
IC.
ID.
2.
3.
3A.
3B.
4.
5.
-I
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
1 O-83
BRAKE VALVE
BRAKE VALVE
BRAKE VALVE (RIGHT)
2.
3.
4.
5.
6.
7.
a.
lo-84
BRAKE VALVE
SDWOO108
Outline
l
There are two brake valves installed in parallel under the front of the operators
cab,
and these are actuated by depressing
the
pedal.
When the right pedal is depressed,
oil is
sent to the brake cylinder to apply the brakes.
When the left pedal is depressed, oil is sent
to the right pedal to apply the brakes in the
same way as when the right pedal is depressed.
1O-85
STRUCTURE
AND
FUNCTION
BRAKE VALVE
Operation
Brake applied (right brake valve)
Upper portion
l
When brake pedal (1) is depressed, the operating
force is transmitted
to spool (3)
through rod (2) and spring (4). When spool
(3). goes down, drain port a is closed, and
the oil from the pump and accumulator flows
from port A to port C and actuates the rear
brake cylinders.
Lower portion
.
When brake pedal (I) is depressed, the operating
force is transmitted
to spool (3)
through rod (2) and spring (4). When spool
(3) goes down, spool (5) is also pushed down
by plunger
(6). When this happens, drain
port b is closed, and the oil from the pump
and accumulator
flows from port B to port D
and actuates the front brake cylinders.
From pump 6
From DumD
.
z&
Acbumulator
)\\
*To.rear brake
cyknder
1 O-86
STRUCTURE
AND FUNCTION
BRAKE VALVE
Applying
brake when upper valve fails (right
brake valve1
.
Even if there is leakage of oil in the upper
piping, spool (5) is moved down mechanically when pedal (I) is depressed,
and the
lower portion is actuated normally.
The upper brake is not actuated.
Applying
brake when lower valve fails (right
brake valve)
.
Even if there is leakage of oil in the lower
piping, the upper portion is actuated normally.
g
z
f
Lower portion
.
When spool (3) in the upper portion moves
up and the circuit between port A and port C
is shut off, oil also fills the front brake cylinder at the same time, so the pressure in the
circuit between port B and port D rises. The
oil entering port J from orifice f of spool (5)
pushes up spool (5) by the same amount
that spool (3) moves, and shuts off port B
and port D. Drain port b is closed, so the oil
entering the brake cylinder is held, and the
brake is applied.
.
The pressure in the space in the upper portion is balanced with the operating force of
the pedal, and the pressure in the space in
the lower portion is balanced with the pressure in the space in the upper portion. When
spools (3) and (5) move to the end of their
stroke, the circuits between ports A and C
and between ports Band D are fully opened,
so the pressure in the space in the upper
and lower portions and the pressure in the
left and right brake cylinders is the same as
the pressure from the pump.
Therefore, up to the point where the piston
moves to the end of its stroke, the effect of
the brake can be adjusted by the amount
that the pedal is depressed.
From
pump @
From
pump @
To front brake
sLwoc513
1 O-87
STRUCTURE
AND
BRAKE VALVE
FUNCTION
1O-88
L
v
To rear brake
cylinder
To front brake
ACCUMULATOR
CHARGE VALVE
- (oh
PP
ACC
PP
SDWMJ114
A. To PPC valve
ACC. To brake valve
PP. To brake valve
P. From pump
T. Drain
Function
The accumulator charge valve is actuated to
maintain the oil pressure from the pump at
the specified pressure and to store it in the
accumulator.
When the oil pressure reaches the specified
pressure, the oil from the pump is connected
to the drain circuit to reduce the load on the
pump.
l
1O-89
0
ACCUMULATOR
A-A
1.
2.
3.
4.
5.
c-c
D-D
Valve body
Safety relief valve (R3)
Relief valve (RI)
PPC relief valve (R2)
Relief valve (HI)
E-E
1O-90
CHARGE VALVE
ACCUMULATOR
CHARGE VALVE
ACC
PP
A
D-4
A. To PPC valve
ACC. To brake valve
PP. To brake valve
P. From pump
T. Drain
SOW02804
Function
The accumulator charge valve is actuated to
maintain the oil pressure from the pump at
the specified pressure and to store it in the
accumulator.
When the oil pressure reaches the specified
pressure, the oil from the pump is connected
to the drain circuit to reduce the load on the
l
pump.
10-90-l
0
ACCUMULATOR
CHARGE VALVE
A-A
D-D
E-E
1. Valve body
2.
3.
4.
5.
6.
1O-90-2
0
SDWO2805
ACCUMULATOR
CHARGE VALVE
Operation
Serial No. 50001 and up
1. When no oil is being supplied to accumulator (cut-out condition)
l
2.
Front accumulator
1) Cut-in condition
.
When the pressure at port B is lower than
the set pressure of the relief valve (Rl), piston (8) is pushed back down by spring (5).
Valve seat (7) and poppet (6) are brought
into tight contact, and port C and port T are
shut off.
.
The spring chamber at the right end of spool
(15) is also shut off from port T, so the pressure rises, and the pressure at port P also
rises in the same way.
When the pressure at port P goes above the
pressure at port B (accumulator pressure),
the supply of oil to the accumulator starts
immediately. In this. case, it is decided by
the size (area) of orifice (17) and the pressure difference (equivalent to the load on
spring (14)) generated on both sides of the
orifice. A fixed amount is supplied regardless of the engine speed, and the remaining
oil flows to port A.
ront accumulator
17
15
SDWW117
10-91
0
ACCUMULATOR
CHARGE VALVE
Front accumulator
sure.
SDWOOl 18
3.
.
Front accumulator
accumulator
-p
1 O-92
SDWGOllS
ACCUMULATOR
ACCUMULATOR
(FOR BRAKE)
(FOR BRAKE)
1. Valve
Top cover
3. Cylinder
4. Piston
2.
Function
.
The accumulator
is installed
between
the
charge valve and the brake valve.
It is
charged with nitrogen gas between cylinder
(3) and free piston
(41, and uses the
compressibility of the gas to absorb the pulse
of the hydraulic pump or to maintain
the
braking force and to make it possible to operate the machine if the engine should stop.
Specifications
Gas used:
Charge amount:
Charging pressure:
Nitrogen gas
3000 cc
3.4 + 0.15 MPa
(35 + 1.5 kg/cm?
(at 50C)
10-93
ACCUMULATOR
1.
2.
3.
4.
5.
(FOR BRAKE)
Top cover
Piston
Cylinder
End cover
Plug
SAww516
Function
.
The accumulator
is installed
between
the
brake valve and brake cylinder. Nitrogen gas
is injected between cylinder (I) and free piston (21, and its compression
is used to maintain braking force operability when the engine is stopped.
1o-94
Specifications
Gas used:
Charge amount:
Charging pressure:
Nitrogen
45 cc
gas
(at 50C)
STRUCTURE
BRAKE
1.
2.
3.
4.
5.
BRAKE
AND FUNCTION
Differential
Piston
Inner ring
Disc
Outer ring
housing
Outline
.
The brakes have a wet-type multi-disc strutture, and consist of piston (2), inner ring (31,
disc (41, outer ring (5) and spring (8).
.
The brake cylinder consists of differential
housing (I) and bearing carrier (IO), and incorporates piston (2).
Inner ring (3) and outer ring (5) are coupled
by the brake housing (9) spline.
6.
7.
8.
9.
IO.
Axle housing
Sun gear shaft
Spring
Brake housing
Bearing carrier
1o-95
STRUCTURE
AND
Operation
When the brakes
l
BRAKE
are activated
When
l
FUNCTION
the brakes
are released
1O-96
1.
2.
3.
Parking
Parking
Parking
brake switch
brake emergency
release
brake solenoid valve
switch
4.
5.
6.
Transmission
control valve
Emergency parking brake valve
Transmission
(built-in parking brake)
When the parking brake is applied, the neutralizer relay shuts off the electric current to
the transmission
solenoid valve and keeps
the transmission
at neutral.
Emergency release switch (2) for the parking brake is installed for use when moving
the machine if the machine has stopped (the
parking brake is automatically
applied) because of trouble in the engine or drive system.
Outline
l
1o-97
PARKING BRAKE
PARKING
BRAKE
1.
2.
3.
4.
5.
6.
7.
1 O-98
Outline
.
The parking
(4).
The pushing force of spring (3) pushes piston (2) against disc (5) and plate (6), braking
output shaft (41.
STRUCTURE
AND FUNCTION
PARKING
PARKING
BRAKE SOLENOID
BRAKE SOLENOID
VALVE
VALVE
1.
2.
3.
A.
B.
Coil
Valve assembly
Body
IN port
OUT port
SLvvmm
Function
This solenoid valve is controlled by the parking brake switch in the operators compartment and acts to switch the flow of oil to the
parking brake.
l
Operation
Parking brake applied
When the parking brake switch in the operators compartment
is turned ON, the solenoid valve is turned OFF (electric current is
cut), and the oil in the pilot circuit from the
transmission
pump flows from the IN port
to the OUT port and opens the drain circuit.
l
1o-99
STRUCTURE
AND
FUNCTION
2.
.
1o-1 00
PARKING
BRAKE VALVE
RELEASE SOLENOID
1.
2.
VALVE
Valve assembly
Solenoid valve
A: To parking brake
B: From parking brake valve
c: From pilot circuit
T: Drain
P: From brake (accumulator
circuit)
SLwoG525
Function
l
The emergency
stalled
between
release
the
solenoid
transmission
valve is inand
the
transmission
control valve. If the engine
breaks down and no oil pressure is supplied
from the transmission
pump, it is possible
to actuate the solenoid for the parking brake
release switch in the operators
compartment. This allows the accumulator
charge
pressure in the brake circuit to flow to the
parking brake cylinder.
To paking
brake
From paking
brake valve
Operation
.
When
parking
brake emergency
release
switch (3) is turned ON, solenoid valve (2) is
actuated and the pressure stored in accumulator (4) enters from port P. The circuit is
switched by the pilot pressure, so the oil
flows from port A to the parking brake to
release the parking brake.
10-101
WORK EQUIPMENT
WORK EQUIPMENT
LEVER LINKAGE
LEVER LINKAGE
8
SLwo1248
1.
2.
3.
4.
Boom lever
Kick-down switch
Bucket lever
Attachment
lever
5.
6.
7.
8.
10-107
HYDRAULIC TANK
HYDRAULIC TANK
1.
2.
3.
4.
5.
6.
Breather
Filter bypass valve
Oil filler
Oil filter
Sight gauge
Hydraulic tank
Outline
.
The oil sent to the cylinders from the hydraulic
tank via the pump and through the work equipment control valve merges with the oil of the
various parts in the return circuit. Some of this
oil is cooled by the oil cooler, flows into the
tank, is filtered by oil filter (4), and returns to
hydraulic tank (6).
lo-108
STRUCTURE
AND
FUNCTION
HYDRAULIC
TANK
~ From main
control vah fe
@To main
control vatve
JJ
SBWO3534
BREATHER
.
Preventing
negative pressure inside tank
The tank is a pressurized sealed type, so if
the oil level inside the hydraulic tank goes
down, there will be negative pressure in the
tank. If this happens, a poppet is opened by
the difference between the pressure inside
the tank and the atmospheric
pressure, and
air is let in to prevent negative pressure from
forming inside the tank.
li
Suction pressure: 3 KMPa (0.03 kg/cm*)
Preventing rise in pressure inside tank
If the pressure in the circuit rises above the
set pressure during operations
because of
the change in the oil level in the hydraulic
cylinders or the rise in the temperature,
the
sleeve is actuated to release the pressure
inside the hydraulic tank.
*
Checking pressure: 0.16 MPa (1.6 kg/cm*)
4
1.
2.
3.
4.
Body
Filter element
Poppet
Sleeve
SEW00141
10-109
PPC VALVE
PPC VALVE
P2
10-l10
P3
P4
PI
PPC VALVE
STRUCTURE
AND
FUNCTION
9
A-A
1.
2.
3.
4.
5.
6.
7.
8.
Bolt
Piston
Plate
Collar
Retainer
Centering
Metering
Valve
9.
Body
c-c
SEW00143
spring
spring
10-111
STRUCTURE
AND
PPC VALVE
FUNCTION
To cylinder
PBl
From pump
-
Function
.
The oil :from the pump enters port P. The
circuit is closed by spool (81, so the oil is
drained from relief valve (1).
At the same time, the oil at port PAI of the
main control valve is drained from port f of
spool (8).
In addition,
the oil at port PBI is drained
from port f of spool (8).
10-112
STRUCTURE
AND FUNCTION
PPC VALUE
(Fig. I)
(Fig. 2)
sEwco145
sEwoo146
10-113
STRUCTURE
3.
AND
PPC VALVE
FUNCTION
Control lever moved back from slightly operated position to hold (Fine control) (Fig. 3):
When plate (IO) starts to be pushed back,
piston (2) is pushed up by a force corresponding to the force of centering spring (6)
and the pressure at port P4.
At the same time, fine control hole (f) of
valve (8) is connected to drain chamber D,
so the oil at port P4 escapes.
If the pressure at port P4 drops too far, valve
(8) is pushed down by spring (7). Fine control hole (f) is shut off from drain chamber
D, and at almost the same time it is connected to pump pressure chamber PP. The
pump pressure is supplied until the pressure at port PA1 returns to a pressure equivalent to the position of the lever.
When the spool of the control valve returns,
the oil in drain chamber D flows in from fine
control hole (f) of the valve which has not
moved. The extra oil then flows through port
PI to chamber PBI.
(Fig. 3)
4.
sEwco147
(Fig. 4)
10-114
SEW00148
1.
2.
3.
4.
5.
6.
Main valve
Spring
Valve seat
Pilot poppet
Spring
Screw
\
6
SDWO0149
Function
.
The PPC relief valve
is between
the PPC,
brake pump and the PPC valve. When the
PPC pump is not being actuated, or when
any abnormal pressure is generated, the oil
sent from the pump is relieved from this
valve to prevent any damage to the pump
or circuit.
Operation
l
SDWOOlE.0
SDW00151
10-115
STRUCTURE
AND
ACCUMULATOR
FUNCTION
ACCUMULATOR
Gas plug
Shell
Poppet
Holder
Bladder
Oil port
Specifications
Type of gas: Nitrogen gas
Gas amount:
500 cc
Max. actuation pressure: 3.4 MPa (35 kg/cm*)
1.2 MPa (12 kg/cm21
Min. actuation pressure:
Function
The accumulator is installed between the hydraulic pump and the PPC valve. Even if the
engine stops when the boom is raised, it is
possible to lower the boom and bucket under their own weight by using the pressure
of the nitrogen gas compressed
inside the
accumulator to send the pilot oil pressure to
the main control valve to actuate it.
Operation
.
After the engine stops, if the PPC valve is at
hold, chamber A inside the bladder is compressed by the oil pressure in chamber B.
.
When the PPC valve is operated, the oil pressure in chamber B goes below 2.9 MPa (30
kg/cm2). When this happens, the bladder is
expanded
by the pressure of the nitrogen
gas in chamber A, and the oil inside chamber B is used as the pilot pressure to actuate
the main control valve.
10-l16
Before operation
After operation
MAIN
CONTROL VALVE
Z-SPOOL
B
D
G
E
A.
B.
C.
D.
E.
F.
10-l 18
valve)
G. To bucket
H. From PPC
I.
From PPC
J. From PPC
K. From PPC
cylinder bottom
valve port Pl
valve port P3
valve port P4
valve port P2
side
D-D
B-B
A-A
G-G
E-E
F-F
1.
2.
3.
4.
5.
6.
7.
8.
9.
IO.
11.
10-l 19
3-SPOOL
T
D
GF
A.
B.
C.
D.
E.
F.
G.
H.
10-120
valve)
I.
J.
K.
L.
M.
N.
0.
From
From
From
From
From
From
From
work equipment
pump
attachment
PPC valve
PPC valve port PI
PPC valve port P3
attachment
PPC valve
PPC valve port P4
PPC valve port P2
STRUCTURE
MAIN
AND FUNCTION
CONTROL VALVE
D-D
B-B
A-A
.I0
11
G-G
IO
E-E
H-H
F-F
1.
2.
3.
4.
5.
6.
7.
8.
Boom spool
Check valve
Suction valve
Cut-off relief valve
9.
10.
11.
12.
Screen
Safety valve (with suction)
Check valve
Main relief valve
10-121
RELIEF VALVE
1.
2.
3.
4.
5.
Main valve
Valve seat
Pilot poppet
Spring
Adjustment
screw
SAWCE41
Function
The relief valve is installed to the inlet portion of the main control valve. If the oil goes
above the set pressure, the relief valve drains
the oil to the tank to set the maximum
pressure for the work equipment
circuit, and to
protect the circuit.
Operation
.
Port A is connected
1o-1 22
/
A
34
SAWWSb3
B
SAWE-W
STRUCTURE
AND
FUNCTION
MAIN
CONTROL
VALVE
1.
2.
3.
4.
5.
6.
Suction valve
Main valve
Pilot piston
Main valve spring
Suction valve spring
Valve body
Function
.
The safety valve is in the bucket cylinder
circuit inside the main control valve. If any
abnormal pressure is generated by any shock
to the cylinder when the main control valve
is at the neutral position, this valve relieves
the abnormal
pressure to prevent damage
to the cylinder.
Operation
Operation as safety valve
.
Port A is connected to the cylinder circuit
and port B is connected to the drain circuit.
The oil pressure at port A is sent to port D
from the hole in pilot piston (3). It is also
sent to port C by the orifice formed from
main valve (2) and pilot piston (3).
Pilot piston (3) is secured to the safety valve,
and the size of the cross-sectional
surface
(cross-sectional
area) has the following relationship: dz > dl > d3 > da.
.
If abnormal
pressure is created at port A,
suction valve (I) is not actuated because of
relationship
dz > dl >, but relationship
between port A and port C is d3 > d4, so main
valve (2) receives oil pressure equivalent to
the difference between the areas of d3 and
d4. If the oil pressure reaches the force (set
pressure) of main valve spring (4), main valve
(2) is actuated, and the oil from port A flows
to port B.
A2
SALVE546
1O-l 23
STRUCTURE
AND
FUNCTION
MAIN
Operation
as suction valve
.
If any negative pressure is generated at port
A, port D is connected with port A, so there
is also negative pressure at port D. The tank
pressure of port B is applied to port E, so
the suction valve (I) receives oil pressure a,
which is equal to the difference in the area
of dz and dl because of the tank pressure at
port E. Therefore,
oil pressure e moves the
valve in the direction of opening,
and oil
pressure a acts to move suction valve (I) in
the direction of closing.
When the pressure at port A drops (and
comes close to negative pressure),
it becomes lower than hydraulic pressure e. The
relationship
becomes
oil pressure
e > oil
pressure a + force of valve spring (51, and
suction valve (I) opens to let the oil from
port B flow into port A and prevent any negative pressure from forming at port A.
Main poppet
Sleeve
Spring
SAW00549
pres-
Operation
.
If any negative pressure is generated
at port
A (boom cylinder rod end) (when a pressure
lower than tank circuit port B is generated),
main poppet (1) is opened because of the
difference in area between dl and dz, and oil
flows from port B at the tank end to port A
at the cylinder port end.
dl
lo-124
1.
2.
3.
Function
This valve acts to prevent any negative
sure from forming in the circuit.
VALVE
SUCTION VALVE
CONTROL
STRUCTURE
MAIN
AND FUNCTION
CONTROL
VALVE
Fi
4
Operation
1. When the work equipment
valve is held
The oil at the switch pump (the oil from
the steering valve) presses up check valve
(I), merges with the oil from the work
equipment
pump and flows to the work
equipment valve.
2.
655
M
Steeringpump Switchpump
SBwco744
10-725
STRUCTURE
2)
AND
MAIN
FUNCTION
lo-126
CONTROL
VALVE
Accumulator
Operation
.
The oil from the switch pump which has
passed through the cut-off valve and the
work equipment pumps oil enter port A and
the maximum pressure is regulated by relief
valve (1).
.
Since the bucket spool (2) is at the neutral
position, the bypass circuit is open, and the
oil at port A passes around the spool and
flows to port B. The boom (3) spool is also
lo-127
Accumulator
\ \
I I
M
N
*
From PPC valve
I %P I--
Operation
.
When boom lever (4) is pulled, oil flows from
PPC valve port L to port N and port S. The
lo-128
the boom spool (3) bypass circuit. The bypass circuit is closed by boom spool (31, so
the oil pushes open check valve (5). The oil
from check valve (5) flows to port D and to
the cylinder bottom side.
The oil on the cylinder rod side enters drain
port F from port E and returns to the tank,
causing the boom to raise.
lator
li
From PPC valve
I--*
Ek
Operation
l
10-129
LI
I---*
Operation
.
When boom
10-130
From PPCvalve
Accumulator
fl1-i
From PPCvalve
I--*
c/--
SLWlm558
Operation
l
When bucket lever (6) is pulled, the oil pressure at PPC valve port L is released from
port P to port R, and the oil at port V flows
to the drain circuit. The oil pressure at port
R sets bucket spool (2) to the TILT position.
Since the bypass circuit is closed by bucket
spool (21, the oil at port A pushes open check
valve (7).
IO-131
Accumulator
I--*
1 zy$off
Fromswitchpump
Operation
.
When bucket lever (6) is pushed, the oil pres-
lo-132
WORK EQUIPMENT
WORK EQUIPMENT
1.
2.
3.
Bellcrank
Bucket cylinder
Boom cylinder
10-134
LINKAGE
4.
5.
6.
Boom
Bucket link
Bucket
SAwoosM)
LINKAGE
WORK EQUIPMENT
Fa
A-A
D-D
G-G
LINKAGE
-yLI
B-B
E-E
H-H
c-c
F-F
J-J
sAwoo561
1o-1 35
BUCKET
BUCKET
A4
I
1
A-A
2.
lo-136
(BOC)
BUCKET POSITIONER
1.
2.
3.
4.
5.
Proximity switch
Plate
Bucket cylinder rod
Lever
Proximity switch
A-A
SBwoo563
10-l 37
BUCKET POSITIONER
. The bucket positioner
BOOM KICK-OUT
.
1O-l 38
Operation
of proximity
switch
Boom RAISE
l
When the boom is lower than the set position for the. kick-out, the detector (steel plate)
is not above the detection
surface of the
proximity
switch, so the proximity
switch
load circuit is shut off.
The relay switch is turned OFF and the current for the solenoid is shut off.
Kick-outrelay
Kick-outsolenoid
Boom lever
Proximity switch
Cam
Detect
Boom lever
Cam
Proximity switch
3m
Detector
Position
Proximity
actuation
switch
display
Lights up
Goes out
Current
flows
Current
is shut off
Current
flows
Current
is shut off
10-140
Operation
of proximity
switch
Bucket TILT
l
When the bucket is lower than the set position for the auto-leveler, the detector (steel
plate) is not above the detection surface of
the bucket proximity switch, so electric current flows in the proximity switch load circuit. The relay switch is turned OFF and the
current for the solenoid is shut off.
To battery relay
r relay
Bucket lever
Detector
Proximityswitch
k<;
PPCvalve
To battery relay
r relay
P
Bucket lever
Cam
De&&r
Proiimity switch
u,
rj
PPCvalve
S&VUX70
10-141
ProximiD/switch for
To battery relay
Jr II
Positioner relav
Bucket lever
Cam
Detector
Proximity switch
u-,
C;
Action of proximity
switch
Position
Proximity
actuation
switch
display
lo-142
SSWOCS71
PPC valve
When detector
at detection
proximity
is in position
surface of
switch
Goes out
Lights up
Current
Current
flows
is shut off
Current
is shut off
Current flows
CAB
CAB
Serial No. 50001-52999
I
\
4
1. Front glass
2. Front wiper
3. Rear wiper
4. Door
10-143
0
CAB
cz
I
SOW02807
1.
2.
3.
4.
10-143-l
0
Front glass
Front wiper
Rear wiper
Door
ROPS CAB
ROPS CAB
Serial No. 53001 and up
4
SOW02743
1.
2.
3.
4.
Front glass
Front wiper
Rear wiper
Door
lo- 143-2
0
AIR CONDITIONER
AIR CONDITIONER
AIR CONDITIONER PIPING
SBWw572
1.
2.
3.
4.
Vent
Air conditioner
Dry receiver
Compressor
10-144
condenser
5.
6.
7.
/I
-1
I
L __-
SDW01267
MACHINE
MACHINE
MONITOR
MONITOR
SYSTEM
SYSTEM
Attemator
terminal R Starting motor
Auto-greasing
controller
0
E.C.S.S controlle
sensor?2
1. Fuel level
2. Enginewater temperature
3. Torque converteroil temperature
4. Enginewater level
5. Engine oil level
6. Brake oil pressure
7. Engine oil pressure
8. Air cleaner clogging
sm750
Outline
l
The machine monitor system uses the sensors and other devices installed to various
parts of the machine to observe the condition of the machine. It processes this information swiftly and displays it on the monitor panel to inform the operator of the condition of the machine.
The machine monitor system consists of the
main monitor,
maintenance
monitor,
sensors, switches,
relays, alarm buzzer, and
power source.
The displays can be broadly divided into the
following:
Cautions displayed on the monitors (abnormalities
in the machine where an
alarm is given) and normal conditions which
are always displayed on the instrument panel
(pilot lamps and readings for the gauges,
speedometer,
and service meter).
10455
MAIN MONITOR
AIN MONITOR
4H
3A
5c
5D
5A
5E
58
1.
2.
3.
4.
CHECK lamp
CAUTION
lamp
Caution item
3A. Emergency steering
actuated
Pilot item
4A. Turn signal (left)
48. Turn signal (right)
4D.
4E.
4F.
4G.
4H.
41.
Shift indicator
Speedometer
Parking brake
Emergency steering
Preheating
Failure action code
Outline
.
The main motor has a display function
for
the speedometer
and other gauges and a
switching function to control the electric cornponents and controllers.
There is one CPU (Central Processing Unit)
installed internally, and this processes the
IO-156
5.
4C. Hi beam
normal
signals
-
from
Switches
5A. Auto-greasing
switch
5B. E.C.S.S. switch
5C. Working lamp (front)
switch
5D. Working lamp (rear)
switch
5E. Transmission
cut-off
switch
the sensors
and outputs
the dis-
play.
A liquid crystal display and LEDs are used
for the display. The switches are embossed
sheet switches.
MAIN MONITOR
Check
item
Display
there
1When
abnormality
Check
maintenance
Emergency
actuated
steering
Caution
cI>
CAUTION
lm
Q
Failure
action
code
is
display on
monitor
actuated
Display
method
Display
flashes
Display
sounds
flashes
When there
abnormality
maintenance
Caution
is
display on
monitor
see
and buzzer
Hi beam
When
operated
Display
lights up
Turn signal
(left, right)
When
operated
Display
lights up
Parking
When
operated
Display lights up
Buzzer sounds when parking
brake is applied and shift lever
is not at N
brake
Display
Preheating
When
Lights up
Lighting up time changes
according to engine water
temperature
when starting
switch is turned ON (for details,
see PREHEATING
OUTPUT
FUNCTION)
Travel
0 - 99 km/h
Shift indicator
1 - 4,N
Digital
Failure action
Digital display
Buzzer sounds
(For details of the travel data
display mode, see TROUBLE
DATA DISPLAY MODE)
Emergency
normal
Shift
indicator
When
range
steering
speed
code
preheating
lights up
display
10-157
MAIN MONITOR
Function
Display
Actuation
Auto-greasing
Flashes (slowly)
Flashes (rapidly)
Grease empty
Abnormality in auto-greasing
controller system
Auto-greasing controller not
E.C.S.S.
Working lamp
(front)
Working lamp
(rear)
Transmission
cut-off
lo-158
,__;
Goes out
Lights up
Goes out
Lights up
Goes out
Lights up
Goes out
STRUCTURE
MAIN
AND FUNCTION
MONITOR
Item
QGS
(Quick
glow system
Power
source
ON
Starting
signal OFF
(terminal C)
r-l
I
t
I
ON
Display
I
I
Tl
OFF
output
OFF+
T2
T2
T2
Display time
Tl (set)
Output time
T2 (set)
20 -
p -
Tl
\
-T2
:
-10
60 -
10-159
MAIN
MONITOR
travel
damper,
Item
Switch operation
Method of switching to
trouble data display
mode
controller)
is installed,
Actuation
All switch displays (LED4 go out, and
failure code is displayed on speedometer
display and time elapsed since failure is
displayed on failure action code display.
(1) Failure code is a two-digit display
given in numbers or letters.
The display for the failure now
occurring flashes and the display for
past failures lights up.
If there is no failure, CC is displayed
(000 is displayed for time elapsed
since failure)
(2) The time elapsed since failure is
displayed as a three-digit number
to show how long ago the failure
occurred (the oldest failure time is
displayed. Any time greater than
999H is displayed as 999H).
(3) A maximum of 9 items are stored
in memory for the failure code.
a
uo
work equipment
Method of sending
failure code
27
Cl
SOW00243
ti
10-160
MAINTENANCE
IA
IB
/
7
2.
Outline
.
The maintenance
MONITOR
MONITOR
3A
1.
MAINTENANCE
$4
3l3
2C
2A
?B
2B iD
qC 4D
;A 5B
3.
4.
sLww591
Gauge items
3A. Fuel level
3B. Engine water temperature
3C. Torque converter oil
temperature
Work equipment
control
switches
4A. Bucket auto-leveler set
switch
4B. Bucket auto-leveler
auto-mode
switch
monitor has a display function for the caution items and gauges, and
switch functions to control the work equipment controller (if equipped).
The maintenance
monitor consists of the
monitor
module,
switch module,
service
meter, case, and other mechanisms.
5.
6.
7.
The monitor module has a built-in CPU (Central Processing Unit). It processes the signal
from the sensors, and carries out the display and output.
A liquid crystal display and LEDs are used
for the display portions. The switches are
embossed sheet switches.
lo-161
MAINTENANCE
MAINTENANCE
Display
category
Symbol
Display method
Display range
Below specified
pressure
Below specified
pressure
Check
I0
b-
MONITOR
I 09
Caution
lap
Above 120C
Fuel level
I3
rn
I-
Battery charge
When charge is
defective
Air cleaner
Above specified
negative pressure
Service meter
0 - 9999.9h
c---l
II
Service
meter
Fuel level
I3
Gauges
1O-l 62
8
?I
?I
MAINTENANCE
MAINTENANCE
Function
Item
Bucket auto-
Setting
leveler
setting
(if equipped)
when
automatic
switch
stopping
is pressed
Flashes
is
Goes out
Bucket auto-
Switches
leveler
auto mode
between
Lights up
Actuation
Sets stopping
angle
Bucket auto-leveler
auto mode
ON
is pressed
mode
(if equipped)
Remote
boom
positioner
position
RAISE
setting
(if equipped)
Sets stopping
direction
positioner
switch
position
for remote
(boom
is pressed
Sets remote
boom
direction
RAISE
function
pressed)
each time
Flashes
(2.5 set)
Sets stopping
position
positioner
when
is recorded)
in stopping
positioner
in RAISE
auto mode
OFF
boom
position
of
LOWER
Bucket auto-leveler
Goes out
boom
Selection
remote
(2.5 set)
angle
recorded)
auto
MONITOR
positioner
Goes out
Goes out
(switches
switch
Remote
boom
function
OFF
Remote
boom
is
RAISE
lights up
stop function
(if equipped)
LOWER
RAISE,
lights up
LOWER
Remote
boom
LOWER
stop function
Remote
boom
RAISE/LOWER
light up
positioner
RAISE
ON
positioner
ON
positioner
stop function
ON
10-163
WORK EQUIPMENT
WORK EQUIPMENT
CONTROL
CONTROL SYSTEM
SYSTEM
&
@
@I
(3
@
Auto mode
Level set
Remote positioner
set switch
Remote positioner
RAISE/LOWER
selection switch
Proximity switch
-D
-D
0
D
0
D
0
A:
D:
P:
II
H
0
Analog signal
Digital signal
Pulse signal
D -I
CONTROL FUNCTIONS
Auto leveling
function
positioner
stop control
function
Boom LOWER/RAISE
position
& leveling
function
Sensor adjustment
function
Model
selection
Troubleshooting
control
stop
set
function
function
Outline
Because of the structure of- the Z-bar link
work equipment, the angle of the work equipment to the ground changes according
to
the height.
The auto-leveling
control keeps the angle to
the ground constant regardless of the height
of the work equipment.
This makes it easy
to control operations such as removing the
load from the bucket.
10-164
With the remote positioner control, the operator can set the boom stopping (lever kickout) position to the desired position. This
makes the movement smooth when starting
or stopping the boom, and makes it safer
and easier to operate the machine
when
moving back, carrying out digging operations, or approaching
dump trucks.
STRUCTURE
WORK
AND FUNCTION
EQUIPMENT
CONTROL
SYSTEM
101
G.Buzzeroutput
i!
Lever kick-out
solenoids
Ii
3,4
.
@
ip
@Modelselection
signal
Enginespeed 7
Work equipment
controller
&!yy--+
Bucketcylinder
L-_
L-(0&----J
PPC pump
Boom lever
detentswitch
10-165
STRUCTURE
WORK
AND FUNCTION
2.
-300 -
cl 50
Above horizontal
Manual
(lever control)
priority:
If the
bucket lever is operated during this control and the bucket is set to the desired
angle, the angle to the ground when the
lever is returned to neutral will become
the new control target angle. (However,
this is only if the work equipment
is
within the control range.)
Bucket automatic stop control
Set the bucket to the maximum
dump
and place the bucket lever in the detent.
When the bucket reaches the horizontal
position (or the desired set position), the
lever detent is released and the bucket
stops. T.he set position is retained even
if the key is turned OFF.
1) Setting desired stop position
i) Operate the bucket lever to determine
the position
(-30 +15), then set the lever to HOLD.
ii) Press the auto-leveler set switch.
iii) When the auto-leveler lamp goes
out, the auto-leveler set lamp will
flash. (2.5 set)
lo-166
2)
EQUIPMENT
CONTROL
SYSTEM
8
G
Z!J
STRUCTURE
AND
WORK
FUNCTION
EQUIPMENT
CONTROL
SYSTEM
Boom RAISE/LOWER
position stop
The controller always detects the direction of operation of the lever from the
pressure switch installed to the boom
PPC valve and the angle (position) of the
from
boom
angle
boom
the
potentiometer.
1) RAISE kick-out (RAISE lamp ON)
When the boom lever is placed in
the RAISE detent and the boom rises
to the set position, it slows down
and then stop, and at the same time,
the detent is released. If the boom is
at any position other than the RAISE
detent, it will rise as normal.
2)
LOWER
boom
stop
(LOWER
lamp
ON)
If the boom lever is placed at the
FLOAT or LOWER position and the
boom goes down to the set position,
it will slow down and stop. If the
lever is placed at HOLD, the boom
will stay stopped.
If the lever is
moved back slightly, the boom will
go down again.
The RAISE position (which the operator can set to the desired position) and the LOWER stop position
differ according to the model. For
details, see Table 1.
Table
LOWER
WA320-3
0 - 44.8
-27
WA380-3
0 - 40.5
-27
WA420-3
0 - 39
-260
WA470-3
0 - 38
-26
RAISE 0
0
+c5l
+c3
LOWER 0 = LOWER 0 -
RAISE
0
Lamp ON
2.
:0
RAISE
0
RAISE 0
*c-i?
LOWER 0 - LOWER 0
Lamp OFF : 0
10-167
WORK EQUIPMENT
SENSOR ADJUSTMENT
.
FUNCTION
10-168
CONTROL SYSTEM
This controller has data tables for four models, and can handle these by means of the
following
selection signals when the key is
turned ON. (See Table 2)
When the key is turned ON, the selected
model is displayed for 2 seconds on the controller LED.
if there is any error in the model selection,
18.81 is displayed.
Table 2
TROUBLESHOOTING FUNCTION
l
k
5
WORK EQUIPMENT
1.
2.
Model selection
Connector
display
portion
CNl28
CNLZ7
CNi26
CONTROL SYSTEM
sAwoo595
CONNECTOR SIGNALS
CNL26
1
1 NETWORK
/ Proximity
signal
switch
signal
2
3
1TILT solenoid
I Power source
I GND
CNL27
10 1 Remote
11
1Auto-leveler,
12
NETWORK
13
Sensor
Remote
positioner
Boom
RAISE
Boom
LOWER
input
l+24V)
3
4
switch
pressure
set LED
I Boom
lever
detent
I Sisnal
GND
output
10 I Potentiometer
relay
11
1Bucket
neutral
source
18
19
21
I Auto-leveler
I Pressure
lever
LED
set LED
LED
sensor
signal
(+5V)
16
Bucket
positioner
1Auto-leveler
ify=
Remote
14
20 1 Boom
signal
t+24V)
I
17
speed
switch
signal
signal
switch
switch
power
Engine
switch
pressure
switch
Cc)
positioner
CNL28
kick-out
kick-out
output
(+24V)
1Auto-leveler
19 I Boom
20
1Buzzer
positioner
LOWER
LED
output
_-
17
18
Remote
Bucket
angle
angle
switch
potentiometer
potentiometer
output
10-169
WORK EQUIPMENT
CONTROL SYSTEM
POTENTIOMETER
1
\
__
Q
7
2
6
5
3
4
A4
A-A
SEW00266
1.
2.
3.
4.
Connector
Case
Shaft
Element
5.
6.
7.
Bearing
Contact
Mold
p
= 3
j
a2
s
O 1
0
B
f
Q
1.
0
-60
Potentiometer angle (
60
-60
60
60 WA470
0
-65 Except WA470
Potentiometer angle ( O)
SDWCQ267
Function
The boom angle potentiometer
is installed to
the front frame boom mount and the bucket
angle potentiometer
is installed to the boom
bellcrank mount. They act to detect the angle of
the work equipment.
Inside the potentiometer
the 5V power source
voltage from the angle is converted to a signal
voltage by the resistance value of the variable
resistor, and this is sent to the controller.
10-170
In the diagrams
above, the hatched area is
the abnormal detection area, and if the controller receives this signal, it judges that there
is a disconnection,
short circuit, or other abnormality in the potentiometer
system. In addition, if the correct position cannot be detected, the controller
shuts off the control
output and displays a failure code on the main
monitor.
STRUCTURE
AND
FUNCTION
E.C.S.S.
f2
1. E.C.S.S. (Electronically
Controlled
Suspension System)
. This system uses a combination
of relieving
the hydraulic oil from the work equipment
and switching ON/OFF an accumulator which
is charged with high pressure gas. The controller carries out automatic control of these
in accordance
with the travel condition
of
the machine to give resilience to the up and
down movement of the work equipment
and
to suppress the vibration of the chassis when
traveling at high speed; In this way, it improves the ride for the operator,
prevents
spillage of the load, and improves the operating efficiency.
.
Special solenoid valves (ON-OFF valves) are
used to control the ON-OFF switching of the
accumulator
(high pressure, low pressure)
and the opening and closing of the relief
valves.
. With this system, it is possible to handle
four models (WA320, WA380, WA420,
and
WA4701 with the same system simply
by
changing the connections
of the model selection wiring harness.
Main
-Serial
monitor
2.
Structure of system
The E.C.S.S. consists of the following
electronic devices.
Trave
1) E.C.S.S controller (M type controller)
2) Input devices: E.C.S.S switch (system
switch), pressure switch (boom cylinder
Pressure switch
bottom pressure), travel speed sensor,
model selection wiring harness, speed
range selection wiring harness
3) Output devices: solenoid valves (relief
valve, high pressure accumulator,
low
I
pressure accumulator)
Sneeri rRnnPsdpriinn
communication
+24V
!I
i7!7
Solenoid
7737
I I I I
to main monitor
Model selection
wiring harness
SEW00268
10-171
E.C.S.S.
3.
.
Content of control
In response to the input on the left side of
the table below, the controller carries out
the output on the right side to control the
system.
c: ON
x: OFF
Input
E.C.S.S switch
(system ON-OFF)
Speed
output
Travel
speed
[Note 31
Pressure
switch
ON
OFF
OFF
OFF
ON
ON
ON
OFF
OFF
OFF
ON
ON
ON
Min. 5 km/h
Speed
1st
OFF
ON
2nd
OFF
OFF
3rd
ON
OFF
4th
ON
ON
lo-172
+24V,
OFF:
Note 3: Input
speed
pulse frequency
is 1 km/h
OPEN
when
travel
Output ON
H-L
ON:
Solenoid
(3) (low
pressure)
Speed range
Shift position
Solenoid
(2) (high
pressure)
Min. 5 km/h
Min. 5 km/h
Note
ON
Solenoid
(1)
(relief)
1
Output OFF
3km/h
I
5kmlh
-
Travel
speed
2
2
STRUCTURE
4.
.
AND
FUNCTION
E.C.S.S.
Self-diagnostk
fwxtion
This system always observes the condition
of the system, and displays the condition of
the system (LED code, see table below) in
the controller self-diagnostic display portion.
If there is any abnormality
in the controller
itself or in the input or output devices, the
controller carries out troubleshooting
of the
abnormality.
It turns all the output OFF and
displays the error code (failure code) in the
self- diagnostic display portion and the main
monitor.
LED codes
Pressure switch ON
(disDlavs onlv when
55
ON)
Error / d2 / ~~~~~,~sle,~pi,,,,,,
code
rl.,
9
d4
1)
/Abnormal
Displays on controller
.
Error code displays [El 3 Idxl (where x
is a numeral from 0 to 4 in the table
above) repeatedly in turn.
.
If more than one abnormality
occurs at
the same time, all the appropriate
error
codes are displayed in turn.
When the starting switch is turned OFF
(controller power OFF, the error codes
are reset and not written to memory.
.
When checking the LED display, read the
code with the connector facing down.
Displays on main monitor
.
For details, see MAIN MONITOR TROUBLE DATA DISPLAY.
l
2)
10473
5.
E.C.S.S.
Controller
1.
2.
CNAL2
CNALI
CNAL3
SDWOO270
input/output
CNALl
signals
6 1
7 I
18
19
20
21
Model
selection
1
2
3
4
5
6
7
8
9
Ill
Model
Model
Model
Model
selection
selection
selection
selection
1Pressure
1Network
I
Input
switch
H
18 j
19 I
Il-lpUU
oumut
Input
Input
Input
Input
Name of signal
NO.
13
14
15
16
,,
CNAW
CNAL2
output
output
table
1 CNAL2-1
1 CNAL2-2
1 CNAL2-3
/ CNAL2-4
WA320
X.
WA380
WA420
0: GND
WA470
X: OPEN
10-174
c;
Controller
Self-diagnostic
display
SENSORS
SENSORS
Function
The sensors are a contact type sensor with
one end grounded to the chassis. The signal
from the sensor is input directly to the monitor panel, and when the contacts are closed,
the panel judges the signal to be normal.
However, the engine oil pressure uses a relay to reverse the sensor signal.
Sensor
item
detection
Sensor
method
When
normal
Engine
oil level
Contact
ON
OFF
Contact
ON
OFF
Tvt,ator water
Engine water
temperature
Resistance
Torque converter
oil temperature
Resistance
Fuel level
Resistance
Electromagnetic
Engine
speed
Engine oil
pressure
Contact
When
abnormal
OFF
ON
Structure of circuit
SEW00292
Function
l
1.
2.
3.
4.
Connector
Bracket
Float
Switch
10-175
SENSORS
1.
2.
3.
Structure ofcircuit
Function
Float
Sensor
Connector
8
%
5
@=D
Structure of circuit
1.
2.
3.
Connector
Plug
Thermistor
lo-176
Function
l
SEW00294
SENSORS
E
K
Structure
1.
2.
3.
4.
5.
6.
7.
Connector
Float
Arm
Body
Spring
Contact
Spacer
Y
of circuit
Function
.
The fuel level sensor is installed
to the side
face of the fuel tank. The float moves up
and down as the level of the fuel changes.
As the float moves up and down, the arm
actuates a variable resistance, and this sends
a signal to the maintenance
monitor to display the fuel level. When the display on the
maintenance
monitor reaches the specified
level, the warning lamp flashes.
10-177
SENSORS
4
5
i i
o.mfG
0.85fG 2
Structure of circuit
1.
2.
3.
4.
5.
SBwooM)6
Function
.
The engine speed sensor is installed to the
ring gear portion of the flywheel housing. A
pulse voltage is generated by the rotation of
the gear teeth, and a signal is sent to the
monitor panel.
Magnet
Terminal
Case
Boot
Connector
2345
63
Structure
of circuit
SEW00290
1.
2.
3.
4.
5.
6.
Plug
Contact ring
Contact
Diaphragm
Spring
Terminal
lo-178
Function
.
This sensor is installed to the engine block
and the diaphragm detects the oil pressure.
If the pressure goes below the specified pressure, the switch is turned ON, and a relay is
actuated to turn the output OFF. This makes
the maintenance
monitor flash to warn of
the abnormality. The caution lamp and alarm
buzzer are also actuated at the same time to
warn of the abnormality.
ENGINE STARTING
CIRCUIT
End
Engine stop
motor relav
Preheat
relay
Noncontrnuous
,,,
ihatched portion)
Monitor oreheat
Alternator
relay
Slow-blow fuse
Function
.
A neutral safety circuit which inhibits engine
Operation
.
When the starting switch is set to the START
10-179
ENGINE
STOP CIRCUIT
End
Start
Engine stop
motor relay
L--p1
To preheating relay
e
2%
To neutral
Noncontinuous
portion
(hatched portion)
Alternator
Starting motor
1OA
Function
l
Operation
.
When the starting switch is turned OFF, starting switch terminals B, BR and C are opened.
l
lo-180
When the motor rotates, terminal D also rotates at the same time. When the non-continuous portion of terminal D reaches terminal C, the circuit from terminal A to C opens,
and the current from the battery to the motor is shut off. The motor attempts to continue rotating under inertia, but when the
continuous
portion of terminal
D contacts
terminal C, both poles of the motor are connected to the ground, and the motor stops
rotating.
In this condition, the stop motor cable is
completely
pulled in, and the fuel injection
pump lever is set to the STOP position to
stop the engine.
PREHEATING CIRCUIT
PREHEATING CIRCUIT
QUiCKGLOW SYSTEM (QGSI
Starting switch
Battery relay
tl
I I
Battery
QGS sensor
I
CNL05
Outline
l
Main monitor
CNLOG
CNL07
SLWcc611
Operatibn
When the starting switch is set to the ON
(ACC) position, a signal flows from starting
switch terminal
BR to the controller in the
main monitor, and the preheat output is connected to the ground. The preheat relay coil
is excited, the preheat relay is activated, and
this activates the glow relay.
A current flows in the following circuit: Battery + battery relay -+ glow relay + glow
plug. This sets the preheating mode.
When the signal indicated that preheating is
completed
is sent from the controller, the
preheat relay turns OFF, the glow relay also
turns OFF, and preheating is completed.
lo-181
ELECTRIC TRANSMISSION
ELECTRIC TRANSMISSION
CONTROL
CONTROL
Maintenance monitor
, Relays
Kick-down switch
Speed lever
Directionallever
Parking brake
switch,
\
i
Transmission cut-off
selector Switch
Function
1
Kick-down switch
Transmission
When traveling in F2, it is possible to shift down to 1st using this switch
speed range automatically returned to 2nd.
is shifted to neutral when left brake is operated
Transmission
Neutralizer
when the starting switch is turned. This prevents the machine from
starting suddenly. (For details, see STARTING CIRCUIT.)
Warning function
When traveling in reverse, the backup lamp lights up and the backup
horn sounds to warn people in the area.
lo-182
ELECTRIC TRANSMISSION
CONTROL
COMBINATION SWITCH
IO
Outline
.
The directional
Directional
Speed
lever switch
Speed
lever stopper
Turn signal
lever switch
Switches
Selects
between
speed
Stopper
F, R, and N
range
used to prevent
speed
lever from
entering
operations
indicators
Direction
indicator
Turn signal
Self cancel
Lamp switch
Switches
Dimmer
Selects
Hazard
after
switch
machines
Makes
switch
lamps
indicator
turns
turning
left or right
returns
to central
position
left or right
on clearance
high beam
used when
lever automatically
lamp,
for travel
head lamp,
parking
lamp,
etc.
for passing
indicator
lamps
flash at the
same time
9
10
Emergency
Parking
flashing
brake switch
pilot lamp
Flashes
Applies
or releases
parking
flashing
lamp flashes
brake
1O-l 83
STRUCTURE
AND
FUNCTION
ELECTRIC TRANSMISSION
CONTROL
Operation
Directional
lever (l)and
shaft
(2) of the
speed lever of the combination
switch form
one unit with magnet
(3). and magnet (3)
also moves together with lever (1).
Control switch (5) with built-in hole IC (4) is
installed at the bottom of magnet (31, and
hole IC (4) is positioned
on the board to
match each position.
When directional
lever (I) is operated to the
F position, magnet (3) is immediately
above
hole IC (4) for the F position of the control
switch. The magnetism
from magnet (3)
passes through the gap and case (61, and
magnetism
is applied to hole IC (4).
When this happens,
hole IC (4) is inside a
magnetism
detection circuit, so it detects the
magnetism
of magnet (3)and
sends the F
position signal to the electric current amplification circuit. In the electric current amplification circuit, a signal is output to actuate
the transmission.
SLWw613
lo-184
KICK-DOWN
KICK-DOWN SWITCH
SWITCH
1.
2.
3.
4.
Kick-down switch
Spring
Side cap
Wiring harness
SEW00303
KICK-DOWN SWITCH
Operation
l
When directional.lever
is at N
When directional lever is at R
When speed lever is not at 2nd
When starting switch is OFF
lo-185
H-L
v
Speed
Schoid
4
R
Solenoid
J2_I
pa**ing
J
CNL68
Kickdown
&lV
CNW
REVERSE
relay
CNLE6
FORWARD
relay
CNL.55
TE?nullGsion
clrt-afffelay
10-186
CNL58
CNLY
stop lamp
rekV
CNL57
Neutral
=hV
lamp
wmh
brake
%%ZlUlid
valve
STRUCTURE
AND FUNCTION
KICK-DOWN
ELECTRIC CIRCUIT
DIAGRAM
SLwol616
When the kick-down switch is pressed, electric current flows from the battery @ +
speed lever 2 + FORWARD relay terminal 3
- 4 -$ kick-down switch + kick-down relay
terminal 5 - 6 + ground.
As a result, the kick-down is actuated, and
kick-down relay terminals 1 and 2 and terminals 3 and 4 are closed. A circuit from
kick-down relay terminal 1 - 2 + kick-down
relay terminal 5 - 6 + ground is formed, so
the kick-down relay continues to be actuated even if the kick-down switch is returned.
(Self-hold circuit of kick-down relay)
When the kick-down relay is actuated and
terminals
3 and 4 are closed, electric current flows from the battery @ + kick-down
relay terminal 3 - 4 + solenoid 4 + ground,
and solenoid (4) is actuated. Solenoids (1)
and (4) are actuated, so the transmission
is
set to Fl.
Solenoid
actuation
Solenoid
.Fl
FORWARD
t(l)1 0
REVERSE
(2)
H-L select
(3)
table
F2
10
F3
F4
t 0
10
N
1
Rl
tI
R2
1
I
R3 R4
1
I
1
I
0000
0
3
c
0
lo-187
STRUCTURE
AND
FUNCTION
Canceling actuation
of kick-down switch
(Directional
lever moved to N or RI
KICK-DOWN
CIRCUIT
DIAGRAM
(Case I)
1o-1 88
ELECTRIC
Solenoid
actuation
table
STRUCTURE
AND FUNCTION
KICK-DOWN
ELECTRIC CIRCUIT
DIAGRAM
Parkingswitch
lied1
H-L
speed
R
F
Solenoid Solenoid Sole&d Solenoid
CN37
CM8
SLWCC618
Solenoid
actuation
table
lo-189
STRUCTURE
Canceling
AND
actuation
KICK-DOWN
FUNCTION
of kick-down
switch
(Case
ILlI
10-190
ELECTRIC CIRCUIT
DIAGRAM
TRANSMISSION
TRANSMISSION
CUT-OFF SWITCH
CUT-OFF SWITCH
SDWOO373
1.
2.
3.
4.
Case
Seal film
Disc
Vinyl tape
Outline
l
5.
6.
7.
8.
Tube
Connector
Cover
Spring
Specifications
Voltage
value
c;;r;;t
Mi:-i.
Max.
Min.
Max.
18 V
32 V
10 mA
2.3 A
10-191
STRUCTURE
AND FUNCTION
TRANSMISSION
TRANSMISSION
CUT-OFF FUNCTION
CUT-OFF FUNCTION
Transmission
cut-off Switch
combination switch
Outline
.
If the transmission
cut-off selector switch on
the main monitor is turned ON (pilot lamp
lights up), the transmission
cut-off switch
installed to the left brake pedal is actuated.
When the left brake pedal is operated, the
brakes are applied, and the transmission
is
shifted to neutral at the same time. If the
transmission
cut-off selector switch is set to
the OFF position (pilot lamp goes out), the
transmission
is not shifted to neutral even
when the brake is operated, so the left brake
functions
only as a brake in the same way
as the right brake.
lo-192
Operation
1. Transmission cut-off selector switch ON
.
If the transmission
cut-off selector switch is
turned ON, the transmission
cut-off relay
solenoid is not excited, so transmission
cutoff relay terminals 3 - 5 are not connected.
In this condition,
+24V voltage is applied
through only the transmission cut-off switch
to transmission
control valve solenoids
R
and F.
When the left brake pedal is depressed, the
contacts of the transmission
cut-off switch
are opened, so the voltage to solenoids R
and F is shut off. As a result, the brakes are
applied as normal, and the transmission
is
also shifted to neutral at the same time.
l
TRANSMISSION
CUT-OFF FUNCTION
Transmission
cut-off switch
KicGown
switch
2.
Transmission
CNL 68
Kick-down
relay
CNL 67
REVERSE
relay
CNL 66
FORWARD
relay
CNL 65
Transmission
cut-offrelay
CNL56
Neutralizer
relay
From parking
brake switch
(battery power)
CNL57
Neutral
relay
If the transmission
cut-off selector switch is
turned OFF, the transmission
cut-off relay
solenoid is excited, and transmission
cut-off
relay terminals 3 - 5 are connected. In this
condition, +24V voltage is applied to transmission solenoids R and F regardless of the
position of the transmission
cut-off switch.
As a result, even when the left brake pedal
is depressed, the transmission
is not shifted
to neutral.
10-193
STRUCTURE
AND
ELECTRIC PARKING
FUNCTION
BRAKE CONTROL
Outline
.
The parking brake is a wet-type
multipledisc brake built into the transmission.
When
an electric current flows to the parking brake
valve (solenoid valve), the oil pressure from
the transmission pump is applied to the parking brake cylinder and the parking brake is
released.
.
When the electric current is cut, the oil pressure from the transmission
pump is shut
off, and the oil pressure inside the parking
brake cylinder passes through the parking
brake valve and is drained. The parking brake
is then applied by the force of the brake
spring.
10-194
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
STRUCTURE
AND
ELECTRIC
FUNCTION
Function
1. Applying and releasing parking brake
The parking brake is applied or released by
using the parking brake switch (combination
switch).
Automatic parking brake
When the engine stops (when the starting
switch is OFF), the parking brake is automatically applied to prevent the machine
from running away when the operator
is
away from his seat.
3.
Emergency brake
If the pressure in the oil pump should drop
because of damage to the hydraulic circuit
and the braking force can not be ensured,
the parking brake is applied automatically
to
act as an emergency brake.
4.
6.
PARKING
BRAKE CONTROL
It is dangerous
5.
Neutralizer
The parking brake may seize if the machine
is driven with the parking brake still applied.
To prevent this problem, the caution lamp
lights up and the alarm buzzer sounds to
warn the operator of the mistaken operation. In addition to this, when the parking
brake is applied, the transmission
is forcibly
shifted to neutral to make it impossible to
drive the machine. However, the braking distance will become longer if the transmission
is shifted to neutral when the emergency
brake is applied. It may also be necessary to
move the machine if it stops in places where
it is prohibited to stop (such as on railway
crossings). To overcome this, the circuit is
designed so that the transmission
is not
shifted to neutral when the emergency brake
is applied.
70-l 95
Connection table
ml
10-196
i,
ii
Relay actuation
table
6
5
3
1
2
Internal
1.
2.
Case
Base
connection
diagram
SEW00321
10-197
OPERATION
1. Starting switch OFF
Neutralizer relay
Battery relay
Starting switch
To transmission directionalcircuit
1O-l 98
STRUCTURE
2. Starting
2-1 When
AND FUNCTION
switch
parking
ELECTRIC PARKING
BRAKE CONTROL
ON
brake switch
is ON (actuated)
before starting
switch
is turned
ON
Neutralizer relay
Starting switch
In this condition,
electric current does not
flow to the parking brake solenoid valve, so
the parking brake is actuated.
In addition, in this condition, neutralizer
relay terminals
3 and 5 are open, so electric
current does not flow to the transmission
directional
circuit, and the transmission
is
shifted to neutral.
10-199
STRUCTURE
2-2 When
AND
parking
FUNCTION
ELECTRIC
brake switch
is OFF (actuated)
before
starting
switch
PARKING
is turned
BRAKE CONTROL
ON
Battery relay
Starting switch
r------ +
1O-200
Emergency
brake switch
(installedto accumulator)
STRUCTURE
AND
FUNCTION
ELECTRIC
PARKING
BRAKE CONTROL
QFF (released)
brake switch
is turned
from
switch
is turned
ON
Neutralizer relay
Battery relay
Starting switch
D
I
Alternator
terminal R
To transmission directionalcircuit
To transmissionspeed circuit
@ This circuit is formed from the emergency brake switch + parking brake solenoid valve -+ ground, and the parking brake
is released.
@ This circuit is formed from the battery @
+ battery relay + neutralizer relay terminal
3 - 5 + transmission
directional circuit, so
when the directional
lever is operated, the
machine will move.
1O-201
4.
Parking
brake switch
ON (actuated)
Parkingbrake switch
(manual)
Parkingbrake
safety relay
Neutralizer relay
To transmission
directional circuit
+
t
To transmission weed circuit
If the parking brake switch is turned ON lapplied) after carrying out operations with the
parking brake switch OFF (released), the circuit in the diagram above is formed.
Electric current does not flow to the parking
brake solenoid valve, so the oil pressure from
the transmission
pump to the parking brake
cylinder is shut off. At the same time, the oil
pressure inside the parking brake cylinder
passes through the parking brake valve and
is drained, so the parking brake is applied
by the force of the spring.
1O-202
5.
When
drops (emergency
brake actuated)
Battery relay
n
Starting switch
_
Alternator
terminal R
1
To transmissiondirectional circuit
Operation
.
If the oil pressure
1 O-203
6. Parking
brake emergency
release
Battery
Battery relay
n
To battery
power
BrakzCC
low pressure switch
I-arK
,--A ---void
relearn
SUIGI
t valve
aLWoca6
Operation
.
If the machine should stop because of engine trouble, the oil pressure from the transmission pump to the parking brake cylinder
is shut off and the parking brake is applied.
When this happens, the oil pressure in the
main brake line is stored in the accumulator.
When the emergency release switch is turned
on (released), the buzzer sounds, and at the
same time, electric current flows to the emergency parking brake release solenoid valve.
1 O-204
this relay
keeps the transmission at neutral to prevent
dragging of the parking brake due to mistaken operation.
Transmission
cut off switch
J-I-J
43=
II
power source
Transmission
combination switch
ke
Kick-down
switch
CNL 66
Kickdown
relay
CNL 67
REVERSE
relay
CNL 66
FORWARD
relay
C% 65
Transmission
cut-off relay
CNL58
Neutralizer
relay
CNL 57
Neutral
relay
CNL59
Parking brake
safrty relay
Operation
When the parking brake is actuated
(ON),
electric current flows from the battery relay
+ parking brake switch terminal
1 - 3 +
parking brake safety relay terminal
1 +
ground. For this reason, the safety relay coil
is actuated, terminals 3 and 5 of the safety
relay are connected,
and this circuit
is
formed.
3.
When the parking brake is actuated, no electric current flows to the neutralizer relay coil,
so terminal 3 and terminal 5 of the neutralizer relay are separated. No electric current
flows to the transmission directional circuit,
so when the parking brake is applied, the
transmission
is kept at neutral.
1O-205
Testing and adjusting steering wheel ............. .20Testing and adjusting steering control ........... .20Measuring steering oil pressure ...................... .20Measuring operating force,
travel of brake pedal .................................. .20Measuring brake performance ..........................20Testing brake oil -pressure ................................ .20Testing for brake disc wear.. ............................ .20Bleeding air from brake system.. ......................20Measuring parking brake performance ............ 20Manual release method for
parking brake .............................................. .20Testing wear of parking brake disc .................. 20Measuring work equipment control lever ........ 20Measuring work equipment
hydraulic pressure ...................................... .20Measuring PPC valve pressure ........................ .20Measuring work equipment.. ............................. 20Testing and adjusting bucket positioner.. ....... .20Testing and adjusting boom kick-out ............... 20Adjusting main monitor
(speedometer module) ................................ 20Adjusting boom, bucket angle
potentiometer.. ............................................. 20TROUBLESHOOTING .......................................... 20-
35
38
39
41
42
43
44
45
46
47
48
49
51
53
55
57
58
60
61
101
When using the standard value table to make judgement for testing and adjusting, and troubleshooting,
following precautions are necessary.
the
1.
The standard values in the table are the values for a new machine and are given as reference values for the
time when the machine is shipped from the factory. These values should be used as a guide when estimating
wear and tear after the machine is operated, and when carrying out repairs.
2.
3.
These standard
When
safety
When
carrying
claims.
always
machine
use signals
on level
ground
people
When
checking
the water
level, always
the water
Be careful
to cool down.
If the radiator
cap is removed
when
rotating
parts.
20-l
TESTING
AND
ADJUSTING
STANDARD
STANDARD
model
Item
Measurement
conditions
Unit
speed
vm
Low idling
Rated speed
temperature
High idling
intake
inlet temp.)
resistance
(intake
air temp.
At rated
output
mmHg
acceleration
At high idling
Compression
(SAE30 oil)
value
2,450 2 50
Permissible
2,450 t
value
100
+lOO
760-m
2,200
Max.650
700
950 - 1,200
750
20C)
gas color
Bosch
index
Max.
5.5
7.5
Max.
1.0
2.0
0.34
lnta ke valve
Valve clearance
(cold)
Standard
All speed
At sudden
Exhaust
S6Dl08
C
(Turbine
FOR ENGINE
WA380-3
Engine
Exhaust
TABLE
Machine
Engine
VALUE
mm
Exhaust
pressure
0.66
valve
Oil temperature:
40 - 60C
(engine
MPa
kg/cm*)
Min. 2.9
(Min. 30)
nmf
Max. 80
160
0.29 - 0.49
(3.0 - 5.0)
0.21
(2.1)
Min. 0.12
(Min. 1.2)
0.07
(0.7)
(SAEl OW)
0.25 - 0.44
(2.5 - 4.5)
0.18
(1.8)
(SAEl OW)
Min. 0.1
(Min. 1.0)
0.07
(0.7)
90-110
120
speed:
250 - 300 rpm)
At rated output
Blowby
(SAE30
pressure
oil)
(Water
temperature:
Operating range)
(Water
temperature:
Operating range)
At high idling
(SAE30)
MPa
At low idling
Oil pressure
(SAEBO)
kg/cm
At high idling
At low idling
Oil temperature
Fuel injection
timing
22 2 1
20-2
pulley
- Fan pulley)
mm
5-
10
5-
10
STANDARD
Cate
w!
STANDARD
Item
Measurement
conditions
Unit
Standard
I
m-n
Operating force
value
2,290 ir 50
2,290 * 100
2,305 + 100
2,305 + 200
1,925 + 100
1,925 + 200
58.8 - 73.5
(6 - 7.5)
108
(II)
Operating angle
deg.
11
31 f 3
Stopper height
Operating
force
Operating
force
El
-Gizq
Engine stopped
Torque converter oil
temperature: 60 - 80C
I
Travel
2nd tf 3rd
mm
3rd ts 4th
Priority
pressure
40+
10
40 f 20
40+
10
40 a 20
10
40 + 20
40+
2.9
(30
2.7
(28
0.44
(4.5
High idling
Low idling
MPa
(kg/cm21
*
+
?
+
*
*
0.15
1.5)
0.15
1.5)
0.05
0.5)
0.34 + 0.08
(3.5 -+ 0.8)
0.98
(IO
2.3
(23
2.1
(21.5
2.7
(28
+
*
*
*
+
?
+
+
0.1
1)
0.2
2 )
0.34
3.5)
0.15
1.5)
2.9 $:;$
(30 -;lf 1
2.7 $1;:
(28 -;:f)
0.44 $j
(4.5 :y:g)
0.34 +cJ*
-0.12 (3. 5 +as
-1.2 )
0.98 $1;
2.3 2:;s
(10:;
(23 2
(28 .;:; )
20-3
0
TESTING
AND
CateWY
STANDARD
ADJUSTING
Measurement
Item
Fitting of wheel
lock ring
conditions
Unit
.-E
IClearance of wheel
lock ring
l
?
=
8
Z
Standard
low idling
Max. 4.5
Engine stopped
Machine facing straight
to front
dry paved road surface
Hydraulic oil
temperature: 45 - 55C
Operating
time
Max. 50
11.8 - 19.6
(1.2 - 2.0)
34.3
(3.5)
Max. 4.7
6.0
2.7 f 0.5
5.0
Sec.
Pal
%z
E?
Y,
Relief pressure
Operating force
Engine speed:
Hydraulic oil
temperature:
Engine speed:
Hydraulic oil
temperature:
Engine speed:
Hydraulic oil
temperature:
1,200rpm
mm
45 - 55C
High idling
45 - 55C
Low idling
MPa
(kg/cm?
20.62:;;
(210::
20.6 $1;;
(210:;
472
(43)
I
-
5 + 0.5
deg.
a1
Operating angle
40 t 5
294 + 29.4
(30 f 3)
45 - 55C
Play
45
15+
a2
l
Performance
l
20-4
0
12
Max. 20
mm
High idling
E
2
Perrai,sssble
value
TEW00004
Operating force
Max. 2.5
2TEWoooo3
Play
$
f
VALUE
Max. 5
Max. 5
Max. 0.34
(Max. 3.5)
I(kg/cm?I
Max. 0.34
(Max. 3.5)
Thickness of disc
1 mm /
8.0 f 0.15
MPa
7.2
Category
Measurement
Item
Performance
conditions
Unit
Standard
value
Stopped
I
3.2 + 0.08
2.83
HOLD + RAISE
Max. 23.5
(Max. 2.4)
35.3
(3.6)
RAKE + HOLD
Max. 15.7
(Max. 1.6)
23.5
(2.4)
HOLD + LOWER
Max. 24.5
(Max. 2.5)
37.3
(3.8)
Wear of disc
mm
Thickness of disc
-I-
Boom
LOWER+ HOLD
37.3
(3.8)
LOWER+ FLOAT
FLOAT -_)HOLD
HOLD + DUMP
l
Bucket
HOLD -+ TILT
TILT -3 HOLD
HOLD-+ RAISE
Boom
HOLD-+ LOWER
mm
HOLD + FLOAT
I
I
HOLD + DUMP
Bucket
HOLD + TILT
Max. 23.5
(Max. 2.4)
35.3
(3.6)
Max. 23.5
(Max. 2.4)
35.3
(3.6)
Max. 14.7
(Max. 1.5)
22.6
(2.3)
67+ 15
67 i 30
53+- 75
53 * 30
67 f 15
67 I? 30
60+ 15
60 + 30
6Of: 15
60 f 30
~~~+LzG&G
20.6+_;:;;(210:;)
Bucket horizontal
temperature:
45 - 55C
Engine speed: High idling
Steering valve: Neutral
Sec.
5.3 * 0.3
8.7
2.7 zrz0.5
5.0
1.4 * 0.3
2.1
1.8 f 0.3
2.7
1.2 f 0.3
1.8
20-5
0
Cate-
WY
$1
.E;
z
al >
I
conditions
Hydraulic oil
temperature:
45 - 55C
Leave for 5 minutes after
stopping engine then
measure for next 15
minutes
Bucket empty, boom,
bucket
horizontal
No load
Hydraulic oil
temperature:
45 - 55C
Pevm,is&ble
Retraction of boom
. cylinder rod
Retraction of bucket
cylinder rod
>
Cc
E o
.-.E
Clearance
positioner
E 2
Q
Clearance of boom
kick-out switch
20-6
0
Measurement
item
W *=
:.;
of bucket
switch
Max.
15.0
20
Max.
15.0
20
mm
3-7
3-7
mm
TESTING
AND ADJUSTING
STANDARD
sys
tern
STANDARD
VALUE
TABLE
Name of
component
Zonnectol
No.
Judgment
Measurement
conditions
table
Normal if as follows:
1) ga$ing
2) CNR07
disconnected
CNR07
(male)
Normal if as follows:
Engine water
temperature sensor
1) gtFting
CNROG
(male)
Radiator water
level normal _ Between
@and
Radiator water
level abnormal
7) g;a$ing switch
Continuous
@
CNElO
(male)
CNB13
(male)
CNB08
(male)
1) z;:ing
1) gEaFrtingswitch
Brakeoil
pressurenormal Between
Brakeoil pressure
abnormal
aand
Continuous
@
Noncontinuous
Normal if as follows:
CNE19
(male)
CNE20
(female)
Alternator
1) Starting switch
OFF
2) CNE19
F;cE()2nOnected
1) f$$ing
switch
2) Ring terminal
disconnected
Ring
terminal
letween
alternator
erminal R
Ind chassis
2) CNB13
disconnected
LNBOB
disconnected
disconnected
Normal if as follows:
switch
2) CNElO
disconnected
Normal if as follows:
Dust indicator
2) CNROG
disconnected
Noncontinuous
Normal if as follows:
Engine oil level
sensor
switch
2) CNT07
disconnected
CNT07
(male)
Normal if as follows:
Radiator water
lever sensor
1) S&;Fningswitch
2) CNEOG
disconnected
CNEOG
(male)
Normal if as follows:
To&e
converter
oil temperature
sensor
switch
1) Engine started
20-7
0
STANDARD
Name of
component
terr
-
Measurement
conditions
Judgment table
Between
alternator
terminal R
and chassis
Alternator
1) Engine started
CNE05
(male)
E
.P
z
._
CNTOZ
(male)
R. solenoid
E
aal
:E
SE
. 31
0:
aQ,
CNT03
(male)
HL. solenoid
Qal
ZE
SE
.szJ
3%
aa
&
=
3
a:
5
g Speed solenoid
ZJ
.vl
E
g
CNT04
(male)
20-8
0
%
.z 2
E
I=
valve
$Z
Modulation
solenoid
>I
) ~i?%ected
1) g$ng
500to
1000 !A
switch
2) CNTOG
disconnected
CNTOl
(male)
F. solenoid
m
_c
g
1) Starting switch
BetweenOand@
CNTOG
(male)
5
:
k
;r
z
$
Normal if as follows:
CNTIP
(male)
*
05
2E
SE
.II 2
zz
E
1) Starting switch
OFF
2) Connector
disconnected
and @
Between
@I and chassis
46 to 58 R
1 MR or greater
1) Starting switch
OFF
2) Connector
disconnected
46 to 58 R
1 MR or greater
1) Starting switch
OFF
2) Connector
disconnected
46 to 58 Q
1 MQ or greater
1
and @
Between
0 and chassis
12 to 15 a
1 MR or greater
1) g;$ing
switch
2) Connector
disconnected
sys,
ten
Name of
component
Connector
No.
Inspection
Judgment
method
,.
if within
the following
CNF26
(male)
80,
cE
32
.II 3
$%
ua
E
Normal
if within
Between
the following
range:
(3 and @
18.8 to 20.8 R
Between
1s and chassis
1 MR or greater
range:
if within
the following
range:
switch
1) Starting switch
OFF
2) Connector
disconnected
1) za$ing
switch
1) g;;ing
switch
CNL29
(male)
2) Connector
disconnected
CNF21
1) Starting switch
OFF
2) Connector
disconnected
1) ga$ing
2) Connector
disconnected
CNF28
(male)
Normal
Bucket angle
potentiometer
switch
2) Connector
disconnected
range:
CNF24
(male)
E
solenoid
1) ga$ing
2) Connector
disconnected
(male)
Normal
Dumping
range:
CNF25
solenoid-
Measurement
conditions
table
CNF22
1) gpFting
switch
2) Connector
disconnected
20-9
0
SYS ;-
Name of
component
ten 1
-
Con;ztor
Inspection
method
Judgment
Measurement
conditions
table
E
8Q
Relief
solenoid
CNAF4
(male)
ES
.E 5
$3
UQ
E
Between
and 8
20 to 40 R
1) F;rting
2ia
High pressure
solenoid
CE
CNAFS
(male)
SE
.$ 3
$I
a:
8,
Low pressure
solenoid
Pressure
switch
CNAFG
(male)
dE
SE
.!!? 3
::
!Jz[TL,
E
I) Starting switch
OFF
2) CNAF4
disconnected
Between
Normal
@ and a
20 to 40 R
if as follows:
Between
2) CNAF5
disconnected
1) F;;ing
<I) and 0
20 to 40 R
switch
switch
2) CNAFG
disconnected
I) Starting switch
OFF
2) CNAF7
disconnected
CNAF7
(male)
E:
E
Speed
sensor
CNTOG
(male)
Q)(I)
FE
SE
W v)
2
3
$
20-10
0
Normal
if within
the following
Between % and :z
range:
1) S&rting
500 to 1000 R
2) CNTOG
switch
disconnected
ADJUSTING,
Part
item Symbol
No.
AND TROUBLESHOOTING
AND TROUBLESHOOTING
Part
Name
Remarks
Digital
Engine
speed
799-101-1502
Digital temperature
799-201-I
Wiring
harness
799-101-5002
Analog
hydraulic
790-261-1203
Digital
799-401-2320
Hydraulic
795-502-1590
Compression
795-502-1370
[Adapter
79szol-1511
/Tool
799-201-1541
Gauge
799-201-1571
Tube
799-201-1450
Adapter
Commercially
available
Feeler gauge
799-201-9000
Handy
smoke
pressure
I)
pressure
Commercially
available
Smoke
meter
799-401-2310
Pressure
799-601-7400
1T-adapter
tester
color
Troubleshooting
of wiring
harnesses and sensors
Commercially
available
7gA-264-0020
Pressure gauge
49.0 MPa (500 kg/cm*)
tester
1.0 MPa
gauge
(IO kg/cm*)
gauge
799-201-7504
Discoloration
0 - 70 % (with
standard color)
!Cm)$e;loratron % x l/10 + Bosch
checker
angle
1,500mmHg
gauge
Tester
1Push-pull scale
Commercially
available
Thickness
Commercially
available
Angle
Commercially
available
Push gauge
Commercially
available
Scale
0 - 294N
(0 - 30kg)
-
gauge
gauge
1
i
I
793-605-1001
Length
Commercially
available
Slide calipers
Stop watch
Speed
temperature
G ___
2
exhaust
1Pressure gauge
2.45, 5.88, 39.2, 58.8 MPa
(25, 60, 400, 600 kg/cm2)
Pushing
Measure
hydraulic
: 60 - 2,OOOrpm
: 60 - 19,999rpm
-
E-
Valve clearance
Exhaust
110
display
L
H
gauge
Oil pressure
Blowby
Multi-tachometer
Compression
799-203-8001
measurement
Commercially
available
TESTING
AND
ADJUSTING
ADJUSTING
1.
2.
3.
4.
5.
6.
ADJSTING
VALVE CLEARANCE
Valve
arrangement
Cylinder no.
l
Intake valve
l
l
Exhaust valve
3
l
0
c!
c!
C
:
l
,Z
20-l 2
0
10
.I1
..
VALVE
CLEARANCE
TESTING
AND ADJUSTING
MEASURING
PRESSURE
MEASURING
COMPRESSION
PRESSURE
COMPRESSION
pressure, be
manifold
or
muffler, or to get your clothes caught in the fan,
fan belt or other rotating parts.
Warm up the engine (oil temperature:
40 - 60C)
before measuring the compression
pressure.
4.
5.
Connect
6.
8
:
s
compression
gauge
DI to adapter
D2.
,3
MEASURING
PRESSURE
1.
2.
20-14
a
BLOW-BY PRESSURE
BLOW-BY
MEASURING
E4
El
TBW007 14
TESTING
AND ADJUSTING
TESTING
and adjusting
using mark
alignment
ad-
justment
1.
2.
8
k
3.
Testing
and adjusting
using delivery
valve
adjust-
ment
1.
2.
Remove
Remove
ADJUSTING
FUEL INJECTION
TIMING
AND
tube (5).
?
\
\
\
cm%
3.
4.
5.
i)
5)
*
*
After testing and adjusting, do not forget to reassemble the spring and delivery valve.
Always replace the delivery valves copper gasket and 0 ring with new ones.
20-16
0
e
0
TESTING
AND ADJUSTING
MEASURING
+
MEASURING
EXHAUST
COLOR
with
handy smoke
checker
GI
Measuring
Ir
COLOR
When measuring
in the field when there is no
air or power supply, use smoker the checker;
when recording
official data, use the smoke
meter.
Measuring
EXHAUST
with
smoke
meter
Gz
TEWOOO21
20-l 7
0
MEASURING
MEASURING
INTAKE AIR
PRESSURE (BOOST PRESSURE)
A
When
1.
2.
removing
or installing
the measuring
equipment,
be careful not to touch any high
temperature
parts.
AWhen
carrying
out the measurement,
be
careful not to touch any high temperature
parts or rotating parts.
Note:
Run the engine at a mid-range speed or above,
and use the self-seal portion of the gauge to
bleed the oil from inside the hose.
.
Insert the gauge about half way, and repeatedly open the self-seal portion to bleed the
oil.
f
3.
20-18
0
MEASURING
MEASURING EXHAUST
TEMPERATURE
GAS
AThe
temperature
sensor is installed to the exhaust manifold, so if the machine has been operated, wait for the manifold to cool down before installing the sensor.
1.
2.
Connect to digital
wiring harness.
tempeiature
to the operating
gauge
6 with
Measurement procedure
1. Measuring at torque converter
stall
If the exhaust gas temperature
is measured
only at torque converter stall,
and this is
continued until the sensor core heats up and
a stable value is obtained, the torque converter will overheat.
1) Use the full stall (torque converter stall +
hydraulic relief) to raise the exhaust gas temperature .
2) From the above condition, cancel the hydraulic relief, and carry out only torque converter stall.
(The temperature will start to go down. If it
does not go down and continues to go up,
make the temperature
setting at 1) higher.)
starts to go down,
3) When the temperature
record the stable temperature.
When measuring maximum
value for exhaust
gas temperature
Carry out actual work and measure the maximum value when operating.
t
Use the PEAK mode function (the maximum
value can be recorded) of the temperature
gauge.
*
2.
X type dp-mector
Temperature sensor
#3-naIeI~~
Harness
Tmwo716
20-l 9
0
TESTING
AND
ADJUSTING
MEASURING
PRESSURE
g
When
clothes
Ir
Ir
measuring,
get caught
ENGINE OIL
be careful not to let your
in any rotating part.
20-20
0
MEASURING
ENGINE
OIL PRESSURE
MEASURING
MEASURING
ENGINE SPEED
ENGINE SPEED
When removing
or installing
the measuring
equipment,
be careful not to touch any high
temperature
parts.
1.
port, then
TBW00413
2.
Connect tachometer
cable.
with the
AWhen
carrying out the measurement,
be
careful not to touch any high temperature
parts or rotating parts.
3.
TBW00414
20-Z 1
0
TESTING
AND
ADJUSTING
TESTING
AND ADJUSTING
TBwoo415
Adjusting
20-22
0
TESTING
AND
ADJUSTING
METHOD
FOR ADJUSTING
ENGINE
STOP MOTOR
CABLE
TBWOO417
1.
Temporarily
install ball joint (3) to cable (2) of
engine stop motor (I) (screw in fully, then turn
back approx. l/2 turns), then install the ball joint
to the stop lever of the injection pump.
2.
3.
TBWO3418
20-23
0
METHOD
4.
Tighten
5.
Ir
20-24
0
FOR ADJUSTING
Problems
of engine
caused by improper
stop motor cable
Eng.ine
stop
adjustment
does
not
Engine
does
not
give full output because
of drop in
amount of fuel injected
MEASURING
PEDAL
*
l
Measurement
conditions
range
FORCE OF ACCELERATOR
PEDAL
K at a position
a.
150 mm
Measuring
1)
2)
2.
ACCELERATOR
OPERATING
1.
MEASURING
of push-pull
scale K in
point 150 mm from the
Testing
2)
3)
ACCELERATOR PEDAL
TESTING
AND
ADJUSTING
MEASURING
ACCELERATOR
PEDAL
pedal,
a (a = at - ad when
2.
Adjusting
1) Remove the cover at the bottom of the cab,
and open the inspection cover of the engine
hood.
2)
3)
20-26
0
TBWCOb25
TESTING
AND
ADJUSTING
MEASURING
OPERATING
FORCE, TRAVEL
OF SPEED LEVER
MEASURING OPERATING
FORCE, TRAVEL OF SPEED
LEVER
*
.
Measurement
Engine
Torque
conditions
stopped
converter
oil temperature:
60 - 80C
OPERATING
1.
2.
TRAVEL
OF SPEED
LEVER
1.
2.
20-27
0
MEASURING
MEASURING
STALL SPEED
Measurement
.
.
.
*
*
conditions
under
1.
2.
3.
20-28
0
for
STALL SPEED
HYDRAULIC
MEASURING
STALL SPEED
STALL SPEED
1.
2.
3.
Use multi-tachometer
to measure the engine
*
Do not keep the stall condition for more than
20 seconds. Operate the control lever quickly.
Measure the engine speed when the torque converter stall and hydraulic stall are both carried
out at the same time.
*
Before measuring the full stall, check that
the torque converter stall and hydraulic stall
speeds are normal.
If either of the stall speeds are abnormal,
correct the problem and measure again.
20-29
0
MEASURING
TORQUE
CONVERTER, TRANSMISSION,
PARKING BRAKE OIL
PRESSURE
*
Measurement
conditions
Preparatory
work
The following
preparatory
work is necessary
when measuring
all oil pressures.
.
Remove cover (I) on the left side of the rear
frame.
.
Turn transmission
cut-off selector switch (2)
OFF and use the left brake.
(Check that the pilot lamp is OFF.)
.
Remove the plug from the measurement
port
of the transmission
valve.
.
Install hydraulic tester kit C to the measurement port, extend the gauge to the operators compartment,
then start the engine and
measure the pressure.
Check that no oil is leaking from any connection.
After removing the measurement
plug, always
coat the plug with adhesive.
6
plug: Sealing agent (LG-11
TBWCOb35
20-30
0
Measuring
1.
2.
procedure
Priority pressure
I) Measuring port (Pl or P5, PTV8)
2) Start the engine and measure the pressure
at low and high idle.
Pl,P5
the pressure
P2
3.
Pilot pressure
I) Measuring port (P3, PT1/8)
2) Start the engine and measure the pressure.
Ir Remove hose (1) and elbow (2) and attach the hydraulic test kit to nipple (3).
P3
4.
Clutch pressure
I) Measuring port (P4, PTV8)
2) Start the engine, set the forward/reverse
lever to neutral, and measure
the pressure
when the gear shift lever is operated.
5.
20-3 1
0
METHOD OF OPERATING
EMERGENCY MANUAL SPOOL
Outline
The transmission
valve is controlled electrically,
but
if there should be any failure in the electrical system, or if there is any failure in the solenoid valve
or spool and the machine cannot move, it is possible to operate the emergency manual spool to move
the machine.
&This
operation of the spool is designed only for
use if the machine cannot be moved because of
a failure in the transmission
control, and it is
necessary to move the machine from a dangerous working area to a safe place where repairs
can be carried out.
This spool must not be operated except when
there has been a failure.
a
AAlways
spool.
stop the
engine
before
operating
the
1.
Remove
frame.
2.
3.
Operate emergency
spool (3) to the operating
position according to the direction of movement
of the machine (forward or reverse).
.
REVERSE: Push in the spool until it enters
the detent.
a = Approx. 8 mm
20-32
0
FORWARD:
Puil the spool
detent.
b = Approx. 8 mm
until it enters
the
TESTING
AND ADJUSTING
METHOD
4.
5.
6.
7.
8.
seat and
depress
OF OPERATING
EMERGENCY
MANUAL
SPOOL
the left
position
20-33
0
TESTING
AND
ADJUSTING
MEASURING
CLEARANCE
BETWEEN
MEASURING
CLEARANCE
BETWEEN TIRE AND WHEEL
*
.
Measurement
Tire inflation
conditions
pressure:
Specified
pressure
Method of measuring
1. Fitting of wheel lock ring
Using feeler gauge, measure dimensions A and
B at four places around the circumference.
2.
Clearance of wheel
Measure dimension
lock ring
C.
TEWOM)85
20-34
0
Vehicle
STEERING WHEEL
Ld,
play
Measuring
procedure
1. Turn the steering wheel
8
c:
2.
3.
20-35
0
MEASURING
ING WHEEL
OPERATING
FORCE OF STEER-
Measurement
.
l
Measurement
conditions
method
install
knob.
2.
3.
20-36
0
push-pull
1.
wheel
STEERING WHEEL
MEASURING
OPERATING
STEERING WHEEL
TIME
Measurement
.
.
.
Measurement
1.
*
STEERING WHEEL
FOR
conditions
method
3.
8
c:
5
*
*
20-37
0
STEERING CONTROL
.
l
Measurement
conditions
Hydraulic oil temperature:
45 - 55C
Engine speed: 1,200 rpm
Road surface: Flat, horizontal, dry paved surface
Tire inflation pressure: Standard pressure
Testing
1.
2.
Check the
bolt (1).
3.
looseness
of locknut
to set
(2) of stopper
Adjusting
1. Adjust the stopper
bolt.
I) Screw in stopper bolt (1) to make it the minimum length.
2) Run the engine at low idling and operate the
steering slowly to contact the frame stopper.
3) Turn the stopper bolt until the head of stopper bolt (1) contacts the end face of the spool
of stop valve (3).
4) Set the machine facing straight, and stop
the engine.
5) Loosen stopper bolt (1) 8.5 turns, then lock
it in position with locknut (2).
6) Carry out steps 1) - 5) for both the left and
right sides.
2.
Start the engine and measure clearance a between the front frame and rear frame stopper
when the steering wheel is turned fully to the
left and right.
*
When measuring
the clearance, check that
the end face of the spool of stop valve (3) is
in contact with the head of the stopper bolt.
20-38
0
aWf5mm)
TESTING
AND ADJUSTING
MEASURING
PRESSURE
MEASURING
STEERING
Measurement
.
.
METHOD
SURE
STEERING
OIL PRESSURE
OIL
conditions
OF MEASURING
MAIN
RELIEF PRES-
ALoosen
the oil filler cap to release the pressure
inside the hydraulic tank, then turn the steering
wheel several times to release the remaining
pressure inside the piping.
z!?
:
?I
1.
Apply
2.
Remove
steering
3.
Install hydraulic
port.
4.
measurement
circuit.
TBW00613
TBWW614
20-39
0
MEASURING
Adjusting
g
Always
stop
the
engine
before
adjusting
the
pressure.
1.
2.
Loosen relief valve (4) lock nut (5) and turn adjust screw (6) to adjust.
+
*
20-40
0
Pressure adjustment
for one turn of adjustment screw: Approx. 14.8 MPa (751 kg/cm*)
Turn the adjustment
screw to adjust the set
pressure as follows.
TIGHTEN to INCREASE pressure
LOOSEN to DECREASE pressure
Do not carry out any adjustment if the relief
pressure cannot be measured accurately.
v-n--n--*
I
hhhil
TLWK%SS
MEASURING
MEASURING OPERATING
FORCE, TRAVEL OF BRAKE
PEDAL
Ir
Measurement
conditions
range
2.
150 mm
Travel of pedal
1. Fit push gauge N to your foot.
*
150 mm
2.
3.
Pedal play
1.
2.
20-41
0
MEASURING
BRAKE PERFORMANCE
MEASURING
BRAKE
PERFORMANCE
*
.
l
.
.
Measurement
conditions
Measurement
method
1.
2.
3.
4.
Stopping
posi-
point
Stopping
distance
out
Run-up path
TDW00113
20-42
0
TESTING
AND ADJUSTING
TESTING
ir
.
Measurement
TESTING
Measuring procedure
Stop the engine.
Disconnect brake tube (1) on the side to be measured.
Disconnect union (2), install joint :z! and attach
hydraulic test kit C
'1
TBWCG616
20-43
0
TESTING
TESTING
AND ADJUSTING
TESTING
Measurement
conditions
Measuring
1.
Loosen
-
2.
Install
measuring
plug (2).
3.
against
the
disc.
4.
5.
Axle oil: 32 e
20-44
0
TBWW461
TESTING
AND
ADJUSTING
BLEEDING
AIR FROM
BRAKE SYSTEM
a
a
.
1.
g
:
5
2.
3)
4)
20-45
0
TESTING
AND ADJUSTING
MEASURING
PARKING
PERFORMANCE
*
.
.
.
Measurement
MEASURING
PARKING
BRAKE PERFORMANCE
BRAKE
conditions
Measurement
method
3.
Turn the parking brake switch ON, then gradually release the brake pedal and check that the
machine is held in position.
*
When the engine
is stopped,
the parking
brake is automatically
switched ON.
*
Carry out the measurement
in two ways:
Once with the machine
facing uphill, and
once more with the machine facing downhill.
20-46
0
TDW00124
TDW00125
MANUAL
The parking brake is controlled by hydraulic pressure, so if there should be any failure in the
solenoid valve and it becomes
impossible
to
release the parking brake, it is possible to release it manually to move the machine.
AThe
manual release of the parking brake is designed only to move the machine from a dangerous working area to a safe place where repairs can be carried out. This method must not
be used except when there has been a failure.
ATO
1.
2.
3.
Tighten
tion.
20-47
0
ATo
AAlways
stop the engine before
procedure.
weak,
carrying
measure
out this
f.
2.
Measure dimension
a with the three manual
release bolts (31 in contact lightly with brake
pistons (4).
3.
20-48
a
TBwmm
TESTING
AND ADJUSTING
MEASURING
EQUIPMENT
*
.
Measurement
WORK
EQUIPMENT
CONTROL
LEVER
WORK
CONTROL LEVER
conditions
Measurement
MEASURING
range
method
1.
2.
control lever
Measure travel at each position when operating
the work equipment control lever.
f
Mark the lever knob and use scale to meas-
TBWOO463
ure.
20-49
0
TESTING
AND
ADJUSTING
MEASURING
WORK EQUIPMENT
CONTROL
LEVER
Adjusting
1.
Remove
2.
With solenoid (6) pulled, fix the solenoid in position so that the clearance
between
cam (3)
and. roller (4) is dimension a.
Dimension
a: 0 - 0.5 mm
*
Set the bucket lever and boom lever at the
HOLD position.
If cam (31, roller (41, or spring (51 are broken,
*
replace them before adjusting.
3.
Boom lever
Operate the boom lever and adjust the length of
rod (2) so that roller (4) is dimension
b at the
notch at both ends of cam (3).
Dimension
b: 0 - 1 mm
cover (I 1.
TEW00136
TEWO0137
TEWOOldO
Buck& lever
Operate the lift lever and adjust the length of
rod (2) so that roller (7) is dimension
C at the
notch at both ends of cam (8).
Dimension
C: 0 - 1 mm
T&VW721
20-50
0
TESTING
AND
ADJUSTING
MEASURING
EQUIPMENT
PRESSURE
*
.
l
MEASURING
PRESSURE
range
Work equipment
relief valve pressure
measuring
procedure
+ Raise bucket tip a 30 to 50 mm and ground the
bucket at point b, then stop the engine.
f
After operating the levers, check that both points
a and b on the bottom of the bucket are
touching the ground.
Loosen the oil supply cap to release the presg
sure inside the hydraulic oil tank, then operate
the control levers two or three times to release
any pressure remaining in the piping.
1.
Remove
bucket cylinder
measuring plug (I).
2.
3.
HYDRAULIC
WORK
HYDRAULIC
Measurement
conditions
Engine water temperature:
Within green
on engine water temperature
gauge
Hydraulic oil temperature:
45 - 55C
Engine speed: High idling
WORK EQUIPMENT
circuit
oil
TEW00149
pressure
pressure
20-5 1
0
Adjusting
work equipment
MEASURING
WORK EQUIPMENT
HYDRAULIC PRESSURE
ABe
when
adjusting
1.
2.
Remove
3.
and
the
re-
8
TBbWQ472
20-52
a
TESTING
AND ADJUSTING
MEASURING
PRESSURE
*
.
MEASURING
PPC VALVE
PRESSURE
PPC VALVE
Measurement
conditions
Engine water temperature:
Within engine
temperature
gauge green range
Hydraulic oil temperature
: 45 to 55C
Engine speed
: High idle
water
Raise boom (I), set boom prop (21, set the bucket
to an angle of approximately
45 (not to the
maximum
dump position)
and remove
front
cover (3).
2.
Stop the engine, loosen the oil supply cap, release the pressure inside the hydraulic oil tank,
then stroke the bucket control lever between the
tilt and neutral positions at least 40 times to
completely release the accumulator
pressure.
*
Be sure to stop the engine before operating
the lever.
*
After the accumulator pressure is completely
released, set the bucket lever to the dump
position and check that the bucket does not
dump.
Remove the work equipment dump cylinder circuit pressure measurement
plug (4).
Install hydraulic test kit C to the measuring port.
.
Connect the hose after installing the hydraulic test kit 90 elbow to the measuring
port.
.
Check that there is no oil leakage from any
joints.
.
Use a hose which is long enough to reach
the operators seat.
Start the engine, raise the boom about 400 mm,
tilt back the bucket using the control lever, and
measure the pressure when the relief valve is
activated.
.
Be careful not to apply any sudden pressure
to the pressure gauge.
3.
4.
5.
When
removing
the hydraulic
pressure
gauge,
20-53
0
MEASURING
Adjusting
when
adjusting
the oil
1.
L?mm(Adjustment
amount)
TEW00147
20-54
0
MEASURING
EQUIPMENT
*
.
.
l
Measurement
MEASURING
WORK EQUIPMENT
WORK
conditions
range
/d
Measurement
method
1. Boom RAISE time
TOW00155
TOW00156
3.
/!=A
TDW00157
4.
2)
TDWGUl56
20-55
0
TESTING
MEASURING
AND ADJUSTING
MEASURING
MENT
Measurement
.
.
.
.
conditions
g,
Measurement
method
1.
2.
Leave for 5
ment.
Wait for 15
amount A of
tion amount
3.
WORK EQUIPMENT
posi-
TOW00160
20-56
0
BUCKET POSITIONER
2.
Adjusting
8
z
5
1.
2.
3
1
TBWCO478
20-57
0
2.
Adjusting
1.
2.
Lower
3.
4.
20-58
a
TESTING
AND ADJUSTING
TESTING
AND ADJUSTING
BOOM
+tuation
KICK-OUT
pilot lamp
?roximity switc
actuation
pilot lamp
Detector positio
Lights up
Goes out
_
When detector
is positioned
surface of proximity
at detectio
switch
When
detector
detection
3ucket
)ositioner
Proximity switch
Ditector
has moved
surface
o-_
away from
of proximity
switch
-P
-I
%
Proximity switch
Detector
TEWOOl67
TEWOOl66
Proximity switch
Proximitv switch
3oom kick-out
I
TEW00170
TEW00169
Boom
Proximity
3oom kick-out
machines
equipped with
vlDC monitor)
TEW00171
20-59
0
ADJUSTING
MAIN MONITOR
(SPEEDOMETER MODULE)
ADJUSTING
MAIN MONITOR
(SPEEDOMETER MODULE)
.
The speedometer
on the main monitor is a common part for all machines, and the input signal
for the travel speed differs according to the machine, so it is necessary to adjust the monitor
for use with the particular model.
In addition, the tire diameter also differs according to the type of tire fitted, so it is necessary to
adjust to give the correct travel speed.
It is also necessary to change the switches if the
optional E.C.S.S. (Electronically
Controlled
Suspension System) is installed.
TDW00173
Adjustment procedure
.
Turn off the power, then remove the main monitor and adjust
speedometer.
1.
the switches
2)
>
aswitch
Tire size
(model
selection)
Switch 2
(speedometer correction)
Switch 3
(tachometer input
selection)
DIP SW 1,2,3
DIP SW 4
Without
E.C.S.S.
ON
3
4
ON
ON
position
Reference
Amount
4
With
E.C.S.S.
_*.
ON
OFF
4) After completing
the adjustment,
fit the rubber
caps securely and install the main monitor.
20-60
0
Adjustment
TDW00176
TDWO0175
of correction
forswitch
(2)
)
correction
+6
+4
+2
+0
1.
2.
F2
3
3.
4.
Boom angle
potentionieter
Bucket angle
ootentiometer
TEWOOl78
Auto leveler
Remote positioner
RAISE position set
Auto mode
TDW00179
If the potentiometers
have been adjusted from
the condition in Step 3, always carry out Step 2
again and check that the lamps are actuated as
in Step 3) (set lamps light up for 2 seconds and
then go out).
20-61
0
TROUBLESHOOTING
Points to remember
Precautions
when
carrying
connectors
Handling
charts ............................................................................................
Connector
pin arrangement
locations
..........................................................................................
................................................................................................
diagram..
20-104
20-I 12
............................................................................................................
Connector
20-103
20-l 11
.............................................................................................................................
of using troubleshooting
Connection
i.. ..............................
.....................................................................................
out maintenance
...........................................................
of events in troubleshooting..
Sequence
20-102
.......................................................................................
when troubleshooting
20-I 14
20-122
20-123
pin numbers
....................................................................................
20-128
(S mode)
....................................................................................
20-201
Troubleshooting
of engine system
Troubleshooting
of main monitor
system
monitor
(M mode)
system
Troubleshooting
of maintenance
Troubleshooting
of electrical
system
and mechanical
.......................................................................
(K mode) ...........................................................
(E mode) .................................................................................
Troubleshooting
of hydraulic
B
k
Troubleshooting
of ECSS (Electronically
Troubleshooting
of work equipment
system
Controlled
controller
(Chassis
Suspension
system
related)
System)
20-251
20-301
20-351
(T mode). .....................
20-401
..................
20-451
(D mode)
(W mode) .................................................
20-501
20-101
0
POINTS
TROUBLESHOOTING
POINTS
TO REMEMBER
When
allow
carrying
If the radiator
cap is removed
Be extremely
When
disconnecting
When
removing
careful
the internal
The
aim
prevent
When
the engine
always
first. When
of troubleshooting
carrying
disconnect
the negative
measuring
is to pinpoint
and important
that would
out troubleshooting,
failure occurs:
.
Parts that
have no connection
produce
oil or grease,
do not hurry
immediately
4.
when
carrying
to carry
parts,
anything
before
When
5.
in
spection
occurred
about
failure
the
ma-
these
same
or were there
before
occur?
repairs
kind
out before
carried
of failure
the
any
external
or hydraulic
it as a real fail-
the machine
of op-
to reenact
symptoms,
do not
or measureworse.
of the investigation
in Items
2 - 4 to narrow
of failure,
then
and indown
the
to locate
the
position
of the
exactly.
for troubleshooting
1)
Start from
the simple
2)
Start from
the most
Investigate
be-
of oil from
equipment.
levers.
other
points.
likely points.
related
parts or in-
formation.
6.
cause.
of the control
yourself,
problem
leakage
failure
to handle
operating
of the failure
out?
occurred
troubleshooting
1)
of the
troubleshooting
To prevent
the piping
ex-
is as follows.
condition
been carried
2)
3)
spool.
etc.
ing flowchart
apart from
occurred?
occur suddenly,
repairs
were
for
idea
extent
Troubleshooting
.
Use the results
3)
Check before
of the controlvalve
whether
When
causes
what conditions
Has the
some
prior
fore?
3.
the
carry
failure?
6)
and function.
to form
failure
Confirm
out troubleshoot-
strange
the failure
Had any
and to
the
this?
5)
Confirming
or
there
Under
out thorough
4)
swiftly,
the structure
questions
4)
eration,
of manhours,
problems
it properly.
out repairs
ure or as a problem
3)
various
5)
chine
to carry
ternally,
impossible
it is necessary
investigation
first.
symptoms.
Was
of the failure,
any
the confidence
2)
be sure to connect
the reported
of the failure.
II
of the battery
and judge
become
2.
(-1 terminal
parts.
sembled.
accordance
so wait for
to be necessary.
ing,
in any rotating
the components.
are disassembled
It will
equipment,
troubleshooting
If components
and do not
of the failure.
out troubleshooting,
carrying
signals,
a location which is under pressure from oil, water, or air, always release
installing
to disassemble
to the agreed
fitted.
troubleshooting.
pressure
of possible
When
wiring,
keep strictly
near.
starting
not to touch
reoccurrence
However,
1.
when
before
TROUBLESHOOTING
person to come
to cool down
WHEN
WHEN TROUBLESHOOTING
any unauthorized
the engine
TO REMEMBER
this,
always
occurred.
investigate
Then,
remove
why
the
the
root
::
g
5
TROUBLESHOOTING
SEQUENCE
OF EVENTS IN TROUBLESHOOTING
mber of machine
2)
Details of jobsite,
etc.
Ask questions
IO gain an outiine
lenl.
.
Condition
of failure
of the pro
TEWOO182
Operating
Past history,
environment
details of maintenance,
etc.
Step 2
Determining
1)
probable
location
manual
to find
TEWOOl83
of cause
section
locations
)
5
<
of the
of possible
causes.
I
*llullll.l!.
,,a,1..1*.11
i
?
ci$
TEW00184
step
3
Preparation
of troubleshooting
tools]
oa
1)
and prepare
tools in
the necessary
tools.
.
T-adapter
.
2)
Hydraulic
pressure
Pinpoint
locations
(carry out
replacement
parts.
Decide
1)
Before
action to take
the necstarting
repair
21
simple
troubleshooting,
Drive
select
matches
and
and
items
Section
of the shop
a troubleshooting
the symptoms,
operate
the condition
locate
failures.
manual.
step
of failure
troubleshooting)
the
and judge
flowchart
and carry
machine
if there
out
to confirm
is really
4
IGo
Ask operator
Was there
questions
anything
to
strange
confirm
about
details
of
the ma-
occurred?
occur suddenly?
20-l 03
0
TROUBLESHOOTING
PRECAUTIONS
PRECAUTIONS
WHEN CARRYING
OUT MAINTENANCE
To maintain
the performance
of the machine
over a long period, and to prevent failures or
other troubles before they occur, correct operation, maintenance
and inspection, troubleshooting, and repairs must be carried out. This section deals particularly with correct repair procedures for mechatronics
and is aimed at improving the quality of repairs. For this purpose,
it
gives sections on Handling electric equipment
and
Handling
hydraulic
equipment
{particlularly
hydraulic oil).
1.
I)
20-l 04
0
TEw00191
Improper insertion
TEW00192
TROUBLESHOOTING
(2) Defective
compression
or soldering
of
connectors
The pins of the male and female
connectors are in contact at the compressed
terminal or soldered portion, but there
is excessive force on the wiring, and the
plating peels to cause improper
correction or breakage.
(3) Disconnections
in wiring
If the wiring is held and the connectors
are pulled apart, or components
are lifted
with a crane with the wiring still connected, or a heavy object hits the wiring,
the compression
of the connector
may
be lost, or the soidering may be damaged, or the wiring may be broken.
TEwoo193
connector
The connector is disigned to make it difficult for water to enter (drip-proof
structure),
but if high-pressure
water
is
sprayed directly on the connector, water
may enter the connector depending
on
the direction of the water jet.
The connector is designed
to prevent
water from entering, but at the same
time, if the water does enter, it is difficult for it to be drained. Therefore,
if
water should get into the connector, the
pins will be short-circuited
by the water,
::o if any water gets in, immediately
dry
the connector or take other appropriate
action before passing electricity through
it.
TEW00194
TEW00195
TEWW196
TROUBLESHOOTING
21 Removing,
and wiring
Disconnecting
connectors
(1) Hold the connectors when disconnecting.
When disconnecting the connectors, hold
the connectors and not the wires.
For connectors held by a screw, loosen
the screw fully, then hold the male and
female connectors in each hand and pull
apart. For connectors which have a lock
stopper,
press down the stopper with
your thumb
and pull the connectors
apart.
TEW00197
(2) Action
Connecting
connectors
(I) Check the connector visually.
a. Check that there is no- oil, dirt, or
water stuck to the connector
pins
(mating portion).
b. Check that there is no deformation,
defective contact, corrosion, or damage to the connector pins.
Check that there is no damage or
C.
breakage to the outside of the connector.
*
If there is any oil, water, or dirt stuck
to the connector, wipe it off with a
dry cloth. If any water has got inside
the connector,
warm the inside of
the wiring with a dryer, but be careful not to make it too hot as this will
cause short circuits.
-k
If there is any damage or breakage,
replace the connector.
20-106
0
TEWOOl98
L
TROUBLESHOOTING
PRECAUTIONS
WHEN
CARRYING
OUT
MAINTENANCE
with a
dryer.
If water gets inside the connector, use a
dryer to dry the connector.
+ Hot air from the dryer can be used,
but be careful not to make the connector or related parts too hot, as
this will cause deformation
or damage to the connector.
TEW00196
TROUBLESHOOTING
PRECAUTIONS
WHEN
CARRYING
OUT MAINTENANCE
T-adapter
TEW00203
3)
(2)
(3)
(4)
(5)
(6)
(7)
20-108
0
TEW00204
TROUBLESHOOTING
2.
POINTS TO REMEMBER
WHEN
DLING HYDRAULIC
EQUIPMENT
PRECAUTIONS
WHEN
CARRYING
OUT MAINTENANCE
HAN-
environment.
Avoid adding hydraulic oil, replacing filters,
or repairing the machine
in rain or high
winds, or places where there is a lot of dust.
2)
s
2
3
3)
4)
Disassembly
and maintenance
work in the
field
If disassembly
or maintenance
work is carried out on hydraulic equipment
in the field,
there is danger of dust entering the equipment. It is also difficult to confirm the performance after repairs, so it is desirable to
use unit exchange. Disassembly
and maintenance of hydraulic equipment
should be
carried out in a specially prepared dustproof
workshop, and the performance
should be
confirmed with special test equipment.
Sealing openings
After any piping or equipment
is removed,
the openings should be sealed with caps,
tapes, or vinyl bags to prevent any dirt or
dust from entering. If the opening is left open
or is blocked with a rag, there is danger of
dirt entering or of the surrounding
area being made dirty by leaking oil so never do
this.
Do not simply drain oil out on to the ground,
collect it and ask the customer to dispose of
it, or take it back with you for disposal.
TEW00207
TEW00208
TEWOO209
20- 109
0
TROUBLESHOOTING
PRECAUTIONS
5)
6)
Flushing operations
After disassembling
and assembling
the
equipment,
or changing the oil, use flushing
oil to remove the contaminants,
sludge, and
old oil from the hydraulic circuit.
Normally,
flushing is carried out twice: primary flushing is carried out with flushing
oil, and secondary
flushing
is carried out
with the specified hydraulic oil.
71
Cleaning operations
After
repairing
the hydraulic
equipment
(pump, control valve, etc.) or when running
the machine,
carry out oil cleaning to remove the sludge or contaminants
in the hydraulic oil circuit.
The oil cleaning equipment
is used to remove the ultrafine (about 3~) particles that
the filter built into the hydraulic equipment
cannot remove, so it is an extremely
effectivm
1_device.
20-110
0
WHEN
CARRYING
OUT MAINTENANCE
TEW00211
TROUBLESHOOTING
HANDLING
1.
HANDLING
CONNECTORS
CONNECTORS
I
2.
When disconnecting
male and female connectors, release the lock and pull in parallel with
both hands.
f
Never try to pull out with one hand.
3.
When the wiring harness clamp of the connector has been removed, always return it to its
original condition and check that there is no
looseness of the clamp.
mwoo485
TROUBLESHOOTING
Judgement
standard
Remedy
Add fuel
Clean, drain
Add oil
Replace
Add oil
Add oil
Add water
Clean or check
Tighten or replace
Tighten or replace
Il.
Repair or replace
Repair or replace
Repair
Repair
Bleed air
Adjust or repair
24 - 26V
Repair or replace
Add electrolyte or
replace
Replace
Repair
!I.
Replace
Replace
!8.5 - 29.5V
Repair or check
20-112
0
Replace
TROUBLESHOOTING
METHOD
2.
METHOD
OF USING
OF USING TROUBLESHOOTING
TROUBLESHOOTING
CHARTS
CHARTS
20-114
a
0
5
zl
METHOD
TROUBLESHOOTING
< Example
(1)
OF USING
TROUBLESHOOTING
CHARTS
>
M-15 Abnormality
in buzzer
when
starting
switch
is turned
ON (during
self-check)
Remedy
Cause
Defective contact, or
disconnection in wiring
harness between CNLOG
(female) (8) and CNL43
(male)
(3)
YES
After inspectior
repair or replac
Does buzzer
2 YES
1) Turn starting
2) Contact CNL43
(female) to
chassis ground.
Defective buzzer
Replace
Defective contact, or
disconnection in wiring
harness between CNL42
(female) and CNFSP (9)
After inspection
repair or replac
CNL42 (female)
1)20-30V
2) Turn starting
switch ON.
NO
CNLIS
CNFS2 @ ,
+24V
CNL42
Buzzer output
i
CNLOG
Maintenance
monitor
(1
Buzzer
CNL43
TAWO0722
(4)
*
Before carrying out troubleshooting,
check that all the related connectors are properly
*
Always connect any disconnected
connectors before going on the next step.
inserted.
20-115
0
TROUBLESHOOTING
3.
Using troubleshooting
failure
This troubleshooting
chart is divided into three
sections: questions, check items, and troubleshooting. The questions
and check items are used to
pinpoint high probability causes that can be iocated
from the failure symptoms or simple inspeciton without using troubleshooting
tools.
Next, troubleshooting
tools or direct inspection
are used to check the high probability
causes to
make final confirmation.
[Questions]
Sections @ + @ in the chart on the right corresponds to the items where answers can be obtained from the user. The items in @ are items
that can be obtained from the user, depending
on the users level.
[Check items1
The serviceman carries out simple inspection to
narrow down the causes. The items under @ in
the chart on the right correspond to this.
The serviceman
narrows down the causes from
information
@ that he has obtained from the
user and the results of Q that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting
is carried out in the order of
probability,
starting with the causes that have
been marked as having the highest probability
from information
gained from [Questions] and
[Check items].
20-l 16
0
CHARTS
TROUBLESHOOTING
METHOD
OF USING TROUBLESHOOTING
CHARTS
20-117
a
TROUBLESHOOTING
METHOD
OF USING
TROUBLESHOOTING
CHARTS
Example of troubleshooting
when exhaust gas is black
Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three
symptoms have causal relationship with this problem: [Exhaust gas slowly became black], [Power
slowly became weaker], and IDust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with
five causes. Let us explain here the method of using this causal relationship to pinpoint the most
probable cause.
combustion)
s-7 Exhaust gas is black (incomplete
General causes why exhaust gas is black
.
Insufficient intake of air
.
Improper condition of fuel injection
.
Excessive injection of fuel
Legend
20418
0
TROUBLESHOOTING
ic
CHARTS
7 7
Five causes
Step 1
Three symptoms
Step 2
Add up the totai of Oand 0 marks where the
horizontal lines for the three symptoms and the
vertical columns for the causes intersect.
(I 1 Clogged air cleaner element:
000
(2) Air leakage between turbocharger
and head:
00
(3) Clogged, seized injection nozzle:
0
(4) Defective contact of valve, valve seat: 0
(5) Worn piston ring, cylinder:
0
Step 3
The calculation in Step 2 show that the closest
relationship is with [Clogged air cleaner
element]. Follow this column down to the
troubleshooting
area and carry out the
troubleshooting
item marked 0. The Remedy is
given as [Clean], so carry out cleaning, and the
20-119
0
TROUBLESHOOTlNG
4.
METHOD
OF USING
TROUBLESHOOTING
CHARTS
Step 1. Questioning
the operator
The questions to ask the operator are given
below the failure symptom. If the answers
to the questions match the information given,
follow the arrow to reach the probable cause
of the failure.
Consider the contents of the questions and
consult the table while proceeding to Steps
2 and 3 to grasp the true cause.
1.
Checks before
Steering
Symptom
[Exam-
plel
Ask the operator about the following points.
.
Did the steering suddenly stop working? + Breakage in steering equipment
.
Had the steering gradually been becoming heavy? + Internal wear of steering
equipment,
defective seal
starting
[Example
[Example]
and type
of oil in the
II
NO.
Steering does not work to the left or right
Same as Item 1, but abnormality in actuation of work equipment
Steering can only be operated to one side.
Steering wheel is heavy and cannot be turned.
[Example
21
TROUBLESHOOllNG
3)
4)
5)
6)
7)
CHARTS
Operate the machine and check the troubleshooting items other than those in 1).
Operate the machine and check the items in
the same way as in I), and if the symptom
appears, mark that item. (In the chart on the
right, the symptom appears again for item
5).
Find the appropriate cause from the cause
column. In the same way as in Step 2), if the
symptom appears, the o marks on that line
indicate the possible causes. (For item No.5
in the table on the right, the possible causes
are b or e.)
Narrow down the possible causes.
There is one common
cause among the
causes located in Steps 2) and 4). (One cause
marked o appears on the line for both items.)
This cause is common to both the symptoms in troubleshooting
Steps 1) and 3).
*
The causes which are not common
to
both troubleshooting
items (items which
are not marked o for both symptoms)
are unlikely causes, so ignore them.
(In the example given on the right, the
causes for Troubleshooting
Item 2 are c
or e, and the causes for Troubleshooting
Item 5 are b or e, so cause e is common
to both.)
Repeat the operations in Steps 3), 4) and 5)
until one cause (one common
cause) remains.
If the causes cannot be narrowed down
*
to one cause, narrow the causes down
as far as possible.
Remedy
If the causes are narrowed down to one common cause, take the aciton given in the remedy column.
The symbols given in the remedy column
indicate the following:
X: Replace, a: Repair, A; Adjust, C: Clean
Common causes
Action to take
20-l 21
0
TROUBLESHOOTING
CONNECTOR
TYPES AND
MOUNTING
LOCATIONS
drawing).
(l/3)
Mounting location
Mounting location
Front combination
CNFRI
S type
zo- 122
0
10
~~~~ef:~me wiring
Dl
drawing
TROUBLESHOOTING
DIAGRAM
CNL68
CNL64
CNL58
CNl57
CNL52
r3
Front
c;ul_48
CNL48
CNL53
!2
CNFS3
CNAR
-. __
CNA14
CNL03
CNAS
CNLOI
CNL02
CNLO6
CNL07
CNL08
CNLOS
CNL63
CNA7
CNAG
CNL04
20- 125
0
TROUBLESHOOTING
CNEOG IX type
2 ~/~;~;rtemperature
B5
CNE08
Glow relay
D6
CNEOS
X type
Glow relay
D6
CNE13
X type
Starting
F2
CNE15
Alternator
A4
ICNE16
1 -
1 7 1Alternator
1 A4
ICNE17
I A3
CNEIS
lCNE20
;pc;;-,
1L,y&,
CNERI
;;L
motor
1Alternator
Dust indicator
1Dust indicator
E6
14
Engine wiring
ZO-126
0
;!;
F3
harness
CNERP
E6
Engine wiring
harness
F3
DIAGRAM
TROUBLESHOOTING
DIAGRAM
CNE04
CNEO5
CNEl5
CNElG
CNE17
CNERZ
&El2
CNElO
ZO-127
0
TROUBLESHOOTING
CONNECTION
CONNECTION
Ir
No.
of
pins
PIN NUMBERS
PIN NUMBERS
the terms
male
housing
and female
housing
X type connector
Male (female
housing)
Female
(male
housing)
TEW00220
at
TEWO0221
TEW00222
TEW00223
TEW00224
TEwoo225
20-128
0
2
TEW00226
TROUBLESHOOTING
No.
of
pins
CONNECTION
AMP040
Male (female
TABLE
FOR CONNECTOR
type connector
housing)
Female
12
(male
housing)
TEWO0227
PIN NUMBERS
TEW00228
12
12
7
TEW00229
TEW00230
16
16
16
TEWOO231
TEW00232
20- 129
0
TROUBLESHOOTING
No.
of
pins
CONNECTION
4
6
CEII
I 1
bk
6
TEW00235
1
\
TEWOOZ36
8
TEW00237
14
20-130
0
11
11
CONNECTION
TROUBLESHOOTING
No.
of
pins
M type connector
Male (female
Female
housing)
(male
housing)
TEW00244
TEW00243
2
TEW00246
6
TEW00247
TEW0024E
20-l 31
0
TROUBLESHOOTING
No.
of
pins
CONNECTION
S type connector
Female (male housing)
r
8
TEWO0249
TEWOOZSO
TEW00251
TEWO0252
10
$3
12
16
\
5
TEW00253
1s
TEW00254
16
20-132
0
TEWO0255
TEW00256
CONNECTION
TROUBLESHOOTING
PIN NUMBERS
L type connector
No.
of
pins
Male (male
En
Female
housing)
(female
housing)
FFE3
TEW00258
TEWOO257
No.
of
:
pins
Male (female
Female
housing)
(male
housing)
21
TEW00260
TEwoo259
No.
of
pins
Female
housing)
(female
housing)
TEW00261
TEW00262
zo- 133
0
TROUBLESHOOTING
No.
of
pins
CONNECTION
Simple
Male (male
connector
housing)
PIN NUMBERS
(ring connector)
Female
(female
housing)
TEW00263
TEWOO26d
4
TEWOO263
zo- 134
0
TEWO0265
s-
s- 2
performance
Starting
is poor (Starting
20-203
(1) Engine
20-203
(3) Exhaust
.20-202
!z
7
gas comes
injected)
s- 4
s- 5
Engine
S- 6
Engine
lacks output
s- 7
Exhaust
S- 8
Oil consumption
s- 9
Oil becomes
s-10
Fuel consumption
S-l 1
Oil is in cooling
s-12
Oil pressure
s-13
s-14
Water
s-15
Abnormal
S-q6
Vibration
20-204
...............
20-205
(Follow-up
is poor). .......................................................
s- 3
operations
...................
..............................................................................................
(hunting)
...........................................................................
contaminated
(or exhaust
quickly
is excessive
water,
combustion).
or water
.....................................................................
.........................................................................................
................................................................................................
spurts back, or water
temprautre
becomes
.............................................................
...............................................................................................................
20-206
20-207
20-208
20-209
20-210
.20-211
20-212
20-213
20-214
.20-215
20-216
.20-217
20-218
20-219
20-20 1
0
TROUBLESHOOTING
S-l
S-l
1.26
1.24
1.23
1.22
0C
1.29
1.27
1.25
1.24
1.23
-10C
1.30
1.28
1.26
1.25
1.24
The specific gravity should exceed the value for the charging
rate of 70% in the above table.
In cold weather the specific gravity must exceed the value for
the charging rate of 75% in the above table.
Legend
0 : Possible causes (judging from Questions and check items)
0 : Most probablecauses (judgingfrom Questions and Check items)
A : Possible causes due to length of use (used for a long period)
0
on
I I I I I
__
z
L
I I I I I I I1 I I
I
00
00
00
010
I I lnl Inl I I
000
Illlllllllllll
1
I I I I I I I I I I I I I I
l
l
l
E.kcrcg$X$:zb.kr
20-202
0
TROUBLESHOOTING
s-2
Causes
Legend
0: Possible causes (judging from Questions and check items)
0 : Most probable causes (judging from Questions and Check items)
A: Possible causes due to length of use (used for a long period)
l : Items to confirm the cause.
~
I d
Degree of use
.3
. z
ij
ol
I
Remedy
20-203
0
TROUBLESHOOTING
s-2
gas comes
out
General causes why engine turns but no exhaust gas comes out
.
Supply of fuel impossible
.
Supply of fuel is extremely small
.
Causes
f//////l/
_** _4
I-30
-20
,4
32
68
-10
10
20
86
30
104122F
40 50%
/.~I~/
Diesel fuel
Legend
0: Possible causes (judging from Questions and check items.1
0 : Most probable causes (judging from Duestions and Check items)
A: Possible causes due to length of use fused for a long period)
l:
Items to confirm the cause.
I-
Remedy
20-204
0
TROUBLESHOOTING
s-2
does
20-205
0
TROUBLESHOOTING
s-3
(Follow-up
is poor)
I Dearee
1Ooeratedforlonaoeriod
of use
lAlA!Al
Q Q 0
I I I
Clanoina
sound
is heard
Black
from
around
cvlinder
I I I
00
8
0
0
I 101 I
I I I I I I I I I IQ1
head
@@
000
00
1 1 I 1 1 I I ] I
I I I I
1.1
I 1.1
I I I I I I I I
0
I I I I I I I 1.1I i
Remedy
20-206
0
TROUBLESHOOTING
S-4
Causes
Legend
0 : Possible causes (judging from Questions and check items)
0 : Most probable causes (judgingfrom Questions and Check items)
n : Possible causes due to length of use (used for a long period)
l : Items to confirm the cause.
000
000
II
00
080000
fifi
1~1~1
000
00
I
0
0
0
1 I I I I I I I44 I I I t2
Kw I I I I lolol I I I z
I I I I I I I I I I I
20-207
0
TROUBLESHOOTING
s-5
(hunting)
Legend
0: Possible causes (judging from Questions and check items)
0 : Most probable causes (judgingfrom Questions and Check items)
a:
l
Condition of hunting
Remedy
20-208
0
Ocuurs on slopes
TROUBLESHOOTING
S-6
(no power)
(if non-specified
fuel is used, output
drops)
Lack of output due to overheating
If there is overheating and insufficient
*
output, carry out troubleshooting
for
overheating.
00
I I I
I I I I l
s found to be clogged
c 2 z c c .L s
Remedy
Y-Y
20-209
0
TROUBLESHOOTING
S-7 Exhaust
s-7
combustion)
Legend
0 : Possible causes (judging from Questions and check items)
0 : Most probable causes (judging from Questionsand Check items)
A : Possible causes due to length of use (used for a long period)
l : Items to confirm the cause.
@
0
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp
When turbocharger is rotated by hand, it is found to be heavy
When air cleaner is inspected directly, it is found to be clogged
When comuression oressure is measured, it is found to be low
Stop fuel injection to one cylinder at a time. If there is no
change in engine speed, that cylinder is not working
When check is made using delivery method, injection timing
is found to be incorrect
Injection pump test shows that injection amount is incorrect
When valve clearance is checked directly it is found to be
outside standard value
When muffler is removed, exhaust gas color returns to normal
When control rack is pushed, it is found to be heavy, or does
not return
20-2 10
0
000
j
I 1 I I 1 I I p/
1 (
I I I I IQ
!
I
l
I I
1 1 1l / 1 1 1 1 1 !01 1
IIIIIII
I
I I I.I I I I I I I
l
l
0
0
S-8
TROUBLESHOOTING
Legend
I I
! , , / ,
1.1
I I I I I I I I I I I I IN
Remedy
TROUBLESHOOTING
s-9
quickly
Legend
0 : Possible causes (judging from Questions and check items)
0 : Most probable causes (judgingfrom Questionsand Check items)
A: Possible causes due to length of use (used for a long period)
l : Items to confirm the cause.
broken
Remedy
z
d
20-2
0
12
IT
t
4
2
cd
z
d
4
E
d
5
0 oz
TROUBLESHOOTING
S-IO
Fuel consumption
s-10
is excessive
Causes
Legend
0: Possible causes (judging from Questions and check items)
0
n
lnlnl
I I lal
0
00
I I I lolol
Suddenlv increased
Slack
lwl
White
lol
I I Ic
loI
lol
I I I I I I
00
0
0
00
Q
i@l
1 I
I I I.1
I I 1~ -11
I I I I I I.1
I I I I I I.1 I I
I I I I I I I.1 I
20-213
0
TROUBLESHOOTING
S-11
S-l 1
down
or water
level goes
Causes
TROUBLESHOOTING
S-12
s-12
lamp lights
UP
.
Leakage, clogging, wear of lubricating
system
.
Defective oil pressure control
.
Improper oil used (improper viscosity)
.
Deterioration
of oil due to overheating
Standards for engine oil selection
Selection of oii SAE number according
to ambient temperature
Type of oil
-22
-30
-4
-20
14
-10
32
0
50
10
68
20
86
30
104122OF
40 5oYI
Causes
Engine oil
Legend
estions and check items)
Questionsand Chockitems)
se (used for a long period)
ration manual
TROUBLESHOOTING
S-13
s-13
Legend
0: Possible causes (judging from Questions and check items)
0 : Most probable causes (judging from Questions and Check items)
a
c3
4
Leave radiator cap open. When engine is run at idling, an
lololal
i to
20-2 16
a
s-14
TROUBLESHOOTING
Causes
S-14
Water temperature
(overheating)
becomes
too high
too high
of fan)
for chassis.
Legend
0 : Possible causes (judging from Questions and check items)
0 : Most probable causes (judgingfrom Questions and Check items)
A:
l : Items to confirm
I I I I I I I I loI
101
lot
(i f
1 101
1 I
I
1 /
Id
101 I I I I
IQ 1 /
161
1 I
I I I 101 I 1
I I I
20-2
0
17
TROUBLESHOOTING
S-55
Abnormal
s-15
noise is made
Causes
Legend
0 : Possible causes (judging from Questions and check items)
0 : Most probable causes (judgingfrom Questions and Check items)
n : Possible causes due to length of use fused for a long period)
l : Items to confirm
f
0
the cause.
loIn
lal
Blue under
Color or exhaust gas
Black
Metal particles are found in oil filter
01
00
00
20-218
0
S-16
TROUBLESHOOTING
S-16
Vibration
is excessive
.
.
age)
Improper
Abnormal
alignment
combustion
Causes
Legend
Possible causes (judging from Questions and check items)
0 : Most probablecauses (judgingfrom Questionsand Check items)
n : Possible causes due to length of use (used for a long period)
l : Items to confirm the cause.
0:
00
00
C
Y
I.1
I I I I I I I
TROUBLESHOOTING
OF
MAIN MONITOR SYSTEM
(M MODE)
TROUBLE
M- 1
M- 2
M- 3
M- 4
M- 5
M- 6
M- 7
M- 8
M- 9
M-10
M-11
M-12
M-13
DATA DISPLAY
20-255
20-256
20-257
20-258
20-258
20-258
20-258
20-259
20-259
20-259
20-260
20-260
20-261
20-262
20-262
20-262
20-263
20-263
20-263
20-264
20-264
20-265
20-265
20-266
20-267
20-268
20-268
20-268
20-268
20-269
20-269
20-269
20-269
20-271
Abnormality
in transmission
cut-off ........................................................................................
(a) When monitor switch is pressed, cut-off function is not switched and
20-271
display is not given ............................................................................................................
20-271
(b) Monitor display goes out but cut-off function stays on .................................................
20-272
(c) Monitor display lights up but cut-off function is not actuated ......................................
20-273
Abnormality
in parking brake dragging warning ..................................................................
(a) When parking brake is applied, buzzer sounds (intermittently)
20-273
even when directional lever is at N, and caution lamp flashes ....................................
(b) When parking brake is applied, buzzer does not sound and caution lamp
does not light up even when directional lever is at position other than N ................ .20-273
20-25 1
0
M-14
M-15
M-16
M-17
M-18
M-19
M-20
M-21
M-22
M-23
When parking brake dragging warning is given, buzzer and caution lamp
20-274
are actuated continuously, or they are not actuated ............................................................
20-274
(a) Actuated continuously ........................................................................................................
.20-274
(b) Not actuated ........................................................................................................................
20-275
in buzzer.. .............................................................................................................
Abnormality
(a) Buzzer does not sound when starting switch is turned ON (during self-check). ........ .20-275
20-275
(b) Buzzer always sounds ........................................................................................................
20-276
Condition of monitor switches is not stored in memory .....................................................
20-277
in failure display mode ......................................................................................
Abnormality
................... 20-277
(a) Does not enter failure display mode ~............................................................
(b) Time for time elapsed since failure on failure display mode does not advance ...... ..20-27 7
20-278
in emergency steering normal display .............................................................
Abnormality
20-278
(a) Emergency steering normal display does not light up ..................................................
20-278
(b) Emergency steering normal display stays lighted up ....................................................
20-279
in emergency steering actuation display .........................................................
Abnormality
20-279
(a) Emergency steering actuation display does not light up.. .............................................
20-279
(b) Emergency steering actuation display stays lighted up .................................................
20-280
in auto-greasing
system .....................................................................................
Abnormality
20-280
(a) Forced greasing cannot be carried out .............................................................................
20-280
(b) Monitor display flashes rapidly (2 times/set). ..................................................................
......... ..20-28 0
(c) When no more grease remains, monitor display flashes rapidly (2 times/set)
20-281
(d) Monitor display flashes slowly (1 time/set). ....................................................................
20-281
(e) Monitor display goes out.. .................................................................................................
20-282
in ECSS system ...................................................................................................
Abnormality
20-282
(a) Display does not change when switch is pressed ..........................................................
20-282
(b) Monitor display lights up but ECSS function does not work ........................................
20-282
switch is actuated ...........................................
Buzzer does not sound when auto-leveling
20-283
in network) ...................................
Failure code is not sent to main monitor (abnormality
20-252
0
g
c)
$
TROUBLESHOOTING
TROUBLE
DATA DISPLAY
Abnormality
in failure action code
This code informs the operator directly of
the abnormality,
and takes action, such as
stopping the machine immediately.
There are four types of action code: EOO,
EOl+CALL (EOI and CALL are displayed alfailternately), E03+CALL, and CALL. If a
ure occurs suddenly, one of these codes is
shown on the speedometer
display.
For details of the action taken by operator
for the action codes, see Item 4.
Failure code and time elapsed since failure
The failures detected by each controller are
changed to a code and displayed. It is possible to tell from this code which system in
which controller has failed, so carry out troubleshooting for the applicable controller.
For failures that have occurred and been reset, the failure code and the time elapsed
since failure are displayed to make it easy to
check failures
that are not occurring
at
present.
The failure codes for failures that are now
occurring flash, and the codes for failures
that are not occurring light up.
For details of the method of operating and
transferring data to the trouble data display
mode, see STRUCTURE AND FUNCTION
for
the main monitor.
Note:
If the engine is not stopped, it is impossible to switch to the trouble data
display mode, so the codes for failures which can only be detected
when the engine is operating
light
SPEED
Action code
TDW00283
SPEED
Failure code
.Time elapsed
since failure
20-253
0
TROUBLESHOOTING
4.
Action
Action
TROUBLE
code table
code: EClCl+CALL
code
Problem
Dumping
circuited
source
CALL
equipment
system
Action
solenoid is short
to+terminal
of power
24V
of machine
code chart
equipment
control
system
solenoid
solenoid
-r
d0
41
Dump/tilt
system
42
43
Damping
solenoid
system
44
Damping
solenoid
system
45
Damping
solenoid
system
d,
Bucket
kickout
50
Auto
5,
Boom RAISE-LOWER
system
leveler
system
d3
Abnormality
! selection
20-254
0
Relief
solenoid
High pressure
switch
in model
system
system
solenoid
Low pressure
system
solenoid
Speed
system
sensor
Abnormality
selection
relay system
relay system
ECSS control
I system
iijLzJ
48
alternately
Alarm
buzzer
Action
by operator
source
Boom movement
is slow
Stops remote positioner
function, possible that control-
dump
54
control
system
5. Failure
Work
Work
Action
EOl+
CALL
DATA DISPLAY
in model
Yes
TROUBLESHOOTING
M-l
Ir
*
M-l
Main monitor
Cause
YES
1 Defective
inserted.
Remedy
main monitor
1
Is voltage
between CNLOS
(1). (2) - (3)
normal?
1)20-30V
2t Tur~c~t~~ng
YES
2
Is there continuity
between CNL05
NO (female) (3) and
chassis ground?
1) Turn starting
switch OFF.
2) Disconnect
CNLOB.
NO
Defective contact, or
disconnection in wiring
harness between CNL05
(female) (1). (2) and
CNFS2 (9)
After inspection
repair or replace
Defective contact, or
disconnection in wiring
After inspection
harness between CNL05
repair or replacf
(female) (3) and CNLR2 (11)
Power source
Maintenance
monitor
Buzzer
Battery
relay
TDW00285
20-255
0
M-2
TROUBLESHOOTING
Remedy
Cause
1 YES
Is voltage
between CNL05
(4) and chassis
ground normal?
1)20-30V
2) Turn starting
switch START.
NO
Neutral
inserted.
Replace
Defective contact, or
disconnection in wiring
harness between CNLOB
(female) (4) and CNL57 (3)
After inspection
repair or replact
relav
Start signal,
neutral signal
Starting
motor
CNL57
Rear frame
20-256
GND
M-3
TROUBLESHOOTING
M-3 Speedometer
*
*
*
inserted.
Remedy
Replace
.--
YE j between CNL07
(female) (I) and
1
(2) normal?
1)500R-7
kQ
2) Turn starting
switch OFF.
3) Disconnect
CNL07.
between CNTOG
(male) (1) and (2)
1)500R-1
kc2
2) Turn starting
switch OFF.
3) Disconnect
CNTOG.
H
NO
Defective contact, or
disconnection in wiring
harness between CNL07
(female) II ), (2) - CNTL2
(11, (2)-CNTOG (1). (2)
After inspection
repair or replace
Replace
NO
Speedometer
CNL07
CNTLZ
CNTOG
Speed sensor
/MY
20-257
0
TROUBLESHOOTING
M-4 Abnormality
*
*
*
M-4
in shift indicator
Cause
Iefective
between CNLOB
(7) and chassis
ground normal?
(b) Stays
NO
at N even when
directional
l)ZO-30V
2) Turn starting
switch ON.
3) Directional
lever: R
main monitor
Replace
Iefective contact. or
lisconnection in wiring
rarness between CNLOS
female) (7) and CNL04 (2)
After inspection,
repair or replace
lefective
Replace
lever is at R
1 YES
Is voltage
between CNL08
(8) and chassis
ground normal?
Remedy
lever is at F
Is voltage
1)20-30V
2) Turn starting
switch ON.
3) Directional
lever: F
inserted.
1
NO
main monitor
lefective contact, or
lisconnection in wiring
rarness between CNLOS
female) (8) and CNL04 (4)
After inspection,
repair or replace
Replace
20-258
0
,
/
NO
TROUBLESHOOTING
M-4
Cause
Is voltage
between CNL08
(7) and chassis
ground normal?
NO
l)O-5v
2) Turn starting
switch ON.
3) Directional
lever: N
I-
1120-30V
2) Turn starting
switch ON.
3) Speed lever: 1
(R
leplace
ifter inspection
epair or replacc
leplace
Defective contact, or
disconnection in wiring
harness between CNLOB
(female) (12) and CNL04 (5)
ifter inspection
epair or replact
:eplace
lst, 4th
1 YES
Is voltage
between CNL05
(12) and chassis
ground normal?
Remedy
NO
between CNL05
(13) and chassis
Defective contact, or
disconnection in wiring
harness between CNLOB
[female) (13) and CNL04 (7)
1)20-30V
2) Turn starting
switch ON.
3) Speed lever: 3
Relationship
between monitor
input signal and display
CNL0912)
: 20 - 30 V
L : ov
CNL05(13)
fter inspection
epair or replacr
Display
20-259
0
M-4
TROUBLESHOOTING
Remedy
Cause
(91 Does not display
2nd, 3rd
1 YES
Is voltage
between CNLOB
(12) and chassis
ground normal?
NO
l)O-5v
2) Turn starting
switch ON.
3) Speed lever: 2
Replace
After inspection,
repair or replace
Replace
1st. 2nd
1 YES
Is voltage
between CNL05
(13) and chassis
ground normal?
NO
l)O-5v
2) Turn starting
switch ON.
31 Speed lever: 2
CNL04
Transmission
range
FORWARD
relay
CNL66
0
20-260
0
REVERSErelay
CNL67
0
After inspection,
repair or replace
Transmission
lever
TROUBLESHOOTING
M-5
inserted.
Cause
Remedy
Replace
chassis ground?
disconnection in wiring
harness between CNLOG
(female) (13) and CNLOZ (3)
NO
between CNLOG
(12) and chassis
switch OFF.
2) Disconnect
1)20-30V
2) Turn starting
switch ON.
3) Dimmer switch:
Hi
After inspection
repair or replacl
Defective contact, or
After inspection
disconnection in wiring
repair or replacl
harness between CNLOG
(female) (12) and CNFSZ (2)
NO
beam
CNLOG
CNFS2
r
gl
$-j
Lamp switch
Dimmer
CNLRI
CNFRI
switch
CNFOI
R.H. head lamp
TOW00290
20-26 1
0
M-6
TROUBLESHOOTING
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on the next step.
Before starting troubleshooting, check that the tamp bulb of the turn signal indicator on the
monitor is not blown.
Cause
Remedy
Iefective
between CNLOG
(14) and chassis
1) Repeat OV and
20-30V.
2) Turn starting
switch ON.
NO
teplace
main monitor
Iefective contact, or
kconnection in wiring
larness between CNLOG
female) (14) and CNL03 (4)
ifter inspection
epair or replacx
Iefective
teplace
Is voltage
between CNLOG
(15) and chassis
ground normal?
1) Repeat 0 V and
20-30V.
2) Turn starting
switch ON.
Turn signal
CNLOG
main monitor
Iefective contact, or
%sconnection in wiring
iarness between CNLOG
female) (15) and CNLOB (3)
NO
\fter inspection
epair or replacf
CNL03
Hazard switch
Turn signal unit
TDW00291
20-262
0
M-7
TROUBLESHOOTING
M-7 Abnormality
*
*
in parking display
Cause
inserted.
Remedy
YES
switch ON.
3) Turn parking
switch ON.
fb) Parking
1I Disconnect
CNTOS.
21 Turn starting
switch ON.
3) Turn parking
switch OFF.
1) Disconnect
CNTOS.
qeplace
main monitor
After inspection
.epair or replacf
Is there continuity
between CNTOS
_
(male) (1) and
(2)?
Iefective
up
3 YES
Is there continuity
YES between CNTOS
(female) (2) and
chassis ground?
1
qeplace
NO
1)20-30V
2) Turn starting
switch ON.
3) Turn parking
switch ON.
l)O-2v
2) Turn starting
switch ON.
3) Turn parking
switch OFF.
Iefective contact, or
lisconnection in wiring
tarness between CNLOG
female) (11) - CNTL2 (3) ZNTOS (female) (1)
NO
NO
NO
Vter inspection
,epair or replace
Defective contact, or
disconnection in wiring
harness between CNTOS
(female) (2) - CNTLl (8) chassis ground
After inspectior
repair or replao
Replace
Parking signal
CNTL2
CNT08
Parking brake
indicator switch
20-263
0
M-8
TROUBLESHOOTING
M-8 Abnormality
*
*
in preheating
system
(QGS)
*
Check that the water temperature
is below
(1) Monitor display also does not light up
inserted.
5C.
2 YES
leplace
ifter inspection
epair or replacf
leplace
leolace
teplace
Defective contact, or
disconnection in wiring
larness between CNEOB
snd slow blow fuse
ifter inspection
epair or replace
Defective contact, or
disconnection in wiring
?arness between CNL56
:3) - CNLR4 (7) - CNERl
:4) - CNEOS (female) (1). o
oetween CNEOS (female)
12) - CNERP (5) -chassis
around
Uter inspection
epair or replacc
Is resistancebetween
YES CNLOS (female) (7)
and chassis ground
1
-
normal?
Is resistance
1) Disconnect
CNE05.
2) Turn starting
switch OFF.
3) Min. 4 kR
NO
1) Disconnect
CNL05.
2) Turn starting
switch OFF.
3) Min. 4 kR
between CNEOB
(male) and chassis ground normal?
NO
1
Is vottage
between CNEOS
(1) and (2)
normal?
Is voltage
between CNE07
and chassis
ground normal?
1) 20-30V
2) Turn starting
switch ON.
NO and chassis
ground normal?
1)20-30V
2) Turn starting
switch ON.
1)20-30V
2) Turn starting
switch ON.
NO
20-264
0
3 YES
Is voltage
L between CNE08
NO
TROUBLESHOOTING
M-8
2 YES
Is resistancebetween
YES CNL05 (female) (7)
and chassisground
1
normal?
Is resistance
between CNE05
(male! and chassis ground normal?
1)Max.8kQ
2) Turn starting
switch OFF.
3) Disconnect
CNE05.
(cl Preheating
NO
1) Max. 8 !&
2) Turn starting
switch OFF.
3) Disconnect
CNL05.
NO
Remedy
Cause
fqeplace
Defective contact, or
disconnection in wiring
harness between CNL06
(female) (7) - CNLR4 (2) CNERl (8) - CNEO5 (female
IVter inspection
repair or replace
Fkplace
FIeplace
Defective preheating
f3eplace
stays on
YES
1
I
YES
Does preheating
stop?
XJ
0 Turn starting
switch ON.
2) Disconnect
CNLOG.
Is voltage
Does preheating
NO stop?
1) Turn starting
switch ON.
2) Remove
preheating
relay.
1)20-3ov
2) Turn starting
switch ON.
I
NO
NO
relay
Vter inspection
epair or replace
After inspection
epair or replace
20-265
0
M-8
TROUBLESHOOTING
(d) Preheating
time
becomes
shorter,
or there
is variation
Cause
3 YES
Is voltage
YES between CNLDB
(3) and chassis
2
ground normal?
Is resistancebetween
1)
Max. 0.1 V
YES CNLOSIfemale)(71
2) Turn starting
and chassis ground
If
normal?
switch ON.
Is resistance
between CNEOS
(male) and chassis
ground normal?
11 Are temperature
and resistance
value as shown
in table below?
2) Turn starting
switch OFF.
p
NO
1) Are temperature
and resistance
value as shown in No
table below?
2) Turn startin
switch OFF.
No
Temperature(%)
Resistance
qeplace
\fter inspection,
pepair or replace
4fter inspection,
repair or replace
Replace
(Tolerance
Table
valueM2)
f 0.5 kR)
-10
-8
-6
-4
-2
7.7
7.1
6.5
6.0
5.5
5.1
4.7
4.3
Preheating
I----+-
Starting
Remedy
TDW00293
CNLR5
Water temperature
signal
@Battery%
HII
CNL05
CNERl
CNE05
Engine water
temperature
sensor
Tow00294
20-266
0
TROUBLESHOOTING
M-9
inserted.
Cause
1 YES
Is voltage
between CNLOB
(16) and chassis
ground normal?
ll20-30V
2) Turn starting
switch ON.
3) Turn side lamp
switch ON.
NO
Side
CNL05
Remedy
Replace
Defective contact, or
disconnection in wiring
harness between CNL05
(female) (16) and CNFSZ (5)
After inspection
repair or replact
CNFS2
CNL02
Lighting
switch
I
I
1
TDW00295
20-267
0
M-10
TROUBLESHOOTING
M-10
+
*
*
Abnormality
in front working
lamp
YES
,
between CNLGO
(1) and chassis
YES
l)O-3v
2) Turn starting
ON.
Is voltage
between CNLGO
(6) and chassis
t ground normal?
l)O-3v
2) Turn starting
switch ON.
I
1)20-30V
2) Turn starting
switch ON.
(b) Working
..
4 YES
Is voltage
i between CNLOG
NO (1) and chassis
ground normal?
l)O-3v
2) Turn starting
switch ON.
Cause
Remedy
Defective contact, or
disconnection in wiring
harness between CNLGO ( 1)
- CNLOB (17). CNCLl (7)
bfter inspectior
spair or replac
ieplace
Defective contact, or
disconnection in wiring
harness between CNLOG
(1) and CNLGO (6)
&ter inspectior
epair or replac
leplace
Defective contact, or
disconnection in wiring
harness between CNLGO
(2). (5) - CNFS5 (1)
ifter inspectior
epair or replac
leplace
Defective contact, or
disconnection in wiring
harness between CNLOS
(female) (17) and CNLGO (1)
\fter inspectior
epair or replac
Defective contact, or
disconnection in wiring
harness between CNLGO
(1) - CNCLl (7) -front
working lamp, or blown
working lamp bulb
Uter inspectior
epair or replac
YES
Is voltage
between CNL05
(77) and chassis
ground normal?
1)20-30V
2) Turn starting
switch ON.
NO
1
NO
II
inserted.
NO
20-268
0
TROUBLESHOOTING
M-l1
*
*
*
Abnormality
M-l 1
in rear working
lamp
inserted.
Remedy
(a) Neither monitor display nor rear working lamp light up
F==
disconnection in wiring
harness between CNL61
(1) - CNLOB (18). CNLRl
(12)
ES
YES
3
between CNL61
(1) and chassis
I is voltaae
-I
I
I
4fter inspection
repair or replac
Replace
.
After inspectiol
repair or replac
1)20-3ov
21 Turn starting
switch ON.
Replace
1)20-30V
2) Turn starting
switch ON.
After inspectiol
repair or replac
(b) Working lamp lights up but monitor display does not light up
YES
Replace
Is voltage
between CNLOS
(78) and chassis
ground normal?
l)ZO-3ov
2) Turn starting
switch ON.
Defective contact, or
disconnection in wiring
harness between CNLOB
(female) (18) and CNL61
NO
After inspectior
repair or replac
(1)
After inspectiol
repair or replac
20-269
0
TROUBLESHOOTlNG
M-11
CNL60
Working lamp F
CNL05
\
CNCLI
i
CNFSS
+24V
CNL61
Working lamp R
+24V
TDWOOz96
20-270
0
M-12
TROUBLESHOOTING
M-12 Abnormality
*
*
in transmission
cut-off
inserted.
Remedy
Cause
leolace
Defective contact, or
disconnection in wiring
narness between CNL65
:l) and CNFSZ (8)
Uter inspection
epair or repiacf
Defective contact, or
disconnection in wiring
harness between CNLOS
:female) (3) and CNL65 (2)
ifter inspection
epair or replace
teplace
Is voltage
2) Turn starting
switch ON.
l)O-3v
2) Turn starting
switch ON.
NO
5 YES
Defective transmission
off relav
cu:
teplace
YE
El_
--I
Is voltage
between CNL65
(3) and chassis
ground normal?
1)20-30V
2) Turn starting
switch ON.
3) Turn parking
switch OFF.
1)20-30V
21 Turn starting
switch ON.
3) Turn parking
switch OFF.
4) Remove cut-off
relay.
5) Stop machine
cut-off function.
JO
NO
Defective contact, or
disconnection in wiring
harness between CNL65
(5) and CNL12 (female) (2
After inspectior
*epair or replac
Defective contact, or
disconnection in wiring
harness between CNL65
(3) and CNLIP (female) (1
After inspectior
,epair or replacl
20-271
0
TROUBLESHOOTING
(c) Monitor
display
M-12
function
Cause
is not actuated
YES
Replace
Replace
After inspection,
repair or replace
After inspection,
repair or replace
2
Is voltage
YES between CNL65
(2) and chassis
ground normal?
1
-
1) Turn starting
switch ON.
2) Remove cut-off
relay.
1)20-30V
2) Turn starting
switch ON.
3 YES
L Does cut-off
ND function work?
L
1) Turn starting
switch ON.
2) Disconnect
CNL06.
NO
NO
Transmission
Transmission
cut-off
relay
Remedy
CNL65
cut-off
a
6
CNFS2
-
+24V
lever
CNL12
Transmission
3
3
Neutralizer
relay
CNL58
20-272
a
FORWARD
CNL66
relay
CNTLl
REVERSE
CNL67
relay
cut-off switch
TROUBLESHOOTING
M-13
M-13 Abnormality
Ir
Ir
warning
Cause
Iefective
Remedy
main monitor
Iefective contact, or
jisconnection in wiring
larness between CNL05
female) (8) and CNL04 (3)
NO
11 20-30V
21 Turn starting
switch ON.
inserted.
f?eplace
I Wer
inspectior
r.epair or replac,
YES
1
Iefective
i?eplace
~~~,~
2) Turn starting
main monitor
NO
1)3kR-4kR
2) Turn starting
switch OFF.
3) Disconnect
CNLOS.
Neutral
Start signal,
neutral signal
main monitor
relav
lI?A
Starting
motor
CNL57
ear frame
GND
TDWOO286
20-273
0
M-14
TROUBLESHOOTING
M-14
-k
f
Cause
inserted.
Remedy
1) Turn starting
switch ON.
2) Connect CNL19
(female) (5) to
chassis ground.
NO
lefective maintenance
monitor
eplace
lefective contact, or
isconnection in wiring
arness between CNL07
emale) (6) and CNL19
emale) (5)
ifter inspection
epair or replacf
Leplace
jefective maintenance
nonitor
teplace
NO
II
I
1) Turn starting
switch ON.
2) Disconnect
CNL07.
_, 1) Turn starting
switch ON.
I 2) Disconnect
CNLl9.
NO
Vter inspectior
epair or replacl
7eplace
NO
Synchronous
CNL07
20-274
0
flashing
signal
CNL19
M-15
TROUBLESHOOTING.
M-15 Abnormality
*
Ir
in buzzer
Remedy
Cause
(a) Buzzer does not sound when
turned ON (during self-check)
starting
switch
is
Defective contact, or
disconnection in wiring
harness between CNLOG
(female) (8) and CNL43
(male)
YES
1
~
NO
1)20-30V
2) Turn starting
switch ON.
chassis ground.
inserted.
4fter inspectior
,epair or replac
Defective buzzer
qeplace
Defective contact, or
disconnection in wiring
harness between CNL42
(female) and CNFS2 (9)
4fter inspectior
epair or replac
qeolace
sounds
YES
1
Does buzzer
stop?
I) Turn starting
switch ON.
2) Disconnect
CNLOG.
YES
Go to Troubleshooting
maintenance monitor
2
Does buzzer
NO Stop?
1) Turn starting
switch ON.
2) Disconnect
CNL19.
3 YES
Does buzzer
NO Stop?
1) Turn starting
switch ON.
2) Disconnect
CNL43.
CZ
Buzzer output
ifter inspectior
.epair or replac
Defective buzzer
Replace
ND
CNFS2
,CNL42
, ,
ml
Maintenance
monitor
for
Buzzer
CNL43
TDW00301
20-275
0
M-16
TROUBLESHOOTING
M-16
*
*
Condition
of monitor
switches
Remedy
Cause
YES
Is voltage
between CN LO7
(10) and chassis
ground normal?
1)20-30V
2) Turn starting
switch ON.
NO
Starting
Replace
Defective contact. or
disconnection in wiring
harness between CNL07
(female) (10) and CNLOS (2)
After inspection
repair or replacf
switch ACC
CNLOS
CNL07
Starting
CNLR4
I-/$$
To battery
switch
relay
TDWO0302
20-276
a
inserted.
TROUBLESHOOTING
M-17
Ir
Ir
Abnormality
M-17
inserted.
Cause
(a) Does not enter failure
display
mode
1 YES
Is voltage
between CNLOB
(5) and chassis
ground normal?
l)O-5v
2) Turn starting
switch ON.
Remedy
NO
Xeplace
Mer inspection
,epair or replace
Ieplace
Is
I
8
:
Defective contact, or
I disconnection in wiring
After inspection
epair or replacf
1)20-30V
2) Start engine.
Charge
Alternator
CNL05
CNLR4
CNERI
CNE16
20-277
0
TROUBLESHOOTING
M-18
*
*
M-18
Abnormality
in emergency
steering
normal display
Remedy
Cause
(a1 Emergency
steering
normal
up
YES
1
Is there continuity
between CNTlO
(male) cl) and
(2)?
_
2 YES
Is voltage
i between CNLOS
NO (10) and chassis
ground normal?
I)
Disconnect
CNTlO.
2) Turn starting
switch ON.
NO
1)20-30V
2) Turn starting
switch ON.
(b1 Emergency
steering
normal
Is there continuity
YES between CNTlO
(female) (2) and
1
chassis ground?
Is there continuity
between CNTlO
(male) (7) and
PI?
1) Disconnect
CNTlO.
l)O-2v
2) Turn starting
switch ON.
Defective emergency
steering normal sensor
kplace
teplace
4fter inspectior
epair or replac
teplace
Defective contact, or
disconnection in wiring
harness between CNL05
(female) (10) - CNTLl (2) CNTlO (female) (1)
4fter inspectior
epair or replac
Defective contact, or
disconnection in wiring
harness between CNTlO
(female) (2) - CNTLI (8) chassis ground
4fter inspectior
epair or replac
up
3 YES
Is voltage
YES between CNLOB
(10) and chassis
2_
ground normal?
NO
NO
11Disconnect
CNTlO.
2) Turn starting
switch ON.
Defective emergency
steering normal sensor
NO
Emergency
steering
normal
CNL05
CNTLI
CNTlO
.D
Emergency steering
normal sensor
rf7
TOW00307
20-278
0
inserted.
TROUBLESHOOTING
M-19
M-19 Abnormality
+
*
in emergency
steering
actuation
display
inserted.
r
Cause
(a1 Emergency
steering
actuation
YES
1
Is there continuity
between CNTll
(male) (1) and
(2)?
_
(b)
2 YES
Is voltage
between CNL05
NO (11) and chassis
ground normal?
1) Disconnect
CNTll.
2) Turn starting
switch ON.
NO
1)20-30V
2) Turn starting
switch ON.
Emergency
steering
actuation
display
stays lighted
1) Disconnect
CNTll.
2) Turn starting
switch ON.
1) Disconnect
CNTll.
P
NO
Replace
Replace
~p~~~pee~orrr
Replace
A$~~pecec~~~;
Defective contact, or
disconnection in wiring
harness between CNTll
(female) (2) - CNTLl (8) chassis ground
NO
Defective emergency
steering actuation sensor
NO
Emergency
Defective emergency
steering function sensor
up
3 YES
Is voltage
YES between CNL05
(Ill and chassis
2
ground normal?
is there continuity
l)O-2v
YES between CNTll
- 2) Turn starting
(female) (21 and
switch ON.
1
chassis ground?
Is there continuity
between CNTll
(male) (1) and
(2)?
steering
Remedy
After inspection,
repair Or repace
Replace
actuation
CNTLI
CNL05
CNTI 1
1,
I-I-J
Emergency steering
actuation sensor
n
20-279
0
TROUBLESHOOTING
M-20
M-20 Abnormality
f
f
in auto-greasing
system
Cause
(al Forced greasing
cannot
be carried
inserted.
Remedy
out
;oto
2
Is voltage
between CNGRE
(I) and chassis
ground normal?
YI
1
Is voltage
between CNLOG
(5) and chassis
iaround normal?
l)O-3v
2) Turn starting
switch ON.
3) Turn autogreasing switch
ON.
l)O-3v
2) Turn starting
switch ON.
3) Turn autogreasing switch
ON.
(b) Monitor
lperation maintenance
nanual for handling
uto-greasing system
YES
display flashes
rapidly
YES
1)20-30V
2) Turn starting
switch ON.
YES
between CNGRE
NO (3) and chassiis
Iground nom tal?
Is voltage
1)20-30V
2) Turn starting
switch ON.
20-280
0
Ieplace
ieplace
Iefective contact, or
lisconnection in wiring
ramess between CNLO6
female) (5) and CNGRE (3)
\her inspectio
epair or replan
monitor
YES
I1
between CNGRE
NO (2) and chassis
ground normal?
L
1) 20-30V
2) Turn starting
switch ON.
NO
display
Iefective
between CNL07
(I 1) and chassis
rfter inspectior
epair or replac
;o to
operation maintenance
nanual for handling
auto-greasing system
NO
1)20-30V
2) Turn starting
switch ON.
Iefective contact, or
lisconnection in wiring
larness between CNLO6
female) (5) and CNGRE (1)
(2 timeskec)
main monitor
Iefective contact, or
iisconnection in wiring
larness between CNL07
female) (11) and CNGRE (2)
50 to
operation maintenance
nanual for handling
auto-greasing system
After inspectio
,epair or replag
TROUBLESHOOTING
M-20
Cause
(d1 Monitor
display flashes
slowly
Remedy
(1 time/set)
Go to
operation maintenance
manual for handling
auto-greasing system
(e) Monitor
display
goes out
YES
Is voltage
II
between CNL07
(11) and chassis
mound normal
l)O-3v
2) Turn starting
switch ON.
~0
YES
Is voltage between
CNGRE (female)
(2) and chassis
ground normal?
8
2
CNL07(11)
between
CNL08(5)
5
L
Replace
After inspection
repair or replace
Go to
operation maintenance
manual for handling
auto-greasing system
NO
l)O-3v
21 Turn starting
switch ON.
3) Disconnect
CNGRE.
Relationship
and display
input signal
Display
Rapid flashing
(2 timeskec)
Slow flashing
(I time/set)
OFF
ON
Auto-greasing
CNLOG
\
CNGRE
I
3
3
CNLO7
-3
A
CNL08
TDW00309
20-281
0
M-21,
TROUBLESHOOTING
M-21
*
*
Abnormality
M-22
in ECSS system
inserted.
Remedy
lb) Monitor
display
Replace
Go to
Troubleshootirq
for ECSS
controller
Defective contact, or
disconnection in wiring
harness between CNLOG
(7) and CNDPZ (1)
After inspection
repair or replacf
Replace
does
not work
2 YES
Is voltage
YES between CNDPZ
1 r (1) and chassis
Is voltage
between CNLOG
(7) and chassis
ground normal?
l)O-3v
2) Turn starting
switch ON.
II
NO
l)O-3v
2) Turn starting
switch ON.
NO
ECSS
CNDP2
CNLQG
TDW00310
M-22
Cause
2 YES
Is resistancebeh~een
byte
2) Disconnect
CNL34.
3) Connect CNLOI
(6) to power
source.
NO
ECSS
CNL08
CNL34
TAW00493
20-282
0
Remedy
Defective auto-leveling
controller
Go to
Troubleshooting
for auto-leveling
controller
Defective contact, or
disconnection in wiring
harness between CNL08
(female) (6) and CNL34
(male) (7)
After inspection,
repair or replace
Replace
TROUBLESHOOTING
M-23
*
*
*
M-23
Remedy
Cause
2 YES
Is voltage normal
Applicable controller
defective
YE
between CNL08
(male) (1) and (2)
1) Repeat OV and
12V?
2) Turn starting
switch ON.
3) Disconnect
CNL08.
1) Repeat OV and
12v.
2) Turn starting
switch ON.
3) Disconnect
connector to be
measured.
is
Defective contact, or
disconnection in wiring
harness between CNL08
(female) (f)(3), CNL08
ffemale) (2)(4)-applicable
connector pins
1
NO
inserted.
(eplace
rfter inspectior
epair or replac
IO
ii
Table
Connector
1 CNL34(female)
I CNDPS(female)
Pin No.
CNDP2
Auto
20-283
a
TROUBLESHOOTING
OF MAINTENANCE
MONITOR SYSTEM
(K MODE)
K- 1
When
starting
switch
is turned
maintenance
monitor
do not
monitor
monitor
When starting
switch
is turned
monitor
20-303
light up
20-303
When
engine
(within
K- 4
When
is started
3 seconds),
starting
immediately
switch
is turned
When
starting
switch
display
K- 6
CAUTION
K- 7
There is no abnormality
K- 8
CAUTION
K- 9
K-II
ON
stopped),
ON (engine
display flashes
display
20-305
20-305
20-306
CAUTION
.................................................................................
20-308
20-309
....................................................................................
20-310
flashes .................................................................................................
but alarm
in monitor
display
but warning
.20-311
but alarm
CAUTION
20-307
20-307
..................................................................................
flashes
flashes
started),
20-304
20-312
lamp)
20-313
20-313
(b) CAUTION
20-313
lamp.. ..................................................................................................................
There is no abnormality
warning
K-10
monitor
is turned
flashes.. ..................................................................................
level display
switch
flashes .........................................................................................
is turned
ON (engine
level display
after starting
.20-302
20-302
(b) Some
K- 2
on maintenance
in maintenance
CAUTION
monitor
lamp)
display
but
lights up ......................................................
20-314
20-314
(b) CAUTION
lamp ....................................................................................................................
20-314
Night lighting
lamp switch
.(only lighting
of maintenance
Night lighting
monitor
lamp switch
is turned
ON
20-315
lighted
up ...................................................................................................................................
20-316
Service
20-317
K-13
Service
meter
K-14
Abnormality
K-12
is running
even when
engine
is stopped
......................................................
20-317
items ....................................................................................................
20-318
(a) Abnormality
20-318
(b) Abnormality
in engine
water
(c) Abnormality
in torque
converter
in gauge
temperature
gauge ..........................................................
oil temperature
gauge ...............................................
-20-319
20-320
20-301
0
K-l
TROUBLESHOOTING
K-l
*
*
1
Is voltage
between CNL18
(1). (2) - (3)
normal?
1)20-30V
2) Turn starting
switch ON.
YES
3
Is voltage between
YES CNFS~ (female) (2)
and chassis
ground normal?
2_
- is there continuity
1)20-30V
2) Disconnect
between CNL18
CNFSl.
NC (female) (3) and
3) Turn starting
chassis ground?
switch ON.
1) Turn starting
switch OFF.
2) Disconnect
NO
CNL18.
Fuse box
NO
inserted.
Remedy
Cause
Defective maintenance
monitor module
Replace
Defective contact, or
disconnection in wiring
harness between CNLl8
(female) (l), (2) - CNFS2
(9) -fuse box - CNFSl
(male) (2). or blown fuse
Repair wiring
harness,
replace, or
replace fuse
Defective contact, or
disconnection in wiring
harness between CNFSl
(female) (2) - CNLRG (1) slow blow fuse - battery
relay, or blown fuse
Repair wiring
harness,
replace, or
replace fuse
Defective contact, or
disconnection in wiring
harness between CNLl8
(3) - CNLR4 (12) - chassis
ground
Repair wiring
harness or
replace
Battery
relay
rfr
TDW00314
20-302
0
TROUBLESHOOTING
K-l,
K-2
Remedy
F
Replace
Cause
Defective maintenance
monitor module
inserted.
Remedy
?eplace
20-303
0
TROUBLESHOOTING
K-3
When
engine.
starting
_YES
is voltage
between CNLIS
(female) (1) and
chassis ground
normal?
1)20-30V
2) Disconnect
CNL19.
31 Start engine.
4) Measure when
starting motor is
turning.
NO
Cause
inserted.
Remedy
Defective maintenance
monitor module
Replace
Defective contact, or
disconnection in wiring
harness between CNL19
(female) (1) and neutral
relav
Repair wiring
harness or
replace
CNLOS
Starting
Speed
switch
lever
I
Neutral relay
TDW00315
20-304
0
TROUBLESHOOTING
K-4
ON (engine stopped),
CHECK items
Cause
inserted.
Remedy
2 YES
Is there continuity
YES between CNL18
1(female) (13) and
chassis ground?
Is there continuity
between CNElO
_ 1) Turn starting
(male) (1) and
switch OFF.
chassis ground?
. 2) Disconnect
NO
CNL~S.
1)Turn
starting
switch OFF.
2) Disconnect
CNElO.
disconnection in wiring
harness between CNL78
(female) (131- CNLR4 (4) CNERl (3) - CNEIO
(female) (7)
Defective engine oil level
sensor
NO
CNL18
CNLR4
CNERl
CNEIO
Engine
Repair wiring
FzarB,;aT
Or
Replace
TDW00316
20-305
0
K-4
TROUBLESHOOTING
YI
1
Is there continuity
between CNROG
Is there continuity
YES between CNL18
(female) (8) and
3
2
\-,
chassis ground?
P
P
Is there continuity
NO
1) Turn starting
between CNROG
switch OFF.
(female) (1) and
2) Disconnect
chassis ground?
CNLIB.
1) Turn starting
switch OFF.
NO
2) Disconnect
CNROG.
1) Turn starting
switch OFF.
2) Disconnect
CNROG.
CNLR3
Ocl
CNROG
3
3
20-306
0
Defective maintenance
monitor module
Replace
Defective contact, or
disconnection in wiring
harness between CNLl8
(female) (8) - CNLR3 (2) CNROG (female) (1)
Repair wiring
harness or
replace
Defective contact, or
disconnection in wiring
harness between CNROG
(female) (21 and chassis
ground
Repair wiring
harness or
replace
Replace
Radiator
TROUBLESHOOTING
K-5
switch is turned
ON (engine started),
CAUTION
Cause
(a) Engine oil pressure
display
inserted.
Remedy
flashes
YES
Replace
Defective maintenance
monitor module
Replace
Defective contact, or
disconnection in wiring
harness between CNL18
(female1 (10) -engine oil
pressure relay-chassis
ground, or defective relay
Repair wiring
harness,
replace, or
replace relay
Repair wiring
harness,
replace, or
replace relay
1
3 YES
Does display go
out when ring
terminal is
removed?
YE
jZj!ZJZJHP
2
1) Start engine.
Is voltage between
L ring terminal and
NO chassis ground
normal?
1) Disconnect
CNLIS.
2) Turn starting
switch OFF.
NO
1)20-30V
2) Remove ring
terminal.
3) Start engine.
CNLR4
CNERI
essure sensor
Engine
oil pressure
relay
TDWOO318
20-307
0
K-5
TROUBLESHOOTING
Remedy
Cause
(b) Battery
charge
Is
voltagebetween
Is voltage between
alternator terminal R _
and chassis ground
normal?
1)20-30V
2) Start engine.
1)20-30V
2) Start engine.
Disconnection in wiring
harness between CNLl8
[female) (12) - CNLRO 6)
ZNERl (9) -alternator
terminal R
NO
Replace
Replace
Defective alternator
NO
Repair wiring
harness or
replace
Starting
motor
Alternator
CNR04
CNR12
Battery
20-308
0
relay
TROUBLESHOOTING
K-5
Cause
(c) Brake oil pressure
display flashes
YES
YE
between CNLl8
(11) and chassis
I) Start engine.
2)0-3V
YE
between CNB13
(female) (2) and
chassis ground?
1) Stan engine.
2) Disconnect
CNB13.
Defective maintenance
monitor module
Defective contact, or
disconnection in wiring
harness between CNL18
(female) (I I) and CN41
NC
(female) (2). or between
CN41 (female) (I) - CNLR2
~(8) - CNBRl (6) - CN813
(female) (I), or defective
diode
11 Turn starting
switch OFF.
2) Disconnect
CNBIS.
Defective contact, or
disconnection in wiring
harness between CNB13
(female) (2) and CNBOB
(female) (I), or between
CNB08 (female) (2) CNBRl (4) -chassis ground
IO
between CNB13
Remedy
I) Start engine.
21 Disconnect
CNBOI.
Defective
Repair wiring
harness,
replace, or
replace diode
Repair wiring
harness or
replace
brake
1
NO
Replace
Replace
CN41
CNLR2
CNB13
CNBRI
@
@-
ciJ/
-3
CNB08 _
Brake accumulator
pressure switch
oil
-3
20-309
0
K-5
TROUBLESHOOTING
Cause
display
Remedy
flashes
YES
I
Ez!!
1) Turn starting
switch ON.
21 Disconnect
CNE19.
3)20-30V
switch OFF.
2) Disconnect
CNLIB.
R:eplace
Defective maintenance
monitor module
R:eplace
Defective contact, or
disconnection in wiring
harness between CNL18
Rlepair wiring
(female) (15) and CNL80
h arness,
(female) (3), or between
CNL80 (female) (6) - CNLREi r,eplace, or
rieplace relay
(2) -chassis ground, or
YIES
1) Start engine.
2) Disconnect
CNEl9.
NO
hIO
+24
Dust indicator
CNER2
CNE20
CNLR5
Dust indicator
CNL80
20-310
0
relay
TDW00321
K-6
TROUBLESHOOTlNG
K-6 CAUTION
*
Ir
*
The buzzer does not sound for CHARGE or ENGINE OIL LEVEL.
Before carrying out troubleshooting,
check that all the related connectors are properly
Always connect any disconnected
connectors before going on the next step.
Defective maintenance
monitor module
2
YE
inset-ted.
Replace
Replace
to chassis ground?
1
I) Turn starting
switch ON.
h
Replace
switch ON. -
1)20-30V
2) Disconnect
CNL42.
3) Turn starting
switch ON.
Defective contact, or
in wiring
I disconnection
,,Y*,l---
.,..._.,..
_..___
+24V
CNFS2
CNL42
Repair wiring
harness or
replace
Alarm buzzer
1
Maintenance
CNLIS
monitor
CNL43
TOW00322
20-311
0
K-7
TROUBLESHOOTING
in monitor
Cause
YES
1
Is there continuity
between CNL43
(female) (1) and
Ichassis ground?
1) Turn starting
switch OFF.
2) Disconnect
CNL43.
2 YES
Is there continuity
_ between CNLl9
NO (female) (4) and
chassis ground?
1)Turn
starting
switch OFF.
2) Disconnect
CNL19.
+24V
NO
CNFS2
CNL42
1
Maintenance
monitor
CNLIS
Main monitor
CNLOG
20-3 12
0
CNL43
Remedy
Defective buzzer
Seplace
Repair wiring
harness or
replace
Defective maintenance
monitor module
Replace
Alarm
buzzer
TROUBLESHOOTING
K-8 CAUTION
CAUTION
*
*
*
K-8
Cause
inserted.
Remedy
chassisground?
2) Turn starting
switch ON.
Defective maintenance
monitor module
eplace
Defective contact, or
disconnection in wiring
harness between CNL19
(female) (2) and CNLOG
(female) (10)
:epair wiring
arness or
splace
eplace
Defective maintenance
monitor module
eplace
1) Disconnect
CNLOG.
2) Turn starting
switch ON.
z
3
YES
1
Does caution lamp
light up when
CNL19 (female) pin
(3) is connected to
chassis ground?
Disconnect
CNL19.
2) Turn starting
switch ON.
1)
YES
Maintenance
CNL19
NO
monitor
Defective contact, or
disconnection in wiring
harness between
CNL19
(female) (3) and CNLOG
(female) (9)
repair wiring
larness or
eplace
ieplace
Main monitor
CNLOG
TDW00324
20-3
13
K-9
TROUBLESHOOTING
Cause
Remedy
(b) CAUTION
ND
lepair wiring
larness or
eplace
lefective maintenance
nonitor module
leplace
tepair wiring
rarness or
eplace
Iefective maintenance
nonitor module
teplace
lamp
1 YES
Is there continuity
between CNL19
(female) (3) and
chassis ground?
1) Turn starting
switch OFF.
2) Disconnect
CNLIS.
ND
Maintenance
CNLIS
monitor
Main monitor
CNLOG
TDW00324
20-3
0
14
K-10
TROUBLESHOOTING
K-IO
*
*
Ir
Cause
Disconnection in wiring
harness of lamp holder
1 YES
Is voltage
between CNL.21
(female) (1) and
(2) normal?
1)20-30V
2) Disconnect
CNL21.
3) Turn starting
switch ON.
4) Turn lamp
switch ON.
ON
inserted.
Remedy
Reolace
Defective contact, or
Repair wiring
disconnection in wiring
,harness or
harness between CNL21
replace
(female) (1) and CNFSZ (51
NO
Fuse box
Lighting
CNL21
CNFS2
+24V
CNL02
f
Lamp switch
-3
c
TDWO0326
20-3 15
0
K-l 1
TROUBLESHOOTING
K-II
Ir
f
Cause
Is voltage between
YES CNFSP (female) (4)
7
and chassis
ground normal?
1p
1)OV
2) Disconnect
_
CNFS2.
3) Turn lamp
switch OFF.
4) Turn starting
switch ON.
1) Turn starting
switch OFF.
2) Disconnect
CNLOP.
3) Check that
continuity
between CNLO2
(male) (1) and
(5) is as shown
in table below
when lamp
switch is turned
ON-OFF.
NO
NO
inserted.
Remedy
Repair wiring
harness or
replace
Repair wiring
harness or
replace
Replace
Fuse box
Lighting
CNL21
CNFS2
+24V
yL,z,
LaBh
CNLR5
77%
TDW00326
20-3 16
0
K-12, K-13
TROUBLESHOOTING
K-12
*
*
inserted.
Cause
YES
between CNL22
(female) (2) and
YE
1)20-30V
2) Start engine.
3) Disconnect
CNL22.
2
Is voltage between
alternator terminal
h 3
4 R and chassis
ground normal?
WP
switch OFF.
2) Disconnect
CNL22.
1)20-30V
2) Start engine.
K-13
*
*
NO
Replace
Defective contact, or
disconnection in wiring
harness between CNL22
(female) (21- CNLR4 (6) CNERl (9) -alternator
terminal R
Repair wiring
harness or
replace
Defective contact, or
disconnection in wiring
harness between CNL22
(female) (1) - CNLRB (2) chassis ground
Repair wiring
harness or
replace
Defective alternator
Replace
r
1 YES
Is voltage
between CNL22
(female) (2) and
(1) normal?
l)O-4v
2) Turn starting
switch ON.
3) Disconnect
CNL22.
NO
Cause
inserted.
Remedy
Replace
Defective alternator, or
contact of wiring harness
between CNL22 (female)
(2) - CNLRI (6) - CNERl
(9) alternator terminal R
with +24V
Replace
alternator, or
repair, replace
wiring harness
Starting
motor
Service meter
Alternator
TDW00328
20-3 17
a
K-14
TROUBLESHOOTING
K-14
*
*
Abnormality
in gauge items
inserted.
(1)
3 YES
BHP
1) Disconnect
CNR07.
2) Connect short
3) Turn starting
switch ON.
1) Turn starting
switch OFF.
2) Disconnect
CNR07.
1) Turn starting
switch OFF.
2) Connect short
connector to
CNR07 (female).
31 Disconnect
CNL18.
ND
Replace
Defective maintenance
monitor module
Replace
Defective contact, or
disconnection in wiring
harness between CNR07
(female) (1) - CNLR4 (10) CNLlS (female) (6)
Repair wiring
harness or
replace
Defective contact, or
disconnection in wiring
harness between CNR07
(female) (2) and chassis
ground
Repair wiring
harness or
replace
1
Do all display
areas on fuel
gauge go out?
2 YES
_
1) Disconnect
CNR07.
2) Turn starting
switch ON.
Is there continuity
L between CNR07
NO (female) (I) and
chassis ground?
1) Turn starting
switch OFF.
2) Disconnect
CNRO7.
NO
Repair wiring
harness or
replace
Defective maintenance
monitor module
Replace
Fuel sensor
CNLR4
CNR07
3
.a
20-3
0
18
TROUBLESHOOTING
(b1 AbnormaMy
(I)
K-14
in engine water
Nothing
is displayed
temperature
in the display
gauge
Remedy
area
C)efective engine water
t emperature sensor
YES
1
Does engine water
temperature gauge _
display minimum
level?
1) Disconnect
CNEOG.
2) Turn starting
switch ON.
l-
Cause
2 YES
Is there continuity
L between CNEO6
NO (female) (1) and
chassis ground?
IIefective maintenance
I nonitor
1) Turn starting
switch OFF.
2) Disconnect
CNEOG.
module
Fteplace
I
Fqepair wiring
tlarness or
*eplace
FIeplace
FXeplace
B
k
5
Do all display
areas on engine
water temperature
gauge go out?
3 YES
Is there continuity
YES between CNL18
(female) (4) and
2
chassis ground?
1) Disconnect
Is there continuity
CNEOG.
1) Turn starting
2) Connect short
- between CNEOG switch OFF.
NO
(female)
(2)
and
connector to
2) Connect short
chassis
ground?
CNEOG (female).
connector to
3) Turn starting
1) Turn starting
CNEOG (female).
switch ON.
switch OFF.
3) Disconnect
2) Disconnect
CNLIS.
CNEOG.
NO
CNLR4
CNERI
IIefective maintenance
nconitor module
P
NO
CNEOG
fqeplace
cjefective contact, or
dlisconnection in wiring
_h larness between CNEOG
(1female) (1) - CNERl (6) C:NLRQ (1) - CNL16
(.female) (4)
Rlepair wiring
h arness or
nsolace
f Iefective contact, or
Clisconnetiion in wiring
-i- larness between CNEOG
t Female) (2) - CNERl (7) C:hassis ground
Alepair wiring
hiarness or
rleplace
Water
temperature
sensor
.$J
3
TDWOO330
20-319
0
K-14
TROUBLESHOOTING
(c) Abnormality
(II
Cause
Remedy
switch ON.
1) Turn starting
switch OFF.
2) Disconnect
CNT07.
NO
Reolace
Repair wiring
harness or
replace
Defective maintenance
monitor module
Replace
I
I
Is there continuity
YES between CNLl8
(female) (5) and
2
chassis ground?
1) Disconnect
Is there continuity
CNT07.
1) Turn starting
2) Connect short
_ between CNT07
switch OFF.
NO
(female)
(2)
and
connector to
21 Connect short
chassis ground?
CNT07 (female).
connector to
3) Turn starting
1) Turn starting
CNT07 (female)
switch ON.
switch OFF.
3) Disconnect
2) Disconnect
CNL18.
CNT07.
NO
3 YES
NO
CNTL2
@:a:-
20-320
0
Defective maintenance
monitor module
Replace
Defective contact, or
disconnection in wiring
harness between CNT07
(female) (1) - CNTU (4) CNL18 (female) (5)
Repair wiring
harness or
replace
Defective contact, or
disconnection in wiring
harness between CNT07
(female) (2) - CNTLZ (5) CNLR4 (12) -chassis
ground
Repair wiring
harness or
replace
CNT07
E- 1
Engine
20-352
(b) Starting
20-356
E- 2
E- 3
E- 4
Parking
Engine
20-358
Engine
stops when
20-358
machine
parking
(b) Parking
brake is applied
E- 6
Parking
brake is released
E- 7
Transmission
E- 8
Transmission
when
when
is traveling
starting
switch
to neutral
normally
when
is turned
on.. .......................
20-359
............................................................
20-360
is turned ON ............................................
.20-362
...................................................................................
20-364
20-366
(c) Problem
20-367
20-367
Contact
(g) Contact
20-368
20-370
20-372
in FORWARD
Problem
(j)
Problem
in common
circuit (REVERSE
parking
is normal) .......................................................
20-374
is normal) .......................................................
20-376
and REVERSE
circuit .............................................................................................
in common
Kick-down
in position)(self-holding
operation
kick-down
function))
cannot
switch is ON (Kick-down
..............................................................
be canceled..
switch
.............................................................................
directional
even when
by mistake
when traveling
20-388
F to N or R .......................
4th) ......................................................................................................................
switch is actuated
20-386
even when
(becomes
20-382
20-384
Kick-down
20-380
Kick-down
Kick-down
-20-378
(m) Problem
20-366
(h) Problem
Contact
(i)
(I)
(always
20-362
(b) Problem
(f)
20-359
in common
(e) Contact
E-12
machine
brake switch
20-359
(a) Problem
(d) Problem
E-II
..............................................................................
(a) Parking
Parking
E-10
is traveling..
E- 5
E- 9
20-352
(a) Starting
in 2nd .......................................
20-388
20-390
.20-392
20-351
0
...
E-l
TROUBLESHOOTING
E-l
*
*
*
YES
Is voltage between
starting motor
terminal (B) and
;I
1) Turn starting
switch ON.
1) Turn starting
switch ON.
2) Check voltage
between chassis
and both
terminals
connected by
thick cable.
6
I Is vottaae 20 - 3ov
YE
~~!iiizJzpl
1) Turn starting
switch OFF.
1) Turn starting
switch ON.
1
between CNE13
(female) (I) and
chassis 20 - 30 V?
20-352
0
1) Starting switch
ON -OFF.
1) Disconnect
CNE13.
2) Directional
lever: Neutral
3) Turn starting
switch to
START.
N0
Go to A on next page
TROUBLESHOOTING
E-l
Cause
Remedy
After inspectior
repair or replac
* If answer
is NO for both
terminals: Defective
contact or disconnection
in wiring harness
between battery and
battery relay
- If answer is NO for one
terminal: Defective
battery relay
Defective battery relay
YES
0-l
a
2
1
7
Is voltage between
starting switch
terminal BR and
chassis 20 - 30 V?
1) Turn starting
switch ON.
j
NO
After inspection
repair or replac
Replace
Replace
Defective contact, or
disconnection in wiring
harness between starting
switch terminal BR - CNLOS
(2) - CNLR4 (9) - CNR03
After inspectior
Idiode) - CNRl2 (female),
repair or replac
or defective contact, or
disconnection in wiring
harness between CNRl3
and chassis ground
Defective starting switch
Defective contact, or
disconnection in starting
motor ground cable
After inspectior
repair or replac
20-353
0
E-l
TROUBLESHOOTING
YEiS
1) Disconnect
CNL57.
2) Turn starting
switch to
START.
1) Replace neutral
relay fCNL57)
with stop lamp
relay (CNL53).
2) Directional lever:
Neutral
3) Turn starting
switch to START.
YES
:E~ZZZg&bZejj
Is voltage between
-I
L starting switch
NC terminal B and
chassis 20 - 30 V?
1) Turn starting
switch OFF.
NO
1) Turn starting
switch to
START.
YES
YE
EHP
1) Disconnect
CNL57.
2) Directional lever:
Neutral
3) Turn starting
switch to START.
1) Connect Tadapter to
CNL04.
2) Directional lever:
Neutral
3) Turn starting
switch ON.
Is voltage
YE S between CNL04
(female) (1) and
chassis 20 - 30 V?
6
, Is there continuity
1) Disconnect
CNL04.
2) Turn starting
switch ON.
1) Turn starting
switch OFF.
2) Disconnect
CNL57.
20-354
0
NO
YES
FH-IZ-J
1) Starting switch
ON *OFF.
NO
page
E-l
TROUBLESHOOTING
Remedy
Cause
Replace
Defective contact, or
disconnection in wirina
harness between CNL57
(female) (3) - CNLR4 (8) CNROl, 02 {diode) - CNERl
(10) - CNE13 (female) (1)
Aher inspection,
repair or replace
I,
,I
After inspection
/ repair or replace/
1CNR17 - slow blow fuse
30A - battery relay
Defective contact, or
disconnection in wiring
harness between CNL04
(female) (3) and CNL57
I (female) (1 I
1 DzD;;;ive directional lever /
After inspection,
repair or replace
Replace
I
YES
jg1
.\
Amf$~~r$,~~e
7____
2) Check voltage
between chassis
ana both
terminals
connected by
thick cable.
Defective contact, or
disconnection in wiring
harness between battery
relay-slow
blow fuse 80A
-CNR15-CNLRG(l)CNFSl (2) -fuse - CNFSZ
(8) - CNL04 (female) (1)
NO
Defective contact, or
disconnection in wiring
harness between CNL57
(female) (2) and chassis
After inspection,
repair or replace
20-355
0
E-l
TROUBLESHOOTING
(b) Starting
motor
turns
YES
1) Connect Tadapter to
CNE03.
2) Turn starting
switch ON.
1) Turn starting
switch ON *
OFF and check
visually.
between CNEOB
1) Turn starting
switch OFF.
2) Disconnect
CNE03.
between CNL62
1
1) Disconnect
2) Turn starting
switch ON.
20-356
0
YES
1) Turn starting
switch OFF.
2) Disconnect
CNL62.
1
NO
TROUBLESHOOTING
E-l
Cause
Remedy
Defective adjustment of
wire between engine stop
motor and lever
Adjust
1chassis ground
Defective engine stop
relay
YES
I
I
Replace
I Replace
I
between CNE03
(female) (5) and
1) Disconnect
CNE03.
2) Turn starting
switch ON.
NO
Defective contact, or
disconnection in wiring
harness between CNEOB
(female) (5) - CNERP (3) _ CNLR3 (5) - CNL62 (female)
(5). or between CNE03
(female) (7) - CNER2 (4) CNLRB (6) - CNL62 (female)
(3)
Defective contact, or
disconnection in wiring
harness between CNL62
(female) (2) and chassis
ground
After inspeck
repair or replac
Defective contact, or
disconnection in wiring
harness between CNL62
(female) (1) and CNLOS
(female) (2)
After inspectiol
repair or replan
m{
A$~~pr~t~~~
After inspectior
repair or replac
(female) (4)
20-357
0
E-2, E3
TROUBLESHOOTING
*
*
Cause
YES
Remedy
Defective adjustment
jetween engine stop
notor and stop lever
\djust
teplace
>efective contact, or
fisconnection in wiring
tarness between CNE03
female) (3) - CNERZ (2) :NLR3 (4) - CNL62
female), or between
:NL62 (female) (3) :NLR3 (6) - CNERZ (4) 3NE03 (female)
7), or defective relay
CNL62)
Wter inspection
epair or replacc
1L
.Il
motor work?
-1
1) Turn starting
switch ON c--(
OFF and check
visually.
YES
Is voltage
between CNEOB
NO (7) and (8) 20 - 30
V?
1) Connect
T-adapter to
CNE03 (engine
stop motor
connector) 18
pin).
2) Turn starting
switch OFF.
<ES
3
Is voltage
between CNE03
NO (3) and (8) 20 - 30
V?
Iefective
notor
1) Connect
T-adapter to
CNE03.
2) Turn starting
switch OFF.
Is voltage
between CNE03
) (4) and (8) 20 - 30
V?
i_-_t
1) Connect
T-adapter to
CNE03.
engine stop
3efective contact, or
disconnection in wiring
qarness between CNE03
:female) (4) - CNERZ (2) CNLR3 (3) - CNFSZ
:female) (11). or blown
fuse
Vter inspectior
.epair or replac
Defective adjustment
between engine stop
motor and stop lever
4diust
2
Doesv&age between
CNEOBi-7,and (8)
No z%ygr
1) Connect
T-adapter to
CNEOB.
2) Turn starting
switch ON ~1
OFF.
20-358
0
YES
1) Turn starting
switch ON ~1
OFF and check
visually.
_
i
~0
YES
Is voltage between
CNL62 (female) (21
and (female) (1) 20
-3OV?
1) Disconnect
CNL62 (engine
stop relay).
2) Turn starting
switch ON.
NO
After inspectior
repair or replac
E-4
TROUBLESHOOTING
Ir
*
*
Cause
Remedy
ON (parking)
YES
1
Is problem
removed when
CNLOI is
disconnected?
YES
2
leplace
dter inspectior
epair or replac
leplace
Uter inspectior
epair or repiac
Iefective emergency
xake switch CNR21
leplace
Iefective emergency
Drake switch CNR22
teplace
seplace
1) Disconnect
(Charge brake
oil pressure)
1) Disconnect
2) Turn starting
switch OFF.
31 Disconnect
CNL58.
4) Disconnect
CNL59.
1) Connect
T-adapter to
CNTOS.
2) Start engine.
(Charge brake oil
pressure)
3) Turn parking
brake switch ON.
NO
as emergency
brake)
YES
1
gijFjg,
..
1 Is problem
I) Turn starting
ND
switch ON.
2) Turn parking
brake switch ON
- OFF.
..
YES
removed when
CNR22 is
disconnected?
1) Turn starting
switch ON.
2) Turn parking
brake switch ON
- OFF.
ND
20-359
a
TROUBLESHOOTING
E-5
when
machine
is traveling
NO
1) Disconnect
CNT05.
2) Turn starting
switch OFF.
YES
removed when
relay is replaced?
between CNTOB
(female) (1) and
chassis 20 - 3OV?
I) Replace parking
brake safety
relay (CNL59)
with stop lamp
relay (CNL53).
2) Start engine.
(Charge brake oil
pressure)
1) Connect
T-adapter to
CNTOS.
2) Start engine.
(Charge brake
oil pressure)
removed when
short connector is
1) Connect short
connector to
CNR20 (female)
and CNR21
(female).
2) Start engine.
(Charge brake
oil oressure)
3
Is continuity of
CNLOl (male)
(1 )(Z)(3) as shown
in Table l?
1) Disconnect
CNLOl.
2) Turn starting
switch OFF.
3) Operate parking
brake switch
ON/OFF.
\ iS
-
YI
I;;yaleI
6
Is voltage
between CNL59
(female) (5) and
1) Disconnect
2) Turn starting
switch ON.
Table
Operation
ON (parking)
No continuity
OFF (travel)
Continuity
20-360
0
continuity
!l! and
1) Disconnect
CNL59.
2) Turn starting
switch OFF.
lo
TROUBLESHOOTING
E-5
Cause
Remedy
YES
11
Is voltage
YES between CNR20
(female) (1) and
chassis 20 - 30 VI
10
p
1) FiD2;nect
NO
y
Is voltage
YES between CNR21
(female) (1) and
chassis
20
30
V?
9
p
Is there continuity
YES between CNL59
(female) (2) and
8
chassis?
1) Disconnect
CNL59.
2) Turn starting
switch OFF.
between CNL59
(female) (1) and
chassis 20 - 30 V?
1) Disconnect
CNL59.
2) Turn starting
switch ON.
3) Turn parking
brake switch
ON.
RIO
1) Disconnect
-
CNRPl.
2) Turn starting
switch ON.
3) Turn parking
brake switch ON
+ OFF.
NO
2) Turn starting
switch ON.
3) Turn parking
brake switch ON
* OFF.
NO
Defective contact, or
disconnection in wiring
harness between CNTOS
(female) (2) and chassis
After inspectio
repair or replan
Replace
Defective emergency
brake switch
Replace
Defective contact, or
disconnection in wiring
harness between CNR20
(female) (2) and CNT05
(female) (I)
Mter inspectio
repair or replan
Defective contact, or
disconnection in wiring
harness between CNRPl
(female) (2) and CNR20
(female) (1)
4fter inspectio
vepair or replan
Defective contact, or
disconnection in wiring
harness between CNR21
(female) (1) and CNLOl
(female) (2)
4fter inspectio
pepair or replan
Defective contact, or
disconnection in wiring
harness between CNL59
(female) (2) and chassis
Wter inspectio
,epair or replan
Defective contact, or
disconnection in wiring
harness between CNL59
(female) (1) and CNLOl
[female) (3). or between
FS2 (female) (7) and LO1
[female) (1)
Wter inspectio
.epair or replac
Defective contact, or
disconnection in wiring
harness between CNl59
:l) and CNL59 (3)
4fter inspectio;
.epair or replac
>efective contact, or
jisconnection in wiring
iarness between CNL59
female) (5) - CNFSL (7) use
4her inspectiol
,epair or replac
leplace
20-36 1
a
E-6, E-7
TROUBLESHOOTING
switch is turned
ON
Remedy
Cause
YES
removed when
relay is replaced?
1) Replace parking
safety relay
(CNL59) with
h
stop lamp relay
(CNL53).
2) Start enaine.
(Charge-brake
oil pressure)
3) Turn starting
switch ON.
2) Start engine.
(Charge brake
oil pressure)
3) Turn starting
switch ON.
1) Disconnect
CNL59.
2) Turn starting
switch OFF.
3) Turn parking
brake switch
OFF.
NO
20-362
0
<eDlace
leplace
Uter inspectior
,epair or replao
Wter inspectior
.epair or repiac
Abnormal contact of
viring harness between
:NL58 (female) (5) :NL12 (female) (11, CNLG!
female) (31, or between
:NL12 (female) (2) :NL65 (female) (5). CNLGI
female) (1). CNL67
female) (1)
vith +24V wiring harness
Wter inspectior
repair or replac
Iefective
neutralizer
relay
E-8
TROUBLESHOOTING
E-8 Transmission
*
*
f
+
Cause
If condition is as shown in
Table 2 - 1 (transmission is
always in 2nd)
Remedy
Problem in common
:ircuit for transmission
ioto E-S(a)
;oto E-S(b)
io to E-S(c)
;o to E-S(d)
Contact in H - L circuit
;o to E-S(e)
50 to E-S(f)
;o to E-S(g)
Problem in FORWARD
circuit
20 to E-S(h)
Problem in REVERSE
circuit
Go to E-S(i)
Problem in common
circuit for FORWARD and
REVERSE
Go to E-S(j)
Contact in FORWARD
circuit
Go to E-S(k)
Contact in REVERSE
circuit
Go to E-S(l)
Problem in common
circuit for FORWARD and
REVERSE
Go to E-S(m)
If condition is as shown in
If condition is as shown in
2
l;;;fe;W
and
1) Disconnect
CNTOJ and
CNTOI.
2) Turn starting
switch ON.
3) Turn parking
switch ON OFF.
4) Operate speed
lever with
directional lever
at FORWARD,
NEUTRAL, and
REVERSE to
Travels in only
check condition.
FORWARDor
3
REVERSE,or
does not travel ~),a,_..
___
CL voltage
in either
between (:NTOl (1)
1) Start engine.
2) Turn parking
switch ON +
OFF.
3) Operate
directional lever
FORWARD *
REVERSE.
is
as shown in
If condition
is as shown
Table 2 - 8
fi.jsyt
.x
(lfx;$t?,n
in
If condition
is as shown in
Table 3 or Table 4 - 1
(REVERSE is normal)
I r
direction.
-l(I)
(female) and
1chassis.
I
If condition is as shown in
Table 4 - 5 (FORWARD is
1) Disconnect
CNTOl and
CNT02-.
If condition is as shown in
2) Turn starting
Table 4 - 6 (does not travel
switch ON.
3) Turn parking
switch ON OFF.
4) Operate directional lever with speed lever in
all positions (1st to 4th) to check condition.
Go
20-364
0
to
applicable
item.
E-8
TROUBLESHOOTING
Cause
1
Is voltage between
CNL04 (5)(6)(7)(8)
and chassis as
shown in fable?
Remedy
YES
_
NO
1) Connect
T-adapter to
CNL04.
2) Turn starting switch ON.
3) Shift speed lever and check.
Replace
. : 20 - 30 v
0:
0 - 0.5 v
Between
CN04(5)
Between
- chassis
CN04(6)
- chassis
Between
CN04(7) - chassis
Between
CN04(8) - chassis
I
YES
ES
between CNT03
(female) (2) and
1) Disconnect
CNT03.
2) Turn starting
switch OFF.
1) Disconnect
CNTOB.
2) Turn starting
switch ON.
3) Speed lever: 3rd
20-366
0
YES
Is voltage
between CNL04
NO (7) and chassis 20
- 3OV?
1 I Connect
T-adapter to
CNL04.
2) Turn starting
switch ON.
3) Speed lever: 3rd
NO
Cause
Remedy
Defective H - L solenoid
Defective contact, or
disconnection in wiring
harness between CNL04
(female) (7) - CNTLl (5) CNTOB (female) (1)
Wer inspection,
,epair or replace
Defective contact, or
disconnection in wiring
harness between CNTO3
(female) (2) and chassis
ground
Wter inspection
.epair
E-8
TROUBLESHOOTING
(c! Prcblem
in speed circuit
Cause
YES
2
Is voltage
I
1
Is there continuity
between CNT04
(female) 12) and
11Disconnect
CNT04.
2) Turn starting
switch OFF.
(d) Problem
3
Is voltage
_
between CNL04
_
NO (5) and chassis 20
- 30 V?
NO
1) Connect
T-adapter to CNLOL.
2) Turn starting switch ON.
3) Speed lever: 1st
NO
YES
between CNL04
(8) and chassis
around 20 - 3OV?
1) Connect
T-adapter to
CNLOO.
2) Turn starting
switch ON.
3) Speed lever: 4th
NO
YES
Remedy
leplace
Iefective contact, or
lisconnection in wiring
rarness between CNL04
female) (5) - CNTLl (6) :NT04 (female) (1)
kfter inspectior
epair or replac
teplace
Iefective contact, or
lisconnection in wiring
tarness between CNT04
female) (2) and chassis
ground
Kter inspection
epair or replac
4th)
lefective contact, or
fisconnection in wiring
tarness between CNL04
Mer inspectior
female) (8) - CN37 epair or replac
:NTLl (male) (6) or CNLOg4
female) (8) - CN38 :NTLl (male) (5)
Defective speed lever
rwitch
Ieplace
20-367
0
TROUBLESHOOTING
E-8
YES
1
between CNT03
(female) (1) and
chassis 20 - 30 V?
YES
1) Disconnect
CNT03.
2) Disconnect
CNTLl
3) Turn starting
switch ON.
Is there continuity
between CNTLI
I) Turn starting
switch OFF.
2) Disconnect
CNTOS.
3) Disconnect
CNTLl.
YES
ts voltage
between CNTLl
(male) (5) and
I
chassis 20 - 30 V?
YES
1) Disconnect
CNTLl.
2) Disconnect
CNLD4.
3) Turn starting
switch ON.
1) Turn starting
switch OFF.
2) Disconnect
CNTLl .
3) Disconnect
CNL04.
1
YES
NO
Is there continuity
between CNL04
(female) (7) and
(lKZH3)(4)(6)?
I) Turn starting
switch OFF.
2) Disconnect
CNTLI.
3) Disconnect
CNL64.
4) Disconnect
CNL66.
20-368
0
NO
E-8
TROUBLESHOOTING
Cause
Remedy
Abnormal contact of
wiring harness between
CNTOB (female) (1) and
CNTLl (female) (5) with
+24V wiring harness
After inspectior
,epair or replac
After inspectior
,epair or replac
Mer inspection
epair or replao
Uter inspection
epair or replace
ifter inspection
epair or replace
/-mission
20-369
0
TROUBLESHOOTING
E-8
YES
1) Disconnect
CNTOA
2) Disconnect
CNTLI.
3) Turn starting
switch ON.
YES
between CNTLI
1) Turn starting
switch OFF.
2) Disconnect
CNT04.
3) Disconnect
CNTLl .
between CNTLl
1) Disconnect
CNTLI.
2) Disconnect
CNL68.
3) Disconnect
CNL04.
4) Turn starting
switch ON.
Is there continuity
between CNTLl
N
1) Turn starting
switch OFF.
2) Disconnect
CNTLl.
3) Disconnect
CNL68.
4) Disconnect
CNL04.
YES
57
Is there continuity
between CNL04
1) Turn starting
switch OFF.
2) Disconnect
CNTLl.
3) Disconnect
CNL68.
4) Disconnect
CNLOI.
5) Disconnect
CNL66.
20-370
0
NO
TROUBLESHOOTING
E-8
Cause
Abnormal contact of
wiring harness between
CNT04 (female) (1) and
CNTLl (female) (6) with
+24V wiring harness
Remedv
4fter inspectior
spair or replac
Wter inspectior
,epair or replac,
Uter inspection
epair or replacl
After inspection
epair or replace
Defective transmission
controi switch, or
abnormal contact of
CNL68 (3)(4) (male)
Mter inspectior
repair or replac
20-371
0
E-8
TROUBLESHOOTING
1
between CNL04
(female) (8) and
chassis 20 - 3OV?
1) Disconnect
CNL04.
2) Turn starting
switch ON.
20-372
0
YES
I
No
Remedy
Abnormal contact of
CNL04 (female) (8) - CN37
(female) (2), CN38 (female:
(2) with +24V wiring
harness
\Rer inspection
epair or replao
?eplace
TROUBLESHOOTING
E-8
2 YES
YESKzKGzl
between CNTOl
(female) (2) and
chassis?
1Is voltage
NO
1) Disconnect
CNTOl.
2) Turn starting
switch OFF.
YES
between CNTOI
(female) (1) and
chassis 20 - 3OV7
1) Disconnect
CNTOl.
2) Turn starting
switch ON.
3) Turn parking
switch ON +
OFF.
4) Directional
lever:
FORWARD
20-374
0
7 YES
YE
1::--,..
relay is replaced?
1 t Replace
FORWARD
solenoid relay
(CNL66) with
REVERSE
solenoid relay
(CNL67).
2) Start engine.
3) Turn parking
switch ON +
OFF.
4) Directional
lever:
FORWARD
6
YE
between CNL66
(female) (6) and
5
YE
4
between CNL66
2) Turn starting
switch ON.
3) Turn parking
switch ON -+
OFF.
between CNL66
(female) (2) and
1) Disconnect
CNL66.
2) Turn starting
switch OFF.
NO
1) Disconnect
CNL66.
2) Turn starting
switch OFF.
JO
NO
1) Disconnect
CNL66.
2) Turn starting
switch ON.
3) Directional
lever: FORWARD
JO
E-8
TROUBLESHOOTiNG
Remedy
Cause
Defective contact, or
Ai.zr*nne&Tmq in wirino
After inspection,
repair or replace
la..llllrLl.
Replace
Replace
After inspection,
repair or replace
Replace
After inspection,
repair or replace
Defective contact, or
disconnection in wiring
harness between CNL66
(female) (2) - CNTLI (3) CNTOl (female) (1)
After inspection,
repair Or repace
20-375
0
E-8
TROUBLESHOOTING
(iI
Problem
in REVERSE
circuit (FORWARD
is normal)
2 ,YES
YE
Is there continuity
between CNTOL
(female) (2) and
chassis?
1) Disconnect
CNTOZ.
2) Turn starting
switch OFF.
NO
7 YES
1) Disconnect
CNTOZ.
2) Turn starting
switch ON.
3) Turn parking
switch ON -+
OFF.
h
4) Directional
lever: REVERSE
ES
EH
1) Replace
REVERSE
solenoid relay
(CNL67) with
FORWARD
solenoid relay
(CNL66).
2) Start engine.
31 Turn parking
switch ON +
OFF.
4) Directional
lever: REVERSE
5
YE
4
between CNL67
(female) (1) and
I) Disconnect
2) Turn starting
switch ON.
3) Turn parking
switch ON *
OFF.
20-376
0
1) Disconnect
CNL67.
2) Turn starting
switch ON.
3) Directional
lever: REVERSE
Is there continuity
YE S between CNL67
removed when
NO
between CNL67
(female) (2) and
1) Disconnect
CNL67.
2) Turn starting
switch OFF.
1) Disconnect
CNL67.
2) Turn starting
switch OFF.
IUO
NO
i
N0
TROUBLESHOOTING
E-8
Cause
Remedy
Defective contact, or
disconnection in wiring
harness between CNT02
(female) (2) and chassis
I Defective
rve
contact, or
directional
After inspection,
repair or replace
lever
Defective contact, or
disconnection in wiring
harness between CNL67
(female) (6) and chassis
Defective contact, or
disconnection in wiring
harness between CNL67
(female) (2) - CNTLl (4) CNTO2 (female) (1)
Defective contact, or
disconnection in wiring
harness between CNL66
(female) (1) and CNL67
(female) (1)
Replace
After inspection,
repair or replace
After inspection,
repair Or repace
After inspection,
repair or replace
20-377
0
E-8
TROUBLESHOOTING
(j)
YES
YEiS
Is voltaoe
3YES
I I
T-adapter to
CNL04.
2) Turn starting
switch ON.
3) Directional
lever:FdN-rR
NL04
NO (female) (1) and
chassis 20 - 30 V?
1) Disconnect
CNLOL.
2) Turn starting
switch ON.
11
YE
1) Disconnect
CNL66.
2) Turn starting
switch ON.
3) Turn parking
brake switch ON
+ OFF.
turned OFF?
when shonconnector
is connectedinstead
of transmissioncut-off
1) Connect short
connector to
CNLl2 (female).
2) Start engine.
3) Turn
transmission
cut-off selector
switch ON.
NO
YES
11Start engine.
6
Is voltage
1 I Replace
neutralizer relay
(CNL58) with
stop lamp relay
(CNL53).
2) Start engine.
YE
between CN L58
1) Disconnect
CNL58.
2) Turn starting
switch ON.
3) Turn parking
brake switch ON
+ OFF.
l : 20 - 30 v
0 - 0.5 v
0:
20-378
0
Between
CN04(2) - chassis
Between
CN04(4) - chassis
Is there continuity
between CNL58
_
(female) (2) and
chassis?
1) Disconnect
CNL58.
2) Turn starting
switch OFF.
NO
TROUBLESHOOTING
E-8
Remedy
/ DzI;;ive
directional lever
Replace
Defective contact, or
disconnection in wiring
,.......,_
....._..
_...
-..
After inspection
repair or replac
Replace
Defective contact, or
disconnection in wiring
harness between CNL65
(female) (3) and CNL12
(female) (1). or between
CNLIP (female) (2) and
CNL65 (female) (5)
After inspectioc
repair or replac
Replace
Defective contact, or
disconnection in wiring
harness between CNL58
(female) (5) and CNLlZ
(female) (1). or between
CNL12 (female) (2) CNL66 (female) (1). CNL67
(female) (1)
After inspectior
repair or replac
Defective contact, or
disconnection in wiring
harness between CNL58
(female) (3) - CNFS2 (8) fuse - CNFSl (male) (21
After inspectior
repair or replac
After inspectior
repair or replac
Defective contact, or
disconnection in wiring
harness between CNL58
(female) (1) and CNLOl
(female) (2)
After inspectior
repair or replac
20-379
a
TROUBLESHOOTING
E-8
YI
removed when
relay is replaced?
1) Replace
FORWARD relay
(CNL66) with F
working lamp
relay (CNLGO). h
2) Start engine.
3) Turn parking
brake switch ON
+ OFF.
4) Directional
lever:
FORWARD
2
YES
between CNTOl
(female) (1) and
chassis 20 - 30 V?
11 Disconnect
CNTOl.
2) Disconnect
CNTLl .
3) Turn starting
switch ON.
h
ES
between CNTLl
(female) (3) and
1) Turn starting
switch OFF.
2) Disconnect
CNTOl.
3) Disconnect
CNTLl.
ES
between CNTLl
1) Disconnect
CNTLl.
2) Disconnect
CNL66.
3) Turn starting
switch ON.
between CNTLl
1) Turn starting
switch OFF.
21 Disconnect
CNTLl.
31 Disconnect
CNL66.
YES
I
I
between CNL04
(l)(3)(4)(5)(6)(7)(8)?
1) Turn starting
switch OFF.
2) Disconnect
CNL66.
3) Disconnect
CNL04.
20-380
0
L
NO
E-8
TROUBLESHOOTING
Cause
Remedy
Replace
After inspection
repair or replace
After inspection
repair or replace
After inspection
repair or replace
After inspection
repair or replace
1ljlg?oY~~~~;~~Ye
CNL04 (female) (4)CNL67
(female) (5). CNL04 (female)
(5) - CNTLl (male) (6),
CNL04 (female) (6) - CNL66
(female) (31, CNL04 (female)
(7) - CNTLl (male) (5).
CNL04 (female) (6) - CN37
(2) or CN36 (2)
rmission
Aher inspectior
I repair
Or replac
Replace
20-38 1
0
TROUBLESHOOTING
(I)
E-8
1
Is problem
removed when
relay is replaced?
1) Replace
REVERSE relay
(CNL67) with F
working lamp
_
relay (CNLGOL NO
21 Start engine.
3) Turn parking
brake switch ON
- OFF.
4) Directional
lever: REVERSE
2
Is voltage
between CNTOS
(female) (1) and
chassis 20 - 30 V?
I) Disconnect
CNTOS.
21 Disconnect
CNTLl.
3) Turn starting
switch ON.
Is there continuity
between CNTLI
Y ES
h
1) Turn starting
switch OFF.
2) Disconnect
CNT02.
3) Disconnect
CNTLl.
between CNTLl
I
chassis 20 - 30 V?
1) Disconnect
CNTLl.
2) Disconnect
CNL67.
_
3) Turn starting
switch ON.
5
Is there continuity
between CNTLI
NO (male) (4) and
(3)(51(6)?
I
1) Turn starting
switch OFF.
2) Disconnect
CNTLl .
3) Disconnect
CNL67.
YES
between
CNL04
switch OFF.
2) Disconnect
CNL67.
3) Disconnect
CNL04.
20-382
0
NO
TROUBLESHOOTING
E-8
Remedy
Cause
Replace
Abnormal contact of
wiring harness between
CNTOZ (female) (1) and
CNTLl (female) (4) with
+24V wiring harness
After inspection,
repair or replace
After inspection,
repair or replace
Defective transmission
control switch
Replace
20-383
0
E-9
TROUBLESHOOTING
(m)
YES
1
~~~~,-
1) Turn starting
switch OFF.
2) Disconnect
CNLOL.
20-384
0
NO
Cause
Remedy
Jter inspection
apair or replace
&her inspection
epair or replact
befectiue transmission
ontrol switch
Leplace
E-9
TROUBLESHOOTING
Is problem
removed when
relay is replaced?
1) Replace kickdown relay
(CNL68) with
REVERSE
solenoid relay
(CNL67).
2) Start engine.
removed when
1)Replace
1
Is there continuity
between CNL15
1) Disconnect
CNL15.
2) Press kick-down
switch.
3) Turn starting
switch OFF.
YE
FORWARD
solenoid relay
(CNL66) with
REVERSE
solenoid relay
(CNL67).
2) Start engine.
5
YI
(female) (5) and
CNL15 (female) I2)?
4
Is there continuity
between CNL68
1) Disconnect
CNL68.
2) Turn starting
switch OFF.
20-386
0
YES
1) Disconnect
CNL68 and
CNLl5.
2) Turn starting
switch OFF.
JO
between CNLlS
(female) (1) and
CNL66 (female) (4)?
1) Disconnect
CNL15 and
CNL66.
2) Turn starting
switch OFF.
JO
NO
TROUBLESHOOTING
E-9
Cause
s YES
I
Yf
7
between CNL66
(female) (3) and
7) Disconnect
CNL66.
2) Speed lever:
2nd
3) Turn starting
switch ON.
between CNL68
(female) (3) and
1) Disconnect
CNL68.
2) Speed lever:Znd
3) Turn starting
switch ON.
9
I
NO
YES
Is voltage
between CNL04
(6) and chassis 20
- 3OV?
NO
1) Connect
T-adapter to CNL04.
2) Speed lever: 2nd
3) Turn starting switch ON.
Remedy
Replace
Defective FORWARD
solenoid relay
Replace
Defective contact, or
disconnection in wiring
harness between CNL68
(female) (41 and CNL04
(female) (5)
After inspectiol
repair or replac
Defective contact, or
disconnection in wiring
harness between CNL68
(female) (3) and CNL04
(female) (6)
After inspectior
repair or replac
Defective contact, or
disconnection in wiring
harness between CNL66
(female) (3) and CNL04
(female) (6)
After inspectior
repair or replac
Replace
Defective contact, or
disconnection in wiring
harness between CNL15
[female) (1) and CNL66
(female) (4)
After inspectior
repair or replac
Defective contact, or
disconnection in wiring
harness between CNL68
[female) (5) and CNLl5
[female) (2)
Mter inspectior
repair or reptac
Defective contact, or
disconnection in wiring
narness between CNL68
Ifemale) (6) and chassis
ground
After inspectior
,epair or replac
Defective kick-down
switch
Xeplace
20-387
0
E-10, E-l 1
TROUBLESHOOTING
E-10
Ir
When connecting
or disconnecting
the T-adapter (or socket adapter) or short connector to carry
out checks, always turn the starting switch OFF before starting.
When connecting the T-adapter (or socket adapter), connect to the connector specified as CNOLV 1.
After checking, connect the disconnected
connectors and disconnect the T-adapter immediately
to
return to the original condition before going on to the next check.
*
*
1 YES
Is problem
removed when
relay is replaced?
E-11
(a)
NO
Kick-down
Not canceled
operation
even when
directional
Replace
Defective contact, or
disconnection in wiring
harness between CNL66
(female) (4) - CNL68
(female) (1) or CNL68
(female) (2) - CNL68
(female) (5)
After
inspection,
repair or
replace
cannot be canceled
lever is moved
from F to N or R
Cause
1
Is problem
removed
when
relay is replaced?
1) Replace
FORWARD
solenoid
relay
(CNL66)
with
REVERSE
solenoid
relay
(CNL67).
2) Start engine.
20-388
YES
Defective
solenoid
FORWARD
relay
Contact
between
NO
(3) and
of wiring
harness
CNL66
(female)
(4)
Remedy
Replace
After
inspection,
repair
or
replace
E-II
TROUBLESHOOTING
(b) Not canceled even when speed lever is moved from 2nd to other position (becomes 4th)
between CNL04
(female) (1) and
CNL04 (female) W?
11 Turn starting
switch OFF.
2) Disconnect
CNL04.
3) Disconnect
CNL66.
20-390
0
Is there continuity
between CNLD4
r
1) Turn starting
switch OFF.
2) Disconnect
CNL04.
3) Disconnect
CNL66.
F
I
--I
1) Disconnect
CNL66.
2) Disconnect
CNL04.
3) Turn starting
switch ON.
lr
Is Cjitage
L __
oetween CNL66
YES
-hq (-Tale)
(4) and
I
,1=11
chas;sis 20 - 30 V?
L_. _.
I) ursconnect
51
CNL66.
Is voltage
2) Disconnect
\
between CNL68
_
CNL68.
ND (female) 12) and
3) Disconnect
chassis 20 - 30 V?
CNL15.
6
1)
Disconnect
4) Turn starting
Is there continuity
CNL68.
switch ON.
_ between CNL04
2) Disconnect
ND (female) (1) and
CNL15.
CNL04 (female) (5)?
3) Turn starting
1) Turn starting
switch ON.
switch OFF.
2) Disconnect
I
CNL04.
3) Disconnect
CNFTI.
zz
iS
-
j_
2
f
TROUBLESHOOTING
E-l 1
Cause
Remedy
Abnormal contact of
wiring harness between
CNL04 (female) (1) (6)
After inspection,
repair or replace
Abnormal contact of
wiring harness between
CNL04 (female) (2) (6), or
defective speed lever
switch
After inspection,
repair or replace
After inspection,
repair or replace
YES
7
Is voltage
between CNL68
(female) (4) and
chassis 20 - 3OV?
1) Disconnect
CNL68.
2) Disconnect
CNTLl.
3) Disconnect
CNL04.
4) Starting switch
ON.
NO
Abnormal contact of
wiring harness between
CNL6i (female) (4) CNL68 (female) (1). CNL15
(female) (1) with +24V
wiring harness
After inspection,
repair or replace
Abnormal contact of
wiring harness between
CNL68 (female) (2) CNL68 (female) 15), CNL15
(female) (2) with c24V
wiring harness
After inspection,
repair or replace
Abnormal contact of
wiring harness between
CNL04 (female) (1) (5)
After inspection,
repair or replace
Abnormal contact of
wiring harness between
CNLOI (female) (5) CNL68 (female) (4). CN37
(female) (l), CNTLl (male)
(6) with +24V wiring
harness, or defective
speed lever switch
After inspection,
repair or replace
Abnormal contact of
wiring harness between
CNTLl (6) and CNTO4 (1)
with +24V wiring harness
After inspection,
repair or replace
20-391
0
E-12
TROUBLESHOOTING
E-12 Kick-down
*
+
+
switch is actuated
in 2nd
Cause
Defective kick-down
switch
between CNL15
YES
20-392
0
Remedy
qeplace
2
Is there continuity
between CNL66
(male) (1) - (21
and (3) - (4)?
1) Disconnect kick_
down relay
ND
(CNL68).
21 Turn starting
switch OFF.
YES
3
Is there continuity
between CNL15
_
(female) (1) and
CNLl5 (female) l2)?
_
1) Disconnect
NO
CNL15.
2) Turn starting
switch OFF.
3) Directional
lever: N
4 YES
-
Is there continuity
between CNL68
(female) (1) and
CNL68 (female) W?
1) Disconnect
CNL68.
2) Turn starting
switch OFF.
3) Directional
lever: N
NC
Vter inspection
epair or replao
Vter inspection
,epair or replac
Wter inspection
,epair or replaci
POWER TRAIN
Machine
T- 2
T- 3
Excessive
shock when
T- 4
Excessive
T- 5
Torque
STEERING
20-402
T- 1
converter
power
is weak,
machine
starting
or shifting
machine
starting
lacks power
20-404
on slopes ............................
gear.. ..................................................
.20-406
gear ...............................................
.20-407
or shifting
20-408
is high ..............................................................................
oil temperature
SYSTEM
T- 6
Steering
T- 7
Steering
wheel
or there is excessive
20-409
:. .......................................................
is heavy ..................................................
20-410
.20-411
shock.. .........................................................
T- 8
Steering
wheel wobbles
T- 9
Machine
...........................................................................
20-411
T-10
Turning
..........................................................................
.20-411
.20-412
BRAKE SYSTEM
T-II
T-12
20-413
.20-414
T-13
WORK
EQUIPMENT
T-14
-z
J
is slow or boom
T-15
Boom movement
T-16
When
T-17
T-18
Excessive
T-19
T-20
T-21
20-416
height.. ...............................................
.20-417
20-417
20-417
hydraulic
when
control
lever is operated
from
is slow or tilt-back
T-23
Bucket movement
becomes
T-24
operation
...............................................
T-25
Excessive
T-26
T-27
Bucket dumps
T-28
loading
momentarily
20-417
...............................................................................................
operation
T-22
hydraulic
20-415
operation
when
................................................................................
control
lever is operated
20-418
20-419
.20-420
20-421
20-421
20-421
20-422
..................................
.20-423
20-40 1
0
T-l
TROUBLESHOOTING
POWER TRAIN
T-l
Machine
Remedy
20-402
0
TROUBLESHOOTING
T-l
20-403
0
T-2
TROUBLESHOOTING
When
oil temperature
abnormal
Abnormality
in high
idling
Abnormality
in each
stall engine
Torque
converter
pressure
I*
/ Transmission
Metal
particles
speed
0000
is low
in every
transmission
Low
in certain
oil level
range
Cut-off
work
ranges
and fluctuates
violently
20-404
0
valve
does
not cut-off
circuit
illill
chanaes
stuck to transmission
equipment
00
strainer
or torque
converter
filter
13
00000
transmission
is unstable
00
speeds
pressure
Indicator
10
11
Low
relief
converter
Transmission
clutch
from
00
Torque
noise comes
oil overheats
8
_
is low,
even when
is hight
hydraulic
pressure
in
I
0
on
TROUBLESHOOTING
T-2
l//////
Ill I
20-405
0
TROUBLESHOOTING
T-3
T-3
machine
or shifting
gear
B
k
20-406
0
TROUBLESHOOTING
T-4
machine or shifting
gear
00
20-407
0
T-5
TROUBLESHOOTING
oil temperature
is high
No.
oil temgauge
Problems
0
0
0000
1Toraue
-I
0
o
cow
Transmission
clutch pressure
L0W In cenan
10 I Trysnyission
11
20-408
0
00
TROUBLESHOOTING
T-6
STEERING SYSTEM
T-6 Steering
20-409
0
T-7
TROUBLESHOOTING
k
f
0
0
000
20-410
0
0.
equipment
circuit, SO if any
of the work equipment.
TROUBLESHOOTING
Valves
a
bc
Remedy/AA
No. ,1 Problems
1
/a/.
I 0
101
1 0
0
n
T-10
20-411
0
T-l 1
TROUBLESHOOTING
BRAKE SYSTEM
T-11
questions.
start?
broken
appear?
seal, wear
effect is poor
of
11
12
13
20-412
0
000
000
-L
TROUBLESHOOTING
T-12
T-12
or brakes drag
the
un-
No. Problems
1
Brake
When brake pedal is released and oil is bled from air bleeder,
circuit pressure goes down and brake is released
Jack up 4 wheels and set axles on stand. When engine is stopped
and parking brake is released, certain wheels are heavy when they
20-413
0
T-13
TROUBLESHOOTING
T-13
When emergency
parking brake switch is turned ON, parking brake is not released
In such a case, the probable cause is following.
a. Defective operaction of emergency
parking brake cancel valve
b. Breakage in wiring harness in line for emergency
parking brake cancel switch
c. Insufficient gas pressure in brake accumulator,
damaged
piston seal
20-414
0
T-14
TROUBLESHOOTING
WORK EQUIPMENT
T-14
4
5
Bucket
cannot
be operated
Chassis
can be raised
bucket
can be operated
Boom
when
can be raised
there
boom
but boom
when
there
cannot
but boom
cannot
be raised
cannot
lolololol
be raised,
noise
Excessive
hydraulic
engine
comes
from
hydraulic
drift of boom
I i
I I I
loi
lol
engine
and slow
I loi
loi
be raised
pump
cylinder
I I 101 I
00
0
is running
at full throttle,
steering
operation
is too
is running
at full throttle,
steering
operation
is heavy
When
lol lolol
or
be raised
is a load
Abnormal
When
with
and boom
lever
I I lol
I I I I I
20-4 15
0
TROUBLESHOOTING
T-15
Boom movement
T-15
Bucket tilting power and speed are abnormal and boom lifting
20-416
0
TROUBLESHOOTING
T-16
T-17
movement
is slow
or boom
is slow
or
valve properly
adjusted?
valve
T-19
movement
T-18
Boom
from
20-47 7
0
T-20
TROUBLESHOOTING
T-20
when
control
lever is operated
from
Checking problem
.
When the engine is run at low idling and the boom control lever is operated slowly from HOLD
to RAISE, the boom goes down under its own weight.
When the lever is operated fully to the
RAISE position, the condition returns to normal.
Cause
.
Defective seating of check valve for boom spool in main control valve
20-4 18
0
TROUBLESHOOTING
T-21
T-21
lever
20-419
0
TROUBLESHOOTING
T-22
Bucket movement
T-22
is slow or tilt-back
20-420
0
lacks power
TROUBLESHOOTING
T-23
Bucket movement
becomes
operation
Cause
Swelling or internal damage to bucket cylinder tube
.
For other abnormalities when the bucket is operated, go to T- 22 Bucket
tilt-back lacks power.
l
T-24
movement
is slow or
See 7-22
Bucket movement
is slow
or tilt-back
lacks power.
valve
properly
adjusted?
Cause
.
Defective seating of safety valve (with suction valve) at bucket cylinder
valve
Oil leakage from bucket cylinder piston seal
T-25
Cause
Oil leakage inside bucket cylinder
.
Defective seating of safety valve (with suction valve) at bottom
.
Defective oil tightness of bucket spool
excessive.
end
20-42
0
T-26, T-27
TROUBLESHOOTING
T-26
T-27
operation
linkage
pin, bushing. 7
(Is there
any abnormal
Checking problem
.
When the engine is run at low idling and the bucket control lever is operated
HOLD to TILT, the bucket dumps momentarily
under its own weight.
When
operated fully to the TILT position, the condition returns to normal.
Cause
.
Defective
20-422
0
seating
noise?)
valve
from
slowly from
the lever is
T-28
TROUBLESHOOTING
T-28
Checking
for abnormalities
Check the values in the Standard Value
Table to check if the operating force of
the lever is actually excessive.
Remedy
NO.
Al
I-
xx
Problems
Levers are heavy when there is a load and oil pressure is high
00
00
000
I I I I I I I I I I I
20-423
0
Judgement
D- 1
electrical
20-452
20-453
..............................................................................................
20-454
is displayed
..............................................................................................
20-454
..............................................................................................
20-455
..............................................................................................
20-455
..............................................................................................
(R
No abnormality
display
20-456
is given .......................................................................................
D- 2
D- 3
Output
20-456
20-460
is turned ON
8
z
system . . . .. . . . . . . . . . . . . . . . . . . . .. . . . . .. . . . . .. . . . .. . . .._..............................
5 km/h) (deviates
around
5 km/h) ...................
. ................ .20-461
D- 4
Output
is turned ON when
transmission
is in 1st ................................................................
D- 5
Output
is turned ON when
transmission
is in 4th ................................................................
D- 6
Controller
D- 7
ECSS is abnormal
.20-461
20-462
......................................................................................
20-463
20-463
display .........................
20-451
0
JUDGEMENT
TROUBLESHOOTING
JUDGEMENT
Self-diagnosis
Solenoid
(relief)
system
mode
be
Output is turned
ON but travel
speed, does not
become 5 km/h
(deviates)
rI;;tp,hi;
FOR CONTROLLER
ELECTRICAL
SYSTEM
Error code
Failure
TABLE
table (abnormality
Travel speed
Solenoid
Solenoid
(high pressure) (low pressure) sensor
system
system
system
display)
Model
selection
abnormality
d0
dl
d2
d3
d4
D-l (a)
D-l (b)
D-l (c)
D-l (d)
D-l (e)
Troubleshooting
code when no
abnotmalii
displayisgiven
D-l (f)
D-2
D-3
turned
transmission
1st
is in
D-4
Output is turned
ON when
transmission
is in
4th
D-5
D-6
ECSS is abnormal
but main monitor
does not give
abnormality
display
D-7
20-452
0
TROUBLESHOOTING
D-l
*
*
f
+
D-l
Cause
inserted.
Remedy
Go to Item (a)
Go to Item (b)
2
Which code is
monitor
displaying?
IDisplaying
[d2].
I-
So to Item (c)
Displaying [d31.
50 to Item (d)
Is there en
abnormality
display?
50 to Item (e)
;o to Item (f)
20-453
0
D-l
TROUBLESHOOTING
Cause
YES
Is resistancebetwean
CNALl (female) I211
and chassisground
normal?
P
1) Disconnect
CNALl.
2) DC resistance:
20-40R
YES
21
Is there
betweel
NO (female
chassis
.I\ n:___
I
1) Disconnect
CNAF4.
CNAFC
3) Connect short
connector to
CNAF4 (female).
NO
Remedy
Defective controller
Replace
Defective solenoid
Replace
Disconnection in wiring
harness between CNALl
(female) (21) - CNSAS (4)
- CNAF4 (female) (1)
After inspection
repair or replace
Disconnection in wiring
harness between CNAF4
(female) (2) - CNTLI (8) CNCLl (12) -chassis
ground
After inspection
repair or replace
Defective controller
Replace
Defective solenoid
Replace
Disconnection in wiring
harness between CNALI
(female) (20) - CNSAS (5)
- CNAFS (female) (1)
After inspection
repair or replace
Disconnection in wiring
harness between CNAF5
(female) (2) - CNTLI (8) CNCLl (12) -chassis
ground
After inspection
repair or replacc
is displayed
YES
1
Is resistancebetween
CNALl (female1 (201
and chassis ground
normal?
-m
1) Disconnect
CNALl.
2) DC resistance:
20-40R
2
L between CNALl
NO (female) (20) and
chassis ground?
1) Disconnect
CNALI.
F
2) Disconnect
CNAF5.
3) Connect short
connector to
CNAR (female).
20-454
0
YES
1
CNAF5.
NO
D-l
TROUBLESHOOTING
Remedy
-t Iefective
controller
Replace
-t Defective
solenoid
Replace
1
Is resistancebetween
CNALl
(female) I111
ES
CNALl
2) DC resistance:
20-40R
there continuity
between CNALl
NO (female) (11) and
chassis ground?
Is
IIisconnection in wiring
tlarness between CNALl
(female) (11) - CNSAS (6)
YES
1) Disconnect
CNALl.
h$ (female) (2) and
2) Disconnect
I chassis ground?
1
CNAFG.
1) Disconnect
3) Connect short
CNAFG.
connector to
CNAFG (female).
- CNAFG
i
NO
After inspection
repair or replact
(female) (1)
IIisconnection in wiring
ttarness between CNAFG
-( female) (2) - CNTLl (8) (INCLI (12) -chassis
saround
Mter inspection
pepair or replact
r:
1
Does error
display go off?
2 YES
Is there continuity
between CNAL3
1) co nnect short
NO
4 (female) (4) and
CO!tnector
~~ to
CNTOG (female). -_ fT2)?
2) Turn starting
L
I) Disconnect
switch OFF CNAW.
ON.
2) Connect short
- [Iefective
controller
qeplace
qeplace
connector to
CNTOG (female).
[Iisconnection in wiring
tiarness between CNAL3
I4) - CNSAS (9) or CNAL3
I 12) - CNSAS (10)
After inspection
,epair or replace
If any other
:ontroller is
sbnormal, check
all the wiring
mrnesses
for the
speed sensor
system)
20-455
0
D-l
TROVSLESHOOTING
Id41 is displayed
Cause
2 YES
YES Is.cpntinuity of
- w~rmg harnesses
normal?
NO
1) Disconnect
Is connection of
wiring harnesses
normal?
CNAL2.
2) Is continuity between CNAL2
(female) (1) - (4) and chassis
ground as shown in table?
1) Disconnect
CNAL4.
2) Is continuity
NO
between CNAL4 (female)
(1 j,(2),(3),(5) -chassis ground as
shown in table?
Remedy
Defective controller
leplace
Disconnection in wiring
harness between CNAL2
(female) and CNAL4
(male), or contact with
chassis ground
&her inspectiol
epair or replac
Defective contact, or
disconnection in wiring
harness between CNAL4
(female) and chassis
ground, or contact with
chassis ground
ifter inspectiol
epair or replac
Table
(f)
WA420
No
Yes
No
No
No
Yes
No
NO
WA470
No
Yes
Yes
Yes
No
Yes
Yes
Yes
No abnormality
display is given
(1) Does not work at all
3efective controller
1
Is voltage
between CNALZ
(15) and chassis
ground normal?
2 YES
_
l)O-3v
2) Turn starting
switch ON.
3) Turn main
monitor ECSS
switch ON.
20-456
0
30
Defective main monitor
Is voltage between
L CNLOG (female) (7)
NO snd chassis
ground normal?
1)20-30V
2) Disconnect
CNLOG.
NO
Disconnection in wiring
harness between CNALZ
[female) (15) - CNDPZ (1)
CNLOG (female) (7)
to
troubleshootin!
3f main monitc
After inspectia
repair or repla
TROUBLESHOOTING
D-l
bucket
is loaded
empty
YES
I
Is there continuity
YES between CNA!?
(male) (1) and
(2)?
,
Does controller
LED display 55?
1) Turn starting
switch ON.
2) Disconnect
CNAF7.
3) Empty bucket.
1) Turn starting
switch ON.
2) Empty bucket.
(3) Works
3 YES
Is there continuity
L between CNALZ
NO (female) (8) and
chassis ground?
Does controller
k
zl
1) Turn starting
switch ON.
2) Load bucket.
leplace
Hter inspectior
epair or replac
Defective controller
leolace
Defective chassis
hydraulic system
bucket is empty
ES
Remedy
1) Turn starting
switch OFF.
NO
when
Cause
Defective chassis
hydraulic system
1
2
Is there continuity
between CNAF7
_
NO (male) (1) and
(2)7
1) Turn starting
switch ON.
2) Disconnect
CNAF7.
3) Load bucket.
loaded
NO
NO
Defective controller
leplace
Defective contact, or
disconnection in wiring
harness between CNALZ
(female) (8) - CNSAS (7) CNAF7 (female) (1). or
between CNAF7 (female)
(2) - CNSAS (8) - CNAL4
(4) -chassis ground
dter inspectior
epair or replac
20-457
0
D-l
TROUBLESHOOTING
Solenoid
electric
circuit
diagram
system
CNALI
CNSAS
3
@
----a
@
@
---a
r-hi
CNAFG
CNAF5
I
CNAF4
Solenoid 1
(relief)
t
CNTLI
CNCLI
Solenoid 3
(low
pressure)
Solenoid 2
(high
pressure)
CNSAS
CNALB
CNTL2
Speed (+)
Speed t-1
CNTOG
-3
Speed sensor
TDwuo350
Model selection
system
TOW00904
20-458
0
TROUBLESHOOTING
D-l
CNALI
CNL08
Network (+)
.a
I
1
3
CNAL2
I
Network 6)
-3
CNLOG
I
ECSS operation switch
TDW00352
circuit
CNAL2
diagram
CNSAS
CNAF7
Pressure switch
CNAL4
20-459
0
D-2
TROUBLESHOOTING
Cause
YES
Is voltage
between CNALZ
(15) and chassis
ground normal?
1)20-30V
2) Turn starting
switch ON.
3) Turn main
monitor ECSS
switch OFF.
Remedy
Replace
Defective controller
2 YES
_
Is there continuity
L between CNAL2
NO (female) (15)and
chassis ground?
After inspection,
repair Or repace
Go to
troubleshooting
of main monitor
1) Disconnect
CNALZ.
2) Disconnect
CNLOG.
inserted.
CNDP2
CNALI
Network
(+)
3
I
a
CNAL2
i
Network
a
\
(4
3
a:-
CNLOG
@
ECSS operation
switch
(
TDW00352
20-460
a
TROUBLESHOOTING
D-3, D-4
5 km/h)
Remedy
Cause
2 YES
YES Is monitor speed
Idisplay incorrect?
Is machine model
code normal?
1) Check LED
display code.
2) See
STRUCTURE
AND FUNCTION
for details of the
codes.
I) Start engine.
NO
inserted.
Replace or
adjust
Defective controller
Replace
Go to Troubleshooting
D-l (e)
No
Replace
Defective contact, or
disconnection in wiring
harness between CNALP
(female) (14) - CNSAS (3)
- soeed solenoid
NO
I)
Disconnect
CNALZ.
2)50-70R
CNSAS
CNAL2
@,
Hi/Lo
Speed
e
a
CNTLI
3
h
After inspection
repair or replacf
CNL04
.B
.s
Directional,
speed switch
To solenoid
TDW00355
20-46 1
0
TROUBLESHOOTING
D-5 Output
*
*
*
*
D-5
is in 4th
Cause
1 YES
between
(female)
1) Disconnect
CNAL2.
2) 50-70R
CNAL2
Replace
Defective contact, or
disconnection in wiring
harness between CNAL2
(female) (13) - CNSAS (2)
-Hi/Lo solenoid
NO
Remedy
Defective controller
CNALZ
(13) and
CNSAS
Hi/Lo
Speed
@
@
CNTLI
0
_
inserted.
After inspection
repair Or repacf
CNL04
%,
$J
Directional,
speed switch
1
1
To solenoid
TDWDO355
20-462
0
D-6. D-7
TROUBLESHOOTING
D-6 Controller
*
*
*
*
Remedy
Cause
1
3 YES
1)20-30V
2) Measure voltage
between CNALl h
(8). (18) - (9).
(19).
Is voltage between
YES CNDPl (male) (1)
and chassis
2
ground normal?
Is there continuity
between CNALl
- 1)20-30V
(female) (9), (19) 2) Disconnect
CNDPl.
1) Disconnect
CNALl.
inserted.
Defective controller
Replace
Defective contact, or
disconnection in wiring
harness between CNALl
(female) (8). (13) - CNDPl
(female) (1)
After inspection,
repair or replace
Abnormality
Repair
in fuse box
NO
Defective contact, or
disconnection in wiring
harness between CNALl
(female) (9). (19) - CNSAS
(1) - CNTLl (8) - CNCLl
(12) -chassis ground
NO
After inspection,
repair or replace
Ei
CNALI
CNDPI
+24V
Fuse box
a
E
CNTLI
CNCLI
@
TDW00359
Remedy
Cause
is displaying
an error code.
So to troubleshooting
main monitor
of
20-463
0
TROUBLESHOOTING
OF WORK EQUIPMENT
CONTROLLER SYSTEM
(W MODE)
OUTLINE
. . . . .. . .. . . . . .. .. . . .. . . .. . .. .. . . . . . . . .. . . . . .. . . . . . . . . . . . . . . . . . . . .. .. . . . .. . .. . . .. . .. . . . . . . . .. . ... .. . . . . . . . . . . . . . . . . .. . . . . .........................
1.
Function . .. . . . . .. . . .. .. . . . . . .. . .. . . . .. . .. . . .. . . . .. . . . . . .. . . . . . .. . . . . . . . . . . . . . . . .. . .. .. .. . .. .. . . .. .. .. . .. .. . .. . . . . . . . . . . .. . . . . . . . ....................
2.
When carrying
3.
4.
Table of troubleshooting
w-
out troubleshooting
w-
in bucket dump
solenoid
w-
in damping
20-508
solenoid
system
.............................................................................
20-509
solenoid.. ........................................
.20-510
solenoid .....................................
.20-510
relay system
..............................................................
.20-517
in boom
lever kick-out
20-513
relay system
..............................................................................
20-514
LOWER
detection
pressure
switch.. ..................................
.20-515
potentiometer
system
.............................................................
.20-516
w-13
................. .I .......................................................
Abnormality
w-12
system..
Disconnection
w-11
20-507
Abnormality
W-IO
Abnormality
w-
TILT solenoids
Abnormality
W- 8
DUMP,
bucket
.20-506
Abnormality
:
z
system .....................................................................
Abnormality
4
20-503
w-
20-503
. . . . . . . . .. . . . . . . . . . . . . . .. . . .. .. . . .. .. . . . .. . .. . .. .. ... . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. .. . . .. .. . . . 20-503
w-
modes
20-503
system .............................................................
20-516
in model selection
w-14
w-15
wiring
harness.. ..................................................................
......................................................................................................
(a) Auto-leveler
(b) Auto-leveler
system
..................................................................................
20-518
20-519
20-520
20-520
20-521
20-522
W-16
w-17
Auto-leveler
w-19
be set
(b) Auto-leveler
Remote
positioner
RAISE,LOWER
positioner
Remote
positioner
(a1 Remote
positioner
switch
(b) Remote
positioner
w-20
. . . .. . . .. . . . . . . . . . . . .. .. . . .. . . . .. .. . . . . .. .. . . . . . . . . . . . .. . . . . .. . . . .. . . . . . .. . . . . . . . . . . . . .. . 20-523
(a) Auto-leveler
(a) Remote
W-18
cannot
w-22
remote
positioner
is at
is ON . . . . . . . . . .. . .. .. .. . . . . . . . . . . . . . .. . . .. . . . .. . .. . . . . .. . . . . . . . . . . .. . .. .. .. . . . .. . .. . . . . . . . . .. . . . . . . . . . . . 20-526
operation
w-21
at boom
bucket is at maximum
tilt . . . . . . . . . . . . . .. . . . . . . . . . 20-529
W-23
Failure
W-24
Maintenance
20-502
0
monitor
on main monitor
.. . . .. . . .. . .. .. . . . .. . .. . . . . . . . . .. .. . . . .. .. . . . . . . .. . . . . . . . . .. . . . . . . . . . 20-532
check . . . . .. . . . . . . .. . . .. . . . . . . . .. . . . . . . .. .. .. . . . . . . . .. . .. . .. . . . . . .. . . . . . .. . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . 20-533
:
$
TROUBLESHOOTING
OUTLINE
OUTLINE
1.
Fupction
The control mechanism
of the work equipment controller
consists of the controller,
input switches, potentiometer
input, soienoid
output, and buzzer output. It is used mainly
for control of auto-leveling.
The controller
receives the data from the
potentiometer,
processes it according to the
input signal for each switch and carries out
control of the solenoid.
2.
When carrying
out troubleshooting
The
has
controller
a troubleshooting
func-
3.
and
Failure
code
Failure
No.
W-l
40
Abnormality
in bucket dump
solenoid system
w-z
41
42
Abnormality
in bucket tilt
solenoid system
w-4
43
Abnormality
in damping
solenoid system
w-5
44
w-3
Failure
Failure code
Sensor
cannot
be adjusted
w-14
w-15
W-16
Auto-leveler
w-17
Remote
LOWER
up
positioner
RAISE,
LEDs do not light
W-18
Remote
LOWER
positioner
RAISE,
LEDs do not flash
out
cannot
be set
w-20
Abnormality
in auto-leveler
relay system
w-21
Bucket correction,
boom
stop response are slow
51
Disconnection
in boom RAISE,
LOWER detection pressure
switch
w-22
Bucket
N-II
52
Abnormality
in boom angle
potentiometer
system
W-23
N-12
53
Abnormality
in bucket angle
potentiometer
system
W-24
Maintenance
N-13
54
Abnormality
in model
wiring harness
W-8
49
Abnormality
in boom
kick-out relay system
w-9
50
N-10
lever
(lever)
operation
control
monitor
check
selection
20-503
0
TROUBLESHOOTING
OUTLINE
Cause of failure
Failure mode
Main monitor
20-504
0
positioner
1 10101
1 1
1 1
I
I
I
I
I I 1 I
LED system
G Remote positioner
I 1
switch system
CJ Remote positioner
(~1 Proximity
switch system
00
041903
!I
2
l-b
E!
-.
K
iit
9.
W-l
TROUBLESHOOTING
W-l
*
*
*
system
Remedy
Cause
YES
2
II
n0rrlXJ?
2) Min. 1 MR
between CNLX
(female) (6) and
1)Disconnect
CNL26.
2) 7 - 10 R
N
4 YES
Is resistance
between CNF25
(male) (1) and (2)
normal?
1) Disconnect
CNF25.
2,7-ton
Replace
Wiring harness
CNL26 (female)
CNF25 (female)
short circuiting
chassis ground
Repair or
replace wiring
harness
between
(6). (16) (1). (2)
with
Replace
Defective contact, or
disconnection in wiring
harness between CNL26
(female) (6). (16) - CNF25
(female) (1). (2). or short
circuit
Repair or
replace wiring
harness
Replace
CNF25. No
2) Min. 1 MR
1) Disconnect
Defective controller
NO
CNL26
CNLR12
I I
CNFR4
I i
CNF26
1
i 1
Damping solenoid
Damping solenoid (4
Damping solenoid (+)
DUMP solenoid (+I
noid
TAWO0494
20-506
0
TROUBLESHOOTING
w-2
bucket
Cause
YES
Remedy
Defective controller
Is voltage
between CNL26
(6) and chassis
normal?
m.
z
T
.z
1) Max. 1 V
2) Turn starting
switch ON.
3) Turn auto mode
OFF.
Is voltage
between CNL26
(7) and chassis
normal?
p
Is voltage
_ between CNL26
1) Max. 1 V
ND (7) and chassis
2) Turn starting
switch ON.
3) Turn auto mode
1) Disconnect
NO
OFF.
CNF24.
2) Max. 1 V
3) Turn starting switch ON.
4) Turn auto mode OFF.
Is voltage
i-
1) Disconnect
CNF25.
2) Max. 1 V
3) Turn starting
switch ON.
4) Turn auto mode
OFF.
NO
Repair or
replace wiring
harness
Repair or
replace wiring
larness
qepair or
-eplace wiring
larness
?epair or
.eplace wiring
iarness
CNL26
CNLR12
CNFR4
CNF26
Damping solenoid H
.a
?-.I
Damping solenoid
@
s\
(+)
DUMP/TlLTsolenoid
(-)
CNF24
BucketTILT solenoid
TAWOO494
20-507
0
w-3
TROUBLESHOOTING
Abnormality
_..E
Remedy
Replace
Is insulation
between CNL26
(female) (7) and
, chassis normal?
I
Is resistance
between CNL.26
(female) (7) and
I16) normal?
1) Disconnect
CNL26.
2) Min. 1 MD
Wiring harness
CNL26 (female)
CNF24 (female)
short circuiting
chassis ground
3 YES
p
Is insulation
between CNF24
NO (male) (1) and
chassis normal?
between
(7). (16) (1). (2)
with
Replace
1) Disconnect CNF24. No
2) Min. 1 MR
Defective contact, or
disconnection in wiring
1) Disconnect
CNL26.
2) 7 - 10 R
Repair or
replace wiring
harness
Repair or
replace wiring
harness
Replace
CNF24.
2)7-10R
CNL26
CNLR12
a-
DUMP/TILT
solenoid f-j
-3
CNF25
(?$
CNF24
20-508
0
TROUBLESHOOTING
w-4
in damping
solenoid
system
Cause
YES
s I
Is insulation
YESlbetween CNL26
11
Replace
Viring harness
ZNL26 (female)
:NF26 (female)
hart circuiting
hassis ground
Repair or
replace wiring
harness
between
(5). (15) (l), (2)
with
Replace
jefective contact. or
lisconnection in wiring
rarness between CNL26
female) (5). (15) - CNF26
female) (1). (2). or short
ircuit
Is resistance
between CNF26
(male) (1) and (2)
normal?
1) Disconnect
jefective controller
defective damping
olenoid
I) Disconnect CNF26. No
2) Min. 1 MR
Remedy
il
between CNL26
(female) (5) and
1) Disconnect
CNL26.
2) 18-22R
defective damping
olenoid
NO
I
I
Repair or
~a~~~saswiring
Replace
CNF26.
2) 18-22R
CNL26
CNLR12
CNFR4
&yJ
@I-
Damping solenoid (4
($
$)
CNF26
Damping solenoid
solenoid (4
CNF24
TAWOO494
20-509
0
TROUBLESHOOTING
W-5, W-6
W-5 Failure code 1441 Short circuit in power source at hot end of
damping solenoid
*
*
*
1 YES
Is voltage
between CNL26
(female) (5) and
chassis normal?
NO
1) Disconnect
CNF26.
2) Turn starting
switch ON.
3) Max. 1 V
Defective controller
Replace
Repair or
replace wiring
harness
W-6 Failure code 1451 Short circuit in power source at return end of
damping solenoid
I
1 YES
Is voltage
between CNL26
(female) (15) and
chassis normal?
I) Disconnect
CNF26.
2) Turn starting
switch ON.
3) Max. 1 V
NO
Cause
Replace
Defective controller
Wiring harness
CNL26 (female)
- CNF26 (female)
circuiting with
source
Remedy
between
(15) and
(2) short
power
Repair or
replace wiring
harness
Tl LT solenoid (+)
TAWOO494
20-5 10
0
TROUBLESHOOTING
w-7
relay
Cause
switch ON.
3)20-30V
4) Turn auto mode
ON.
Xepair or
.eplace wiring
7arnes.s
Defective controller
%splace
Xepair or
.eplace wiring
tarness
NO
YE:
5r
Is resistance
YES_ between CNL48
(female) (2) and
chassis normal?
4
Is resistance
YES_ between CNL48
(male) (1) and (2)
normal?
I) Disconnect
CNL48.
2) Max. 1 R
L
N(
1)Disconnect
3
A-
Remedy
CNL48.
NO
2) 50-110R
ON?
Is insulation
YES_ between CNL51
(female) (3) and
6
chassis normal?
YE!
Repair or
replace wiring
harness
Replace
Defective controller
Replace
Repair or
replace wiring
harness
Repair or
*eplace wiring
7arness
1) Disconnect
CNL51 and CNL48.
2) Min. 1 MR
NO
3efective contact, or
disconnection in wiring
harness between CNL48
(female) (2) and chassis
NC
20-511
0
w-7
TROUBLESHOOTING
CNDIODE
Bucket relay
CNL48
r
!
1
CNL32
CNL26
Proximity switch
:i
t-
CNL50
Power GND -
I
I-
CNL33
I
I
Auto leveler relay
CNL51
CNFR2
CNF05
To proximity
switch for bucket
TDW00364
20-512
0
TROUBLESHOOTING
W-B
relay system
I
YES
1
is resistance
between CNL26
(female) (20) and
chassis normal?
1) Disconnect
CNL26.
2) 50- 1lOR
_
Is insulation
_ between CNL26
NO (female) (20) and
chassis normal?
1) Disconnect
CNL49.
2) Min. 1 MR
NO
Cause
Remedy
Defective controller
Replace
Disconnection in wiring
harness between CNL26
(female) (20) and CNL49
(female) (1)
Repair or
replace wiring
harness
Repair or
replace wiring
harness
Q
Work equipment
controller
CNL26
Boom relay
CNL49
CNL33
.a
+24V -
20-513
0
w-9
TROUBLESHOOTING
in auto-leveler
relay system
Cause
YES
1
Is resistance
between CNL26
(female) (11) and
chassis normal?
1) Disconnect
CNL26.
2)50-110R
YES
Is resistance
_ between CNL51
NO (male) (1) and (2)
normal?
1) Disconnect
CNLBI.
2)50-110R
Is continuity
YES between CNL51
2
(female) (2) and
chassis normal?
-
1) Disconnect
CNL51.
2) Max. 1 R
NO
NO
Defective controller
Replace
Defective contact, or
disconnection in wiring
harness between CNL26
[female) (11) and CNL51
[female) (11, or short
circuit with ground
Repair or
replace wiring
harness
Defective contact, or
disconnection in wiring
harness between CNL51
(female) (2) and chassis
Repair or
replace wiring
harness
Replace
Q
%
Bucket relay
CNDIODE
CNL48
I
1
CNL32
2
3
5
a:-
I t-
To battery
s
Proximity
Power GND
switch
CNL50
-i
CNL33
To proximity
for bucket
20-5
0
switch
To bucket
solenoid
Auto leveler
positioner
J
relay
relay
TROUBLESHOOTING
W-IO
*
*
*
W-IO
Remedy
YES
2
Is continuity
YES between CNL27
(female) (6) and
Is continuity
between CNL27
(female) (5) and
(9) normal?
1) Disconnect
CNL27.
2) Max. 1 R
2) Max. 1 R
4 YES
Is continuity
between CNF21
NO (male) (1) and (2)
normal?
1) Disconnect
CNF21.
2) Max. 1 R
Work equipment
Defective controller
Replace
Defective contact, or
disconnection in wiring
harness between CNL27
(female) (6). (9) - CNF22
(female) (l), (2)
Repair or
replace wiring
harness
Replace
Defective contact, or
disconnection in wiring
harness between CNL27
(female) (5), (9) - CNF21
(female) fl), (2)
Repair or
replace wiring
harness
Replace
NO
controller
CNL27
CNSLIP
pressure
TAWO0495
20-5 15
0
w-11,
TROUBLESHOOTING
W-11
*
*
*
Abnormality
w-12
YES
Is failure code 52
YES displayed in
condition for
measuring Item l?
1
Is voltage
between CNL27
(9) and (19)
normal?
1)0.3-4.7v
2, ~~~c,$n
~0
3) Insert T-adapter.
NO
I) Turn starting
switch ON (after
resetting).
3 YES
Is resistance
between CNF28
(male) (1) - (21,
(2) - (3) normal?
1) Between (1) and
(2): 0.2 7 5 lu2
2) Between (21 and
(3): 4 - 5 kD
3) Disconnect
CNF28.
W-12
No
Replace
Already
reset
Defective contact, or
disconnection in wiring
harness between CNF28
(female) (1) and CNL27
(female) (19). or short
circuit with ground
Repair or
replace wiring
harness
Replace
Cause
r
Isfailure
YE
between CNL27
1)0.3-4.7v
2) Turn starting
switch ON.
N
3) Insert T-adapter.
2 YES
Iefective
controller
Remedy
leplace
code 5.3
displayed in
condition for
measuring Item l?
NO
1) Turn starting
switch ON (after
resetting).
3 YES
Is resistance
between CNF29
[male) (1) - (2).
(2) - (3) normal?
1) Between (1) and
(2):0.2-5kQ
2) Between (2) and
(3):4-5kQ
3) Disconnect
CNF29.
20-516
a
Remedy
No
Uready reset
Iefective contact, or
fisconnection in wiring
tarness between CNF29
female) (1) and CNL27
female) (20). or short
:ircuit with ground
tepair or
eplace wiring
larness
teplace
w-11,
TROUBLESHOOTING
sr
When
YES
YE
1) Disconnect
CNF29.
2) Min. 1 MR
1
Is voltage
between CNL27
(male) (9) and
(IO) normal?
I
I
1) Disconnect
CNF28.
2) Min. 1 MR
I
NO
1) 4-6V
2) Turn starting
switch ON.
3) Disconnect
CNL27.
4) Insert T-adapter.
CNSLIP
NO
Cause
w-12
Remedy
Defective contact, or
disconnection in wiring
harness between CNL27
(female) (9). (10) - CNF28
(female) (2). (3), CNF29
(female) (2). (3). or short
circuit with ground
Repair or
replace wiring
harness
Replace
Replace
Defective controller
Replace
Bucketangle potentiomete
iometer
TAWO0496
20-5 17
0
w-13
TROUBLESHOOTING
W-13
Abnormality
harness
Cause
YE
YE
2
YE
l-l
Is voltage
between CNL27
(9) and (12) as
shown in Table l?
NO
between CNL26
(13) and CNL27
NO
1)20-30V
Table
Remedy
>efective controller
3eplace
Iefective contact, or
disconnection in wiring
Tarness between CNL26
:female) (13) - CNHYDZ
:4), CNHYD2 (3) - CNL27
:female) (14). or short
:ircuit
qepair or
.eplace wiring
iarness
Defective contact, or
disconnection in wiring
harness between CNL26
[female) (13) - CNHYDZ
(41, CNHYDZ 12) - CNL27
[female) (13). or short
circuit
qepair or
*eplace wiring
larness
Defective contact, or
disconnection in wiring
harness between CNL26
[female) (13) -CNHYD2
(4), CNHYD2 (1) - CNL27
(female) (121, or short
circuit
Repair or
replace wiring
harness
Defective controller
Replace
1
WA320
WA380
Between CNL27
(12) and (9)
Max.
Max.
Between CN L27
(13) and (9)
Max.
20-
Between CNL27
(14) and (9)
WA420
/ 20-30
30
Max.
WA470
120-30
20 -30
1
Work equipment controller
I
Max. 1
20 - 30
20 -30
Max. 1
Model selectic
CNL27
I
I
CNHYD2
I I
I
Model selection 1
(ij@
Model selection 2
@Q
Model selection 3
@@
GND
CNL26
Power source 24V
for sensor
TAWO0497
20-5
0
18
W-l 4
TROUBLESHOOTING
W-14
*
*
*
*
I
3 YES
YES
2
1
Corresponding
LED lights up and does not flash.
1) Turn auto
leveler set
switch and
remote
positioner set
switch ON
simultaneously.
2) Auto leveler set
LED and remote
positioner set
LED light up or
flash.
1) See
Troubleshootina
W-16.
Is remote
positioner set
signal system
normal?
1) See
Troubleshooting
W-18.
No
NO
Cause
1 Remedy
Defective controller
Replace
Defective remote
positioner set switch or
LED system
Repair or
replace wiring
harness
Repair or
replace wiring
harness
20-5 19
0
w-15
TROUBLESHOOTING
W-15
Ir
Ir
Ir
Ir
(a) Auto-leveler
(b) Auto-leveler
switch system
LED system
Cause
3 YEI
Is insulation
YES between CNL28
(female) (8) and
chassis normal?
2
YE
1) Disconnect
CNL27.
2) Maintenance
monitor auto
mode switch
ON: Max. 1 R
OFF: Min. 1 MD
Is insulation
between CNL28
(female) (8) and
chassis normal?
1) Disconnect
CNL28 and
CNL20.
2) Min. 1 MR
1) Disconnect CNL28
and CNLZO.
2) Short circuit of
CNL20 (femalet
(11) with ground
3) Max. 1 R
NC
NO
UO
Work equipment
controller
>efective controller
Replace
Iefective contact, or
disconnection in wiring
?arness between CNL28
ifemale) (8) and CNL20
Ifemale) (17 t
Repair or
replace wiring
harness
Repair or
replace wiring
harness
Defective contact, or
disconnection in wiring
harness between CNL27
(female) (18) and CNLZO
(female) (6). or short
circuit with ground
Repair or
replace wiring
harness
Maintenance
CNL27
monitor
CNL20
IV
TDW00370
20-520
a
Remedy
TROUBLESHOOTING
w-15
switch
Cause
YES
1
Bucket lever
neutral switch
signal
Is continuity
between CNL27
-
ffemale)
(11) and
3
-
CNL26 Ifemale)
(13) normal?
1)Disconnect
CNL27 and
CNL26.
2) Lever at
neutral:
Max. 1 R
3) Lever at other
than neutral:
Min. 1 MR
YES
2
I
Is continuity
between CNFZO
NO (male) (11 and (2)
normal?
1) Disconnect
CNFZO.
2) Lever at neutral:
Max. 1 R
3) Lever at other
than neutral:
Min. 1 MD
CNLRII
Is insulation
between CNL27
(female) (11) and
chassis normal?
I) Disconnect
CNL27 and
CNL26.
2) Min. 1 MR
YES
-
No
Defective controller
Replace
Defective contact, or
disconnection in wiring
harness between CNL26
(female) (13) - CNFZO
(female) (l), (21- CNL27
(female) (11). or short
circuit
Repair or
replace wiring
harness
Wiring harness
CNL26 (female)
CNF20 (female)
short circuiting
chassis ground
Repair or
replace wiring
harness
between
113) and
(I), (2)
with
NO
CNFR3
Remedy
CNMO
Replace
(3
CNL26
Power source of sensor
TAW00498
20-52 1
0
TROUBLESHOOTING
(d) Engine
w-15
Cause
Y ES
4 YEI
El
Remedy
Go to other
system
3efective controller
Replace
3efective contact, or
jisconnection in wiring
iarness between CNL28
ifemale) (4) and CNE04
Ifemale) (2)
Repair or
replace wiring
harness
Repair or
replace wiring
harness
Replace
Is voltage
between CNL26
(7 1) and (9)
normal?
1) Insert T-adapter.
21 Turn auto mode
ON.
3)20-30V
IIs insulation
11 Disconnect
4-l
NO
Is resistance
between CNE04
(male) (2) and (3)
normal?
1) Disconnect
CNE04;CNL28,
and CNLG.
2) Min. 1 MR
1) Disconnect
CNE04.
212-3kR
CNEO4,
3) Max. 1 R
NO
NC
TDWOO372
20-522
0
W-16
TROUBLESHOOTING
W-16
Auto-leveler
cannot be set
Remedy
3 YES
Is continuity
YES between CNU~
(female1 (7) and
chassis normal?
2
Is insulation
YES between CNL28
(female) (7) and
1
2
0
is continuity
between CNL27
(female) (3) and
chassis normal?
1) Disconnect
CNL27.
2) Maintenance
monitor auto
mode switch
ON: Max. 1 $2
OFF: Min. 1 MR
1) Disconnect
CNL28 and
CNL20.
2) Min. 1 Ma
1) Disconnect
No
CNL28 and CNLPO.
2) Short circuit CNL20
(female) (9) with
ground.
3) Max. 1 R
NO
NO
Defective controller
Defective contact, or
disconnection in wiring
harness between CNL28
(female) (7) and CNL20
(female) (9)
Repair or
replace wiring
harness
Repair or
replace wiring
harness
Defective contact, or
disconnection in wiring
harness between CNL27
(female) (3) and CNL20
(female) (4), or short
circuit with ground
Repair or
replace wiring
narness
Work equipment
controller
Maintenance
CNL27
monitor
CNL20
i@P
TDWOO370
20-523
0
w-17
TROUBLESHOOTING
W-17
*
*
f
*
Remote positioner
(a) Remote
(b) Remote
positioner
positioner
switch system
LED system
Cause
3 YE!
Remedy
Iefective controller
eplace
Iefective contact, or
iisconnection in wiring
tarness between CNL28
female) (6). (14) - CNLZO
female) (12). (13)
:epair or
aplace wiring
arness
Niring harness
:NL28 (female)
:NL20 (female)
short circuiting
:hassis ground
lepair or
eplace wiring
iarness
YE
FH
NC
1) Disconnect
CNL28 and CNL20.
2) Short circuit CNL20
(female) (12), (13) with
ground.
3) Max. 1 Q
IO
1) Disconnect
CNL27.
2) Maintenance
monitor remote
positioner
switch
ON: Max. 1 R
OFF: Min. 1 MR
Iefective contact, or
disconnection in wiring
larness between CNL27
[female) (4) and CNL20
[female) (7), or short
circuit with ground
1
No
Work equipment
between
(6). (14) (121, (13)
with
controller
CNL26
Maintenance
display
monitor
CNL20
CNL27
Remote
switch
positioner
Positioner
selector
set
switch
CNL28
1
I
20-524
0
Fib&&
positioner
LOWER/
4.
TDW00375
repair or
eplace wiring
rarness
W-l 8
TROUBLESHOOTING
W-18
t
*
Ir
+
Remote positioner
(a) Remote
(b) Remote
positioner
positioner
switch system
LED system
Cause
YES
Is continuity
YES between CNL26
(female) (10) chassis normal?
2
Is insulation
YES between CNL26
(female) (10) chassis normal?
Remote
positioner set
signal system
Is continuity
between CNL27
(female) (2) and
chassis normal?
1) Disconnect
CNL27.
2) Maintenance
monitor remote
positioner set
switch
ON: Max. 1 Q
OFF: Min. 1 MD
1) Disconnect
CNL26 and
CNLZO.
2) Min. 1 MR
NO
1I Disconnect
CNL26 and CNLZO.
2) Short circuit CNl.20
(female) (10) with
ground.
3) Max. 1 R
NO
NO
Work equipment
Remedy
Defective controller
R.eplace
Defective contact, or
disconnection in wiring
harness between CNL26
(female) (10) - CNL20
(female) (10)
.
Rlepair or
rreplace wiring
harness
Rlepair or
rleplace wiring
hlarness
Defective contact, or
disconnection in wiring
harness between CNL27
(female) (2) and CNL20
(female) (51, or short
circuit with ground
Flepair or
eplace wiring
c:,arness
controller
CNL26
Remote
display
positioner
set
.Maintenance
monitor
CNL20
CNL27
Remote
switch
positioner
Positioner
selector
set
switch
20-525
0
w-19
TROUBLESHOOTING
W-19
Ir
*
f
when
I
YES
1
Boom lever
As+an+ -witch
Is continuity
between CNL27
(female) (8) and
2 YES
l-l
1) Disconnect
NO
CNL27.
I2) Boom lever at
neutral: Max. 1 Q
3) Boom lever
detent: Min. 1 MD
oenween t
(female) (1) and
(2) norma
1) Disconnect
CNF23.
2) Boom fever at
NO
Cause
Remedy
Defective controller
Replace
Defective contact, or
disconnection in wiring
harness between CNL27
(female) (81, (9) - CNF23
(1). (2). or short circuit
Repair or
replace wiring
harness
Replace
neutral: Max. 1 R
3) Boom lever
detent: Min. 1 MR
CNL27
CNLRI 1
CNFR3
CNF23
Boom lever
detent switch
20-526
0
w-20
TROUBLESHOOTING
W-20
f
*.
*
*
Check that the main monitor and alarm buzzer work properly.
Before carrying out troubleshooting,
check that all the related connectors are properly inserted.
Always connect any disconnected
connectors before going on the next step.
When disconnecting
connectors
to connect the T-adapter
(or socket adapter),
always turn the
starting switch OFF.
Cause
2 YES
pHG
iEH--
1) Disconnect
CNL28 and
CNLOS.
2) 5-6R
Work equipment
NO
1) Disconnect
CNL28 and CNLOI.
2) Short circuit between CNL08
(female) (6) and chassis.
3) Max. 1 R
VO
Remedy
Defective controller
leplace
Defective contact, or
disconnection in wiring
harness between CNL28
(female) (16) and CNLOB
(female) (6)
tepair or
eplace wiring
ramess
* Defective contact, or
disconnection in wiring
harness between CNL28
(female) (16) - resistor CNL34 (8) -chassis
Wiring harness between
CNL28 (female) (161 and
CNLOB (female) (6) short
circuiting with chassis
ground
lepair or
eplace wiring
rarness
Main monitor
controller
CNL34
CNL28
Buzzer output
CNL08
$J
-8
Resistor
20-527
0
w-21
TROUBLESHOOTING
W-21
*
*
*
Ir
Bucket correction,
Check that the boom cylinder bottom pressure sensor works properly.
Before carrying out troubleshooting,
check that all the related connectors are properly inserted.
Always connect any disconnected
connectors
before going on the next step.
When disconnecting
connectors
to connect the T-adapter
(or socket adapter),
always turn the
starting switch OFF.
Remedy
Cause
ES
Iefective
YE!
YE
1) Insert T-adapter.
2) Turn starting
switch ON.
3)1-5v
between CNL28
(female) (9) and
between CNF30
(female) (11 and
1) Disconnect
CNFBO.
2) Turn starting
switch ON.
3)20-30V
CNL28 and
CNF30.
2) Min. 1 MR
IO
qeplace
controller
3efective contact, or
disconnection in wiring
7arness between CNL28
Ifemale) (9) and CNF30
[female) (3)
Repair or
replace wiring
harness
8Wiring
harness between
CNL28 (female) (9) and
CNF30 (female) (3) short
circuiting with chassis
ground
*Wiring harness between
CNL28 (female) (9) and
CNM13 (1) short
circuiting with chassis
ground
Repair or
replace wiring
harness
Defective contact, or
disconnection in wiring
harness between CNL26
(female) (13) and CNF30
(female) (2). or short
circuit
Repair or
replace wiring
harness
CNM13
Work equipment c
Oil pressure sensor for
boom cylinder bottom
Power
GND
20-528
0
TAW00501
w-22
TROUBLESHOOTING
W-22
+
*
*
(a) Bucket kick-out does not work even when bucket is at maximum
Check that failure code [481 is not being output.
.
Tilt the -bucket fully.
.
Auto mode: OFF
tilt
Cause
Defective proximity
switch
Go to
CNF05.
11 Short circuit
CNL48 (female)
(3). (5).
2) Turn starting
L
switch ON.
NO
3) Check that
voltage between
CNL48 (female)
(3) and chassis
is20-30V.
1) Disconnect
CNLBO.
2)20-30V
YES
7
Is continuity
between CNL48
(female) (3) and
chassis normal?
1) Disconnect CNL17
and CNL48.
RIO
2) Short circuit
CNL17 (female)
1) Disconnect
(1). (2).
CNL17.
3) Max. 1 Q
2) Max. 1 R
5
YES
Is continuity
between CNLSO
(male) (3) and (6)
normal?
(Al
NO
1) Disconnect
CNLSO.
2) Max. 1 R
6 YES
Is continuity
between CNL51
(male) (3) and (61
normal?
II
1) Disconnect
CNLSl.
2) Max. 1 R
NO
NO
NO
leplace
(A)
Defective contact, or
disconnection in wiring
harness between CNL50
(female) (3) and +24V, or
short circuit
lepair or
aplace wiring
arness
Defective bucket
positioner solenoid
leplace
IDefective contact; or
fdisconnection in wiring
Iharness between CNL17
,[female) (1) and CNL48
,[female) (5). or short
Icircuit
Remedy
epair or
aplace wiring
arness
IDisconnection in wiring
Iharness between CNL17
,(female) (2) and chassis
epair or
splace wiring
arness
IDefective
Irelay
eplace
CNL48 bucket
Defective CNLSO
proximity switch relay
Ieplace
Defective contact, or
disconnection in wiring
harness between CNL51
(female) (6) and CNL50
(female) (6). or short
circuit
Iepair or
eplace wiring
rarness
teplace
20-529
0
w-22
TROUBLESHOOTING,
of auto mode
switch
Cause
2 YES
Is voltage
between CNL48
(female) (5) and
chassis normal?
A
Iefective function of
bucket lever detent
Is insulation
YES between CNL48
1(male) (3) and (5)
normal?
-
NO
1) Disconnect
CNL48.
2) Min. 1 MR
L
NO
1) Disconnect
CNL48.
2) Max. 1 V
3) Turn starting
switch ON.
epair or
aplace
epair or
splace wiring
amess
)efective proximity
iwitch
leplace
lefective contact, or
lisconnection in wiring
rarness between CNL50
female) (2) and CNF05
female) (2)
lepair or
eplace wiring
arness
lefective proximity
.witch relay
leplace
lepair or
eplace wiring
arness
(2) Lever is not held by detent only when auto mode switch
is OFF
.
Tilt the bucket fully.
YES
1
Is voltage
between CNL51
(female) (6) and
chassis normal?
I) Disconnect
CNL51 and
CNFOS.
2) Short circuit
CNFOS (2) and
(3).
3) Turn starting
switch ON.
4) Max. 1 V
20-530
0
3 YES
Is resistance
1) Disconnect
CNL50.
2)50-110R
NO
TROUBLESHOOTING
w-22
CNDIODE
Bucket relay
CNL48
m
CNL32
CNL26
a:-
Proximityswitch
Bucketlever kick-out
output
@
-
To battery
I--
CNL50
Power GND e
CNL33
CNL51
17
To battery
~~,c$gsitioner
Power GND 4
CNLR2
CNFR2
(I$
CNF05
To proximity
switch for bucket
8
TOW00364
20-531
0
W-23
TROUBLESHOOTING
W-23
*
*
*
on main monitor
Remedy
Replace
Repair or
replace wiring
harness
2) Short circuit CNL08 (11, (3).
3) Max. 1 R
1) Disconnect
CNLOS and
CNDP2
2) Min. 1 MR
Wiring harness
CNL26 (female)
CNL08 (female)
short circuiting
chassis ground
I
NO
between
(l), (12) (l), (3)
with
Work equipment
controller
CNL26
CNL34
CNDP2
ECSS
CNLO6
I
20-532
0
Main monitor
Repair or
replace wiring
harness
TROUBLESHOOTING
W-24
*
*
*
*
W-24
Maintenance
monitor
check
YE:
io to (A)
between CNLZO
,A,
Check switch
system
between CNL20
(male) (6) and
chassis normal?
1) Auto mode
switch:
ON: Max. 1 R
OFF: Min. 1 MR
ichassis normal?
Is resistance
1) RAISE position
set switch:
ON: Max. 1 R
OFF: Min. 1 MR
I
NO
NC
jefective maintenance
nonitor
YES
?eplace
_.
Is resistance
I) RAISE, LOWER
switch:
ON: Max. 1 Q
OFF: Min. 1 MR
.
.
jefective maintenance
nonitor
NO
qeplace
Check switch
system
I) Connect CNUO
(10) to power
source (1). (2).
1) Connect CNLZO
(9) to power
source (1). (2).
1) Connect CNL20
(11) to power
source (11, (2).
io to IB)
NOI
NC
NO
Iefective maintenance
nonitor
qeplace
6YE:
1) Connect CNLZO
(12) to GND (3).
light up?
1) Connect CNLSO
(13) to GND (3).
NC
No
refective maintenance
70nitor system
20-533
0
g
2
;
30-
3030-
4
6
30-
30-
30- 10
30- 11
30- 12
30- 13
30- 14
30- 15
30- 16
30- 17
30-22
30- 24
30-27
30- 28
30-.33
30- 34
30-35
30- 36
30- 40
30- 41
30-43
30-46
30- 56
TRANSMISSION
CLUTCH PACK
Disassembly
........................................
30- 70
Assembly .............................................
30- 76
TRANSMISSION
CONTROL VALVE
Removal ...............................................
30- 88
Installation ...........................................
30- 90
Disassembly
........................................
30- 92
Assembly .............................................
30- 94
TRANSMISSION
ACCUMULATOR
VALVE
Disassembly
........................................
30- 97
Assembly .............................................
30- 98
TRANSMISSION
MODULATING
VALVE
Disassembly
........................................
30- 99
Assembly .............................................
30-100
DRIVE SHAFT
Disassembly
........................................
30-101
Assembly .............................................
30-104
FRONT AXLE
Removal ...............................................
30-106
Installation ...........................................
30-108
REAR AXLE
Removal ...............................................
30-109
Installation ...........................................
30-I 13
DIFFERENTIAL
Disassembly
........................................
30-l 15
Assembly .............................................
30-I 20
AXLE HOUSING
Disassembly
........................................
30-130
Assembly .............................................
30-137
CENTER HINGE PIN
Removal ...............................................
30-I 47
Installation ...........................................
30-151
STEERING VALVE
Removal ...............................................
30-154
Installation ...........................................
30-156
Disassembly
........................................
30-157
Assembly .............................................
30-161
ORBIT-ROLL VALVE
Removal ...............................................
30-164
Installation ...........................................
30-165
Disassembly
........................................
30-166
Assembly .............................................
30-l 69
30-l
0
STEERING CYLINDER
Removal ...............................................
30-174
installation ...........................................
30-175
BRAKE VALVE
Removal ...............................................
30-176
Installation ...........................................
30-177
RIGHT BRAKE VALVE (TANDEM)
Disassembly
........................................
30-178
Assembly .............................................
30-179
LEFT BRAKE VALVE (SINGLE)
Disassembly
.............. ;. ........................ 30-180
Assembly .............................................
30-181
PARKING BRAKE DISC
Removal ...............................................
30-182
Installation ...........................................
30-184
HYDRAULIC
TANK
Removal ...............................................
30-185
Installation ...........................................
30-187
HYDRAULIC
FILTER
Removal and Installation .................. .30-188
HYDRAULIC,
STEERING, SWITCH,
PPC PUMP
Removal ...............................................
30-189
Installation .......................................
.;.. 30-192
MAIN CONTROL VALVE
Removal ...............................................
30-193
Installation ...........................................
30-195
Disassembly
........................................
30-196
Assembly .............................................
30-198
PPC VALVE
Removal ...............................................
30-201
Installation ...........................................
30-203
Disassembly
........................................
30-204
Assembly .............................................
30-205
BUCKET CYLINDER
Removal ...............................................
30-206
Installation ...........................................
30-208
BOOM CYLINDER
Removal ...............................................
30-209
Installation ...........................................
30-210
HYDRAULIC
CYLINDER
Disassembly
........................................
30-211
Assembly .............................................
30-214
WORK EQUIPMENT
Removal ...............................................
30-217
installation ...........................................
30-220
COUNTERWEIGHT
Removal and Installation ................... 30-222
FUEL TANK
Removal ...............................................
30-223
Installation
...........................................
30-225
CAB, FLOOR FRAME
Removal ...............................................
30-226
Installation
...........................................
30-229
30-2
0
CAB
Removal .. .. . . . . . .. . .. . .. . . . . . .. . . . . . . . .. . . . . . . . . . . . .. . 30-230
Installation . . . .. .. . .. . .. . . . . . . . . . . . . . . . . .. . . .. . . . . .. . . 30-231
MAIN MONITOR
Removal .. . . .. . . .. . . . . .. .. . . . . . . . . . . . . . .. . . . . . .. . . .. . . . 30-232
Installation .,.........................................
30-233
MAINTENANCE
MONITOR
Removal and Installation
. . .. . . . . . . . . .. . .. . . 30-234
AIR CONDITIONER
UNIT
Removal ._.___..
_....._................................ 30-235
Installation . . . . . .. . .. . . . . .. . . .. .. . . . . . . . . . . . . . . . . . . . .. 30-240
AIR CONDITIONER
CONDENSER
Removal . .._.._........................................
30-241
Installation . . . . . .. . . . .. . .. .. . . .._.....................
30-242
DRY RECEIVER
Removal and Installation . . . . . . . . . . . .. . . . .. . 30-243
AIR CONDITIONER
CONDENSER
COMPRESSOR
Removal and Installation . . . . . .. . . .. . . . . .. . . 30-244
METHOD
1.
OF USING
MANUAL
When removing or installing a unit assembly, the order of work and techniques
used are given
for the removal operation; the order of work for the installation operation is not given.
(2) Any special techniques applying only to the installation procedure are marked m,
and the
same mark is placed after the relevant step in the removal procedure to indicate which step in
the installation procedure it applies to.
(Example)
REMOVAL OF 0 0 0 ASSEMBLY .. . .. . . . .. . . Title of operation
. .. . .. . . . ... .. . . . .. .. ... .. .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . .. . . . . .. . Precautions
related to safety when carrying
out
A
the operation
1. XXXX (I)
.. . .. . . ..-...............................
Step in operation
*
. .. . . . . .. .. .. . . .. . .. .. .. . .. . . .. . . . .. .._...................
Technique or important
point to remember
when
removing XXXX (I).
Indicates that a technique
is listed for use
2. A A A (2): . . .. . .. . .. .. . . . .. . . . . .. . . .. .. . .. . . . . . . .. . . .. .. m
during installation
3. 0 0 0 0 assembly (3)
:
.. . .. .. . .. . .. . .. .. . . . . . . . .. . . . . . . .. . . . . . . . . .. . . . . .. .
See Lubricant
and Coolant
Table
INSTALLATION
OF 0 0 0 ASSEMBLY .. . . Title of operation
l
Carry out installation in the reverse
order to removal.
p
........... ...... .... ................ ....... ... . Technique used during installation
point to remember
when
. .. . . .. . . .. . .. . . . . . . . . . . .. .. . .. . . . . . . . .. . . .. .. . . Technique or important
installing DA A (2).
l
Adding water, oil . . .. .. . .. . . . .. . .. . . . .. . .. . . . . Step in operation
*
. .. .. . .. . . . . . . .. . .. . . .. . .. ... .. . . . . . . . . .. . . . .. . . Point to remember when adding water or oil
QI
. .. .. . .. . .. . . . . . . .. . . .. . .. ... .. .. . .. .. . .. . . . .. . .
Quantity
of filling
2.
3.
(disassembly
OPERATION,
or assembly) of units
so be sure to follow
For details of the description, part number, and quantity of any tools (Al, etc.) that appear
the operation procedure, see the SPECIAL TOOLS LIST given in this manual.
in
30-3
0
PRECAUTIONS
WHEN CARRYING
OUT OPERATION
2)
30-4
0
disassembly
02
07376-50210
07221-20210 (Nut),07222-00210
(Plug)
03
0737650315
07221-20315 (Nut),07222-00312
(Plug)
04
07376-50422
07221-20422 (Nut),07222-00414
(Plug)
05
0737650522
07221-20522 (Nut),07222-00515
(Plug)
06
07376-50628
07221-20628 (Nut),07222-00616
(Plug)
10
07376-51034
07221-21034 (Nut),07222-01018
(Plug)
12
07376-51234
07221-21234 (Nut),07222-01219
(Plug)
~~~~e~'
3)
it during
Sleeve head
(tube end)
Splitflange
04
07379-00400
07376-10400
07371-30400
05
07379-00500
07378-10500
07371-30500
14
07049-01418
14
1 11.5
18
16
07049-01620
16
13.5
20
18
07049-01822
18
15
22
20
07049-02025
20
17
25
22
07049-02228
22
18.5
28
24
07049-02430
24
20
30
27
07049-02734
27
22.5
34
pressure,
the following
DEW00401
operations.
DISASSEMBLY
Precautions
AND ASSEMBLY
for installation
PRECAUTIONS
WHEN
CARRYING
OUT OPERATION
operations
Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
Install the hoses without twisting or interference.
Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
Bend the cotter pin or lock plate securely.
When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded
portion with 2 - 3 drops of adhesive.
When coating with gasket sealant, clean the surface and remove all oil and grease, check that there
is no dirt or damage, then coat uniformly with gasket sealant.
Clean all parts, and correct any damage, dents, burrs, or rust.
Coat rotating parts and sliding parts with engine oil.
When press fitting parts, coat the surface with antifriction compound
(LM-P).
After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
When connecting wiring connectors,
clean the connector to remove all oil, dirt, or water, then
connect securely.
When using eyebolts, check that there is no deformation
or deterioration,
screw them fully, and
align the direction of the hook.
When tightening
split flanges, tighten uniformly
in turn to prevent excessive tightening
on one
side.
When operating the hydraulic cylinders for the first time after reassembling
cylinders, pumps and
other hydraulic equipment
removed for repair, alwavs bleed the air as follows:
.
run at low idling.
I) Start the engineand
control lever to operate the hydraulic
cylinder 4 - 5 times,
2) Operate the work equipment
stopping 100 mm from the end of its stroke.
3) Next, operate the steering, bucket, and boom cylinders 3 - 4 times to the end of their strokes,
then stop the engine and loosen air bleed plug (1) to bleed the air from the hydraulic tank.
After bleeding the air, tighten plug (I).
4
Following this, raise the engine speed, repeat the procedure in Step 3)
to bleed the air. Repeat this operation
until no more air comes out from
the plug hole.
w
Plug : 11.3 + 1.5 Nm (1.15 k 0.15 kgm)
5) After doing this, run the engine at normal speed.
*
When using the machine for the first time after repair or
long storage, follow the same procedure.
Precautions
when
completing
the operations
If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run
the engine to circulate the water through the system. Then check the water level again.
If the hydraulic equipment
has been removed and installed again, add engine oil to the specified
level.
Run the engine to circulate the oil through the system. Then check the oil level again.
If the piping or hydraulic equipment,
such as hydraulic cylinders, pumps, or motors, have been
removed for repair, always bleed the air from the system after reassembling
the parts.
+
For details, see TESTING AND ADJUSTING,
Bleeding air.
Add the specified amount of grease (molybdenum
disulphide
grease) to the work equipment
related parts.
30-5
0
DISASSEMBLY
AND ASSEMBLY
of work
iymbol
Disassembly,
transmission
assembly
of
Part No.
Part
793-305-I
2 I
793-415-1210
793-415-l
793-415-I
Lifting
tool
I Lifting
tool
1 1
220
Lifting
tool
150
Plate
Bolt
600
Remarks
Oty
Name
Rear
housing
IFor F - R clutch
For 1st 2nd, 3rd 4th clutch
assembly
01010-51075
Removal,
parking
01580-11008
Nut
1 1 793-310-1300
Disassembly,
assembly
transmission
clutch
lifting tool
installation
brake
1 Stand
11
~1~~~:::
of
of
disc
installation
of
pack
assembly
793-415-1250
Seal
holder
793-415-I
Seal
holder
Disassembly,
differential
assembly
of
assembly
130
120
Ist _ 4th
piston
seal
793-422-l
F-R
Mandrel
01011-01010
Bolt
01643-32060
Washer
Joint
mo-sol-1720
III
Disassembly,
assembly
axle housing
assembly
of
790-101-2910
Puller
790-101-2920
Bolt
assembly:
790-101-2900
Removal
790-101-2930
Nut
793-422-l
Seal support
2-l
30-6
0
1 set Puller
51
140
010 16-30840
793-422-~1~lder
Adjustment
2
2
bolt
1 1
of axle shaft
bearing
Holder for oil seal when
press fitting oil seal
DISASSEMBLY
Nature
AND ASSEMBLY
symbol
of work
Part No.
1 1 1 793-840-1310
I4
Installation
hinge pin
792-103-0400
Part Name
Grip
Remarks
Oty
1 Push tool
I 1
of center
Press fitting
1 6 1 793-520-2370
17
1 793520-2350
1 Push tool
1 Push tool
I 1
783-520-2540
Guide
793-520-2360
Bar
790-502-I
003
Cylinder
of bearing
repair
stand
790-5~;-2000
I
790-101-1102
1 790-330-1100
Commercially
available
790-101-5027
I 1
I Pump
1 Wrench
assy
Socket
(width across flats: 46)
Grip
Steering
Removal, installation
Steermg
Removal, mstallatton
B&j
Disassembly,
assembly
hydraulic cylinder
Installation
of
of piston
ring
1
Boom
cylinder
J
796-720-1690
Ring
07281-01919
Clamp
I
~
796-720-1640
I Ring
Bucket
cylinder
I 1
07281-00909
Clamp
790-101-5021
Grip
01010-50816
Bolt
790-201-1650
Plate
790-201-1560
I Plate
30-7
0
DISASSEMBLY
AND ASSEMBLY
STARTING MOTOR
REMOVAL OF STARTING
MOTOR ASSEMBLY
ADisconnect
the cable from the negative
minal of the battery.
1.
Open
tion.
2.
Disconnect
hose (I 1.
3.
Disconnect
wiring
(2).
4.
Disconnect
wiring
connector
5.
Remove
engine
(-1 ter-
starting
motor
(3).
assembly
(4).
INSTALLATION
OF STARTING
MOTOR ASSEMBLY
l
Carry out
removal.
30-8
0
installation
in the
reverse
order
to
ALTERNATOR
REMOVAL OF ALTERNATOR
ASSEMBLY
ADisconnect
the cable from
minal of the battery.
1. Open engine
tion.
2.
the negative
(-1 ter-
to prevent
misDEW01348
3.
Loosen mounting bolt and nut (2). and adjustment plate mounting bolt (3).
m
4.
5.
INSTALLATION OF
ALTERNATOR ASSEMBLY
l
Carry out
removal.
installation
in the
reverse
order
to
To prevent interference
with the fan belt, set
with the mount bolt and nut facing in the direction shown in the diagram on the right when
installing.
30-9
0
DISASSEMBLY
ENGINE
AND ASSEMBLY
OIL COOLER
hood assembly.
2.
3.
Disconnect
4.
5.
Remove cooler
cover assembly
6.
Remove 4 nuts (6) from oil cooler cover assembly (51, then remove cooler (7).
oil pressure
sensor wiring
(1).
(2) together
oil cooler
XD
DEW00010
INSTALLATION
OF ENGINE
COOLER ASSEMBLY
.
Carry out
removal.
installation
in the
reverse
OIL
order
to
30-l 0
0
DISASSEMBLY
AND ASSEMBLY
boost compensation
tube (1).
2.
to-
3.
Disconnect accelerator
gether with mounting
to-
4.
5.
Disconnect
*
(6) tom
After disconnecting
hose (IO), bend it and
tie with wire to prevent fuel from leaking
m
out.
6.
7.
Remove mounting
bracket (14) at rear of fuel
injection
pump assembly
(13), remove
front
mounting bolts, then remove fuel injection pump
B
assembly (13).
pipes
(II),
and rea
D&VOX07
30-l 1
0
DISASSEMBLY
AND ASSEMBLY
INSTALLATION
OF FUEL
INJECTION PUMP ASSEMBLY
.
Carry out
removal
installation
in the
reverse
order
to
m
w
-w
Mounting bolt of fuel injection pump assembly : 66.7 + 7.8 Nm (6.8 f 0.8 kgm)
30-12
0
Test-
WATER PUMP
Drain engine
2.
Remove radiator
fan guard (2).
3.
4.
Remove
5.
Remove
thermostat
6.
Loosen adjustment
bolt (7) and mount bolt (8)
of alternator assembly (61, remove adjustment
bolt, then move alternator assembly (6) towards
a
frame.
Remove fan (IO) and spacer (11).
Loosen clamp of hose (12). then remove mounting bolts, and remove water pump assembly
7.
8.
coolant.
upper tube
(I),
then
remove
sensor connector
housing
assembly
(31
(5).
(13).
INSTALLATION OF WATER
PUMP ASSEMBLY
l
Carry out
removal.
installation
in the
reverse
order
DBhWOl3
to
a
Adjust the belt tension.
ING AND ADJUSTING,
fan belt tension.
l
30-l 3
0
DISASSEMBLY
WATER PUMP
AND ASSEMBLY
2.
3.
4.
5.
6.
7.
8.
INSTALLATION
OF WATER
PUMP ASSEMBLY
.
Adjust the belt tension. For details, see TESTING AND ADJUSTING, Testing and adjusting
fan belt tension.
Refilling with water
Add water through the water filler to the specified level.Run the engine to circulate the water
through the system. Then check the water level
again.
30-l 3-l
0
DBWOCO14
DISASSEMBLY
TURBOCHARGER
AND ASSEMBLY
REMOVAL OF
TURBOCHARGER
ASSEMBLY
1.
2.
3.
Remove muffler assembly (21, then remove lubrication inlet tube (3).
4.
INSTALLATION
OF
TURBOCHARGER ASSEMBLY
.
in the reverse
order to
m
m
*
m
m
30-14
0
DISASSEMBLY
NOZZLE HOLDER
AND ASSEMBLY
REMOVAL OF NOZZLE
HOLDER ASSEMBLY
1.
hood assembly.
2.
3.
Remove
fuel injection
4.
Remove
holder
5.
Remove spill
holder (5).
(3).
hoses
(41, then
remove
nozzle
J
-1
%3
DEW01374
INSTALLATION OF NOZZLE
HOLDER ASSEMBLY
.
Carry out
removal.
installation
in the
reverse
order
to
/12
w
Holder
mounting bolt :
44.1 + 4.9 Nm (4.5 f 0.5 kgm)
30-l 5
0
DISASSEMBLY
THERMOSTAT
AND ASSEMBLY
REMOVAL OF THERMOSTAT
ASSEMBLY
1.
Open
engine
2.
Drain
engine
coolant.
3.
Remove
4.
5.
Remove
connector
thermostat
INSTALLATION
THERMOSTAT
.
Carry out
removal.
installation
the hose.
(3).
OF
ASSEMBLY
in the
reverse
order
to
m
Clamp
30-l 6
0
DISASSEMBLY
CYLINDER HEAD
AND ASSEMBLY
2.
3.
Serial No.50001
- 52999
Serial
No.53001
DUW0507'
4.
5.
DUW05072
6.
7.
8.
9.
and up
DBWOOOt9
DBW00023
DBWOOOZO
DBWOO021
DBWOOO22
DISASSEMBLY
AND ASSEMBLY
CYLINDER HEAD
30-l 8
0
DISASSEMBLY
AND ASSEMBLY
CYLINDER HEAD
15. Disconnect
16. Remove
17. Remove
18. Disconnect
(23).
(24).
20. Remove
injection
pipes
clamp (26).
I
w
DBWOOO31
DISASSEMBLY
AND
CYLINDER
ASSEMBLY
HEAD
..
22. Remove
fuel injection
23. Remove
5 leads (28).
24. Remove
holders
-I
DBW00032
(29).
DBW0003b
DBW00035
30-20
DISASSEMBLY
AND ASSEMBLY
CYLINDER
HEAD
32
28. Remove
DBW00039
29. Remove
cylinder
head assembly
(35).
30-2 1
0
DISASSEMBLY
AND
ASSEMBLY
CYLINDER
HEAD
INSTALLATION
OF CYLINDER
HEAD ASSEMBLY
.
in the
reverse
order
to
w
*
Tightening
1st step
O-0
2nd step
0-Q
3rd step
O-0
m
w
order
Tightening
torque
DEW01398
(Nm (kgm))
14.8 -+ 4.9
(1.5 + 0.5)
63.7 + 9.8
(6.5 + 1.0)
63.7 I 9.8
(6.5 i 1.0)
Mounting
bolt of after-cooler
assembly:
24.5 f 9.8 Nm (2.5 k 1.0 kgm)
(Only the bolts marked :: in the diagram
on the right.)
Fuel injection pipe
Sleeve nut : 22.6 f 2.9 Nm (2.3 i 0.3 kgm)
m
w
Mounting
Mounting
30-22
0
DEW01399
DISASSEMBLY
*
*
*
m
m
a
m
AND ASSEMBLY
HEAD
1st
CYLINDER
steo
torque
Intake side
Front
Rear
flj
Exhaust side
DEW01 400
@Jr-n (kgm))
After tightening,
make one punch mark on
the bolt head to indicate the number of times
it has been tightened.
If any bolt already has five punch marks, do
not reuse it. Replace it with a new bolt.
Refilling with water
Add water through the water filler to the
specified level.
Run the engine to circulate
the water through the system. Then check
the water level again.
DEW01401
30-23
0
DISASSEMBLY
AND
ASSEMBLY
RADIATOR
REMOVAL OF RADIATOR
ASSEMBLY
AStop
the machine on level ground and install
the safety bar on the frame. Lower the bucket to
the ground and stop the engine. Then apply the
parking brake and put blocks under the wheels
to prevent the machine from moving.
g
Release
the remaining
pressure
in the piping.
When operating
the levers, raise portion a of
the bucket 30 - 50 mm and lower portion b to
the ground, then stop the engine.
After operating the levers, check that the whole
bottom
surface of the bucket (both portion a
and portion b) are in contact with the ground.
Loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank. Then operate
the control levers several times to release the
, remaining
pressure in the hydraulic piping.
A
Disconnect the cable from the negative (-)terminal of the battery.
1.
Cover
1) Remove
spection
2)
mounting
cover (I).
bolts,
then
remove
DEW00447
in-
2.
ti
. _
mWOlE65
u
Drainmg water
Loosen drain valve (4) and drain coolant.
Ir
If the colant contains antifreeze, dispose
, it correctly.
&
Coolant : 53 e
of
DLWOlS6
30-24
0
DISASSEMBLY
3.
4.
AND ASSEMBLY
RADIATOR
Grill
1) Loosen mounting bolts of grill (51, then fit
grill to engine hood (6) temporarily,
and remove light wiring from clip portion of engine hood (6).
2) Disconnect wiring connector (71, and remove
grill (5).
*
Open left and right side panels (8) to
make it possible to fit the lifting tool.
Engine hood
1) Remove radiator left and right plates (9) and
bottom cover (IO).
2)
3)
Remove the front, rear, left, and right mounting bolts and top front mounting
bolts of
engine hood (6).
Hood assembly :
200 kg (without
rear fender)
Hood assembly :
Lelkg
260 kg (with rear fender)
*
Thread size when using eyebolts for removal : 12 mm
&I kg
5.
Wiring
1)
2)
DISASSEMBLY
AND ASSEMBLY
RADIATOR
6.
7.
Radiator hoses
m
1) Disconnect
radiator upper hose (17) at engine end.
2) Disconnect radiator lower hose (18) at radiator end.
*
Loosen the hose clamp of the connection portion at the radiator end.
8.
Hydraulic piping
Disconnect oil cooler hoses (19) I (20) , (211%
I
(22) at connection portion of tube at bottom of
radiator.
*
Mask the openings to prevent water or dust
from entering.
9.
Radiator
Remove
a
mounting
bolts of radiator
Off.
el kg
30-26
0
Radiator : 166 kg
Be careful not to damage
when removing.
the
radiator
fins
DISASSEMBLY
INSTALLATION
ASSEMBLY
l
Carry out
removal.
RADIATOR
AND ASSEMBLY
OF RADIATOR
installation
in the
reverse
order
to
m
*
f
B
Temporarily
install the radiator stays.
Mounting bolt :
110.3 f 12.3 Nm (11.25 f 1.25 kgm)
Install the fan guard so that the clearance
between the fan and fan guard is uniform.
*
113
w
m4
Ir
m
1) Tighten
2)
%a
Transmission
: 35 .Q.
-1
Tighten plug at top of hydraulic tank filter
and plug of pump piping, then add hydraulic oil through oil filler to specified level.
30-27
0
DISASSEMBLY
AND
ENGINE
ASSEMBLY
REMOVAL OF ENGINE
ASSEMBLY
AStop
the machine on level ground and install
the safety bar on the frame. Lower the bucket to
the ground and stop the engine. Then apply the
parking brake and put blocks under the wheels
to prevent the machine from moving.
ARelease
*
the remaining
pressure
in the piping.
ADisconnect
the cable from the negative
minal of the battery.
1.
2.
(-1 ter-
m
Air conditioner
compressor assembly
*
Remove air conditioner compressor.
For details, see REMOVAL OF AIR CONDITIONER COMPRESSOR.
Ir Leave air conditioner
hoses (I) installed to
compressor (2). then remove mounting bolts
(3) and put the compressor assembly on top
of the fuel tank.
Radiator assembly
m
+
Remove radiator assembly.
For details, see REMOVAL OF RADIATOR ASSEMBLY.
t
Loosen connecting hose clamp (5) of radiator lower tube (4) at engine end, then disconnect.
3. Heater hoses
1) Leave left heater.hose
tor lower tube (4).
(6) installed
to radia-
2)
3)
30-28
0
C&O1678
4.
Electric wiring
ENGINE
Starting
DEW01879
2)
3)
Disconnect cable (15) between starting motor and battery relay from starting motor
end.
4)
DBWOlE81
5.
Fuel hoses
a
Disconnect fuel hoses (17), (18), and (19) from
fuel tank end.
*
When disconnecting
the hoses, fit tags to
distinguish them.
Ir Disconnect the hose clamps and bands.
*
Disconnect the connectors of the fuel tank
level sensor wiring.
DISASSEMBLY
6.
AND
ENGINE
ASSEMBLY
a
Fuel control cable
Remove locknut of fuel control cable (20), then
remove.
Ir
Before removing
the locknut, make match
marks to act as a guide when assembling.
8.
9.
Drive shaft
Remove rear drive shaft (27).
*
Make match marks to show
position.
oil cooler
a
the
mounting
Transmission
support stand
Set..support stand @ under transmission.
*
Use a stand with adjustable height and fix it
securely so that it does not slip.
*
Adjust to the correct height.
30-30
0
DISASSEMBLY
AND ASSEMBLY
ENGINE
Remove
(29).
DEW01888
3)
4)
32
DEW01889
DEW01890
11 Muffler assembly
Sling muffler (35), remove left and right mounting bolts, then lift off muffler together
with
bracket (36).
*
When removing the muffler, be careful not
to damage drain tubes (37).
+
It is difficult to stand, so be extremely
careful when removing the muffler.
rllkg
Muffler
assembly
(with bracket)
: 30 kg
DISASSEMBLY
AND ASSEMBLY
ENGINE
DBWOl893
Engine
assembly
: 730 kg
30-32
0
A-7
DBWO169S
DISASSEMBLY
AND
ASSEMBLY
INSTALLATION
ASSEMBLY
l
Carry out
removal.
installation
ENGINE
OF ENGINE
in the
reverse
order
to
the electric
wiring
z
2
3
OF RADIA-
connectors
se-
tags
and connect
for details
I%7
*
Washer
Cushion
Cushion
- Washer
DRWlRq7
-
DEW01898
L
30-33
0
DISASSEMBLY
TORQUE
AND ASSEMBLY
REMOVAL OF TORQUE
CONVERTER CHARGING
ASSEMBLY
CONVERTER
CHARGING
PUMP
PUMP
AStop
the machine on level ground and install
the safety bar on the frame. Lower the bucket to
the ground and stop the engine. Then apply the
parking brake and put blocks under the wheels
to prevent the machine from moving.
*
Open the left inspection cover and apply the
lock.
1. Cover
Remove
cover (1) at bottom of cab, transmission inspection
cover (2). and side inspection
cover (3).
hose, fuel control cable
2. Air conditioner
Remove clamp of air conditioner
hose (4), and
raise air conditioner
hose and fuel control cable
(5) with wire.
DLWOlEB
3.
Hydraulic piping
Disconnect
the following hydraulic
.
Tube (6) between transmission
charging pump
.
.
30-34
0
piping.
strainer
and
DISASSEMBLY
4.
AND ASSEMBLY
PUMP
Remove mounting
bolts, and pull out torque
converter charging pump (9) from cover removal
portion.
*
The working space is confined, so be careful
not to crush your hands or fingers.
+ Carry out the removal operation
with two
workers, and fit lifting tool @ to prevent the
pump from falling.
el
kg
Torque
converter
charging
pump :
10 kg
INSTALLATION OF TORQUE
CONVERTER CHARGING PUMP
ASSEMBLY
l
Carry out
removal.
installation
in the
reverse
order
DLWOlW2
DLWO1903
to
30-35
0
DISASSEMBLY
AND ASSEMBLY
REMOVAL OF TORQUE
CONVERTER, TRANSMISSION
ASSEMBLY
AStop
the machine on level ground
and install
the safety bar on the frame. Lower the bucket to
the ground and stop the engine. Then apply the
parking brake and put blocks under the wheels
to prevent the machine from moving.
Drain transmission
oil.
ALoosen
the oil filler cap slowly to release the
pressure inside the hydraulic tank. Then operate
the control levers several times to release the
remaining
pressure in the hydraulic piping.
ADisconnect
the cable from the
minal of the battery.
1.
2.
3.
negative
(-) ter-
assembly.
OF CAB,
FLOOR
DBWO1904
I
DBWO1905
30-36
0
I
DBW01406
5)
mounting
bolt,
DBWO1908
4.
5.
Disconnect hoses (11) and (12) mounted at bottom of hydraulic and steering pump.
m
*
The hose flange and spacer are tightened
together, so be careful not to lose them when
disconnecting
hoses (11).
6.
Disconnect
7.
transmission
cooler
hose (13).
(141,
DISASSEMBLY
AND ASSEMBLY
8.
9.
Remove
nect.
3 connectors
valve
and cooler
I
10. Remove
nect.
connector
11. Disconnect
(17) from
DBwo1912
DBWO1913
12. Disconnect
13. Remove
+
30-38
0
m
fall out.
DISASSEMBLY
AND ASSEMBLY
and support
TORQUE CONVERTER,
TRANSMISSION
2i
lXWO1916
E:
z
3
I-
24
28
27
DBWo1917
assembly:
700 kg
30-39
0
DISASSEMBLY
TORQUE
AND ASSEMBLY
CONVERTER,
TRANSMISSION
INSTALLATION
OF TORQUE
CONVERTER, TRANSMISSION
ASSEMBLY
.
Carry out
removal.
installation
in the
reverse
order
to
Air conditioner
hose sleeve nut :
22.1 f 2.5 Nm (2.25 fr 0.25 kgm)
m
pKJ
*
F/PI
w
m
.
m
w
24
28
27
DBWO1917
28
DEW01919
30-40
0
DISASSEMBLY
AND ASSEMBLY
TORQUE CONVERTER
DISASSEMBLY OF TORQUE
CONVERTER ASSEMBLY
1. Turbine, case assembly
(2)
(3).
-2
DEW00529
2) Disassemble
follows.
i) Remove
ii) Remove
turbine
as
4
pilot (4).
snap ring (51, then remove
plate
(1).
DEW00530
18
DEW00534
DISASSEMBLY
2.
AND
Stator
1) Remove
2) Remove
ASSEMBLY
TORQUE
CONVERTER
DEW00535
3.
Stator shaft
Using forcing screws 0,
(11) end and disconnect
(121.
4.
5.
Gear
Remove
Bearing
Remove
bearing
DEW00538
30-42
0
DISASSEMBLY
TORQUE CONVERTER
AND ASSEMBLY
ASSEMBLY OF TORQUE
CONVERTER ASSEMBLY
1.
13\
Bearing
install bearing
DEW00533
2.
Gear
Install gear (13) to pump (141.
Mounting bolt:
66.2 f 7.4 Nm (6.75 + 0.75 kgm)
3.
Stator shaft
1)
6
2)
shaft (II).
seal
ring
uni-
DEW00541
DISASSEMBLY
4.
TORQUE CONVERTER
Stator
I)
2)
5.
AND ASSEMBLY
DEW00543
ii)
18
DEW00533
iii)
and
install
30-44
0
DEW00545
DISASSEMBLY
AND ASSEMBLY
TORQUE CONVERTER
VI
Thread tightener
w
(LT-21
Mounting bolt:
30.9 ?I 3.4 Nm (3.15 +_0.35 kgm1
DEW00531
2)
(3) to stator
Thread tightener
w
DEW00530
(LT-2)
Mounting bolt:
30.9 k 3.4 Nm (3.15 + 0.35 kgm)
DEW00529
30-45
0
DISASSEMBLY
AND
ASSEMBLY
DISASSEMBLY
TRANSMISSION
.
1.
TRANSMISSION
OF
ASSEMBLY
DLww170
2.
3.
Hydraulic piping
I)
Remove,tube
hose (3) between
charging pump.
2) Remove tube hose (4) between
verter filter and transmission
transmission
valve.
*
Remove the tube clamps.
strainer
and
Transmission
control valve
1) Remove modulation
valve (5).
2) Remove accumulator
valve (6).
3) Lift off transmission
control valve (7).
*
Leave the upper valve and lower valve
assembly set bolts installed.
&I kg
Transmission
DBWW172
-6
DBwoo173
4. Charging pump
I) Remove hoses and flanges (8) and (9) from
charging pump (IO) and housing.
2) Remove charging pump (IO).
DBWOO174
30-46
0
DISASSEMBLY
5.
TRANSMISSION
AND ASSEMBLY
Hydraulic piping
I)
2)
DEWCOY
6.
Oil filter
1)
176
7.
Rear housing
1) Remove torque converter pilot cap (13).
2) Install tool Al to rear housing (14) and sling.
*
Install tool Al securely so that it does
not come off.
Al
14
DBWO0177
3)
Rear housing,
torque converter
assembly : 190 kg
_.-A1
15
DBwm178
30-47
0
DISASSEMBLY
8.
AND ASSEMBLY
TRANSMISSION
Torque converter
,
Lift off torque converter (16) from rear housing
(14).
*
i3efore removing,
use a felt pen to make
match marks on the mating surface of the
housing and torque converter.
rel
kg
Torque
converter
Rear housing
assembly
: 55 kg
: 135 kg
\
9.
16
DEW00179
converter
DEW@3180
2)
18
22
DLWWlF3
17
3)
30-48
0
DBWOO182
DISASSEMBLY
4)
AND ASSEMBLY
TRANSMISSION
23
24
DBW00165
1) Remove
25
2)
DBW00185
DISASSEMBLY
3)
TRANSMISSION
AND ASSEMBLY
25
DBW00188
12. FORWARD,
REVERSE clutch
1) Using tool A2, pull out FORWARD, REVERSE
clutch (27).
LL Be careful not to get your fingers caught
between gear (32) and the housing.
&I kg
FORWARD,
13. Bearing
I) Remove FORWARD, REVERSE outer bearing
(28), lst, 3rd outer bearing (29), and 2nd, 4th
outer bearing (30) from housing.
30-50
0
remove
idler
DISASSEMBLY
AND
ASSEMBLY
TRANSMISSION
2) Remove
39-
mounting
bolts, then remove
plate (38) and manual cancel bolt (39).
3)
40
front
lock
4)
5)
Install manual
brake housing
condition.
6)
7)
38
40-I
DBWoo193
DBWW194
44
45
Df3WWlSS
30-5 1
0
DISASSEMBLY
8)
AND ASSEMBLY
TRANSMISSION
9)
Set guide bolts (43-I) to parking brake housing (431, then remove mounting
bolts, and
lift off.
*
Loosen the mounting bolts uniformly
a
little at a time.
*
Guide bolt : (12 mm, pitch 1.75 mm,
length: 130 mm)
*
Install the lifting tool. (12 mm, pitch: 1.75
mm)
el
kg
: 21
kg
Ii DEW00197
(43) and
52
DBW00199
30-52
0
DLWM199
DISASSEMBLY
12) Remove
piston
AND ASSEMBLY
piston
(53).
seal rings
TRANSMISSION
53
56
parking
I
5758
60
62
DLWCU205
2)
Remove
retainer
bearing
(60).
parking
brake
DBWW202
DISASSEMBLY
18. Output
I)
TRANSMISSION
shaft gear
Support
remove
AND ASSEMBLY
output
shroud
and
(64).
Cover
DBWCO207
2)
hand on the
64
3)
30-54
0
Remove
towards
position
DISASSEMBLY
TRANSMISSION
AND ASSEMBLY
4)
5)
Remove
bearing
cup (67).
DLWOQ210
6)
19. Covers
1) Remove covers (70) and (71).
*
Remove both the O-rings.
2)
Remove
O-ring
(72).
DBWW212
30-55
0
DISASSEMBLY
AND
ASSEMBLY
ASSEMBLY OF
TRANSMISSION
TRANSMISSION
ASSEMBLY
72,
1.
Covers
Assemble O-rings and assemble covers (70) and
(71) to front housing.
*
Be careful not to the O-rings fall out.
*
Install O-ring (72) to the mating surface of
the parking brake housing.
6
Outside circumference
of O-ring :
Grease
2.
(G2-LI)
2)
3)
DLWDo211
it.
67
4)
30-56
0
DISASSEMBLY
AND ASSEMBLY
TRANSMISSION
5)
portion,
and
6)
Coat mounting
bolts with thread tightener,
and install shroud (64).
Wash and remove all oil and grease from
the mounting
bolt hole and mounting
bolt.
Insert the shroud
from immediately
above the gear, then turn over and assemble.
Check that the gear does not interfere
with the shroud.
w
Mounting bolt :
110.3 * 12.3 Nm (11.25 + 1.25 kgm)
6
Mounting bolt :
Thread tightener
(LT-21
64
3.
60
I
2)
62
MWW214
DISASSEMBLY
3)
4)
ASSEMBLY
TRANSMISSION
59
60
d
c!uass:
.95mm
II II
III II
DBWOO216
*
*
5)
AND
kgm)
If a small torque wrench is not available,
it is possible to measure as follows.
Install measurement
plate (63-I) and retainer plate to shaft (631, tighten coupling mounting bolts, then install pushpull scale to tip of plate (63-l) and measure.
.
Plate length I?.: 100 mm
.
Reading of push-pull scale : 1.0 - 9.8
Nm (0.1 - 1.0 kgm)
When measuring the rotating torque, do
not measure at the point where movement begins. Measure while it is rotating.
If the rotating torque is not within the
standard value, change the shim thickness to adjust again.
If the rotating torque is within the standard value, check that the end play is 0.
Assemble
selected
shims (61) to parking
brake retainer (60), then assemble to front
housing.
*
Assemble
the thinnest shim on the inside and the thickest shim on the outside.
f
Assemble
so that the casting holes (3
places) are at the bottom.
w
Mounting bolt (59):
110.3 It 12.3 Nm (11.25 L- 1.25 kgm)
DLWCO2C-S
30-58
0
DISASSEMBLY
4.
AND ASSEMBLY
2)
TRANSMISSION
43-l
*
53
56
I
3)
DLW00201
Assemble
snap ring (54) to parking brake
housing (431, and install piston (53).
*
Check that the snap ring is fitted securely
in the groove.
*
Knock in the piston uniformly a little at a
time with a plastic hammer.
6
Outside circumference
of seal ring,
sliding surface : Transmission
oil
I
4)
DLWW159
52
DBWOO198
DISASSEMBLY
5)
AND ASSEMBLY
TRANSMISSION
6)
*
*
m
7)
11 DEW00197
Install manual
brake housing
position.
58
DLWOOZZO
8)
9)
30-60
0
output
DISASSEMBLY
AND ASSEMBLY
TRANSMISSION
IO) Assemble
A4
44
45
DBWCO195
12) Press fit oil seal (42) and dust seal (41) to
cover (40).
Press-fitting dimension a : 28.5 + 1 mm
Press-fitting dimension II : 17.5 + 1 mm
&
Lip of oil seal : Grease (G2-LI)
Coat lip of
oil seal with G2-LI
13) Install gasket (40-I) to parking brake housing (43), align with dowel pi;~, then install
cover (40).
Knock the cover in uniformly with a plas*
tic hammer.
Be careful not to let the oil seal contact
*
the shalt.
w
Mounting bolt :
110.3 f 12.3 Nm (11.25 + 1.25 kgm)
DLWOOPl
DLWWZZZ
40-l
DBWOJ193
DISASSEMBLY
AND ASSEMBLY
5.
6.
Idler gear
I) Press fit bearings (33) to idler gear (32).
2) Press fit idler gear (32) to shaft, and install
snap ring (31).
+r If the shaft has been removed, cool the
shaft to -7OC, then press fit it to dimension g.
t
Shaft dimension g : 46.5 f: 0.5 mm
TRANSMISSION
.
33
7.
Bearing
1) Assemble FORWARD, REVERSE outer bearing (281, Ist, 3rd outer bearing (291, and 2nd,
4th outer bearing (30) to housing.
30-62
0
DBWOD191
8.
TRANSMISSION
REVERSE
clutch (27) in housing, then align REVERSE
gear and idler gear (32) and assemble.
A Be careful not to get your fingers caught
in the gears.
226
9.
2)
3)
30-63
0
DISASSEMBLY
4)
IO.
AND ASSEMBLY
TRANSMISSION
Seal rings
Install seal rings (24) to each clutch shaft.
+
Coat the seal rings well with oil, then assemble and check that the rotation is smooth.
&Seal
ring : Transmission
oil
I
11. Pump (torque converter, loader)
I) Press fit bearing (23) to shaft (22).
*
Press fit so that there is no clearance
the rear of the shaft.
24
DBWO3185
Press
at
23
I
2)
DLWW321
Assemble
gear (18), ring washer (201, and
snap ring (19) to inside of rear housing (14),
then insert shaft (22) from pump mount end.
8
22
30-64
0
DLWW232
DISASSEMBLY
3)
4)
AND ASSEMBLY
TRANSMISSION
Assemble split spacer (21) to stepped portion of shaft, then assemble ring washer (20)
to split spacer, and install snap ring (19).
DEW00180
\
DBW00234
DISASSEMBLY
AND ASSEMBLY
TRANSMISSION
*
*
*
&
w
2)
Outside
Al
14
30-66
0
DBwco177
DISASSEMBLY
AND ASSEMBLY
TRANSMISSION
17. Transmission
control valve
1) Install guide bolt to mount portion of transmission control valve (7).
Ir Wash and remove all oil and grease from
the control valve mounting bolt hole and
mounting bolt thread.
2) Align with guide bolt and assemble gasket,
then fit control valve (7) temporarily.
3) Coat mounting bolts of control valve (7) with
thread tightener and tighten.
*
Tighten the mounting
bolts in turn on
diametrically opposite sides and be careful not to tighten too much.
*
The length of the mounting
bolts is different, so be careful when using them.
&
Mounting bolt :
Thread tightener
(LT-21
m
Mounting bolt :
34.3 +4.9 Nm (3.5 f 0.5 kgm)
DBW00175
-6
DBW00173
4)
5)
Assemble
O-ring to accumulator
valve (6),
and install to transmission.
*
Wash and remove all oil and grease from
the mounting
bolt hole and mounting
bolt.
&
Mounting bolt :
Thread tightener (LT-2)
w
Mounting bolt :
34.3 + 4.9 Nm (3.5 + 0.5 kgm)
Align gasket with modulation
valve (5) and
assemble to transmission
valve.
*
Wash and remove all oil and grease from
the mounting
bolt hole and mounting
bolt.
&
Mounting bolt :
Thread tightener (LT-2)
w
Mounting bolt :
34.3 f 4.9 Nm (3.5 f 0.5 kgm)
TRANSMISSION
DLWW238
Dl3WOX72
2)
DLWO0170
30-68
0
DISASSEMBLY
3)
AND ASSEMBLY
TRANSMISSION
Transmission case
3
76
75
c
I/Z - 1 turn
DLWWZ40
30-69
0
DISASSEMBLY
AND ASSEMBLY
DISASSEMBLY
TRANSMISSION
ASSEMBLY
TRANSMISSION
CLUTCH PACK
OF
CLUTCH PACK
DEW00241
DBWBJ242
Bearing
Using puller and remove
2.
Bl
bearing
(I).
3.
End plate
I) Install tools B3 and B5, then tighten
tool B4,
tool B3.
DEW00244
2)
30-70
0
Remove
4.
TRANSMISSION
CLUTCH PACK
Clutch plate
Remove plate
from housing.
Ill),
disc
(12),
and
spring
(13)
DBWOO245
5. Piston
Blow air in FORWARD oil hole of shaft and remove piston (14).
*
If the piston is at an angle and cannot be
removed, push the piston in and try to remove it again.
*
Do not use force to remove it. The inside
circumference
of the cylinder will be damaged.
DEWLW247
6.
7.
8.
Snap ring
*
Set on tool Bl with the REVERSE
at the top.
Remove snap ring (15).
clutch side
22
23
24
Shaft, cylinder
1)
2)
Remove snap ring (26) from shaft and housing (25), then remove housing (27).
Remove snap ring (28), then remove housing (27).
27
28
26
DLWW249
30-71
0
DISASSEMBLY
AND ASSEMBLY
TRANSMISSION
CLUTCH
PACK
Disassembly
of lst, 3rd clutch
Ir Set on tool Bl with the 1st clutch side at the
top.
1. idler gear
I) Remove snap ring (291, then using puller,
remove spacer (30), inner bearing (31), and
idler gear (32).
32
2.
1st gear
1) Remove snap ring (331, then remove thrust
washer (34).
2) Remove 1st gear (35), and needle bearings
(36) and (37).
37
36
DBWCO252
3.
End plate
I)
Install tool B3 and B5, then tighten tool B4,
and remove ring (38).
*
After removing the ring, remove tool B3.
2)
Remove
DEW03254
30-72
0
DISASSEMBLY
TRANSMISSION
AND ASSEMBLY
4.
Clutch plate
1.) Remove plate (401, disc (411, and spring (42)
from housing.
2) Remove thrust washer (43).
5.
Piston
Blow air in REVERSE oil hole of shaft, and remove piston (44).
*
If the piston is at an angle and cannot be
removed, push the piston in and try to remove it again.
* Do not use force to remove it. The inside
circumference
of the cylinder will be damaged.
6.
7.
Bearing
Set on tool Bl with the 3rd clutch
top.
Using puller, remove bearing (45).
side at the
3rd gear
Remove spacer (461, thrust washer (471, needle
bearing (481, and 3rd gear (49).
*
Use the same procedure as in Steps 3 - 5
for the 1st gear to continue disassembly.
CLUTCH
PACK
DISASSEMBLY
TRANSMISSION
AND ASSEMBLY
Disassembly
of 2nd, 4th clutch pack
*
Set on tool Bl with the 4th clutch side at the
top.
1. Idler gear
Fit puller to idler gear (501, then remove bearing
(51) together with idler gear.
CLUTCH
PACK
51
50
1
2.
4th gear
1) Remove thrust washer (521, 4th gear (531,
needle bearing (541, and thrust washer (55).
2) Remove snap ring (561, spacer (57), and needle bearing (58) from 4th gear (53).
55
53
54
52
DEW00261
3.
End plate
1) Install tools B3 and B5, then tighten tool B4,
and remove ring (59).
t
After removing the ring, remove tool B3.
2)
Remove
56
57 58
53
DLW02260
85
B3
DEW@263
30-74
0
TRANSMISSION
4.
Clutch plate
Remove plate
from housing.
5.
CLUTCH PACK
(61),
disc (62),
and
spring
(63)
Piston
Blow air in 4th oil hole of shaft,
and remove
piston (64).
*
If the piston is at an angle and cannot be
removed, push the piston in and try to remove it again.
*
Do not use force to remove it. The inside
circumference
of the cylinder will be damaged.
cc)
6.
Idler gear
* Set on tool BI with the 2nd clutch side at
the top.
I) Remove snap ring (65).
2) Using puller, remove spacer (66), inner bearing (671, and idler gear (68).
* When fitting the puller, put the plate in contact with the center first.
69
70
7.
2nd gear
Remove thrust washer (69), needle bearing (70),
2nd gear (71), and thrust washer (72).
Ir Use the same procedure as in Steps 3 - 5
for the 2nd gear to continue disassembly.
72
71
70
69
30-75
Q
DISASSEMBLY
AND ASSEMBLY
ASSEMBLY OF
TRANSMISSION
ASSEMBLY
CLUTCH
PACK
CLUTCH PACK
4.
TRANSMISSION
-47
73
73-l
Piston seal
before using tool B6
73
(F-R)
DLWOO268
REVERSE piston
Install REVERSE piston (73).
*
Be careful not to damage the piston seal.
*
Check that the spring pin does not extend
from the circumference
of the shaft.
&
Sliding surface of piston seal :
Transmission
oil
DEW00269
5.
Clutch plate
Insert tool B2 into housing, then assemble plate
(741, disc (751, and spring (76) in turn.
t
Soak disc (75) in clean transmission
oil for
at least 2 minutes before assembling.
J, Be careful to assemble so that disc (75) and
spring (76) are not resting on each other.
k
Be careful that the plate or spring are not
caught in the clutch housing ring groove
when assembling.
30-76
0
DISASSEMBLY
6.
AND ASSEMBLY
TRANSMISSION
End plate
I) Install tools B3 and B5, then tighten tool 84
to push in end plate (77).
2) Assemble ring (781, and remove tooi B3.
+ Check that the disc rotates smoothly by
hand.
CLUTCH PACK
I
85
78
DEW00271
7.
8.
Thrust washer
Assemble washer (241, thrust
thrust washer (22).
bearing
(231, and
REVERSE gear
Align spline groove on inside of plate with a
screwdriver to assemble gear (17).
*
If the gear spline does not match, turn lightly
when assembling.
Never use force to push
21
17
22
23
ij
k
5
9.
Needle bearing
Assemble needle bearing (21) and thrust washer
(20).
+ Check that the end face of the thrust washer
is below the surface of the stepped portion
of the shaft.
24
DLW02269
10. Bearing
1) Assemble spacer (191, then press fit inner
bearing (18) and spacer (IS).
*
Press fit completely
so that there is no
clearance.
a
Thrust washer : Transmission
oil
2) Assemble snap ring (15).
3)
After press fitting bearing; check that clearance a between thrust washer and spacer
is within standard value.
+
a = 0.106 - 0.991 mm
DISASSEMBLY
AND ASSEMBLY
TRANSMISSION
CLUTCH
PACK
DEW00272
DBWW273
DBWCO274
30-78
0
bearing
(4).
D&V00275
DLWW276
DISASSEMBLY
AND ASSEMBLY
TRANSMISSION
CLUTCH
PACK
17. Spacer
Assemble
thrust washer
(3), then assemble
spacer (2).
f
Check that the end face of the thrust race of
the thrust washer is below the surface of the
stepped portion of the shaft.
6
Thrust washer : Transmission
oil
18. Bearing
Press fit bearing (1).
*
Press fit completely so that the spacer is in
tight contact with bearing (I) at the stepped
portion of the shaft.
Ir
DLW02271
DBWW279
DISASSEMBLY
AND
ASSEMBLY
TRANSMISSION
CLUTCH
PACK
1.
Piston seal
Assemble piston seal (79-l) to piston (79).
*
When assembling
a new piston seal, use
tool B7 to make the seal fit well (time: approx.
2 - 3 minutes), then assemble the seal.
*
If the seal is assembled to the cylinder without making it fit first, the seal will be damaged.
&
Inside surface of tool B7 :
Transmission
oil
79.
87
2.
3rd piston
Install 3rd piston (79).
*
Be careful not to damage the piston seal.
*
Check that the spring pin does not extend
from the circumference
of the shaft.
6
Sliding surface of piston seal :
Transmission
oil
3.
Clutch plate
Assemble plate (801, disc (81). and spring (82) in
turn to housing.
*
Soak disc (81) in clean transmission
oil for
at least 2 minutes before assembling.
*
Be careful to assemble so that disc (81) and
spring (82) are not resting on each other.
*
Be careful that plate (80) or spring (82) are
not caught in the clutch housing ring groove
when assembling.
82
81
80
DBwal282
30-80
0
DISASSEMBLY
4.
AND ASSEMBLY
TRANSMISSION
CLUTCH
PACK
End plate
I) install tools B3 and B5, then tighten tool B4
to push in end plate (83).
2) Assemble ring (84), and remove tool B3.
*
Check that ring (84) is fitted securely in
the groove.
*
Check that the disc rotates smoothly by
hand.
3)
Assemble
thrust washer
(85).
5:
3rd gear
Assemble 3rd gear (491, then assemble
needle
bearing (48).
Ir If the gear spline does not match, turn lightly
when assembling.
Never use force to push
it in.
*
Assemble the needle bearing at the bottom
first.
6.
Bearing
Assemble
thrust washer (47) and spacer (461,
then press fit bearing (45).
*
Check that the end face of the thrust washer
is below the surface of the stepped portion
of the shaft.
*
Press fit completely so that the spacer is in
tight contact with bearing (45) at the stepped
portion of the shaft.
n49
8
46
DBW00286
After press fitting bearing, check that clearance d between thrust washer
(47) and
spacer (46) is within standard value.
*
d = 0.1 - 0.9 mm
DiWO2272
30-81
0
DISASSEMBLY
AND ASSEMBLY
TRANSMISSION
7.
1st piston
1) Turn over clutch pack.
g
When turning over the clutch pack, be
careful not to get your fingers caught
between the stand and clutch pack.
2) In the same way as with 3rd piston, make
sure that.piston
seal fits well before assembling it to piston (44).
3) Assemble
piston (44) in the same way as
3rd piston.
&
Sliding surface of piston seal :
Transmission
oil
8.
Clutch plate
Assemble plate (401, disc (41), and spring (42) in
turn to housing.
or Assemble
in the same way as for the 3rd
clutch plate.
42
CLUTCH PACK
41
8
DLWWZES
9.
End plate
I) Install tools 83 and B5, then tighten tool 84
to push in end plate (39).
2) Assemble
ring (381, and remove tools 83
and B4.
*
Assemble
in the same way as for the
3rd end plate.
85
39
38
3)
Assemble
thrust washer
(43).
(37).
*
Assemble
3rd gear.
in the same
way
bearing
as for the
DBWWZ90
30-82
0
DBWOaZ91
c:
2)
3)
TRANSMISSION
Assemble
needle bearing (36) and thrust
washer (34).
a
Thrust washer : Transmission oil
Assemble snap ring (33).
+
Fit the snap ring securely in the groove
of the shaft.
CLUTCH PACK
36
29
12. Bearing
1) Press fit inner bearing (31) and spacer (30).
2) Assemble snap ring (29).
*
Fit the snap ring securely in the shaft
groove.
30-83
0
DISASSEMBLY
AND
TRANSMISSION
ASSEMBLY
CLUTCH
PACK
1.
Piston seal
Assemble
piston seal (86-I) to piston (86).
*
When assembling
a new piston seal, use
tool B7 to make the seal fit well (time: approx.
2 - 3 minutes), then assemble the seal.
*
If the seal is assembled to the cylinder without making it fit first, the seal will be damaged.
&
Inside surface of tool B7 :
Transmission
oil
-n
86
seai
Piston before
using tool B7
86-l
2.
2nd piston
Install 2nd piston 186).
*
Be careful not to damage the piston seal.
J, Check that the spring pin does not extend
from the circumference
of the shaft.
3.
Clutch plate
Assemble plate (87), disc (881, and spring (89) in
turn to. housing.
*
Soak disc (88) in clean transmission
oil for
at least 2 minutes before assembling.
t
Be careful to assemble so that disc (88) and
spring (89) are not resting on each other.
f
Be careful that the plate or spring are not
caught in the clutch housing
ring groove
when assembling.
30-84
0
DLW01926
DISASSEMBLY
4.
AND ASSEMBLY
TRANSMISSION
CLUTCH
PACK
End plate
I) Install tools B3 and B5, then tighten tool B4
to push in end plate (90).
21 Assembie ring (911, and remove tool B3.
*
Check that the disc rotates smoothly by
hand.
DEW03298
5.
6.
7.
8.
Thrust washer
Assemble thrust washer (72).
2nd gear
Assemble 2nd gear (71), then assemble needle
bearing (70).
*
If the gear spline does not match, turn lightly
when assembling.
Never use force to push
it in.
Idler gear
Assemble thrust washer (69) and idler gear (68).
*
Check that the end face of the thrust washer
is below the surface of the stepped portion
of the shaft.
&
Thrust washer : Transmission
oil
Bearing
1) Press fit inner bearing (67) and spacer (66).
2) Assemble snap ring (65).
*
Fit the snap ring securely in the shaft
groove.
*
After press fitting the bearing, check that
clearance e between the thrust washer
and the idler gear is within the standard
value.
*
e = 0.34 - 1.66 mm
,
c
DBWW390
69
DLW02267
67
66
DISASSEMBLY
9.
AND ASSEMBLY
TRANSMISSION
CLUTCH PACK
4th piston
I) iurn over clutch pack.
g
When turning over the clutch pack, be
careful not to get your fingers caught
between the stand and clutch pack.
2) In the same way as with 1st piston, make
sure that piston seal fits well before assembling it to piston (64).
piston (64) in the same way as
3) Assemble
2nd piston.
&
Sliding surface of piston seal :
DBWCGQ2
DBWW303
85
DBWW3U4
3)
30-86
0
Assemble
thrust washer
(55).
DISASSEMBLY
AND ASSEMBLY
TRANSMISSION
56
57 58
CLUTCH
PACK
53
DLWO2260
13. Bearing
Assemble
52
(51).
53
DBWOEC6
50
51
DLW02274
DBWW3a7
30-87
0
DISASSEMBLY
AND ASSEMBLY
REMOVAL
CONTROL
TRANSMISSION
CONTROL
VALVE
OF TRANSMISSION
VALVE ASSEMBLY
AStop
the machine on level ground and install
the safety bar on the frame. Lower the bucket to
the ground and stop the engine. Then apply the
parking brake and put blocks under the wheels
to prevent the machine from moving.
1.
Remove
covers
I
2.
Remove parking
nipple 6).
3.
Remove
accumulator
& kg
4.
(5), and
valve : 8.5 kg
30-88
0
DBWCCQ84
valve (7).
Accumulator
dBWOO312
DBWOO310
DISASSEMBLY
5.
AND ASSEMBLY
TRANSMISSION
CONTROL VALVE
Electric wiring
I)
2)
6.
7.
Remove
8.
Sling transmission valve assembly (191, then remove mounting bolts, and lower assembly under chassis.
m
*
Leave upper and lower valve mounting bolts
(20) installed.
*
Remove together with the wiring bracket.
The
working space is confined,
so be exA
treme!y careful when carrying out this operation.
*
When fitting the lifting tool, avoid the connectors, fit securely to the valve body, and
be careful to maintain the balance.
r+ kg
modulating
Transmission
11 (TO51
valve (18). a
valve : 46 kg
DBWCO315
DISASSEMBLY
AND ASSEMBLY
TRANSMISSION
CONTROL
VALVE
INSTALLATION OF
TRANSMISSION
CONTROL
VALVE ASSEMBLY
.
480
Carry out
removal.
*
t
6
m
installation
in the
reverse
order
e90
to
Connect
the wiring
connector
securely.
a
Ir
*
*
*.
+
jr
6
m
w
30-90
0
The working space is confined, so be extremely careful when carrying out this operation.
Use a new part for the gasket.
Use guide bolts to prevent the part from
falling out during installation.
Lock with upper and lower valve set bolts
(20).
Wash and remove
the valve mounting
Mounting bolt
Mounting bolt
34.3
49
Set bolt :
:
+ 4.9 Nm (3.5 f 0.5 kgm)
? 4.9 Nm (5.0 + 0.5 kgm)
e115
DBWOO317
DISASSEMBLY
AND ASSEMBLY
TRANSMISSION
CONTROL
VALVE
DISASSEMBLY OF
TRANSMISSION
CONTROL
VALVE ASSEMBLY
57
\
43
60
20
bl
42
10
51
21
f$P@
Al/
Modulating
valve
DBWOl929
30-92
0
DISASSEMBLY
AND ASSEMBLY
1.
Disconnection
Remove mounting bolts, and disconnect upper
valve (2) from lower valve (I), then remove gasket (3).
2.
3.
z!
N
4
3)
4)
5)
6)
7)
8)
9)
IO)
11)
TRANSMISSION
CONTROL
VALVE
(37).
Remove mounting bolts, then remove solenoid valve (381, and O-rings (39) and (401.
Remove mounting bolts, then remove cover
(41), gasket (421, F return spring (43), and
sleeve (44).
Remove priority valve (45).
Remove brake valve (46) and return spring
(47).
Remove mounting bolts, then remove cover
(48), gasket (491, and priority spring (50).
Remove F return spring (51) and sleeve (52),
then remove F-R valve (53).
Remove plug (54) from F-R valve (53).
Remove return spring (55) and spring spacer
(56), then remove speed valve (57) and ii-L
valve (58).
Remove orifices (591, (60), and (61), and plugs
(62) and (63) from lower valve (I).
30-93
0
DISASSEMBLY
AND ASSEMBLY
TRANSMISSION
CONTROL VALVE
ASSEMBLY OF
TRANSMISSION
CONTROL
VALVE ASSEMBLY
57
_a
Gasket
valve
DEW01923
30-94
0
DISASSEMBLY
1.
TRANSMISSION
AND ASSEMBLY
f3-7mm
DLWal319
f:
5)
2
3
CONTROL VALVE
Assemble O-rings (40) and (39) to solenoid valve (38), then install solenoid
valve (38).
Ir Check that there are no scratches,
cracks, deformation,
or any other
deterioration
in the O-rings.
*
Set the mounting
angle of reverse
solenoid
valve
(38) to 45, then
tighten the nut.
w
Mounting bolt :
1.62 + 0.15 Nm (0.165 f 0.015 kgm)
w
Solenoid nut :
12.5 + 4.7 Nm (1.275 f 0.475 kgml
IO) Fit O-rings (37) and (36) to parking brake
solenoid (351, then instatl parking brake
solenoid (35).
*
Check that there are no scratches,
cracks, deformation,
or any other
deterioration
in the O-rings.
w
Mounting bolt :
1.62 f 0.15 Nm (0.165 + 0.015 kgm)
11) Assemble O-ring (34) to pilot filter (33),
then install pilot filter (33).
*
Check that there are no scratches,
cracks, deformation,
or any other
deterioration
in the O-rings.
m
Mounting bolt :
66.2 f 7.4 Nm (6.75 + 0.75 kgm)
9)
Guide
48
DSWOO320
6)
7)
8)
Mounting bolt :
30.9 ? 3.4 Nm (3.15 + 0.35 kgml
Ir Install guide bolts.
Replace the gasket with a new part.
*
Install return spring (47) (L=46) and brake
valve (46).
Install priority valve (45).
Install sleeve (44) and F return spring (43)
(L=42), and set gasket (42) in position, then
install cover (41).
w
Mounting bolt :
30.9 + 3.4 Nm (3.15 f 0.35 kgm)
*
Install guide bolts.
Replace the gasket with a new part.
*
30-95
0
DISASSEMBLY
2.
AND ASSEMBLY
TRANSMISSION
3.
CONTROL
VALVE
Connection
Set gasket (3) to lower valve (I), and assemble upper valve (2) with set bolts (2-I).
*
Install guide bolts.
Ir Replace the gasket with a new part.
w
Set bolt : 49 * 4.9 Nm (5.0 f 0.5 kgm)
&7mm
2-3mm
DLWW319
30-96
0
TRANSMISSION
ACCUMULATOR
VALVE
DISASSEMBLY OF
TRANSMISSION
ACCUMULATOR UALVE
ASSEMBLY
1.
2.
3.
Remove accumulator
valve (4) from transmission assembly (3).
Remove O-rings (I) and (2) from accumulator
valve (4).
Using pads, set accumulator
valve body (9) in
vice.
4.
Remove mounting bolts (5) and (61, and assemble guide bolts.
.
M = 10, P = 1.5, L = Approx. 40 mm
5.
ii
I
6.
il
DBWW323
Pull out valves (II), springs (12) and (141, stoppers (13) and (15), and spacers (16) and (17)
from cover (IO).
or Fit tags to each spring, stopper, spacer, and
use for reference when assembling.
Reference
,
Spring
Stopper
Spacer
FWD
e = 184.8
e = 135.8
e=10
IST
e = 157.5
e=iio
e = 50
2ND
e = 157.5
e=110
e = 50
DEW03324
12
14
16
16
DLWoo325
30-97
0
DISASSEMBLY
7.
AND ASSEMBLY
18
19
10
DEW00326
6-jmm
2-3mm
DAW00327
ASSEMBLY OF
TRANSMISSION
ACCUMULATOR
ASSEMBLY
1.
2.
3.
4.
5.
VALVE
30-98
0
16
TRANSMISSION
MODULATING
VALVE
DISASSEMBLY OF
TRANSMISSION
MODULATING
VALVE ASSEMBLY
DLww3i9
1.
2.
3.
4.
30-99
0
DISASSEMBLY
AND ASSEMBLY
TRANSMISSION
MODULATING
VALVE
ASSEMBLY OF
TRANSMISSION
MODULATING
VALVE ASSEMBLY
6
1.
Assemble
sembly
a
f
Be careful
(LG-1 or LG-51
not to let the sealant drip.
I
&7mm
valve as-
(1).
Plug : Sealant
Coat with
sealant
Z-3mm
DLwm319
2.
3.
30-100
0
4.
Assemble
spring (8) (L=22), stopper (7), inner spring (6) (L=88), outer spring (5) (L=49),
and ACC valve (4) to modulating
valve assembly (I), then assemble
O-ring (3) and
cover (2).
m
Mounting bolt :
30.9 k 3.4 Nm (3.15 + 0.35 kgm)
DRIVE SHAFT
DISASSEMBLY OF DRIVE
SHAFT ASSEMBLY
a
1.
Make match marks a to prevent the coupling from being installed in the opposite direction.
Cover (2) is caulked at 2 places with a
punch, so do not remove it unless necessary.
If cover (2) was removed and the oil seal
was replaced.
i)
Remove cover (2).
t
When removing
cover (21, be
careful not to damage cover (2)
or tube (3).
*
When removing the caulking, use
a screwdriver to raise the caulked
portion.
ii) Remove washer (4), oil seal (5) and
washer (6).
DEWOOBO!
Caulking
5
\
DBW01931
2)
3)
bearing
DBW01332
DLWO1933
(9).
30-101
0
DISASSEMBLY
DRIVE SHAFT
AND ASSEMBLY
4)
5)
I)
DEW01939
DEW01997
30-102
0
DISASSEMBLY
DRIVE SHAFl-
AND ASSEMBLY
2)
3)
t
inside
DSWO1940
30-l 03
0
DISASSEMBLY
AND ASSEMBLY
ASSEMBLY
1.
OF DRIVE SHAFT
Spider, bearing
I) Set bearing (12) of spider (13) in mounting
position, and after assembling
spider (13),
assemble ring (II), then install.
*
Assemble so that the grease nipples are
facing in the same direction.
*
Use the same procedure
for the front,
center, and rear drive shafts.
2)
2.
DRIVE SHAFT
bearing
18
Caulking
in di-
30- 104
0
DBW01942
DISASSEMBLY
2)
AND ASSEMBLY
DRIVE SHAFf
19
3)
DEW00819
as in Step 3)
D&V01936
DISASSEMBLY
AND
FRONT
ASSEMBLY
AXLE
Tire, wheel
Put sling around tire (I), then remove
bolts and lift off.
6 kg
3.
4.
Tire, wheel
DLWO1944
I
mounting
m
: 317 kg
Drive shaft
Disconnect front drive shaft (2).
113
pzJ
Axle
1) Disconnect brake tube (3).
When removing the front frame inspection
cover and disconnecting
the brake tube to
carry out the operation, set support 0 under the lift arm.
DLW01946
DISASSEMBLY
2)
FRONT AXLE
Using jack and hoist, sling axle (41, and remove mounting bolts (5), then lift off. m
Awhen
installing the nylon lifting tool,
tighten the nylon rope fully. After removing the axle assembly, make sure that it
does not fall.
*
Adjust the height of the jack, then remove the mounting bolts.
+I kg
3)
AND ASSEMBLY
oil 37&l
30- 107
0
DISASSEMBLY
FRONT AXLE
AND ASSEMBLY
INSTALLATION
OF FRONT
AXLE ASSEMBLY
.
Carry out
removal.
installation
in the
reverse
order
to
m
Ir
Mounting bolt :
927 f 103 Nm (94.5 + 10.5 kgm)
(Width across flats : 36 mm)
pJ
*
w
a
Ir
m
30-108
0
DISASSEMBLY
REAR AXLE
AND ASSEMBLY
2.
Fuel tank
Remove fuel tank (1).
For details, see REMOVAL
SEMBLY.
OF FUEL TANK
AS-
Jacking up chassis
1) Set blocks @ between
left and right rear
axles and rear frame.
*
Set the blocks so that the angle of the
tire angle on the opposite side does not
change when the tire assembly
is removed.
2)
DLW01952
DLW01953
3)
30-109
0
DISASSEMBLY
3.
Tire, wheel
Put sling around tire (31, then remove
bolts and lift off.
&I kg
4.
REAR AXLE
AND ASSEMBLY
Tire, wheel
mounting
m
: 317 kg
Drive shaft
Remove rear drive shaft (4).
*
Make match marks to show
position.
the
m2/
mounting
DLWU1956
5.
DLWO1957
2)
30-110
0
DLWO1958
DISASSEMBLY
6.
AND ASSEMBLY
REAR AXLE
Axle
1)
2)
MWO1960
8
k
5
3)
4)
DEW01964
DISASSEMBLY
7.
AND ASSEMBLY
REAR AXLE
Rear Divot
cap (14).
Sling the rear pivot.
1) Remove trunnion
*
2) Remove mounting
3)
Remove
4)
plate (17).
DBW01965
DLW01966
8
DBW01367
DLWO1970
8.
5)
6)
Remove bushing
Front pivot
1) Remove
remove
2)
30-112
0
DBWOlStXI
DISASSEMBLY
INSTALLATION
ASSEMBLY
Carry out
removal.
REAR AXLE
AND ASSEMBLY
installation
OF REAR AXLE
in the
reverse
order
to
Mounting bolt :
927 5 103 Nm (94.5 + 10.5 kgm)
(Width across flats: 36 mm)
a
*
Ir
*
m
8
:
5
Align the match marks, and take care to assemble the coupling facing in the correct
direction.
Align the pilot portion securely and take care
to assemble with the yoke facing in the correct direction.
Mounting bolt :
110.3 + 12.3 Nm (11.25 * 1.25 kgm)
a
+
*
*
w
*
t
&
Mounting
bolt :
108 rt 14.7 Nm (11.0 * 1.5 kgm)
@qz-pg
t
&
c
Dust
seal
side
Retainer
Grease
side
Grease
side
Bushing
1
Dust
seal side
DBW01972
30-l 13
0
DISASSEMBLY
&
AND
Bushing
: Grease
(G2-LI)
Greasing
Grease each pivot well.
*
Wipe off any grease
30-l 14
0
REAR AXLE
ASSEMBLY
that is squeezed
out.
DISASSEMBLY
DISASSEMBLY
DIFFERENTIAL
1.
Draining
Remove
%#I
2.
OF
ASSEMBLY
oil
drain plugs (I), and drain oil.
Axle oil : 37 e
Axle assembly
1) Set axle assembly
(2) on pallet.
Axle assembly
2)
DIFFERENTIAL
AND ASSEMBLY
el
R:iove
: 1,021 kg (front)
3.
4.
Differential cover
Remove bleeder screws (4). then remove
ential cover (5).
differ-
Axle housing
1) Sling axle housing assembly (6), and remove
housing mounting bolts.
* Make match marks on the housings to
prevent mistakes between
the left and
right axle housings.
* Set blocks to prevent the assembly from
tilting when the housing assembly
on
one side is removed.
2)
assembly
DBW01975
(6).
& kg
: 280 kg (front)
kg
C5?I
: 270 kg (rear)
DBW01976
30-l 15
0
DISASSEMBLY
5.
DIFFERENTIAL
ASSEMBLY
Cage
I)
Screw in forcing screws, and using guide
bolts (7) (16 mm, P=2, L=50mm),
remove
cage assembly (81.
Ir Check the number of shims and use as
reference when assembling.
*
Loosen the mounting bolts of the coupling, and fit temporarily.
2)
6.
AND
Cage assembly : 46 kg
&I kg
Remove O-ring (9) from cage.
Brake piston
Install bleeder screw, blow in compressed
air
from portion a, raise housing and piston (IO),
and remove.
*
If the D-ring is damaged,
blow in air suddenly to make a gap between the housing
and piston, then use a screwdriver to lever it
out and remove it.
When removing the piston, be careful not to
*
damage the housing and piston surface.
DEW01979
7.
8.
Differential
carrier assembly
1) Lift off differential carrier assembly (I I) from
differential
housing (13).
*
Be extremely careful not to let the lifting
tool come off when removing.
r+lkg
Differential
carrier assembly
: 120 kg
DBW01980
30-116
0
DISASSEMBLY
AND ASSEMBLY
DIFFERENTIAL
car-
carrier
DEW01991
3)
16
17
15
DEW01992
4)
Remove
spherical
spider shaft,
washers (18).
pinion
shaft,
and
18
DEW01983
5)
DBWO1984
30-l 17
0
DISASSEMBLY
6)
Remove
AND
side
DIFFERENTIAL
ASSEMBLY
gear
(22) and
thrust
washer
(23).
23
7)
Turn over bevel gear and flange half assembly (151, then remove mounting
bolts (241,
and remove flange half (25).
25
half : 25 kg
15
DBWO1986
(25).
9.
Coupling
I)
Remove
mounting
bolt (281, then remove
holder (291, coupling (301, and O-ring (31).
*
Do not remove the protector press fitted
to the coupling unless necessary.
2) Remove oil seal (32).
26
25
14
DEW01987
31
28
29
28
30-118
0
DISASSEMBLY
AND ASSEMBLY
DIFFERENTIAL
Press
4
stand
DLWcQ3m
2)
11. Cage
Remove
bearing
(39) from
cage
(37).
39
DEW01991
30-l 19
0
DISASSEMBLY
DIFFERENTIAL
AND ASSEMBLY
ASSEMBLY
ASSEMBLY
OF DIFFERENTIAL
1. Cage
Press fit bearing cups (39) and (38) to
Sr After press fitting the cup, check
is no clearance at portion a.
*
Coat the cup press-fitting portion
&
Cup press-fitting portion : Oil
cage (37).
that there
with oil.
(axle oil)
DLWOQ34
2.
Pinion gear
1) Press fit bearing cone (36) to pinion gear
(33), and assemble spacer (35).
J, Check that there is no clearance at the
mating surface of each part.
2) Assemble pinion gear (33) to cage (371, and
press fit bearing cone (34).
Ir Use a press to apply pressure
at the
specified load to the bearing, and rotate
the case to settle the bearing.
Sr Press load : 145 KN (14.8 ton)
&
Bearing : Oil (axle oil)
*
Reference
.
Starting turning force @: Max. 62 N
DBW019!3
(6.3 kg)
End play : 0 - 0.187 mm
*
When the case has been rotated at the
specified load, check that it can be rotated smoothly by hand.
Ir If the rotation is heavy, replace the bearing and spacer, then check again.
Coat seal press-fitting
portion of cage (37)
with gasket sealant, then press fit oil seal
.
3)
(32).
Ir Press fit so that the oil seal is level with
the surface of portion b.
6
Oil press-fitting portion :
Gasket sealant (Seal end 2421
6
Lip of oil seal : Grease (G2-Ll)
33
275rnm
\\
/J
DEWOlS94
30- 120
0
DISASSEMBLY
AND ASSEMBLY
DIFFERENTIAL
3.
Coupling
Install coupling (30), O-ring (31), and holder (29)
to pinion gear (33), and tighten mounting bolts.
*
Tighten the mounting bolts temporarily,
and
tighten fully after assembling.
*
When inserting the coupling, be extremely
careful not to damage the seal.
&
Mounting bolt : Thread tightener
(LT-2)
(When tightening
fully)
m
Mounting bolt :
549 f 59 Nm (56.0 t 6.0 kgm)
4.
27
k
f
u
C
25
DLWOO393
2)
DLWC03.94
40
DBW01996
25
e\
e
40
D&v01997
DISASSEMBLY
3)
5)
DIFFERENTIAL
Turn over bevel gear and flange half assembly (151, align.with
dowel pins (411, install
thrust washer (23), coat with thrust washer
oil, then assemble side gear (22).
+
When assembling the thrust washer, be
careful not to assemble it upside down.
&
4)
AND ASSEMBLY
Thrust washer
23
sliding surface :
Oil (axle oil)
Coat spider shaft (19) with oil, assemble pinion gears (21), then assemble spherical washers (201.
&
Spider shaft : Oil (axle oil)
&
Spherical washer : Oil (axle oil1
Assemble
spider shaft, pinion gear, and
spherical washer (18), then assemble to bevel
gear and flange half assembly (15).
DBW01993
18
DLWOO339
6)
Assemble
side gear (17) to bevel
flange half assembly (15).
7)
30-122
0
gear and
6
DISASSEMBLY
AND ASSEMBLY
DIFFERENTIAL
8) Align
5.
!z
2
i
f
L Dimension
DBW02002
(unit: mm)
Dimension a
(unit: mm)
30- 123
0
DISASSEMBLY
6.
AND
DIFFERENTIAL
ASSEMBLY
Bearing carrier
Press fit bearing cones (42) and (43) to bearing
carrier assemblies
(12) and (12-l).
&
Bearing cup press-fitting portion :
Oil (axle oil)
*
After press fitting the bearing, check that there is no
4243
clearance at portion f.
42
43
a
7.
Adjusting
shim of bearing carrier
1) Raise differential carrier assembly (1 I), then
set to mounting position on differential housing.
11
IL
DBWOZ'XJE
I)
12
3)
Tighten
mounting
bolts of bearing carrier
assemblies
(12) and (12-I).
w
Mounting
bolt :
176.5 -t 19.6 Nm (18.0 + 2.0 kgm)
4)
30- 7 24
0
Spring balance
DBWO2WB
DISASSEMBLY
8.
AND ASSEMBLY
Cage
1) Fit O-ring (9) in groove of cage assembly
&
O-ring : Oil (axle oil)
*
Coat thinly with oil.
DIFFERENTIAL
(8).
I
2)
9.
0Ewo2010
Adjusting
backlash
2)
/ b
30-125
0
DISASSEMBLY
DIFFERENTIAL
AND ASSEMBLY
Tooth
contact
Procedure
Cause
The tooth contact
pattern
Adjust
should
about
start from
when
the pinion
adjusting
gear
for adiustment
by adjusting
the shims
at
way as
backlash.
It should
be in the center
the tooth
Bevel pinion
far from
of
height.
gear is too
bevel
1. Reduce
shims
gear to bring
gear.
at pinion
closer
to bevel gear.
2. Move
away
pinion
correctly.
DEW00908
DEW00904
Bevel pinion
gear
is too
1. increase
shims
gear to move
from
at pinion
away
bevel gear.
2. Move
bevel gear
closer
to pinion
backlash
correctly.
DEW00909
1. Reduce
shims
at pinion
gear
gear.
2. Move
away
pinion
correctly.
DEW00908
1. increase
shims
gear to move
gear.
from
at pinion
away
bevel gear.
2. Move
bevel gear
to pinion
adjust
closer
gear and
backlash
correctly.
?
When
adjusting
30-126
0
the preload
total thickness
of the bearing.
of shims.
Adjust
by moving
DEW00909
shims
between
DISASSEMBLY
AND ASSEMBLY
DIFFERENTIAL
DEW02015
DBWOZO16
Adjustment
washer
Differential housing
DBWJ2019
--
DBWOiUlS
DISASSEMBLY
AND ASSEMBLY
DIFFERENTIAL
.,,,,,,,,
A 47
y@&
c5 A6
yi.1
Differential housing
DLwo202c
DEW02021
14. Coupling
Tighten mounting bolts of coupling (30) fully.
&
Mounting bolt : Thread tightener
(LT-2)
w
Mounting bolt :
549 + 59 Nm (56.0 + 6.0 kgm)
cover
15. Differential
1) Wash and remove all oil and grease from
mounting surface of differential cover (5) and
differential
housing (13), then coat with gasket sealant.
J, Guide bolt : 14 mm, P = 2, L = 40 mm
*
When
installing the differential
cover,
screw the mounting bolts into the forcing screw holes, and raise.
Ir Temporarily
assemble the bleeder screw
so that gasket sealant does not get into
the mounting hole of the bleeder screw.
*
See the diagram on. the right for details
of coating.
.
Coat continuously with a bead diameter of 2 - 3 mm.
.
The shape of the differential cover at
portion * is different, so coat and
take care that the bead does not
come off.
30- 128
0
DEW02022
\
Bead diameter of 2-3mm
5
DLW01587
DISASSEMBLY
AND ASSEMBLY
DIFFERENTIAL
21
Install differential
cover (5) to differential
housing.
Coat carefully with gasket sealant so that
*
there is no break in the gasket sealant.
&
Cover mating surface :
Gasket sealant (Loctite 515)
w
Cover mating surface :
176.5 * 19.6 Nm (18.0 + 2.0 kgm)
3)
I
16. Axle housing
DEW02023
1
assembly
OF
30- 129
0
DISASSEMBLY
AND ASSEMBLY
AXLE HOUSING
DISASSEMBLY OF AXLE
HOUSING ASSEMBLY
1.
Draining oil
Remove drain plugs (I) and drain oil.
I
%k
&I kg
2.
Axle oil : 37 f?
(2) on pallet.
Axle assembly
: 1,021 kg (front)
Axle assembly
: 971 kg (rear)
Differential
cover
Using forcing screws,
remove
differential
cover
(3).
*
Do not remove the differential cover unless
necessary.
*
When removing
the differential
cover, be
careful not to damage the bleeder screw.
*
When moving the differential
assembly, remove the 4 cover mounting bolts, and use
eyebolts to lift at 4 points and move.
eJ
ks
3.
(F) Differential
assembly
: 300 kg
(RI Differential
assembly
: 320 kg
Axle housing
1) Sling axle housing assembly (4), and remove
housing mounting bolts.
Sr Make match marks on the housings to
prevent mistakes between the left and
right axle housings.
*
Set blocks to prevent the assembly from
tilting when the housing assembly
on
one side is removed.
DLWO2026
30-130
0
DISASSEMBLY
2)
AND ASSEMBLY
Axle housing
assembly
assembly
AXLE HOUSING
(4).
280 kg (front)
Axle housing assembly : 270 kg (rear)
l+l kg
Ir Change the place for the axle housing
lifting tool, and stand the axle housing
assembly upright.
DBWOZ027
4.
7
6
DBWOi!028
DLW01599
5.
2)
3)
Remove
face in contact
DISASSEMBLY
6.
AND
AXLE
ASSEMBLY
Brake housing
Remove mounting bolts (1 I), then remove
housing (12).
*
Remove the O-ring.
HOUSING
brake
O-ring
IiF
Detail P
ei
kg
7.
Brake housing
DBW02032
: 25 kg
Planetary
carrier assembly
DBWOZOU
: 48 kg
Lifting tool @
5
\lb
DBWO2033
2)
8.
and
30-132
0
DEQV02034
use for
Ring gear
Use puller 13 and pull up uniformly to remove
ring gear (15) from axle housing (16).
*
Assemble
spacer @ to the end face of the
puller bolt to adjust the height.
+ When
pulling
up with the puller, be extremely careful that the teeth of the puller
do not come off the ring gear.
&?Ikg
DLWOlKJZ
15
Ring gear : 15 kg
DISASSEMBLY
9.
AXLE HOUSING
AND ASSEMBLY
Axle shaft
housing (16).
Put a copper hammer in contact with end
face of axle shaft (171, then knock in shaft
and rotate housing (16) to remove shaft.
Copper hammer
16
D&V02036
16
DLW01609
16
el
el kg
Axle housing : 85 kg
kg
: 90 kg
DE.%.02037
3)
DBW02033
Remove
4)
the bearing
as follows.
grip
b of
/
DBWOZ039
30- 133
0
DISASSEMBLY
5)
AXLE HOUSING
AND ASSEMBLY
DLWOI611
6)
Insert tool Dl under bearing (181, and assemble tools D2 and D3.
t
When installing tool Dl, be careful not
to deform portion e of oil seal sleeve
It
7)
(19).
When doing this, fix the bearing puller
securely in place so that there is no play.
30-l 34
0
DBW02042
AXLE HOUSING
1)
Remove
(16).
2)
16
24
zz
k
4
DEW02044
carrier
pin in
27
17
2)
DLWO1614
DISASSEMBLY
3)
Remove
AND
ASSEMBLY
spring
AXLE
HOUSING
shaft (27).
,\.I
DEW02045
4)
Remove pinion gear (28) from planetary carrier (251, then remove bearing cone (29) and
spacer (30).
el
kg
Planetary
carrier
: 30 kg
28,
\
30-136
0
29
DISASSEMBLY
AND ASSEMBLY
ASSEMBLY
ASSEMBLY
1.
AXLE HOUSING
OF AXLE HOUSING
Axle housing
Press fit bearing cups (24) and (23) to axle housing (16).
*
Coat the bearing cup press-fitting portion of
the axle housing with oil.
*
After press fitting the cup, check that there
is no clearance at portion a.
a
DBWO2047
DBWO2051
2.
Bearing
cup press-fitting
portion :
Oil (axle oil)
Axle shaft
I) Press fit axle shaft (17) and oil seal sleeve
(19).
Be careful not to deform the parts when
*
hitting with a hammer.
*
Coat the sleeve contact surface portion
b of the oil seal thinly with axle oil.
&
Sleeve contact surface of shaft :
Oil (axle oil)
*
After press fitting the oil seal sleeve,
check that surface c is level with the surrounding surface.
2)
OBW02049
DBWOaOl
DBW02050
DISASSEMBLY
3.
AND ASSEMBLY
AXLE HOUSING
Housing, shaft
I)
2)
D4
D4
DEW02052
Flange surface
&
DEW02053
DEW02054
4)
Raise axle housing (16) to a horizontal position, then insert to shaft carefully.
*
Stop axle housing (16) before press fitting the oil seal.
Align axle housing (16) with oil seal pressfitting portion, then lower housing slowly.
*
Use the weight of the axle housing to
insert it.
16
DBWO2055
30-138
0
5)
AXLE HOUSING
Press fit bearing (30) to shaft (171, then rotate axle housing by hand, and press fit until
end play is 0.1 mm.
Ir Do not press fit so that there is no end
play.
&Bearing
Press-fitting
cone press-fitting
force :
Approx.
portion :
Oil (axle oil)
19.6 KN (2 ton)
DBW02056
6)
Flange surface
Ir
/
I/
A///O//A////
4.
DEW02057
/
,/,,,,,,
Flange sur&e
DEW02058
DBWO2059
DISASSEMBLY
AND ASSEMBLY
AXLE HOUSING
3)
4)
25
31
rl l-l
lows.
.
If the starting
\
h
20 - 30mm
DLWOlK30
30-140
0
DISASSEMBLY
AND ASSEMBLY
AXLE HOUSING
5)
5.
Planetary carrier
1)
2)
Assemble
spacer (32) inside planetary
carrier (25).
*
Assemble
the spacer from the brake
housing side.
Assemble bearing cone (29) to gear (281, lift
up spacer (321, and set gear (28) in position.
DBW02060
53)
29
DLW01636
1 28.
DEW02070
27
27
DLWO1637
DBWOlE34
DBW02071
DISASSEMBLY
4)
AND
AXLE
ASSEMBLY
HOUSING
Tap differential
side of gear (28) and end
face of shaft (271, and push back bearing
(29) so that the gear can rotate smoothly.
t
Check that the gear rotates smoothly.
DEW02072
I
6.
Ring gear
Press fit ring gear (15) to axle housing
insert pins (34).
t
+
(161, then
34
DBWO2073
7.
DBW02076
6
m
t
bolt :
Thread tightener
(LT-2)
Mounting bolt :
927 i 98 Nm (94.5 i 10.0 kgml
Clean the end face of the shaft and the
planetary
carrier spline before assembling.
When assembling the planetary carrier,
be extremely careful not to get your fingers caught in the gear.
Mounting
DBW02075
30-142
0
DISASSEMBLY
2)
3)
8.
AND ASSEMBLY
AXLE
HOUSING
B:ake housing
1) Assemble O-ring (35) in groove of axle housing (4).
+ Coat the O-ring thinly with grease.
&
O-ring : Grease (G2-LI)
2)
Dswozcvs
Mounting bolt
DEbW2f178
30- 143
0
DISASSEMBLY
9.
AXLE HOUSING
AND ASSEMBLY
Match marks
DEW02080
DBWO.2082
2)
I
IO. Brake disc, plate
1) Align end gap of wave spring (81, then assemble both to range (h).
Ir Assemble
so that the end gap of the
wave spring is on the O-ring boss hole
side for measuring the disc wear, and is
also within range (h).
or Always use 2 wave springs together.
embly of spring en
1
2)
DBW02030
DEW02081
Assemble
brake disc (5), plate (6), wave
spring (8), brake disc (51, and plate (6) in
order.
J, Be careful not to damage the front face
of the brake disc.
*
Check that there is no damage
to the
front face of the plate when assembling.
L----w
30- 144
0
DEW02029
DISASSEMBLY
3)
AND
ASSEMBLY
AXLE HOUSING
(61, then
7
6
11. Axle
housing
DBWo2084
assembly
2)
3)
from
mounting surface of axle housing
(4) and
differential housing (361, then coat with gasket sealant.
See the diagram on the right for the coat*
ing procedure.
.
Coat with a continuous
bead diameter of 2 - 3 mm.
.
The shape at portion f is different
at the differential housing end. Coat
so that the bead does not come off.
Wash and remove all oil and grease from
*
the axle housing and differential
housing mounting surface, then coat with a
continuous line of gasket sealant so that
there is no break.
a
Mating surface of housing :
Gasket sealant (Loctite 515)
Raise axle housing (4) horizontally, then align
spline groove and guide bolts 3 (20 mm,
P=2.5, L=230mm), and assemble carefully.
*
When assembling the axle housing, be
careful not to cut the gasket bead.
+ When assembling, be careful not to damage the plate surface.
Bead
diameter
: 2-3mm
DBWO2302
DEW02083
DISASSEMBLY
AND
AXLE
ASSEMBLY
12. Differential
cover
If differential
cover (3) was removed, see DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL
ASSEMBLY.
HOSlNG
3
P^n
oil level)
Set to a horizontal
the oil level.
30-146
0
position
when
checking
OBWO2243
DISASSEMBLY
REMOVAL
PIN
AND ASSEMBLY
OF CENTER HINGE
AStop
the machine on level ground and install
the safety bar on the frame. Lower the bucket to
the ground and stop the engine. Then apply the
parking brake and put blocks under the wheels
to prevent the machine from moving.
ALoosen
the oil filler cap slowly to release the
pressure inside the hydraulic tank. Then operate
the control levers several times to release the
remaining pressure in the hydraulic piping.
ADisconnect
the cable from
minal of the battery.
the negative
(4 ter-
1.
2.
B
z
5
3.
Remove lock bolt at rod end of steering cylinder, then remove pin (3).
a
.
Do the same for both left and right steering
cylinders.
*
If there are shims, check the number and
thickness of the shims, and keep in a safe
place.
4.
Disconnect
DEW01904
DISASSEMBLY
AND
ASSEMBLY
5.
Disconnect
hoses (5) and (61, and cable (7).
*
Disconnect
hose (5) at the connecting
portion at the rear frame end, then disconnect
hose (6) at the valve end.
6.
Disconnect
stop valves as follows.
(I) and (2) from the steer1) Disconnect-hoses
ing valve.
2) Remove blocks (3) on the front and rear
frame sides.
adjustment
brackets
(4) for stop
3) Remove
@-Y-J
valves on the left and right sides.
4) Remove left and right stop valves (5).
f
Remove the left side stop valve (5) and
under spacer. Then put them aside on
the right side of the frame.
7.
a
Disconnect frame as foiiows.
I) Adjust height of rear frame (IO) and set block
@ in position.
*
Set block @ under the frame on the left
and right sides.
2) Adjust height of front frame (111, then set
block @ in position, and assemble rollers @
between frame (11) and block 0.
Ir Set block @ and rollers @ under the
frame on the left and right sides.
*
Adjust the height of the frame carefully.
3)
4)
30-148
0
CENTER
HINGE PIN
bolts, and
remove pin (13) from top.
*
Adjust the height of the front frame and
rear frame carefully and set so that the
pin can be removed.without
using force.
6)
DEW02091
7)
DLWO2092
Remove mounting
bolts, then remove
retainer (15) at rear frame end.
*
There are shims, so check the number
and thickness of the shims, and keep in
a safe place.
16
\
MWO3805
8)
16
9)
Front frame
Rear frame
30-l 49
0
DISASSEMBLY
8.
AND ASSEMBLY
CENTER
HINGE
PIN
\
DBW02095
DLWO2101
9.
2)
24
(23)
and
seal
(24)
23
DBW02039
DAW02102
3)
Remove
bearing
(25).
25
30- 150
0
...
DLWO2100
DISASSEMBLY
AND ASSEMBLY
INSTALLATION
HINGE PIN
l
Carry out
removal.
installation
OF CENTER
in the
reverse
order
to
OF CAB, FLOOR
m
*
f
m
Adjust the clearance between the front and rear
frames.
For details,
see TESTING
AND ADJUSTING
STEERING CONTROL.
/f
Connect the frame as follows.
I) Jack up front differential, then move front
frame towards rear frame end, and align pin
holes.
Ir Be careful that the spacer at the bottom
of the upper hinge does not interfere
with the rear frame.
*
Align the pin holes securely.
When
aligning the position of the pin
g
hole, always use a bar. Never insert your
fingers in the pin hole.
2) Assemble spacer (16) to upper hinge.
*
Assemble
spacer (16) from the top so
that the large chamfered side is on the
bearing side.
*
Be careful not to damage the dust seal
lip.
&
Outside circumference
of hinge :
Grease (G2-LI)
&
Inside circumference
of spacer :
Grease (G2-LI)
3) Assemble
upper hinge pin (14) from bottom.
4) Tighten retainer (15) to upper hinge pin with
3 mounting bolts (27), then select shims so
that clearance b between hinge and retainer
is below 0.2 mm, and assemble.
m
Pin mounting bolt :
19.6 _+2 Nm (2.0 f 0.2 kgm)
(When adjusting shims)
Temporarily tighten mounting bolts (28),
*
leaving a clearance of approx. 5 mm from
the surface of retainer (15).
-15
DLW02104
30-151
0
DISASSEMBLY
5)
6)
7)
8)
AND ASSEMBLY
CENTER
After
adjusting
shims,
tighten
retainer
mounting
bolt (28) to specified torque, then
tighten pin mounting bolt (27) fully.
&
Retainer mounting bolt :
Thread tightener
(LT-2)
w
Retainer mounting bolt :
206 + 19.6 Nm (21.0 f 2.0 kgm)
&
Pin mounting bolt :
Thread tightener
(LT-2)
m
Pin mounting bolt :
206 + 9.8 Nm (21.0 + 1.0 kgm)
m
Retainer mounting bolt :
112.8 f 9.8 Nm (11.5 f 1.0 kgm)
Inset-t lower hinge pin (13) and secure
lock bolt.
a
Outside circumference
of hinge
Remove
support from
front and rear frames.
Install safety bar.
15
28
HINGE
PIN
27
Clearance b
with
pin :
Grease (G2-LI)
counterweight,
and
DEW02107
1.
2)
30-152
0
18
DISASSEMBLY
AND
ASSEMBLY
CENTER
HINGE
PIN
m
2.
::
z
5
E4
E9
E6
E8
25
25
DBWO2111
DLWO21l.l
Mounting bolt :
19.6 + 2.0 Nm (2.0 f 0.2 kgm)
(When adjusting shims)
m
Mounting bolt :
112.8 rt 9.8 Nm (11.5 + 1.0 kgm)
Install dust seal (24) and spacer (23) from
under front frame.
a
Lip of dust seal : Grease (G2-LI)
6
Inside circumference
of spacer :
Grease (G2-LI)
* Replace the dust seal with a new part,
and press fit so that the lip surface is
facing the outside.
* Assemble spacer (23) from the bottom
so that the large chamfered
side is on
the bearing side.
w
4)
r-
24-
23
DLW02113
DISASSEMBLY
AND ASSEMBLY
STEERING VALVE
REMOVAL OF STEERING
VALVE ASSEMBLY
AStop
the machine on level ground and install
the safety bar on the frame. Lower the bucket to
the ground and stop the engine. Then apply the
parking brake and put blocks under the wheels
to prevent the. machine from moving.
*
Raise the boom, set a support under the boom,
then remove front frame inspection cover (1).
(gSet
support @ in position securely.
*
Loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank. Then operate
the control levers several times to release the
remaining
pressure in the hydraulic piping.
1.
Cover
1) Remove
mounting
bolts, then remove
inspection cover (2).
*
Remove the covers on the front and right
side at the bottom of the cab.
2)
2.
Hydraulic piping
Disconnect
hoses (6) and (6A) between
valves from steering valve (5).
*
Remove clamps and brackets.
30-154
0
stop
DISASSEMBLY
3.
AND ASSEMBLY
Hydraulic piping
STEERING VALVE
4.
Steering valve
Sling steering valve (61, and remove
bolts (141, then lift off steering valve.
m
mounting
Steering valve : 24 kg
& kg
* Carry out the removal operation with two
workers.
AThe
steering valve is oily, so be careful not
to let it slip.
30- 155
0
DISASSEMBLY
STEERING
AND ASSEMBLY
INSTALLATION
OF STEERING
VALVE ASSEMBLY
.
Carry out
removal.
installation
in the
reverse
order
to
m
*
*
force
30-156
VALVE
DISASSEMBLY
AND ASSEMBLY
DISASSEMBLY
VALVE
1.
Remove
*
STEERING VALVE
OF STEERING
(I).
DKWO3808
2.
Remove
*
(2).
sm
is
I/
cu
5
3.
DKW03809
Remove
plug (3).
DKW03810
2)
Remove
spring (4).
DKW03811
DISASSEMBLY
3)
AND ASSEMBLY
STEERING VALVE
DKW03812
4)
Remove
plag (6).
DKW03814
2) Remove
*
I
30-l 58
0
DKWO3815
DISASSEMBLY
3)
AND
ASSEMBLY
STEERING
VALVE
DKW03616
41
DKW03617
5.
Disassembly
I)
Remove
of steering
spool assembly
2)
16
DKW03816
DKW03819
30- 159
DISASSEMBLY
6.
AND ASSEMBLY
Disassembly
I)
Remove
STEERING
VALVE
of check valve
plug (17).
DKW03821
2)
Remove
(19).
DKW03822
7.
Remove
30-l 60
0
plug (20).
DISASSEMBLY
AND ASSEMBLY
ASSEMBLY
VALVE
1.
STEERING
OF STEERING
I
body.
I
2.
Assembly
1)
VALVE
DKW03823
of check valve
DKW03822
2)
DKW03821
3.
Assembly
I)
2)
of steering
spool
to spool.
# 271)
16
bd
DKW03811
DKW0381E
30-l 61
0
DISASSEMBLY
4.
Installation
AND
ASSEMBLY
of demand
STEERING
VALVE
spool
OKWO3824
2)
DKW03825
3)
Install
spring
(4).
DKW03826
4)
DKW03827
30-162
0
DISASSEMBLY
AND
5.
of steering
Installation
ASSEMBLY
STEERING
VALVE
spool assembly
I)
2)
3)
DKW03829
4)
5)
6.
Install
body.
w
DKW03830
relief valve
assembly
(2) to valve
7.
m
DKW03808
DKW03809
30- 163
DISASSEMBLY
ORBIT-ROLL VALVE
AND ASSEMBLY
REMOVAL OF ORBIT-ROLL
VALVE ASSEMBLY
and install
the bucket
Then apply
under the
moving.
release the
Then operlevers sevpressure in
1.
Remove
steering
2.
Remove
*
3.
Remove
Remove
column
connecting
bolt (3). a
DEW01696
4.
Remove
covers
DLWOB32
5.
Piping
Disconnect
valve.
I)
2)
the following
piping
from
orbit-roll
30-164
0
DISASSEMBLY
6.
AND ASSEMBLY
ORBIT-ROLL
3)
4)
Steering
VALVE
valve
Orbit-roll
valve : 8 kg
INSTALLATION OF ORBIT-ROLL
VALVE ASSEMBLY
.
in the
reverse
order
to
m
QZEI
Column
Orbit-roll
8
z
4
connecting bolt:
55.9 + 7.8 Nm (5.7 & 0.8 kgm)
m
Ir
valve bolt:
52 + 6.8 Nm (5.3 2 0.7 kgm)
Bracket bolt:
88.3 f 34.3 Nm (9.0 2 3.5 kgm)
Align the spline at the steering column end
and the spline at the orbit-roll valve end.
tank)
specified
30- 165
0
DISASSEMBLY
ORBIT-ROLL VALVE
AND ASSEMBLY
DISASSEMBLY
VALVE
OF ORBIT-ROLL
Carry out the operation in a clean place to prevent dirt or dust from sticking to the valve.
As far aspossible,
disassembling.
DISASSEMBLY
OF ROTOR
1.
2.
Remove
screw
3.
Remove
O-ring
4.
5.
Be careful
rotor set.
Remove
spacer
hold
mounting
not.to
drop the
O-ring
star
(5).
inside
the
(6).
6
DLW01702
30- 166
0
DISASSEMBLY
AND ASSEMBLY
ORBIT-ROLL VALVE
6.
Remove
7.
Remove
spacer
plate (8).
8.
Remove
O-ring
(10).
I
DISASSEMBLY
9.
DLWU1703
OF CONTROL SIDE
from
and
housing.
DLWO1704
11. Turn spool and sleeve to place pin in a horizontal position, then push in spool and sleeve with
your thumb, and remove bushing (12) from housing.
DLW01705
12. Remove
X-ring
Be careful
not to damage
bushing
(12).
(12) with
12
\
the bushing.
14
\
Q
Q
bQ
3
DLWO1706
DISASSEMBLY
AND ASSEMBLY
ORBIT-ROLL
VALVE
needle
DLW01707
assem-
DLWOl-KB
18. Turn spool (20) slowly and pull out from rear of
sleeve (19) (in the direction of the arrow).
19. IRemove
O-ring
20. IRemove
22. IRemove
O-rings
check sheet
(24).
28
23. Tap housing,
(28).
30-168
0
and remove
DLW01710
DISASSEMBLY
AND ASSEMBLY
ASSEMBLY
VALVE
ORBIT-ROLL
OF ORBIT-ROLL
+r
ASSEMBLY
1.
or burrs.
OF CONTROL
Insert retainer
and blow
rough
(No need to
set with
a small
SIDE
is not inserted
3.
4.
DLW01711
5.
e-23
at an
2.
VALVE
Assemble
spool (20) and sleeve (19) so that
spring groove is on same side.
t
Rotate the spool and slide it in.
Ir Grip the splined portion of the spool lightly
and check that the spool rotates smoothly
inside the sleeve.
*
If there are match marks, check that the
match marks are aligned.
SP
DLW01712
DISASSEMBLY
ORBIT-ROLL VALVE
AND ASSEMBLY
I
7. Insert pin (18) in spool and sleeve assembly
DLwO1713
(17).
DLW01714
2)
*
3)
9. Install
IO.
O-ring
Fit 2 bearing
case (IO).
(22) to housing
(IO).
(16) in
DLWO1716
30-170
0
DISASSEMBLY
AND ASSEMBLY
ORBIT-ROLL
13. Insert
stall.
l
(12).
bushing
(12) in spool,
VALVE
and
(fzlD--ll
(12).
rotate
eQ
12
to in-
14
_A
G
e
/
10
/,
e=-.
DLwo1717
2
F+?
DLWO1718
ASSEMBLY OF ROTOR
15. Hold flange of housing lightly
*
*
in vice.
DLW01719
(9) in housing.
positions
of
DLW01720
DISASSEMBLY
18.
AND
ORBIT-ROLL
ASSEMBLY
VALVE
DLW01721
19. Insert
O-ring
(5) in rotor
set (4).
5
DLW01722
Make line
Pin
Port Surface
DLW01723
22. Set end cap (2) on rotor set, and align bolt hole.
DLW01724
30- 172
0
DISASSEMBLY
AND ASSEMBLY
of screw with
ORBIT-ROLL
grease,
VALVE
and tighten
DLW01725
30-173
0
DISASSEMBLY
REMOVAL
CYLINDER
STEERING
AND ASSEMBLY
CYLINDER
OF STEERING
ASSEMBLY
AStop
the machine on level ground and install
the safety bar on the frame. Lower the bucket to
the ground and stop the engine. Then apply the
parking brake and put blocks under the wheels
to,prevent
the machine from moving.
ARelease
the remaining pressure in the piping.
For details, see REMOVAL OF RADIATOR
ASSEMBLY.
1.
Hydraulic piping
Discoqnect
steering cylinder rod and bottom
hoses (I) and (2) at cylinder end.
*
After removing the hoses, fit plugs to prevent the entry of dirt or dust.
2.
Steering cylinder
I) Remove rod bolt, then remove
m
pin (3).
DEW00965
2)
3).
4)
Disconnect
bottom grease tube (4).
Remove bottom bolt, then remove pin
*
Check the shim thickness and use
guide when assembling.
Remove steering cylinder (6).
*
Carry out the removal operation with
people.
i
Be careful not to scratch the cylinder
r&lkg
Steering
cylinder:
(5).
as a
two
rod.
25 kg
DEW01083
30-174
0
STEERING CYLINDER
INSTALLATION OF STEERING
CYLINDER ASSEMBLY
Carry out
removal.
installation
in the
reverse
order
to
a
AAlways
use a bar when aligning
Never insert your fingers.
*
*
*
DEW01084
30- 175
0
DISASSEMBLY
AND
ASSEMBLY
2.
Covers
Remove
Piping
covers
1) Disconnect
2)
3)
4)
3.
4.
30- 176
0
BRAKE VALVE
DISASSEMBLY
5.
6.
AND ASSEMBLY
BRAKE VALVE
Pedal
Pull out cotter pin (16) of pin (15) of brake pedal
(141, then pull out pin, and remove pedal.
*
Carry out the same procedure for both the
left and right brake pedals.
f+GJ
Brake valve
1) Remove brake valve mounting bolts (171, and
disconnect mount flange (18) and body (191,
then pull out cap (20).
2) Remove mount flange mounting bolts, then
remove mount flange from floor portion.
INSTALLATION OF BRAKE
VALVE ASSEMBLY
.
30- 177
0
DISASSEMBLY
AND ASSEMBLY
DISASSEMBLY
OF RIGHT
BRAKE VALVE ASSEMBLY
(TANDEM)
1.
Bracket assembly
I)
2)
3)
DEW01091
2.
Valve
I)
21
Install valve to jig @ with bolts (5), and secure jig in vice.
*
Make match marks before disassembling
the valve.
Remove valve mounting bolts (IO), then remove S cylinder assembly (7).
DEW01092
3)
4)
DEW01093
5)
Jr
DEW01095
30- 178
0
DDWO1096
DISASSEMBLY
AND ASSEMBLY
2.
Valve
Install T flange assembly (9) to jig (iJ with bolts
(5), and hold jig % in vice.
1) Install springs (19), (IS), and (17) to T flange
assembly (9) in order, then install holder (16)
on top of spring.
2) Install O-ring (20) to T flange assembly (9).
Use a new part for the O-ring.
+
&
O-ring: Lithium grease
3) Set P cylinder assembly (8) to T flange assembly (9).
When setting in position, align the match
*
marks.
4) Install spring (11) and spring (15) inside
plunger of P cylinder assembly to P cylinder
assembly (8).
5) Install O-ring (12) to P cylinder assembly (8).
Use a new part for the O-ring.
*
6
O-ring: Lithium grease
(7) to P cylinder
6) Set S cylinder assembly
assembly
(S), and tighten
with mounting
bolts (10).
When setting the S cylinder assembly in
*
position, align the match marks.
w
Mounting bolt:
58.8 - 73.6 Nm (6.0 - 7.5 kgml
7) Install spring (14) and O-ring to S cylinder
assembly (7), and tighten with plug (13).
Use a new part for the O-ring.
*
a
Thread of plug: Thread tightener
(Thread lock 1303B)
w
Plug:
152.0 f 24.5 Nm (15.5 + 2.5 kgm)
DEW01095
DDW01096
DEW01093
DDWO1094
Bracket assembly
Remove valve from jig 0.
1) Set T flange assembly facing up, and install
oil seal (6).
Ir Use a new part for the oil seal.
&
Lip of oil seal: Lithium grease
2) Install bracket assembly (4), and tighten with
mounting bolts (5).
m
Mounting bolt:
58.8 - 73.6 Nm (6.0 - 7.5 kgm)
3) ,lnstall seat (I), pedal stopper (2), and boot
(3) to valve.
30-179
0
DISASSEMBLY
AND ASSEMBLY
DISASSEMBLY
OF LEFT BRAKE
VALVE ASSEMBLY (SINGLE)
1.
Bracket assembly
1) Remove seat(l),
(3) from
2) Remove
sembly
3)
2.
pedal stopper
brake valve.
mounting
bolts (5) of bracket as(4), then remove bracket assembly.
upper
portion
of
Valve
1) Install valve to jig @ with bolts (51, and secure jig in vice.
*
Make match marks before disassembling
the valve.
2)
3)
4)
Ir
(9), then
re-
The cylinders, plungers, and spools inside the S flange and the S cylinder form
sets, so be careful not to mix the parts
for any set.
Fit seals to prevent dirt or dust from entering, and be careful not to damage the
cylinders or flange assembly.
16
DDW01107
30- 180
0
DISASSEMBLY
AND ASSEMBLY
Valve
Install S flange assembly (8) to jig @ with bolts
(51, and hold jig @ in vice.
1) Install springs (74) and (15) to S flange assembly (81, then install holder (13) on top of
spring.
2) Install O-ring (IS) to S flange assembly (8).
*
Use a new part for the O-ring.
6
O-ring: Lithium grease
3)
4)
2.
DEW01090
Set S cylinder assembly (7) to S flange assembly (81, and tighten with mounting bolts
(9).
*
When setting the S cylinder assembly in
position, align the match marks.
w
Mounting bolt:
58.8 - 73.6 Nm 16.0 - 7.5 kgm)
Install spring (11) and O-ring (12) to S cylinder assembly (71, and tighten with plug (IO).
*
Use a new part for the O-ring.
6
O-ring: Lithium grease
&
Thread of plug: Thread tightener
(Thread lock 1303B)
m
Plug:
152.0 + 24.5 Nm (15.5 f 2.5 kgm)
Bracket assembly
Remove valve from jig 0.
I) Set S flange assembly facing up, and install
oil seal (6).
f
Use a new part for the oil seal.
&
Lip of oil seal: Lithium grease
2) Install bracket assembly (41, and tighten with
mounting bolts (5).
m
Mounting bolt:
58.8 - 73.6 Nm (6.0 - 7.5 kgm)
3) Install seat (I), pedal stopper (21, and boot
(3) to valve.
16
DDW01107
DEW01106
DEW01104
DDWOl105
30-181
0
DISASSEMBLY
PARKING
AND ASSEMBLY
REMOVAL
DISC
OF PARKING
BRAKE DISC
BRAKE
AStop
the machine on level ground,
lower the
work equipment
to the ground, apply the parking brake, and put blocks under the wheels to
prevent the machine from moving.
*
Release the parking brake.
1. Loosen
oil.
-
2.
drain
plug
Transmission
(1) and
drain
transmission
oil : 40 J?
DEW01729
Drive shaft
Remove protectpr (2-1) of drive shaft, and disconnect center drive shaft (2) at transmission
a
end.
-k After disconnecting
the drive shaft, move it
to the right end.
DBWO213.2
3.
Remove
mounting
bolt (4) and washer
coupling (3) at front end of transmission
coupling.
*
Remove together with the O-ring.
(5) of
from
@J
4.
DBWO1732
30- 182
0
DISASSEMBLY
5.
AND ASSEMBLY
&I kg
Cover assembly
: 6.2 kg
6.
7.
bolt (4).
DBW01734
8.
Remove
tool A4.
0
DEW01735
9.
30- 183
0
DISASSEMBLY
INSTALLATION
BRAKE DISC
.
Carry out
removal.
AND ASSEMBLY
OF PARKING
installation
in the
reverse
order
to
w
*
w
*
*
w
Be careful to
in the correct
Fit the O-ring
Mounting
facing
m
Ir
w
&
Ig
2
*
30- 184
0
Transmission
oil : 40 f?
oil
HYDRAULIC TANK
REMOVAL
OF HYDRAULIC
TANK ASSEMBLY
AStop
the machine on level ground and install
the safety bar on the frame. Lower the bucket to
the ground and stop the engine. Then apply the
parking brake and put blocks under the wheels
to prevent the machine from moving.
AOperate
the steering wheel and control levers
several times to release the remaining pressure
in the hydraulic piping. Then loosen the oil filler
cap slowly to release the pressure inside the
hydraulic tank.
1.
Cover
Remove
C-Y
2.
Ladder
Sling ladder (21, then remove mounting
bolts,
and lift off.
*
Use the lifting tool to lift at two places.
3.
Hydraulic piping
I)
30-185
0
DISASSEMBLY
HYDRAULIC TANK
AND ASSEMBLY
2) Disconnect following
4.
with
Hydraulic tank
1)
2)
el
kg
30-186
0
Hydraulic
tank (12).
tank :
365 kg (including
DISASSEMBLY
AND ASSEMBLY
HYDRAULIC TANK
INSTALLATION
OF HYDRAULIC
TANK ASSEMBLY
l
*
*
in the
reverse
order
to
30-187
0
DISASSEMBLY
HYDRAULIC FILTER
AND ASSEMBLY
REMOVAL OF HYDRAULIC
FILTER ASSEMBLY
a
1.
the
Cover
Remove
mountina
bolts. then remove covers
(1-l and (l-1).
~~.
AThe
tension of the spring is applied to cover
(l-l),
so be careful when removing.
*
Be careful not to damage the O-ring at the
mating surface of cover (l-1) and the tank.
DBWO2140
2.
Filter
Remove spring (2) and
remove filter (4).
bypass
valve
(31, then
I-1,
0
0
3oooor
DEwoZl41
INSTALLATION
OF HYDRAULIC
FILTER ASSEMBLY
.
Carry out
removal.
installation
in the
reverse
order
to
$GJ
f
*
30-188
0
ooooc
DEW22162
REMOVAL OF HYDRAULIC,
STEERING, SWITCH, PPC
PUMP ASSEMBLY
Astop
the machine on level ground and install
the safety bar on the frame. Lower the bucket to
the ground and stop the engine. Then apply the
parking brake and put blocks under the wheels
to prevent the machine from moving.
Aoperate
the control levers several times to release the remaining
pressure in the hydraulic
piping. Then loosen the oil filler cap slowly to
release the pressure inside the hydraulic tank.
1.
Cover
Remove
2.
Ladder
Sling ladder (21, then remove mounting
bolts,
and lift off.
*
Use the lifting tool to lift at two places.
3.
II
II
Lxwo2133
OLwo2135
30-189
0
DISASSEMBLY
4.
AND ASSEMBLY
\
HYDRAULIC,
STEERING,
SWITCH,
PPC PUMP
Floor support
j?g
I)
Remove inspection covers (5) and (6) on right
side.
2)
: 19 kg
5.
DBwO2106
Hydraulic piping
I) Remove clamps of air conditioner
hose (8)
and hydraulic hoses (91, then move to rear.
(9
2)
O&V02147
I\+ 11
I\\/
1 \
IO
12
13
-
30-190
0
oBwo2148
3)
4)
After disconnecting
the tubes, fit plugs
to prevent dirt or dust from entering.
After disconnecting the tubes, mark them
with tags to distinguish them.
I
6.
DBWl2149
Hydraulic pump
Remove mounting bolts, and take care to maintain balance when lifting off hydraulic pump (IO).
m
*
The working space is confined,
so be extremely careful when carrying out this operation.
*
Carry out the removal operation
with two
workers.
E2lk9
Hydraulic
pump : 46 kg
30491
0
DISASSEMBLY
AND ASSEMBLY
INSTALLATION
OF
HYDRAULIC, STEERING,
SWITCH, PPC PUMP
ASSEMBLY
.
Carry out
removal.
f
&
*
m
installation
in the
reverse
order
to
Tighten
the floor support mounting
bolts
fully after installing the floor.
Mounting
bolt :
277 +- 31.9 Nm (28.25 + 3.25 kgm)
30-192
0
DISASSEMBLY
REMOVAL OF MAIN
VALVE ASSEMBLY
AND ASSEMBLY
CONTROL
the control
A Operate
lease the remaining
Ir
.
1.
2.
a
PPC hoses
Disconnect following
hoses from main control
valve.
Hose (5) for bucket spool between PPC valve
(P4) and main control valve (J)
Hose (6) for boom spool between PPC valve
(P2) and main control valve K)
Hose (7) for bucket spool between PPC valve
(PI) and main control valve (H)
Hose (8) for boom spool between PPC valve
(P3) and main control valve (I)
After disconnecting
the hoses, move them
towards the rear of the machine.
After disconnecting
the hoses, mark them
with tags to distinguish them.
DEW02753
m
Hydraulic hoses
Disconnect following hydraulic piping.
*
After removing each hose and tube, move
them to the side.
.
Hose (9) between steering valve and main
control valve
30-193
0
DISASSEMBLY
AND ASSEMBLY
*
*
3.
main
control
main
control
them
/zJ
30- 194
0
INSTALLATION OF MAIN
CONTROL VALVE ASSEMBLY
l
in the
reverse
order
to
jf
*
*
pTJ
*
pJ
*
*
*
(Replacement amount)
30- 195
0
DISASSEMBLY
AND ASSEMBLY
MAIN
CONTROL
VALVE
DISASSEMBLY
OF MAIN
CONTROL VALVE ASSEMBLY
?
n
27-
@
g
28 -=
c@
Q\
29-q
26
24
DOW01547
30-196
0
DISASSEMBLY
1.
Remove
AND ASSEMBLY
MAIN
CONTROL
VALVE
body (1).
6
2.
3)
4)
5)
Loosen bolt (6) with spool (19) assembled to body (1). (To prevent damage to
the spool)
Remove bolt (6), then remove washer (7),
retainer (8), spring (9), retainer (lo), collar
(II), and retainer (12).
Remove case (13), then remove retainer (14),
spring (15), retainer (16), spring (17), and
retainer (18).
Remove spool (19) from body (1).
*
Check the correct direction for assembling spool (19) to the body.
DEW01548
(24).
5.
6.
7.
8.
(26).
(28)
30- 197
0
DISASSEMBLY
AND ASSEMBLY
ASSEMBLY OF MAIN
CONTROL VALVE ASSEMBLY
DDW01547
30-198
0
1.
2.
Screen3i3&49Nm
(35+05kgmI
Pilot valve :
.
147 + 9.8 Nm (15.0 f 1.0 kgm)
c:
2)
3)
Plug (44) :
152 + 24.5 Nm (15.5 f 2.5 kgm)
Install flange (30).
B
Mounting bolt :
66.7 f 7.8 Nm (6.8 + 0.8 kgm)
Assemble valve (29) and spring (28) to body
(I), then fit O-ring to plug (27) and install.
w
Plug : 466 + 24.5 Nm (47.5 + 2.5 kgm)
3.
4.
5.
30-199
0
DISASSEMBLY
6.
7.
8.
MAIN
AND ASSEMBLY
CONTROL
VALVE
11
19
DEW01548
DEW01551
30-200
0
DISASSEMBLY
.REMOVAL
AND ASSEMBLY
PPC VALVE
OF PPC VALVE
Remove
covers (1).
+a
0
1.
Cover
1) Remove
floor inspection
cover (4).
c)
oT--
,,=I
-20
m2153
2.
Hydraulic piping
Disconnect following hydraulic piping from PPC
valve.
.
Hose (6) between PPC valve and PPC valve
.
Hose (7) between PPC valve and hydraulic
tank
.
Hoses P2 (8) and P3 (9) for boom spool
.
Hoses P4 (IO) and PI (11) for bucket spool
J,
30-20 1
0
DISASSEMBLY
PPC VALVE
AND ASSEMBLY
After disconnecting
the hoses,
with tags to distinguish them.
mark
them
Front of
machine
Linkage
1)
Remove
console
2)
linkage
DEW02161
D&W2162
PPC valve
Remove mounting bolts, then remove PPC valve
(14) from under floor.
*
The working space is confined,
so be extremely careful when carrying out this operation.
30-202
@
DISASSEMBLY
AND ASSEMBLY
INSTALLATION
ASSEMBLY
l
Carry out
removal.
installation
PPC VALVE
OF PPC VALVE
in the
reverse
order
to
m
*
AND ADJUSTING.
30-203
0
DISASSEMBLY
AND ASSEMBLY
DISASSEMBLY
ASSEMBLY
PPC VALVE
OF PPC VALVE
1. Remove
bolt (1).
2.
Remove
plate (2).
3.
4.
Remove
5.
Remove
valve assembly
6.
Remove
collar (81, then remove
retainer
(91,
spring (IO), and shim (II) from valve (12).
*
Check the number
and thickness
of the
shims, and keep in a safe place.
7.
(6) from
body (7).
7
DEW01221
DEW01222
30-204
0
DISASSEMBLY
AND ASSEMBLY
ASSEMBLY
ASSEMBLY
1.
PPC VALVE
OF PPC VALVE
PI Bucket TILT
11
P2 Boom RAISE
P3 Boom LOWER
14
P4 Bucket DUMP
*
8
zi
on the
2.
3.
Assemble
4.
valve assembly
(9)
5.
6.
7
DEW01221
DEW01222
30-205
DISASSEMBLY
REMOVAL
CYLINDER
AND
OF BUCKET
ASSEMBLY
AOperate
the control
lease the remaining
piping.
Then loosen
release the pressure
1.
BUCKET
ASSEMBLY
Bucket positioner
1) Disconnect connector (1).
2) Remove
wiring
clamps
positioner.
jl
(1-I)
for
bucket
2.
m
Rod pin
Sling cylinder, and remove lock bolt, then remove pin (2).
f
Be careful of the center of gravity when slinging, and lift at two places.
t
Check the number
and thickness
of the
shims, and keep in a safe place.
3.
Hydraulic piping
1) Disconnect
hose (3) at rod end from
der.
30-206
0
a
cylin-
CYLINDER
DISASSEMBLY
AND ASSEMBLY
BUCKET CYLINDER
2) Disconnect
4.
Bucket cylinder
1)
2)
3)
bottom
pin
(6).
*
If there are shims, check the number and
thickness of the shims, and keep in a
safe place.
Lift off bucket cylinder (7).
J, Be careful not to damage the cylinder
rod portion.
&I kg
Bucket cylinder
30-207
0
DISASSEMBLY
AND ASSEMBLY
INSTALLATION
CYLINDER
l
BUCKET CYLINDER
OF BUCKET
in the reverse order to
Awhen
aligning the position of the pin hole, use
a bar. Never insert your fingers in the pin hole.
DBW02171
*
*
DBW02172
30-208
0
BOOM CYLINDER
REMOVAL OF BOOM
CYLINDER
AStop
the machine on level ground
the safety bar on the frame.
Lower
to the ground and stop the engine.
the parking brake and put blocks
wheels to prevent the machine from
and install
the bucket
Then apply
under the
moving.
1.
Rod pin
js
I) Sling boom cylinder (I), and remove lock
bolt, then remove pin (2).
t
If there are shims, check the number and
thickness of the shims, and keep in a
safe place.
2) Start engine, and operate control lever to
retract cylinder rod of cylinder which has
been removed.
2.
Hydraulic piping
m
I) Disconnect tube (3) and hose (4) at rod end
from disconnection.
2) Disconnect tube (5) and hose (6) at bottom
end from connection.
3.
Boom cylinder
I)
Remove
DBWO217b
a
remove
bottom
pin
(7).
t
If there are shims, check the number and
thickness of the shims, and keep in a
safe place.
2)
DEW02176
30-209
0
DISASSEMBLY
AND ASSEMBLY
INSTALLATION
OF BOOM
CYLINDER ASSEMBLY
Clearance
1;
+
Sr
30-210
0
BOOM CYLINDER
HYDRAULIC
CYLINDER
DISASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
(STEERING,
SEMBLY)
BOOM,
BUCKET
assembly
CYLINDER
AS-
Steering cylinder
(1) to tool F.
1.
Set cylinder
2.
2)
Pull out cylinder head and piston rod assembly (3) from cylinder (41, and lift off.
*
Oil will flow out when the piston rod
assembly is removed from the cylinder,
so place a container under the cylinder
to catch the oil.
Steering cylinder
DEW01246
.
1)
Bucket cylinder
head (2).
Boom, Bucketcylinder
1
27
DBWO1795
2)
Pull out cylinder head and piston rod assembly (6) from cylinder (71, and lift off.
t
Oil will flow out when the piston rod
assembly is removed from the cylinder,
so place a container under the cylinder
to catch the oil.
DISASSEMBLY
3.
AND ASSEMBLY
BOOM
CYLINDER
Cylinder head
.
Steering cylinder assembly
1) Set cylinder head and piston rod assembly
(3) to tool F.
2) Using tool H, remove nut (8).
-f Width across fiats of nut: 46 mm
piston (9), then remove
cylinder
3) Remove
head (2).
.
1)
2)
4.
DEW01797
pis-
I
DEW01251
5.
30-212
0
DISASSEMBLY
6.
AND ASSEMBLY
BOOM
I
I
CYLINDER
17
I,
I
2
20
21
19
DEW01253
.
1)
2)
3)
k
f
22
23
24
30-2 13
0
DISASSEMBLY
AND ASSEMBLY
HYDRAULIC
CYLINDER
ASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
(STEERING, BOOM, BUCKET CYLINDER ASSEMBLY)
*
1.
DEW01793
24
264
DEW01257
4)
Steering
assembly
30-214
0
DEW01799
DISASSEMBLY
4)
5)
AND ASSEMBLY
HYDRAULIC
CYLINDER
DEW01260
2.
16
J2
9,?2
8
G
3
3.
9, 12
16
DEW01252
4.
DEW01251
NmOw-4
110.8+
12.8(11.3+1.3)
30-215
0
DISASSEMBLY
5.
HYDRAULIC CYLINDER
AND ASSEMBLY
across flats1
46
I
Nm(kgm)
785 f 78 (80 f 8)
Cylinder head
.
Boom, bucket cylinder
1) Set cylinder (7) to tool F.
2) Raise cylinder head and piston rod assembly (6) and assemble to cylinder (7).
3) Install cylinder head (2) to cylinder (7).
w
Mounting bolt:
Cylinder
Boom cylinder
Bucket cylinder
Nm(kgm)
1,324f 147 (135f 15)
343 + 34 (35 z!z3.5)
I I
Remove
1)
2)
3)
4)
5)
cylinder
assembly
from tool F.
4)
DBW01853
Steering cylinder
DEW01246
30-216
0
WORK EQUIPMENT
REMOVAL OF WORK
EQUIPMENT ASSEMBLY
A
and install
the bucket
Then apply
under the
moving.
1. Bucket link
I) Remove bucket link mounting pin (I). m
Ir Secure the bucket link to the bellcrank
with wire.
I
2)
3)
Bucket
Move machine towards
nect bucket (2-I).
& kg
2.
rear, then
DElwo2179
DBWO21SU
discon-
edge)
m
Bucket cylinder mounting pin
Sling bucket cylinder (3) and pull out pin (4),
then disconnect cylinder rod and bellcrank.
*
Set block @ between the cylinder bottom
and the frame.
el
kg
Bucket cylinder
: 166 kg
DBWO2183
3.
Boom cylinder
: 164 kg (each)
DISASSEMBLY
4.
WORK EQUIPMENT
I.&lkg
*
5.
AND ASSEMBLY
Boom,
bellcrank,
DEW02186
2)
6.
DBW02187
Bellcrank
: 310 kg
m
(76) from
16
DLWo2190
DfJWO2189
30-218
0
DISASSEMBLY
WORK EQUIPMENT
AND ASSEMBLY
2)
(18) from
3)
(20) from
.l
30-219
0
DISASSEMBLY
WORK EQUIPMENT
AND ASSEMBLY
INSTALLATION
OF WORK
EQUIPMENT ASSEMBLY
*
*
a
Operate the control levers, align the mounting pin holes for the bucket and bucket link,
install cord rings (211, insert shims so that
clearances a and b on the left and right are
uniform, then assemble the mounting
pin
and lock with the bolt.
Be careful not to get the cord ring caught.
Clearance a : Max. 1.5 mm (bucket link portion)
Clearance
portion)
b : Max.
1.5 mm
(bucket
DBWOZ195
hinge
DEW02196
*
*
DBWO2197
pin, remove
DBWO2396
30-220
0
Clearance
d : Max. 2.0 mm
WORK EQUIPMENT
J,
Ir
*
&
After installing
the boom,
install
boom
kickout switch.
Clearance e : Max. 1.5 mm
After assembling the pin, set the support to
the tip of the boom.
16
15
DBWO2199
Sr Greasing
Coat each pin with grease.
30-22 1
0
DISASSEMBLY
AND
COUNTERWEIGHT
ASSEMBLY
REMOVAL OF
COUNTERWEIGHT
AStop
the machine on level ground and instail
the safety bar on the frame. Lower the bucket to
the ground and stop the engine. Then apply the
parking brake and put blocks under the wheels
to prevent the machine from moving.
1.
Grill
I) Sling grill (I), and remove from engine hood
(Z), then make a clearance.
2) Disconnect wiring connector (31, then lift off
grill (1).
2.
Counterweight
m
Sling counterweight
(51, then remove mounting
bolts (4) and lift off.
*
Be careful to maintain the balance when lifting off.
DEWOPOZ
D6WO2203
& kg
Counterweight:
1,170 kg
INSTALLATION
OF
COUNTERWEIGHT
.
Carry out
removal.
installation
in the
reverse
order
to
DEW02204
30-222
0
Mounting
bolt :
927 + 103 Nm (94.5 i 10.5 kgm)
_.
(Width across fiats: 36 mm)
DISASSEMBLY
AND ASSEMBLY
FUEL TANK
Grill
1) Loosen mounting
2)
2.
DLWOZ339
Draining fuel
Loosen drain valve (4) and drain fuel.
3.
Drain valve
Remove engine oil drain valve (5) from fuel tank.
*
Remove the drain valve, then tie with wire
and move to the side.
DBWOZZOE
30-223
DISASSEMBLY
4.
5.
AND
FUEL TANK
ASSEMBLY
Disconnect
3)
Disconnect
wiring connector
m
Fuel tank
1) Sling fuel tank (IO), then remove mounting
bolts and lift off.
*
Use two nylon ropes of a length of
approx. 5 m to sling the tank.
t
Set a pallet under the tank, then slowly
tower the fuel tank on to the pallet, taking care to maintain the balance.
I3
kg
30-224
0
m
Tilt breather tube (11) to the side to prevent it from hitting the chassis.
When pulling the fuel tank out from under the chassis, remove it from the right
side.
DBWOZZ12
DISASSEMBLY
AND ASSEMBLY
INSTALLATION
ASSEMBLY
l
FUEL TANK
OF FUEL TANK
in the
reverse
order
to
Bolt
a
+
m
*
*
in the fol-
DEW02215
and add
fuel
through
oil
30-225
0
DISASSEMBLY
AND ASSEMBLY
Ladder
(-1 ter-
: 60 kg
2.
Remove 8 connectors
(2) from clip and disconnect.
*
To distinguish
the connectors,
mark them
with tags.
Ir After disconnecting,
fit the connectors at the
cab end to the clip, and take steps to prevent oil or mud from getting on the connectors at the chassis end.
3.
Disconnect ground
and chassis.
connection
(3) between
cab
DBWO2218
4.
DLWM842
5.
Disconnect
brake hoses (8), (9). (IO), and (II).
t
To distinguish
the hoses, mark them with
tags.
30-226
0
DISASSEMBLY
6.
AND ASSEMBLY
7.
Disconnect
work
equipment
PPC valve
hoses
DEW02221
8.
Disconnect accelerator
ti-on pump end.
cable
DISASSEMBLY
AND ASSEMBLY
9. Disconnect
2 window
washer
tubes (17) at
washer tank end.
*
Fit blind plugs to prevent the water inside
the washer tank from leaking out.
*
After disconnecting the tubes, check the position for inserting them into the tank, then
coil the tubes and secure them to the cab.
11. Sling
30-228
0
DISASSEMBLY
AND ASSEMBLY
INSTALLATION OF CAB,
FLOOR FRAME ASSEMBLY
l
Carry out
removal.
installation
in the
reverse
order
to
a
*
Thread
size
Tigh;;i;;B
to;que
R
M6 bolt at receiver
portion
Other M6 bolts
rel
Ir
ks
(R-134a).
DEW02227
30-229
0
DISASSEMBLY
CAB
AND ASSEMBLY
REMOVAL
OF CAB ASSEMBLY
1.
Cover
1) Remove
floor.
covers
under
2) Remove
3)
DBWOle33
2.
Electric wiring
1)
3.
Disconnect
cab wiring connectors (7). m
+
Fit tags to distinguish the connectors.
(Connectors
CLI, CL2, CL31
Hoses
1) Disconnect
Ir
Sr
4.
Cab
1) Remove
steering
post and cab mounting
bolts (9).
f
Pull the steering post to tip it down.
30-230
0
DISASSEMBLY
2)
AND ASSEMBLY
CAB
bolts
..L
( IUI,
DBWOlm
3)
Cab : 295 kg
13
l--_._-/
DBW0183
INSTALLATION
ASSEMBLY
.
Carry out
removal.
Connect
installation
the wiring
DBWOl840
OF CAB
in the
reverse
connectors
order
to
securely.
30-231
0
DISASSEMBLY
AND ASSEMBLY
REMOVAL OF MAIN
ASSEMBLY
MAIN
MONITOR
MONITOR
Astop
the machine on level ground and install
the safety bar on the frame. Lower the bucket to
the ground and stop the engine. Then apply the
parking brake and put blocks under the wheels
to prevent the machine from moving.
ADisconnect
the cable from the negative
minal of the battery.
(-) ter-
1.
Remove
dashboards
2.
Remove
and (4).
steering
3.
Remove
steering
4.
bolts (3)
post
DLW01841
5.
6.
Remove
bracket
DEW01307
30-232
0
DISASSEMBLY
AND ASSEMBLY
MAIN
7.
8.
k
INSTALLATION OF MAIN
MONITOR ASSEMBLY
l
in the
reverse
I
order
MONITOR
DEW01309
15
14
13
to
@lJ
Ir
lock securely.
30-233
DISASSEMBLY
REMOVAL
MONITOR
AND ASSEMBLY
MAINTENANCE
OF MAINTENANCE
ASSEMBLY
AStop
the machine on level ground and install
the safety bar on the frame. Lower the bucket to
the ground and stop the engine. Then apply the
parking brake and put blocks under the wheels
to prevent the machine from moving.
a
1.
Cover
1)
2)
3)
2.
Maintenance
I)
3.
Disconnect
*
*
monitor
electrical
wiring
INSTALLATION
OF
MAINTENANCE
MONITOR
ASSEMBLY
. Carry out installation in the reverse
removal.
m
f
30-234
0
Connect
the connectors
securely.
order
to
MONITOR
DISASSEMBLY
AIR CONDITIONER
AND ASSEMBLY
UNIT
REMOVAL OF AIR
CONDITIONER UNIT
ASSEMBLY
Stop the machine on level
A the
safety bar on the frame.
If the refrigerant gets in your eyes, there is danger of losing your sight, so always wear protective goggles.
1.
Remove
inspection
2.
Remove
3.
z?
2
f
4.
DBW02230
then
I III
DEiV01316
\
/
DEW01318
DEW01317
30-235
0
DISASSEMBLY
5.
AIR CONDITIONER
AND ASSEMBLY
UNIT
Remove
cool and hot box assembly
(6) and
mounting
bolts (71, then remove cool and hot
box assembly.
DEW01319
6.
Remove
console
7.
8.
30-236
0
DISASSEMBLY
9. Remove
AND ASSEMBLY
left console
AIR CONDITIONER
UNIT
DEW01323
10. Remove
left console box mounting
bolts (20)
and (211, then remove left console box (22).
,21
11. Remove
mounting
II
DEW01325
unit (23).
DEW01326
26
DEW01327
30-237
0
DISASSEMBLY
AND ASSEMBLY
AIR CONDITIONER
UNIT
13. Disconnect
air conditioner
tubes (28) and (29)
from air conditioner
unit.
m
*
Check that the pressure has been reduced.
14. Remove
cover
I-
DEW01329
15. Remove
air conditioner
filter (311, then remove
duct mounting bolts (32).
32
I
16. Remove connecting bolts (33) of air conditioner
unit (23) and air conditioner damper (25).
30-238
0
/25_
DEW01331
17. Remove
AIR CONDITIONER
wir-
/
18. Disconnect
conditioner
(23).
6 kg
UNIT
DEWO? 333
Air conditioner
unit assembly:
38 kg
19. Disconnect
air conditioner damper wiring connector (37) from floor wiring, then remove air
conditioner damper (25).
*
After disconnecting,
take steps
the entry of dust or water.
to prevent
II
II
DEW01336
30-239
0
DISASSEMBLY
AND
INSTALLATION
CONDITIONER
ASSEMBLY
.
AIR CONDITIONER
ASSEMBLY
OF AIR
UNIT
in the
reverse
order
to
removal.
w
*
m
Jr
hose through
30-240
0
UNIT
DISASSEMBLY
AND ASSEMBLY
CONDITIONER
ASSEMBLY
AIR CONDITIONER
CONDENSER
CONDENSER
AStop
the machine on level ground and install
the safety bar on the frame. Lower the bucket to
the ground and stop the engine. Then apply the
parking brake and put blocks under the wheels
to prevent the machine from moving.
1.
Remove
left and right covers (I) under bulkhead, and open left and right engine hood inspection covers (21, then apply lock.
or
*
D&V02231
DEW02232
2.
a
Disconnect hoses (4) and (5).
*
After disconnecting the hoses and tubes, fit
covers to prevent dirt, dust, or water from
entering the joint.
3.
4.
30-241
0
5.
6.
Remove
mounting
bolts of condenser
and
bracket assembly, then remove condenser
(12)
together with bracket assembly from inside of
bulkhead (1 I).
+
Leave dry receiver
(13) installed
to the
bracket when removing.
Condenser, bracket assembly : 20 kg
&I kg
(including dry receiver)
Remove condenser
piping, then remove cona
denser (12) from brackets (14) and (15).
*
After disconnecting
the hoses and tubes, fit
covers to prevent dirt, dust, or water from
entering the joint.
Condenser (each) : 5.4 kg
&I kg
INSTALLATION
OF AIR
CONDITIONER CONDENSER
ASSEMBLY
. Carry out installation in the reverse order
to
removal.
/-EJfi]
*
*
6
*
Ml6
x 1.5
M22 x 1.5
M24 x 1.5
M6 bolt at receiver
portion
size
Other
M6 bolts
CompF
30-242
0
DBLWQ233
Correct
Low
Remedyi
Almost completely
transparent; even if there
are bubbles, becomes
transparent when engine
speed is raised or
lowered
Continuous
stream of bubbles
passes
Connect charging
hose to compressor, then add
refrigerant until
condition becomes normal
DISASSEMBLY
AND ASSEMBLY
DRY RECEIVER
2
f
DBW02232
INSTALLATION OF DRY
RECEIVER ASSEMBLY
l
Carry out
removal.
installation
in the
reverse
order
to
Hose.mounting
bolt :
5.4 i 1.5 Nm (0.55 & 0.15 kgm)
f To prevent dirt, dust, or water from entering,
do not remove the covers from the air conditioner hoses until immediately
before installing.
a
Hose joint : Compressor
oil
w
m
U-bolt : 18.6 + 7.8 Nm (1.9 f 0.8 kgm)
* Be careful not to tighten the U-bolts too far.
Amount of bubbles in
receiver sight glass
Correct
Almost completely
transparent; even
if there
are bubbles, becomes
transparent when engine
speed is raised or
lowered
Low
Continuous
stream of bubbles
passes
Remedy
Connect charging
hose to compressor, then add
refrigerant until
condition becomes normal
30-243
0
DISASSEMBLY
AND ASSEMBLY
AIR CONDITIONER
CONDENSER
COMPRESSOR
REMOVAL OF AIR
CONDlTlONER CONDENSER
COMPRESSOR ASSEMBLY
AOpen
ADisconnect
the cable from
minal of the battery.
the negative
(-1 ter-
1.
2.
Disconnect
3.
4.
electric wiring
INSTALLATION
CONDITIONER
COMPRESSOR
.
Carry out
removal.
installation
from connector
(I).
OF AIR
CONDENSER
ASSEMBLY
in the
reverse
order
to
Adjust belt
with adjustment
m
Hose mounting bolt :
7.8 - 11.8 Nm (0.8 - 1.2 kgm)
w
112
30244
0
DBW038M
40
MAINTENANCE
STANDARD
40- 2
40- 3
40- 4
40- 5
40-14
40-18
40-19
40-20
40-21
40-24
40-26
40-28
40-30
40-31
40-32
40-33
40-34
40-38
40-39
40-40
40-44
40-45
40-46
40-48
40-49
40-l
MAINTENANCE
ENGINE
ENGINE MOUNT,
STANDARD
MOUNT,
TRANSMISSION
TRANSMISSION
MOUNT
ZNm
MOUNT
(B6kgm)
(5&6kgm)
J
!I
II
113tlONm
(lE&l.Okgm)
ii
w
27%34Nm
(28.523.5kgm)
r-i
w
549t59Nm
(56*6kgm)
SLwoo639
Unit: mm
I
No.1
1
40-2
I
Check item
Crearance between transmission bracket and
adjustment bolt
Criteria
l-2
Remedy
Adjust
MAINTENANCE
STANDARD
TORQUE CONVERTER
CHARGING
PUMP
(SAL(2)45+20)
A-A
w
113+10Nm
(ll.hl.Okgm)
Unit: mm
No.
Criteria
Check item
1Standard
Model
Remedy
clearance
0.19
0.10 - 0.15
SAL (2) 45
in pin
0.20
0.060 - 0.125
Replace
SAL (2) 20
Standard
Model
3
SAL (2) 45
Tolerance
size
0
- 0.5
12
SAL (2) 20
4
Rotating torque
spline shaft
limit
SAL (2) 45
Side clearance
SAL (2) 20
1 Clearance
of
Discharge amount
Oil: EOlO-CD
Oil temperature:
45 - 55C
SAL (2) 20
3,000 rpm
,3~~g~cp~*j
59 Umin
53 elmin
40-3
MAINTENANCE
TORQUE
STANDARD
TORQUE CONVERTER
CONVERTER
m
66.2z7.4Nm
30.9*3.4Nm
(6.75+0.75kgm)
(3.15-9.35kgm)
66.227.4Nm
30.%3.4Nm
(6.75_9.75kgm)
(3.150.35kgm)
SAWW64l
I
No.
Check
Standard
Outside
diameter
size
Tolerance
Repair
limit
52
- 0.010
- 0.040
110
+ 0.035
0
110.5
Width
- 0.01
- 0.03
2.7
Thickness
4.3
+ 0.1
3.9
of pilot
Wear of stator
shaft seal ring
40-4
Remedy
Criteria
item
Unit: mm
0.18 - 0.49
51.75
Repair
chrome
plating of
replace
Replace
MAINTENANCE
TRANSMISSION
STANDARD
Unit: mm
No.
Check
Criteria
item
Clearance between
drive shaft bearing
housing
pump
and
Clearance
between
Clearance between
pump
drive shaft and bearing
Clearance
and
between
drive
housing
shaft bearing
Hole
Standard
clearance
Clearance
limit
60
co.030
+O.Oll
0
-0.015
-0.011 -0.045
110
4.015
+0.022
-0.013
-0.013 0.037
85
4.015
+0.022
-0.013
-0.0130.037
50
+0.025
+0.009
Jo12
-0.009
-0.037
90
-0.015
0
+0.022
-0.013
-0.0130.037
pump
and
Shaft
pump
drive
housing
shaft bearing
Standard
size
Tolerance
Remedy
Clearance between
drive shaft bearing
housing
pump
and
Clearance between
shaft and bearing
idler
35
2::;:
1 :::i,i
) .%I,,
47
-Z.Oll
+0.014
-0.011
-0.011 0.025
60
+0.023
+O.Oll
4.015
-0.011
-0.038
-0.042
-0.005
Replace
lo
11
between
ward/reverse
bearing and housing
clutch
Clearance
between
110
-Lo15
-0.042
-0.020
100
4.015
+0.030
0
o- 0.045
for(RI
for-
12
ward/reverse
bearing and housing
clutch
90
-EL01 5
+0.030
0
o- 0.045
13
110
+0.030
0
o-
-Lo15
14
130
+0.030
0
o-
-:.OlS
15
110
+0.030
0
o-
4.015
16
140
+0.030
0
o-
l.018
I7
Clearance between
output
shaft and bearing (RI
65
io.030
+O.Oll
-0.015
0
-0.011
-0.045
18
;@ft
100
-0.015
0
-0.015
-0.040
o- 0.040
,g
Clearance
shaft and bearing
between (F)
output
65
+O.Oll
+0.030
J.015
120
i.015
100
+0.35
+0.15
Clearance .between
beanng
Clearance
sF,ft bearing
21
;$ft
Clearance
0.048
0.045
0.048
-0.011
-0.045
-0.040
-0.015
o- 0.040
+0.054
0
-0.096-0.35
output
and housing
between
0.045
output
and housmg
between
20
(F)
output
40-7
MAINTENANCE
TRANSMISSION
STANDARD
Unit: mm
No.
-
Check item
Criteria
Remedy
22
23
24
Inner diameter of housing
seal ring contact surface
25
26
Replace
27
28
30
40-8
Adjust shim.
MAINTENANCE
TRANSMISSION
STANDARD
FORWARD/REVERSE
Clutch
10
2
SAAOWS
NO
Tolerance
Standard
size
Clearance at forward/
reverse clutch shati~bearinn Dress-fitted section (R)
Clearance at forward/
reverse clutch shaft bearing press-fitted section (F)
Clearance at forward/
reverse clutch shaft spacer
press-fitted section (R)
Clearance at forward/
reverse clutch shaft spacer
Dress-fitted section (F)
Shaft
Hole
110
-0.27
-0.32
+0.06
-0.07
140
-0.20
-0.25
+0.13
0
4.015
55
+0.030
+O.Oll
50
%i;:
1.012
Standard size
1.7
0.02 0.38
0.43
0.02 0.38
0.43
1 -.?Oi6
k
f
2.2
-0.041 -0.074
I
Tolerance
kO.05
I
I
Reoair limit
1.6
0.1
0.15
+0.08
1.95
40-10
Clearance
limit
-0.011 -0.045
-0.020
-0.040
+0.034
+0.021
50
1
Standard
clearance
Replace
Remedy
Criteria
Check item
0.1
0.25
MAINTENANCE
STANDARD
TRANSMISSION
Unit: mm
No.
Criteria
Check item
Standard size
Tolerance
Remedy
Repair limit
(103 kg)
(k10.3 kg)
804 N
(82 kg)
2.7
1,010 N
+I01
,o
Thickness of forward/reverse
clutch thrust washer
3.0
*o. 1
,,
Thickness of forward
clutch spacer
5.0
+0.05
5.5
kO.05
Thickness of reverse
I2
clutch spacer
13
0.106 - 0.991
14
0.106 - 0.991
Replace
40-11
MAINTENANCE
TRANSMISSION
STANDARD
Unit: mm
No.
Remedy
Criteria
Check item
8
z
s
Clearance between
piston and cylinder
(inner)
110
-0.27
-0.32
+0.06
-0.07
0.20 -
(outer)
165
-0.27
-0.32
+0.06
-0.07
0.20 0.38
0.38
0.43
0.43
60
io.054
+0.044
4.015
-0.044 -0.069
60
+0.030
+O.Oll
1.015
-0.011 -0.045
60
+0.054
+0.044
-0.02
-0.04
-0.064 -0.094
61
+0.030
+O.Oll
-:.03
-0.011
-0.06
Standard size
Tolerance
Repair limit
3.0
kO.1
2.7
5.0
+0.05
40-l 2
0.02 - 1.58
0.1 - 0.9
Replace
MAINTENANCE
STANDARD
TRANSMISSION
4_
Unit: mm
No
lCheck item
Criteria
Remedy
Clearance
limit
Clearance between
piston and cylinder
(inner)
110
-0.27
-0.32
+0.06
-0.07
0.20 0.38
0.43
0.43
60
-I-o.033
+0.017
1.015
-0.017 -0.048
65
+0.059
+0.049
0
-0.015
-0.049 -0.074
65
+0.059
qo.049
-0.021
-0.041
-0.070 -0.100
0.34 - 1.66
0.17 - 1.43
II
Standard
Thickness
of thrust washer
Replace
3.0
Tolerance
size
kO.1
Repair
limit
2.7
40-l 3
MAINTENANCE
STANDARD
TRANSMISSION
TRASMISSION
CONTROL VALVE
CONTROL VALVE
UPPER VALVE
30.923.4Nm
(3.15e0.35kgm)
8
39.&4.9Nm
13
40-14
A-A
MAINTENANCE
STANDARD
TRASMISSION
CONTROL
VALVE
Unit: mm
No.
Check item
Criteria
Standard
size
Remedy
Tolerance
Shaft
Standard
clearance
Hole
Clearance
limit
14
-0.02
-0.03
+O.Oll
0
+0.020 +0.044
0.050
25
-0.035
-0.045
+0.013
0
+0.035 +0.058
0.065
25
-0.020
-0.028
+0.013
0
+0.020 i-o.041
0.044
25
-0.035
-0.045
+0.013
0
+0.035 +0.058
0.065
15
-0.02
-0.03
+0.018
0
+0.020 to.048
0.055
25
-0.035
-0.045
+0.013
0
+0.035 +0.058
0.065
Clearance between
dummy spool and body
25
-0.02
-0.03
+0.013
0
+0.020 to.048
Replace
Standard size
8
74.2
,
9
Quick return
Free length
Repair limit
Installed load
463+23 N
(47.2k2.4 kg)
417 N
(42.5 kg)
49
71.2
valve spring
I
I
10
11
12
Main
73
0.055
I
I
,
I
,
4.9+0.25 N
(0.5+0.025 kg)
4.41 N
(0.45 kg)
31.5
27
26
19
5.7kO.3 N
(0.58ti.03 kg)
25.0
5.1 N
(0.52 kg)
163.5
131.3
315.8k15.8 N
(32.2i1.61 kg)
157.0
284.4 N
(29.0 kg)
30.2
converter regulator
valve spring
Torque
40-15
MAINTENANCE
STANDARD
TRASMISSION
CONTROL VALVE
LOWER VALVE
w
1.62-9.15Nm
(0.165=0.015kgm)
12.S4.66Nm
w
30.9z3.4Nm
(3.15d35kgm)
(1.275_9.475kgm)
30.9&3.4Nm
(3.15z0.35kgm)
m
1.62d.15Nm
(0.165e0.015kgm)
30.9d3.4Nm
(3.15dl.35kgm)
m
30.%3.4Nm
(3.15*0.35kgm)
B-B
4
8
A-A
40-16
MAINTENANCE
STANDARD
TRASMISSION
CONTROL VALVE
Unit: mm
Check item
No.
Tolerance
Hole
Standard
clearance
Clearance
limit
19
-0.02
-0.03
+0.013
0
+0.02 +0.043
0.050
19
-0.02
-0.03
+0.013
0
+0.02
+0.043
0.050
19
-0.035
-0.045
+0.013
0
+0.035
+0.058
19
between
selector
Standard
size
spool
-J$
Standard
6
Remedy
Shaft
Clearance
directional
and body
Criteria
Directional
spring
Parking
selector
spool
Free length
1.
+i.013
/ +:$):;3
size
0.065
1
Reoair
0.050
limit
Installed load
78.9f3.9
N
(8.05+0.4 kg)
70.6 N
(7.2 kg)
42
32
48
36.7
150
111
46
37
69.8k3.5 N
(7.12kO.36 kg)
841 A42.2
N
(85.B4.3 kg)
81.4f3.9
(8.3kO.4
N
kg)
40.3
46.1
144
44.2
Replace
62.8 N
(6.4 kg)
757 N
(77.2 kg)
73.5 N
(7.5 kg)
40-l 7
MAINTENANCE
STANDARD
MODULATION
MODULATION
VALVE ASSEMBLY
VALVE ASSEMBLY
8
4
.l
A-A
sAbvx65.4
Unit: mm
No
Check item
Criteria
Standard
size
Remedy
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
25
-0.030
-0.040
+0.013
0
0.030
0.053
0.060
25
-0.020
-0.030
25
-0.020
-0.030
1 +op
/ o.o;yo~3
0.040
0.063
+0.033
+0.020
0.050
0.067
I
4
27
-0.040
-0.050
Accumulator spring
38
-0.025
-0.050
0.065
0.091
+0.041
+0.025
I
+0.025
0
0.100
I
0.025
0.075
0.080
Accumulator spring
Accumulator spring
40-18
100
78.5
607? 30.4 N
(61.ti3.1 kg)
g6
546 N
(55.7 kg)
Replace
%
k
f
MAINTENANCE
STANDARD
ACCUMULATOR
ACCUMULATOR
VALVE
VALVE
A-A
&9?79.6Nm
(5.5&.0kgm)
Unit:
No.
Check item
Forward clutch
tor spring
accumula-
Criteria
Remedy
mm
MAINTENANCE
STANDARD
DRIVE SHAFT
DRIVE SHAFT
110zlZNm
(11.25~ 1.25kgm)
_..A
277t32Nm
(28.25 + 3.25 kgm)
40-20
110+12Nm
(1125+1.25kgm)
w
927 -c103 Nm
(94.5 -c10.5 kgm)
I ---
llOk12Nm
(Il.252 1.25 kgm)
MAINTENANCE
DIFFERENTIAL
STANDARD
DIFFERENTIAL
(l/2)
177dONm
(18dZkgm)
177s2ONm
(18dkgm)
17L20Nm
(18dkgm)
w
\
152z25Nm
(15.%2.5kgm)
w
4.4+1.5Nm
(0.45+0.15kgm)
w
549+59Nm
(56Skgm)
177dONm
(18dkgm)
&
5=m
279d9Nm
(28.5=3.0kgm)
152&!5Nm
(15.5&.5kgm)
(5t0.5kgm)
I
No.
-
Criteria
Check item
Bevel gear starting rota-
1 tional force
0.4 - 1.0
0.66 - 1.86
I
diameter
of bevel gear)
Unit: mm
Remedy
I
Adjust
40-2 1
MAINTENANCE
STANDARD
DIFFERENTIAL
40-22
DIFFERENTIAL
(Z/2)
11
4-
8.
MAJNTENANCE
DIFFERENTIAL
STANDARD
Unit:
mm
No
-
Check
Tolerance
Standard
size
Clearance
1
Remedy
Criteria
item
Shaft
Hole
at
Standard
clearance
Clearance
limit
lace
150
-:.018
-0.045
-0.085
-0.085
-0.027
Inner lace
100
+0.059
+0.037
-Lo20
-0.079
-0.037
Clearance at
pinion shaft
gear side
Outer
171.45
+0.025
0
-0.028
-0.068
-0.093 -0.028
bearing
Inner lace
76.2
+0.043
+0.062
+0.013
0
-0.062
-0.030-
Clearance at
pinion shaft
coupling side
Outer
lace
140
-:.Ola
-0.048
-0.088
-0.088 -0.030
bearing
Inner lace
65
+0.039
+0.020
-0.015
0
-0.054
-0.020-
differential
bearing
side
Outer
Clearance between
gear and spider
lace
Replace
pinion
5
I
Thickness
washer
of side gear
Thickness
washer
of pinion gear
-0.110
-0.191
304
+0.081
0
0.110 0.272
Standard
size
Tolerance
Repair
limit
20.05
3.8
1.5
+0.09
-0.01
1.35
IO
11
Differential
12
66.61
kO.025
0.30 - 0.46
gear backlash
I
I
0.10 - 0.25
Adjust
40-23
MAINTENANCE
STANDARD
FINAL DRIVE
FINAL DRIVE
549d9Nm
(%6kgm)
152d4Nm
(15.5S.5kgm)
927k103Nm
(94.5~10.5kgm)
927+103Nm
(94.5+10.5kgm)
40-24
MAINTENANCE
FINAL DRIVE
STANDARD
Unit: mm
No.
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
-0.10 0.07
io.10
0
12
+0.025
co.007
+0.207
+0.145
0.120 0.200
Outer lace
160
-0.025
0
-0.045
-0.085
-0.085
-0.020
105
+0.035
+0.013
Jo20
Inner lace
-0.055 -0.013
axle
Clearance at
housing
bearing pressfitted section
Tolerance
+O.lO
+0.03
374
Remedy
Criteria
Check item
Replace
4
180
-:.025
-0.045
-0.085
-0.085
-0.020
120
+0.045
+0.023
0
-0.020
-0.065 -0.023
Housing
215
+0.072
0
Shaft
180
1.063
40
+0.013
+0.002
-0.025 -0.002
Outer lace
Clearance at
axle housing
bearing pressfitted section
inner lace
Clearance between
gear bearing
pinion
and shaft
between
oil seal
4.012
o-o.1
Adjust
0.1 - 1.9
40-25
MAINTENANCE
AXLE MOUNT
STANDARD
AXLE MOUNT
1324 e 147 Nm
Unit: mm
Standard size
Tolerance
22
iO.5
+0.3
-0.1
Clearance
between hole
and shaft at rear support
end
40-26
Remedy
Criteria
Check item
Standard
size
Tolerance
Shaft
Hole
Repair limit
-
Standard
clearance
Clearance
limit
190
-0.050
-0.122
+0.472
0
0.050 0.594
170
-0.005
-0.124
+0.522
+0.050
0.055 0.646
Replace
MAINTENANCE
STANDARD
CENTER
HINGE PIN
w
w
19.6z2.ONm
(2.010.2kgm) (when adjusting with shim)
112.8=9.8Nm
(11.5zl.Okgm) (final value)
19.6Q.ONm
(2.0=0.2kgml (when adjusting with shim)
279.5Q9.4Nm
(28.5*3.0kgm) (finalvalue)
w
112.8&.8Nm
(11.5~l.Okgm)
12
IO
II
6
8
6
40-28
7
19.6G?.ONm
(2.&0.2kgm) (when adjusting with shim)
112.8*9.8Nm
(11.5=l.Okgm) (finalvalue)
SBWCC663
MAINTENANCE
NO.1
E
:
2
STANDARD
Tolerance
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
80
-0.030
-0.049
+0.071
+0.036
0.066
0.130
80
-0.030
-0.049
+0.060
+0.030
0.060
0.109
Clearance between.upper
hinge pin and bearing
80
-0.030
-0.049
-EL015
0.015
0.049
80
-0.030
-0.049
+0.030
0
0.030
0.079
frame
Clearance
and between
rear
spacer (large)
95
-0.071
-0.036
+0.071
+0.036
0.072 0.142
130
4.025
-0.048
-0.088
80
-0.030
-0.076
+0.054
0
Clearance between.lower
hinge pin and beanng
8o
%%!
j.015
-0.088
-0.023
1 o:50;s
25.5
Replace
0.030
0.130
Tolerance
Standard size
Height of upper hinge
spacer (small)
Remedy
Criteria
Check item
Repair limit
f0.1
f0.1
t
1o
,,
12
56
Standard size
Standard clearance
Clearance limit
2.5
0.05
0.1
0.1
2.5
I
0.2
I
Adjust
40-29
MAINTENANCE
STEERING
STEERING COLUMN
STANDARD
COLUMN
29.4Q.9Nm
(3.&0.3kgm)
No.
Criteria
Check item
Clearance between
steering shaft and column
bearing
Standard
size
Hole
Standard
clearance
Clearance
limit
Replace
19
40-30
Tolerance
Shaft
Remedy
Jo*
to.15
-0.05
0.05 - 0.23
0.4
MAINTENANCE
STEERING VALVE
STANDARD
STEERING VALVE
SLwo1253
Unit: mm
No.
Remedy
Criteria
Check item
Repair limit
Standard size
1
Free length Installed length Installed load Free length Installed load
37.2
32.0
56.9 N
(5.8 kg)
47.1 N
(4.8 kg)
20.9
13.2
9.3k4.9 N
(0.95kO.5 kg)
7.8 N
(0.8 kg)
136.1 N
(13.88 kg)
114.7 N
(11.7 kg)
75.1
68.5
24.0
22.19
182.4 N
(18.6 kg)
145.1 N
(14.8 kg)
21.6
17.0
2.3 N
(0.23 kg)
1.8 N
(0.18 kg)
Replace
40-31
MAINTENANCE
STEERING
STANDARD
CYLINDER
MOUNT
3.4
Unit: mm
No
-
Check item
Clearance between
mounting pin and bushing
at connection of steering
cylinder rod and frame
Clearance between
mounting pin and bushing
at connection of steering
cvlinder bottom and frame
Connection between
steering cylinder
front frame
and
Tolerance
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
50
0
-0.025
+0.20
+O.lO
0.10 0.225
50
l.025
+0.150
+0.050
0.050 0.175
_
2
Remedy
Criteria
Width of boss
Width of hinge
60+0.8
0
632~1
Standard clearance I
(clearance
a + b)
Connection between
steering cylinder and
rear frame
40-32
6. +0.8
0
66fl
Max. 0.5
(after adjusting
with shim)
Replace
MAINTENANCE
STANDARD
BRAKE
BRAKE
sAwooEa3
Unit: mm
No
-
Criteria
Check item
0.9
_+O.l
Repair limit
Tolerance
Standard size
Remedy
+0.15
5.5
7.2
0.8 (min.)
0.4
0.9 (min.)
I
I
Lining thickness
1.0
Replace
kO.1
Standard size
A
Spring load
0.3
Reoair limit
Installed length
Installed load
Installed load
7.8
682 N
(69.5 kg)
549 N
(56 kg)
40-33
MAINTENANCE
STANDARD
BRAKEVALVE
BRAKE VALVE
BRAKE VALVE (LEFT)
66.2+7.3Nm
7.8GNm
(0.8=0.2kgm)
3
w
66.&73Nm
(6.7550.75kgm)
15&24.5Nm
(155&.5kgm)
sAwc&e69
5
Unit: mm
No
Check
I.
item
Criteria
Standard
Free length
Control
Remedy
size
Repair
limit
Installed loac I
spring
34
93.2 N
(9.5 kg)
21.8
Control
spring
46.3
34.3
j (&g
Return
spring
86.2
58
Return
spring
31.5
Clearance
and pin
33
Fg) j
45.3
78
roller
-0.025
-0.075
IO
Standard
7
Outside
diameter
of roller
30
40-34
16.7 N
(1.7 kg)
between
:8k;)
size
Tolerance
0.175
0.025
+O.l
0
1.5
28
29.2
I
Repair
limit
29.2
Replace
MAINTENANCE
STANDARD
BRAKE VALVE
66.&7.3Nm
(6.75=0.75kgm) .
7.8dNm
(0.8dJ.Zkgm)
66.Z7.3Nm
(6.75t0.75kgm)
40-36
152d4.5Nm
(15.5t2.5kgm)
MAINTENANCE
BRAKE VALVE
STANDARD
Unit: mm
No.
Check
Standard
Free length
1
Control
I
I
Control
I
I
spring
I
I
spring
Clearance
Clearance
7 I and pin
I
between
between
Outside
21.8
93.2 N
(9.5 kg)
33
46.3
34.3
459 N
(46.8 kg)
45.3
86.2
58
60.8 N
(6.2 kg1
78
15
69.6 N
(7.1 kg)
16.2
19.5
16.7 N
(1.7 kg)
28
17
31.5
Tolerance
limit
installed load
0.175 0.025
-0.025
-0.075
+O.l
0
0.175 -
10
Tolerance
0.025
Replace
+O.l
0
size
-0.025
-0.075
10
Standard
Clearance
limit
Standard
clearance
Hole
Shaft
roller
I
diameter
34
Standard
size
pedal
1
8
Repair
size
spring
Return spring
Return
Remedy
Criteria
item
0.25
29.2
Repair
limit
I
1
of roller
30
j.5
29.2
40-37
MAINTENANCE
STANDARD
PARKING
BRAKE
PARKING BRAKE
SAWCCE71
Unit: mm
No
Check item
Criteria
Tolerance
Standard
size
1
Clearance
between piston Inner side
and cylinder
Shaft
I
215
I,
I
250
Standard
clearance
Hole
2.05
o-
I
1
0.10 0.28
+0.13
0
Standard size
2
Repair limit
68.7
53.7
438f21.6 N
44.7f2.2 kg)
66.0
944 N
(96.3 kg)
76.5
53.7
1,049+52.9 N
(107f5.4 kg)
68.9
394 N
(40.2 kg)
0.33
Parking brake
spring
Standard size
4
0.23
0.18
I
1
-0.10
-0.15
Clearance
limit
+0.13
0
Outer side
Remedy
Tolerance
Repair limit
Brake disc
Distortion
Thickness
3.2
Depth of
lining
groove
0.45
Lining
thickness
0.7
40-38
0.05
0.6
kO.08
2.97
+0.175
0
1
0.375
I
kO.075
I
892 N (91 kg)
(Height: 3.2 mm)
MAINTENANCE
HYDRAULIC
STANDARD
HYDRAULIC
PUMP (Hydraulic,
switch,
steering,
PUMP
PPC pump)
(SAL(3)100+50+36+(1)25)
&a
c+
279iBNm
(28.53kgm)
279Q9Nm
(28&3kgm)
279Q9Nm
(28&3kgm)
113&8Nm
(11.5Alkgm)
s6vVrn572
Unit:
2
5
No
Standard
Model
SAL (3) 100
1
Remedy
Criteria
Check item
mm
Clearance
clearance
0.13 - 0.18
0.22
0.10 - 0.15
0.19
limit
SAL (3) 50
Side clearance
SAL (3) 36
SAL
(1) 25
Clearance
between
inside
diameter
of plain bearing
and outside of diameter of
gear shaft
SAL (3) 50
0.060 - 0.149
0.20
SAL (3) 36
SAL (1) 25
Model
Rotating torque
shaft
Discharge
of spline
amount
Oil: EOIO-CD
Oil temperature:
Standard
size
Tolerance
in pin
Model
Replace
0.060 - 0.119
Rotating
speed
Delivery
pressure
Standard deliDelivery
very amount amount limii
231 l/min
214 B/min
45 - 55C
SAL (1) 25
40-39
MAINTENANCE
STANDARD
13.3AMNm
w
UG+lONm
(23=1 kgm)
I,
0
&z3.4Nm
(3.15*0.35kgm)
w
15295Nm
(15.5dL5kgm)
w
22GlONm
(23rlkgm)
w
152&?5Nm
(15.M.5kgmJ
31+3Nm
(3.15dL35kgm)
w
466+25Nm
(47.5z2.5kgm)
U
0
SAW@3673
40-40
MAINTENANCE
STANDARD
Unit: mm
Standard
1
Spool
Remedy
Criteria
Check item
Free length
return spring
(for bucket)
54.8
limit
53.5
54.8
Repair
size
52.2
g5k;)
40
233 N
(23.8 kg)
86.8
83.5
208 N
(21.2 kg)
Main relief
spring valve main
valve
39.5
23.2
33.3 N
(3.4 kg)
49.3
41.9
26.8
55.3
235 N
(24 kg)
30.7
Installed load
Spool
Spool
return spring
(for boom)
return spring
(for boom)
spring
32.6
24.5
1 (;y;k;)
Suction
27.9
&t$
I - I
Replace
47.8
259 N
(26.4 kg)
valve spring
208 N
(21.2 kg)
40-41
MAINTENANCE
STANDARD
3-SPOOL VALVE
w
13.3+1.5Nm
a.5kgm_\
(JQJ;
4 7
226zlONm
, (23+lkgm)
fB+lONm
-I
152+25Nm
(15.5z2.5kgm)
w
226elONm
(2351 kgm)
w
226elONm
3tlkgm)
w
275GONm
(28*3kgm)
40-42
(47.5LEkgm)
.8
MAINTENANCE
No.
-
STANDARD
Criteria
Check item
I
Spool return spring
(for bucket and attachment)
I
I
Standard size
Remedy
Reoair limit
53.5
125 N
(12.7 kg)
54.8
52.2
235 N
(24 kg)
30.7
26.8
235 N
(24 kg)
Spool return
spring
(for boom)
55.3
40
233 kg)
N
(23.8
86.8
83.5
208 N
(21.2 kg)
Main relief
valve
springvalve main
39.5
23.2
33.3 N
(3.4 kg)
49.3
41.9
32.6
27.9
I Replace
259 N
(26.4 kg)
47.8
208 N
(21.2 kg)
24.5
44.1 N
(4.5 kg)
19
6.9 N
(0.7 kg)
40-43
MAINTENANCE
STANDARD
PPC VALVE
PPC VALVE
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Centering spring
(bucket DUMP,
boom LOWER)
Repair limit
Free length
x O.D.
installed
length
Installed
load
Free
length
installed
load
52.73 x 1.3
36.0
29.4 N
(3.0 kg)
23.5 N
(2.4 kg)
Replace spring
- if damaged
Centering spring
(bucket TILT, boom RAISE)
2
3
Metering spring
40-44
52.78 I*3
31.4 x 7.4 1
39.2 N
(4.0 kg)
36.0
2g.4
(:677k;)
31.4 N
(3.2 kg)
(:347k;)
or deformed
MAINTENANCE
STANDARD
HYDRAULIC
HYDRAULIC CYLINDER
CYLINDER
Bucket
Steering
:1152=123Nm
(117.5=12.5kgm)
:343*34Nm
(35.0t3.5kgm)
:588*59Nm
Boom
Bucket
:110+12Nm
(11.25*_1.25kgm)
:110=12Nm
(11.25~1.25kgm)
Steering
(6&6kgm)
No.
Check
item.
:78!%78Nm
(80+8kgm)
Standard
size
Tolerance
SBWOW76
Remedy
Criteria
SBwcom
Shaft
Hole
Standard
clearance
Clearance
go
-0.036
-0.123
+0.270
+0.061
0.097 0.393
Bucket
90
-0.036
-0.123
+0.270
+0.061
0.097 0.393
0.693
Steering
45
-0.025
-0.087
+0.152
+0.007
0.032
0.239
0.539
limit
0.693
Replace
bushing
40-45
MAINTENANCE
STANDARD
WORK EQUIPMENT
WORK EQUIPMENT
LINKAGE
J
/
a
A-A
LINKAGE
B-B
c-c
16
D-D
F-F
17
40-46
G-G
H-H
J-J
SAWCC677
MAINTENANCE
STANDARD
WORK
EQUIPMENT
LINKAGE
Unit: mm
No
Check
Criteria
item
85
-0.036
-0.090
+0.207
+0.120
95
-0.036
-0.090
+0.207
co. 120
Remedy
5
.z
Width
9
0.156 0.297
1.0
0.156 0.297
1.0
Replace
replace if there
is s.cufZngon
pin
1
Connection of bucket
cylinder and frame
of boss
110+0.8
0
Width
Standard
clearance
(Clearance
a + b)
of hinge
114kl.5
I
1.7 - 5.5
I
Replace
IO
11
12
13
14
15
-
16
Connection
frame
of boom and
Connection
bucket
of boom and
Connection
and bucket
of bucket link
122k1.5
129+;
5.5 - 11.5
Connection of boom
cylinder and frame
Connection
and bucket
of bellcrank
link
g;;ne;;icmn
of bellcrank
106f1.5
112.5,2.;
+0.8
0
go
112.5_
+2.8
o.5
116
+I.5
o
93.5+;
0.5 - 5
0.7 - 5
2.7 - 6.5
117k1.5
0.2 - 6.5
223h0.5
0.5 - 5.5
Replace
Connection of bucket
cylinder and bellcrank
220+;
llo+"-8
0
117fl.5
4.7 - 8.5
17
insert shims on
bath sides so
that clearance
is less than 1.5
mm on both
left and right
103kl.5
106i1.5
O-6
insert shims on
both sides so
that clearance
is less than 1.5
mm on both
left and right
rdjustwith shims
o that clearance
; lessthan 2.0
im on both left
nd t-k&
40-47
MAINTENANCE
BUCKET
STANDARD
BUCKET
(76+11kgm)
&
3
A-A
902a39Nm
(92+4kgm)
902=39Nm
l92+4kgm)
N
902239Nm
(9?,4kgm)
A-A
SAW00676
Unit: mm
Remedy
Criteria
Check item
No.
Standard
1
Bucket tooth
Clearance
wear
of bucket
base
I tooth mountinq
3
Cutting
40-48
edge wear
Repair limit
size
18.5
50
Max.
93
0.5
Adjust or
replace
Reverse
replace
or
MAINTENANCE
STANDARD
BUCKET POSITIONER
BUCKET
POSITIONER
AND BOOM
KICK-OUT
-;.
=+I.
1
~..
i
==? ::
..
;.
w
53.%19.6Nm
(5.5Qkgm)
w
17.7QONm
(1.8-92kgm)
A-A
Unit: mm
No.
1
2
Check item
Criteria
Clearance at bucket
positioner switch
3-7
Clearance at boom
kickout switch
3-7
Remedy
Adjust
40-49
PROPOSAL
FOR MANUAL
REVlslON
NAME OF COMPANY:
PHONE NO:
:
S
DEPARTMENT:
E
R
NAME:
MANUAL NAME:
MANUAL NO:
MACHINE MODEL:
S/N IF APPLICABLE:
PAGE NO:
PROBLEM:
PFMRl 081696
LOCATION:
DATE: